090G Basket Case

[Bob95065]

Back in February I got my 090G basket case off the shelf. I originally posted this to another forum but thought I would start a parallel thread here in case someone can benefit from the information I have learned.

The handlebar is all busted up and the mounts are too. Pretty ingenuous repair on the left side. The case half needs to be replaced to fix it right. The throttle shaft has tons of play in the carburetor body too. Anyone know a source for parts?

 

[Bob95065]

 

[Bob95065]

Post from April 5:

I got into the saw this weekend. I split the case and made a list of needed parts from the dealer. A member here was very helpful with knowledge and parts that will get this project off the ground.

The P/C are 66mm.

This was by far the easiest case I have ever split because of the roller bearings. I am used to pressed bearings on smaller saws. I removed the nuts off the studs and gently tapped the case halves with a rubber mallet and it came apart very easily. I am very impressed with the quality of the build of the 090G.

I plan on posting pictures of progress on this saw in case someone else here gets into one with no experience with them like I did here. Thank you all for pointing me in the right direction.

 

[Bob95065]

Post from April 7:

I had some time after work today so i cleaned up the parts. Really, I just knocked the heavy gunk off the parts. I'm leaning toward powder coating it. If I'm going this far this is the time to do it.

 

[Bob95065]

April 17:

Last weekend while working on the saw I ran into a n interesting problem. I was dry-fitting the case together to check the cylinder interface for flatness. The left case half that I bought seemed to have different alignment pin spacing from the original right case half. I let NewtoStihl know who helped me out with the parts and information big time.

I took some measurements this morning.

First thing I did was engage the aft pin and take a picture of the fore pin through the hole to show misalignment.

Aft pin engaged:




Fore pin misaligned:




Next I measured outside of pin to outside of pin. On the left half i got 110.33mm, right 109.71mm, difference 0.62mm.

 

[PJLink]

No pics showed up for me, anyone else see them?

 

[d4570]

Nope, can't see pics either

Sent from my SM-G970U using Tapatalk

 

[Bob95065]

Strange. I see them on my screen.

I'll work on this later today.

 

[Bob95065]

Can you see the images in the first two posts now?

 

[Backtroller]

I can see all of the pictures for the days prior to April 17th. April 17th pictures are not coming up.

 

[Backtroller]

 

[Bob95065]

Second half of April 17th post:

Next i measured in the pin bores outside to outside. Left i show 110.54mm, right 109.72mm, difference 0.82mm








Next i held one end of the caliper just inside one hole and tried to do the same on the other to get the center to center distance. I got 104.26mm on the left half and 103.32 on the right, difference 0.94mm








I trust the second measurement set most which would put me at a 0.82mm which is 0.032". This is a significant difference that will cause the pins to not engage.

Based on the early features in my saw I believe my right case half is early and the replacement left case half is later. Stihl must have changed the pin spacing dimension sometime between manufacturing the two case halves that I am working with. I hope this helps anyone who may be working with a saw from this series.

I'll try to keep this current for anyone who may be interested. Thanks for looking

Bob

 

[PJLink]

Now i can see them. Nice project you have going. Id love to have an 090 one day.

 

[BuckthornBonnie]

Nice project for sure.

 

[Homemade]

Looks like you got an early g model. Just like mine. I was told in the first years Stihl used leftover contra parts. Not sure which ones, but maybe looking into That Avenue.

 

[Bob95065]

Thanks for the posts. I had a hard time with these case halves and with the damage I am going with a different pair. The right half looks like a replacement due to the lack of paint and the serial number stamped in the wrong place. NewToStihl on the other board told me that.

 

[Bob95065]

I sent the parts to Shaun Carr (@scarr52) for repairs and machine work. He let me know that the repairs were completed and parts ready to go.

When I got this basket case I had little hope of getting it running. Shaun took the mess i sent him and reworked the parts into a saw worthy of a full restoration. Eye candy below:


There was a step between the case halves. Shaun milled the cylinder interface flat.


Cylinder repair. The spark plug hole was stripped and had a poorly done helicoil repair. The top cover holes were stripped out and similarly repaired. They are fixed now.


Top cover and gearcase cover repairs. The mounting holes on the top cover were wallowed out due to incorrect fasteners and stripped holes in the cylinder. Shaun filled them and re-drilled the mounting holes. The bar mount on the gearcase cover was broken off and half of it was missing. Shaun recreated the missing portion and welded it on. He's a master craftsman and more an artist with metal.


The handlebars were sent to Shaun in three parts. It is now one piece again. Amazing work.



Look back in this thread at the before pictures and you will see that one of the ribs on this starter was missing. Now you can hardly tell. The mounting flange was broken off completely and missing. Shaun recreated these parts and welded them on. Simply amazing, outstanding work.

I can't thank Shaun enough for the incredible work he has done on this abused saw. He's given it a new lease on life and an opportunity for a concourse restoration.

The parts were boxed up along with the rest of the things I mailed Shaun and sent to Mike in Pittsburgh for powder coating. Stay tuned for more updates.

 

[jacob j.]

Shaun is amazing for sure - some of the stuff he's repaired is way beyond most folks.

 

[srcarr52]

I should have taken more pictures through this project but here are some more.

Muffler before.


The patch.


After with an extra louver. Moar powa!


Heat shield and brace added.

 

[Lee H]

Shaun knows his *s-word. He has done a couple small jobs for me as well.
He is a great asset to the chainsaw forums.