044 Stihl Chainsaw Service Repair Manual

The Stihl 044 chainsaw is a professional-grade power tool designed for demanding cutting applications. This comprehensive service and repair manual provides detailed instructions for maintenance, troubleshooting, disassembly, and reassembly of the Stihl 044 model. It covers engine systems, fuel system, ignition, carburetor, chain brake, bar and chain, and electrical components to ensure proper operation and longevity.

1. Safety Precautions 2. Specifications & Technical Data 3. Tools & Equipment Required 4. Routine Maintenance 5. Engine System Repair 6. Fuel System Service 7. Ignition & Electrical System 8. Chain Brake & Clutch Assembly 9. Bar & Chain Maintenance 10. Troubleshooting Guide 11. Parts List & Diagrams

Safety Precautions

Always prioritize safety when servicing chainsaws. Wear appropriate personal protective equipment (PPE).

Precaution	Description
Disconnect Spark Plug	Always remove spark plug wire before performing any service to prevent accidental starting.
Work in Well-Ventilated Area	Service in areas with good airflow to avoid fume inhalation.
Use Proper Tools	Utilize Stihl-approved or recommended tools to avoid damage and ensure safety.
Secure Chainsaw	Clamp or secure the unit in a vise during disassembly to prevent movement.
Handle Fuel Safely	Drain fuel tank before service; no smoking or open flames nearby.
Chain Tension	Ensure chain is properly tensioned and sharpened to prevent kickback.
Wear Gloves & Eye Protection	Protect against sharp edges, fuel, and debris.
Follow Torque Specifications	Use a torque wrench for critical fasteners to avoid over/under tightening.

Specifications & Technical Data

Key technical specifications for the Stihl 044 chainsaw.

Engine Type: 2-stroke, single cylinder, air-cooled.
Displacement: 70.7 cc (4.3 cu. in.).
Power Output: Approx. 4.4 kW (6.0 HP).
Fuel/Oil Mix Ratio: 50:1 (Stihl HP Ultra or equivalent).
Idle Speed: 2,800 RPM.
Maximum Power Speed: 13,000 RPM.
Ignition System: Electronic, capacitor discharge (CDI).
Carburetor: Zama C1Q-S series or Walbro.
Bar Length Range: 16" to 32" (recommended).
Chain Pitch/Gauge: .325" pitch, .063" gauge (standard).
Weight (Powerhead): Approx. 6.2 kg (13.7 lbs).

Tools & Equipment Required

Specialized and standard tools needed for service.

Stihl combination wrench or socket set.
Torque wrench (capable of 5-50 Nm).
Piston stop tool (for flywheel removal).
Flywheel puller (Stihl tool # 1128 893 4500 or equivalent).
Clutch removal tool (Stihl # 0000 893 4302).
Compression tester.
Vacuum/pressure tester (for crankcase seals).
Feeler gauges (for spark plug gap, points if applicable).
Carburetor adjustment tool (splined).
Chain sharpening file and guide.

WARNING! Using incorrect tools can damage components and void warranty.

Routine Maintenance

Regular maintenance schedule to ensure optimal performance.

Daily/Before Use: Check chain tension and sharpness, inspect bar for wear, ensure all fasteners are tight.
After Each Use: Clean air filter, check for fuel/oil leaks, wipe down exterior.
Every 10 Hours: Clean spark arrestor screen (if equipped), inspect fuel filter.
Every 20 Hours: Replace air filter, check spark plug condition and gap (0.5 mm / .020").
Every 50 Hours: Clean cooling fins, inspect clutch drum and sprocket, check anti-vibration elements.
Every 100 Hours: Replace fuel filter, inspect crankcase seals, check cylinder/piston through exhaust port.

CAUTION! Use only Stihl-approved replacement parts and lubricants.

Engine System Repair

Procedures for cylinder, piston, crankshaft, and bearings.

Cylinder & Piston Inspection: Remove muffler to inspect cylinder walls and piston skirt for scoring. Measure piston clearance.

Top End Rebuild: Steps for replacing piston rings, piston, and cylinder.

Remove carburetor, intake boot, and ignition module.
Remove cylinder base nuts, carefully lift off cylinder.
Remove piston pin circlips, drive out pin, remove piston.
Clean all gasket surfaces, install new piston with arrow facing exhaust port.
Lubricate rings, install cylinder, torque base nuts to specification (typically 10-12 Nm).

Crankcase Seals: Test with pressure/vacuum. Replace if leaks detected using seal puller and installer.

Fuel System Service

Carburetor adjustment, repair, and fuel line replacement.

Carburetor Adjustment (Standard Settings): Initial settings: L screw - 1 turn open, H screw - 1 turn open, LA (idle) screw - 1 turn open. Fine-tune for smooth acceleration and idle.
Carburetor Rebuild: Disassemble, clean in ultrasonic cleaner, replace diaphragms, gaskets, inlet needle. Use rebuild kit.
Fuel Line & Filter: Remove old fuel line from tank, attach new line with filter, route correctly through tank grommet.
Impulse Line: Inspect the line connecting carburetor to crankcase; replace if cracked or brittle.

Tip: Always use fresh, properly mixed fuel. Stale fuel is a common cause of running issues.

Ignition & Electrical System

Testing and replacing ignition module, spark plug, and stop switch.

Component	Test Procedure	Specification
Ignition Module (Coil)	Check primary/secondary resistance with multimeter.	Primary: ~0.2-0.5 Ω; Secondary: ~4-8 kΩ (refer to manual).
Spark Plug	Check gap (0.5 mm), condition (tan deposits normal).	NGK BPMR7A or equivalent.
Stop Switch	Continuity test: switch should be open when off, closed when on.	Replace if faulty.
Flywheel & Key	Inspect for sheared woodruff key causing timing issues.	Key must be undamaged; flywheel nut torque: 40-50 Nm.

WARNING! Never crank engine with spark plug removed and wire grounded against cylinder if testing for spark with fuel present.

Chain Brake & Clutch Assembly

Service of the chain brake band, clutch, drum, and sprocket.

Clutch Removal: Use clutch tool to hold piston, rotate clutch clockwise (left-hand thread) to remove.
Clutch Inspection: Check shoes for wear, springs for fatigue. Replace if worn.
Chain Brake Band: Inspect for thinning or glazing. Replace if thickness is below specification.
Bearing & Drum: Inspect clutch drum bearing for smooth rotation. Replace sprocket if teeth are hooked.
Reassembly: Lubricate bearing, install drum, torque clutch to 35-40 Nm (right-hand thread for reassembly).

Bar & Chain Maintenance

Proper care to extend bar and chain life.

Bar Maintenance: File down any burrs on rails, clean oil grooves and holes, flip bar regularly for even wear.
Chain Sharpening: Use correct file size (typically 4.0 mm / 5/32" for .325" pitch). Maintain correct filing angle (30°). Ensure all cutters are uniform length.
Chain Tension: Proper tension: snug against bar but pullable by hand. Re-tighten after initial warm-up.
Oil System: Check oiler output, clean oil passages. Adjust oil flow if adjustable.

CAUTION! Always wear cut-resistant gloves when handling chain.

Troubleshooting Guide

Problem	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, fuel issue, compression low	Check spark, plug condition. Dry plug if flooded. Check fuel line/filter. Test compression (should be >120 psi).
Engine starts then dies	Clogged fuel filter, carburetor issue, tank vent blocked	Replace fuel filter. Clean/rebuild carb. Check tank vent.
Lacks power under load	Clogged air filter, exhaust port carboned, carb adjustment, compression	Clean/replace air filter. Decarbon exhaust. Adjust H needle. Check compression.
Chain does not turn	Clutch worn, sprocket seized, brake engaged, drive spring broken	Inspect clutch/sprocket. Disengage brake. Check clutch drum bearing.
Excessive vibration	Unbalanced chain, loose components, worn anti-vibration mounts	Sharpen chain evenly. Tighten all fasteners. Replace AV mounts.
Oil not lubricating chain	Clogged oil passages, worn oil pump, incorrect oil	Clean bar oil holes. Inspect oil pump gears. Use correct bar & chain oil.

Reset: For electronic ignition issues, ensure flywheel key is not sheared.

Parts List & Diagrams

Reference for major assembly part numbers (example numbers; verify with current list).

Cylinder Assembly: 1128 020 1205
Piston Kit: 1128 030 2001
Crankshaft: 1128 023 1000
Ignition Module: 1128 400 1301
Carburetor Kit: 1128 007 1055
Clutch Assembly: 1128 160 2003
Chain Brake Band: 1128 650 7701
Fuel Line: 1128 358 7700
Air Filter: 1128 120 1600

Service: For genuine Stihl parts and technical support, contact an authorized Stihl dealer or visit www.stihlusa.com.