Stihl FS 350 Service Manual Download Page 43

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Summary of Contents for FS 350

Page 1: ......

Page 2: ...pe Starter Grip ElastoStart 32 7 Throttle Control 33 7 1 Throttle Trigger Interlock Lever Bike Handle 33 7 2 Contact Springs Detent Spring in Control Handle Bike Handle 34 7 3 Throttle Trigger Interlock Lever Loop Handle 34 7 4 Slide Control Loop Handle 35 7 5 Throttle Cable 36 7 5 1 Replacing 36 7 5 2 Adjusting 37 8 Fuel System 38 8 1 Air Filter 38 8 2 Carburetor 39 8 2 1 Removing and Installing ...

Page 3: ... 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 The manual lists all special servicing tools currently available from STIHL Symbols are included in the text and pictures for greater clarity The meanings are as follows In the descriptions Action to be taken as shown in the illustration above the text Action...

Page 4: ...m Reserve pull on rope rotor min 1 2 turn Starter rope 3 0 mm 0 12 in dia x 800 mm 31 5 in Clutch Centrifugal clutch without linings Clutch engages at 4 300 rpm Crankcase leakage test at gauge pressure 0 5 bar 7 25 psi under vacuum 0 5 bar 7 25 psi 2 2 Fuel System Carburetor Diaphragm carburetor Standard setting on carburetors with three adjusting screws High speed screw H Open approx 1 turn Low s...

Page 5: ...bevel gear drive Gear ratio 1 1 4 1 1 235 Bearings Deep groove ball bearings Lubrication STIHL gear lubricant 0781 120 1117 7 g 0 25 oz 2 5 Special Accessories 2 5 1 For User Full harness Safety glasses Transport guard for metal cutting tools STIHL gear lubricant 80 g 3 oz tube 0781 120 1109 STIHL gear lubricant 80 g 3 oz tube 0781 120 1117 2 5 2 For Service Carburetor parts kit 4134 007 1060 Set ...

Page 6: ...ire crankcase 6 0 4 4 1 2 Spline screw IS DG5x26 Fuel tank crankcase 6 0 4 4 Spline screw IS DG5x24 Bracket crankcase 6 0 4 4 1 Spline screw IS DG5x20 Shroud clutch housing 6 0 4 4 Spline screw IS DG5x26 Guard plate fuel tank crankcase 6 0 4 4 1 2 Spline screw IS DG5x24 Cylinder crankcase 8 5 6 3 Spline screw IS DG5x24 Muffler crankcase 8 5 6 3 Spline screw IS DG5x24 Muffler cylinder 8 5 6 3 Splin...

Page 7: ...ing tool 25 0 18 5 Spline screw IS M5x16 Cutting tool deflector gearhead 4 3 3 2 Spline screw IS M6x14 Spring support plate 10 0 7 5 2 5 Spline screw IS M6x25 Housing shaft clamp screw 4 5 3 3 2 5 Spline screw IS M6x14 Bearing housing support frame 10 0 7 5 2 5 Spline screw IS M10x20 Support plate ball bearing support frame 20 0 15 0 2 5 Use the following procedure to fit a DG or P screw in an exi...

Page 8: ...see 4 1 Pull off the spark plug boot Unscrew the spark plug FS 120 350 FR 350 Fit locking strip 1 0000 893 5903 FS 400 450 FR 450 Fit locking strip 1 4221 893 5900 Take out screws 1 Remove cover 2 Remove clutch shoes with bushings Take bushings out of the clutch shoes Twist the clutch shoes and detach the springs Important Clutch shoes and springs must always be replaced in pairs 3 CLUTCH 3 1 Remo...

Page 9: ...5 lbf ft Important If the spark plug comes with a separate terminal nut always fit the nut on the thread and tighten it down securely Fit the boot on the spark plug Fit the shroud see 4 1 Fit clutch housing see 9 1 or 11 2 Remove clutch see 3 1 Unscrew carrier from end of crankshaft Fit the carrier and tighten it down to 24 Nm 17 7 lbf ft Install the clutch see 3 1 3 2 Clutch Carrier 250RA232 VA 2...

Page 10: ... screen if necessary Tighten down screw to 2 5 Nm 1 8 lbf ft Muffler FS 400 450 FR 450 Remove air filter cover see 8 1 All models Remove screws from clutch housing Take out screws 1 Press down the decompression valve 2 Remove the shroud 3 Take out the screws Lift away the muffler Remove the gasket Reassemble in the reverse sequence Use a new gasket Tighten down screws to 8 5 Nm 6 3 lbf ft 250RA006...

Page 11: ...and the vacuum pump Remove the carburetor see 8 2 1 and 8 2 2 Set the piston to top dead center T D C This can be checked through the inlet port Make sure the spark plug is properly tightened down Slide a new gasket over the carburetor studs Push the test flange 1 1128 850 4200 into position Fit and tighten down the nuts 2 firmly Back off the muffler mounting screws half way Slide the sealing plat...

Page 12: ...t Carry out the vacuum test see 4 2 3 After finishing the test open the vent screw and disconnect the hose Remove the test flange Slacken off the muffler mounting screws Pull out the sealing plate and tighten down the screws to 8 5 Nm 6 3 lbf ft Install carburetor see 8 2 1 or 8 2 2 Oil seals tend to fail when sub jected to a vacuum i e the sealing lip lifts away from the crankshaft during the pis...

Page 13: ...h No 3 1 jaws 0000 893 3706 Tension the arms Pull out the oil seal Important Take care not to damage crankshaft stub Clean sealing surface with a standard solvent based degreas ant containing no chlorinated or halogenated hydrocarbons see 13 2 Lubricate sealing lips of oil seal with grease see 13 2 Slide the oil seal open side facing the crankcase over the end of the crankshaft Use the press sleev...

Page 14: ...le shooting handbook Remove the muffler see 4 1 Remove the carburetor see 8 2 1 and 8 2 2 Take out screws 1 Pull away the carburetor housing 2 FS 400 450 FR 450 Disconnect hose from fuel pump and pull it out of the guide Take out screws 1 Pull away the carburetor hous ing 2 ease grommet out of carburetor housing and pull the extended throttle cable out of the housing opening Assemble in the revers...

Page 15: ...models Illustrations show the FS 200 engine Pull out the sealing ring Release and unscrew the four cylinder base screws Pull the cylinder off the piston Inspect the cylinder and replace it if necessary If a new cylinder has to be installed always fit the matching piston New cylinders are only available with piston Before removing the piston decide whether or not the crank shaft has to be removed a...

Page 16: ...re in place Fit them if necess ary Lubricate the needle cage 3 with oil and fit it in the connecting rod To simplify assembly heat the piston and slip it over the con necting rod Installed position of piston 1 Marking 2 Flywheel Push the assembly drift small diameter first through the piston and small end needle cage and line up the piston Fit the piston pin 1 on the assembly drift 2 and slide it ...

Page 17: ...d the piston and check that the piston rings are correctly positioned Lubricate the inside of the cylinder with oil and line it up so that it is positioned as it will be in the installed condition It is im portant to observe this point as the piston rings might otherwise break Slide the cylinder over the piston the clamping strap is pushed downward as the piston rings slip into the cylinder Remove...

Page 18: ...2 and 5 3 3 Remove the fuel tank see 8 5 Remove the cylinder see 4 5 1 All models Take out screw 1 Remove top of cable guide 2 FS 120 350 FR 350 Take throttle cable 1 out of base of guide 2 Take short circuit wire 3 out of base of guide and remove it from the retainers 4 FS 400 450 FR 450 Remove short circuit wire from the retainers Ease the grommets out of the housing and pull out the short circu...

Page 19: ...crews 2 in holes marked 17 and tighten them down against the drilled plate Note ZS installing tools without holes 16 17 and 18 and notches 16 and 17 can be modified as shown in the illustration Holes 16 and 18 are needed at the starter side of the crankcase The illustration shows the under side of the drilled plate 250RA056 VA 250RA062 1 VA 17 250RA063 2 17 16 2 1 VA 41 25 33 85 9 7 26 85 2 25 250...

Page 20: ... installing tool 1 5910 890 2220 against starter side of crankcase so that the notch marked 16 is at the bottom Insert screws 1 9022 341 1190 from ZS installing tool kit in holes marked 16 fit washers at other side and screw on nuts FS 400 450 FR 450 Hold ZS installing tool against starter side of crankcase so that the notch marked 17 is at the bottom Insert M5x60 screws in holes marked 18 fit was...

Page 21: ...y must be cleaned very thoroughly to ensure a perfect seal Check that bushings are in posi tion If necessary drive bushings into the crankcase Heat area of bearing seat on starter side of crankcase to approx 120 C 250 F Fit ball bearing in crankcase by hand and push it home as far as stop Note This operation must be carried out very quickly because the bearing absorbs heat immedi ately and begins ...

Page 22: ...leeve 2 left hand thread Hold the crankshaft steady and screw the spindle 1 clockwise onto the stub 2 as far as stop Hold the spindle steady and rotate sleeve counterclockwise until it butts against the ball bearing Hold the sleeve steady and rotate spindle clockwise until the crankshaft butts against the ball bearing Important During this process the connecting rod without piston must point towar...

Page 23: ...down to 8 5 Nm 6 3 lbf ft Lubricate sealing lips of oil seals with grease see 13 2 Fit installing sleeve 1 4112 893 2400 over the clutch end of the crankshaft Slide the oil seal open side facing the crankcase over the installing sleeve Press home with press sleeve 1 1118 893 2401 Remove the installing sleeve Slide the oil seal open side facing the crankcase over the starter end of the crankshaft P...

Page 24: ...he electronic breakerless ignition system basically consists of an ignition module 1 and flywheel 2 The illustration shows the FS 200 Remove the shroud see 4 1 Pull off the spark plug boot On FS 400 450 FR 450 take cable holder off the cylinder 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...

Page 25: ...securely On FS 400 450 FR 450 attach the cable retainer to the cylinder Fit the boot on the spark plug Fit the shroud see 4 1 Remove the ignition module see 5 3 3 Remove spark plug boot 1 see 5 1 Pull off the cable retainer 2 Remove the retainer Pull rubber boot 1 off the high voltage output Unscrew the ignition lead from the contact pin and pull it out of the high voltage output 5 2 Ignition Lead...

Page 26: ...e components required to control ignition timing FS 120 350 FR 350 There are two electrical connec tions on the coil body 1 the high voltage output 1 with ignition lead 2 2 the connector tag 3 for the short circuit wire A vibration damping pad is bonded to the side of the ignition module FS 400 450 FR 450 There are two electrical connec tions on the coil body 1 the high voltage output 1 2 the conn...

Page 27: ...ing see 6 2 Remove clutch housing see 9 1 Remove ignition lead from the retainers Pull short circuit wire connector 1 off tag on ignition module 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 Important Before installing a new ignition module make sure area for vibration damping pad is free from grease dirt a...

Page 28: ...le all other parts in the reverse sequence Remove the shroud see 4 1 Remove the fan housing see 6 2 Pull boot 1 off the spark plug Pull cable retainer 2 out of cylinder Take ignition lead out of guide Take out the screws Lift ignition module away slightly and disconnect short circuit wire from ignition module Remove the ignition lead see 5 2 Connect the short circuit wire place the module in posit...

Page 29: ...ut Pull off the flywheel Note If the flywheel cannot be removed by hand screw on the puller 1 4133 893 0800 and tap its end to release the flywheel Unscrew the puller Inspect the flywheel 1 and magnet poles 2 If you find any damage install a new flywheel Installing the flywheel Important Clean the stub of the crankshaft and the flywheel hub bore with a standard commercial solvent based degreasant ...

Page 30: ...re out of housing bore and remove grommet Push out the grommet 1 Pull short circuit wire 2 out of housing bore remove it from the retainers and pull off the grommet All models Take out the screw 1 Remove top of cable guide 2 Lift the throttle cable 1 a little Remove short circuit wire connector 2 from base of cable guide Assemble in the reverse sequence Check and adjust throttle cable see 7 5 2 5 ...

Page 31: ... parts in paraffin or white spirit Lubricate the rewind spring and starter post with STIHL special lubricant see 13 2 before installing Troubleshooting chart see Standard Repairs Trouble shooting handbook Take out the screws Remove fan housing with rewind starter Remove the rope rotor see Standard Repairs Trouble shooting handbook Take out the screw and remove any remaining pieces of spring from t...

Page 32: ...e starter grip firmly to keep the rope tensioned Let go of the rope rotor and slowly release the starter rope so that it can rewind properly Note The rewind spring is cor rectly tensioned when the starter grip sits firmly in the rope guide bush without drooping to one side If this is not the case tension the spring by one additional turn When the starter rope is fully extended it must still be pos...

Page 33: ... is supplied with starter rope Remove the rope rotor see Standard Repairs Trouble shooting handbook Pull the knot out of the recess in the rope rotor Undo the knot and pull the rope out of the rotor and fan housing On FR 350 450 slip tube 75 mm 2 95 over the starter rope Thread the starter rope 0000 195 8200 through the guide bush from outside the fan housing Thread rope through the hole in the si...

Page 34: ... Pull the interlock lever off the peg Remove the torsion spring Take the throttle trigger 1 with torsion spring 2 and throttle cable 3 off the peg Disconnect throttle cable from trigger Assemble in the reverse sequence Attach the throttle cable then position torsion spring as shown and push its long arm into the slot The interlock lever must be behind the throttle trigger Check correct positions o...

Page 35: ... Assemble in the reverse sequence Engage contact spring correctly in groove of collar screw FR 350 450 Use screwdriver 1 5910 890 2301 to remove screw Push guard 2 forward All models Warning To avoid risk of electric shock do not start the unit while the control handle is open Use screwdriver 1 5910 890 2301 to take out the screws Remove handle molding Remove torsion spring 7 2 Contact Springs Det...

Page 36: ... peg Remove contact spring from interlock lever Assemble in the reverse sequence Check positions of throttle cable 1 contact spring 2 protective tube 3 and insulator 4 Tighten screws to 1 0 Nm 0 75 lbf ft Remove the interlock lever see 7 3 Pull slide control off the handle molding Remove screws from clamps Take handle molding off the drive tube Remove torsion spring from peg 7 4 Slide Control Loop...

Page 37: ...ct spring see 7 2 and 7 3 Note On FS 120 350 FR 350 remove spark plug boot and take ignition lead out of retainers on top and base of cable guide Take out the screw 1 Remove top of cable guide 2 FS 120 350 FR 350 Remove screw 1 from extended throttle cable 2 Disconnect throttle cable nipple 1 from slotted pin 2 on throttle lever Take throttle cable 1 out of base of cable guide 2 and retainer 3 on ...

Page 38: ...Nm 4 4 lbf ft Adjust throttle cable see 7 5 2 Throttle lever 1 must butt against the stop on the carbure tor cover 2 when throttle trigger is squeezed full throttle On carburetors with an idle speed screw Throttle lever must butt against the idle speed screw when the trigger is in the idle position Note The filter housing is not shown in the illustration Adjustment is effected by moving the thrott...

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Page 60: ...3501 Testing crankcase for leaks 15 Nipple 0000 855 9200 16 Fuel hose 1110 141 8600 17 Sealing plate 0000 855 8106 Sealing exhaust port for leakage test 18 Test flange 1128 850 4200 For leakage test 19 Setting gauge 1127 890 6400 Setting air gap between ignition module and flywheel 20 Socket 13 mm 5910 893 5608 Clutch and flywheel nut decompression valve 21 Torque wrench 5910 890 0301 0 5 18 Nm 5 ...

Page 61: ...ess arbor 1120 893 7200 Removing ball bearing in clutch housing 41 Press arbor 1118 893 7200 Installing ball bearing in clutch housing removing and installing ball bearing in bearing housing support frame 2 42 Assembly stand 5910 890 3100 Holding FS and FR units 43 Clamp 5910 890 8800 Holds drive tube of FS units for repairs in conjunction with assembly stand 44 Clamping plate 5910 890 2101 Holds ...

Page 62: ...15 Bearing bore in rope rotor rewind spring in rope rotor 4 Ignition lead HTR 10 m 33 0000 930 2251 5 Dirko sealant 0783 830 2120 Crankcase sealing faces 100 g 3 1 2 oz tube 6 STIHL gear lubricant Drive shaft and clamp screw on 80 g 3 oz tube 0781 120 1109 bike handle 225 g 8 oz tube 0781 120 1110 7 STIHL gear lubricant Gearhead lubrication 80 g 3 oz tube 0781 120 1117 225 g 8 oz tube 0781 120 111...

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Stihl FS 350, Service Manual

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Summary of Contents for FS 350

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