1999–2004 STIHL 024 & 026 Chainsaw Service Manual with Parts Lists (P/N 0455 127 0123)

This set combines the STIHL service manual for 1989–2004 024 and 026 chainsaws with two illustrated parts lists. The manual covers 024 S, heated-handle, catalytic-converter and quick-tensioning versions and carries the cover date 2004-08 and printed code 0455 127 0123.

Text search and diagram detail: Searchable text spans the service manual and parts lists. Bookmarks cover service chapters and the start of each parts list. Small markings in electrical test illustrations benefit from zooming.

• Engine repair: Cylinder and piston service, crankshaft removal and installation, oil-seal replacement, and crankcase pressure and vacuum testing.

• Chain drive and lubrication: Clutch and chain-brake service, front and side chain tensioners, and adjustable and nonadjustable oil pumps.

• Fuel system: Carburetor leakage testing, removal, installation and adjustment, plus tank-vent checks, air-filter service and fuel-hose replacement.

• Ignition and heating: Ignition-module and flywheel replacement, wiring-harness service, and electrical diagnosis of handle and carburetor heating systems.

• Starter and controls: Rewind-spring replacement and tensioning, AV handle buffers, Master Control levers, throttle triggers and interlocks.

• Workshop references: Heating troubleshooting flowcharts, test-connection tables, exploded parts views, component torque specifications and special-tool references.

Written for STIHL servicing dealers, this manual assumes workshop experience and access to the specified test equipment and service tools.

Engine Repair and Leakage Diagnosis

The engine section covers crankcase separation, main-bearing replacement and piston-ring work. It also describes oil-seal replacement without disassembling the complete crankcase.

The pressure and vacuum tests help distinguish air leaks that upset idle quality from carburetor-adjustment problems. Illustrations show the test connections and sealing arrangements.

Muffler and spark arresting screen service, catalytic-converter construction, and decompression-valve replacement are included. The cylinder-installation notes warn that incorrect alignment can break piston rings.

Fuel System and Carburetor Coverage

Fuel-system work extends to tank-vent pressure and vacuum checks, tank-housing replacement and carburetor preheating. The text distinguishes the revised 026 air filter from serial number X 32 252 039 and later tank-housing and vent arrangements at X 36 348 620.

Tillotson and Walbro service-kit references are listed. The 026 parts list adds carburetor exploded views for WT-426, WT-427, WT-590, WT-195, WT-155 and WT-403A.

Internal carburetor repair is referred to the separate Carburetors handbook, which is not included.

Ignition and Heated Handles

The electronic magneto uses fixed, nonadjustable ignition timing. Service covers spark-plug leads, ground and short-circuit wires, and harness routing alongside ignition-module and flywheel replacement.

Heating diagnosis: The handle-heating Troubleshooting Chart and Test Connections and Test Values table cover the switch, generator and heating elements. Carburetor heating has its own troubleshooting flowchart, thermostat tests and printed-circuit-board checks.

At X 33 339 218, the 026 VH carburetor-heating arrangement changes. The handle-heating sections also distinguish revised elements and their matching flywheel/front-handle combinations, helping identify compatible components before replacement.

The manual warns that a rear-handle heating element fitted with creases can overheat and fail.

Chain Brake, Oil Pump and Controls

Chain-brake repair includes the spring, band, bell crank and anchor pins. Oil-pump coverage separates adjustable and nonadjustable designs and provides an exploded service view for the 026 pump.

Quick chain tensioner parts appear in the appended exploded views; the dedicated tensioner procedures cover the front and side designs. AV-system coverage distinguishes normal and soft buffers.

Some clutch, rope-rotor and 026 ElastoStart procedures refer to the separate Standard Repairs, Troubleshooting handbook, which is not included.

Parts Identification and Service Tools

The 026 parts list identifies 026 W, C, PRO, WVH and Arctic versions. Its Ignition system and Heating illustrations show the associated components and connections.

The additional 021/023/023 L/025 list provides parts identification only; it does not extend the 024/026 repair procedures to those models.

Engine and fuel-system specifications accompany the fastener torque tables. The tool register identifies the carburetor/crankcase tester 1106 850 2905 and oil-seal puller 5910 890 4400, with their applications.

Fuel handling, chain-brake work and ignition testing carry specific hazards; follow the manual's safety precautions and use the required workshop equipment.

Included Publications and PDF Page Count

One printable 182-page PDF contains the 024/026 service manual (72 pages, including its front and back covers), the 021/023/025 parts list (58 pages) and the 026 parts list (52 pages). Both parts lists are dated 07/2004 and include English, German and French part descriptions. Their covers and symbol-key pages are already included in these totals.