Table of Contents
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Service Manual
020 T Chain Saws
This manual contains detailed
descriptions of all repair and
servicing procedures for 020 T
chain saws.
You should make use of the
illustrated parts list while carrying
out repair work. It shows the
installed positions of the individual
components and assemblies.
Microfilmed parts lists are always
more up to date than printed lists.
A fault on the machine may have
several causes. Consult the
"Troubleshooting Charts" when
tracing faults.
Refer to the "Technical Information"
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list until a re-
vised edition is issued.
The special servicing tools mentioned
in the descriptions are listed in the last
chapter of this manual. Use the part
numbers to identify the tools in the
"STIHL Special Tools" manual.
The manual lists all special servicing
tools currently available from STIHL.
Service manuals and all technical
information bulletins describing
engineering changes are intended
exclusively for the use of STIHL
servicing dealers. They must not be
passed to third parties.
STIHL 020 T
Servicing and repairs are made
considerably easier if the machine
is mounted on the assembly stand
(1). This enables the machine to be
swivelled to the best position for the
ongoing repair and leaves both hands
free.
The machine is secured to the stand
by means of the guide bar mounting
nut (after removing the sprocket
cover).
Always use original STIHL
replacement parts.
They can be identified by
the STIHL part number, the
STIHl logo
and the STIHL parts symbol
The symbol may appear alone on
small parts.
STIHl
© 1999, Andreas Stihl AG & Co., Waiblingen
(
1
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Summary of Contents for Stihl 020 T
- Page 1 Service manuals and all technical information bulletins describing engineering changes are intended exclusively for the use of STIHL servicing dealers. They must not be passed to third parties. STIHl © 1999, Andreas Stihl AG & Co., Waiblingen STIHL 020 T...
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Page 2: Table Of Contents
Handle Housing Oil Seals Cylinder and Piston Chain Lubrication 4.4.1 Removal 4.4.2 Installation Suction Hose/ Piston Rings Pickup Body Crankcase Vent Valve 4.6.1 Removing the Oil Pump Crankshaft 9.3.1 Removing and 4.6.2 Installing the Installing Crankshaft 9.3.2 Servicing STIHL 020 T... -
Page 3: Specifications
SPECIFICATIONS STIHL single-cylinder two-stroke engine with special Engine impregnated cylinder bore Displacement: 35.2 cm (2.15 cu.in) Bore: 40 mm (1.57 in) Stroke: 28 mm (1.10 in) Compression ratio: 7.41:1 Power output: 1.6 kW (2.2 bhp) Max. torque: 1.8 Nm (1.3 Ib.ft) at 7,500 r.p.m. -
Page 4: Ignition System
8-tooth 1/4" spur sprocket 1129 640 2051 Elastostart 1128 190 3400 Air filter (flocked) 1129 120 1606 1.5.2 For Service Shop Carburetor parts kit 1129 007 1060 Gasket kit 1129 007 1050 Spur gear/tensioning screw kit 1129 007 1000 STIHL 020 T... -
Page 5: Tightening Torques
3) A washer must be fitted under the screw head. Note: Screws secured with adhesive are easier to release if the adhesive is heated first with a hot air blower (hair dryer). Exercise caution on polymer components. STIHL 020 T... -
Page 6: Troubleshooting Charts
Check chain lubrication and rectify problem Worn chain sprocket Fit new sprocket Chain does not stop immediately Brake spring broken Fit new brake spring when brake is activated Brake band stretched or Fit new brake band broken STIHL 020 T... -
Page 7: Engine
Clean muffler (inlet and exhaust), replace spark arresting screen (if fitted) Insufficient cylinder cooling. Thoroughly clean all cooling air Engine overheating Air inlets in fan housing openings and cylinder fins blocked or cooling fins on cylinder very dirty STIHL 020 T... -
Page 8: Ignition System
Fit new flywheel. ignition lead. Does spark test now Is spark test positive? produce sparkover? Replace ignition module. Does engine Ignition system in order. now run after positive spark test? Look for fault in fuel system and carburetor. STIHL 020 T... -
Page 9: Rewind Starter
(strainer) in white spirit and blow out hose ruptured with compressed air; replace if necessary Valve in oil tank blocked Clean or replace valve Teeth on pump piston and/or Fit new pump piston and/or worm worn new worm STIHL 020 T... -
Page 10: Fuel System
Inlet control lever too low Set inlet control lever flush with (relative to design position) bottom of metering chamber Inlet needle sticking to valve Remove inlet needle, clean and seat refit Connecting bore to atmosphere Clean bore blocked STIHL 020 T... - Page 11 Pump diaphragm damaged or Fit new pump diaphragm fatigued Main jet bores or ports Clean bores and ports blocked Fuel pickup body dirty Clean pickup body, fit new filter Fuel strainers dirty Clean fuel strainers See also 2.2 STIHL 020 T...
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Page 12: Clutch, Chain Drive, Chain Brake And Chain Tensioner
• Set piston to bottom dead center. • Clamp the clutch, e.g. one shoe, in a vise. • Push the locking strip (1), thicker end (2) first, into spark plug hole and then rotate it 180°. STIHL 020 T... -
Page 13: Chain Sprocket
• Install clutch - see 3.2. • Fit sprocket cover so that pin (1) • Carefully pry the brake spring (1) engages hole (2). off the anchor pin and unhook it from the bell crank (2). • Fit the collar nut. STIHL 020 T... -
Page 14: Assembling Chain Brake
• Remove lever (1) with pivot pin • Fit hand guard in the sprocket • Attach brake band to the bell and flat spring (2). cover. crank. • Inspect parts. Replace any worn or damaged parts. STIHL 020 T... -
Page 15: Chain Tensioner
(1) to the anchor pin. • Rotate the spur gear (2) to unscrew the adjusting screw (3) fully from the • Fit the segment and tighten tensioner slide (4). screws to 3.2 Nm (2.4 Ibf.ft). STIHL 020 T... -
Page 16: Engine
Reassemble in the reverse sequence. Note: Install a new gasket. Tighten screws of upper casing to 4 Nm (3 Ibf.ft) and muffler mounting screws to 11.5 Nm (8.5 Ibf.ft). • Pull out the muffler. • Remove the gasket. STIHL 020 T... -
Page 17: Preparations
If the flange has only three holes, • Fit the test flange on the drill a fourth hole as shown in the carburetor studs. drawing. • Fit nuts (1) and tighten down firmly. STIHL 020 T... -
Page 18: Vacuum Test
• Install the muffler - see 4.1. hose to test flange nipple. • Make sure spark plug is tight. • Pull out the pump piston several times until the gauge indicates a vacuum of 0.5 bar (7.25 psi). STIHL 020 T... -
Page 19: Oil Seals
• Clean sealing face on crankshaft stub with standard commercial, solvent-based degreasant contai- ning no chlorinated or halogena- ted hydrocarbons - see 11.2. • Pack cavity between sealing lip and oil seal with grease – see 11.2. STIHL 020 T... -
Page 20: Cylinder And Piston
• Remove the cylinder gasket. • Inspect piston rings and replace if • Use a scriber or similar tool to ease the hookless snap rings out necessary - see 4.5. of the grooves in the piston bosses. STIHL 020 T... -
Page 21: Installation
(2) so that the snap ring and small end (needle cage) and gap is on the flat side of the tool's line up the piston. shank (see illustration). Note: Inner pin must again point towards flat face of tool's shank. STIHL 020 T... - Page 22 • Lubricate piston and piston rings around the piston. with oil. Rest the piston (1) on the • Fit the fuel tank - see 10.6. wooden assembly block (2). • Check that piston rings are correctly positioned. STIHL 020 T...
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Page 23: Piston Rings
• Install the piston - see 4.4.2. ignition module. • Take Woodruff key out of slot in • Unscrew clutch from crankshaft. stub of crankshaft. Caution: Clutch has left-hand thread. STIHL 020 T... - Page 24 • Withdraw the chain tensioner (2). • Pull off the worm. • Take out the screw (1). • Unscrew the six mounting screws which join the two halves of the • Lift away annular buffer (2). crankcase. STIHL 020 T...
- Page 25 • Fit collar nut (for sprocket cover) on stud and screw on fingertight. • Remove the gasket from the • Carefully drive the oil seals out of crankcase mating face. the two halves of the crankcase. STIHL 020 T...
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Page 26: Installing The Crankshaft
(5) with pickup body. • Use a 5 mm (0.2") drift to push • Fit end of filler cap retainer cord out the vent valve. (1) in groove (2) and pull forwards to secure in position. STIHL 020 T... - Page 27 (1) as far as stop they will go. into clutch side of crankcase. • Use M8 stud puller to screw in Lubricate bearing with oil. stud as far as stop. STIHL 020 T...
- Page 28 11.2. • Fit new gasket on mating face of • Press home the oil seal with the press sleeve (1). clutch side of crankcase. Assembly of the remaining parts is a reversal of the disassembly sequence. STIHL 020 T...
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Page 29: Ignition System
• Bend the ground electrode as magneto ignition system basically necessary. consists of an ignition module (1) and flywheel (2) and is easily Important: Always fit a new spark accessible. plug if the electrodes are badly eroded. STIHL 020 T... - Page 30 Smeared with oil: Coating of damp oil carbon Too much oil in fuel mix and soot Welding beads on insulator Overheated: Mixture too lean, spark plug nose, pitted electrodes loose, wrong spark plug (heat range too low) STIHL 020 T...
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Page 31: Spark Plug Terminal
• Pull the lead back into the ignition lead. terminal so that the leg spring locates properly inside it. • Slip the spark plug terminal off the lead. • Fit terminal on spark plug and refit chain sprocket cover. STIHL 020 T... -
Page 32: Ignition Module
• Starting from the clutch side, thread the ignition lead (1) through the crankcase bores and the grommet (2). • Fit the grommet in the bore. Assembly of the remaining parts is a reversal of the disassembly sequence. STIHL 020 T... -
Page 33: Removing And Installing
• Use the locking strip to block the piston - see 3.1. Note: Before fitting the ignition lead, pack the high voltage output • Remove the fan housing - with STIHL multipurpose grease - see 6.2. see 11.2. Important: Do not use graphite grease (Molykote) or silicone insulating paste for this job. -
Page 34: Ground Wire
Assembly of the remaining parts is now ing screw (1) and screws (2) from through the side of the crankcase a reversal of the disassembly annular buffer (3). and pull it up to the top. sequence. • Remove the annular buffer. STIHL 020 T... -
Page 35: Rewind Starter
Lubricate the rewind spring and starter post with STIHL special Note: The rope rotor will spin back lubricant, see 11.2, before installing. and relieve the tension of the rewind • Coat the bore in the rope rotor spring. -
Page 36: Replacing The Starter Rope
Note: The new rewind spring is supplied ready for installation with a retainer (1). It should be lubri- cated with a few drops of STIHL special lubricant before installation - see 11.2. • The retainer (1) slips off as the rewind spring is pressed into the fan housing. -
Page 37: Tensioning The Rewind Spring
• Push the rewind spring into the fan • Hold the rope rotor steady. housing and then remove the assembly tool. • Pull out the rope with the starter grip and straighten it out. • Install the rope rotor - see 6.2. STIHL 020 T... -
Page 38: Pawl
• Refit the rope rotor - see 6.2. • Refit the fan housing. • Check that washer is fitted on starter post. Install the spring clip - see 6.2. • Refit the fan housing. STIHL 020 T... -
Page 39: Av Handle System
• Unscrew the annular buffer. and removeannular buffer (2). • Tighten front handle mounting • Note that ground wire (3) is screw to 6 Nm (4.4 Ibf.ft). secured with the lower rear screw. • Refit the fan housing. STIHL 020 T... -
Page 40: Master Control/Handle System
Assemble in the reverse sequence. • Take out the screw (1). • Disconnect choke rod (1) from lever on switch shaft and throttle • Pull the lever (2) off the switch rod (2) from throttle trigger. shaft. STIHL 020 T... -
Page 41: Interlock Lever/Throttle Trigger
• Install the throttle trigger – see 8.3. Note: Lubricate switch shaft with grease - see 11.2. • Pull out the contact spring. • Take the torsion spring off the throttle trigger. Assemble in the reverse sequence. Assemble in the reverse sequence. STIHL 020 T... -
Page 42: Double Lever (Choke/Throttle)
• Take out lower front handle must be fitted in the upper hole. mounting screw. Throttle double lever: • Pull front handle out of handle housing. • Remove the carburetor - see 10.2.1. • Disconnect short throttle rod. STIHL 020 T... -
Page 43: Handle Housing
Note: The manifold flange is thus pulled through the handle housing intake opening without damaging the manifold. • Remove center screw from front • Pull the impulse hose off the annular buffer. nipple. STIHL 020 T... -
Page 44: Chain Lubrication
• Pull the worm off the crankshaft • Pull the pickup body out of the Note: Coat flange on hose with a stub. suction hose. little oil to simplify fitting. Assembly is a reversal of the disassembly sequence. STIHL 020 T... -
Page 45: Vent Valve
• Take out the screws (1). • Use a 5 mm (0.2") drift to careful- ly drive the vent valve out of the • Remove the cover (2). crankcase from inside the tank. • Blow valve clear with compressed air (from outside). STIHL 020 T... -
Page 46: Oil Pump
Lubricate pump piston and worm with grease, see 11.2, before Note: The worm and chain sprok- installing. must always have the same number of teeth. • Remove the plug. Install in the reverse sequence. STIHL 020 T... -
Page 47: Fuel System
Installation is a reversal of the removal sequence. • Rotate twist lock (1) on carburetor • Push the fuel hose off the elbow box cover (2) one quarter turn connector. counterclockwise and remove the cover. STIHL 020 T... -
Page 48: 10.2.2 Leakage Testing
In either case the carburetor must be them down to 3.3 Nm (2.4 Ibf.ft). removed and serviced. • After completing test, open the vent screw and pull the fuel line off the elbow connector. • Install the carburetor - see 10.2.1. STIHL 020 T... - Page 49 The inlet needle valve is located in a recess in the metering diaphragm chamber. • Take out the screws of the metering chamber end cover and lift away the cover. STIHL 020 T...
- Page 50 If necessary, use suitable pliers to carefully bend the lever. • After fitting new sealing plug, fill gap between carburetor body and plug with Loctite - see 11.2. • Place gasket on metering diaphragm. STIHL 020 T...
- Page 51 • Fit the pump diaphragm. • Take out the throttle shutter. • Place gasket on pump • Disconnect the torsion spring • Remove the torsion spring. (1) from the groove in the throttle diaphragm. shaft (2). STIHL 020 T...
- Page 52 • Coat the fastening screw with with Loctite, see 11.2, and tighten Loctite, see 11.2, and tighten it down firmly. down firmly. • Carry out the leakage test – see 10.2.2. • Install the carburetor - see 10.2.1. • Remove the E-clip. STIHL 020 T...
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Page 53: Carburetor Adjustment
- and then turn it back one Maximum engine speed with bar quarter turn - and check that the and properly tensioned chain: engine accelerates smoothly when 14,500 r.p.m. the throttle is opened. STIHL 020 T... -
Page 54: Pickup Body/Fuel Hose
(2) in • Open the tank again and drain it. the fuel tank. Fuel intake hose • Remove the air filter - see 10.1. • Unscrew the carburetor mounting nuts (1). • Remove the filter base (2). STIHL 020 T... -
Page 55: Tank Vent
• Use suitable tool to remove filter • Remove upper screws from tank element. housing. Note: Remove handle housing if necessary - see 8.8. STIHL 020 T... - Page 56 (2) in the new tank housing. • Pull out the impusle hose (1) • Pull the pickup body off the fuel and grommet (2). Take out screws hose. (3 and 4). Remove annular buffer (5) and retainer (6). STIHL 020 T...
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Page 57: Special Servicing Tools And Aids
0000 890 4400 Removing oil seals - Jaws 0000 890 3700 Socket T20x125 0812 542 2041 Tightening IS-P screws (4 mm) Remarks: 1) Plastoform and DG screws must always be tightened with torque wrench. 2) Wrench has optical/acoustic signal. STIHL 020 T... -
Page 58: Servicing Aids
Bearing bore in rope rotor, rewind spring in rope rotor Ignition lead HTR (10 m/33') 0000 930 2251 Electrician's repair kit 0000 007 1013 Graphite grease Guide peg on starter pawl Molykote grease Sliding and pivot points of chain brake STIHL 020 T...
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