026 Stihl Chainsaw Troubleshooting (5 Pro Fixes You Must Know)

Introduction: The Indomitable Stihl 026 – A Chainsaw That Endures

I’ve spent countless hours in the woods with a chainsaw in my hands. Over the years, I’ve come to appreciate the sheer reliability of certain models, and the Stihl 026 is undoubtedly one of the greats. This guide isn’t just about fixing problems; it’s about understanding the heart of a workhorse. I’m going to share my experiences, insights, and practical fixes to keep your Stihl 026 roaring for years to come. I’ve seen these saws brought back from the brink, and I’m confident you can do the same with the right knowledge. Let’s dive into the common issues and pro fixes that can breathe new life into your trusty 026.

026 Stihl Chainsaw Troubleshooting: 5 Pro Fixes You Must Know

The Stihl 026 is known for its robust design and reliable performance. However, even the best chainsaws experience issues over time. In this guide, I will walk you through five common problems with the Stihl 026 and provide pro-level fixes that you can implement yourself.

1. Chainsaw Won’t Start: Fuel and Ignition System Checks

One of the most frustrating issues is when your chainsaw refuses to start. This problem often stems from issues within the fuel or ignition systems.

Fuel System Issues

The fuel system is the lifeline of your chainsaw. If the fuel isn’t flowing correctly, your saw won’t start.

Step 1: Check the Fuel Tank and Fuel Line

• Action: Ensure the fuel tank has fresh fuel. Old fuel can degrade and cause starting problems.
• Details: I always recommend using a fuel stabilizer, especially if the saw sits idle for extended periods. I learned this the hard way after struggling to start a saw that had been sitting for just three months with untreated fuel.
• Measurement: Use a fuel stabilizer at the ratio recommended by the manufacturer (usually around 1 oz per gallon).
• Tool: Fuel stabilizer, fresh fuel.
• Next Step: Inspect the fuel line for cracks, kinks, or leaks. These can prevent fuel from reaching the carburetor. Replace any damaged fuel lines.
• Case Study: I once worked on a saw that wouldn’t start, and the fuel line had a tiny pinhole that was almost invisible. Replacing the line solved the problem instantly.
• Metric: Check fuel line integrity every 6 months.
• Takeaway: Fresh fuel and intact fuel lines are crucial for starting your Stihl 026.

Step 2: Clean or Replace the Fuel Filter

• Action: A clogged fuel filter restricts fuel flow.
• Details: The fuel filter is located inside the fuel tank, attached to the fuel line.
• Tool: Small pliers, new fuel filter.
• Procedure: Use small pliers to carefully remove the fuel filter from the fuel line. Inspect the filter for debris. If it’s clogged, try cleaning it with carburetor cleaner. If cleaning doesn’t work, replace the fuel filter with a new one.
• Measurement: Replace the fuel filter annually or more frequently if you use the saw heavily.
• Best Practice: Always use a genuine Stihl fuel filter for optimal performance.
• Takeaway: A clean fuel filter ensures a steady supply of fuel to the carburetor.

Step 3: Inspect and Clean the Carburetor

• Action: The carburetor mixes fuel and air. If it’s clogged, the engine won’t get the right mixture.
• Details: This is where things can get a bit more complex, but don’t worry, I’ll guide you through it.
• Tool: Screwdrivers, carburetor cleaner, compressed air (optional).
• Procedure:
  1. Remove the air filter and carburetor cover.
  2. Carefully disconnect the fuel lines from the carburetor.
  3. Remove the carburetor from the engine.
  4. Disassemble the carburetor, paying close attention to the location of each part. Take pictures as you go to help with reassembly.
  5. Clean all carburetor parts with carburetor cleaner. Use compressed air to blow out any remaining debris.
  6. Reassemble the carburetor and reinstall it on the engine.
• Expert Advice: Pay special attention to the jets in the carburetor. These are very small and can easily become clogged. Use a small wire or needle to clean them thoroughly.
• Common Mistake: Forgetting the order of the carburetor parts during reassembly. This is why taking pictures is essential.
• Takeaway: A clean and properly adjusted carburetor is essential for a smooth-running engine.

Ignition System Issues

If the fuel system is working correctly, the next step is to check the ignition system. This system provides the spark needed to ignite the fuel-air mixture.

Step 1: Check the Spark Plug

• Action: A faulty spark plug can prevent the engine from starting.
• Details: The spark plug creates the spark that ignites the fuel-air mixture in the cylinder.
• Tool: Spark plug wrench, wire brush, spark plug tester (optional).
• Procedure:
  1. Remove the spark plug from the engine.
  2. Inspect the spark plug for cracks, carbon buildup, or damage.
  3. Clean the spark plug with a wire brush.
  4. Check the spark plug gap using a spark plug gap tool. The correct gap for the Stihl 026 is typically around 0.020 inches.
  5. If the spark plug is damaged or heavily fouled, replace it with a new one.
• Measurement: The spark plug gap should be 0.020 inches.
• Best Practice: Replace the spark plug annually or more frequently if you use the saw heavily.
• Takeaway: A clean and properly gapped spark plug is essential for a strong spark.

Step 2: Test the Ignition Coil

• Action: The ignition coil provides the high voltage needed to create a spark.
• Details: This can be a bit more technical, but I’ll break it down.
• Tool: Multimeter.
• Procedure:
  1. Disconnect the spark plug wire from the spark plug.
  2. Set the multimeter to measure resistance (Ohms).
  3. Touch one probe of the multimeter to the spark plug wire terminal on the ignition coil and the other probe to the engine ground.
  4. Check the resistance reading. The specific resistance value will vary depending on the ignition coil, but a reading of infinity or zero indicates a faulty coil.
• Original Research: I’ve found that ignition coils often fail due to heat and vibration. Keeping the engine clean and well-maintained can help extend the life of the ignition coil.
• Takeaway: A faulty ignition coil can prevent the engine from starting.

Step 3: Check the On/Off Switch

• Action: A faulty on/off switch can prevent the ignition system from working.
• Details: Sometimes, the simplest things are the culprit.
• Tool: None (visual inspection).
• Procedure:
  1. Visually inspect the on/off switch for damage or loose connections.
  2. Use a multimeter to test the continuity of the switch in both the on and off positions.
• Best Practice: Replace the switch if you find any issues.
• Takeaway: A functioning on/off switch is critical for proper ignition.

2. Chainsaw Starts Then Dies: Carburetor Adjustment and Air Leaks

Sometimes, the chainsaw will start but then die shortly after. This issue often relates to carburetor adjustments or air leaks.

Carburetor Adjustment

• Action: Proper carburetor adjustment is crucial for maintaining a stable engine idle and smooth acceleration.
• Details: The carburetor has three adjustment screws: L (low speed), H (high speed), and LA (idle speed).
• Tool: Screwdriver, tachometer (optional).
• Procedure:
  1. Start the chainsaw and let it warm up for a few minutes.
  2. Adjust the LA (idle speed) screw until the chain stops moving at idle.
  3. Adjust the L (low speed) screw until the engine idles smoothly and accelerates without hesitation.
  4. Adjust the H (high speed) screw until the engine runs smoothly at full throttle. Use a tachometer to ensure the engine speed is within the manufacturer’s specifications (typically around 12,500 RPM for the Stihl 026).
• Measurement: Adjust the H screw to achieve approximately 12,500 RPM.
• Expert Advice: If you’re not comfortable adjusting the carburetor yourself, take the chainsaw to a qualified technician.
• Common Mistake: Over-tightening the adjustment screws, which can damage the carburetor.
• Takeaway: Correct carburetor adjustment ensures a stable idle and smooth acceleration.

Checking for Air Leaks

• Action: Air leaks can cause the engine to run lean, which can lead to stalling and engine damage.
• Details: Air leaks can occur around the carburetor, intake manifold, and crankshaft seals.
• Tool: Carburetor cleaner or starting fluid.
• Procedure:
  1. Start the chainsaw and let it idle.
  2. Spray carburetor cleaner or starting fluid around the carburetor, intake manifold, and crankshaft seals.
  3. Listen for changes in the engine’s idle speed. If the engine speed increases, there is likely an air leak in that area.
• Case Study: I once found an air leak in a saw that was causing it to stall repeatedly. The leak was around the intake manifold, and replacing the manifold gasket solved the problem.
• Best Practice: Replace any worn or damaged gaskets to prevent air leaks.
• Takeaway: Identifying and fixing air leaks can prevent stalling and engine damage.

3. Chainsaw Chain Not Oiling: Oil Pump and Bar Inspection

A properly lubricated chain is essential for efficient cutting and preventing premature wear. If the chain isn’t oiling correctly, it can lead to serious problems.

Checking the Oil Tank and Oil Line

• Action: Ensure the oil tank has sufficient oil and the oil line is clear.
• Details: The oil pump draws oil from the tank and delivers it to the chain and bar.
• Tool: None (visual inspection).
• Procedure:
  1. Check the oil tank to ensure it has enough oil.
  2. Inspect the oil line for cracks, kinks, or leaks.
  3. Ensure the oil line is properly connected to the oil pump.
• Measurement: Keep the oil tank at least half full during operation.
• Takeaway: Sufficient oil and an intact oil line are crucial for proper chain lubrication.

Cleaning the Oil Pump

• Action: A clogged oil pump can prevent oil from reaching the chain.
• Details: The oil pump is responsible for delivering oil to the bar and chain.
• Tool: Screwdrivers, compressed air, carburetor cleaner.
• Procedure:
  1. Remove the oil pump from the chainsaw.
  2. Disassemble the oil pump and clean all parts with carburetor cleaner.
  3. Use compressed air to blow out any remaining debris.
  4. Reassemble the oil pump and reinstall it on the chainsaw.
• Original Insight: I’ve found that using high-quality bar and chain oil can help prevent the oil pump from clogging.
• Takeaway: A clean oil pump ensures proper chain lubrication.

Inspecting the Bar and Chain

• Action: A damaged bar or chain can prevent proper oiling.
• Details: The bar has oiling holes that need to be clear, and the chain needs to be in good condition.
• Tool: Bar groove cleaner, wire brush.
• Procedure:
  1. Clean the bar groove with a bar groove cleaner.
  2. Ensure the oiling holes on the bar are clear.
  3. Inspect the chain for damage or wear.
  4. Sharpen the chain if necessary.
• Measurement: Clean the bar groove and oiling holes every time you sharpen the chain.
• Best Practice: Use a high-quality bar and chain oil to prolong the life of the bar and chain.
• Takeaway: A clean bar and sharp chain are essential for efficient cutting and proper oiling.

4. Chainsaw Chain Binds or Cuts Unevenly: Chain Sharpening and Bar Maintenance

If the chain binds or cuts unevenly, it’s likely due to a dull chain or a damaged bar.

Chain Sharpening

• Action: A sharp chain is essential for efficient cutting and preventing kickback.
• Details: There are several ways to sharpen a chainsaw chain, including using a file, a chain grinder, or taking it to a professional.
• Tool: Chainsaw file, file guide, depth gauge tool.
• Procedure:
  1. Secure the chainsaw in a vise.
  2. Use a chainsaw file and file guide to sharpen each cutter on the chain.
  3. Maintain the correct filing angle and depth.
  4. Use a depth gauge tool to adjust the depth gauges on the chain.
• Measurement: Sharpen the chain every time you refuel the chainsaw or when you notice it’s cutting poorly.
• Original Research: I’ve found that using a file guide can help maintain the correct filing angle and depth, which results in a sharper and more efficient chain.
• Takeaway: A sharp chain cuts efficiently and reduces the risk of kickback.

Bar Maintenance

• Action: A damaged or worn bar can cause the chain to bind or cut unevenly.
• Details: The bar groove needs to be clean and the bar rails need to be square.
• Tool: Bar groove cleaner, flat file.
• Procedure:
  1. Clean the bar groove with a bar groove cleaner.
  2. Inspect the bar rails for wear or damage.
  3. Use a flat file to square the bar rails.
  4. Check the bar for straightness.
• Measurement: Clean the bar groove and square the bar rails every time you sharpen the chain.
• Best Practice: Rotate the bar regularly to distribute wear evenly.
• Takeaway: A properly maintained bar ensures smooth chain movement and even cutting.

5. Excessive Vibration: Mounts, Clutch, and Flywheel Inspection

Excessive vibration can indicate a problem with the engine mounts, clutch, or flywheel.

Checking the Engine Mounts

• Action: Worn or damaged engine mounts can cause excessive vibration.
• Details: The engine mounts isolate the engine from the frame, reducing vibration.
• Tool: None (visual inspection).
• Procedure:
  1. Visually inspect the engine mounts for cracks or damage.
  2. Check the tightness of the engine mount bolts.
• Best Practice: Replace any worn or damaged engine mounts.
• Takeaway: Functioning engine mounts reduce vibration and prolong the life of the chainsaw.

Inspecting the Clutch

• Action: A worn or damaged clutch can cause excessive vibration and poor performance.
• Details: The clutch engages the engine with the chain.
• Tool: Screwdrivers, clutch removal tool.
• Procedure:
  1. Remove the clutch cover.
  2. Inspect the clutch shoes for wear or damage.
  3. Check the clutch spring for damage.
  4. Replace any worn or damaged clutch parts.
• Measurement: Replace the clutch shoes when they are worn to the minimum thickness specified by the manufacturer.
• Common Mistake: Forgetting to lubricate the clutch bearing during reassembly.
• Takeaway: A properly functioning clutch ensures smooth power transfer to the chain.

Checking the Flywheel

• Action: A loose or damaged flywheel can cause excessive vibration and engine damage.
• Details: The flywheel helps to smooth out the engine’s power delivery.
• Tool: Flywheel puller, torque wrench.
• Procedure:
  1. Remove the flywheel cover.
  2. Inspect the flywheel for damage.
  3. Check the tightness of the flywheel nut.
  4. Use a torque wrench to tighten the flywheel nut to the manufacturer’s specifications.
• Original Research: I’ve found that using a flywheel puller is essential for removing the flywheel without damaging it.
• Takeaway: A properly secured flywheel ensures smooth engine operation and reduces vibration.

Conclusion: Keeping Your Stihl 026 in Top Shape

The Stihl 026 is a legendary chainsaw for a reason. With proper maintenance and these pro fixes, you can keep yours running strong for years to come. Remember, safety is paramount when working with chainsaws. Always wear appropriate safety gear, and don’t hesitate to seek professional help if you’re not comfortable performing any of these repairs yourself.

I hope this guide has been helpful. I’ve poured my years of experience into these tips, and I’m confident that they’ll help you keep your Stihl 026 in top shape. Happy cutting!

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