Need to rebuild 038 magnum

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Great pics! another question...this saw was always a hard start...should i consider changing the ignition or wouldnt that have anything to do with it???
I used my 038M today and it had been sitting for a couple months, took about 10-12 pulls to get gas back in the carb. After that it would fire right up warm, needed a pull or two on choke if it sat while I played with chunks of cordwood ( was below freezing today)

Does yours fire up OK warm, and with a splash of mix in the carb cold?

If so, check the choke inside the airfilter. It may not be shutting all the way. Sometimes it's the linkage/switch shaft not making proper contact to lever on filter, can be due to worn linkage, sometime it's the filter. assy. Some aftermarket airfilters have faulty chokes.

For the shaft check that it makes contact with lever from choke on airfilter, and moves it far enough to close the choke on choke position. You should be able to move that lever with your finger when switch shaft is in run or off position and feel the choke shut. The ends of the shaft can wear, along with the holes where it fits in the tank housing, check there is not slop there.

My 038 saws have pretty new Stihl flocked airfilters.
 
I used my 038M today and it had been sitting for a couple months, took about 10-12 pulls to get gas back in the carb. After that it would fire right up warm, needed a pull or two on choke if it sat while I played with chunks of cordwood ( was below freezing today)

Does yours fire up OK warm, and with a splash of mix in the carb cold?

If so, check the choke inside the airfilter. It may not be shutting all the way. Sometimes it's the linkage/switch shaft not making proper contact to lever on filter, can be due to worn linkage, sometime it's the filter. assy. Some aftermarket airfilters have faulty chokes.

For the shaft check that it makes contact with lever from choke on airfilter, and moves it far enough to close the choke on choke position. You should be able to move that lever with your finger when switch shaft is in run or off position and feel the choke shut. The ends of the shaft can wear, along with the holes where it fits in the tank housing, check there is not slop there.

My 038 saws have pretty new Stihl flocked airfilters.
Yes warm it starts like a dream! In the past after a long time not using it i gave the air filter a shot of starting fluid to give it a boost and started alot easier...is starting fluid a bad thing as there is no oil in it??? I have this air cleaner on it
1637775893769.png
 
Hello all...hope everyone had a nice Thanksgiving!...got her cleaned up...got the cylander off and it looks perfect...hard to see in the pics as i will clean it tomorrow but all the wear marks are on the piston only....also found the intake boot had a huge crack in it but the whole crack was under the clamp holding it on the cylinder...explains why i couldnt get a bit of pressure/vacuum...i will post some pics of the cylinder cleaned tomorrow to see if it passes your inspection...working on my parts list tonight


question tho why did the rings wear on the one side and stick out the other side of the piston???? Thanks as always for any input!!!!! Steve
 

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this is my list so far...cant find an impulse line part number anywhere....anyone???

parts list

gasket set part # 1119 007 1050 2 oil seals and gaskets

air filter 11191201611

STIHL INTAKE BOOT (manifold) # 1119-141-2200

9022 341 1010 4 Spline screw IS-M5x18 for muffler

Piston ring 52x1.5mm 1115 034 3010
Piston Ø 52mm 1119 030 2002
 
Someone who knows 038s better than I will correct if I'm wrong, but the impulse on that model is a piece of hose. See part # 29 in the IPL.
i think you may be right...thats what is on there and the rubber got real hard so its been there awhile...thanks for finding it ...i was searching for the word impulse.and part number for it...skipped right by it...but now i can search out the dimensions!
 
so got the cylinder and the body clean and there are no rough spots or rub marks on it...looks great...next figure piston removal ...is the piston made softer so its the wearable part????

another question...does there need to be anything put on the new gaskets like permatex as a sealer???
 

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When I rebuilt my o38 mag that i bought from some shady tweeker burned up , I used wolf creek saw shop in Colorado. I ordered from ebay from them. Was cheap for piston and rings. As I recall the parts that were "d to me by still were ridiculous gillis and I went with the taco mountais the techomec piston and caber rings. My saw had been straight gassed I think. Im sure there's a thread on here when I re did it back a few years ago.
https://www.wolfcreeksawshop.com/
 
Adding these pics for the next newb trying a rebuild...the c clips take off like a bullet ...and i knew it was going to but missed it anyway...also found a crack on the piston...wondering if this is uncommon????
Does the new piston come with the clips and bearing????
 

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Adding these pics for the next newb trying a rebuild...the c clips take off like a bullet ...and i knew it was going to but missed it anyway...also found a crack on the piston...wondering if this is uncommon????
Does the new piston come with the clips and bearing????

I'd say the crack is uncommon.
New pistons come with clips, rarely with a bearing.
 
still waiting for parts to come in...decided on this for the new gaskets...any input on anything better????

1640136244530.png
 
this is my list so far...cant find an impulse line part number anywhere....anyone???

parts list

gasket set part # 1119 007 1050 2 oil seals and gaskets

air filter 11191201611

STIHL INTAKE BOOT (manifold) # 1119-141-2200

9022 341 1010 4 Spline screw IS-M5x18 for muffler

Piston ring 52x1.5mm 1115 034 3010
Piston Ø 52mm 1119 030 2002
The intake boots are no longer available from Stihl, you'll have to source a good used one or go aftermarket. The piston will come with rings, wrist pin, and circlips. Wrist pin bearing is separate. I don't think there's a part number for the pulse hose I'll have to check the IPL tomorrow at work. It's just bulk hose, I'll get you the part number tomorrow unless someone else beats me to it. Don't put anything on the gaskets, install them dry.
 
Hello all...hope everyone had a nice Thanksgiving!...got her cleaned up...got the cylander off and it looks perfect...hard to see in the pics as i will clean it tomorrow but all the wear marks are on the piston only....also found the intake boot had a huge crack in it but the whole crack was under the clamp holding it on the cylinder...explains why i couldnt get a bit of pressure/vacuum...i will post some pics of the cylinder cleaned tomorrow to see if it passes your inspection...working on my parts list tonight


question tho why did the rings wear on the one side and stick out the other side of the piston???? Thanks as always for any input!!!!! Steve

I have some new 038 OEM stihl intake boots, if you need one.



DSCN7201.JPG
 
There is a FLECK of metal missing in that crack in your pic of the piston. Did you find it.. Hate to see it come back to haunt you.
hmmmm....nice catch there...i will have to check that out when i am replacing the seals...would think there was no where for it to go but down????
 
hmmmm....nice catch there...i will have to check that out when i am replacing the seals...would think there was no where for it to go but down????
Hopefully it went through the transfers and out the exhaust. Not take up residence around a bearing or in the bottom of the crankcase. Odds are you won't find it but a serious peek a boo can't hurt.
 
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