Stihl 076av rebuild

[Brewz]

I had a bit of a grind in the muffler flange to smooth it out and open it a bit but the neck looks very restrictive and it seems to be baffled to hell inside.

I would really love to hear from anyone who has done some mods to the mufflers on these saws.

 

[Brewz]

While I am waiting on parts, I think I may pull the piston and open up the windows more.
Thinking about the design, It relies on the windows in the piston for moving of charge into the transfers.
I doubled the size of the after market pistons windows and matched the OEM size

I think I will do some measuring and take them further. I see gains in this area.
They are long and squared, so some rounding out inside the piston to help flow is in order

 

[drf256]

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

Ended up with timing at 97/121.5/95 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

View attachment 26074

95 intake? Is this a typo Tony?

 

[Brewz]

95 intake? Is this a typo Tony?

No mate, I ground about 1/4 inch from the bottom of the intake to let more air in

Well picked up on the typo mate, I have corrected it.

I should have some o-rings and seals tomorrow or Wednesday with any luck and can continue the build.
Will give me a break from that damn 090

 

[Brewz]

I also have a bit of a plan/idea for the muffler involving a @Red97 deflector to replace the 4 little factory slots.
While I have it open, I might see what I can do to get gas flow from the muffler improved by hacking at the baffles..... in a tasteful manor of course.

 

[Brewz]

New worm gear oil seal showed up as well as all the o-rings.
Replaced the o-rings in the aux oiler button and the bar oil adjusting lever. They now feel a lot tighter.
Port matched all the new intake tract gaskets as there was a bit of restrictive overhang and dug out the carb kit ready to give it a birthday in the morning.
Flywheel on.
New clutch fitted up with a new 7 pin 404 rim sprocket on the clutch drum. It all just went on the after market crank perfectly, not an issue so very happy with it.
Fitted up the ignition coil and will continue the build tomorrow.

I am hoping to make it blow smoke from the muffler tomorrow night. With any luck, all the hard stuff is done. Its not leaving the bench till running now!

 

[smokey7]

Raisman crank?

 

[Brewz]

I used this one from China

http://www.ebay.com.au/itm/cranksha...234565?hash=item4d3dcb9785:g:cuUAAOSwYIhWjyzR

 

[CR888]

There is an 076 OEM P&C on eBay atm for $79 or $99 bucks local Brews. Its unused and a pretty reasonable price I reckon. I'd imagine there's not to many new OEM ones floating around. Just thought I'd let ya know, you would have to look for it as I'm not good at adding links.

 

[Brewz]

Ahhhhhhhhggghhhhhhh

He has an entire stripped saw for sale in bits.

too late now, this one is what it is and I am very happy with it.
I have replicated super cylinder timing and ported it mildly, new cabers,

What I do need is for someone to break up an 090 AV like that

 

[skip sail]

i had a look at the ebay stuff,but it wont fit my 076av Super AFAIK

 

[Brewz]

I am thinking about doing a respray on the fuel tank and chain cover which look fairly rough.
Also freshen up the tip orange bits to make them look fresh.

I have ordered a new 076 AV Super badge from the states and plan to fit it up to the top of the tall TS760 cover that came with the saw.

Hell........ it I am going this far, I may as well make it look pretty as well.

I have a local fastener supply shop that also sells good quality enamel paint. Will go see if they have white and orange.

 

[Brewz]

i had a look at the ebay stuff,but it wont fit my 076av Super AFAIK

I was interested in the chain cover till I noticed it had no chain brake

 

[Brewz]

Any suggestions on good paint to use.... thats available in Aus?

 

[Brewz]

Its looking more like a tiger tank than a box of parts again

 

[jake wells]

reminds me of my 041.
thought im sure it weights more.

 

[VinceGU05]

Any suggestions on good paint to use.... thats available in Aus?

paint is short lived. looks pretty but doesnt last 5 mins. well thats been my experience. i blasted back to metal, etched primed and painted. oven baked where possible. swore never again. will powdercoat.
i used the Galmet brand.

 

[Brewz]

I got it together and it would not start. I found I had the fuel and impulse lines back to front on the carb.

In my excitement on finding my error, I put it all back together and forgot to tighten the fuel tank screws back up.

It fired up easy and sounded great untill the loose fuel tank caused the pull start mechanism to jam in the flywheel.

Now I have to fix the pull start

 

[jake wells]

I had a bit of a grind in the muffler flange to smooth it out and open it a bit but the neck looks very restrictive and it seems to be baffled to hell inside.

I would really love to hear from anyone who has done some mods to the mufflers on these saws.

would the 041 muffler work it is just a empty can with no baffles.

 

[VinceGU05]

I got it together and it would not start. I found I had the fuel and impulse lines back to front on the carb.

In my excitement on finding my error, I put it all back together and forgot to tighten the fuel tank screws back up.

It fired up easy and sounded great untill the loose fuel tank caused the pull start mechanism to jam in the flywheel.

Now I have to fix the pull start

hast makes waste.