Table of Contents
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CONTENTS
1.
2.
2.1
2.2
2.3
2.4
2.5
Special Accessories
2.6
3.
3.1
3.2
3.3
3.4
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
STIHL 088
2
5.
3
5.1
5.1.1
5.1.2
3
Installing
3
5.2
4
4
5.3
5
5.4
5
5
5.5
5
6.
7
6.1.
6.2
6.2.1
6.2.2
7
8
9
7.
9
10
8.
12
13
13
14
8.1
8.2
15
9.
15
16
16
9.1
17
18
9.2
19
9.3
20
9.4
20
9.4.1
20
21
9.4.2
24
24
24
28
32
33
10.
Fuel System
33
10.1
Air Filter
34
10.2
Carburetor
10.2.1
34
Installing
10.2.2
35
10.2.3
Adjustment
36
10.3
Tank Vent
10.4
Pickup Body
37
10.5
Fuel Hoses
37
10.6
Tank Housing
38
11.
38
11.1
38
11.2
38
39
40
41
41
42
43
43
44
44
45
45
45
STIHl
© 1996. Andreas Stihl. Waiblingen
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47
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48
49
50
51
51
52
53
56
56
58
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Summary of Contents for Stihl 088
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Page 1: Table Of Contents
Spur Gear Exposing the Cylinder Oil Pump Cylinder and Piston 9.4.1 Removing and 4.5.1 Removal Installing 4.5.2 Installation 9.4.2 Servicing Piston Rings Crankcase 4.7.1 Removing the Crankshaft 4.7.2 Installing the Crankshaft Decompression Valve STIHl © 1996. Andreas Stihl. Waiblingen STIHL 088... -
Page 2: Introduction
Always use original STIHL several causes. Consult the replacement parts. They can be troubleshooting charts for all = Direction of movement identified by the STIHL part number, assemblies in the "Standard Repairs, the STIHl logo Troubleshooting" handbook. Service manuals and all technical... -
Page 3: Specifications
SPECIFICATIONS Engine STIHL single cylinder two-stroke engine with special impregnated cylinder bore Displacement: 121.6 cm (7.42 cu.in) Bore: 60 mm (2.35 in) Stroke: 43 mm (1.69 in) Engine power: 6.3 kW (8.6 bhp) Max. torque: 8.0 Nm (5.9 Ib.ft) at 6,000 rpm Max. -
Page 4: Ignition System
Length of thread: 9.5 mm (0.37 in) Heat range: Cutting Attachment Guide bars STIHL Rollomatic with nose sprocket STIHL Duromatic with Stellite-tipped nose. Both types with corrosion- resistant finish and induction hardened rails. Bar tail: Bar lengths: 3002 Rollomatic: 53, 63, 75, 90... -
Page 5: For User
Special Accessories 2.5.1 For User STIHL repair kit 084/088 1124 900 5001 HD air filter kit 0000 120 1650 Intake air preheating kit 1124 007 1005 2.5.2 For Service Carburetor parts kit 1124 007 1061 Gasket kit 088 1124 007 1051 Tightening Torques Plastoform screws are used for polymer components. - Page 6 4) R version only Note: Use hot air blower (hair dryer) to release screws secured with adhesive. Take special care with polymer components. Power screwdriver speed for use in polymer: Plastoform screws max. 600 rpm, DG screws max. 500 rpm. STIHL 088...
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Page 7: Clutch, Chain Drive, Chain Brake And Chain Tensioner
• Remove the E-clip (1). • Take the needle cage out of the sprocket. • Remove the washer (2). - Clean and inspect the clutch drum/chain sprocket. STIHL 088... -
Page 8: Clutch
- Install decompression valve - see 4.8. - Install clutch drum/chain sprocket - see 3.1. • Unscrew the spark plug. • Push the locking strip • Fit cover washer so that "TOP" 0000 893 5903 into the cylinder. faces outward. STIHL 088... -
Page 9: Chain Brake
(1) on the crankcase. • Remove the rubber bushing (2). from the bell crank (2). • Unhook the brake band from the bell crank (2). - Inspect parts and replace if damaged. STIHL 088... -
Page 10: Assembly
3.3.2 Assembly • Unhook the spring (2) and take it Lubricate sliding and bearing points of chain brake with STIHL away. multipurpose grease or, prefer- ably, Molykote grease - see 11.2. • Pull off the cam lever (3). - Inspect parts. Replace any worn or damaged parts. - Page 11 - Coat brake band with chain oil - Coat the mounting screw with the housing. (STIHL Bioplus), see 11.2, to Loctite, see 11.2. and torque protect it from corrosion and down to 3.0 Nm (2.2 Ibf.ft).
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Page 12: Checking Function
- the brake manually - the chain - must come to an abrupt stop. Note: The braking time is in order if deceleration of the saw chain is imperceptible to the eye. • Attach the brake spring to the bell crank. STIHL 088... -
Page 13: Brake Spring Anchor Pin
Install the chain brake - see 3.3.2. In such a case neither the new anchor pin nor the brake spring would locate properly. Furthermore, the crankcase could be damaged in this way and possibly impair correct operation of the chain brake. STIHL 088... -
Page 14: Chain Tensioner
• Take out the screw (2). • Remove the cover plate. • Take out the tensioner slide with • Check that O-ring is fitted in spur adjusting screw and thrust pad. gear and lubricate it with a little oil before installing. STIHL 088... -
Page 15: Engine
• Ease away the clips (1). • Take out the screws (1). • Remove the exhaust gasket. • Remove the retainers (2). • Remove the cover (2). Reassemble in the reverse sequence. • Remove the muffler (3). STIHL 088... -
Page 16: Leakage Test
- Remove the muffler - see 4.1. - Remove the carburetor - see 10.2.1. - Set the piston to top dead center (T.D.C.). This can be checked through the intake port. • Check that sleeve is in position. STIHL 088... -
Page 17: Pressure Test
- Pump air into the crankcase with rubber bulb until the gauge indicates a pressure of 0.6 bar (8.7 psi). If this pressure remains constant for at least 20 seconds, the crankcase is airtight. • Fit the flange (1) 1124 850 4205 in position. STIHL 088... -
Page 18: Vacuum Test
0000 850 3501 to test flange nipple. - Install decompression valve see 4.8. • Close the vent screw (1) on the pump. • Operate lever (2) until pressure gauge (3) indicates a vacuum of 0.4 bar (5.8 psi). STIHL 088... -
Page 19: Oil Seals
- Apply thin coat of sealant (see 11.2) to outside diameter of oil seal. • Apply puller (1) 5910 890 4400 • Use the press sleeve (1) (with No. 3.1 jaws 1127 893 2400 to install the oil 0000 893 3706). seal. STIHL 088... -
Page 20: Exposing The Cylinder
- Install the spur gear - see 9.3. • Unscrew the spark plug. • Carefully separate the cylinder gasket from the cylinder base. Reassemble in the reverse sequence. - Pull the cylinder off the piston. STIHL 088... -
Page 21: Installation
• Ease the hookless snap rings out • Push the assembly drift, small necessary - see 4.6. of the grooves in the pistons. diameter first, through the piston and small end (needle cage) and line up the piston. STIHL 088... - Page 22 "b" between the two ends of the hose clamp is 6.5 - 7 mm (0.25 - 0.27 in). • Install the new piston rings in the grooves so that the radii at the ring gap face upward and meet at the fixing pin. STIHL 088...
- Page 23 Assembly is now a reversal of the disassembly sequence • Pull the ends of the string • Slide the cylinder over the piston - outward. the clamping strap is pushed downward as the piston rings slip into the cylinder. STIHL 088...
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Page 24: Piston Rings
• Install the new piston rings in the • Take out the screw (1). grooves so that the radii face - Remove the ignition module. • Remove the spiked bumper (2) upward. with deflector (3). - Install the piston - see 4.5.2. STIHL 088... - Page 25 • Pry the plugs out of the annular • At chain tensioner side of crank- buffers at the clutch side. case. use a 5 mm (3/16”) drift (2) to drive the dowel pin (1) out of the two halves of the crankcase. STIHL 088...
- Page 26 • Turn spindle (1) • Pry the oil seal out of the ball counterclockwise until the bearing at the clutch side. - Unscrew spindle of service tool crankshaft is pushed out of the ZS a little (left-hand thread). ball bearing. STIHL 088...
- Page 27 1119 893 2401 to remove the starter side of the crankcase. ball bearing. Note: To replace the crankcase, • Unscrew the oil tank filler cap (2). carry out the following operations. • Remove cord (3) from the groove. STIHL 088...
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Page 28: Installing The Crankshaft
• Check that dowel pin is in position. If • If it is not possible to heat the necessary, drive dowel pin into new crankcase, use the press arbor crankcase. (1) 1124 893 7200 to press in the ball bearing as far as stop. STIHL 088... - Page 29 (1) 1124 893 7200 to press in the guide until its lugs are behind the its tab locates in the recesss at the ball bearing as far as stop. edge of the housing. top left. STIHL 088...
- Page 30 • Release the spindle by turning it • Apply threaded sleeve (1) to counterclockwise and then hold the thread (2) on crankshaft stub and screw it on. crankshaft steady and unscrew the service tool counterclockwise. STIHL 088...
- Page 31 • Screw threaded sleeve (1) • Use a 5 mm (3/16") drift to drive the 5910 893 2408 onto the spindle as dowel pin into the two halves of the far as it will go (left-hand thread). crankcase from the sprocket side. STIHL 088...
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Page 32: Decompression Valve
• Press it fully home with press • Remove the grommet (1). sleeve (1) 1127 893 2400. • Unscrew the decompression Note: The press surface must be flat valve (2). and free from burrs. STIHL 088... -
Page 33: Ignition System
(1) and flywheel (2) and is easily accessible. • Fit the shroud and make sure the ignition lead is correctly positioned in the shroud recess. Reassemble all other parts in the reverse sequence. STIHL 088... -
Page 34: Ignition Timing
(2). • Take out the screws. • Rotate the flywheel until the magnets are between the arms of the ignition module. - Remove the ignition module. - Remove the ignition lead - see 5.2. STIHL 088... -
Page 35: Spark Plug Boot
15 mm (5/8") from the end of the lead. • Use suitable pliers to grip the leg • Pull the lead back into the boot spring and pull it out of the spark so that the leg spring locates plug boot. properly inside it. STIHL 088... -
Page 36: Flywheel
- Slip the insulating hose and grommet onto the lead. - Pack the high voltage output with STIHL multipurpose grease - see 11.2. Important: Do not use graphite grease (Molykote) or silicone insulating paste. -
Page 37: Ground Wire
- Check that upper and lower grommets are properly seated. - Distance "a" between terminal and insulating tube should be 15 mm (0.6 in). • Pull short circuit wire (1) and ground wire (2) out of lower grommet. STIHL 088... -
Page 38: Rewind Starter
It should be lubricated in the clockwise direction in the fan with a few drops of STIHL special housing, starting outside and lubricant before installation working inwards. -
Page 39: Tensioning
Do not overtension the rewind spring - it might break. - Refit the fan housing - see 5.1.2. • Hold the rope rotor steady. • Pull out the rope with the starter grip and straighten it out. STIHL 088... -
Page 40: Av Handle System
• Remove the annular buffer (4). Note: Remove the tank housing, see 10.6, for access to the other annular buffers. • Push the stop buffer into the guide until the groove (1) engages the housing rib (2). STIHL 088... -
Page 41: Master Control/Handle System
• Ease the switch shaft out of its carburetor - see 10.2.1. left-hand pivot mount. - Remove the switch shaft. • Pull short circuit wire out of the • Remove the choke lever (1) and switch shaft. double lever (2). STIHL 088... -
Page 42: Throttle Trigger/Interlock Lever
• Pull the throttle rod out of the • Press the interlock lever (1) down. throttle trigger. • Pull the throttle trigger (2) up and move the Master Control lever (3) to "Choke". STIHL 088... -
Page 43: Chain Lubrication
• Use assembly hook (1) • Pull suction hose and pickup body out of the crankcase. 5910 893 8800 to pull the pickup body out of the oil tank. Note: Avoid stretching the oil hose. STIHL 088... -
Page 44: Valve
Reassemble in the reverse - Remove the inner side plate - sequence. see 3.3.1. • Apply a drift from outside and ca- refully drive the vent valve out of the crankcase and remove it from the oil tank. STIHL 088... -
Page 45: Oil Pump
• Remove the cover (2). sequence. • Ease the spur gear off the pump. • Take out the screws (1). • Remove the cover (2). • Take out the screws. • Pry away the oil pump. - Pull out the oil pump. STIHL 088... - Page 46 Inspect the parts for damage and the worm. replace as necessary. Reassemble in the reverse sequence. - Always install new O-rings. - Coat pump piston and worm with grease, see 11.2, before installing. • Press home with press plate (1) 1124 893 5100. STIHL 088...
- Page 47 • Unscrew the collar nuts (1). • Remove the carburetor box • Pull off the flange (2). cover (2). • Remove the air filter. • The word "TOP" must face up. • Remove the filter base. Reassemble in the reverse sequence. STIHL 088...
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Page 48: Removing And
• Lift away the carburetor. - see 8.2. Reassemble in the reverse • Disconnect the throttle rod from sequence. the double lever. • Before installing the carburetor, • Disconnect choke rod from the check that sleeve is in position. choke lever. STIHL 088... -
Page 49: Leakage Test
(foreign matter in valve seat or sealing cone of inlet needle is damaged or inlet control lever sticking). 2. The metering diaphragm is damaged. In either of these cases the carburetor • Pull off the fuel hose. must be removed and serviced. STIHL 088... - Page 50 Maximum engine speed with bar and properly tensioned chain: 12,000 rpm Note: If no tachometer is available, do not turn the high speed or low speed screws beyond the standard setting to make the mixture leaner. STIHL 088...
- Page 51 - Close the tank and shake the saw vigorously. - Open the tank again and drain it. Note: Dispose of old fuel at approved disposal site. • Pull the sintered filter (1) and valve (2) out of the tank. STIHL 088...
- Page 52 Reassemble in the reverse sequence. sequence. • Pull fuel hose (1) off the - Coat the flange of the fuel hose connector (2). with a little oil. • Straight side (1) of flange must locate against tank housing. STIHL 088...
- Page 53 • Take out the annular buffer • Pry the plug out of the annular Important: Heat the screwed joints. Do not overheat polymer. mounting screws. buffer at the starter side. • Remove the mounting screws from the side of the front handle. STIHL 088...
- Page 54 15 mm. • Push the manifold down. • Remove the rings from the tank • Fit an M6x10 screw with washer in housing. the thread insert. - Screw the thread insert into the tank housing. STIHL 088...
- Page 55 • All wires must be properly located in their retainers. - Coat threads of front handle mounting screws with Loctite, see 11.2, and torque down to 8.0 Nm (5.9 Ibf.ft). STIHL 088...
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Page 56: Special Servicing Tools And Aids
(0.325 to 13.5 Ibf.ft) 5910 890 0302 Torque wrench 5910 890 0311 6 to 80 Nm (4.5 to 60 Ibf.ft) 5910 890 0312 Base 1124 893 5200 Assembling oil pump Press plate 1124 893 5100 Installing oil pump shaft seal STIHL 088... - Page 57 (clutch side) Press arbor 1119 893 2401 Removing and installing ball bearing (starter side) Remarks: 1) Always use torque wrench to tighten 'P' screws. 2) Wrench has optical/acoustic signal. 3) On 'P' screws, use for releasing only. STIHL 088...
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Page 58: Servicing Aids
Standard commercial, Cleaning crankshaft stub solvent-based degreasant without chlorinated or halogenated hydrocarbons STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in starter cover Ignition lead HTR (10 m/33”) 0000 930 2251 Electrician's repair kit...