Stihl 024 AV Carburetor (Removal Steps)
To remove the carburetor, work on a cold, clean Stihl 024 AV with the chain brake on and spark-plug boot disconnected. Photograph the hoses and linkages, then disconnect them by their routing, remove the mounting fasteners, and lift the carburetor straight off. Confirm your exact saw and carburetor before ordering parts or using adjustment data.
A saw that will not start can make carburetor removal feel like the next obvious move. But the 024 AV came in different versions, and carburetors may have been changed during past repairs. A careful check before disassembly can save you from buying the wrong parts or creating a fuel or air leak.
I treat removal as a record-and-replace job, not a chance to guess at hose positions. Take clear photos before touching the connections. That small step matters: a line or linkage put back in the wrong place can cause poor running, a dangerous open throttle, or a lean condition that may damage the engine.
Equipment Identification and Safety Preparation
Identification means confirming which 024 you have and reading the markings on the carburetor itself. Safety preparation means removing ignition and fire risks before opening the fuel and intake areas. These checks help you avoid applying specifications from a different saw or carburetor.
The standard Stihl 024 has a 40.2 cm³ engine. The 024 Super is a different version, so do not rely on a badge or a carburetor part listed for “024” alone. Check the saw’s identification and compare the installed carburetor’s stamped maker and model with the correct parts information.
Carburetors can differ by production version or replacement history. The model stamped on the carburetor is more useful than the saw name when checking parts or service data. Do not assume that a carburetor adjustment speed or fastener torque is universal across every 024 AV.
Before starting:
- Work outdoors or in a well-ventilated service area.
- Let the engine cool fully. Engage the chain brake.
- Remove the spark-plug boot so the engine cannot start by accident.
- Clean dirt and sawdust from the top of the saw before opening it.
- Keep flames, sparks, smoking materials, and other ignition sources away from fuel.
- Have a phone or camera ready to record the linkage and line routing.
Set the saw on a stable work surface. If the fuel tank cap or nearby parts are wet with fuel, stop and clean the area before continuing. Keep the removed parts together so small fasteners do not get lost.
Carburetor Access and Removal
Access is the process of opening only the areas needed to reach the carburetor. On the 024 AV, the exact layout can depend on the saw’s version and parts fitted to it. Use the saw and carburetor layout in front of you; do not force parts to match a diagram for another version.
-
Remove the top cover. Follow the fastener layout on your saw. Lift the cover without pulling on any wires or hoses that may run near it.
-
Remove the air filter. Note how it sits and how its fasteners attach. Brush or wipe away loose dirt around the opening before it can fall into the intake.
-
Photograph the setup. Take close, well-lit photos of the carburetor, the throttle and choke linkages, and every hose connection. Include a wider photo that shows how those parts sit in relation to the air-filter housing.
-
Expose the carburetor as needed. Remove the air-filter housing or related pieces only if they block access. Keep track of their orientation. Avoid pulling, twisting, or stretching the intake boot, which joins the carburetor area to the engine.
-
Identify each connection before disconnecting it. Trace fuel and impulse lines to their actual connections. The impulse line carries pressure pulses used by the fuel pump in the carburetor. Do not identify a line by color or position alone.
-
Disconnect linkages and lines carefully. Note which linkage operates the throttle and which operates the choke. Ease each connection free without pulling on the hose. Do not use a screwdriver as a lever against a hose or linkage.
-
Remove the carburetor fasteners. Keep each fastener in a labeled tray or a small container. Once the fasteners are out, lift the carburetor straight away from its mounting surface. Do not pry against the intake boot or bend the throttle shaft.
If a hose feels stuck, pause and inspect the connection. Pulling hard can damage the hose or fitting, and the damage may not be easy to spot later. If the carburetor does not lift freely after its fasteners are removed, check for a connection or retaining part you have missed.
| What you find | What to do before continuing |
|---|---|
| Carburetor model marking | Record it; use it to check parts and service information |
| Unclear hose routing | Take more photos and trace each hose to its other end |
| Cracked or hardened hose | Do not assume it will seal after refitting |
| Carburetor still held in place | Check for an overlooked fastener or connection; do not pry |
| Different layout from a parts diagram | Confirm the saw version and carburetor before ordering |
Reinstallation, Linkage Check, and Functional Test
Reinstallation means returning the carburetor, hoses, and linkages to their original positions and checking that they seal and move correctly. A clean-looking assembly is not enough. Confirm each connection against your photos and the correct service diagram before reconnecting the spark-plug boot or attempting to start the saw.
Inspect these parts while the carburetor is off:
- Intake boot: Look for cracks, splits, looseness, or hard areas.
- Fuel and impulse lines: Check for damage, loose fits, hardening, or signs of a leak.
- Grommets and mounting surfaces: Look for damage that could prevent a proper fit or seal.
- Linkages: Check for bends, wear, and free movement.
A leak at the intake or a misplaced fuel or impulse line can make the engine run lean. A lean-running two-stroke may overheat and suffer serious engine damage. A linkage fitted incorrectly can also stop the throttle from returning fully, so do not treat either check as optional.
Refit the carburetor in its original orientation. Start the mounting fasteners by hand and use the correct service data for tightening them; do not guess at a torque value. Reconnect each line and linkage by comparing it with your photos and the service diagram for your exact setup. Then reinstall the air-filter assembly, filter, and covers.
Before reconnecting the spark-plug boot:
- Move the throttle control through its normal travel.
- Confirm that the throttle linkage moves freely and returns to its closed position.
- Check that the choke linkage moves as intended.
- Look again at every hose connection and confirm that none is pinched or partly detached.
- Confirm that the air filter, covers, and carburetor connections are properly installed.
Do not start or tune the saw with the air filter, covers, or carburetor connections improperly installed. If routing or sealing remains uncertain, stop and use the correct service diagram or ask a qualified technician to verify the assembly.
Workbench scenarios
These examples show how I apply the checks; they are not reports of a specific repair.
- A replacement carburetor does not match the old one: I compare the stamped carburetor identification and the intake layout before fitting it. If the connections or linkages differ, I stop and confirm compatibility rather than forcing a hose or changing the adjustment to make it run.
- A saw still has a no-start problem after removal and refitting: I check the fuel and impulse connections, intake boot, and throttle return first. I do not assume the carburetor itself is faulty just because it was removed, and I do not use adjustment screws to mask a possible air leak.
Maintenance, Fuel-System Checks, and Storage
Maintenance after removal means restoring the saw with the correct fuel, clean air filtration, and sealed connections. The 024 AV is a two-stroke saw, so fuel must be mixed according to the correct saw manual and the oil maker’s instructions. Do not copy a ratio from another model or oil product.
Before a first start after refitting, confirm that the tank contains the specified fuel mixture and that the air filter is installed and seated. Check the service information for the exact carburetor before adjusting it. There is no safe universal adjustment RPM or fastener torque that can be inferred from “024 AV” alone.
If the saw still will not start after correct reassembly, avoid repeated adjustment changes. Recheck the line routing, intake boot, and linkage. A carburetor removal cannot by itself prove that the original fault was in the carburetor; a separate ignition, fuel-supply, or engine condition may remain.
For storage, follow the instructions in the correct saw manual and the fuel-product label. Keep the saw away from ignition sources and deal with fuel only in a well-ventilated area. If fuel has leaked, find and correct the cause before starting the engine.
Conclusion and FAQ
The safest carburetor removal is controlled and reversible: identify the saw and carburetor, record every connection, lift the carburetor without prying, and verify the intake and linkages before starting. If a fitting, seal, or adjustment specification is uncertain, pause and check the service information for the parts actually installed.
Does every Stihl 024 AV use the same carburetor?
No. Production versions and past replacements can change the installed carburetor. Read the identification stamped on the carburetor and compare it with the correct parts information before ordering parts or applying adjustment data.
How do I tell a standard 024 from an 024 Super?
Check the saw’s identification and the correct model-specific parts or service information. The standard 024 has a 40.2 cm³ engine, while the Super is a different version. Do not use a carburetor listing for one version without confirming it fits yours.
Should I drain the fuel before removing the carburetor?
Work with the engine cold, in a ventilated area, and keep ignition sources away. If fuel is present near the work area or leaks during service, stop and clean it up safely. Follow the saw manual for fuel handling and storage.
Can I remove the carburetor without removing the air-filter housing?
That depends on the layout and access on your saw. Remove related parts only as needed. Do not force the carburetor past the housing or strain the intake boot, hoses, or linkages to avoid removing another part.
How can I tell which hose is the impulse line?
Trace each hose to its connection and compare the routing with the correct service diagram. Do not identify hoses by color or position alone. If the routing is unclear, do not reconnect by guesswork or start the saw.
Can I pull a stuck fuel hose off with pliers?
Do not pull on the hose or lever it off with a screwdriver. That can damage the hose or fitting and create a leak. Inspect the connection and use the correct service method for the installed parts.
What should I check before starting after refitting?
Confirm the hoses and linkages match your photos and service diagram. Check that the intake boot is sound, the air filter and covers are installed, and the throttle moves freely and returns to its closed position.
What if the saw still will not start after carburetor removal?
First recheck hose routing, sealing, and linkage movement. Removing the carburetor does not prove it caused the no-start. Do not change adjustment settings to cover a possible intake leak; use the correct service data to continue diagnosis.
(This article was written by one of our staff writers, Robert Callahan. Visit our Meet the Team page.)
