Stihl 041 Parts Manual
Sthil 041 Av Hello to all the members here at this forum my name is Brett and i have a sthil o41 av that needs some help. So here we go my previous analysis is carb issue but the symptoms are high idle though its set low short amounts of running time before choking out constant needing of chock throttle reconfiguration to keep her running and so i have done all i know how to help her out changed the gas multiple times but feel i need to go through the saw and rebuild it and having said that i need a exploded view on how to take it apart or sbs instructions this saw is my life please help if u can -thanks.
Tgren64 said: “ If I take the spark plug out, I can pull the start cord easily. But with the spark plug in place, it is almost impossible to pull the cord. I drained all the gas and bar oil out. With the spark plug out, I get what looks like oil coming out of the spark plug hole when I pull the rope. The oil pump is leaking into the crankcase.
Very common problem with the 040, 041, and 051. Many had the problem when less then a year old. Easy fix with a new o-ring and rubber pump-housing sleeve. I was a Stihl dealer mechanic back 1960s-1970s-1980s and have many manuals.
NOT in PDF however. For the 041, I have: 041 Farm Boss owners manual # 0458 159 0121 M10; 041 Farm Boss owners manual # 0458 159 0121 M20; 041 AV tech-manual # 0455 110 0123 M13 (three copies); and tech manual 041/041AV/041AV Electronic # 0455 110 0123 M4. Lskid92 said: “ Hello to all the members here at this forum my name is Brett and i have a sthil o41 av that needs some help. So here we go my previous analysis is carb issue but the symptoms are high idle though its set low short amounts of running time before choking out constant needing of chock throttle reconfiguration to keep her running and so i have done all i know how to help her out changed the gas multiple times but feel i need to go through the saw and rebuild it and having said that i need a exploded view on how to take it apart or sbs instructions this saw is my life please help if u can -thanksHave you checked the intake manifold gaskets and the fuel-pump impulse hose?
Two major failure areas on all 041s. Tgren64 said: “ need Stihl 041 repair manual I too am looking for a repair manual for a Stihl 041 saw. Seba board class 9 maths guide.
I bought this saw at an auction sale. If I take the spark plug out, I can pull the start cord easily. But with the spark plug in place, it is almost impossible to pull the cord. I drained all the gas and bar oil out. With the spark plug out, I get what looks like oil coming out of the spark plug hole when I pull the rope.
I have been searching Google for any help I can find. If anyone has any repair details on this saw in PDF format, please email them to me. As far as im aware the oil lube pipe?
Runs through the crank case I think there a link on yuotube how to repair this failure. Another common problem with this saw is the amount of gasgets between the carb and the cylinder, the engine shrud gaskets are prone to decay, thus letting air in and allowing a lean fuel mix which ends up scoring the piston/barel not to mention the crap it can suck in whats sitting around the gaskets, ive done 3 in the last 2 months.
Bellow is one I fitted new carb kit. Fuel line, inpulse line and gasgets too, sounds lovely;o) enjoy your saw they are a classic.
In the late 60's ( or early 70's) my dad bought an 041-AV and I used it for probably 50 hours before going off to college and away for 25 years. In 1995 I got it back from dad who had never used it and I had it tuned it up and cut with it for probably 25 hours before the fuel pump broke. The estimate for repair was the same price as a new Poulan chain saw and the repair center told me that many repair parts were no longer available so I filled with oil and mothballed. I sure miss the use of that saw but I cant throw it away. I still fantasize about repairing and using again but I think is not cost effective.
Would it be best to part it out? Are there collectors of these old saws? BTW, I have been through three Poulan saws in 10 years so maybe I should have stuck with the 041-AV and I would have saved money in the long run. Preventec47 said: “ In the late 60's ( or early 70's) my dad bought an 041-AV and I used it for probably 50 hours before going off to college and away for 25 years.
In 1995 I got it back from dad who had never used it and I had it tuned it up and cut with it for probably 25 hours before the fuel pump broke. The estimate for repair was the same price as a new Poulan chain saw and the repair center told me that many repair parts were no longer available so I filled with oil and mothballed. I sure miss the use of that saw but I cant throw it away. I still fantasize about repairing and using again but I think is not cost effective. Would it be best to part it out? Are there collectors of these old saws?
BTW, I have been through three Poulan saws in 10 years so maybe I should have stuck with the 041-AV and I would have saved money in the long run.I don't 'do' Stihls, but I think someone was F.O.S. And just wanted to sell a new saw.
How hard is that!!! Yep, I think you are right. IT was the oil pump part that was not available many years ago( and NOT the fuel pump ) when I had in the shop for repair so I just said let me take it home and I just went and bought whatever was on sale at SEARS. I seem to recall observing that the bar was awfully dry and the oil tank was not being depleted with the gas at the same rate so I knew pretty quickly I had an chain oiler problem. It is also pretty obvious when the chain starts smoking too. If I recall, isnt the oil pump gear driven? I always told my friends that the Stihl seemed like it was cutting in 1st gear and could just rip the wood out without stalling and the SEARS ( poulan) models ran in 5th gear and did all the work with high chain speed and would stall easily but man they really seemed to spray the sawdust.
Stihl 041 Parts Manual Pdf
I didnt know till now that the displacement of the 041 was a lot more than the hi revving Poulans. So if the parts were not available more than ten years ago I am even more concerned but, I could see that the internet could help to tilt the decision towards repair if I can find parts from guys who must have stockpiled them.
I did some other searching here for 041-AV and I do not know if it is points or electronic. I had been led to believe that the AV designation basically stood for new electronics.
So are there in fact some points AV models? ALSO some guys who are familiar mechanics? I honestly dont have the knowhow or tools so I need a mechanic AND parts sources. Scott in Atlanta, GA. Have you checked site sponsor chainsawr.com? Preventec47 said: “ Yep, I think you are right.
IT was the oil pump part that was not available many years ago( and NOT the fuel pump ) when I had in the shop for repair so I just said let me take it home and I just went and bought whatever was on sale at SEARS. I seem to recall observing that the bar was awfully dry and the oil tank was not being depleted with the gas at the same rate so I knew pretty quickly I had an chain oiler problem. It is also pretty obvious when the chain starts smoking too. If I recall, isnt the oil pump gear driven?
I always told my friends that the Stihl seemed like it was cutting in 1st gear and could just rip the wood out without stalling and the SEARS ( poulan) models ran in 5th gear and did all the work with high chain speed and would stall easily but man they really seemed to spray the sawdust. I didnt know till now that the displacement of the 041 was a lot more than the hi revving Poulans.
So if the parts were not available more than ten years ago I am even more concerned but, I could see that the internet could help to tilt the decision towards repair if I can find parts from guys who must have stockpiled them. I did some other searching here for 041-AV and I do not know if it is points or electronic. I had been led to believe that the AV designation basically stood for new electronics.
So are there in fact some points AV models? ALSO some guys who are familiar mechanics? I honestly dont have the knowhow or tools so I need a mechanic AND parts sources. Scott in Atlanta, GA I think I have a few 041 oil pumps. Let me check and see.
If I can find one You can have it. Sounds like this 041 has had little use so I don't believe that is anything wrong with the pump gears.
Your trouble most likely lies with one simple o-ring that is in the very end of the pump body. Once you pull the whole pump out, you can pull the steel plunger out of the aluminum pump body. There is a recess in the end of the pump body where a tiny o-ring sits.
It is supposed to be 6mm in diameter by 1.5 mm thickness. Yes it is metric, but even though you may not be able to find metric you can find an SAE (english) size from any assortment of o-rings. The closest size stretches slightly over the plunger, but is slightly too big to fit into the recess in the body. Don't worry it will still work. I have an 041 with an o-ring like this and it works fine.
Bob Edit to add: The drive pin that runs this oil pump may also be sheared. The drive pin goes from the sprocket to the oil pump gear. If this pin is sheared, oil pump no workey.
Remove the sprocket, and you should see the pin. There is a hole in the end of the sprocket for the pin. I have a good collection of basic tools such as wrenches sockets and screwdrivers etc. Will I need any special tools to take overhaul my Stihl 041-AV been sitting for more than 10 or 12 years in dry shed with oil in cylinders.
And I am sure I dumped the gas out of tank. Should I take it apart down to the crank shaft and inspect bearings? I probably need to disassemble soak and rebuild carburator. Where can I find any manuals or instructions anywhere to show how to get to the oil pump?
Any other suggestions or recommendations? Got nothing much to lose here as if I get it all taken apart I will carefully store all the parts and in the worst case, I can sell someone an old saw that has already been disassembled for inspection:- ) Scott in Atlanta, GA. If it aint broke dont fix it, if you dumped the fuel years ago the carb may be fine, I have seen them set up drained properly for 10+ years, for instance, same era saw 076, fresh fuel and fuel lines and it fired right up!!! If yours needs a carb kit no biggie, if it was running fine and low hours like you say why tear it down all the way??? Fix the easy stuff, as other poster said, oilpump plunger/oring maybe cartb kit and fuel lines, try it, if it runs, its all good, keep us posted on this thread, we will help you with it, you can do it!!!! Send me you email on a PM and I will send you the IPL Illustrated parts list, sorry I dont have the service manual You can clearly see the oil pump plunger and all the associated parts.
If you don't know where the oiler is located,It is in the front of the saw, right next to the chain ajustment screw. Yep, that hole there. Clean it up, and you will see a snap ring that you have to remove first thing. Then you need to take any 5mm screw and insert into the top hole of the oiler body. Take a screw from the starter cover, as it is the right size. Once you have the screw inserted, you can pry the oiler out with a screwdriver.
Then pull the steel plunger with the gear thingy out of the aluminum housing. The o-ring might come out with the plunger or it may get left in the housing. I already gave you a heads up abut the o-ring. If the search function was working there are quite a few threads about 041 oilers. That silly o-ring causes much trouble. Bob Edit to add,NO don't disassemble the whole saw at this point. In order to put it back together again correctly you will need seals and gaskets that are a pain to find these days.
Go for the obvious easy fixes before tearing it to pieces!!!! Your old 041 probably has points ignition. The fuel pump is just half of the carb,a Tillotson HS carb kit will rebuild it.I would get it running and SEE if the oiler is working or not. If the oiler isn't working it could be a worn out worm gear on the crank under the clutch.Also the worm gear was driven by the clutch drum,sometimes a little pin connected the 2 and could break or wear out.There were a few different setups.Some of the crank worm gears may not be available new anymore,but should be lotsa used ones 'Stihl' around. Get the saw running and go from there. Those old 041's ran forever.
Bobt said: “ If you don't know where the oiler is located,It is in the front of the saw, right next to the chain ajustment screw. Yep, that hole there. Clean it up, and you will see a snap ring that you have to remove first thing. Then you need to take any 5mm screw and insert into the top hole of the oiler body. Take a screw from the starter cover, as it is the right size.
Once you have the screw inserted, you can pry the oiler out with a screwdriver. Then pull the steel plunger with the gear thingy out of the aluminum housing. The o-ring might come out with the plunger or it may get left in the housing. I already gave you a heads up abut the o-ring. If the search function was working there are quite a few threads about 041 oilers.
That silly o-ring causes much trouble. Bob Edit to add,NO don't disassemble the whole saw at this point. In order to put it back together again correctly you will need seals and gaskets that are a pain to find these days. Go for the obvious easy fixes before tearing it to pieces!!!!here ya go. WOW that is some great info in that google search.
Stihl 041
Most of it here at the AS site. I went out and checked on my AV saw and then printed out all the pages of the Illustrated Parts Manual from the PDF that was given to me and then I pulled the spark plug out and pulled the starter cord several times to see if I could get spark to jump and it did so I am off to the races. Tomorrow I will take some photos of the filter cover and some other parts to add as reference as I do not know what version of 041-AV it is except that I know it does NOT have a chain brake of any kind. I'll clean up the spark plug and add some gas and maybe even a little starter fluid and see if the carburator works to deliver fuel mixture enough to keep it running. THEN I will focus on the oil pump if I can get it to run pretty good. I will say this it has a ton of compressioin and I have to pull the starter at least twice as hard as my Sears/Poulan 38cc saw.
Stihl 041 Parts Manual
Maybe just because the Stihl has 60cc that would make a big difference in the pull effort. I also have a bid in on EBAY for the shop manual. IF I win I will try to have scanned so we can all have a digital version of it.
Very good sir! Now that you know you have spark, and before you go any farther toward seeing if she'll run (which she will), let me recommend one thing. Tighten the two allen head bolts that hold the intake stack on!! (trust me.it's worth it) -take at least the air filter plate off (2x 8mm nuts and 1x machine screw probably) -should be able to get a 4mm allen down inside, past the brown plastic shield (look with a flashlight) and tighten those bolts.one on either side of the carb then carry on! And if it ain't too much to ask, post a pic of your 041.we're all interested!