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1. Safety Precautions
1
2. Introduction
2
3. Specifications
33 . 1 E n g i n e 3 3 . 2 F u e l
S y s t e m 3 3 . 3 I g n i t i o n S y s t e m 4 3 .4 Cu tt in g
A t t a c h m e n t 4 3.5 Special Accessories 43 . 5 . 1 F o r
U s e r 4 3 . 5 . 2 F o r S e r v i c e 5 3. 6 Tigh t en in g
Torqu e s 5
4 . C l u t c h , C h a i n D r i v e , Chain Brake andChain Tensioner
74 . 1 C l u t c h D r u m a n d C h a i n S p r o c k e t 7 4 . 2
C l u t c h 8 4 . 3 C h a i n B r a k e
9 4.3.1 Checking Function 94 . 3 . 2 D i s a s s e m b l i n g
9 4 . 3 . 3 A s s e m b l i n g 1 1 4.3. 4 Ancho r Pin f or B r a k e
S p r i n g 1 3 4.3.5 Pin for Hand Guard 134.4 Front
C h a i n T e n s i o n e r ( 0 2 4 ) 1 4 4 . 5 S i d e C h a i n Ten s i o n e r 1 4
5 . E n g i n e
155 . 1 M u f f l e r / S p a r k A r r e s t i n g S c r e e n 1 5 5 . 2 C a t a l y t i c C o n v e r t e r
1 6 5.2.1 Construction and F u n c t i o n 1 6 5 . 3 L e a k a g e
T e s t 1 7 5 . 3 . 1 P r e p a r a t i o n s 1 7 5 . 3 . 2 P r e s s u r e
T e s t 1 8 5 . 3 . 3 V a c u u m T e s t 1 8 5 . 4 O i l
S e a l s 1 9 5.5 Exposing the Cylinder 215 . 6 C y l i n d e r a n d
Piston 215 . 6 . 1 R e m o v i n g 2 1 5 . 6 . 2
I n s t a l l i n g 2 2 5 . 7 P i s t o n R i n g s 2 5 5 . 8
C r a n k c a s e 2 5 5.8.1 Removing theC r a n k s h a f t
2 5 5.8.2 Installing theC r a n k s h a f t 2 8 5.9 Decompression
Valve 33
6. Ignition System
336 . 1 S p a r k P l u g B o o t / I g n i t i o n L e a d 3 3 6 . 2 I g n i t i o n
M o d u l e 3 4 6 . 2 . 1 I g n i t i o n T i m i n g 3 5 6.2.2 Remo ving and
Installing35 6 . 3 S h o r t C i r c u i t W i r e / G r o u n d W i r e 3 6 6 . 4
W i r i n g H a r n e s s 3 7 6 . 5 C o n t a c t S p r i n g 3 8 6 . 6
F l y w h e e l 3 8
7. Rewind Starter
397 . 1 G e n e r a l 3 9 7 . 2 R e w i n d S p r i n g
3 9 7 . 2 . 1 R e p l a c i n g 3 9 7 . 2 . 2 T e n s i o n i n g
4 0 7.3 Starter Rope/StarterG r i p ( E l a s t o S t a r t ) 4 1
8. AV Handle System
42
9 . M a s t e r C o n t r o l / Handle System
439 . 1 S w i t c h S h a f t 4 3 9.2 Interlock Lever/ T h r o t t l e
Trig ge r 43
1 0 . E l e c t r i c H a n d l e Heating System
451 0 . 1 T r o u b l e s h o o t i n g 4 5 10.1.1 TroubleshootingC h a r t
4 6 10.1.2 Test Connections andT e s t V a l u e s 4 7 1 0 . 2
H e a t e r S w i t c h 4 8 10.3 Heating Element in R e a r H a n d l e
4 8 10.4 Heating Element in F r o n t H a n d l e 4 9 1 0 . 5
G e n e r a t o r 5 0
11. Chain Lubrication
521 1 . 1 P i c k u p B o d y / S u c t i o n H o s e 5 2 1 1 . 2
V a l v e 5 3 1 1 . 3 O i l P u m p
5 3 1 1 . 3 . 1 S e r v i c i n g 5 5
12. Fuel System
5512.1 Air Filter/Choke Shutter 55 1 2 . 2 C a r b u r e t o r P r e h e a t i n g 5 6 1 2 . 3 C a r b u r e t o r
H e a t e r 5 6 12.3.1 Construction andF u n c t i o n 5 6 1 2 . 3 . 2
T e s t i n g 5 7 12.3.3 TroubleshootingC h a r t
5 9 12.4 Printed Circuit Board 601 2 . 5 C a r b u r e t o r
6 0 1 2 . 5 . 1 L e a k a g e T e s t i n g 6 0 12.5.2 Removing andI n s t a l l i n g
6 1 1 2 . 5 . 3 A d j u s t i n g 6 3 1 2 . 6 T a n k V e n t
6 4 1 2 . 7 F u e l H o s e 6 5 1 2 . 8 T a n k H o u s i n g
6 5
1 3 . S p e c i a l S e r v i c i n g Tools and Aids
681 3 . 1 S p e c i a l S e r v i c i n g T o o l s 6 8 1 3 . 2
S e r v i c i n g A i d s 7 0
1 . S A F E T Y PRECAUTIONS
If the engine is started up in thecourse of repairs or maintenancework, observe all local and country-
specific safety regulations as wellas the safety precautions and war-nings in the owners manual.Gasoline
is an extremely flamm-able fuel and can be explosive incertain conditions.Improper handling may result
inburns or other serious injuries.
Warning!
Do not smoke or bringany fire or flame near the fuel. Allwork with fuel must be performedoutdoors only.
Spilled fuel must bewiped up immediately.Wash hands thoroughly afterevery contact with waste oil.Do not
pour waste oil down thedrain or allow it to soak into theground.Collect waste oil and take it to anofficial
disposal site for environ-ment-friendly disposal.
1999 Andreas Stihl AG & Co., Waiblingen
024,026CONTENTS0 2 4 ,
0 2 6 1
This service manual containsdetailed descriptions of all therepair and servicing proceduresspecific to this
power tool series.There are separate handbooksfor servicing procedures forstandardized parts and
assem-blies that are installed in severalSTIHL power tool models.Reference is made to thesehandbooks
in the appropriatechapters of this manual.As the design concept of model024 and 026 chainsaws is
almostidentical, the descriptions andservicing procedures generallyapply to both. Differences
aredescribed in detail.Servicing procedures on thecarburetor are described in the"Carburetors"
handbook.You should make use of theillustrated parts lists while carryingout repair work. They show
theinstalled positions of the individualcomponents and assemblies.Refer to the latest edition of
therelevant parts list to check the partnumbers of any replacement partsneeded.Parts lists on microfiche
and CD-ROM are always more up to datethan printed lists.A fault on the machine may haveseveral
causes. To help locate thefault, consult the troubleshootingcharts for all assemblies in the"Standard
Repairs, Troubleshoot-ing" handbook.Refer to the "Technical Informa-tion" bulletins for
engineeringchanges which have been intro-duced since publication of thisservice manual. Technical
informa-tion bulletins also supplement theparts list until a revised edition isissued.The special servicing
toolsmentioned in the descriptions arelisted in the last chapter of this ma-nual.Use the part numbers to
identifythe tools in the "STIHL SpecialTools" manual.The manual lists all specialservicing tools currently
availablefrom STIHL.Symbols are included in the textand pictures for greater clarity.The meanings are as
follows:In the descriptions:

= Action to be taken asshown in the illustration(above the text)- = Action to be taken thatis not shown
in theillustration(above the text)In the illustrations:= Pointer= Direction of movementService manuals and
all technicalinformation bulletins describingengineering changes are intendedexclusively for the use of
STIHLservicing dealers. They must notbe passed to third parties.Servicing and repairs are
madeconsiderably easier if the machineis mounted on assembly stand (
1
)5910 890 3100.Remove the chain sprocket coverand secure the machine to theassembly stand with the
sprocketcover nuts. Machines with a quickchain tensioning system andsecure with one M8 nut
andwasher.The complete unit can then beswivelled to the best position forthe ongoing repair. This
leavesboth hands free.
Always use original STIHLreplacement parts.
They can be identified by theSTIHL part number,t h e l o g o and the STIHL parts
symbol
(
The symbol may appear alone onsmall parts.
2. INTRODUCTION
V A 1 3 3 R A 0 0 1
1
2
0 2 4 ,
0 2 6
3 . 1 E n g i n e
STIHL single-cylinder two-stroke engine with special impregnated cylinder bore
0 2 4 0 2 4 S 0 2 6
D i s p l a c e m e n t : 4 2 c m
3
(2.56 cu.in) 44.3 cm
3
(2.70 cu.in) 48.7 cm
3
(2.97 cu.in)B o r e : 4 2 m m ( 1 . 6 5 i n ) 4 2 m m
( 1 . 6 5 i n ) 4 4 m m ( 1 . 7 3 i n ) S t r o k e : 3 0
m m ( 1 . 1 8 i n ) 3 2 m m ( 1 . 2 6 i n ) 3 2 m m
( 1 . 2 6 i n ) Engine power to ISO 7293: 2.1 kW (2.85 bhp) 2.3
kW (3.1 bhp) 2.6 kW (3.5 bhp)a t 7 , 0 0 0 r p m a t 7 , 0 0 0 r p m
a t 7 , 0 0 0 r p m Max. permissible engines p e e d w i t h b a r a n d
c h a i n : 1 3 , 0 0 0 r p m 1 3 , 0 0 0 r p m 1 4 , 0 0 0 r p m I d l e
s p e e d : 2 , 5 0 0 r p m Bearings: Crankshaft
s u p p o r t e d i n h e a v y - d u t y d e e p - g r o o v e b a l l b e a r i n g s , needle cages on
small and big endsP i s t o n p i n d i a m e t e r : 1 0 m m ( 0 . 3 9 i n ) R e w i n d
s t a r t e r : S i n g l e p a w l s y s t e m Reserve pull on rope rotor:
min. 1/2 turnS t a r t e r r o p e : 3 . 5 m m ( 0 . 1 4 i n )
d i a . C l u t c h : C e n t r i f u g a l c l u t c h w i t h o u t
l i n i n g s C l u t c h e n g a g e s a t : 3 , 6 0 0 r p m Crankcase
leakagetesta t g a u g e p r e s s u r e : 0 . 5 b a r ( 7 . 2 5 p s i ) u n d e r
v a c u u m : 0 . 5 b a r ( 7 . 2 5 p s i )
3.2 Fuel System
C a r b u r e t o r : D i a p h r a g m c a r b u r e t o r SettingH i g h
spe e d scre w H: ap p ro x. 1 t u rn o pe n L o w s p e e d s c r e w L :
a p p r o x . 1 t u r n o p e n (standard setting)Carburetor leakage testa t g a u g e
p r e s s u r e : 0 . 8 b a r ( 1 1 . 6 p s i ) Function of tank ventat gauge pressure:

0.3 bar (4.35 psi)under vacuum: *

0.05 bar (0.725 psi)F u e l t a n k c a p a c i t y : 0 . 4 7 L ( 1 6

f l . o z ) O c t a n e n u m b e r : m i n . 9 0 R O N F u e l
m i x t u r e : R e g u l a r b r a n d - n a m e g a s o l i n e and two-stroke engine
oilMix ratio:
50:1
with STIHL 50:1 two-stroke engine oil
25:1
with other brand-name two-stroke, air-cooled engine oilsA i r f i l t e r : L a r g e a r e a ,
b i s e c t i o n a l f l a t f i l t e r , additional prefilter in carburetor box cover* Original
tank vent
3.
S PE CI FI CATI O NS 0 2 4 ,
0 2 6 3

3.3 Ignition System

T y p e : E l e c t r o n i c m a g n e t o
i g n i t i o n (breakerless) with integraltrigger unitA i r g a p : 0 . 2 - 0 . 3
m m ( 0 . 0 0 8 - 0 . 0 1 2 i n ) Spark plug (suppressed): Bosch
W S R 6 F , NGK BPMR 7 A orChampion RCJ 6YE l e c t r o d e g a p : 0 . 5 m m
( 0 . 0 2 0 i n )
3.4 Cutting Attachment
G u i d e b a r s : S T I H L R o l l o m a t i c with nose
sprocket,corrosion-resistant finish andinduction hardened railsB a r l e n g t h s : 3 2 , 3 7
a n d 4 0 c m ( 1 3 , 1 5 , 1 8 i n ) O ilom at ic ch a in : 0. 32 5"
(8 . 25 mm ) Rap id ch a in C h a i n s p r o c k e t : 7 - t o o t h
0 . 3 2 5 " C h a i n s p e e d : 1 8 . 3 m / s ( 6 0 f t / s ) a t 9 , 5 0 0
r p m Chain lubrication: Speed-controlled or
a d j u s t a b l e reciprocating pumpOil feed rateo n n o n - a d j u s t a b l e p u m p : 6 c m
3
/min (0.2 fl.oz/min)at 6,000 rpm9.5 cm
3
/min (0.3 fl.oz/min)at 10,000 rpmo n a d j u s t a b l e p u m p : 4 . 5 - 1 1 . 5 c m
3
/min(0.15-0.4 fl.oz/min)at 10,000 rpmO i l t a n k c a p a c i t y : 0 . 3 2 L ( 1 1
f l . o z )
3.5 Special Accessories3.5.1 For User
E l a s t o S t a r t 0 0 0 0 1 9 0 3 4 0 1 A ir f ilte r,
" f l e e c e " 0 2 4 1 1 2 1 1 2 0 1 6 2 5 0.325", 8-tooth chain sprocket 1121
640 2001 1)1121 640 2005 2)Intake air preheating kit 024 1121 007
1 0 3 0 I n t a k e a i r p r e h e a t i n g k i t 0 2 6 1 1 2 1 0 0 7 1 0 2 7 (up to serial number X 30 976
774)I n t a k e a i r p r e h e a t i n g k i t 0 2 6 1 1 2 1 0 0 7 1 0 4 4 (from serial number X 30 976
775)0 . 3 2 5 " , 7 - t o o t h r i m s p r o c k e t k i t 1 1 2 1 0 0 7 1 0 0 1 1 ) 1 1 2 1 0 0 7 1 0 3 7
2)0.325", 8-tooth rim sprocket kit 1121 007 1002 1)1121 007 1038
2 ) 3 / 8 " P i c c o , 7 - t o o t h r i m s p r o c k e t k i t 112 1 0 0 7 1 0 0 4 1 ) 1 1 2 1 0 0 7 1 0 3 9 2 ) 3 / 8 "
P i c c o , 8 - t o o t h r i m s p r o c k e t k i t 11 2 1 0 0 7 1 0 0 5 1 ) 1 1 2 1 0 0 7 1 0 4 0 2 ) 3 / 8 " , 7 -
t o o t h r i m s p r o c k e t k i t 1 1 2 1 0 0 7 1 0 3 5 1 ) 1 1 2 1 0 0 7 1 0 4 1 2 ) Chain scabbard
extension( f r o m 4 5 c m / 1 8 i n ) 0 0 0 0 7 9 2 9 1 3 1 C A T
m o u n t i n g k i t 1 1 2 1 0 0 7 1 0 4 2 1) 0242) 026
4
0 2 4 ,
0 2 6

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Stihl 024 026 Service Manual

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