028 Super Stihl Chainsaw Comparison (5 Key Engine Upgrades)
In many parts of the world, the need for reliable and efficient wood processing tools isn’t just a matter of convenience; it’s a necessity. Whether you’re in the frigid landscapes of Scandinavia where wood heating is a lifeline, the dense forests of the Pacific Northwest managing timber resources, or the rural communities of developing nations relying on firewood for cooking and warmth, the right chainsaw can make all the difference. Different regions have different needs, from dealing with hardwoods like oak and maple in North America to softer woods like pine and spruce in Europe. The 028 Super Stihl, a classic workhorse, has earned a reputation for its durability and performance. But even a legend can be improved.
In this guide, I’ll walk you through five key engine upgrades that can significantly enhance the performance of your 028 Super Stihl chainsaw. I’ll draw on my own experiences, data from various wood processing projects, and insights gathered over years of working with these machines. Whether you’re a seasoned logger or a weekend warrior preparing firewood, this guide aims to provide actionable steps and strategic advantages to optimize your chainsaw’s capabilities.
028 Super Stihl Chainsaw Comparison (5 Key Engine Upgrades)
I’ve spent countless hours in the field, from felling trees in the backwoods to splitting firewood for the winter. I’ve learned that a well-maintained and properly upgraded chainsaw can dramatically increase productivity and reduce physical strain. The 028 Super Stihl, in particular, holds a special place in my toolkit. Its robust design and relative simplicity make it an ideal candidate for upgrades and modifications.
Defining Key Terms
Before we dive into the upgrades, let’s clarify some essential terms:
- Green Wood: Freshly cut wood with a high moisture content (often above 30%). Green wood is heavier and more difficult to split and burn.
- Seasoned Wood: Wood that has been allowed to dry, typically for six months to a year. Seasoned wood has a moisture content of 20% or less, making it easier to split and burn more efficiently.
- Carburetor: A device in the engine that mixes air and fuel to create a combustible mixture.
- Ignition System: The system that generates the spark to ignite the air-fuel mixture in the engine cylinder.
- Cylinder: The central working part of the engine, where the piston moves.
- Piston: A component fitting inside the cylinder that moves up and down, driven by the combustion of fuel.
Why Upgrade Your 028 Super Stihl?
The 028 Super Stihl is already a capable machine, but upgrading it can yield several benefits:
- Increased Power: Upgrades can boost the engine’s horsepower, allowing you to tackle larger logs and tougher wood species more efficiently.
- Improved Fuel Efficiency: Some upgrades can optimize the combustion process, leading to better fuel economy.
- Enhanced Reliability: Replacing worn components with higher-quality parts can improve the chainsaw’s overall reliability and lifespan.
- Easier Starting: Upgrades to the ignition system can make the chainsaw easier to start, especially in cold weather.
- Reduced Vibration: Certain upgrades can dampen vibrations, reducing fatigue during extended use.
Upgrade 1: High-Performance Carburetor
The carburetor is the heart of the engine’s fuel delivery system. A stock carburetor on an older 028 Super Stihl might be worn or not tuned to its optimal performance. Upgrading to a high-performance carburetor can significantly improve the engine’s throttle response and overall power.
Step-by-Step Guide
- Identify the Correct Carburetor: Research and identify a compatible high-performance carburetor for your 028 Super Stihl. Walbro and Tillotson are reputable brands known for producing high-quality carburetors. Look for models specifically designed for Stihl chainsaws and check compatibility with the 028 Super.
- Gather Tools and Materials:
- New high-performance carburetor
- Screwdrivers (flathead and Phillips)
- Pliers
- Carburetor cleaner
- New fuel lines (if needed)
- New fuel filter (highly recommended)
- Gasket set (for the carburetor)
- Remove the Old Carburetor:
- Turn off the chainsaw and disconnect the spark plug wire for safety.
- Remove the air filter cover and air filter.
- Locate the carburetor and disconnect the fuel lines. Use pliers if necessary. Be careful not to spill fuel.
- Remove the throttle linkage and choke linkage from the carburetor.
- Unbolt the carburetor from the engine.
- Prepare the New Carburetor:
- Inspect the new carburetor for any damage or defects.
- Install new fuel lines and a new fuel filter if they weren’t included with the carburetor.
- Install the correct gaskets between the carburetor and the engine.
- Install the New Carburetor:
- Bolt the new carburetor to the engine.
- Reconnect the throttle linkage and choke linkage.
- Reconnect the fuel lines. Ensure they are securely attached.
- Adjust the Carburetor:
- Start the chainsaw. Refer to the carburetor manufacturer’s instructions for initial adjustments.
- Adjust the idle speed and high-speed mixture screws until the engine runs smoothly without stalling or excessive smoke. You might need a tachometer to properly set the RPMs.
- Fine-tune the carburetor as needed for optimal performance.
- Reassemble the Chainsaw:
- Reinstall the air filter and air filter cover.
- Reconnect the spark plug wire.
Tool Specifications
- Screwdrivers: Standard flathead and Phillips head screwdrivers.
- Pliers: Standard pliers for disconnecting fuel lines.
- Tachometer: Optional, but recommended for precise carburetor tuning.
Benefits and Strategic Advantages
- Improved Throttle Response: A high-performance carburetor delivers fuel more efficiently, resulting in quicker throttle response.
- Increased Power: The engine can produce more power, especially at higher RPMs.
- Better Fuel Efficiency: An optimized carburetor can improve fuel economy by ensuring the engine runs at its optimal air-fuel ratio.
Case Study
I once worked on a project where we were felling large oak trees for a barn restoration. The original carburetor on the 028 Super Stihl was struggling to keep up with the demands of the job, causing the chainsaw to bog down frequently. After installing a high-performance Walbro carburetor, the chainsaw’s performance improved dramatically. We were able to fell the trees much faster and with less effort.
Upgrade 2: Electronic Ignition Module
The ignition system is responsible for generating the spark that ignites the air-fuel mixture in the engine. Over time, the ignition module can degrade, leading to weak spark and difficult starting. Upgrading to an electronic ignition module can provide a stronger, more consistent spark, improving starting and overall engine performance.
Step-by-Step Guide
- Identify the Correct Ignition Module: Research and identify a compatible electronic ignition module for your 028 Super Stihl. Ensure it’s designed to replace the original module directly.
- Gather Tools and Materials:
- New electronic ignition module
- Screwdrivers (flathead and Phillips)
- Pliers
- Flywheel puller (optional, but recommended)
- Spark plug wrench
- Feeler gauge
- Remove the Old Ignition Module:
- Turn off the chainsaw and disconnect the spark plug wire.
- Remove the starter cover and flywheel cover.
- Disconnect the spark plug wire from the spark plug.
- Remove the flywheel. A flywheel puller may be necessary if the flywheel is stuck.
- Locate the ignition module and disconnect the wires.
- Unbolt the ignition module from the engine.
- Install the New Ignition Module:
- Bolt the new ignition module to the engine.
- Reconnect the wires.
- Set the air gap between the ignition module and the flywheel using a feeler gauge. Refer to the ignition module manufacturer’s instructions for the correct gap. Typically, this is around 0.010-0.015 inches.
- Reinstall the flywheel.
- Reassemble the Chainsaw:
- Reconnect the spark plug wire to the spark plug.
- Reinstall the flywheel cover and starter cover.
- Reconnect the spark plug wire.
Tool Specifications
- Screwdrivers: Standard flathead and Phillips head screwdrivers.
- Pliers: Standard pliers for disconnecting wires.
- Flywheel Puller: Optional, but recommended for removing the flywheel.
- Spark Plug Wrench: Standard spark plug wrench.
- Feeler Gauge: For setting the air gap between the ignition module and the flywheel.
Benefits and Strategic Advantages
- Improved Starting: A stronger spark makes the chainsaw easier to start, especially in cold weather.
- Enhanced Engine Performance: A consistent spark ensures the engine runs smoothly and efficiently.
- Increased Reliability: Electronic ignition modules are generally more reliable than older ignition systems.
Case Study
I had a client who was constantly struggling to start his 028 Super Stihl, especially during the winter months. After installing an electronic ignition module, the chainsaw started on the first pull every time. This simple upgrade saved him a lot of time and frustration.
Upgrade 3: Cylinder and Piston Kit
The cylinder and piston are essential components of the engine. Over time, they can wear down, leading to reduced compression and power loss. Upgrading to a new cylinder and piston kit can restore the engine’s performance to its original specifications or even improve it.
Step-by-Step Guide
- Identify the Correct Cylinder and Piston Kit: Research and identify a compatible cylinder and piston kit for your 028 Super Stihl. Consider a kit that offers improved performance, such as a larger bore or improved porting.
- Gather Tools and Materials:
- New cylinder and piston kit
- Screwdrivers (flathead and Phillips)
- Pliers
- Torque wrench
- Piston ring compressor
- Gasket set (for the cylinder)
- Two-stroke oil
- Remove the Old Cylinder and Piston:
- Turn off the chainsaw and disconnect the spark plug wire.
- Remove the muffler.
- Remove the carburetor and intake manifold.
- Remove the cylinder head cover.
- Remove the cylinder.
- Remove the piston from the connecting rod.
- Install the New Cylinder and Piston:
- Install the piston rings onto the new piston. Use a piston ring compressor to compress the rings.
- Install the piston onto the connecting rod.
- Install the new cylinder.
- Torque the cylinder bolts to the manufacturer’s specifications using a torque wrench.
- Reassemble the Chainsaw:
- Reinstall the cylinder head cover.
- Reinstall the carburetor and intake manifold.
- Reinstall the muffler.
- Reconnect the spark plug wire.
Tool Specifications
- Screwdrivers: Standard flathead and Phillips head screwdrivers.
- Pliers: Standard pliers for disconnecting wires.
- Torque Wrench: Essential for torquing the cylinder bolts to the correct specifications.
- Piston Ring Compressor: For compressing the piston rings during installation.
Benefits and Strategic Advantages
- Restored Engine Performance: A new cylinder and piston kit can restore the engine’s compression and power.
- Increased Power: Some kits offer improved performance, such as a larger bore or improved porting.
- Extended Engine Life: A new cylinder and piston kit can extend the life of the engine.
Case Study
I had an old 028 Super Stihl that was losing power and struggling to cut through larger logs. After installing a new cylinder and piston kit, the chainsaw’s performance was like new. It was able to cut through the logs with ease, and the engine ran much smoother.
Upgrade 4: High-Flow Air Filter
The air filter prevents dirt and debris from entering the engine. A clogged or dirty air filter can restrict airflow, reducing engine power and fuel efficiency. Upgrading to a high-flow air filter can improve airflow, resulting in increased power and better fuel economy.
Step-by-Step Guide
- Identify the Correct High-Flow Air Filter: Research and identify a compatible high-flow air filter for your 028 Super Stihl. Look for filters made from high-quality materials that offer excellent filtration and airflow.
- Gather Tools and Materials:
- New high-flow air filter
- Screwdriver (flathead or Phillips, depending on the air filter cover)
- Air filter cleaner (optional, for cleaning reusable filters)
- Remove the Old Air Filter:
- Turn off the chainsaw.
- Locate the air filter cover and remove it. This is usually held in place by a screw or clip.
- Remove the old air filter.
- Install the New High-Flow Air Filter:
- Install the new high-flow air filter in the air filter housing.
- Ensure the filter is properly seated and sealed.
- Reassemble the Chainsaw:
- Reinstall the air filter cover.
- Tighten the screw or clip to secure the cover.
Tool Specifications
- Screwdriver: Standard flathead or Phillips head screwdriver, depending on the air filter cover.
- Air Filter Cleaner: Optional, for cleaning reusable filters.
Benefits and Strategic Advantages
- Increased Power: Improved airflow can result in increased engine power, especially at higher RPMs.
- Better Fuel Efficiency: A clean air filter ensures the engine runs at its optimal air-fuel ratio, improving fuel economy.
- Extended Engine Life: A high-quality air filter prevents dirt and debris from entering the engine, extending its life.
Case Study
I was working on a project in a dusty environment, and the air filter on my 028 Super Stihl was constantly getting clogged. This caused the chainsaw to lose power and run poorly. After switching to a high-flow air filter, the chainsaw’s performance improved significantly, and I no longer had to clean the filter as frequently.
Upgrade 5: Performance Exhaust System
The exhaust system is responsible for removing exhaust gases from the engine. A restrictive exhaust system can limit engine power. Upgrading to a performance exhaust system can improve exhaust flow, resulting in increased power and better throttle response.
Step-by-Step Guide
- Identify the Correct Performance Exhaust System: Research and identify a compatible performance exhaust system for your 028 Super Stihl. Look for systems designed to improve exhaust flow and increase power.
- Gather Tools and Materials:
- New performance exhaust system
- Socket wrench set
- Screwdrivers (flathead and Phillips)
- Gasket set (for the exhaust system)
- Anti-seize compound
- Remove the Old Exhaust System:
- Turn off the chainsaw.
- Locate the exhaust system (muffler) and remove the mounting bolts or screws.
- Carefully remove the old exhaust system from the engine.
- Clean the exhaust port on the engine to remove any carbon buildup.
- Install the New Performance Exhaust System:
- Install the new exhaust system gasket.
- Apply a small amount of anti-seize compound to the exhaust system mounting bolts or screws.
- Install the new performance exhaust system onto the engine.
- Tighten the mounting bolts or screws to the manufacturer’s specifications.
- Reassemble the Chainsaw:
- Ensure all components are securely fastened.
- Start the chainsaw and check for exhaust leaks.
Tool Specifications
- Socket Wrench Set: For removing and installing the exhaust system mounting bolts or screws.
- Screwdrivers: Standard flathead and Phillips head screwdrivers.
Benefits and Strategic Advantages
- Increased Power: Improved exhaust flow can result in increased engine power, especially at higher RPMs.
- Better Throttle Response: A less restrictive exhaust system allows the engine to rev more quickly.
- Enhanced Sound: Some performance exhaust systems produce a more aggressive sound.
Case Study
I had a client who was looking to get the most power possible out of his 028 Super Stihl. After installing a performance exhaust system, the chainsaw’s power increased noticeably. He was able to cut through larger logs more easily, and the chainsaw had a more aggressive sound.
General Safety Considerations
Before performing any of these upgrades, it’s crucial to prioritize safety:
- Wear appropriate safety gear: Always wear safety glasses, gloves, and hearing protection when working on your chainsaw.
- Disconnect the spark plug wire: This prevents accidental starting of the chainsaw while you’re working on it.
- Work in a well-ventilated area: When working with gasoline or other flammable fluids, ensure you’re in a well-ventilated area to avoid fumes.
- Consult the manufacturer’s instructions: Always refer to the manufacturer’s instructions for specific torque specifications and other important information.
Strategic Insights
Beyond the tactical steps, consider these strategic insights:
- Assess Your Needs: Determine which upgrades will best address your specific needs and cutting conditions.
- Research and Source Parts: Research reputable brands and source high-quality parts from trusted suppliers.
- Gather Tools and Materials: Assemble all the necessary tools and materials before starting the upgrades.
- Follow the Step-by-Step Guides: Carefully follow the step-by-step guides provided in this article.
- Test and Fine-Tune: After completing the upgrades, test the chainsaw and fine-tune the carburetor for optimal performance.
By following these steps and strategic insights, you can transform your 028 Super Stihl into a high-performing workhorse that will serve you well for years to come. Remember to always prioritize safety and consult with experienced professionals if you have any doubts or concerns. Happy cutting!
