A 038av needs a little help

[BigChopper]

Hey all
So I've bought a really old 038av, the one with the metal tank. It looks like it's been in a damp shed for the last 10 years. It has a broken handle so I've ordered a plastic replacement from ebay.
As its 99 percent complete I've decided to revive it from its slumber.

I've stripped the broken handle off and cleaned up main chunk but as I was disassembling it I noticed lots of different types and lengths of fasteners which is making me worry that I won't be able to rebuild it. It has the Tillotson carburettor which I've bought a rebuild kit for I also bought the following parts to "freshen it up"

A muffler, a coil setup, a pull cord, sparkplug, new fuel/oil caps, an impulse pipe and a secondhand genuine clutch cover as it had a large crack in the original.

It was very very dirty and looks like it was never stripped or cleaned in its entire life but after a few hours with a toothbrush and an airline it's comeback quite clean. The carb looks clean, the piston looks good with no scoring and the fins are all intact. There was what looks to be a wire missing as I found some eye crimp connectors with no wire attached.

The chain brake is functioning fine, the pull start mechanism works now I've had it apart and cleaned it and I will replace the 1 foot of cord with a fresh meter long bit.

I'm not 100 percent sure of what screw/torx goes where on the rebuild hence I thought I'd better make a login, hopefully it's the right place to ask.

I'll update the thread when all the parts arrive.
Thanks in advance.
Chopper.

 

[pioneerguy600]

Maybe @ray benson can help with an IPL and shop manual

 

[ray benson]

Hey all
So I've bought a really old 038av, the one with the metal tank. It looks like it's been in a damp shed for the last 10 years. It has a broken handle so I've ordered a plastic replacement from ebay.
As its 99 percent complete I've decided to revive it from its slumber.

I've stripped the broken handle off and cleaned up main chunk but as I was disassembling it I noticed lots of different types and lengths of fasteners which is making me worry that I won't be able to rebuild it. It has the Tillotson carburettor which I've bought a rebuild kit for I also bought the following parts to "freshen it up"

A muffler, a coil setup, a pull cord, sparkplug, new fuel/oil caps, an impulse pipe and a secondhand genuine clutch cover as it had a large crack in the original.

It was very very dirty and looks like it was never stripped or cleaned in its entire life but after a few hours with a toothbrush and an airline it's comeback quite clean. The carb looks clean, the piston looks good with no scoring and the fins are all intact. There was what looks to be a wire missing as I found some eye crimp connectors with no wire attached.

The chain brake is functioning fine, the pull start mechanism works now I've had it apart and cleaned it and I will replace the 1 foot of cord with a fresh meter long bit.

I'm not 100 percent sure of what screw/torx goes where on the rebuild hence I thought I'd better make a login, hopefully it's the right place to ask.

I'll update the thread when all the parts arrive.
Thanks in advance.
Chopper.

Check your inbox.

 

[BigChopper]

Check your inbox.

Thank you so much, I was about take pictures and label holes!
It's definitely got a better chance of going back together properly.
Thanks for taking the time.
I'll update you all when all the parts arrive.

 

[Bob Hedgecutter]

Thank you so much, I was about take pictures and label holes!
It's definitely got a better chance of going back together properly.
Thanks for taking the time.
I'll update you all when all the parts arrive.

Update with photographs- we all love saw photos.

 

[Bob95065]

I brought a beat up 038 back to life a few years ago. A good friend and member here gave it to me and I bought parts from another member of the forum. My 038 is one of the most reliable saws in my firewood arsenal and well worth reviving. Good job bringing yours back to life.

 

[Mad Professor]

Using baggies as you take parts off will help keep the parts organized with their assys.

Label the bags with a sharpie.

 

[pioneerguy600]

Using baggies as you take parts off will help keep the parts organized with their assys.

Label the bags with a sharpie.

Some fellas like to take cell phone pics as they go, helps when put back together comes around. Not like me where the pics are already stored in my head.

 

[Mad Professor]

Some fellas like to take cell phone pics as they go, helps when put back together comes around. Not like me where the pics are already stored in my head.

Thin wire or produce twist ties, are good to organize things with holes in them like clutch assys,flywheel and nut/washer....... Can put them in the order and orientation in which they were removed.

 

[pioneerguy600]

Thin wire or produce twist ties, are good to organize things with holes in them like clutch assys,flywheel and nut/washer....... Can put them in the order and orientation in which they were removed.

I have worked with guys that would sketch the outline of a part on a piece of cardboard box then punch the screws in where they fit, helps them with the correct size and length of screw during reassembly, fortunate for me as I have not needed visual aids. If the screws are just pushed in through the cardboard they stay retained very well.

 

[president]

Hey all
So I've bought a really old 038av, the one with the metal tank. It looks like it's been in a damp shed for the last 10 years. It has a broken handle so I've ordered a plastic replacement from ebay.
As its 99 percent complete I've decided to revive it from its slumber.

I've stripped the broken handle off and cleaned up main chunk but as I was disassembling it I noticed lots of different types and lengths of fasteners which is making me worry that I won't be able to rebuild it. It has the Tillotson carburettor which I've bought a rebuild kit for I also bought the following parts to "freshen it up"

A muffler, a coil setup, a pull cord, sparkplug, new fuel/oil caps, an impulse pipe and a secondhand genuine clutch cover as it had a large crack in the original.

It was very very dirty and looks like it was never stripped or cleaned in its entire life but after a few hours with a toothbrush and an airline it's comeback quite clean. The carb looks clean, the piston looks good with no scoring and the fins are all intact. There was what looks to be a wire missing as I found some eye crimp connectors with no wire attached.

The chain brake is functioning fine, the pull start mechanism works now I've had it apart and cleaned it and I will replace the 1 foot of cord with a fresh meter long bit.

I'm not 100 percent sure of what screw/torx goes where on the rebuild hence I thought I'd better make a login, hopefully it's the right place to ask.

I'll update the thread when all the parts arrive.
Thanks in advance.
Chopper.

Get a shop manual and IPL.
the fasteners for all asemblys will be quoted,

 

[BigChopper]

So more of the parts have arrived, as well as those parts listed above I also bought a selection of stihl fixings from ebay incase anything broke on the way out.

I've rewound the starter with a fresh meter of rope, the exhaust has arrived as well as the new coil. The handle arrived but its broken, it looks like it will be hidden under the airbox cover but I'm not happy building it on a broken base. Have to wait for a reply from China!


Top left corner missing and the top right got crunched, I could probably glue it and make it good fingers crossed.
My next problem Is removing the fly wheel so I can get the new coil wire under it.

I've read it's a left hand thread, just a bit worried about giving it to much incase it sheers off. That wire that comes out from under the fly wheel to the coil looks like it has a join in it already.

I already tried a rag in the exhaust to stop the piston so I could try and undo the center nut but It didn't budge so my next step will be the impact gun tomorrow remembering left isn't loosey, and right isn't tighty!

Here's my sweet little 021 that takes a licking but keeps on ticking.


I'll get the 660 out tomorrow, it's the cleanest I've ever seen.

 

[Bob Hedgecutter]

Flywheel nut is standard rht lefty loosey, righty tighty.

 

[BigChopper]

Flywheel nut is standard rht lefty loosey, righty tighty.

So it's not a left hand thread... that'll be why it didn't budge! Glad I didn't give it any beans.

 

[irhunter]

How "broken" was the original handle? Got a pic?

Yes, it is the clutch which is the left thread...not flywheel.

 

[BigChopper]

How "broken" was the original handle? Got a pic?

Yes, it is the clutch which is the left thread...not flywheel.

I'll take a picture tomorrow, the trigger was still there and functional but behind that it was gone. The previous owner said he dropped it from up a tree.

 

[guym3]

No need to remove flywheel to put on the coil. Check on youtube as its easy, just needs the correct spacing with a business card.

 

[Bob Hedgecutter]

No need to remove flywheel to put on the coil. Check on youtube as its easy, just needs the correct spacing with a business card.

Um, depending on the age of the unit- being a metal tank saw and all- there are two piece ignitions with a module under the flywheel as well as the coil in the usual position.

 

[guym3]

Fair point didn't realise that. I've just rebuilt two of them that were not like that but appreciate some may be.

 

[BigChopper]

How "broken" was the original handle? Got a pic?

Yes, it is the clutch which is the left thread...not flywheel.

Everything behind the throttle is gone. The entire saw was coated like this.