owain038

Only 2 things left. ... (that I can think of)
1) the mounting face on the saw has been machined back,  or filed or what ever. ...to get rid of a badly worn face. (Pretty unlikely I guess).
2) the perimeter of the side cover contacts the saw early,  stopping the clamping face from doing is job. (Wrong side cover,  get creative with a file or an angle grinder [emoji44])
 
 
 
 
 

Here's a close up of the adjuster, seems to fit fairly well but I guess it could have the wrong one....

Removing the adjuster didn't change anything unfortunately

Really appreciate the help it's been driving me nuts [emoji23]

well I guess I missed the chain adjuster being at the front. Doh.. it’s amazing what you miss.. after all it a 024av. Not a 024 as I know.. so there are a few differences. 
 
My simple suggestion of removing the chain adjuster, to only test that it is the adjuster fouling the cover. While there check the plastic cover for fitment.  It would be easy to remove some plastic from the plastic cover if it fitted well without the chain adjuster. ( I would not file down the chain adjuster, as I think you may find it hard to get another)
 
 after reading some threads on 024 av there are a few variations and the original cover only had one bar nut but peeps changed them out to a two stud cover. 
But unfortunately some things go undocumented.  
 
Then in I guess the choice is yours 
 
https://www.arboristsite.com/community/threads/stihl-024-av-super-1149-version-ipl.316832/
 
https://www.arboristsite.com/community/threads/stihl-024-av-eq-chain-tensioner.260484/
 

The clutch cover might be the problem and you might have to get a known good one, one you know really belongs to a 024...
But back up a bit, put the bar on the saw with out clutch cover (or chain). Can you confirm the collar on the bar stud  below the surface of the bar ?
 
If that's ok then take the chain adjuster out,  it's not hard, then put the metal cover on. Can you see the thread on the bar stud continuing into the hole? (.....so the nut isn't bottoming on the stud before it clamps the clutch cover).
 
If that's ok pop the nuts on and do them up. Still the same or fixed? 
 
bmp01 

Well the second hand cover does not have a hole to adjust the chain,, 1119 series number for still is for a 038 maybe it has a front chain adjuster 
 
the other cover should fit as it is 1125 series. Albeit a plastic one [emoji848]. I think thinner bar no backing  etc is a problem
 
as for the bar studs I always thought it was the long thread into the case.. not that it should make any difference 

Right I'm looking at the saw now. Few things measurements all seem very close to what bmp01 posted. My bar is 4mm thick though versus the 4.5mm.

I've got two side covers, one plastic one that came with the saw, with a strange hole drilled in-between the bar mounts.

I then thought this was an issue so bought a used side cover off an 024 being broken for parts on eBay. This is a metal cover, however as bmp01's keen eye spotted it contacts the chain adjuster slightly.

However the original plastic cover that came with the saw does not have this issue, however the original problem is still present.

There also seems to be more play with the original plastic cover

Studs are installed with the short thread into the case. They couldn't be installed upside down. Also had the same issue before changing the studs.

Collar on the studs does not protrude beyond the bar, they are slightly recessed

Owh hang on a minute...  what's this in your picture? Is the tensioner holding the cover off ?
 

 

Studs wound fully down in to crankcase?

The studs are not supposed to be a real tight fit, you should lift the bar when tightening nuts and that clamps it tight to stop movement.

I notice the gauge is .050 whereas I think .063 would be normal, but that shouldn't be a problem. If you hadn't changed the studs I would say check the threads, I have seen damage that stops the nut going down before it gets properly tight against the cover. As you have changed the studs I would ask if they are definitely right and fitted correctly, and aren't stopping the cover closing

Bar number from 1st post shows as being the right one for a MS260 so assume the 024 is the same and therefore correct, def try the spacer

Totally agree. Try taking the saw to a dealer and trying a stihl bar on it.

A plate will do nothing to overcome the movement, the gap between the slot in the bar and the studs is so big I could drive a bus through without my glasses on.

Cupboards, draws and pigeon holes. Get as many as you can squeeze in before you start because its  almost impossible once you start to use it.
 
Cave   http://s1116.photobucket.com/user/mypickys/slideshow/mancave
 
Also worth knocking up simple gadgets like below for working on saws rather than chasing them around a bench
 

 

 

 

 

 

 
 

Whipped this up the other day to keep the saws up off the ground.

I've just looked on L&S engineerings website and they do show one that clips over the bar studs..... no little screw like we are used to. [emoji6]

It's missing the inner side plate so the bar isn't nipping up 

Do you lift the bar tip while you are tightening the nuts ? There looks a fair bit of play in the bar slot.

I was wondering about that too, doesn't seem to have a wear plate but also can't see a mounting location for one [emoji848]

Hi I recently got a Stihl 024 with no bar and chain. Cleaned her up and got a new Oregon bar and chain. Fitted it up but once tightened down the bar moves up and down 5-10mm. Initially I thought the cover might be the culprit as it was a plastic piece. Had the same issue after trying the metal cover off my 038 but decided to order a genuine metal 024 cover. Same issue. Decided to then replace the bar studs as I thought they could be worn. But still having the same issue... Any suggestions?

Hey guys been lurking here for a while.
Waiting on time to do arborist courses, but have been cutting trees for a few years.
Just qualified as a mechanical engineer but not really too interested in going into engineering just yet.
Just starting to piece together some climbing gear for my own rec fun at the moment.
Work with a local landscaper most of the time with the occasional day cutting trees with an arborist.