Stihl FS 240 Service Manual Download

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FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

Engine

5.1

Muffler

Check and if necessary repair the
fuel supply, carburetor, air filter and
ignition system before looking for
faults on the engine.

Troubleshooting,

– Remove shroud,

5.4

– Remove protective hip plate,

11.9.3

To keep dirt particles from entering
the cylinder, move piston to top
dead center before removing the
muffler.

Remove screw (1)

Tilt insert (2) upward and out

Remove screws (1)

Take out and examine the
muffler (2), replace if necessary

5904RA029 TG

5904RA030 TG

Remove the exhaust gasket (1)
and cooling plate (2)

– Installing and removing the spark

arresting screen, see Instruction
Manual

Installation

– Cover exhaust bore and remove

any fouling on the cylinder and
exhaust bore

Examine and clean the mating
surfaces (arrows) on the exhaust
bore, cooling plate and muffler,
remove any gasket residues if
necessary – there must not be
any gasket residues or dirt
particles in the exhaust bore

Parts with damaged mating
surfaces must be replaced.

5904RA031 TG

5904RA032 TG

Position and orient exhaust
gasket (1) on muffler (2)

Slide cooling plate (1) with the
lugs (arrows) into the recesses of
the muffler (2) and position

Hold cooling plate (1) and insert
screws (3)
– Position of the gasket and the
cooling plate is secured

5904RA033 TG

5904RA034 TG

Summary of Contents for FS 240

Page 1: ...STIH STIHL FS 240 260 360 410 460 2011 09 ...

Page 2: ...llation 46 6 6 3 Short circuit wire with M Tronic on engine removal and installation 48 6 6 4 Short circuit wire on control handle for loop handle removal and installation 51 6 6 5 Short circuit wire on control handle for bike handle removal and installation 52 6 6 6 Ground wire 54 6 6 7 Contact spring versions with control handle for bike handle 54 6 7 Troubleshooting Ignition System 55 7 M Troni...

Page 3: ... 103 11 6 Carburetor adjustment without M Tronic 103 11 6 1 Basic setting 103 11 6 2 User adjustment 104 11 7 Spacer flange 105 11 8 Tank vent 107 11 8 1 Testing 107 11 8 2 Removal and installation 108 11 9 Fuel intake 108 11 9 1 Pickup body 108 11 9 2 Fuel hose 109 11 9 3 Fuel tank 110 12 Drive tube assembly 112 12 1 Drive tube assembly with loop handle 112 12 2 Drive tube assembly with control h...

Page 4: ...ted edition is issued The special tools mentioned in the descriptions are listed in the chapter Special Servicing Tools of this manual The tools can be identified according to part number in the STIHL Special Tools manual The manual lists all tools supplied by STIHL Symbols are included in the text and pictures for greater clarity The meanings are as follows In the text N Action to be taken as sho...

Page 5: ...and damage before installation replace if necessary Only use the machine with the shroud mounted otherwise the rotating fan wheel poses a risk of injury and there is a risk of engine damage due to overheating The chapter Tightening Torques lists all components of this machine that must be tightened with the specified tightening torques or coated with thread locking adhesive These specifications mu...

Page 6: ...nings Clutch engages at 3600 rpm 3600 rpm 3600 rpm Crankcase leakage test at gauge pressure pü 0 5 bar pü 0 5 bar pü 0 5 bar under vacuum pu 0 5 bar pu 0 5 bar pu 0 5 bar 2 2 Fuel system Carburetor leakage test at gauge pressure pü 0 8 bar pü 0 8 bar pü 0 8 bar Operation of tank vent at gauge pressure pü 0 5 bar pü 0 5 bar pü 0 5 bar Fuel as specified in instruction manual as specified in instruct...

Page 7: ... assembly 5 0 Screw P 4x10 Diagnostic jack bushing 1 5 7 Screw M 5x21 Filter cover 6 0 Collar nut M 5 Filter housing 3 5 Screw M 6x35 Gearbox drive tube assembly 10 0 1 Screw D 5x24 Gear housing drive tube assembly 1st stage 4 0 1 Screw D 5x24 Gear housing drive tube assembly 2nd stage 9 0 1 Screw M 5x10 Gear housing guard ring 8 0 2 Screw M 5x48x22 Left handle handlebar locknut 2 5 Screw D 5x24 S...

Page 8: ... 5 M 10x1 Spark plug cylinder 12 0 Screw D 4x18 Ignition module cylinder 4 0 1 Screw M 5x20 Spacer flange cylinder 8 0 2 Screw D 5x32 Cylinder crankcase 9 0 1 Remarks 1 Easy slide coating with locking serration 2 Microencapsulated with locking serration 3 Microencapsulated with washer 4 Connection between crankshaft and flywheel must be degreased and oil free 5 1 point antivibration system 6 4 poi...

Page 9: ... speed screw LA Versions with M Tronic Carry out diagnosis Tension springs of the clutch shoes are stretched Replace tension springs replace clutch if necessary Tension springs of the clutch shoes are broken Replace tension springs Loud noises Tension springs stretched Replace all tension springs Ball bearing of the clutch drum is damaged Replace ball bearing Screws of the clutch are loose Tighten...

Page 10: ...sembly 25 4 mm Add gear lubricant Gearbox drive tube assembly 28 mm Remove drive pinion and add gear lubricant Gearbox runs rough and stops running under load Drive shaft does not fully engage drive pinion Push gearbox onto drive tube assembly until the drive shaft fully engages the drive pinion Square profile or serration in the drive train is damaged or worn Check drive pinion drive shaft and cl...

Page 11: ...ing attachment out of true Resharpen cutting attachment evenly replace if necessary Drive tube assembly becomes very warm Drive shaft not sufficiently lubricated Lubricate drive shaft along its entire length the entire length of the flexible liner must be lubricated Bike handle does not clamp Clamps are greasy or oily Clean clamps and bike handle Bike handle can no longer be adjusted Clamps are di...

Page 12: ...rease tension Rewind spring broken Replace rewind spring Starter rope cannot be pulled out far enough Rewind spring overtensioned Check rewind spring and reduce tension Starter rope can be pulled out almost without resistance crankshaft does not turn Guide peg on pawls or pawls themselves are worn Replace pawls Spring clip fatigued Replace spring clip Spring clip improperly installed Install sprin...

Page 13: ...t spring housing is fatigued Replace ErgoStart At very low outside temperatures Lubricant oil on the rewind spring becomes viscous spring winding stick together or moisture has penetrated the rewind spring spring windings are frozen Coat rewind spring with a little standard solvent based degreasant containing no chlorinated or halogenated hydrocarbons then pull rope carefully several times until n...

Page 14: ...le control unit and flywheel Set the correct air gap Flywheel cracked or has other damage or pole shoes have turned blue Install new flywheel Incorrect ignition timing flywheel out of adjustment Key in flywheel has sheared off Install new flywheel Weak magnetization in flywheel Install new flywheel Irregular spark Check proper functioning of lever for stop function contact spring or slide control ...

Page 15: ...Replace metering diaphragm Metering diaphragm is deformed Replace metering diaphragm Poor acceleration version without M Tronic Low speed screw too lean Check basic carburetor setting correct if necessary High speed screw too lean Check basic carburetor setting correct if necessary All versions Inlet needle sticking to valve seat Remove inlet needle clean and refit Diaphragm gasket leaking Replace...

Page 16: ...Throttle shutter does not close Replace carburetor Versions with M Tronic Parts in carburetor or M Tronic wiring harness defective Carry out M Tronic diagnosis if necessary replace carburetor or M Tronic wiring harness Engine stops when idling versions without M Tronic Idle speed screw too rich or too lean Correct setting of low speed screw L Idle speed screw LA setting incorrect throttle shutter ...

Page 17: ...ine speed drops quickly under load low power all versions Air filter dirty Clean air filter replace if necessary Throttle shutter not opened fully Check throttle cable and rod Tank vent faulty Replace tank vent Fuel pick up body dirty Replace pickup body Fuel strainer dirty Clean fuel strainer in carburetor replace if necessary Leak in fuel line between tank and carburetor Seal connections or repl...

Page 18: ...power and has very low final speed Choke shutter does not open Check carburetor and choke shaft if necessary repair lever at the choke shaft choke lever or replace carburetor Engine does not start No spark Replace spark plug check ignition module control unit replace if necessary Starter grip not pulled forcefully enough Fuel air mixture too rich flooded Remove and dry the spark plug crank the eng...

Page 19: ...er full power or runs erratically Piston rings worn or broken Replace piston rings Muffler spark arresting screen carbonized Clean muffler inlet and outlet openings replace spark arresting screen replace muffler if necessary Air filter dirty Clean or replace air filter Fuel line kinked or cracked Fit new lines and ensure they are installed without kinking Engine is overheated Insufficient cylinder...

Page 20: ... 2 1 Remove screws 1 Remove filter cover 2 with screws Remove screws 1 Remove bushing 2 Detach short circuit wire and cable holder from engine b 6 6 2 Versions with M Tronic Remove the plug 1 5904RA002 TG 1 2 1 5904RA003 TG 1 1 2 1 2 5904RA290 TG 2 3 Remove screws 2 and tilt bushing 3 to the side Detach short circuit wire and cable holder from engine b 6 6 3 Remove screws 1 Remove clutch housing 2...

Page 21: ...Heat the inner race of the ball bearing to approx 120 C 250 F Position clutch drum 1 on ball bearing 2 and push it on as far as it will go This must be done quickly as the clutch drum absorbs heat and begins to expand If it is impossible to heat the inner race the clutch drum must be pressed on cold Support the clutch housing on the opposite side with a suitable pipe on the inner race of the ball ...

Page 22: ... b 11 9 3 Refit the shroud b 5 4 Install starter b 8 2 Versions with 1 point antivibration system Orient cover 1 so that the guide groove arrow faces the protective tube 2 Position cover 1 Insert and tighten down the screws 3 5904RA012 TG 1 2 2 5904RA013 TG 1 3 3 2 Insert protective tube with control handle in the guide groove arrows Position cable holder 1 and slide it into the slits on the side ...

Page 23: ...s out ball bearing using a suitable pipe 3 Replace ball bearing Examine clutch housing replace if necessary Examine rubber insert and clamp install in new clutch housing if necessary b 9 1 4 point antivibration system Examine both rubber buffers push onto new clutch housing if necessary b 9 2 Examine clutch replace if necessary b 4 2 5904RA017 TG 1 2 3 Installation Rubber insert or rubber buffers ...

Page 24: ...strip 1 0000 893 5904 in the cylinder Locking strip 1 0000 893 5904 must rest against the cylinder wall arrow Position as shown Remove bolts 1 SW 10 Remove clutch 2 complete with cover washers 5904RA022 TG 1 5904RA407 TG 1 5904RA023 TG 2 1 1 Remove clutch 1 from the lower cover washer Lift up clutch shoes 1 and unhook tension springs 2 Clutch shoes must be oriented so that the markings arrows are ...

Page 25: ...asher 3 Position upper cover washer 1 so that the holes arrows match S M SM 5904RA026 TG 1 2 1 3 S M SM 5904RA027 TG 1 Fit coupling 1 complete with cover washers in the threaded holes arrows of the flywheel 2 Insert and tighten down the screws 3 SW 10 Pull the locking strip out of the cylinder Install clutch housing b 4 1 Reassemble remaining parts in reverse order 5904RA028 TG 1 2 3 3 ...

Page 26: ...t gasket 1 and cooling plate 2 Installing and removing the spark arresting screen see Instruction Manual Installation Cover exhaust bore and remove any fouling on the cylinder and exhaust bore Examine and clean the mating surfaces arrows on the exhaust bore cooling plate and muffler remove any gasket residues if necessary there must not be any gasket residues or dirt particles in the exhaust bore ...

Page 27: ...ed idle speed difficult if not impossible Moreover the transition from idle speed to part or full throttle is not smooth Always start with the vacuum test and then continue with the pressure test The engine can be thoroughly checked for leaks under vacuum and at gauge pressure using the pump 0000 850 1300 5 2 1 Preparations Remove shroud b 5 4 Take off the spark plug boot and remove the spark plug...

Page 28: ...he crankcase is reduced further the oil seals must be replaced b 5 3 After testing slide the ring on the pump back to the right to vent the pump Continue with pressure test b 5 2 3 5 2 3 Pressure test The same preparatory steps are required as for the vacuum test b 5 2 2 Slide ring 1 to the right Pressure test Operate the lever 2 until the pressure gauge 3 indicates a pressure of 0 5 bar If this p...

Page 29: ... jaws profile no 3 1 0000 893 3706 Clamp the puller arms Pull out the oil seal Installation Clean the mating surface b 14 Grease the sealing lips of the new oil seal b 14 Fit the installing sleeve 1 1141 893 4600 Slide the oil seal 2 over the installing sleeve with the sealing lip facing the crankcase Remove the assembly sleeve 5904RA046 TG 1 2 Press the new oil seal 1 fully home with press sleeve...

Page 30: ... Slide the oil seal 2 over the installing sleeve with the sealing lip facing the crankcase Remove the assembly sleeve Orient press sleeve 1 4147 893 2400 with the base arrow facing the crankcase and press in the oil seal 2 The seating face must be flat and free from burrs Slide on the starter cup 2 Tightly screw on nuts 1 Reassemble remaining parts in reverse order 5904RA051 TG 2 1 5904RA052 TG 1 ...

Page 31: ... is blocked by placing the piston on the wooden assembly block in order to remove the clutch The mating surfaces must be in perfect condition and without any damage whatsoever The cylinder must be replaced if the mating surfaces are damaged b 3 7 Remove starter b 8 2 Remove shroud b 5 4 Remove drive tube assembly 1 point antivibration system b 12 1 4 point antivibration system b 12 2 Remove clutch...

Page 32: ... Orient new cylinder gasket 1 so that the tab 2 is located at the ridge 3 the openings must match with the crankcase Guide cylinder gasket 1 over the piston and lay it in the sleeves arrows Cylinder gasket is secured Place wooden assembly block 1 1108 893 4800 between piston and crankcase Avoid damage to the cylinder gasket 5904RA062 TG 3 2 1 5904RA063 TG 1 Coat piston piston rings and inside of c...

Page 33: ...through the holes crosswise Reassemble remaining parts in reverse order 5904RA065 TG 1 2 5904RA066 TG 5 6 Crankshaft Empty the fuel tank in accordance with regulations b 1 1 Remove the starter cup b 5 3 Remove the flywheel b 6 5 Remove the cylinder b 5 5 Remove piston b 5 7 Remove insert b 5 1 Remove fuel tank b 11 9 3 Always fit new ball bearings and oil seals when removing the crankshaft b 5 6 1...

Page 34: ... always be replaced as such Examine ignition side 1 and starter side 2 halves of case for cracks and check all mating surfaces arrows for damage If the original crankcase is reused the oil seals and ball bearings must be replaced all gasket residues removed and the mating surfaces cleaned thoroughly also in the circumferential groove of the ignition side half of the case The mating surfaces must b...

Page 35: ...ankcase on the cylindrical crankshaft stub so that the cylindermatingsurfaces arrows match Heat only the inner race of the ball bearing to approx 120 C 250 F Slide the crankcase half 1 on until the guide sleeves 2 are in as far as they will go 5904RA076 TG 5904RA077 TG 1 2 2 The crankcase must be fitted rapidly as the heat is transmitted to the crankshaft stub and the inner bearing race contracts ...

Page 36: ...e absolutely flawless and clean to guarantee a perfect seal Examine both halves of the crankcase for cracks and check all mating surfaces for signs of damage Refer also to troubleshooting b 3 7 Remove crankshaft b 5 6 Ignition side half of the crankcase Carefully drive the oil seal out with a punch Examine and clean the crankcase replace if necessary Replace ball bearings if the crankcase is in go...

Page 37: ...if necessary use press arbor 4119 893 7200 to press the ball bearing fully home Install crankshaft b 5 6 Install the oil seals b 5 3 Reassemble remaining parts in reverse order 5 7 Piston Remove the cylinder b 5 5 The assembly drift can be inserted through the fitted snap ring thus only one snap ring must be removed 5904RA083 TG 1 Use a suitable tool to pry the hookless snap ring out at the recess...

Page 38: ...piston on the side with the installed snap ring Push the assembly drift 2 1110 893 4700 with the stub end first through piston hole and rod eye needle cage and secure the piston Coat the piston pin with oil Fit the piston pin 1 on the stub of the assembly drift 2 and slide it into the piston Remove the sleeve 1 5910 893 1709 from the installing tool 2 5910 890 2211 5904RA088 TG 1 2 5904RA089 TG 2 ...

Page 39: ...e until the snap ring slips into the groove The tool must be precisely aligned in axial direction of the piston pin Install new oil seals b 5 3 Install the cylinder b 5 5 Reassemble remaining parts in reverse order 5 8 Piston rings Remove piston b 5 7 Remove piston rings from piston Use a piece of old piston ring to scrape the grooves clean 5904RA093 TG Align the new piston rings so that the radiu...

Page 40: ...d after checking that the wiring and stop switch are in good condition 6 1 Ignition timing Ignition timing is fixed and cannot be adjusted during assembly work Since there is no mechanical wear in these systems ignition timing cannot get out of adjustment during operation 6 2 Ignition module Remove shroud b 5 4 Unplug the spark plug boot Remove drive tube assembly 1 point antivibration system b 12...

Page 41: ...ck ignition module and slide setting gauge 1 0000 890 6400 between the legs of the ignition module and the magnetic poles of the flywheel 2 2 5904RA105 TG 1 1 5904RA106 TG Adjustment with clutch housing installed Push back ignition module and slide setting gauge 1 0000 890 6400 between the legs of the ignition module and the magnetic poles of the flywheel Slide setting gauge 1 in the direction of ...

Page 42: ...unt Starting at the lug 2 press the lead 1 of the ignition module into the guides arrows as far as it will go Screw in the screw 3 and tighten Reassemble remaining parts in reverse order 1 5904RA109 TG 2 3 1 5904RA240 TG 2 6 2 1 Control unit ignition module M Tronic Remove shroud b 5 4 Unplug the spark plug boot Remove drive tube assembly 1 point antivibration system b 12 1 4 point antivibration s...

Page 43: ... crimped side must face cable holder Insert lead blue of the ignition module 1 with the lug 3 in the mount crimped side must face cable holder Starting at the lug press both leads into the guides arrows as far as they will go Reassemble remaining parts in reverse order 6 3 Testing the ignition module To test the ignition module use either the ZAT 4 ignition system tester 5910 850 4503 or the ZAT 3...

Page 44: ...4 165RA185 TG 1 2 3 4 5 Crank the engine quickly with the rewind starter and check sparkover in the window 3 of the ignition system tester The engine may start and accelerate during the test If a spark is visible in the window 3 the ignition system is in order If no spark is visible in the window 3 check the ignition system with the aid of the troubleshooting chart b 6 7 6 4 Spark plug boot igniti...

Page 45: ...n lead and torsion spring into the spark plug boot 165RA188 TG 5904RA140 TG Ensure that the torsion spring arrow is located in the recess Position cable holder 1 around the ignition lead and press together Press cable holder 1 completely into the hole on the cooling fin Plug in the spark plug boot 5904RA141 TG 1 5904R142 TG 5904RA137 TG 1 Orient cable holder 1 so that it aligns with the contour ar...

Page 46: ...blue discoloration replace flywheel if necessary Installation Flywheel and crankshaft stub must be free from grease for installation Ensure that the machined key arrow engages the slot in the crankshaft Set the air gap between ignition coil and flywheel b 6 2 Reassemble remaining parts in reverse order 5904RA147 TG 5904RA148 TG 6 6 Short circuit wire The short circuit wire and ground wire form a s...

Page 47: ...hrottle cable must also be replaced 1 2 5904RA242 TG If no fault can be found test the ignition system in accordance with flow chart b 6 7 Reassemble parts in reverse order 6 6 2 Short circuit wire on engine removal and installation Remove shroud b 5 4 Unplug the spark plug boot Remove drive tube assembly 1 point antivibration system b 12 1 4 point antivibration system b 12 2 Remove machine cover ...

Page 48: ...the mount arrow Orient throttle cable so that short circuit wire 1 and ground wire 2 face the cable holder Position Bowden cable 3 in the guide arrow and guide protective tube under the tab 4 Position protective tube 1 of the throttle cable in the guide of the clutch housing so that it is aligned with the edge arrow of the cable holder 1 2 5904RA111 TG 4 5904RA112 TG 3 2 1 1 5904RA113 TG As strain...

Page 49: ...in reverse order 6 6 3 Short circuit wire with M Tronic on engine removal and installation Remove shroud b 5 4 Unplug the spark plug boot Remove drive tube assembly 1 point antivibration system b 12 1 4 point antivibration system b 12 2 Remove machine cover b 4 1 Remove screws 1 Pull the red lead 2 and blue lead 3 of the control unit ignition module out of the guides arrows 1 2 5904RA119 TG 3 1 Pu...

Page 50: ...ntrol handle for bike handle b 6 6 5 Position the cable holder 1 on the clutch housing so that it engages behind the groove arrow of the spacer flange 2 and the tab 3 is seated in the recess of the clutch housing 1 5904RA249 TG 1 5904RA250 TG 2 3 The leads of the M Tronic are run along the throttle cable guide of the cable holder under the throttle cable in the guides So that the total length of t...

Page 51: ...mped between the tab of the cable holder and the guide of the clutch housing Hold the cable holder with throttle cable in this position Pull the red and black lead of the M Tronic out of the guides again up to the throttle cable Screw in screw 1 do not tighten Check orientation and position of the protective tube 2 align if necessary and tighten screw 1 5904RA132 TG 1 2 Position ground wire 1 of t...

Page 52: ... face cable holder Starting at the lug press both leads into the guides arrows as far as they will go 2 1 5904RA135 TG 2 5904RA136 TG 3 1 Insert and tighten down the screws 1 Reassemble remaining parts in reverse order 6 6 4 Short circuit wire on control handle for loop handle removal and installation Remove throttle trigger and trigger interlock b 10 1 1 Remove slide control b 10 1 2 Unscrew scre...

Page 53: ...spring arrow must actuate the microswitch this can be heard as a clicking noise Install throttle trigger and trigger interlock b 10 1 1 Install control handle for loop handle b 10 1 Install throttle cable and short circuit wire on engine without M Tronic b 6 6 2 with M Tronic b 6 6 3 Adjust throttle cable on control handle for loop handle b 10 2 4 Reassemble remaining parts in reverse order 5904RA...

Page 54: ...stallation Slide eyelet 1 onto the post 2 of the lever so that the eyelet opening faces the stop arrow Twist eyelet 1 as far as it will go into the locking groove arrow Push lever 1 with ground wire 2 onto the post 3 and turn in the opening arrow 5904RA161 TG 1 2 5904RA162 TG 1 5904RA163 TG 1 2 3 Press ground wire 1 as far as it will go into the guide arrows The ground wire 1 must not be stretched...

Page 55: ...ration Eyelet of the ground wire must touch the contact spring in STOP position arrow Install throttle trigger and trigger interlock b 10 2 2 Install control handle for bike handle b 10 2 1 Adjust throttle cable on control handle for bike handle b 10 2 4 Reassemble remaining parts in reverse order 5904RA169 TG 1 2 5 4 3 5904RA170 TG 6 6 6 Ground wire Testing and installation of ground wire is the ...

Page 56: ...eared with oil black Sooted Electrode gap correct Contacts shorted threads Clean adjust or replace spark plug b 6 3 Check spark plug boot Firmly seated on spark plug torsion spring Torsion spring hook in center of ignition lead Spark plug boot damaged Replace spark plug boot and or torsion spring if necessary b 6 4 Check ignition with ZAT 3 or ZAT 4 use ZAT 3 as main spark gap see TI 32 94 b 6 3 1...

Page 57: ...ing Spark plug boot Holes cracks Resistance of spark plug boot to ground Required 1 5 12 kΩ Check resistance of spark plug lead to ground spark plug boot and ignition module have been removed Value Required 10 Ω Replace spark plug boot and or ignition module if necessary b 6 4 Check short circuit wire Wire damaged Plug connections firmly seated Check continuity replace switch if necessary b 6 6 1 ...

Page 58: ...trol or lever for stop function is working properly Short circuit wire chafed Control handle for loop handle Function between slide control and contact spring of the microswitch Position F microswitch not pressed Position 0 microswitch pressed Control handle for bike handle Function between lever for stop function and contact spring Lever for stop function not pressed no connection Lever for stop ...

Page 59: ...e carry out several short load changes let engine idle then accelerate again to full throttle Let the engine idle for approx 5 seconds Let the machine run four or five times for approx 30 seconds at full throttle in the cut off range Let the engine idle for periods of approx 5 seconds each between the full throttle phases 7 2 Resetting the control unit to factory defaults If the control unit and o...

Page 60: ...nd solenoid valve Screws 1 must be tight Leads arrows must be seated completely and firmly in the cable lugs 1 5904RA277 TG 1 Plug 1 must be seated completely and firmly in the recess of the solenoid If necessary remove plug 1 and check contacts Set choke lever 1 to position the cam on the lever 2 must actuate the microswitch arrow Clicking noise 1 5904RA278 TG 2 5904RA279 TG 1 7 3 4 Checking the ...

Page 61: ...chgear microswitch is intact and the choke lever is set to the position the following target values will be attained Measurement in direction of flow target value 0 3 volts to 0 7 volts Move choke lever to position F slide control or lever for stop function on control handle is not pressed Reverse biased measurement Target value 1 2 volts to infinity If target values are not attained replace M Tro...

Page 62: ...and angled terminal socket Blade receptacle and angled terminal socket must be firmly connected with one another in the event of contact problems the M Tronic wiring harness must be replaced b 7 4 Check leads between solenoid valve and diagnostic jack Connect the test lead b 7 3 2 Disconnect the plug 1 from the solenoid valve 2 Measure the resistance between red lead 1 at the plug of the solenoid ...

Page 63: ...eads out of the guides arrows Unscrew screw 1 and remove diagnostic connector 2 from the mount of the bushing 3 5904RA173 TG 1 5904RA174 TG 5904RA175 TG 2 1 3 Installation With a new switchgear first the thin leads must be inserted in the guides of the switchgear Leads and plug connections must not be damaged Leads with plug 1 to solenoid valve of the carburetor Press red lead 2 and black lead 3 i...

Page 64: ...ead 1 and black lead 2 as far as they will go into the guides arrows on the plug Run the black lead under the red lead for left guide see illustration Press black lead 1 and red lead 2 as far as they will go into the guide that is offset by 90 arrows 5904RA178 TG 1 2 5904RA179 TG 2 1 Insert switchgear 1 with the pegs in the mounts arrows Insert and tighten down the screw Run the thick leads to the...

Page 65: ...ess plug 2 into the diagnostic connector arrow as far as it will go Orient plug 1 so that the lug arrow aligns with the groove in the mount 2 Push plug into the mount as far as it will go 2 1 5904RA184 TG 1 15904RA185 TG 2 Do not expose plug to tensile loads thus run leads so that they form a 90 loop at the plug Press black lead 1 as far as it will go into the guides arrows starting at the plug Pr...

Page 66: ...lever Clicking noise b 11 4 5 Examine switch gear clean or replace if necessary b 7 4 Check start detection and wiring harness electrically b 7 3 5 b 7 3 6 yes Mechanically OK Are target values attained b 7 3 Look for a fault in the fuel path check engine for leaks b 11 Replace switchgear b 7 4 no yes no no Engine does not start Is it possible to start the engine yes no Check solenoid valve b 7 3 ...

Page 67: ...f necessary Examine switch gear clean or replace if necessary b 7 4 Check start detection and wiring harness b 7 3 yes Mechanically OK Are target values attained Look for a fault in the fuel path inlet needle lever spring membrane check engine for leaks b 11 4 b 5 2 Replace switchgear b 7 4 yes no no Engine does not start in position engine floods Can the flooded engine be started in position F ye...

Page 68: ...rops under load low power Look for a fault in the fuel path check engine for leaks b 11 4 b 5 2 Examine the air filter replace if necessary b 11 1 Troubleshooting completed Cut off speed 12300 rpm yes no Engine speed drops under load low power Calibrate control unit b 7 1 ...

Page 69: ...Check the flywheel two pairs of poles b 6 5 Combination OK Check air gap between control unit and flywheel b 6 2 Establish correct control unit flywheel combination yes Air gap OK Test ignition system according to flow chart Ignition system troubleshooting b 6 7 Set correct air gap b 6 2 no No ignition spark yes no yes Can engine be started ...

Page 70: ...the lugs OK Push plug on all the way and tighten screwed connections b 7 3 3 replace switchgear if necessary b 7 4 yes no no Engine stops suddenly no yes Check start detection actuation of switchgear clean if necessary Replace switchgear b 7 4 Check start detection wiring harness and plug and screwed connections b 7 3 Mechanically OK Replace switchgear b 7 4 yes no Check solenoid valve b 7 3 4 Are...

Page 71: ...ut off speed greater than 12300 rpm Maximum speed less than 11500 rpm Look for a fault in the fuel path check engine for leaks b 11 b 5 2 no Troubleshooting completed yes Check screwed connections of the control unit leads b 6 2 1 Connection and firm seat in the lug OK Tighten screwed connections and push plug on all the way if necessary replace switchgear or control unit b 7 4 b 6 2 1 no yes Chec...

Page 72: ...refully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored Before installing lubricate the rewind spring and starter post with STIHL special lubricant b 14 If clogged with dirt or pitch the entire starter mechanism including the rewind spring must be removed and disassembled Take particular care when removing the rewind spring Clean all compon...

Page 73: ...rse order 5904RA191 TG 1 5904RA192 TG 8 4 ErgoStart rope rotor Relieve tension of rewind spring The system will not be under tension if the starter rope or rewind spring is broken Remove starter b 8 2 Remove pawls b 8 3 Pull out the starter rope 1 between rope rotor and starter cover with assembly hook 3 5910 893 8800 then hold rope rotor 2 tight Take all turns off the rope rotor Pull out the rope...

Page 74: ...904RA197 TG 1 Insert the carrier 1 in the spring housing so that the recess arrow engages the anchor loop 2 Fit washer 1 Slide circlip 2 into the lower groove arrow of the starter post Install pawls and spring b 8 3 Tension the rewind spring b 8 6 Grease the pegs of the pawls b 14 Reassemble remaining parts in reverse order 5904RA198 TG 2 1 5904RA199 TG 1 2 8 5 Starter rope starter grip Remove sta...

Page 75: ...04RA200 TG 1 5904RA230 TG 4903RA131 TG Pull the rope through the grip until the knot at the end of the rope is in the recess arrow Then thread the rope 1 through the opening arrow Thread starter rope 1 into rope rotor Secure the rope 1 with a simple overhand knot 4903RA132 TG 5904RA201 TG 1 5904RA202 TG 1 Insert starter rope 1 in the recess arrow and press the knot into the depression 2 as far as ...

Page 76: ...ot the case the rewind spring must be tensioned by one additional turn When the starter rope is fully extended it must still be possible to rotate the rope rotor at least another full turn before the the max spring tension is reached If not the spring tension must be reduced otherwise it will break Reduce spring tension Pull the rope out hold the rope rotor steady and take off one turn of the rope...

Page 77: ...e spring housing into the mount in the starter cover as far as it will go The rewind spring may pop out Insert and tighten down the screws 1 Make certain that the inner anchor loop 1 protrudes at the spring housing orient if necessary anchor loop must engage the carrier on the rope rotor 5904RA210 TG 1 1 5904RA211 TG 1 Reinstalling a rewind spring that has popped out If the rewind spring pops out ...

Page 78: ... 893 4900 with the 25 4 mm shaft into the clamp 2 as far as it will go Tighten bolt 3 O 25 4 5904RA213 TG 1 2 3 Clamp square profile of installing tool 1 with clutch housing 2 in the vise Move the clutch housing back and forth while apply sufficient STIHL press fluid between clamp and rubber insert b 14 Pull off clutch housing 2 Pull off rubber insert 1 from clamp 2 2 5904RA214 TG 1 1 2 5904RA216 ...

Page 79: ...with the middle of the opening arrow the guide ribs in the clutch housing must line up with the depressions in the rubber insert Slide on the clutch housing 1 until the rubber insert 3 is completely inside the clutch housing Loosen bolt 1 and remove clutch housing 2 with rubber insert 3 and clamp 4 Reassemble remaining parts in reverse order 5904RA215 TG 1 2 3 5904RA221 TG 1 2 3 4 9 2 Rubber buffe...

Page 80: ... annular buffers 1 over the spring nuts 2 and remove Lever off the clamp 3 Insert screwdriver through the holes in the plugs of the large anitvibration spring 1 and small antivibration spring 2 Remove the screws and antivibration springs 5904RA227 TG 1 1 2 5904RA228 TG 1 1 2 2 3 5904RA550 TG 1 2 Installation Insert screwdriver through the holes in the plugs of the large anitvibration spring 1 and ...

Page 81: ...5904RA236 TG 1 2 2 Press the rubber buffers 1 onto the plugs 2 of the clutch housing as far as they will go Orient antivibration housing 1 so that the support 2 faces the drive tube assembly 3 Push the antivibration housing 1 onto the end of the drive tube assembly 3 with the built in shakeproof washer until the drive tube assembly 3 protrudes a little on the opposite side 5904RA237 TG 1 2 1 2 590...

Page 82: ... under the drive tube assembly narrow side of the support and clamping screw must face the cutting attachment 5904RA253 TG a 1 5904RA254 TG 1 2 Orient bike handle 1 so that the control handle 2 is on the muffler side Slide spring 3 into the mount on the clamp 4 Throttle cable must be routed under the drive tube assembly Position bike handle 1 on profile of the antivibration housing and insert clam...

Page 83: ...erlock Take out the screws arrows Remove handle molding 1 5904RA261 TG 1 5904RA262 TG 1 Remove torsion spring 1 from the guide 2 and pull out under the throttle cable 3 Remove throttle trigger 1 Rotate throttle trigger 1 by 90 clockwise until the hook 2 rests against the surface arrow 5904RA263 TG 2 1 3 5904RA264 TG 1 5904RA496 TG 1 2 Thread out the throttle cable 1 on throttle trigger 2 Carefully...

Page 84: ...old it there 5904RA267 TG 1 2 5904RA268 TG Slide throttle interlock 1 onto the post 2 Release upper end of the torsion spring Torsion spring 1 must lie in the notch arrow Thread throttle cable 1 into throttle trigger 2 Turn throttle trigger by 90 counterclockwise 5904RA269 TG 2 1 5904RA270 TG 1 5904RA393 TG 1 2 Slide throttle trigger 1 onto the post 2 Orient throttle trigger 1 so that the lug 2 en...

Page 85: ...G 1 2 3 4902RA126 TG 1 5904RA262 TG 1 10 1 2 Slide control Remove control handle for loop handle b 10 1 Remove throttle trigger throttle trigger interlock b 10 1 1 Remove slide control 1 Remove torsion spring 1 Installation Slide torsion spring 1 onto the post 2 so that the angled end arrow faces upward 5904RA291 TG 1 5904RA292 TG 1 5904RA293 TG 1 2 Short end 1 must lie between the ridges arrows O...

Page 86: ... remaining parts in reverse order 5904RA297 TG 1 2 5904RA298 TG 1 2 3 10 2 Control handle for bike handle The control handle for bike handle 1 with lever for stop function arrow is pushed directly onto the bike handle diameter 25 4 mm or 22 mm and secured with a transverse screw 10 2 1 Removal and installation Unscrew and remove the screw 1 remove nut on the opposite side Remove control handle 2 f...

Page 87: ...antivibration system Press protective tube 1 into the guides arrow so that the protective tube 1 lies against the drive tube assembly 2 and does not form any kinks 4 point antivibration system Press protective tube 1 into the guide arrows as far as it will go protective tube must lie tight against the machine Press fairing 1 with the hooks in the openings arrows and slide toward support 2 5904RA30...

Page 88: ...alled stud With a new throttle trigger or after the position of the stud has been changed the throttle cable must be readjusted b 10 2 4 Slide torsion spring 1 onto the post 2 so that the angled end arrow faces the handle housing 5904RA310 TG 1 5904RA311 TG 1 2 Push on the trigger interlock 1 and hook on the torsion spring arrow Turn the angled end of the torsion spring 1 clockwise until it is ali...

Page 89: ...TG 1 5904RA317 TG 1 Turn torsion spring clockwise and hook it into the lever arrow Ground wire and short circuit wire must be inserted completely in the guides arrows Route throttle cable 1 and protective tube 2 in the guides arrows and hold in place 5904RA318 TG 5904RA319 TG 5904RA320 TG 1 2 Carefully fit handle molding 1 until it snaps into place Levers may pop out Insert and tighten down the sc...

Page 90: ...nt Checking throttle cable setting Press throttle trigger 1 as far as it will go and hold it there 5904RA324 TG 1 Push the lever 1 onto the throttle shaft If it is possible to continue turning the lever 1 in the direction of full throttle then the throttle shutter is not completely open in the full throttle position Adjusting throttle cable on control handle for bike handle Press throttle trigger ...

Page 91: ...er close completely which would result in a high idle speed Reassemble parts in reverse order 10 2 5 Throttle rod Remove the shroud b 5 4 Hold lever 1 and press lever 2 of the throttle shaft in the direction of full throttle until the throttle rod 3 slides out of the lever 2 Unhook the throttle rod 1 from the lever 2 Check lever 2 replace if necessary b 11 7 5904RA330 TG 2 1 35904RA331 TG 1 2 Inst...

Page 92: ...1 Versions with M Tronic Remove plug 1 on diagnostic connector arrow All versions Remove screws 1 In versions with M Tronic the grommet 2 is not removed because it is connected to the switchgear Remove grommet 2 5904RA394 TG 1 5904RA003 TG 1 1 2 All versions Remove tank vent hose 1 at the connector arrow always use a new tank vent hose Unscrew nuts 1 and pull off filter housing 2 Press out grommet...

Page 93: ...ntil it encloses the hole completely To simplify installation coat the inside of the grommet with STIHL press fluid b 14 Slide filter housing 1 onto the studs so that the support of the carburetor engages the grommet 2 Fit nuts and screw them tight Use STIHL press fluid to simplify assembly b 14 Push the new tank vent hose 1 completely onto the connector 2 5904RA401 TG 1 2 5904RA402 TG 1 2 Version...

Page 94: ...ide 5904RA405 TG 1 5904RA406 TG 1 2 All versions Hold lever 1 and press lever 2 of the throttle shaft in the direction of full throttle until the throttle rod 3 slides out of the lever 2 Pull off the fuel return line 1 at the connector arrow Pry out connector 1 with fuel hose 2 5904RA330 TG 2 1 3 1 5904RA408 TG 5904RA409 TG 1 2 Remove carburetor 1 Examine the fuel hose 2 with connector 3 replace i...

Page 95: ... bushing 1 with switchgear so that the scale arrow faces the cylinder Guide bushing 1 with switchgear over the choke lever 2 and position Install filter housing b 11 2 5904RA415 TG 1 2 5904RA416 TG 1 2 Versions with M Tronic Orient plug 1 so that the lug arrow aligns with the groove in the mount 2 Push plug into the mount as far as it will go Do not expose plug to tensile loads thus run leads so t...

Page 96: ... line 1 1110 141 8600 onto the double connector 2 0000 855 9200 Push the fuel line with double connector onto the fuel port arrow Push pressure hose of the pump 0000 850 1300 onto the double connector 5904RA338 TG 1 2 2 1 5904RA339 TG Push ring 1 to the right and pump air into the carburetor until the pressure gauge 2 shows a pressure of approx 0 8 bar 80 kPa If this pressure remains constant the ...

Page 97: ... subjected to continuous alternating stresses and eventually shows signs of fatigue In other words the diaphragm distorts and swells and must be replaced Examine the metering diaphragm for signs of damage and wear fit a new gasket Remove the end cover 1 Remove cap 1 5904RA342 TG 1 2 5904RA343 TG 1 5904RA344 TG 1 Installation Note the order in which the metering diaphragm 2 and gasket 1 are install...

Page 98: ...ssemble remaining parts in reverse order 5904RA347 TG 1 2 3 5904RA348 TG 1 1 1 1 11 4 2 Inlet needle Remove the metering diaphragm b 11 4 1 Remove screw 1 Pull the inlet control lever 1 with spindle 2 out of the groove in the inlet needle The spring under the inlet control lever may pop out 5904RA349 TG 1 5904RA350 TG 2 1 Pull out the inlet needle 1 Take out and examine the spring 2 replace if nec...

Page 99: ... the gasket and pump diaphragm are stuck to the carburetor they must be removed very carefully Carefully remove the pump diaphragm with gasket from the end cover 1 Carefully separate the pump diaphragm 2 and gasket 3 The diaphragm material is subjected to continuous alternating stresses and eventually shows signs of fatigue In other words the diaphragm distorts and swells and must be replaced Exam...

Page 100: ...2 4 4 5904RA359 TG 1 Check that the pump diaphragm and gasket are correctly seated Hold end cover 1 in position screw in and tighten screw 2 Reassemble remaining parts in reverse order 11 4 4 Throttle shaft lever Remove the carburetor b 11 3 Troubleshoot carburetor b 3 6 Remove screw 1 Remove lever 2 5904RA360 TG 2 1 5904RA361 TG 1 2 Installation Orient lever 2 so that the hook engages the choke l...

Page 101: ...Remove torsion spring Versions with M Tronic Push out circlip 1 Pull out lever 2 with torsion spring arrow Remove torsion spring 5904RA366 TG 1 5904RA367 TG 2 1 5904RA368 TG 1 2 Installation All versions Orient the torsion spring 1 so that the angled end points toward the carburetor Slide torsion spring 1 onto the choke shaft and slide the angled end into the hole arrow torsion spring is secured V...

Page 102: ... 2 When pressing on the choke knob the choke shaft must be held in place Place the opposite end arrow of the choke shaft on a solid surface Press the choke knob 1 firmly onto the choke shaft until it snaps into place spring must rest against the base arrow of the black lever 5904RA373 TG 1 2 5904RA392 TG 5904RA374 TG 1 Checking operation without M Tronic In the warm start position lever 1 must eng...

Page 103: ... the low speed screw L have a special hexagonal head and can only be adjusted with screwdriver 5910 890 2307 no limiter caps are used Remove the carburetor b 11 3 See also Troubleshooting on the carburetor b 3 6 Low speed screw Unscrew low speed screw L arrow with screwdriver 1 5910 890 2307 Examine the tip arrow for signs of damage or wear Fit a new low speed screw L 1 if necessary Turn the low s...

Page 104: ...ning and setting the carburetor Basic setting and fine adjustment are required after the adjusting screws have been removed and installed Before the start of the fine adjustment the adjusting screws must be pre set this can not be done if the engine is running or if the carburetor has been removed from the machine With the low speed and high speed screws in their seats turn them counterclockwise S...

Page 105: ...t The new carburetors provide an optimum fuel air mixture in all environments and operating states thus all that is eventually necessary or possible is correction of the idle speed using the idle speed screw LA To avoid problems the following steps must be performed for all settings Troubleshooting b 3 6 5904RA386 TG 2 1 5904RA387 TG Check cutting attachment adjust if necessary Examine the spark a...

Page 106: ... new gasket 5904RA417 TG 1 Unhook the throttle rod 1 from the lever 2 Unhook throttle cable 1 at lever 2 and remove it from the mount arrow Unscrew screws 1 and remove spacer flange 2 Remove gasket use a new gasket Check spacer flange replace if necessary even tiny cracks can lead to impaired engine performance b 3 6 b 3 7 5904RA418 TG 1 2 5904RA419 TG 1 2 5904RA420 TG 1 2 1 1 Examine and clean th...

Page 107: ...4RA423 TG 1 2 3 3 4 5904RA424 TG 2 1 2 2 Orient lever 1 so that the pins arrows face the spacer flange and push it onto the post 2 Push circlip 1 into place Hook throttle cable 1 onto lever 2 and press it into the mount arrow 2 5904RA425 TG 1 5904RA426 TG 1 5904RA419 TG 1 2 Hook the throttle rod 1 onto the lever 2 Orient gasket 1 so that the holes arrows match and the openings engage the ridge 2 P...

Page 108: ... Slide ring 1 to the left and connect the pump 2 0000 850 1300 to the double nipple arrow Create vacuum in fuel tank Pressure is equalized via the tank vent A negative pressure must not build up inside the tank Clean the area around the tank vent Always use a new fuel hose Replace the tank vent or tank if necessary b 11 8 or b 11 9 3 1 5904RA430 TG 2 1 5904RA431 TG 2 Testing with gauge pressure Sl...

Page 109: ... that it is free of kinks Reassemble remaining parts in reverse order 11 9 Fuel intake 11 9 1 Pickup body Impurities which are entrained into the fuel tank with the fuel are trapped by the pick up body With time the fine pores in the pick up body become clogged with very fine dirt particles This reduces the intake diameter and fuel can no longer be delivered in sufficient quantities Always check t...

Page 110: ...1 Pull the fuel suction hose 1 out of the inside of the tank Pull off the fuel return line 1 at the connector arrow Always use new fuel hoses Installation Push fuel suction hose 1 into hole arrow in fuel tank 1 5904RA439 TG 1 5904RA440 TG 1 5904RA449 TG Use STIHL press fluid to simplify assembly b 14 Orient the fuel suction hose 1 and press it into the hole in the housing as far as it will go the ...

Page 111: ...fluid b 14 Push connector 1 into the fuel suction hose 2 so that the fuel hose 3 is between the ribs arrows Connector must be pushed all the way into the fuel suction hose Use hook 5910 893 8800 to pull the fuel suction hose 1 out of the fuel tank Take care not to overextend the fuel suction hose Fit the pickup body b 11 9 1 Close the filler cap Reassemble remaining parts in reverse order 3 1 5904...

Page 112: ...1 in the fuel tank 2 so that the domes arrows on the starter and ignition side engage the recesses of the fuel tank Screw in the screw 3 and tighten Fit protective hip plate 2 so that the bulge is at the tank filler port Insert and tighten down the screws 1 1 3 5904RA459 TG 2 1 1 1 5904RA460 TG 1 2 Push connector 1 into the fuel suction hose 2 so that the fuel hose 3 is between the ribs arrows Con...

Page 113: ...r components must be converted Installation Degrease clamping area b 14 Loop handle and carrying ring must be installed b 12 2 3 b 12 3 3 Orient end of drive tube assembly arrow with stopper installed so that it faces the engine 5904RA442 TG 1 2 3 5904RA443 TG The clamps in the control handle for the loop handle must be loosened Push the control handle for the loop handle 1 onto the side of the dr...

Page 114: ...the screw 1 Pull the drive tube assembly 2 out of the clutch housing Versions with antivibration housing Undo the screw 1 5904RA388 TG 1 2 5904RA224 TG 1 2 Pull drive tube assembly with antivibration housing 2 out of the clutch housing Examine the drive tube assembly repair or replace if necessary b 12 2 2 With a new drive tube assembly the installed parts or components must be converted Installat...

Page 115: ... screw 2 through the opening arrow Drive tube assembly is clamped and secured The sticker on the drive tube assembly must be visible when using the machine Secure antivibration housing b 9 2 install bike handle with control handle b 9 2 Check instruction label on drive tube assembly for damage and legibility replace if necessary 5904RA464 TG 1 2 3 5904RA465 TG 1 2 12 2 1 Disassembling the drive tu...

Page 116: ...bricant to the drive shaft evenly Only pressing lubricant into the hole of the flexible liner and pushing in the unlubricated drive shaft does not ensure sufficient lubrication Push drive shaft 1 with square profile into opening arrow of the flexible insert Slide on the gearbox 1 on the opposite end of the installed stopper as far as it will go Orient drive tube assembly 2 so that the sticker alig...

Page 117: ...serration out of the drive tube assembly If the shaft has blue tarnish on it it must be replaced 2 5904RA475 TG 1 3 5904RA476 TG 1 Pry out shakeproof washer 1 Replace shakeproof washer after removal Pull flexible liner 1 out of the drive tube assembly Assembly Push flexible liner 1 into drive tube assembly 5904RA477 TG 1 5904RA478 TG 1 5904RA479 TG 1 Push flexible liner 1 inside the drive tube ass...

Page 118: ...1 2 3 Orient drive tube assembly 2 so that the sticker aligns with the dome arrow on the gear housing then tighten screw 3 The sticker on the drive tube assembly must be visible when using the machine With gentle twisting motions push the drive shaft into the gearbox as far as it will go turn output shaft on gearbox if necessary Checking operation Turn the serrated end of the drive shaft the outpu...

Page 119: ...or gearbox with 25 4 mm drive tube assembly diameter To preserve the threads in the plastic parts screw the screws into the existing threads and tighten carefully Remove screws 1 Remove plate 2 and deflector 3 Unscrew the bolt 1 Push out mount with line limiting blade 5904RA487 TG 3 1 1 1 1 2 5904RA488 TG 1 Unscrew the bolt 1 Slide line limiting blade 2 down slightly and remove Examine line limiti...

Page 120: ...t 2 faces the deflector and slide it into upper guide arrow as far as the tab Insert and carefully tighten down the bolt Threads in plastic can strip Position deflector 1 and fit plate 2 Insert and tighten down the screws 3 5904RA493 TG 1 2 5904RA494 TG 3 3 3 3 2 1 12 3 2 Deflector for gearbox with 28 mm drive tube assembly diameter Installation and removal of the deflector for metal tools and the...

Page 121: ...rt and tighten down the screws 2 5904RA499 TG 1 5904RA500 TG 1 2 2 2 12 3 3 One piece carrying ring Unscrew screw 1 and bend open and remove clamp 2 Install parts in reverse order 12 3 4 Support Remove drive tube assembly b 12 1 Remove throttle cable holder 1 Install parts in reverse order 2 1 545RA271 TG 5904RA540 TG 1 12 4 Gearbox for drive tube assembly 25 4 mm with square profile 12 4 1 Remova...

Page 122: ...isassembly Removing cutting attachment Remove gearbox b 12 4 1 Observe safety instructions when heating parts b 1 5904RA375 TG 1 2 3 3 Remove the circlip 1 Heat gearbox in the area arrows of the bearing seats of the drive tube assembly connection to approx 120 C 250 F Once this temperature is reached the entire drive side set of pinions 1 can be pulled out Always use new ball bearings Remove the c...

Page 123: ...ing a suitable tool on the inner race press the new ball bearing 1 onto the stub of the drive pinion 3 as far as it will go Position the new ball bearing 2 so that the closed side faces outward using a suitable tool on the inner race press it onto the stub of the drive pinion 3 as far as it will go Fit the circlip 1 2 5904RA507 TG 1 3 5404RA508 TG 1 Using a suitable tool on the inner race press th...

Page 124: ... the drive end in the area of the bearing seats arrows to approx 120 C 250 F Position drive pinion 2 so that the bevel gearing faces the gear housing Press in the drive pinion 2 as far as it will go If necessary turn the output shaft until the drive pinion engages the output shaft The drive pinion must be inserted quickly as it absorbs heat and begins to expand Fit the circlip 1 2 5904RA513 TG 1 1...

Page 125: ...igns with the serrations of the drive pinion turn the output shaft on the gearbox if necessary Tighten bolt 3 Checking correct functioning Unplug the spark plug boot and turn the motor the output shaft on the gearbox must also turn 12 5 2 Disassembly Removing cutting attachment Remove gearbox b 12 5 1 Observe safety instructions when heating parts b 1 Unscrew the stud 1 1 5904RA517 TG Heat gearbox...

Page 126: ... bearing 2 and use a suitable tool to press out the drive pinion 3 3 5904RA539 TG 1 2 4 5404RA519 TG 1 2 3 Unscrew screws 1 and remove guard ring 2 Pry out the guard plugs 1 The locking pin 1 of puller 5910 890 4407 must engage the hole arrow puller is secured against twisting with the locking pin 1 5904RA520 TG 1 1 2 5904RA521 TG 1 5904RA544 TG 1 Orient the ring 1 of puller 5910 890 4407 so that ...

Page 127: ...the nut and remove the puller Check gearbox clean and replace if necessary Always use new ball bearings Pull ball bearing 1 off of the drive shaft 2 Always use new ball bearings Position ball bearing 1 on the outer race of the bearing arrow and use a suitable tool to press out the drive shaft 2 Remove washer 3 Clean and examine all parts replace set of pinions if necessary 1 5904RA523 TG 2 5904RA5...

Page 128: ...ricant b 2 4 2 5904RA527 TG 1 3 1 5904RA528 TG 2 3 4 Coat serrations of the spur bevel gear with STIHL gear lubricant b 14 Heat the gearbox 1 in the location of the bearings on the output end arrow to approx 120 C 250 F Position set of pinions so that the spur bevel gear 2 faces the gear housing Push set of pinions into the gear housing 1 as far as they will go The set of pinions must be fitted ra...

Page 129: ...e drive pinion 2 as far as it will go If necessary turn the output shaft until the drive pinion engages the output shaft The drive pinion must be inserted quickly as it absorbs heat and begins to expand 2 5904RA534 TG 1 Insert and tighten down the stud 1 Checking operation Turn output shaft 1 the inner serration of the drive pinion arrow must also turn Gearbox must turn easily Install gearbox b 12...

Page 130: ...893 7200 Cold forcible insertion of ignition side ball bearing New special tools No Designation Part No Use Re marks 1 Setting gauge 0000 890 6400 Setting the air gap between ignition module and flywheel control unit 2 Installing sleeve 1141 893 4600 Protection of the oil seal Ignition side 3 Press sleeve 4147 893 2400 Pressing in oil seal Starter side 4 Press sleeve 4238 893 2400 Pressing in oil ...

Page 131: ... 890 8800 Clamping drive tube assembly of machine to assembly stand 15 ZAT 4 ignition tester 5910 850 4503 Test ignition system 16 ZAT 3 ignition tester 5910 850 4520 Test ignition system 17 Torque wrench 5910 890 0302 Screw connections 0 5 to 18 Nm 18 Torque wrench 5910 890 0312 Screw connections 6 to 80 Nm 19 Installing tool 11 5910 890 2211 Fit hookless snap rings in piston 20 Bit T 27 x 150 59...

Page 132: ...81 120 1117 0781 120 1118 Gearbox drive shaft 3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor rewind spring in starter 4 STIHL press fluid OH 723 0781 957 9000 Rubber elements antivibration elements 5 Tube of sealant Dirko HT red 0783 830 2000 Sealing the crankcase 6 Standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Cleaning mating surf...

Page 133: ...132 FS 240 C FS 260 C FS 360 C FS 410 C FS 460 C M ...

Page 134: ...englisch english 0455 752 0123 M0 15 A12 FST Printed in Germany ...

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Stihl FS 240, Service Manual

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Summary of Contents for FS 240

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