Stihl 015 015L Chainsaw Service Repair Workshop Manual

T- i .c STTHL AI5 ti} C o

PREFACE The power cirain saws STIHL 015 and015L havebeenfirst introduced at the beginning of July 1973. This service shop manual is ment to serve you as a guide book for proper and skilled repair works on both of thesemachines. Moreover,we suggest to use the illustrated spare parts list in our instruction manuals as a help when repairing. Technical modifications which should be necessary after publication of this repairinstruction will be brought to your attention by our "Technical lnformations". This service shop manual as well as all Technical Informations being subject to modifications shall only be given to personellwhich is in charge of service and repair. Handing over or lending this manual to otherpersons is prohibited. CONTENTS Specifications Engrne Fuelsystem lgnition system Torques for screwsand nuts Cutting attachment ChainDrive and Clutch Function Troublin g Disassembly Repair Reassembly Engine Construction Trou b lin g Exposing the cylinder Cylinder Disassem b ly-cran kcase crankshaft and piston Reassembly-crankcase Pressure testing of crankcase Pressure testing with vacuum pump lgnition System Design and operation Spark plug Hightension lead lgnition stop switch Short circuit wire Flywheel Checking the ignition timing Adjusting the ignition timing lgnition System 015 L electronic Design andoperation Checking the ignition timing Adjusting the ignition timing Flywheel 2 lgnition coil 2 Magneto air gap 2 Trigger plate 3 Magneto edge gap 3 Checking the magneto edge gap 3 Contact plate lgnition coil Trouble shooting for ignition a i'm atu re Rewind Starter Design and operation Troubling Installation of a new starter rope 8 Installation of rewind spring B Tensioning the rewind spring 8 Pawls and hook-on spring 9 General repair 10 Oil Pump Design and operation Troubl ing Disassembly of oil pump Repair to Carburetor with Air Filter 17 Design and operation 17 Disassembly of carburetor 18 Repair 18 Pressure testing 19 Carburetoradjustment 19 Troubling 20 Fuelhose zl 22 SpecialTools 5 q 5 o 6 7 30 JI JI 22 23 ZJ 25 27 32 3Z 5Z J4 34 35 35 11 12 36 JO JO ?1 JI 38 38 39 ?o A'l al 42 43 43 O STTHI: Andreas Stihl Postfach 1760 D -7050 Waiblingen 28 28 29 29 30

SPECIFICATIONS We reservethe right to change design if this is deemed advantageous or necessary. Engine STIHL one-cylinder-two cycle engine Piston displacement: 32 cm3 (1,96 cu. in.) Cylinder bore: 38 mm (1,525 in.) Piston stroke: 28 mm (1,12 in.) Cylinder wall: Heavy chromium impregnated Max.allowed speed: 12500 r.P.m. Mean idle speed: 2500 r.P.m. Crankshaft: One-Part Crankshaft bearing: Both sidesneedle bushings Crankpin: 11,6 mm (0,a5 in.)in diameter Piston pin: 9 mm (0,36 in.)in diameter Length of conrod: 53 mm (2,12 in.) Rewind starter: Forced engagement with automatic rewindof starter roPe Starter rope: Length 960 mm (38'ain.) 3,5mm (0,1a in.)in diameter Clutch: Heavy duty centrifugal clutch without friction linings Clutch engagement at: approx' 3000 r.p.m. Fullengagement: approx. 6000 r.p.m' Pressure test of crankcase with crankcase testing device: Testing pressure 0,5 kp/cm2 (7,1lbf ./in.2) Pressure test of crankcase with vacuum pump: Testing pressure 0,2 kp/ cm2 (2,8lbf./ in.2) Fuelsystem Carburetor: All position Walbrodiaphragm carburetor HDC 17 with integral fuel pump Venturi: 11,1 mm (7/rc") in diameter Highspeedadjustment screw H: slt of a turn open Low speedadjustment screw L: 3lt of a turn open (basic carburetor adjustment from snugseat of adjustment screws) Pressure test of carburetor: 0,4 kp/cm2 (5,7lbf./in.2) Fuel tank capacity: 0,33 l-330 cms(0,70 US pts') U'l tr v

3 Fuelmixture: Air Filter: Mixingratio 1:25 (1 part oil to 25 partsgasoline) 1:40 when usingSTIHL special two-stroke motoroil. Feltpad lgnition Systern Phelon flywheel magneto of separated construction Magneto edge gap: Advanced ignition: Breaker pointgap: Condenser: Armature: Spark plug: 3-7,5 mm (0,12-0,29in.) 2-2.2 mm (0,08-0.09in.)before tnn do:ri aantar 0,35-0,4 mm (0,14-0,16in.) Capacity about 0,17 ,rF Primary winding 0,8-1,3 f2 Secondary wlnding 7200-8800 Q Bosch WKA 175 T 6 (SW 21) Champion CJ-6 (SW 19) Heatrange1 75 Electrode gap 0,5 mm (0,02 in.) Sparkplug threadM 14 14 mm (0,55 in.) 0,2-0,3 mm (0,007-0,011 in.) Spark plugthread: Armature air gap: Torques for Screwsand Nuts Crankshaft nut ignition side Clutch carrier Spark plug Cylinder headscrew M 4 Cylinder headscrew M 4 for fastening of plastic parts Cyl. hd. screw M 5 Cylinder hd. screwsM 5 crankcase screwsat cvlinder bottom 2,5kpm (18,08 ftllbf.) 2,5 kpm (18,08 fvlbf.) 2,5 kpm (18,08 ftllbf.) 0,25 kpm (1,79 ft/lbf .) 0,2 kpm (1,45 fVlbf.) 0,5 kpm (3,62 ftllbf.) 0,7 kpm (5,06 ftllbf.) e lnduction hardened with and without stellite tipping at the bar head. Cutting Attachment Guidebars:

4 v ! Bar lengths: Chain: Chainspeed: Chainlubrication: Oil tank capacitY: Chainsprocket: 25 cm (10 in.) guidebar without stellite tipping at the bar head 30 cm (12 in.) Duromatic Auide bar with stellite tipping at the bar head 30 cm (12 in.) Rollomatic guidebar with star shaped rollernose r/a "-oilomatic chiPPer chain STIHL chain model 3831 t/+ "-oilomatic-S-safetY chain STIHL chain model 3849 r/+ "-micromatic-semi-chisel chain STIHL chain model3856 r/+ "-micromatic-S'safetY chai n STIHL chain model 3855 approx. 14,2 m/sek (46,58 ftlsec.) at 8500 r.P.m. Oil pumpwith pumP Plunger governed by engine speed, PUmPS only when chain is rotating 0,18 l-180 cm3 (0,38 US Pts.) 8 teeth lor 1/+" chain ( v wiih 25 cm (10 in.) bar and chain 015 015L, 4,2k9(9,2a p) Weight of Saw 01 5 L electron ic 4,4 kg (9,68 P.) Extras STIHL emergencY kit Special muffler, handguard ( v

5 SAW CHAIN DRIVE AND CLUTCH I O Function ' I { "l I t l I ! fhe power from the engine is trans- With increasing speed- at approx. Note: a mittedto the saw chainby a centri- 3000r.p.m. the clutch shoes held by The carburetorhas to be adjusted fugalclutch. Thisclutch iscomposed the clutchspring are forced to the in such a way (see "carburetor ad- of clutch carrier,two clutch shoes outside.They are pressed against justment") that the chain does not and one clutch spring.The washer the clutch drum thus transmitting rotate when engine is idling. which is positioned behind the the enginepower to the saw chain. clutch for the guidance of the clutch The chain sprocketalso drives the shoes as well as the chainsprocket oil pump at engaged clutch, as the with clutchdrum rivetedonto it are tooth profileengages in a provided also partof the clutch assembly. recess at the small spur gear for the pump. O Troublins The clutch is maintenancef ree. Normal wear, however, cannot be avoided. Therefore, the clutch and chainsprocket must be checked on propercondition periodically. Troubles Causes How to correct Extraneous noises Engine is running too highwhen Adjustidle speedregulating screw idlino O Saw chain does not stop running Springstretched or fatigued Replace spring when idling Springhooksdamaged Extreme chain wear Worn chain sorocket Replace chain sprocket

Disassembly Starter rooe coiled around handle frame A fouled or improperly operating clutch as well as'a worn chain sprocket must be disassembled and repaired respectively replaced. For disassembly first take off chain sprocket cover and cutting attachment. Carefully pull of spark plug terminal and screw out spark plug. Thereafter pull out starter rope and wind it three to four times around the handle frame. This prevents possible breakage of the starter rope when reinstalling the clutch. Now insertlocking screw into spark plug thread by hand until its snug seat to lock the crankshaft. Then unscrew clutch with combination wrench (SW 13) from the crankshaft. Note! Clutch carrier has left hand thread! Therefore unscrewing is done in clockwise direction. Top: Inserting locking screw Bottom: Looseningthe clutch Repair Prying off worm spring Clutch: Pull off clutch shoes from carrier and unhook springs at the lugs. lf spring stays hooked in the toothed profile of the clutch shoes do not try to pull it out by force. Take a small screw driver and pry out springcarefully of the tooth profile. Damaged parts of the clutch and worn clutch shoes have to be replaced. Don't replace a single clutch shoe, alwaysuse a comPlete set. To mount a new clutch sPring position clutchshoes symmetrically one facing the other. Hook clutch spring together at its ends and oress it onto the clutch shoes. The mounting groove for the clutch spring in the clutchshoes is provided in its center with a tooth profile which prevents the clutch spring from twisting. When pressing on the clutch spring take care that the spring lugs alwaysrest in the middle of the tooth profile of each clutch 'l> - -'' \ rf1 .. ,. -i i.. ; r'l For proper guidanceof the clutch shoes a washer is positioned behind the clutch.lt has to be installed in such a way that it rests with its indented side against the carrier. Washer,chainsprocketand needle cage can now be taken from the crankshaft.

F.y 'g o" c ;ctt sboes shoe.Moreover, it is very important that the clutch spring always rests completely in the groove of the clutch shoe-this is true also for the areaof the toothprofile. lf the clutch springis protruding it is undergoing an unnecessary wearing Process at engaged clutch- as a result of clutch drum friction. lf the spring lugs are placed outside of a clutch shoe a breakage of the springmightoccur. Then slide clutchshoes with clutch springsonto carrier. With a screw- driver pry on the clutch shoesto the carrier. Therebypress clutchshoes with one handto the carrier in order to avoid its jump-backcaused bY the pretensioning of the clutch spri ng. Chainsprocket: The stress on the chainsprocket is extremelyhigh. lf it shows visible wear at the teeth it has to be ex- changed. This wear should not ex- ceed a depthof 0,5 mm (0,019 in.). Tightening the clutch Before reassembling needle cage apply some ball bearing greaseto it. Then mount needle cage, chain sprocketand washer (observe correct inserting position) onto crankshaft and screw in crankshaft with clutch in reverse direction of engine rotationthereby reducingthe starter rope tensiontill limit stop position of the locking screw. Then let starter rope slide back fully. Screw in clutch counterclockwisewith combination wrench and tighten with torque wrench to 2,5 kpm (18,08 ftllbf.).Mount chain sprocket cover and insert spark plug tightening torque of spark plug 2,5 kpm (18,08 ft./rbf.). @ -tt" '' t'.'t9,8 , ,,, jf / FrTZ ) t- t-

ENGINE Construction O( The power chain saws are driven 2 heavy duty needle bushings. At The crankshaft at the ignitionside I by an aircooledone-cylinder two- the bearing seats of the crankcase is providedwith a cam to activate cycle engine.The crankcasecon- the crankshaft is sealedby separate the breaker point set.The conrod is sists of two housing parts; as a oil sealson both sides. The bearing made of a special tempered case ' specialconstruction feature the cy- support between crankshaft and hardened steel. linder at the same time serves as conrod is achieved by 12 cylindrical crankcase half.Cylinder and piston rollers which are individually posi- are made of a special aluminum tioned in a grease layer on the alloy. Thecrankshaft is drop forged. crankshaft and are kept in the It is a onepart crankshaftand is guide groove on the crankshaft by supported in the crankcase with the connecting rod. O( Troubling Causes How to correct Engine stopswhen idling, however, Sealing ring of crankshaft leaks Replace sealing rings ooerates normal at full throttle Crankcase defective (cracks) Replace crankcase Motor doesnot reach full Air filterclogged Clean performance or runs irregularly Engine gets by-pass air by badly Mountcarburetor correctly if fittedcarburetor necessary replace flangegasket Piston ring leaky or broken Replace piston ring Engine overheated lnsufficient cylinder cooling. Air Cleancooling air by passes. intake openings at handle shroud clogged or cooling fins fouled Engine all right Trouble sourcemustbe looked for in fuel system resPectivelY carburetor or ignition system, see respective paragraPh. tl

9 o Exposing the Cylinder Tap U^scret ^g :-9' !e. Cover Solo- I coso' 5'' - Before starting to repair the engine - also when exposing the cylinder - first empty oil- and fuel tankl Then take off chainsprocket cover, unscrew f ilter cover and remove air filter. Pull off choke lever and spark plug terminal. Unscrew spark plug as well as the 4 cyl. hd. screws M 5X20 of handleshroud fixation. Lift off handle shroud from motor half . Top: Looseningthe hexagonal nut Center: Special tool Bottom: Loosenlngthe flywheel o Loosening the cover of the oil pump Then screw in locking screw into spark plug port by hand until its snug seat to lock the crankshaft. Remove clutch f rom crankshaft. Now unscrew the 4 cyl. hd. screws M 4X15 for fixation of the cover which protects the oil pump against saw dust and take off cover with small spur gear. Then unscrewhex. nut for flywheel fixation at blocked crankshaft anti- clockwise, remove washer and loosen flywheel with special tool 111 6 893 0800 from crankshaft. To do so screw the special tool onto the crankshaft(at crankshaft part-ignition side).The specialtool must not rest againstthe flywheel. Now loosen the flywheelwith light hammer blows onto the shaft of the special tool. While doing so hold chain saw at flywhee,. ffi3 i:l f&

Stihl 015 015L Chainsaw Service Repair Workshop Manual

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