Stihl FS 40 Service Manual Download Page 24

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Series 4144 Components FC, FS, KM

5.9.3

Removing and Installing
(Bike Handle Version)

The short circuit wire (black),
ground wire (blue) and throttle cable
are in a protective tube.

Take out the screw (arrow) and
remove the lock nut.

– Pull the control handle (1) off the

handlebar.

– Remove the drive tube,

9.1

– Remove the shroud,

5.1

Pull boot (1) off the spark plug.

545RA073 TG

545RA008 TG

Disconnect the short circuit wire
(1) and ground wire (2).

Pull the short circuit wire out of
the guide (arrow).

Disconnect the throttle cable
(arrow).

– Remove the carburetor,

8.2

Take out the screw (arrow).

– Pull the retainer (1) with throttle

cable out of its seat.

545RA058 TG

545RA072 TG

545RA023 TG

Pull the ground and short circuit
wires with throttle cable out of the
guides (arrows).

Pull the protective tube (1) out of
its inner seat (arrow).

Pull the protective tube (1) out of
its outer seat (arrow).

– Pull the protective tube (1) with

wires and throttle cable out of the
engine housing.

545RA075 TG

545RA076 TG

545RA077 TG

Summary of Contents for FS 40

Page 1: ...STIH STIHL Series 4144 Components FC FS KM 2008 02 FS 40 FS 50 FS 56 FC 56 KM 56 ...

Page 2: ... Handlebar Bike Handle 43 8 Fuel System 44 8 1 Air Filter 44 8 1 1 Baffle 44 8 1 2 Filter housing 44 8 2 Removing and Installing the Carburetor 45 8 3 Leakage Test 47 8 4 Servicing the Carburetor 47 8 4 1 Metering Diaphragm Manual Fuel Pump 47 8 4 2 Inlet Needle 49 8 4 3 Pump Diaphragm 49 8 4 4 Throttle Lever Rotary Knob 51 8 4 5 Adjusting Screws 52 8 5 Adjusting the Carburetor 54 8 5 1 Basic Sett...

Page 3: ...ions are listed in the chapter on Special Servicing Tools in 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 te...

Page 4: ...ly flammable fuel and can be explosive in certain conditions Always wear suitable protective gloves for operations in which components are heated for assembly or disassembly Improper handling may result in burns or other serious injuries Do not smoke or bring any fire flame or other source of heat near the fuel All work with fuel must be performed outdoors only Spilled fuel must be wiped away imme...

Page 5: ...speed 2 800 rpm 2 800 rpm Clutch Centrifugal clutch without linings Centrifugal clutch without linings Clutch engages at 4 200 rpm 4 200 rpm Crankcase leakage test at gauge pressure 0 5 bar under vacuum 0 5 bar 3 2 Fuel System Carburetor leakage test at gauge pressure 0 3 bar Operation of tank vent at gauge pressure 0 5 bar Fuel as specified in instruction manual 3 3 Ignition System Air gap betwee...

Page 6: ...x30 Control handle handle nut with washer 2 0 Screw P 5x14 Filter cover filter housing 3 0 Nut M 5 Filter housing carburetor spacer flange 3 5 Screw P 4x12 Throttle cable engine housing 1 5 Screw D 6x28 Gearbox drive tube clamp FS 56 12 0 Screw D 5x20 Shroud cylinder 6 0 Screw M 6x35 Clamp clamp block clamp 4 5 Screw M 6x25 Clamp loop handle 4 5 Screw P 5x20 Engine housing shroud 4 0 Screw M 5x20 ...

Page 7: ... the hole and rotate it counterclockwise until it drops down slightly Tighten the screw clockwise to the specified torque This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly Coat micro encapsulated screws with medium strength Loctite 242 or 243 before reinstalling Power screwdriver setting for polymer DG and P screws ...

Page 8: ... Cutting attachment runs at idle speed Engine idle speed too high Readjust idle speed screw LA Clutch springs stretched or fatigued Replace the clutch springs or install new clutch Clutch spring hooks broken Replace the clutch springs Loud noises Clutch springs stretched or fatigued Replace all clutch springs Clutch shoe retainer broken Install new clutch Clutch shoes and carrier worn Install new ...

Page 9: ...g overtensioned Check rewind spring and reduce tension Starter rope can be pulled out almost without resistance crankshaft does not turn Guide pegs on pawls or pawls themselves are worn Fit new pawls Spring clip on pawl fatigued Fit new spring clip Starter rope is difficult to pull or rewinds very slowly Starter mechanism is very dirty Thoroughly clean complete starter mechanism Lubricating oil on...

Page 10: ...l Use correct mixture of fuel and oil Incorrect air gap between ignition module and flywheel Set air gap correctly Flywheel cracked or has other damage or pole shoes have turned blue Install new flywheel Ignition timing wrong flywheel out of adjustment key on crankshaft has sheared off Locate flywheel properly or install new flywheel Weak magnetization in flywheel Install new flywheel Irregular sp...

Page 11: ...ulty Install new spark plug Faulty insulation or short in short circuit wire Check short circuit wire for short circuit to ground Break in ignition lead or insulation damaged Check ignition lead replace ignition module if necessary Ignition module faulty Install new ignition module ...

Page 12: ... diaphragm is deformed and presses constantly against the inlet control lever Fit a new metering diaphragm Metering diaphragm deformed Fit a new metering diaphragm Poor acceleration Setting of low speed screw too lean Check basic carburetor setting correct if necessary Setting of high speed screw too lean Check basic carburetor setting correct if necessary Inlet needle sticking to valve seat Remov...

Page 13: ...eaking Seal or replace oil seals crankcase Engine stalls at idle speed Idle jet bores or ports blocked Clean the carburetor Setting of low speed screw too rich or too lean Reset low speed screw L correctly Setting of idle speed screw LA incorrect throttle shutter completely closed Reset idle speed screw LA correctly Tank vent faulty Replace tank vent Leak in fuel hose between tank and fuel pump In...

Page 14: ...ckup body dirty Install new pickup body Fuel strainer dirty Clean fuel strainer in carburetor replace if necessary Leak in fuel hose between tank and fuel pump Install new hose Setting of high speed screw H too rich Check basic carburetor setting correct if necessary Main jet bores or ports blocked Clean the carburetor Pump diaphragm damaged or fatigued Fit new pump diaphragm Ignition timing wrong...

Page 15: ...eaking or damaged cracks Seal or replace the crankcase Engine does not deliver full power or runs erratically Piston ring worn or broken Fit new piston ring Muffler spark arresting screen carbonized Clean the muffler inlet and exhaust replace spark arresting screen replace muffler if necessary Air filter dirty Replace air filter Fuel hose kinked or torn Fit new hose or position it free from kinks ...

Page 16: ...tective cap 1 off the spark plug boot 2 Push the boot on to the spark plug Turn the machine over Take out the screws arrows Turn the machine over Remove the shroud 1 1 2 938RA087 TG 545RA027 TG 545RA028 TG 1 Disconnect the short circuit wire 1 and ground wire 2 Disconnect the tank vent hose 1 from the filter housing arrow Disconnect the fuel return hose 2 and fuel suction hose 1 from the stubs arr...

Page 17: ... for the Series 4144 Powerhead 5 2 Leakage test See service manual for Series 4144 Powerhead 5 3 Oil seals See service manual for Series 4144 Powerhead 5 4 Ignition Module Spark Plug Boot See service manual for Series 4144 Powerhead 5 5 Clutch See service manual for Series 4144 Powerhead 5 6 Flywheel See service manual for Series 4144 Powerhead 5 7 Motor See service manual for Series 4144 Powerhea...

Page 18: ...uction hose 2 b 8 9 2 Connect tank vent hose 1 to filter housing arrow push it fully onto the stub Turn the pin 1 until the slot is in line with the throttle cable Press down the throttle lever 2 545RA289 TG 2 1 1 545RA041 TG 545RA042 TG 1 2 Fit throttle cable 1 in the pin s 2 slot Turn the pin until the nipple is properly seated arrow Check operation squeeze throttle trigger on handle as far as s...

Page 19: ...47 TG 1 Place the shroud 1 in position behind the air baffle arrows Push the shroud 1 down until it engages the locking tabs Fit the screw arrow Turn the machine over Insert screws arrows and tighten them down firmly 545RA048 TG 1 545RA054 TG 1 545RA049 TG 1 1 1 Insert the screws 1 do not tighten them down yet Reassemble all other parts in the reverse sequence Tightening torques b 3 4 Push on the ...

Page 20: ...rk arresting screen if fitted Take out the screw arrow and remove the spark arresting screen 1 Clean the spark arresting screen or replace if necessary Reassemble in the reverse sequence Inspect and clean the sealing faces arrows and remove any gasket residue b 11 545RA052 TG 1 545RA053 TG Use a new exhaust gasket Insert the screws Push the exhaust gasket 1 over the screws Carefully place the muff...

Page 21: ... wires for continuity and check insulation for damage If the wires are in order check operation of stop switch b 5 10 If no fault can be found check the ignition system with the aid of the troubleshooting chart b 5 10 Check ground wire for continuity Reassemble in the reverse sequence 5 9 2 Removing and Installing Loop Handle Version Separate short circuit black and ground blue wires are installed...

Page 22: ...it if necessary Installing Ground and short circuit wires have different lengths position the short circuit wire in the guides first Lay the ground and short circuit wires next to one another do not cross over 545RA063 TG 3 1 2 545RA064 TG 1 2 Push the flag terminals firmly on to the connector tags of the stop switch Push the flag terminal of the short circuit wire 1 onto the rear connector tag se...

Page 23: ...holes arrows 545RA067 TG 1 545RA068 TG 1 2 545RA069 TG Push the support fully home and position the wires short circuit wire first in the guide arrow Push the short circuit into the guides arrows first then the ground wire Lay the wires next to one another without crossing over Fit the short circuit wire 1 in the guide arrow 545RA070 TG 545RA094 TG 545RA071 TG 1 Push short circuit wire 1 and groun...

Page 24: ...short circuit wire 1 and ground wire 2 Pull the short circuit wire out of the guide arrow Disconnect the throttle cable arrow Remove the carburetor b 8 2 Take out the screw arrow Pull the retainer 1 with throttle cable out of its seat 545RA058 TG 1 2 545RA072 TG 545RA023 TG 1 Pull the ground and short circuit wires with throttle cable out of the guides arrows Pull the protective tube 1 out of its ...

Page 25: ...d wire must therefore be tested for good contact and continuity Check operation of the stop switch and replace it if necessary 545RA081 TG 545RA082 TG 3 1 2 Tie a thin piece of string to the straight terminal on the short circuit wire 1 Pull short circuit wire 1 out of the protective tube 2 in direction of throttle cable retainer 3 and undo the string Check the short circuit wire and replace if ne...

Page 26: ...s arrows in the handle molding Fit the wires ground wire first in the guide arrows position the wires next to one another without loops The throttle cable sleeve 1 must locate in its seat in the handle molding 2 Install the control levers b 7 4 Install the throttle cable in the control handle b 8 6 1 545RA088 TG 1 2 545RA089 TG 2 1 Fit the handle molding 1 in position Insert screws arrows and tigh...

Page 27: ...45RA094 TG Fit the short circuit wire 1 in the guide arrow Push short circuit wire 1 and ground wire 2 firmly onto the connector tags Mount the control handle on the handlebar b 7 5 Reassemble all other parts in the reverse sequence Tightening torques b 3 4 Check operation 545RA071 TG 1 545RA045 TG 1 2 5 9 4 Ground Wire A faulty ground wire may impair or prevent operation of the short circuit wire...

Page 28: ...ck the spark plug boot Firmly seated on plug leg spring Leg spring hook in center of ignition lead Boot damaged If necessary install new spark plug boot and or leg spring see Series 4144 Powerhead Test ignition system with ZAT 3 or ZAT 4 use ZAT 3 as main spark gap see TI 32 94 see Series 4144 Powerhead 1 Troubleshooting can be performed with the engine installed Refer to service manuals of Series...

Page 29: ... the ignition lead Severe chafing Spark plug boot Holes cracks Resistance spark plug boot to ground spec 1 5 12 kΩ Check resistance of ignition lead spec 10 Ω If necessary install new ignition lead spark plug boot and or ignition module see Series 4144 Powerhead Check short circuit wire Wire damaged Connectors firmly seated Check the short circuit wire for break and replace if necessary b 5 9 1 3 ...

Page 30: ...d yes no Look for fault in fuel system or carburetor Check engine for leaks Check position of flywheel on crankshaft see Series 4144 Powerhead yes Check stop switch Short circuit wire chafed Operation of stop switch Idle position no connection Position 0 connection Install new short circuit wire if necessary b 5 9 2 3 Powerful spark Engine runs ...

Page 31: ...is restored Before installing lubricate the rewind spring and starter post with STIHL special lubricant 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 spring Clean all components 6 2 Removing and Installing Take out the screws arrows Remove the rewind starter 1 Position the rewind starte...

Page 32: ...ocate against the carrier Check operation Spring force must move the pawls in the direction of the carrier s hexagon as far as stop Reassemble all other parts in the reverse sequence Tightening torques b 3 4 6 3 1 Carrier Remove the rewind starter b 6 2 Check the carrier and replace if necessary A new carrier comes with the pawls and torsion springs preassembled 545RA283 TG 545RA102 TG Pull the bo...

Page 33: ...mes with the rewind spring preassembled Models with ErgoStart The rope rotor accommodates the ErgoStart spring and rewind spring Remove the E clip arrow Remove the carrier 1 Rewind spring must be relaxed Carefully remove the rope rotor 1 the rewind spring may pop out and uncoil Remove the starter rope or remaining rope from the rotor b 6 5 Check the rope rotor and replace if necessary 545RA107 TG ...

Page 34: ...sion of rewind spring b 6 6 The system will not be under tension if the starter rope is broken Remove the rope rotor b 6 4 Remove remaining rope from the rope rotor and starter grip Do not shorten the starter rope Push the end of the starter rope 1 out a little and undo the knot Pull the starter rope 1 out of the rotor 2 545RA113 TG 1 2 Models with ErgoStart Push the end of the starter rope 1 out ...

Page 35: ...tarter rope Tie a simple overhand knot in the end of the new rope and thread the rope through the sleeve Fit the washers and spring Pull the starter rope with sleeve spring and washers into the starter grip 1 Make sure the washers and spring remain on the sleeve while the rope its being pulled into the grip Position cap so that its lug 1 engages the slot arrow in the starter grip Press the cap int...

Page 36: ...2800 to pull out the starter rope 1 from between the rope rotor and housing and engage it in the rotor s notch arrow Use the starter rope 1 to rotate the rope rotor 3 six turns clockwise Rotating the rope and rope rotor causes the rope to become twisted The rewind spring is now tensioned Hold the rope rotor steady since it will otherwise spin back and may damage the rewind spring 545RA120 TG 1 2 3...

Page 37: ...spring is installed in the rope rotor 545RA123 TG A replacement spring is supplied ready to install with a new rope rotor If the rewind spring has popped out refit it in the rope rotor as follows Wear a face shield and work gloves Remove the rope rotor b 6 4 Engage anchor loop 1 in its seat arrow in the rope rotor 2 Fit the rewind in the counterclockwise direction holding the windings steady to pr...

Page 38: ...ne is started in this position Position g cold start cold engine is started in this position 7 3 Interlock Lever Loop Handle Remove the shroud b 5 1 Pull the boot off the spark plug Press down the interlock lever 1 to disengage it from the throttle trigger Pull out the support 2 Ease the interlock lever 1 out of its mounts arrows Turn the interlock lever 1 slightly and pull it out of the support 5...

Page 39: ...lace The leg of the torsion spring must locate against the edge arrow of the support and project slightly Install the support and fit the short circuit wire in the guide b 5 9 2 Check operation the throttle trigger is locked when the interlock lever is not depressed Reassemble all other parts in the reverse sequence Tightening torques b 3 4 7 3 1 Throttle Trigger Remove the support with interlock ...

Page 40: ...the lever 1 onto the pivot pin so that the lug is below the shoulder arrow Push the throttle cable nipple 1 into the lever and engage it in the slot arrow Position the throttle trigger with lever on the mounts arrows so the leg 1 locates against the edge of the engine housing 545RA140 TG 2 1 545RA141 TG 1 545RA142 TG 1 Press the throttle trigger 1 into the mounts until it snaps into place The leg ...

Page 41: ...5 TG 1 1 545RA073 TG Take out the screws arrows Remove the handle molding 1 Disconnect the leg arrow from the lever 1 Remove the torsion spring 2 Remove the throttle trigger 1 and lever 2 Disconnect the throttle cable 3 545RA146 TG 1 545RA147 TG 1 2 545RA148 TG 1 3 2 Carefully remove the interlock lever 1 tension of torsion spring 2 is suddenly relieved Remove the torsion spring 2 Pull the lever 1...

Page 42: ...ght leg 1 clockwise until it engages behind the stiffener arrow Push the interlock lever 2 fully home and check that the straight leg 1 butts against the stiffener arrow Make sure during the next operations that the interlock lever butts against the handle molding the torsion spring may otherwise pop out 545RA154 TG 1 545RA155 TG 2 1 Push the throttle trigger 1 onto the pivot pin Turn the interloc...

Page 43: ... arrows and tighten them down firmly Check operation The throttle trigger 2 must be locked in position when the interlock lever 1 is not depressed 545RA162 TG 1 2 545RA146 TG 1 545RA006 TG 2 1 Release the throttle trigger 2 it must return to the stop Line up the control handle 1 so that the throttle trigger points towards the coupling sleeve Push the control handle 1 onto the handlebar 2 turning i...

Page 44: ...handlebar and drive tube are different Position the clamp 1 with plain holes against the handlebar 2 Position the clamp block 3 slots arrows facing up against the underside of the handlebar Insert the screws through the clamp and clamp block 545RA167 TG 545RA168 TG 2 1 3 Position the preassembled handlebar on the drive tube Fit the clamp 1 with tapped holes against the underside of the drive tube ...

Page 45: ...ing arrow Reassemble in the reverse sequence 545RA025 TG 1 545RA171 TG 1 8 1 1 Baffle Remove the air filter b 8 1 Pull out the baffle 1 check it and replace if necessary Line up the baffle 1 so that it matches the contour of the filter housing Push the baffle 1 into the filter housing until it snaps into position Reassemble all other parts in the reverse sequence 1 545RA172 TG 1 545RA173 TG 8 1 2 ...

Page 46: ... reverse sequence Tightening torques b 3 4 8 2 Removing and Installing the Carburetor Remove the rewind starter b 6 2 Remove the shroud b 5 1 Remove the filter housing b 8 1 2 Open the fuel tank cap and drain the fuel tank Collect the fuel in a clean container b 1 Disconnect the fuel hoses only when the tank cap is open 1 545RA041 TG Press down the throttle lever until the nipple arrow projects Tu...

Page 47: ...Push the carburetor into position To simplify assembly coat the stubs and ends of the new fuel hoses with a little STIHL press fluid b 11 Push the new fuel return hose 1 and fuel suction hose 2 on to the stubs arrows without using pointed or sharp edged tools Fuel hoses must be pushed on firmly as far as stop 545RA182 TG 1 545RA040 TG 2 1 Turn the pin 1 until the slot is in line with the throttle ...

Page 48: ... carburetor is airtight However if it drops there are three possible causes 1 The inlet needle is not sealing foreign matter in valve seat sealing cone of inlet needle is damaged or inlet control lever is sticking Remove to clean b 8 4 2 2 Metering diaphragm or gasket damaged replace if necessary b 8 4 1 3 Pump diaphragm or gasket damaged replace if necessary b 8 4 3 After completing the test push...

Page 49: ...5RA187 TG 1 Check the cap 1 and replace if necessary Line up the gasket 1 and metering diaphragm 2 with the holes arrows Place the gasket 1 and metering diaphragm 2 in position Position the cap 1 in the annular groove arrow Fit the end cover 296RA315 TG 1 545RA188 TG 1 2 545RA190 TG 1 Place the flange in position stub 1 must be on same side as throttle shutter Insert two screws arrows to hold the ...

Page 50: ... new inlet needle Fit the inlet needle 1 Fit the spring 2 in the bore Position the inlet control lever 1 with spindle 2 on the spring s seat arrow first then slide the inlet control lever s clevis into the groove in the inlet needle 533RA309 TG 296RA243 TG 1 2 296RA244 TG 2 1 Make sure the spring locates on the control lever s nipple Press the inlet control lever down and secure it with the screw ...

Page 51: ...ence Fit the gasket 1 so that the contours arrows match and it is held in position by the pegs 2 Fit the diaphragm on the gasket 1 so that the contours arrows match and it is held in position by the pegs 2 545RA195 TG 1 296RA250 TG 2 1 2 296RA251 TG 1 2 2 Position the end cover 1 so that the idle speed screw arrow is at the same side as the adjusting screws Turn lever 2 on throttle shaft a little ...

Page 52: ...tion the throttle lever 1 so that the pin arrow faces up Push the throttle lever 1 on to the end of the throttle shaft arrow Tighten down the screw 2 firmly Check operation Rotate the choke shaft The choke lever 1 must engage the throttle lever arrow 545RA200 TG 1 545RA201 TG 2 1 545RA202 TG 1 Take out the screw arrow Pull off the rotary knob 1 Remove the spring 1 Check the individual parts and re...

Page 53: ...e adjusting screws on the carburetor H high speed screw 1 L low speed screw 2 LA idle speed screw 3 If the carburetor cannot be adjusted properly the problem may be the adjusting screws The high speed screw H and low speed screw L each have a limiter cap which has to be removed before the screw is removed Always install new limiter caps Remove the filter cover b 5 1 It is not necessary to remove t...

Page 54: ...p 296RA263 TG 545RA015 TG 1 Take out the high speed screw 1 Inspect the tip arrow for damage or wear and replace the high speed screw if necessary Screw down the high speed screw H as far as stop 545RA016 TG 1 296RA267 TG Pre installing limiter caps Low speed screw L Always use a new limiter cap and position it so that the long part of the cap butts against the underside of the stop arrow Push the...

Page 55: ...screw L 2 one full turn This completes the basic setting of the high speed screw H and the low speed screw L Mount the deflector and cutting tool mowing head see instruction manual the cutting tool must turn freely clean it if necessary Inspect the spark arresting screen if fitted and clean or replace if necessary b 5 8 The carburetor must be installed Check the air filter and clean or replace if ...

Page 56: ...the spark arresting screen if fitted and clean or replace if necessary b 5 8 Check the air filter and clean or replace if necessary b 8 1 545RA125 TG Standard Setting Shut down the engine Turn the high speed screw H slowly counterclockwise as far as stop but not more than a 3 4 turn Turn the low speed screw L slowly clockwise as far as stop but not more than a 3 4 turn Check running behavior The e...

Page 57: ...utting must rotate freely Turn the high speed screw H clockwise leaner no further than stop Turn the adjusting screws only very slightly Even minor adjustments can noticeably affect engine running behavior If the setting is made too lean there is a risk of engine damage as a result of lack of lubrication and overheating If the adjustments produce no improvement see the troubleshooting charts for t...

Page 58: ...e under the tank vent hose 1 Fit the throttle cable retainer 2 in its seat arrow Push the throttle cable 1 into the guides in the engine housing arrows as far as stop Tighten down the screw 1 firmly Install the carburetor b 8 2 545RA074 TG 1 2 545RA280 TG 1 545RA024 TG 1 Turn the pin 1 until the slot is in line with the throttle cable Press down the throttle lever 2 Fit throttle cable 1 in the pin...

Page 59: ...stop The throttle cable sleeve 1 must butt against the stop arrow Fit the throttle cable at the carburetor end b 5 9 3 Reassemble all other parts in the reverse sequence Tightening torques b 3 4 8 6 2 Adjusting the Throttle Cable Remove the shroud b 5 1 The throttle cable must be adjusted to ensure the throttle shutter opens and closes properly The adjustment procedure is the same for loop handled...

Page 60: ...the engine idle speed will then be too high 545RA228 TG 545RA229 TG Reassemble in the reverse sequence 8 7 Removing and Installing the Spacer Flange Remove the carburetor b 8 2 Disconnect the ground wire arrow Take out the screws arrow together with the connector tag Remove the spacer flange 1 Remove the gasket 1 545RA230 TG 545RA206 TG 1 545RA207 TG 1 Always install a new gasket Inspect the space...

Page 61: ... Check function by performing pressure and vacuum tests on the tank via the fuel hose Open the fuel tank cap and drain the fuel tank Collect the fuel in a clean container b 1 Close the tank cap Remove the rewind starter b 6 2 Remove the shroud b 5 1 Pull the fuel suction hose 1 off the stub arrow Close the tank cap 545RA213 TG 1 Push the nipple 1 0000 855 9200 into the fuel suction hose arrow Vacu...

Page 62: ...e tank vent so that its stub fits in the recess arrow Push the tank vent with hose into its seat until it snaps into place Make sure the hose is pushed fully on to the filter housing stub Reassemble all other parts in the reverse sequence 1 545RA217 TG 2 1 545RA218 TG 8 9 Fuel Intake 8 9 1 Pickup Body Any impurities mixed with the fuel are retained by the pickup body filter The fine pores of the f...

Page 63: ... hand Do not use pointed or sharp edged tools and do not cut open the fuel hoses at the stubs because they could be damaged in this way 1 545RA219 TG 2 To aid assembly use STIHL press fluid at the points recommended Do not use any other oil fuel grease or press fluids since they may damage the fuel hoses Remove the pickup body b 8 9 1 Remove the spacer flange b 8 7 Pull the fuel return hose 1 off ...

Page 64: ...To simplify assembly coat the stubs arrows and ends of the new fuel hoses with a little STIHL press fluid b 11 Push the new fuel return hose 1 and fuel suction hose 2 on to the stubs arrows Fuel hoses must be pushed on firmly as far as stop Use hook 5910 893 8800 to remove the fuel hose 1 from the fuel tank Do not overstretch the fuel hose Fit the pickup body b 8 9 1 Close the tank cap Reassemble ...

Page 65: ...ort circuit wire ground wire and throttle cable must be transferred from the old housing Machines with loop handle Transfer the short circuit and ground wires b 5 9 2 Transfer the throttle cable b 8 6 Machines with bike handle Transfer the short circuit and ground wires b 5 9 3 Transfer the throttle cable b 8 6 1 Check parts before transferring use new parts where necessary Reassemble in the rever...

Page 66: ...the other parts and components must be transferred from the old drive tube Installing Degrease the clamp area with a little standard solvent based degreasant containing no chlorinated or halogenated hydrocarbons b 11 Machines with loop handle Position the drive tube 1 so that the holes are in alignment 2 1 545RA000 TG 1 545RA002 TG Push home the drive tube 1 as far as stop turn the drive shaft to ...

Page 67: ...crew arrow Pull the coupling sleeve 2 off the drive tube 3 545RA007 TG 1 3 2 545RA232 TG Pull the drive shaft 1 out of the drive tube If the drive shaft has turned blue install a new one Pry the plug 1 out of the drive tube Pull the flexible liner out of the drive tube 1 545RA234 TG 1 545RA233 TG 545RA235 TG Grip the collar arrow and pull the complete driver 1 out of the drive tube Do not apply to...

Page 68: ...e driver so that their long sides arrows are offset Push the wire clips home as far as stop they must be firmly seated Push the complete driver 1 into the drive tube so that the lug 2 engages the notch arrow Push the driver home as far as stop Push the flexible liner 1 into the end of the drive tube with the cross holes arrows 545RA240 TG 2 1 545RA242 TG 545RA243 TG 1 Line up the flexible liner 1 ...

Page 69: ... points down Push the coupling sleeve 1 onto the driver end of the drive tube as far as stop Tighten down the screw arrow firmly Reassemble in the reverse sequence Tightening torques b 3 4 9 1 2 Disassembling FC 56 Remove the drive tube b 9 1 Remove the loop handle if necessary b 9 1 6 b 9 1 7 Remove the carrying ring if necessary b 9 2 3 Loosen the screw arrow Pull off the gearbox 1 check it and ...

Page 70: ...h wheel 2 is under the drive tube 3 Push the gearbox 1 on to the drive tube 3 as far as stop Tighten down the screw arrow firmly Reassemble in the reverse sequence Tightening torques b 3 4 9 1 3 Disassembling FS 56 Remove the drive tube b 9 1 Remove the loop handle if necessary b 9 1 6 b 9 1 7 Remove the carrying ring if necessary b 9 2 3 Remove the deflector b 9 2 2 Loosen the screw arrow 545RA29...

Page 71: ... Before installing the drive shaft coat it with STIHL gear lubricant for hedge trimmers b 11 Apply the grease evenly to the drive shaft Do not pump grease directly into the drive tube or flexible liner Push the drive shaft 1 into the flexible liner arrow until it engages the square recess in the gearbox Check operation 1 545RA253 TG 545RA250 TG 1 Rotate the drive shaft the gearbox output shaft mus...

Page 72: ... drive shaft coat it with STIHL gear lubricant for brushcutters b 11 Apply the grease evenly to the drive shaft Do not pump grease directly into the drive tube or flexible liner Push the drive shaft 1 into the flexible liner arrow until it engages the square recess in the bearing housing Check operation Rotate the drive shaft the bearing housing output shaft must rotate too Reassemble in the rever...

Page 73: ...roperly Pull out the bearing housing 2 Leave the clamp in position and do not change its setting to install a new bearing housing Push the new bearing housing into the drive tube so that their holes arrow are in alignment Push the bearing housing fully home Check position of hole turn bearing housing slightly if necessary until holes are exactly in alignment Loosen and remove the clamp Reassemble ...

Page 74: ...dle 1 so that it points away from the throttle trigger Tighten down the star knob screw 2 firmly 1 545RA260 TG a 1 2 545RA261 TG 9 1 7 Loop Handle with Barrier Bar Remove the drive tube b 9 1 Loosen the screw 1 Slip the loop handle 2 off the drive tube Take out the screw Pull the clamp 1 out of the loop handle 2 1 2 545RA262 TG 2545RA263 TG 1 Take out the screw arrow and washer Remove the barrier ...

Page 75: ... 1 Take out the screw 1 Pull off the clamp 2 Reassemble in the reverse sequence Inspect the bearing housing 3 and replace if necessary b 9 1 5 Take out the screw arrow Remove the line limiting blade 1 check and sharpen or replace as necessary 1 2 545RA267 TG 3 1 545RA268 TG Push the line limiting blade 1 into its seat arrow Insert screw and tighten it down firmly To avoid stripping the thread in t...

Page 76: ...ecessary see KombiTools service manual 1 545RA270 TG 1 545RA009 TG Locate deflector 1 against the gearbox Insert screw arrow and tighten it down firmly Reassemble all other parts in the reverse sequence 9 2 3 One part Carrying Ring Take out the screw 2 bend open the clamp 1 and remove it Reassemble in the reverse sequence 1 545RA269 TG 2 1 545RA271 TG 9 2 4 Retainer Remove the drive tube b 9 1 Pul...

Page 77: ...ver Q SW 8x200 5910 890 2420 Carburetor nuts 6 Crimping tool 5910 890 8210 Attaching connectors to electrical wires 7 Torque wrench 5910 890 0301 0 5 to 18 Nm 8 Torque wrench 5910 890 0311 6 to 80 Nm 9 Screwdriver Q T 27x150 5910 890 2400 All IS screws 10 Hook 5910 893 8800 Removing pickup body 11 Installing tool 5910 890 2204 Installing and flaring rope guide bushing 12 Puller 5910 890 4501 Remov...

Page 78: ...earing bore in rope rotor rewind spring in starter 5 Press fluid OH 723 0781 957 9000 Rubber elements of AV system hoses 6 STIHL multipurpose grease 0781 120 1109 High voltage output on ignition module 7 Dirko HT red sealant 0783 830 2000 Crankcase oil seals outside 8 Medium strength threadlocking adhesive Loctite 242 0786 111 2101 9 High strength threadlocking adhesive Loctite 270 0786 111 2109 1...

Page 79: ...78 Series 4144 Components FC FS KM ...

Page 80: ...79 Series 4144 Components FC FS KM ...

Page 81: ...80 Series 4144 Components FC FS KM ...

Page 82: ...englisch english 0455 545 0123 M7 E8 FST Printed in Germany ...

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