STIHL 024 & 026 Chainsaw Service Manual OEM
182 Pages • 6.32 MB • Instant, Printable PDF
Stihl Models Covered & Key Technical Specifications
Models: STIHL 024, STIHL 026
Sub-models / Variants: 024 S, W version, Catalytic Converter versions, Quick Chain Tensioner versions
Model Years: 1999–2004
Serial Numbers: X 30 976 774, X 30 976 775, X 19 830 900, X 36 348 619, X 36 348 620, X 32 611 638, X 32 611 639, X 37 055 376, X 33 339 217, X 33 339 218
Technical Data:
- Engine: Single-cylinder two-stroke with impregnated cylinder bore
- Displacement (024): 42 cm³ (2.56 cu.in)
- Displacement (024 S): 44.3 cm³ (2.70 cu.in)
- Displacement (026): 48.7 cm³ (2.97 cu.in)
- Max Permissible Speed (024/024S): 13,000 rpm
- Max Permissible Speed (026): 14,000 rpm
- Idle Speed: 2,500 rpm
- Clutch Engagement Speed: 3,600 rpm
- Fuel Tank Capacity: 0.47 L (16 fl.oz)
- Oil Tank Capacity: 0.32 L (11 fl.oz)
- Crankcase Leakage Test: 0.5 bar (7.25 psi) pressure/vacuum
- Carburetor Leakage Test: 0.8 bar (11.6 psi)
Stihl Manual Features & Content Preview
- Covers 1989–2004 STIHL 024 and 026 chainsaws (including 024 S, catalytic converter variants, and quick-tensioning models).
- Official 182-page OEM PDF publication (revision 2004–08, P/N 0455 127 0123).
- Features 64 detailed service diagrams, 39 torque specifications, and complete technical data tables for engine and fuel systems.
- Detailed service procedures for rewind starters, AV handle systems, Master Control levers, quick chain tensioners, ElastoStart grips, spark arresting screens, and decompression valves.
- In-depth coverage of Tillotson carburetors, Walbro carburetors, ignition modules, flywheels, oil seals, tank vents, and catalytic converters.
Component and System Servicing
This factory reference delivers an exhaustive breakdown of the STIHL 024 and 026 architecture. Need to diagnose a running issue? The manual covers everything from diaphragm carburetor settings and air filtration maintenance to electronic magneto timing. You will find detailed chapters focused on clutch and chain drive mechanics, chain brake teardowns, oil pump servicing, and complete crankcase management. It provides specialized flow charts, troubleshooting charts, exploded views, component drawings, pressure test schematics, and exact wiring diagrams with electrical resistance values for the handle heating system elements, switches, and generators. Just the numbers you need to get the saw back in the wood.
Advanced Shop-Level Diagnostics
Bypass expensive dealership labor rates by tackling heavy-line repair tasks yourself. This documentation provides the exact step-by-step sequences for advanced procedures that normally require a professional shop. You will learn the factory-approved methods for conducting definitive crankcase vacuum and pressure leakage tests, safely splitting the engine housing, extracting crankshaft oil seals, and diagnosing the complete fuel system. For professional mechanics and dedicated DIYers, having these factory baselines directly at the workbench drastically reduces diagnostic time and eliminates trial-and-error parts swapping.
Technical Specification Highlights
Accurate assembly requires the right numbers. This documentation lists strict torque values for critical fasteners to prevent overtightening and ensure structural integrity. For example, cylinder base screws on the STIHL 024 require 10.5 Nm. Engine assembly data specifies the flywheel nut takes 33.0 Nm, while the decompression valve seats correctly at 14.0 Nm. Spline screws for the crankcase demand exactly 9.0 Nm.
Proper maintenance demands precision, and working with high-performance two-stroke engines carries inherent risks. Always follow standard shop safety protocols and ensure you have the appropriate technical background before handling internal engine or structural components.
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