Stihl 026 Red Lever Restore/Porting

[Paul Fithian]

I recently acquired a red lever 026, SN 226032139. It appears this one is an early 90’s build from Virginia Beach

Spent a bit of time to clean it up. All parts removed outside of the crankcase in the process. Crank bearings/seals smooth and tight.


Aluminum transfer on the OEM Mahle cylinder came right off using Randy’s method, then porting to widen intake and exhaust ports.




Timing ended up at 96/121/74, with gasket measured .023” squish. Ready to build back better.

 

[Sawyer94]

Hey there,
Have you done a pressure vacuum test? Would hate to get all this way and then have a lean seizure due to air leak.

 

[Paul Fithian]

Not yet, but an essential part of every build.

I also fill the case with mineral spirits and let it sit overnight. No leak down in the morning is another good way to check seals.

Cleaned parts ready to install

 

[Paul Fithian]

Finally had a chance to put this together, fired right up and runs perfect. I'll run a tank or so through it, then it's going up for sale. PM if interested.

Final asssembled numbers worked out as:
- Ring gap: 0.009"
- Base gasket: 0.019"
- Squish: 0.015"
- Timing: 97/122/73

 

[Paul Fithian]

Some more pictures:

 

[Paul Fithian]

Test cuts in red oak with a 20” bar. All good, runs strong and clean. Felt/sounded best at ~ 14,000 max RPM, idled smooth at 2,200 RPM.