Stihl 076av rebuild

[Brewz]

Another one of the big saws I picked up for next to nothing, this one cost me $50
The old bloke who owned it couldn't turn it over and nor could I. It turns freely but stops at TDC so I figure there is something in there stopping it.

It came with a second fuel tank assembly, original flat top air filter and cover, the concrete saw tall cover with 2 new air filters, a couple new OEM AV mounts, 5 kilo's of dirt and sawdust and about 10 cockroaches.

I will post pics I take of the rebuild along the way to build a bit of a reference for anyone else who may stumble across it needing info.

Feel free to add any advice or help. I am learning as I go on this one.

 

[Brewz]

Tear down:

Filter rubbers are nice and soft and the 2 x filters I have are top notch.





Everything is coated with a thick hard layer of saw muck!
It will be half the weight and run cooler than it has in 20 years when I am done

 

[Brewz]

It looks like junk but it as actually very well preserved under all the dirt.
I predict it cleaning up really nice!



Mmmmmmmmmm cockroach poo. There was a small family living in there, they didn't get far.

 

[Brewz]

Now......... this is where I got to.

The clutch.

I figure it is screwed on and I could not get it to budge for the life of me.
I heated it, bashed it, sprayed it with penetrating oil, heated it again, bashed it again, swore at it, swore at it again......... and it is still on there.

any tips?

 

[merc_man]

Now......... this is where I got to.

The clutch.

I figure it is screwed on and I could not get it to budge for the life of me.
I heated it, bashed it, sprayed it with penetrating oil, heated it again, bashed it again, swore at it, swore at it again......... and it is still on there.

any tips?

View attachment 22853

Is it left handed thread?

 

[Brewz]

Yep

 

[merc_man]

Iv had some that are pretty darn hard to get off too.

I know its not good fir it but i have used a impact befor. I dont use a piston stop if i have to use impact. Just hold flywheel by hand.

 

[Adirondackstihl]

I have a nice handle for that saw. Too bad you're in Australia

 

[Brewz]

@merc_man its getting a full case split rebuild and probably a new clutch, so not to worried about that.
Do you have a special tool to ho in the gaps like a cut out socket?


@Adirondackstihl
Post up a pic!

 

[Adirondackstihl]

@merc_man its getting a full case split rebuild and probably a new clutch, so not to worried about that.
Do you have a special tool to ho in the gaps like a cut out socket?


@Adirondackstihl
Post up a pic!

Gimme an hour or two

 

[Definitive Dave]

Get the clutch tool from hlsupply or eBay the clutch will break any other way.
Great saws with a bunch of modifications.

 

[Brewz]

@Definitive Dave is that the same clutch tool as for the husky clutches?

Did you say "MODIFICATIONS?"

List em up mate, I am all ears!

 

[merc_man]

@merc_man its getting a full case split rebuild and probably a new clutch, so not to worried about that.
Do you have a special tool to ho in the gaps like a cut out socket?


@Adirondackstihl
Post up a pic!

Ya that what i use is an old socket cut out to fit it. Yout clutch looks like not much room to make one.

 

[Brewz]

At this stage I plan to put a new Hyway clutch on it because the original one on it looks very worn.

I will screw in a piston stop, get it really hot and give it a good bashing tomorrow

 

[lwhaples]

Stepping in to watch the fun. Least now the workbench has a good reason for being there.

 

[Adirondackstihl]

 

[Brewz]

Well the clutch is off
I went and bought a 27mm deep socket and made a tool
Would the rattle gun up to max and gave it a go

Wouldn't move.

Heated it up and still wouldn't move.

Got it glowing red and held the heat on it with the rattle gun hammering away, smoke going everywhere, sparks flying, and then slowly it started to move

It is off but it is dead!

 

[merc_man]

Wow. Must have reallt been on ther.

 

[Adirondackstihl]

Cherry red?
That can't be good for the crank bro......

 

[Brewz]

Glowing red was probably an exaggeration
The springs and back plate were though.

Crank shaft is ok

Got the jug off and it is full of bits of steel bearing race, and both bearings are shot.
Piston is okish but I haven't had a real good look at it yet.
The cylinder will be ok. It has a bit of pot holing in the squish band but should recover well