Project Stihl 025 - for my FIL

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kc4sfe

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Got another project finished this weekend and I wanted to share it. I've been messing with saws for about 3 months now and appreciate all the great help and support I have found on here. Everyone has been great and it's a huge confidence boost for a noob like me to have a resource like this to rely on.

I'm working from the SM and IPL and have no prior small engine (or large engine for that matter) experience.

I picked up a scored burnt 025 since my FIL wanted a light weight saw that would start and run more reliable than his 30 year old craftsman stuff and his yard sale Poulans that he seems to favor. I just couldn't talk him into dropping the cash on a better saw that would work when he needed it to.

This 025 was filthy but complete with BAD scoring in the cylinder and something like 60psi compression when I tested it. The carb looked like someone had tried to melt the diaphragms into S'mores or something so I stripped it down completely, ordered a new P/C online and got to work.

I do have a few small advantages, while I am in no way a machinist I work in a large machine shop and have access to all the cleaners and tools one needs for these sort of projects.


The pictures attached show what I started with - cleaned, and the finished saw. It tuned up beautifully after I built the motor 3 times. I guess I didn't get the gasket sealant right because it would never start. New fuel and oil lines and filters, new sprocket, new starter cord, new plug, new air filter and intake, painted bar nd now it's good to go.
 

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My in-laws are from South Jersey so I love what you listed as a location! These projects are really fun and starting to look like it may become a side business......
 
That's great!

But I'm more interested in that MS 260 PRO behind of it...
 
That's an 026.... I did a lot of work to that one. Cleaned it up, new oil and fuel lines and filters, new plug, new P/C from Hong Kong - 155 psi - and runs well. New brake band, new clutch springs, used OEM FW, replaced FW key, new starter cord, new top cover on the way to allow pressure relief valve, and carb rebuild.

Sent from my C5155 using Tapatalk
 
I was going to keep it but everything is for sale for the right price......

Sent from my C5155 using Tapatalk
 
Yep, the seals look good and the saw does not act like it has any leaks at all. If not, well practice makes perfect. I may sell it yet though, desperately dreaming of doing a rebuild on a 75cc or 90cc Stihl.

I'm just having too much fun with this and there are always more saws out there.........
 
XSKIER - here are some pics of that 026 you see in the background.......
 

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Very nice! Nice pee and see too! I especially like how those saws "barbecue" the oil tank. It makes me hungry for a nice slow smoked brisket.
 
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