Stihl 028 Super Chainsaw: Key Part Upgrades (5 Expert Tips)

Introduction: Taming the Roar – Noise Reduction in Chainsaw Operation

I’ve spent countless hours in the woods, the scent of freshly cut wood a constant companion. But the roar of a chainsaw, while a symbol of productivity, can be deafening and detrimental to long-term hearing. Before we dive into upgrading the legendary Stihl 028 Super, let’s address a crucial aspect often overlooked: noise reduction. A quieter saw isn’t just about comfort; it’s about protecting your health and fostering a more pleasant working environment. While the 028 Super isn’t known for being whisper-quiet, there are steps we can take to mitigate its noise output. This includes ensuring the chain is properly sharpened, the muffler is in good condition, and, most importantly, wearing proper hearing protection. I always recommend investing in high-quality ear muffs with a noise reduction rating (NRR) of at least 25 dB. This simple step can make a world of difference. Now, let’s get to the heart of the matter: upgrading your Stihl 028 Super to enhance its performance and longevity.

Stihl 028 Super Chainsaw: Key Part Upgrades (5 Expert Tips)

The Stihl 028 Super. A workhorse of a chainsaw. I’ve seen these saws, some dating back decades, still felling trees and bucking firewood with impressive power. But like any machine, time and use take their toll. Fortunately, the 028 Super is a relatively simple saw to work on, and a few key upgrades can significantly improve its performance, reliability, and overall lifespan. In this guide, I’ll share five expert tips, drawing on my years of experience, to help you breathe new life into your 028 Super.

1. Ignition System Upgrade: From Points to Electronic

One of the most impactful upgrades you can make to your Stihl 028 Super is converting the ignition system from the original points-based system to a modern electronic ignition module.

Why Upgrade?

• Improved Starting: Points systems are notorious for being finicky, especially in cold or damp conditions. Electronic ignition provides a hotter, more consistent spark, resulting in easier and more reliable starting.
• Reduced Maintenance: Points require periodic cleaning, adjustment, and eventual replacement. Electronic ignition is virtually maintenance-free.
• Enhanced Performance: A stronger spark leads to more complete combustion, resulting in increased power and fuel efficiency.

My Experience: I remember struggling with a stubborn 028 Super that refused to start on a particularly cold morning. After countless pulls and a lot of frustration, I decided to upgrade to electronic ignition. The difference was night and day. The saw fired up on the first pull, and I haven’t had starting issues since.

The Upgrade Process:

1. Identify the Correct Module: Purchase a high-quality electronic ignition module specifically designed for the Stihl 028 Super. Several aftermarket options are available. Ensure compatibility before purchasing.
2. Remove the Old Points System: Carefully disconnect the wires leading to the points and condenser. Remove the flywheel using a flywheel puller. Remove the points and condenser assembly.
3. Install the Electronic Ignition Module: Mount the new module in place of the old points. Connect the wiring according to the module’s instructions. This usually involves connecting a ground wire and a wire to the ignition coil.
4. Set the Air Gap: The air gap between the ignition module and the flywheel is crucial for proper operation. Use a feeler gauge to set the gap to the manufacturer’s specifications (typically around 0.010-0.012 inches or 0.25-0.30 mm).
5. Reinstall the Flywheel: Carefully reinstall the flywheel, ensuring it is properly aligned. Torque the flywheel nut to the manufacturer’s specified torque.
6. Test the Ignition: Connect a spark plug to the spark plug wire and ground it against the engine. Pull the starter cord to check for a strong, consistent spark.

Tools You’ll Need:

• Flywheel puller
• Feeler gauge
• Screwdrivers
• Wrenches
• Torque wrench

Cost: The cost of an electronic ignition module typically ranges from $30 to $60.

Potential Problems:

• Incorrect air gap: If the air gap is too small or too large, the ignition may not function correctly.
• Wiring errors: Ensure all wires are connected correctly according to the module’s instructions.
• Faulty module: Although rare, the module itself may be defective.

Actionable Metric: After the upgrade, measure the time it takes to start the saw from cold. A successful upgrade should result in a significantly faster and more reliable start.

Takeaway: Upgrading to electronic ignition is a worthwhile investment that will improve your 028 Super’s starting reliability and reduce maintenance.

2. High-Performance Carburetor: Optimizing Fuel Delivery

The carburetor is the heart of your chainsaw’s fuel system, responsible for mixing air and fuel in the correct proportions. Over time, carburetors can become clogged, worn, or simply less efficient. Upgrading to a high-performance carburetor can breathe new life into your 028 Super, improving its throttle response, power, and fuel efficiency.

Why Upgrade?

• Improved Throttle Response: A high-performance carburetor is designed to deliver fuel more quickly and efficiently, resulting in snappier throttle response.
• Increased Power: Optimized fuel delivery can lead to increased power output, especially in demanding cutting conditions.
• Enhanced Fuel Efficiency: A properly tuned carburetor can improve fuel efficiency, saving you money on gas.

My Experience: I was working on a large oak log with my 028 Super, and I noticed it was bogging down under heavy load. I suspected the carburetor was the culprit. After installing a high-performance carburetor, the saw cut through the oak with noticeably more power and less hesitation.

The Upgrade Process:

1. Identify the Correct Carburetor: Purchase a high-performance carburetor specifically designed for the Stihl 028 Super. Look for carburetors with adjustable jets for fine-tuning.
2. Remove the Old Carburetor: Disconnect the fuel lines and throttle linkage from the old carburetor. Remove the carburetor mounting bolts and carefully remove the carburetor.
3. Install the New Carburetor: Mount the new carburetor in place of the old one. Connect the fuel lines and throttle linkage.
4. Initial Carburetor Adjustment: Most high-performance carburetors require some initial adjustment. Start by setting the high and low-speed jets to the manufacturer’s recommended settings.
5. Fine-Tune the Carburetor: Start the saw and let it warm up. Use a tachometer to adjust the high and low-speed jets for optimal performance. The goal is to achieve a smooth idle, quick throttle response, and maximum power without excessive smoke or hesitation.

Tools You’ll Need:

• Screwdrivers (including a small flathead screwdriver for adjusting the carburetor jets)
• Wrenches
• Tachometer (optional, but highly recommended)

Cost: The cost of a high-performance carburetor typically ranges from $40 to $80.

Potential Problems:

• Incorrect carburetor adjustment: Improper carburetor adjustment can lead to poor performance, excessive smoke, or engine damage.
• Fuel leaks: Ensure all fuel lines are properly connected and tightened to prevent leaks.
• Air leaks: Check for air leaks around the carburetor mounting flange.

Actionable Metric: After the upgrade, measure the time it takes to cut through a specific piece of wood (e.g., a 12-inch diameter log). A successful upgrade should result in a faster cutting time. Also, monitor fuel consumption over a set period.

Takeaway: A high-performance carburetor can significantly improve your 028 Super’s performance, but proper adjustment is crucial.

3. Cylinder and Piston Upgrade: Unleashing Hidden Power

If your Stihl 028 Super is starting to show its age, or if you’re simply looking to maximize its power output, consider upgrading the cylinder and piston. A new cylinder and piston can restore lost compression and potentially increase the engine’s displacement, resulting in a noticeable power boost.

Why Upgrade?

• Restored Compression: Over time, the cylinder and piston can wear down, leading to reduced compression and power loss. A new cylinder and piston will restore compression to its original levels.
• Increased Displacement (Optional): Some aftermarket cylinder and piston kits offer a slightly larger displacement, resulting in increased power output.
• Improved Engine Life: A new cylinder and piston can extend the life of your engine.

My Experience: I had a 028 Super that was running weak and had low compression. I decided to install a new cylinder and piston kit. The difference was remarkable. The saw had significantly more power, and the engine ran much smoother.

The Upgrade Process:

1. Identify the Correct Cylinder and Piston Kit: Purchase a cylinder and piston kit specifically designed for the Stihl 028 Super. Pay attention to the piston size and cylinder bore.
2. Remove the Old Cylinder and Piston: Disconnect the spark plug wire and remove the muffler. Remove the carburetor and intake manifold. Remove the cylinder head bolts and carefully remove the cylinder. Remove the piston pin retaining clips and slide out the piston pin. Remove the piston.
3. Install the New Piston: Install the new piston onto the connecting rod, ensuring the arrow on the piston points towards the exhaust port. Install the piston pin and secure it with the retaining clips.
4. Install the New Cylinder: Install the new cylinder onto the engine block, ensuring the piston rings are properly seated in the cylinder. Torque the cylinder head bolts to the manufacturer’s specified torque.
5. Reinstall Components: Reinstall the carburetor, intake manifold, muffler, and spark plug wire.

Tools You’ll Need:

• Screwdrivers
• Wrenches
• Piston ring compressor
• Torque wrench
• Piston pin removal tool (optional)

Cost: The cost of a cylinder and piston kit typically ranges from $80 to $150.

Potential Problems:

• Incorrect piston installation: Ensure the piston is installed correctly with the arrow pointing towards the exhaust port.
• Piston ring damage: Be careful not to damage the piston rings during installation.
• Incorrect torque: Torque the cylinder head bolts to the manufacturer’s specified torque to prevent leaks and engine damage.

Actionable Metric: After the upgrade, measure the engine compression using a compression tester. A successful upgrade should result in a significantly higher compression reading.

Takeaway: Upgrading the cylinder and piston can significantly improve your 028 Super’s power and extend its engine life, but it’s a more involved process that requires careful attention to detail.

4. Exhaust System Modification: Optimizing Exhaust Flow

The exhaust system plays a crucial role in engine performance. A restrictive exhaust system can hinder the engine’s ability to breathe, limiting its power output. Modifying the exhaust system, such as by installing a performance muffler or modifying the existing one, can improve exhaust flow and unlock hidden power.

Why Modify the Exhaust System?

• Improved Exhaust Flow: A less restrictive exhaust system allows the engine to expel exhaust gases more easily, resulting in increased power.
• Increased Power Output: Improved exhaust flow can lead to a noticeable increase in power, especially at higher RPMs.
• Enhanced Throttle Response: A less restrictive exhaust system can improve throttle response.

My Experience: I experimented with modifying the muffler on my 028 Super. I carefully opened up the exhaust port and added a second outlet. The result was a noticeable increase in power, especially when cutting larger logs. However, I also noticed a slight increase in noise.

The Modification Process:

Option 1: Performance Muffler:

1. Identify a Compatible Muffler: Purchase a performance muffler specifically designed for the Stihl 028 Super.
2. Remove the Old Muffler: Remove the bolts securing the old muffler to the cylinder. Carefully remove the muffler.
3. Install the New Muffler: Mount the new muffler in place of the old one. Tighten the mounting bolts.

Option 2: Modifying the Existing Muffler (Use caution and consider potential noise increases):

1. Access the Muffler: Remove the muffler from the chainsaw.
2. Enlarge the Exhaust Port: Carefully enlarge the exhaust port using a drill or rotary tool. Be careful not to damage the muffler.
3. Add Additional Outlets (Optional): Drill additional outlets into the muffler to further improve exhaust flow.
4. Reinstall the Muffler: Reinstall the muffler onto the chainsaw.

Tools You’ll Need:

• Screwdrivers
• Wrenches
• Drill or rotary tool (if modifying the existing muffler)

Cost: The cost of a performance muffler typically ranges from $30 to $70. Modifying the existing muffler is generally less expensive but requires more skill and caution.

Potential Problems:

• Increased noise levels: Modifying the exhaust system can significantly increase noise levels.
• Damage to the muffler: Be careful not to damage the muffler during modification.
• Reduced backpressure: Excessive modification can reduce backpressure, which can negatively impact engine performance.

Actionable Metric: After the modification, assess the saw’s cutting speed through a known piece of wood. Compare the time before and after the modification.

Takeaway: Modifying the exhaust system can improve your 028 Super’s power, but it’s important to consider the potential drawbacks, such as increased noise levels. Always wear hearing protection when operating a modified chainsaw.

5. Bar and Chain Upgrade: Optimizing Cutting Performance

The bar and chain are the cutting heart of your chainsaw. Upgrading to a high-quality bar and chain can significantly improve cutting performance, reduce vibration, and extend the life of your cutting equipment.

Why Upgrade?

• Improved Cutting Speed: A high-quality chain with sharp cutters will cut faster and more efficiently.
• Reduced Vibration: A well-balanced bar and chain can reduce vibration, making the saw more comfortable to use for extended periods.
• Increased Durability: A high-quality bar and chain will last longer than a cheaper alternative.
• Better Wood Chip Evacuation: A well-designed chain will evacuate wood chips more effectively, preventing clogging and improving cutting performance.

My Experience: I used to use a cheap, low-quality chain on my 028 Super. I was constantly sharpening it, and it still wouldn’t cut very well. I finally decided to invest in a high-quality chain, and the difference was amazing. The saw cut through wood like butter, and I didn’t have to sharpen it nearly as often.

The Upgrade Process:

1. Identify the Correct Bar and Chain: Determine the correct bar length and chain pitch for your Stihl 028 Super. Consult your owner’s manual or a chainsaw dealer for assistance.
2. Choose a High-Quality Bar and Chain: Look for bars and chains made from durable materials and with features that enhance cutting performance, such as low-vibration designs and advanced cutter technology.
3. Install the New Bar and Chain: Remove the old bar and chain. Install the new bar and chain, ensuring the chain is properly seated in the bar groove and the drive links are engaged with the sprocket. Adjust the chain tension according to the manufacturer’s instructions.

Tools You’ll Need:

• Wrench or screwdriver for adjusting the chain tension
• Gloves

Cost: The cost of a high-quality bar and chain typically ranges from $40 to $100, depending on the bar length and chain type.

Potential Problems:

• Incorrect chain tension: Improper chain tension can lead to premature wear and damage to the bar and chain.
• Chain derailment: If the chain is not properly seated in the bar groove or the drive links are not engaged with the sprocket, the chain may derail.
• Incorrect bar and chain selection: Using the wrong bar length or chain pitch can damage the saw.

Actionable Metric: After the upgrade, track the amount of wood cut before needing to resharpen the chain. A quality chain should require less frequent sharpening.

Takeaway: Upgrading to a high-quality bar and chain is a simple but effective way to improve your 028 Super’s cutting performance and reduce vibration. Always use the correct bar length and chain pitch for your saw.

Conclusion: Revitalizing a Legend

The Stihl 028 Super is a testament to durable engineering. These five upgrades, born from my experience and observations in the field, can significantly enhance its performance, reliability, and longevity. Remember, safety is paramount. Always wear appropriate personal protective equipment, including hearing protection, eye protection, and gloves, when operating a chainsaw. By following these tips, you can keep your Stihl 028 Super running strong for years to come, turning it into an even more formidable tool in your wood processing arsenal. So, get out there, upgrade your saw, and keep those chips flying!

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