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Stihl 041 ignition module to replace points and condenser

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Modern replacement module for the 041, 041AV with points only, this unit is saw specific, not a universal module. This Farm Boss had a bad/weak coil, it cost about the same for the complete module as a replacement coil so I opted to give it a try.IMG_20160615_161052_925.jpg
 

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It seemed that installation would be a snap, but not so as the coil pole shoes rubbed on the magnets of the flywheel. With no adjustment I ended up filing the poles down. Used a magic marker on the poles to see where it was rubbing and hand fit until it was gapped properly. So much for plug and play. The kill switch wire had to be routed in such a way as to not be pinched by the backing plate, finally learned to check and recheck this as it proved problematic at times.IMG_20160620_162727_018.jpg IMG_20160620_161936_457.jpg
 

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Checked to see flywheel was in time as it was supposed to be when made, and it was at .102" BTDC. Not really necessary, but I was curious to know. IMG_20160619_104135_823.jpg IMG_20160619_104118_632.jpg
 

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Other than rebuilding the carburetor, this is the only modification to this saw. I gave the chain a couple laps on the grinder as well. I have to say it was a night/ day scenario on the before and after. This saw as it is now will keep up or pass any modern farm/ranch saw. This one is fitted with a two foot bar and RS chain and pulled extremely well buried in a pine log.
 

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Testing the old coil with a Merc-O-Tronic tester.IMG_20160615_160441_375.jpg
Had a very thin weak sparkIMG_20160615_160349_166.jpg
Did not like it when a gap was introduced and would not jump when a longer one was tryed.IMG_20160615_160258_387.jpg
Timing check proved fruitless when light would not flicker when points opened. Coil also failed ohm meter test on secondary side.IMG_20160620_155202_083.jpg
 

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That's where I acquired this one, the model 79 has the unique ability to test modules as well. Maybe I can do a demo of this in the future. I just won an auction on Fleabay for a Merc-O-Tronic model 98, can't wait for it to get here. It does a more complete job on the old points and condenser testing. For the modern chainsaw the 79 is just excellent. A lot of outboard motor and snowmobile shops had these back in the day, that's where the ones show up from on Fleabay come from. I believe they are still in business, heard they are hard to get a hold of as well, but repairs could be possible, though I'm hoping I do not need to. There are other brands out there as well, but I think the Merc is liked to a Simpson meter, everything else is just a volt/ohm meter.
If my 98 works I'll try and post a bit about it as well, I drug out an 041AV from my bone pile to play around with and see what's possible a little more with these saws while my curiosity is up, as the Farm Boss has to go back to its owner.

IMG_20160615_160458_205.jpg
Here's a better pic of the 79, you can see the probes in the box used for testing modulated coils, I'll try and show more later, have work to do first.
 

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Here's how modules are tested. Just what I had laying around.

281XP/288XP Husqvarna two piece coil and module tested together.

IMG_20160623_164424_437.jpg

Same coil tested separately. This will help determine which one is bad if the first test fails.


IMG_20160623_165414_777.jpg

A common Stihl replacement modulated coil used in numerous saws.

IMG_20160623_165006_566.jpg

Husqvarna 272XP, 55 Rancher type replacement modulated coil. Brand new, and FAILED! The children of China let me down again.

IMG_20160623_170454_483.jpg

Can test pretty much any small engine ignition set up from points and condenser, capacitive discharge and modulated, two or four stroke.
 

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Received this in the mail yesterday, and it works! I'm pretty stoked! I just had to play with around with it. Pretty neat gizmotron I must say! Oh - and the old 041 mag that I'm using here as a guinea pig is still NFG. Speaking of 041's(which was what this thread was about in the first place, I think...wasn't it?) the Farm Boss was picked up as well and its owner was very happy to see how well grandpa's old saw performed, and left all smiles.

IMG_20160625_182146_441.jpg
 

Mastermind

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I'd like to see this thread over in the chainsaw forum. I don't want to move though, it needs to be need as a teaching guide. I just don't think it's getting seen here.

Great stuff for us nerds.
 

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Most folks aren't interested in old timer saws. I just thought that module was so darn interesting with the internal coil combination. With four long magnets inside the flywheel, I still can't wrap my brain around how it picks out one spot to fire. Oh well, maybe I should just rename the title "Boobies and Beer". Seriously though, if you want to move it, change it in any way to make it better, go right ahead, I'm all for it
 

junkman

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This tester would be great in the tools section also ,i think the tittle is why no traffic ,,i love the thread though ,had no idea such a thing existed .
 

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Just got back the 98 today, had a guy called Sparky look at it and repair the DC power source. He said it needed a diode replaced, which he did for me. This makes the unit much handier than using a special 7.5 volt battery, then having to conjure up a 12 volt battery for certain tests. Now it's at the flick of the switch, all from 110vac. I'm just as happy as a pig in slop.

IMG_20160711_203906_843.jpg
 

jake wells

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the nova modules work good also if the coil is still good the condenser went bad on my 041 and I just converted it over the spark is way hotter.
 
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