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Stihl 029, 039 User Manual

Stihl 029, 039
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STIHL 029, 039 1
STIHl
STIHlSTIHl
STIHl
© 1992 Andreas Stihl. Waiblingen
Service Manual
029 and 039
Chain Saws
As the design concept of these two
models is almost identical, the
descriptions and servicing pro-
cedures in this manual generally
apply to both. Differences are
described in detail.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual
components and assemblies.
Microfilmed parts list are always
more up to date than printed lists.
A fault on the machine may have
several causes. Consult the
"Troubleshooting Charts" when
tracing faults.
Refer to the "Technical Informa-
tion" bulletins for engineering
changes which have been intro-
duced since publication of this
service manual.
Service manuals and technical
information bulletins describing
engineering changes are intended
exclusively for the use of STIHL
servicing dealers and staff and
must not be passed on to third
parties.
Chain saw on assembly stand
The STIHL Special Tools manual
lists all special servicing tools
currently available from STIHL.
Always use original STIHL
replacement parts.
Original STIHL parts can be
identified by the STIHL part
number, the
STIHl
STIHlSTIHl
STIHl
logo and
the STIHL parts symbol
(
The
symbol may appear alone on small
parts.
Servicing and repairs are made
considerably easier if the saw is
mounted on assembly stand 5910
850 3100 or 5910 890 3100. This
enables the saw to be swivelled to
the best position for the ongoing
repair and leaves both hands free.
The saw can be quickly secured to
the stand by means of the bar
mounting studs and nuts (after
removing the sprocket cover).

Table of Contents

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Stihl 029, 039 Specifications

General IconGeneral
BrandStihl
Model029, 039
CategoryChainsaw
LanguageEnglish

Summary

1. SPECIFICATIONS

1.1 Engine

Provides specifications for the engine, including displacement, bore, stroke, and power output.

1.2 Fuel System

Details specifications for the fuel system, including carburetor settings, fuel tank capacity, and mixture ratios.

1.3 Ignition System

Lists specifications for the ignition system, covering type, air gap, ignition timing, and spark plug details.

1.4 Cutting Attachment

Specifies guide bars, bar lengths, oilomatic chain types, chain sprockets, and chain lubrication details.

1.5 Special Accessories

Lists special accessories available for users and service shops, including repair kits and carburetor parts.

1.5.1 For user

Details special accessories intended for direct use by the owner, such as repair kits and starter ropes.

1.5.2 For service shop

Lists special accessories recommended for service shops, primarily carburetor parts kits for specific models.

1.6 Tightening Torques

Provides a comprehensive list of fasteners and their specified tightening torques in Nm and lbf.ft for various components.

2. TROUBLESHOOTING CHARTS

2.1 Clutch, Chain Drive, Chain Brake and Chain Tensioner

Troubleshooting guide for issues related to the clutch, chain drive, chain brake, and chain tensioner mechanisms.

2.2 Engine

Troubleshooting guide for common engine faults, covering starting issues, power loss, and overheating scenarios.

2.3 Ignition System

Troubleshooting flowchart for diagnosing problems with the engine's ignition system, from spark plug to ignition module.

2.4 Rewind Starter

Troubleshooting guide for common issues with the rewind starter mechanism, including rope and spring problems.

2.5 Chain Lubrication

Troubleshooting guide for chain lubrication system faults, addressing issues like no oil delivery or low oil flow.

2.6 Fuel System

Troubleshooting guide for fuel system problems, including carburetor flooding, poor acceleration, and engine stalling.

3. CLUTCH, CHAIN DRIVE, CHAIN BRAKE AND CHAIN TENSIONER

3.1 Clutch Drum and Chain Sprocket

Instructions for disassembling and assembling the clutch drum and chain sprocket, including parts identification.

3.2 Clutch

Procedures for removing, disassembling, and assembling the chainsaw's clutch, including component identification.

3.3 Chain Brake

Procedures for the maintenance and repair of the chain brake system, covering disassembly and assembly.

3.3.1 Disassembly

Step-by-step instructions for disassembling the chain brake mechanism, including removing the brake band and spring.

3.3.2 Assembly

Step-by-step instructions for reassembling the chain brake mechanism, ensuring correct placement of components.

3.4 Front Chain Tensioner

Procedure for removing and installing the front chain tensioner assembly, including adjusting screw and nut.

3.5 Side Chain Tensioner

Instructions for converting the front chain tensioner to a side chain tensioner, including drilling details.

3.6 Bar Mounting Studs

Procedures for removing and installing bar mounting studs, including necessary tools and torque specifications.

4. ENGINE

4.1 Removing and Refitting Exhaust Muffler

Instructions for removing and refitting the exhaust muffler, including gasket replacement and torque settings.

4.2 Leakage Testing the Engine

Procedures for testing the engine housing for leaks using specialized testers and vacuum pumps.

4.2.1 Preparations

Steps required before conducting engine leakage tests, including removing the muffler and positioning sealing plates.

4.2.2 Pressure Test

Procedure for performing a pressure test on the engine housing to check for airtightness using a pressure tester.

4.2.3 Vacuum Test

Procedure for performing a vacuum test on the engine housing to detect leaks, particularly affecting oil seals.

4.3 Replacing the Oil Seals

Instructions for replacing oil seals on the engine, covering both the clutch and ignition sides.

4.4 Removing and Installing the Engine

Detailed steps for removing the engine from the housing and reassembling it, including related component removal.

4.5 Cylinder

Procedures for removing and installing the cylinder, including piston and ring handling and cleaning mating faces.

4.6 Piston

Instructions for removing and installing the piston, including piston pin removal, ring inspection, and needle cage fitting.

4.7 Piston Rings

Steps for removing and installing piston rings, ensuring correct positioning and cleaning of grooves.

4.8 Crankshaft

Procedures for removing and installing the crankshaft, including new ball bearings and oil seals.

5. IGNITION SYSTEM

5.1 Repairing Component Parts

Procedures for repairing and maintaining key components of the ignition system.

5.1.1 Spark Plug

Instructions for checking, cleaning, and replacing the spark plug, including electrode gap adjustment.

5.1.2 Ignition Module

Information and procedures related to the ignition module, including its function and testing.

5.1.2.1 Ignition Timing

Details on the fixed ignition timing specifications for the electronic magneto ignition system.

5.1.2.2 Removing and Installing

Step-by-step instructions for removing and installing the ignition module and associated wiring.

5.1.3 Spark Plug Terminal

Procedures for removing and installing the spark plug terminal and its associated dust seal and leg spring.

5.1.4 Ignition Lead

Instructions for cutting, fitting, and connecting the ignition lead, including packing the high voltage output.

5.1.5 Flywheel

Procedures for removing, inspecting, and installing the flywheel, including cleaning and tightening specifications.

5.1.6 Short Circuit Wire/Ground Wire

Instructions for removing and installing the short circuit wire and ground wire, including grommet replacement.

5.1.7 Contact Spring

Procedure for removing and installing the contact spring for the stop switch mechanism.

6. REWIND STARTER

6.1 Routine Maintenance

Guidance on routine maintenance for the rewind starter, addressing stiffness and proper lubrication.

6.2 Rope Rotor/Pawl

Procedures for accessing and removing the rope rotor and pawl mechanism for maintenance or replacement.

6.3 Replacing the Starter Rope

Detailed instructions for replacing the starter rope, including securing the knot and fitting the rope rotor.

6.4 Replacing the Rewind Spring

Instructions for replacing the rewind spring, including handling precautions and proper seating of components.

6.5 Tensioning the Rewind Spring

Procedure for correctly tensioning the rewind spring to ensure proper starter operation.

6.6 Replacing the Starter Rope Guide Bush

Instructions for replacing the starter rope guide bush, addressing wear and proper installation using tools.

7. AV HANDLE SYSTEM

7.1 Repair

Procedures for repairing the AV handle system, focusing on the replacement of damaged anti-vibration buffers.

8. HANDLE HOUSING

8.1 Front Handle

Information and procedures related to the front handle assembly.

8.1.1 Removing and Installing Handle Housing

Detailed steps for removing and installing the complete handle housing, including associated components.

9. MASTER CONTROL

9.1 Switch Shaft

Procedures for removing and installing the switch shaft and its associated multi-function operating lever.

9.2 Interlock Lever/Throttle Trigger

Instructions for removing and installing the interlock lever and throttle trigger assembly.

10. CHAIN LUBRICATION

10.1 Suction Hose/Pickup Body

Procedures for removing, cleaning, and installing the suction hose and pickup body of the chain lubrication system.

10.2 Vent Valve

Instructions for removing and installing the vent valve in the oil tank, ensuring proper pressure equalization.

10.3 Removing and Installing the Oil Pump

Detailed steps for removing and installing the oil pump, including worm and spring replacement.

10.4 Servicing the Oil Pump

Procedures for servicing the oil pump, including cleaning parts, replacing O-rings, and fitting new components.

11. FUEL SYSTEM

11.1 Air Filter

Instructions for removing, cleaning, and replacing the air filter to ensure optimal engine performance.

11.2 Removing and Installing the Carburetor

Detailed steps for removing and installing the all-position diaphragm carburetor, including fuel hose disconnection.

11.3 Leakage Testing the Carburetor

Procedure for testing the carburetor for leaks using a pressure tester to identify faulty components.

11.4 Servicing the Carburetor

Procedures for servicing the Zama and Walbro carburetors, including fuel pump checks and diaphragm replacement.

11.5 Carburetor Adjustment

Guidance on adjusting the carburetor's high and low speed screws for optimal engine performance.

11.6 Automatic Choke

Information on the automatic choke system, its operation, and components.

11.6.1 Description of Operation

Explanation of how the automatic choke system operates, utilizing cylinder temperature and pressure variations.

11.6.2 Troubleshooting Chart

Troubleshooting flowchart for diagnosing issues with the automatic choke system and related components.

11.6.3 Testing Automatic Choke

Procedures for testing the automatic choke's functionality based on control valve temperature and crankshaft revolutions.

11.6.4 Leakage Testing Engine Housing and Control Valve

Instructions for testing the engine housing and control valve for leaks, requiring interruption of air connections.

11.6.5 Testing Control Valve (removed from machine)

Procedure for testing the control valve's functionality when removed from the machine using vacuum and pressure tests.

11.6.6 Leakage Testing the Bellows

Procedure for checking the bellows for leaks using a pressure gauge, either installed or removed from the machine.

11.6.7 Foam Filter/Polymer Sintered Filter

Instructions for removing the foam filter and polymer sintered filter from the air filter box.

11.6.8 Removing and Installing the Carburetor

Specific steps for carburetor removal and installation related to the automatic choke system.

11.6.9 Removing and Installing Lever System on Carburetor

Procedures for removing and installing the lever system components on the carburetor for the automatic choke.

11.6.10 Throttle Shaft/Choke Shaft

Instructions for removing and installing the throttle shaft and choke shaft, including torsion spring replacement.

11.6.11 Hose/Connector

Procedures for removing and installing the hose and connector for the control valve system.

11.6.12 Control Valve

Instructions for removing and installing the control valve, including O-ring replacement and testing.

11.6.13 Bellows

Procedures for removing and installing the bellows, including O-ring lubrication and proper seating.

11.7 Tank Vent

Instructions for removing, cleaning, and installing the tank vent to ensure correct carburetor operation.

11.8 Fuel Pickup Body and Fuel Hose

Procedures for checking and cleaning the fuel pickup body and fuel hose, addressing fuel starvation issues.

11.9 Replacing the Fuel Tank

Instructions for replacing the fuel tank, including removal of related components like the engine and chain tensioner.

12. Special Servicing Tools and Aids

12.1 Special Servicing Tools

A list of special tools and their part numbers required for servicing the chainsaw.

12.2 Servicing Aids

A list of servicing aids, such as lubricants, sealants, and cleaning agents, with their part numbers.