Stihl 019 T User Manual Download Page 48

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STIHL 019 T

11.

SPECIAL SERVICING TOOLS AND AIDS

11.1

Special Servicing Tools

No.

1
2
3
4
5
6
7

8
9

10
11
12
13

14
15

19
20
21
22
23

Part Name

Locking strip for piston
Press sleeve
Guide
Puller
- Jaws (No. 3.1 + 4)
Puller
Crimping tool

Assembly drift
Carburetor and
crankcase tester
Vacuum pump
- Nipple
- Fuel line
Sealing plate

Test flange
Setting gauge

Socket, 13 mm

Torque wrench

Screwdriver bit T27x125
Assembly hook
Assembly tool
Assembly tool
Stud puller

Part No.

0000 893 5903
1123 893 2400
1123 894 7000
5910 890 4400
0000 893 3706
4133 893 0800
5910 890 8210

1130 893 4700
1106 850 2905

0000 850 3501
0000 855 9200
1110 141 8600
0000 855 8106

1128 850 4200
1111 890 6400

5910 893 5608

5910 890 0301

5910 890 0302
5910 890 0311
5910 890 0312
0812 542 2104
5910 893 8800
1117 890 0900
1116 893 4800
5910 893 0501

Application

Rem.

Blocking crankshaft
Installing oil seal
Guiding press sleeve (starter side)
Removing oil seals

Removing flywheel
Attaching connectors to
electrical wires
Removing and installing piston pin
Testing crankcase
for leaks
Testing crankcase for leaks

Sealing exhaust port for
leakage test
For leakage test
Setting air gap between ignition
module and flywheel
Removing clutch and
flywheel nut
0.5 to 18 Nm
(0.325 to 13.5 Ibf.ft)

1)
2)

6 to 80 Nm (4.5 to 60 Ibf.ft)

1)
2)

IS screws
Removing pickup bodies
Removing and fitting the brake spring
Installing rewind spring
Removing and installing
bar mounting stud

Summary of Contents for 019 T

Page 1: ...Module 26 5 2 1 Ignition Timing 26 5 2 2 Removing and Installing 26 5 3 Flywheel 27 5 4 Ground Wire Short Circuit Wire 28 5 5 Contact Spring 29 6 Rewind Starter 30 6 1 General 30 6 2 Fan Housing 30 6...

Page 2: ...ed edition is issued Special servicing tools mentioned in the descriptions are listed in the last chapter of this manual Use the part numbers to identify the tools in the STIHL Special Tools manual Th...

Page 3: ...all bearings needle cages on small and big ends 8 mm 0 3 in 51 mm 2 in Single pawl system min 1 2 turn 3 0 mm 0 12 in dia 800 mm 31 5 in long Centrifugal clutch without linings 64 mm 2 52 in 3 700 rpm...

Page 4: ...t 0 25 mm 0 010 in 1 6 2 3 mm 0 063 0 091 in B T D C at 8 000 rpm NGK BPMR 7 A or CHAMPION RCJ6Y 0 5 mm 0 02 in M14x1 25 9 5 mm 0 37 in 9 32 mm 3 8 Picco Micro Mini 7 tooth 3 8 P spur sprocket 21 7 m...

Page 5: ...e molding front handle Fan housing engine housing Engine pan cylinder Handle molding handle Muffler cylinder Spacer flange cylinder Engine housing cylinder Bar mounting engine housing Intake casing ca...

Page 6: ...y slight pressure at the same same until oil pump drive spring engages properly Take the needle cage out of the sprocket Clean and inspect the chain sprocket Unscrew the nut Pull off the chain sprocke...

Page 7: ...hed brake spring has the same negative effect Start the engine With the chain brake activated locked open throttle wide for brief period max 3 seconds the chain must not rotate With the chain brake re...

Page 8: ...ny point If the brake band is still serviceable use No 120 emery paper or emery cloth grain size approx 120 m to clean and roughen its entire friction surface inside diameter Take out the screw Remove...

Page 9: ...see 11 2 Fit flat spring in position Remove the washer Carefully ease the hand guard 1 and bell crank 2 off the pivot pins and lift them away together Pull the bell crank out of the hand guard Take ou...

Page 10: ...tect it from corrosion an cushion snatching during the first few brake applications Check that flat spring 1 is properly located on face 2 of bearing boss Attach brake band to the bell crank Place str...

Page 11: ...0 893 0501 onto the stud as far as it will go Unscrew the stud Insert stud and torque down to 16 Nm 11 8 Ibf ft Push cover over chain brake until it snaps into position and then tap it home carefully...

Page 12: ...Pull intake pipe 1 out of the intake casing 2 Pull off the worm with drive spring Remove throttle trigger see 8 1 4 ENGINE 4 1 Disassembly Always check and if necessary repair the fuel system carburet...

Page 13: ...d torque down to 8 0 Nm 5 9 Ibf ft Remove engine sideways from housing Throttle cable sleeve must locate in retainer in air baffle Push grommet ledge facing up over the lugs of the intake pipe Fit eng...

Page 14: ...ng in position Install the clutch see 3 2 Remove the spark arresting screen Clean the spark arresting screen or fit a new one if necessary Remove the cover plate Muffler Remove the engine see 4 1 Take...

Page 15: ...y for leaks with the carburetor and crankcase tester and the vacuum pump 4 4 1 Preparations Remove the carburetor see 1 0 5 2 Set the piston to top dead center T D C This can be checked through the sp...

Page 16: ...at the suspect area with oil and pressurize the engine housing again Bubbles will appear if a leak exists Carry out the vacuum test see 4 4 3 and 4 4 4 After finishing the test open the vent screw and...

Page 17: ...the crankshaft during the piston s induction stroke because there is no internal counterpressure An additional test can be carried out with the vacuum pump to detect this kind of fault Close the vent...

Page 18: ...f necessary Fit spacer flange insert screws and tighten down to 8 0 Nm 5 9 Ibf ft Close the vent screw 1 on the pump Operate lever 2 until pressure gauge 3 indicates a vacuum of 0 4 bar 5 8 psi Note I...

Page 19: ...y the sealing ring 2 out of the housing Clean sealing face on crankshaft stub with standard commercial solvent based degreasant containing no chlorinated or halogenated hydrocarbons see 11 2 Note If t...

Page 20: ...ime Check that it has engaged properly Install the flywheel see 5 3 Install the engine see 4 2 Remove the muffler see 4 3 Remove the carburetor see 10 5 2 Take out the screw 1 Remove the ignition modu...

Page 21: ...cer flange 2 Take out the screws Pull the engine pan off the cylinder Lift the crankshaft and pull the piston out of the cylinder Inspect ball bearings and oil seals and replace if necessary see 4 9 A...

Page 22: ...gnition module see 5 2 Install the carburetor see 10 5 2 Install the muffler see 4 3 Install the engine see 4 2 Use the assembly drift 2 1130 893 4700 to push the piston pin 1 out of the piston Note I...

Page 23: ...lean Install the new piston ring in the groove so that the radii face upward to piston head Install the piston see 4 6 Remove the retaining ring Fit the piston pin 1 on the assembly drift 2 and slide...

Page 24: ...oil seals Pull off both ball bearings Lubricate sealing lips of oil seals with grease see 11 2 Slide oil seals over the crankshaft stubs so that their open sides are facing the ball bearings Install...

Page 25: ...flywheel 2 Use pliers to grip the leg spring and pull it out of the spark plug boot Unhook the leg spring from the ignition lead Pull spark plug boot off the ignition lead Coat end of the ignition lea...

Page 26: ...ing and running behavior 5 2 2 Removing and Installing Take out the screws Remove the ignition module Remove the spark plug boot see 5 1 Note The ignition lead is molded to the ignition module The ign...

Page 27: ...3 Ibf ft Push the short circuit wire on to the connector tag Fit boot on spark plug Fit the fan housing see 6 2 Fit locking strip 1 0000 893 5903 in cylinder Note If the flywheel cannot be pulled off...

Page 28: ...Pull ground wire off the contact spring Inspect the condition of the flywheel 1 and magnets 2 If you find any damage e g cracks broken fan blades fit a new flywheel Installing the flywheel Important C...

Page 29: ...ntact spring Wiring harness must not locate against engine housing s filter wall pull wiring harness back in direction of ignition module Position protective tube with ground and short circuit wires c...

Page 30: ...nd the rope rewinds very slowly or not completely it can be assumed that the starter mechanism is mechanically in order but plugged with dirt At very low outside temperatures the lubricating oil on th...

Page 31: ...the fan housing Caution The rewind spring may pop out and uncoil during installation If the rewind spring has popped out refit it as follows The wooden assembly block can be placed over the assembly...

Page 32: ...rough the underside of the starter grip Secure end of rope it with a simple overhand knot Make a loop in the starter rope Note The rewind spring is correctly tensioned when the starter grip sits firml...

Page 33: ...ooting handbook Thread rope through the side of the rotor Push it through the inner bore from the underside pull it out at the top and secure with a simple overhand knot Grip knot and pull it out of r...

Page 34: ...ut of annular buffer Place handlebar in position apply a little oil to the front end of the annular buffer and push it home until its groove 1 engages the rib 2 Push the small end of the annular buffe...

Page 35: ...es Push the annular buffer out of its seat Pry plug without key out of annular buffer Push the small end of the annular buffer oil it first into the seat until its groove 1 engages the rib 2 Rear annu...

Page 36: ...sh the contact spring slightly forward to install the switch shaft Remove the throttle trigger Remove the throttle trigger see 8 1 Pull contact sleeve of short circuit wire out of switch shaft Pull th...

Page 37: ...ontact spring 1 off the lug Pull the ground wire 2 out of the retainer Take the throttle cable out of the retainer Pull the protective tube with ground and short circuit wires out of the retainers Not...

Page 38: ...with key approx 90 degrees and take it out of the annular buffer Position the plug so that the front key 1 lines up with the slot in the inner plug Push the plug in until you feel noticeable resistanc...

Page 39: ...ody in white spirit and if possible blow out with compressed air Always replace a damaged pickup body Flush out the oil tank Assembly is a reversal of the disassembly sequence Remove the engine see 4...

Page 40: ...he oil tank in the engine housing Pull the pickup body out of the oil tank Press the oil tank against the engine housing and pull the suction hose outwards at the same time this pulls the taper into t...

Page 41: ...the oil pump in position so that the left edge 1 of the groove lines up with the left edge 2 of the mark Screw the hex head screw 1 9008 319 1450 into the thrust piece Continue tightening the hex head...

Page 42: ...the fuel are retained by the pickup body filter The fine pores of the filter eventually become clogged with minute particles of dirt This restricts the passage of fuel and results in fuel starvation I...

Page 43: ...l out the valve 3 Install in the reverse sequence Remove the engine see 4 1 Pull fuel hose off carburetor elbow connector Remove the fuel tank 10 4 Fuel Tank Fuel Hose 10 3 Tank Vent Correct operation...

Page 44: ...screw and pull the fuel line off the elbow connector Install the fuel tank see 10 4 Push the nipple into the tester s pressure hose Push the fuel line 1 1110 141 8600 onto the nipple 2 0000 855 9200 C...

Page 45: ...a level For corrections to high speed screw H Use a tachometer do not exceed max permissible engine speed Engine can be damaged by lack of lubricant and overheating Maximum engine speed with bar and p...

Page 46: ...ew The setting of the high speed screw H affects the maximum off load engine speed If the setting is too lean the maximum permissible engine speed will be exceeded and increase the risk of engine dama...

Page 47: ...or see 10 5 2 Seal the opening in the engine pan Take out the screw 1 Remove the support plate 2 Take out the nuts Reassemble in the reverse sequence Use a new gasket Tighten down screw on support pla...

Page 48: ...1 0000 855 9200 1110 141 8600 0000 855 8106 1128 850 4200 1111 890 6400 5910 893 5608 5910 890 0301 5910 890 0302 5910 890 0311 5910 890 0312 0812 542 2104 5910 893 8800 1117 890 0900 1116 893 4800 59...

Page 49: ...stand Part No 1132 890 1700 1132 893 8200 1132 893 8700 1132 893 7200 9008 319 1450 5910 890 2400 5910 890 3100 Application Removing and installing oil pump For all IS screws Holding saw for repairs R...

Page 50: ...lant 100 g 3 5 oz 7 Graphite grease 8 Molykote grease 9 STIHL Bioplus 1 I 2 US pt bottle Part No 0781 120 1111 0781 417 1315 0000 930 2251 0000 007 1013 0783 830 2120 0781 516 3331 Application Oil sea...

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