1979–2007 STIHL 028 and 038 Chainsaw Service & Parts Manual Set (P/N 1118-080-1805)

The 1979–2007 STIHL 028/038 Manual Set combines the service manual with separate illustrated spare parts lists for both models. The repair text centers on the 028; its foreword also extends its use to the 038 because of their shared construction, with later changes subject to the applicable Technical Information bulletins.

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

• Clutch and chain brake: Standard and Quickstop clutch service, chain-drive inspection, and disassembly and reassembly of the brake mechanism.

• Ignition diagnosis: Bosch breaker-controlled and transistor-controlled systems, SEM thyristor ignition, troubleshooting flowcharts, component tests, and ignition-timing checks.

• Fuel system: Diaphragm-carburetor disassembly and repair, leakage testing, inlet control lever checks, mixture adjustment, and fuel-line and tank-vent service.

• Chain lubrication: Oil-pump disassembly and repair, pickup-body and valve service, and troubleshooting for restricted delivery and oil leakage.

• Starter and controls: Starter-rope and rewind-spring replacement, anti-vibration damper repair, and Master Control shaft removal and installation.

• Handle heating: Switch, heating-element, and generator diagnosis, with terminal photographs, a component resistance-test chart, and replacement procedures.

Written for STIHL servicing staff and dealers, the service manual uses specialized assembly tools and workshop test equipment.

Engine and Clutch Repair

The engine section documents the two-part, drop-forged crankshaft and the magnesium-alloy crankcase. It also describes replacing crankshaft oil seals without splitting the engine case.

The vacuum test can reveal oil-seal faults that a positive-pressure test misses, helping trace an unstable idle before further carburetor adjustment. Cylinder-installation illustrations explain how incorrect alignment can break piston rings.

The clutch chapter distinguishes the Quickstop isolating clutch from the standard assembly. Its warning about left-hand threads on the hub and clutch spider identifies a thread-damage risk during removal.

Bosch and SEM Ignition Systems

Separate sections cover armature winding tests, contact sets, condensers, electronic switch units, and the integrated SEM ignition module. Flywheel illustrations distinguish the Bosch and SEM key slots.

Breaker-controlled timing is checked and adjusted mechanically. Electronic timing is checked dynamically with a stroboscope; it is fixed rather than adjustable. The magneto edge-gap discussion explains its priority when breaker-system tolerances conflict.

Working on these high-tension magneto ignition systems presents a severe shock hazard; always exercise extreme caution and observe proper isolation practices during electrical testing.

Carburetors and Model-Specific Parts

The 028 parts list identifies Walbro WT-16B and Tillotson HU-40D carburetors. The 038 list illustrates Bing 48A101C and Brazil-market 48A125A assemblies. These are parts-identification references accompanying the service chapter's carburetor repair procedures.

The 038 catalog distinguishes cylinder assemblies for its M, MW, MRII, and MR versions and shows the wraparound handle components for MR and MRII configurations. Component callouts and part numbers support identification before parts are selected.

Illustrations include Bosch and SEM ignition circuit schematics, carburetor operating-section views, oil-pump intake and delivery diagrams, and exploded engine and clutch assemblies.

Starter, Handle Systems, and Lubrication

The rewind-starter material covers the pawl mechanism, rope guide bush, spring tensioning, and routine maintenance. Handle sections explain vibration-damper attachment, Master Control operation, and heating-element and generator-coil tests.

Oil-pump documentation separates tank-vent and pickup faults from internal pump wear. Tool references include carburetor/crankcase tester 1106 850 2900, vacuum pump 0000 850 3500, and Quickstop clutch socket 1118 893 1300.

A Preview of Cylinder Fastener and Ignition Specifications

These examples are a small selection of the service manual's component-specific specifications. The 028 cylinder-installation section specifies 7.8 Nm for the cylinder base screws, while the Bosch breaker-controlled ignition section gives a magneto edge gap of 4–8 mm.

For the Bosch ignition armature used on the documented 028 configurations, winding-resistance specifications are 0.7–1.0 Ω for the primary winding and 7.7–10.3 kΩ for the secondary winding. These values accompany the component-testing sections.

PDF Search, Bookmarks, and Publication Breakdown

Search and diagram detail: The parts-list text is searchable; the service-manual pages do not have embedded searchable text. PDF bookmarks open the service manual and each parts list. Small labels in the ignition schematics require zooming.

The download is one printable PDF containing 149 pages across three publications:

Both parts-list covers and their two symbol-key pages are already included in these totals.