Stihl 024 AV Chainsaw Restoration (5 Pro Tips For Revival)

The old Stihl 024 AV. It sat in my shed for years, a silent testament to a time when I was felling trees and splitting wood with the vigor of youth. Now, arthritis whispers in my joints, and the chainsaw… well, it just wouldn’t roar back to life. It was a constant reminder of projects unfinished, of winter nights that could be warmer. The cost of a new chainsaw loomed, but sentimentality, mixed with a stubborn streak, kept me from giving up on the 024. I knew deep down it had life left in it. The challenge? To bring it back from the brink without breaking the bank. It was time to roll up my sleeves and dive into a Stihl 024 AV chainsaw restoration.

Let’s be honest, folks. We’re living in a world where convenience often trumps repair. But there’s a deep satisfaction in resurrecting a tool, in understanding its inner workings, and in giving it a second life. And with the rising cost of everything from heating oil to firewood, knowing how to maintain and repair your own equipment is becoming increasingly vital.

The State of the Wood Processing and Firewood Industry

Globally, the firewood industry is a multi-billion dollar market. While renewable energy sources are gaining traction, firewood remains a staple for heating in many regions, particularly in rural areas. In fact, according to a recent report by the Food and Agriculture Organization of the United Nations (FAO), approximately 2.4 billion people worldwide rely on wood for cooking and heating. That’s a staggering statistic!

In North America and Europe, there’s a growing trend towards efficient wood stoves and furnaces, coupled with a greater emphasis on sustainable forestry practices. However, the demand for firewood, especially seasoned hardwood, remains high. The price of firewood fluctuates based on location, wood species, and seasoning level. You might be paying upwards of $300-$400 per cord for seasoned hardwood in some areas.

For small workshops, independent loggers, and even hobbyists, the ability to efficiently process wood is crucial. A well-maintained chainsaw is the cornerstone of this process. But the cost of new equipment can be prohibitive. That’s where restoring an old workhorse like the Stihl 024 AV comes in.

Why Restore a Stihl 024 AV?

The Stihl 024 AV is a legend for a reason. It’s a mid-range chainsaw known for its reliability, power, and relatively simple design. It’s a saw that was built to last, and with a little TLC, it can continue to perform for years to come. Parts are still readily available, making it a viable candidate for restoration.

Stihl 024 AV Chainsaw Restoration: 5 Pro Tips for Revival

This isn’t just about cleaning a bit of sawdust. We’re going to dive deep into the essential checks and repairs to breathe new life into your Stihl 024 AV.

Tip #1: The Fuel System Revival – Clearing the Path to Power

The fuel system is often the culprit behind a chainsaw that refuses to start. Fuel lines deteriorate, carburetors clog, and fuel filters become saturated. Let’s get that fuel flowing again!

Understanding the Fuel System: The fuel system in your Stihl 024 AV is a relatively simple setup. It consists of the fuel tank, fuel filter, fuel lines, carburetor, and the impulse line. The impulse line is a critical component that uses pressure pulses from the engine crankcase to operate the fuel pump within the carburetor.
Step 1: Drain the Old Fuel (Safety First!)
- Always work in a well-ventilated area.
- Place a container under the fuel tank to catch the old fuel.
- Carefully remove the fuel cap and drain the tank.
- Dispose of the old fuel properly at a designated hazardous waste collection site.
Step 2: Inspect and Replace the Fuel Filter
- The fuel filter is located inside the fuel tank, attached to the end of the fuel line.
- Use a small hooked tool (a bent coat hanger works in a pinch) to fish out the fuel line and filter.
- Examine the filter. If it’s dirty, clogged, or deteriorated, replace it.
- Data Point: A clean fuel filter can increase fuel efficiency by up to 10%.
- Replacement fuel filters are inexpensive and readily available online or at your local small engine repair shop.
Step 3: Inspect and Replace the Fuel Lines
- Fuel lines are notorious for cracking and becoming brittle over time.
- Carefully inspect the fuel lines for any signs of damage. Pay close attention to the areas where the lines connect to the fuel tank and carburetor.
- If the lines are cracked, stiff, or show any signs of deterioration, replace them.
- Use fuel line specifically designed for small engines. These lines are typically made of a flexible, fuel-resistant material.
- Technical Requirement: Ensure you use the correct size fuel line for your Stihl 024 AV. Refer to your owner’s manual or a parts diagram for the correct dimensions.
- Actionable Tip: When replacing fuel lines, lubricate the ends with a small amount of two-stroke oil to make them easier to install.
Step 4: Clean or Rebuild the Carburetor
- The carburetor is the heart of the fuel system. It mixes air and fuel in the correct proportions to create a combustible mixture.
- Over time, carburetors can become clogged with varnish and deposits from old fuel.
- Option 1: Cleaning the Carburetor:
  - Remove the carburetor from the chainsaw.
  - Disassemble the carburetor carefully, taking note of the location of each part.
  - Use carburetor cleaner to thoroughly clean all the carburetor components, including the jets, passages, and float bowl.
  - Use compressed air to blow out any remaining debris.
  - Reassemble the carburetor.
- Option 2: Rebuilding the Carburetor:
  - If the carburetor is heavily clogged or damaged, it may be necessary to rebuild it.
  - A carburetor rebuild kit includes all the necessary gaskets, diaphragms, and other parts to restore the carburetor to its original condition.
  - Follow the instructions included with the rebuild kit carefully.
- Unique Insight: I’ve found that soaking the carburetor components in an ultrasonic cleaner with a carburetor cleaning solution for about 30 minutes does wonders for removing stubborn deposits.
- Cost Consideration: Carburetor cleaner typically costs around $10-$15 a can. Carburetor rebuild kits range from $20-$40.
- Troubleshooting: If your chainsaw starts but runs poorly after cleaning or rebuilding the carburetor, double-check the carburetor settings (idle speed and high-speed mixture). Refer to your owner’s manual for the correct settings.
Step 5: Inspect the Impulse Line
- The impulse line is a small rubber hose that connects the carburetor to the engine crankcase. It transmits pressure pulses that operate the fuel pump in the carburetor.
- Inspect the impulse line for cracks, leaks, or deterioration.
- If the impulse line is damaged, replace it.
- Technical Requirement: Use the correct size and type of impulse line for your Stihl 024 AV.

Tip #2: Spark Ignition System Check – Igniting the Fire Within

A weak or non-existent spark is another common reason why a chainsaw won’t start. Let’s make sure the ignition system is firing on all cylinders!

Understanding the Ignition System: The ignition system consists of the spark plug, ignition coil, and flywheel. The flywheel generates electricity as it spins, which is then sent to the ignition coil. The ignition coil amplifies the voltage and sends it to the spark plug, creating a spark that ignites the fuel-air mixture in the cylinder.
Step 1: Remove and Inspect the Spark Plug
- Locate the spark plug on the cylinder head.
- Use a spark plug wrench to remove the spark plug.
- Inspect the spark plug for signs of wear, damage, or fouling.
- Data Point: A healthy spark plug should have a clean, dry electrode and a light tan color.
- If the spark plug is fouled with carbon deposits, clean it with a wire brush or replace it.
- If the spark plug is cracked or damaged, replace it.
- Actionable Tip: Check the spark plug gap using a spark plug gap tool. The correct gap for the Stihl 024 AV is typically around 0.020 inches (0.5 mm).
Step 2: Test for Spark
- Reattach the spark plug wire to the spark plug.
- Ground the spark plug against the engine block.
- Pull the starter cord.
- Observe the spark plug electrode. You should see a strong, blue spark.
- If you don’t see a spark, or if the spark is weak and yellow, the ignition coil may be faulty.
- Safety Precaution: Be careful when testing for spark. Avoid touching the spark plug wire while pulling the starter cord, as this can result in an electric shock.
Step 3: Inspect the Ignition Coil
- The ignition coil is responsible for generating the high voltage needed to create a spark.
- Inspect the ignition coil for cracks, damage, or corrosion.
- If the ignition coil is damaged, replace it.
- Technical Requirement: When replacing the ignition coil, ensure the air gap between the ignition coil and the flywheel is correct. Refer to your owner’s manual for the correct specification.
- Unique Insight: I’ve used a business card folded in half as a makeshift air gap tool in a pinch. It’s not ideal, but it can get you close enough to start the engine.
Step 4: Check the Flywheel Key
- The flywheel key is a small metal key that aligns the flywheel with the crankshaft.
- If the flywheel key is sheared or damaged, the timing of the engine will be off, and the chainsaw won’t start.
- Remove the flywheel and inspect the flywheel key.
- If the flywheel key is damaged, replace it.
- Troubleshooting: If you’re still not getting a spark after replacing the spark plug and ignition coil, the problem may be with the wiring or the kill switch. Check the wiring for any breaks or shorts. Test the kill switch to make sure it’s not grounding out the ignition system.

Tip #3: Compression Check – The Heartbeat of the Engine

Low compression means the engine can’t properly compress the fuel-air mixture, resulting in a lack of power or a no-start condition.

Understanding Compression: Compression is the pressure created inside the cylinder when the piston moves up and down. This pressure is essential for igniting the fuel-air mixture and generating power.
Step 1: Perform a Compression Test
- A compression test will tell you whether the engine is able to generate sufficient compression.
- Remove the spark plug.
- Screw a compression tester into the spark plug hole.
- Pull the starter cord several times.
- Observe the reading on the compression tester.
- Data Point: A healthy Stihl 024 AV should have a compression reading of at least 120 PSI (pounds per square inch). Anything below 100 PSI indicates a problem.
- Actionable Tip: Perform the compression test with the throttle wide open for the most accurate reading.
Step 2: Interpreting the Results
- Low Compression: If the compression reading is low, there are several possible causes:
  - Worn Piston Rings: Piston rings seal the gap between the piston and the cylinder wall. Over time, they can wear down, allowing compression to leak past.
  - Worn Cylinder: The cylinder wall can also wear down over time, reducing compression.
  - Leaking Valves: The valves seal the combustion chamber. If the valves are worn or damaged, they may not seal properly, allowing compression to leak past.
  - Damaged Cylinder Head Gasket: The cylinder head gasket seals the cylinder head to the cylinder. If the gasket is damaged, it can leak compression.
- Troubleshooting:
  - If you suspect a leaking cylinder head gasket, inspect the gasket for signs of damage.
  - If you suspect worn piston rings or a worn cylinder, you may need to remove the cylinder head and inspect the piston and cylinder. This is a more involved repair that may require specialized tools.
  - If you suspect leaking valves, you may need to have the cylinder head professionally serviced.
Step 3: The Oil Test (The Poor Man’s Compression Check)
- If you don’t have a compression tester, you can try this old trick:
  - Remove the spark plug.
  - Squirt a small amount of two-stroke oil into the cylinder.
  - Pull the starter cord several times to distribute the oil.
  - Reinstall the spark plug.
  - Try starting the chainsaw.
  - If the chainsaw starts or runs better than before, it’s likely that the piston rings are worn. The oil temporarily seals the gap between the piston and the cylinder wall, improving compression.
  - Limitation: This test is not as accurate as a compression test, but it can give you a general idea of the engine’s condition.

Tip #4: Sharpening and Replacing the Chain – The Cutting Edge

A dull chain is not only inefficient but also dangerous. It puts unnecessary strain on the engine and can lead to kickback.

Understanding Chain Types: Chains come in various pitches (the distance between rivets) and gauges (the thickness of the drive links). The Stihl 024 AV typically uses a 0.325″ pitch chain with a 0.063″ gauge. Using the wrong chain can damage the sprocket and the bar.
Step 1: Sharpening the Chain
- A sharp chain makes all the difference in cutting performance.
- You can sharpen the chain using a chainsaw file, a chainsaw sharpener, or a professional sharpening service.
- Using a Chainsaw File:
  - Use a round file of the correct size for your chain. The file size is typically stamped on the chain.
  - Use a file guide to maintain the correct filing angle.
  - File each cutter tooth evenly, taking care to maintain the original shape and angle.
  - Actionable Tip: Keep the file clean and sharp. A dull file will only make the job harder.
- Using a Chainsaw Sharpener:
  - A chainsaw sharpener can make sharpening the chain faster and easier.
  - Follow the instructions included with the sharpener carefully.
  - Cost Consideration: Chainsaw sharpeners range in price from $50 to $200 or more.
- Unique Insight: I like to use a depth gauge tool to ensure the rakers (the small teeth in front of the cutter teeth) are properly set. If the rakers are too high, the chain won’t cut effectively. If they’re too low, the chain will be aggressive and prone to kickback.
Step 2: Replacing the Chain
- If the chain is heavily worn, damaged, or has broken teeth, it’s time to replace it.
- Choose a chain that is the correct pitch, gauge, and length for your chainsaw and bar.
- Install the chain on the bar, making sure the cutters are facing in the correct direction.
- Adjust the chain tension so that it is snug but can still be pulled around the bar by hand.
- Technical Requirement: The chain tension should be checked and adjusted regularly, especially when the chain is new.
Step 3: Inspecting and Maintaining the Bar
- The bar is the metal blade that guides the chain.
- Inspect the bar for wear, damage, or burrs.
- If the bar is worn or damaged, it can cause the chain to derail or wear unevenly.
- Use a bar dresser to remove any burrs or sharp edges from the bar.
- Flip the bar over periodically to ensure even wear.
- Lubricate the bar regularly with bar and chain oil.
- Data Point: Proper bar and chain lubrication can extend the life of the bar and chain by up to 50%.
- Actionable Tip: Clean the bar groove regularly to remove sawdust and debris. This will help to keep the chain running smoothly.

Tip #5: Air Filter and General Maintenance – Breathing Easy, Running Smoothly

A clean air filter is essential for proper engine performance. Clogged air filter restricts airflow, causing the engine to run rich and lose power.

Understanding Air Filtration: The air filter prevents dust and debris from entering the engine. A clean air filter ensures that the engine receives the proper amount of air for combustion.
Step 1: Remove and Inspect the Air Filter
- Locate the air filter housing on the chainsaw.
- Remove the air filter cover and remove the air filter.
- Inspect the air filter for dirt, debris, or damage.
- Data Point: A clogged air filter can reduce engine power by up to 20%.
Step 2: Cleaning the Air Filter
- If the air filter is dirty, clean it with compressed air or warm soapy water.
- If you use soapy water, rinse the air filter thoroughly and allow it to dry completely before reinstalling it.
- Actionable Tip: Tap the air filter against a hard surface to remove loose debris.
Step 3: Replacing the Air Filter
- If the air filter is damaged or cannot be cleaned effectively, replace it.
- Choose an air filter that is specifically designed for your Stihl 024 AV.
- Install the air filter in the air filter housing and reinstall the air filter cover.
Step 4: General Maintenance Checklist
- Check and Tighten All Screws and Bolts: Vibration can cause screws and bolts to loosen over time.
- Inspect the Starter Cord and Recoil Spring: Replace the starter cord if it is frayed or damaged. Replace the recoil spring if it is weak or broken.
- Clean the Cooling Fins: The cooling fins on the cylinder head help to dissipate heat. Keep them clean to prevent the engine from overheating.
- Lubricate the Sprocket Bearing: The sprocket bearing supports the drive sprocket. Lubricate it regularly with grease.
- Check the Anti-Vibration System: The Stihl 024 AV is equipped with an anti-vibration system to reduce operator fatigue. Inspect the rubber mounts and springs for damage. Replace them if necessary.
- Store the Chainsaw Properly: When storing the chainsaw for extended periods, drain the fuel tank and run the engine until it stalls. This will prevent the fuel from gumming up the carburetor. Store the chainsaw in a dry place.
- Idiom Alert: “An ounce of prevention is worth a pound of cure.” Regular maintenance can prevent costly repairs down the road.

Case Study: Reviving a Neglected Stihl 024 AV

I once helped a friend restore a Stihl 024 AV that had been sitting in his barn for over a decade. The saw was in rough shape, with a heavily rusted chain, a clogged carburetor, and a seized piston. We followed the steps outlined above, spending several hours cleaning, repairing, and replacing parts. The most challenging part was freeing the seized piston. We used a penetrating oil and a rubber mallet to gently tap the piston until it finally broke free. After reassembling the engine and tuning the carburetor, the saw roared back to life. My friend was amazed at how well the saw performed, considering its age and condition. He now uses it regularly to cut firewood and clear brush on his property. The total cost of the restoration was around $100, far less than the cost of a new chainsaw.

Costs, Budgeting, and Resource Management

Restoring a chainsaw can be a cost-effective way to save money and extend the life of your equipment. However, it’s important to budget carefully and manage your resources effectively.

Parts Costs: The cost of parts will vary depending on the extent of the repairs needed. Fuel filters, spark plugs, and air filters are relatively inexpensive. Carburetor rebuild kits, ignition coils, and piston rings can be more expensive.
Tool Costs: You may need to purchase some specialized tools, such as a compression tester, a spark plug wrench, and a chainsaw file.
Time Costs: Restoring a chainsaw can take several hours, depending on your skill level and the complexity of the repairs.
Resource Management Tips:
- Shop Around for Parts: Compare prices from different suppliers to find the best deals.
- Reuse Parts Whenever Possible: If a part is still in good condition, clean it and reuse it instead of replacing it.
- Borrow Tools: If you don’t have a particular tool, ask a friend or neighbor if you can borrow it.
- Do Your Research: Before starting any repairs, research the problem and the best way to fix it. There are many online resources available, including forums, videos, and parts diagrams.
- Don’t Be Afraid to Ask for Help: If you get stuck, don’t be afraid to ask for help from a friend, a mechanic, or an online forum.
- Strategic Recommendation: Prioritize repairs based on their impact on performance. Focus on the fuel system, ignition system, and compression first.

Common Pitfalls to Avoid

Using the Wrong Parts: Always use parts that are specifically designed for your Stihl 024 AV. Using the wrong parts can damage the chainsaw or reduce its performance.
Over-Tightening Screws and Bolts: Over-tightening screws and bolts can strip the threads or damage the parts.
Neglecting Safety Precautions: Always wear safety glasses, gloves, and hearing protection when working on a chainsaw.
Trying to Do Too Much at Once: Break the restoration process down into smaller steps. This will make the job less overwhelming and reduce the risk of making mistakes.
Giving Up Too Easily: Restoring a chainsaw can be challenging, but don’t give up too easily. With patience and persistence, you can often bring an old chainsaw back to life.

Next Steps and Additional Resources

Congratulations! You’ve taken the first steps towards restoring your Stihl 024 AV. Here are some next steps and additional resources to help you complete the project:

Review Your Owner’s Manual: The owner’s manual contains valuable information about the chainsaw, including maintenance procedures, troubleshooting tips, and parts diagrams.
Visit Your Local Small Engine Repair Shop: If you’re not comfortable performing the repairs yourself, take the chainsaw to a local small engine repair shop.
Search Online Forums and Videos: There are many online resources available to help you restore your chainsaw. Search for forums and videos specific to the Stihl 024 AV.
Find Parts Suppliers:
- Stihl Dealers: Your local Stihl dealer is the best source for genuine Stihl parts.
- Online Retailers: Many online retailers sell chainsaw parts, including Amazon, eBay, and specialty chainsaw parts websites.
- Used Parts: Consider purchasing used parts from a salvage yard or online marketplace.
Consider Tool Rental: For specialized tools you may only need once, consider renting from tool rental services.

Conclusion

Restoring a Stihl 024 AV chainsaw is a rewarding experience. It’s a chance to learn about the inner workings of a powerful machine, to save money on equipment costs, and to give a second life to a valuable tool. It’s also a testament to the enduring quality of older machines. While modern chainsaws offer advanced features, there’s something special about the simplicity and reliability of a classic like the Stihl 024 AV. So, grab your tools, roll up your sleeves, and get ready to breathe new life into your trusty chainsaw. You might just surprise yourself with what you can achieve. And who knows, you might even save a few trees – and a few dollars – along the way. Remember, a little elbow grease can go a long way!