Stihl 076av rebuild

[Brewz]

I am too far in now
It will run again.

If I cant get my money back I will keep it for slabbing on a mill

 

[Lee H]

Sometimes with projects like these you can get way over your head
but the out come usually is worth it and you know what you have.
I have the same saw waiting for a full resto. and i'm sure i will have
some surprises as well.

 

[Brewz]

I am up to about $450 total cost thus far and I am not thinking there will be many more surprises.

 

[Brewz]

Got the case together last night and she spins over really nice.
Hope to get the cylinder on and run some timing numbers tonight

 

[Brewz]

Something I have to ask

Which way should the arrow on the piston top that usually points to exhaust point on a cylinder with intake and exhaust on the same side?

 

[Brewz]

I had fun with the cross performance piston.

It did not have enough clearance inside the piston to fit over the rod so I had to grind and file about .020 off each side.

 

[VinceGU05]

I had fun with the cross performance piston.

It did not have enough clearance inside the piston to fit over the rod so I had to grind and file about .020 off each side.

yeah i have had to do that before too.. cant remember which saw it was tho.. yes arrow to port exit.

 

[Brewz]

Just timed the new motor and it looks good.

97/121.5/71

Anyone got any suggestions on wether its worth doing a bit of grinding?

 

[Brewz]

Went to fit up the oil pump worm gear and oil seals and found a hidden oil seal that is toasted in the oil pump worm gear.

This thing has SOOOOOO many little parts to it.
The little aux oiler button needs new a o-ring and is loose, probably just needs a complete new one cause it will leak.

Now to try and track them down to avoid paying a fortune for OEM

 

[Brewz]

I just measured the oem jug and got almost the same as the after market, so all in all, I am very impressed

97/121/75

Am going to lower the intake on the after market cylinder to match the oem 076 super cylinder and widen out the exhast a bit while I have the rotary scalpel out.

Went to the local bearing distributor and ordered the oil seal that goes in the worm gear and all new o-rings to stop any leaks.

This saw will be a cracker once done

 

[Chainsaw Jim]

I just finished with this today and I'm very interested to see how it cuts. Piss revving it feels like it wants to vaporize a cant. Lol

 

[Chainsaw Jim]

I just measured the oem jug and got almost the same as the after market, so all in all, I am very impressed

97/121/75

Am going to lower the intake on the after market cylinder to match the oem 076 super cylinder and widen out the exhast a bit while I have the rotary scalpel out.

Went to the local bearing distributor and ordered the oil seal that goes in the worm gear and all new o-rings to stop any leaks.

This saw will be a cracker once done

Be very careful widening the exhaust. The ring locating pins are on that side.

 

[Brewz]

I only went a bit, still a long way from the ring pins.

Ended up with timing at 97/121.5/75 with squish at .030

It took a lot of grinding to get it to the same sizes and spec as the OEM gear but I think the work will be worth it.
The worst part of the kit was the tiny little windows in the after market piston

 

[Brewz]

I just finished with this today and I'm very interested to see how it cuts. Piss revving it feels like it wants to vaporize a cant. Lol

What did you do to it to Jim?
What are the performance tricks?
I would be very interested in how to perform a good muffler mod on these too.

 

[Definitive Dave]

I just finished with this today and I'm very interested to see how it cuts. Piss revving it feels like it wants to vaporize a cant. Lol

THIS ROCKS!!

 

[Brewz]

One thing that makes this saw stand out as a good milling saw is the size of the clutch.

It is almost twice the size of a 660 or 395 clutch.
Its HUGE!

would provide big grip pulling a long chain

 

[Chainsaw Jim]

What did you do to it to Jim?
What are the performance tricks?
I would be very interested in how to perform a good muffler mod on these too.

All I've done to this point is cylinder port work and timing advance.
I used an old piston as a mandrel to match the squish band shape to the dome of the piston. The squish is even from edge to center now. The base needed about .030 taken off to get the squish to .017
I also lightened the piston...I actually almost forgot about that.

 

[Brewz]

All I've done to this point is cylinder port work and timing advance.
I used an old piston as a mandrel to match the squish band shape to the dome of the piston. The squish is even from edge to center now. The base needed about .030 taken off to get the squish to .017
I also lightened the piston...I actually almost forgot about that.

What have you done with the muffler to get it flowing better?

 

[Brewz]

Just made a thinner gasket and brought squish down from .030 to .021

That's about as far as I can go till seals turn up.

Off to tinker with the 090 for the day

 

[Chainsaw Jim]

What have you done with the muffler to get it flowing better?

I didn't touch the muffler.