Stihl SR 430 Manual Download

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SR 430, SR 450

5.6

Short Circuit Wire

5.6.1

Testing

If the spark plug, ignition lead and
spark plug boot are in order, check
the short circuit wire and stop
switch,

5.6.2.

– Remove the shroud,

4.4

Disconnect the short circuit
wire (1).

– Connect the ohmmeter to

ground (arrow) and the short
circuit wire (1).

– Move the setting lever to "

" and

hold it in that position.

The resistance measured must be
about 0

. If it is much higher, the

reason may be the stop switch or
the wire. If damage is found, replace
the complete throttle cable,

5.6.2.

– Move the setting lever to "

The resistance measured must be
infinitely high. If not, install a new
throttle cable,

5.6.2.

0002RA083 TG

To locate the fault, test the wires for
continuity and check insulation for
damage. If the wires are in order,
check operation of stop switch,

5.7

If no fault can be found, check the
ignition system with the aid of the
troubleshooting chart,

5.7

– Check ground wire for continuity.

– Reassemble in the reverse

sequence.

5.6.2

Removing and Installing

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

If any part is damaged, the entire
throttle cable must be replaced.

– Remove the shroud,

4.4

– Remove the filter housing,

9.4

Pull off the spark plug boot (1)
vertically.

0002RA066 TG

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

Pull the wiring harness (1) out of
the guides (arrows).

Pull the fuel hoses (1) out of the
guides (arrows).

0002RA025 TG

0002RA084 TG

0002RA085 TG

Summary of Contents for SR 430

Page 1: ...STIH STIHL SR 430 450 2009 06 ...

Page 2: ...oning the Rewind Spring 45 6 7 Replacing the Rewind Spring 46 7 Servicing the AV System 48 7 1 AV Springs at Rear of Backplate 48 7 2 AV Springs at Bottom of Backplate 49 7 3 AV Springs on Backplate Metering Unit SR 450 49 7 4 Stop Buffer on Filter Housing 50 7 5 Stop Buffer on Shroud 50 8 Control Levers 51 8 1 Switch Positions 51 8 2 Setting Lever 51 8 3 Throttle Trigger Interlock Lever 52 8 4 Va...

Page 3: ... 89 10 6 Blower Wheel 90 10 7 Blower Housing SR 430 91 10 8 Blower Housing SR 450 95 10 9 Nozzle Valve 98 10 9 1 Nozzle 98 10 9 2 Valve 99 10 10 Blower Tube 101 10 10 1 Pleated Hose 101 10 10 2 Elbow 101 10 10 3 Hoses 102 11 Backplate 103 11 1 Backplate SR 430 103 11 2 Backplate SR 450 103 11 3 Harness 105 11 4 Back Padding 106 12 Special Servicing Tools 107 13 Servicing Aids 109 ...

Page 4: ... 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 N Action to be taken as shown in the illustration above the text Action to ...

Page 5: ...chine only with the shroud mounted in position there is otherwise a risk of injury from the flywheel and a risk of engine damage due to overheating The chapter on tightening torques lists all machine components that have to be tightened to a specific torque The specifications must be maintained when tightening down screws nuts and other fasteners in all the procedures described in this service man...

Page 6: ...zzle 6 800 rpm 6 800 rpm Idle speed 3 000 rpm 3 000 rpm Crankcase leakage test at gauge pressure 0 5 bar under vacuum 0 5 bar 2 2 Fuel System Carburetor leakage test at gauge pressure 0 8 bar Operation of tank vent at gauge pressure 0 5 bar Fuel as specified in instruction manual 2 3 Ignition System Air gap between ignition module and fanwheel 0 15 0 30 mm Spark plug resistor type NGK BPMR 7 A Bos...

Page 7: ...outer inner 4 0 Screw D 6x32 Blower housing inner engine pan 12 0 3 Screw D 6x32 Blower housing inner cylinder 12 0 3 Nut M 10x1 Blower wheel crankshaft nut 30 0 Screw P 5x18 Housing blower housing 4 0 Screw P 4x19 Handle molding outer inner 1 5 Screw P 6x21 5 Handle molding blower tube 4 0 Screw P 6x25 Lever inner handle molding 4 0 Screw M 4x9 6 Exhaust pipe muffler 4 0 Screw M 6x28 Engine pan c...

Page 8: ...e when refitting a DG or P screw in an existing thread Place the screw in the hole and rotate it counterclockwise until it drops down slightly Tighten the screw clockwise to the specified torque Coat micro encapsulated screws with medium strength threadlocking adhesive before re installing This procedure ensures that the screw engages properly in the existing thread and does not form a new thread ...

Page 9: ...nd spring overtensioned Check rewind spring and reduce tension Starter rope can be pulled out almost without resistance crankshaft does not turn Guide peg on pawl or pawl itself is worn Fit new pawl Pawl spring fatigued Fit new pawl spring Starter rope is difficult to pull or rewinds very slowly Starter mechanism is very dirty Thoroughly clean complete starter mechanism Lubricating oil on rewind s...

Page 10: ...e engine before working on the blower Condition Cause Remedy Blower does not blow Blower wheel loose Tighten down nut on blower wheel firmly Blower wheel blocked Clean blower housing Blower wheel worn or too many blades broken Fit a new blower wheel ...

Page 11: ...oil Incorrect air gap between ignition module and flywheel Set air gap correctly Flywheel shows signs of damage e g scores or pole shoes have turned blue Install new flywheel Ignition timing out of adjustment flywheel warped key in flywheel sheared Install new flywheel Flywheel magnetization weak pole shoes have turned blue Install new flywheel Irregular spark Check operation of stop switch and ig...

Page 12: ...all 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 13: ...et control lever and refit it correctly Perforated disc on metering diaphragm is deformed and presses constantly against the inlet control lever Fit a new metering diaphragm Poor acceleration Setting of low speed screw L too lean Check basic carburetor setting correct if necessary Setting of high speed screw H too lean Check basic carburetor setting correct if necessary Inlet needle sticking to va...

Page 14: ...l seals engine Throttle shutter stiff or torsion spring on throttle shaft fatigued or broken Free off throttle shaft or install new carburetor Engine stops while idling Idle jet bores or ports blocked Clean the carburetor Setting of low speed screw L 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 s...

Page 15: ... Replace tank vent Fuel pickup body dirty Install new fuel pickup body Fuel strainer dirty Clean fuel strainer in carburetor replace if necessary Leak in the fuel suction hose Install new fuel suction hose Setting of high speed screw H too rich Check basic carburetor setting correct if necessary Main jet bores or ports blocked Clean or replace the carburetor Pump diaphragm damaged or fatigued Fit ...

Page 16: ...king Re seal the engine pan Engine does not deliver full power or runs erratically 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 Tank vent faulty Check the tank vent and replace if necessary Fuel suction hose kinked or torn Fit new hose or position it free from kinks Pist...

Page 17: ...lling Inspect and clean the sealing faces arrows b 13 Insert the screws through the upper holes in the muffler Push the gasket 1 over the screws the gasket is held in position Carefully place the muffler 1 in position Check the position of the gasket and fit the screws 2 0002RA006 TG 0002RA007 TG 1 0002RA008 TG 2 2 1 Fit the screws 2 do not tighten down yet Fit the screw 1 Tighten down screws 1 an...

Page 18: ...the pressure test The engine can be checked thoroughly for leaks with the pump 0000 850 1300 0002RA005 TG 1 4 2 1 Preparations Remove the shroud b 4 4 Pull off the spark plug boot vertically Unscrew the spark plug 1 Set the piston to top dead center This can be checked through the spark plug hole Fit the spark plug 1 and tighten it down firmly Loosen the screws arrows Pull the muffler 1 out a litt...

Page 19: ... within 20 seconds it can be assumed that the oil seals are in good condition However if the pressure continues to rise reduced vacuum in the engine the oil seals must be replaced b 4 3 After finishing the test push the ring to the right to vent the pump Continue with pressure test b 4 2 3 1 2 0002RA017 TG 4 2 3 Pressure Test Carry out the same preparations as for the vacuum test b 4 2 2 Always ca...

Page 20: ...other parts in the reverse sequence 4 3 Oil Seals The engine must be disassembled to replace the oil seals Remove the engine b 4 5 Remove the engine pan b 4 6 Pull the crankshaft upwards a little but not out of the cylinder Pull off the oil seals 1 Clean the sealing faces and install new oil seals b 4 6 Install the engine pan b 4 6 Degrease the crankshaft taper b 13 Install the engine b 4 5 0002RA...

Page 21: ...roud 1 until it is properly seated The air guide shroud must engage the guide arrow Insert the screws arrows and tighten them down firmly Tighten down the screw 1 firmly 0002RA175 TG 1 0002RA176 TG 0002RA177 TG 1 4 5 Engine Troubleshooting b 3 5 The complete engine has to be removed for access to the piston cylinder and crankshaft Remove the air guide shroud b 9 3 Disconnect the short circuit wire...

Page 22: ...move for this purpose Inspect the oil seals and replace if necessary b 4 3 Check correct position of the oil seals they must be properly located in their seats Installing Take care to avoid pinching the short circuit and ground wires between the engine and blower housing Push the straight crankshaft stub 1 into the blower housing bore arrow 0002RA029 TG 0002RA030 TG 1 Push the engine against the b...

Page 23: ...2 4 6 Cylinder Crankshaft Remove the engine b 4 5 Remove the muffler 1 b 4 1 Remove the ignition module 2 b 5 2 Remove the flywheel 3 b 5 5 Take out the screws arrows 0002RA035 TG 1 2 3 0002RA036 TG Pull off the engine pan 1 Do not use pointed or sharp edged tools for this job Release the crankshaft 1 from its bearing seats arrows and pull it carefully out of the cylinder Pull off the oil seals 1 ...

Page 24: ...0002RA050 TG 0002RA041 TG 1 Remove the gasket 1 Inspect and clean the sealing face arrow and remove any gasket residue b 13 Inspect the sealing faces on exhaust port The sealing faces must be in perfect condition If the sealing faces are damaged install a new cylinder Inspect the piston and piston rings and replace if necessary b 4 8 0002RA042 TG 1 0002RA043 TG Installing Lubricate the piston pist...

Page 25: ...he cylinder Lubricate sealing lip arrows of new oil seal with grease b 13 Fit the installing sleeve 1 1118 893 4602 on each side before pushing the oil seals into place Push the new oil seals 2 open side facing the ball bearings onto the crankshaft stubs Remove the installing sleeve 1 0002RA461 TG 1 0002RA477 TG 0002RA476 TG 1 2 1 2 Apply thin coating of sealant to outside diameter arrows of the o...

Page 26: ...1 off the tapered crankshaft stub Pull the ball bearing 1 off the straight crankshaft stub The crankshaft 1 connecting rod 2 and needle bearing form an inseparable unit It must always be replaced as a complete unit 296RA064 TG 1 296RA065 TG 1 0002RA055 TG 2 1 When fitting a replacement crankshaft always install new ball bearings and oil seals Clean the crankshaft before installing the bearings b 1...

Page 27: ...G 1 Use a firm base 2 to protect the crankshaft If it is not possible to heat the ball bearing apply a suitable sleeve 1 to the inner race and press the bearing onto the tapered crankshaft stub as far as stop Lubricate the needle bearing with oil Install the piston b 4 8 Fit new oil seals and install the crankshaft b 4 6 Install the engine b 4 5 Reassemble all other parts in the reverse sequence 0...

Page 28: ...cage 1 Installing Lubricate the needle cage with oil and push it into the connecting rod Line up the piston as shown so that the arrow arrow on the piston crown faces to the rear and the tapered crankshaft stub 1 is on the right Place the piston on the connecting rod 1 1 0002RA468 TG 0002RA060 TG 1 Push the assembly drift 1 1108 893 4700 small diameter first through the side of the piston with the...

Page 29: ...ase wooden board Remove the sleeve and push it on to the other end of the shank as far as stop The inner pin arrow must again point towards the flat face 0001RA483 TG 533RA131 TG Install the snap ring at the blower side of the piston Apply the installing tool 5910 890 2212 with the sleeve s taper against the piston boss hold the piston steady center the tool shank exactly and press home until the ...

Page 30: ...om the piston Use a piece of old piston ring to scrape the grooves arrows clean Position the new piston rings in the groove so that the radii arrows at the ring gaps face upwards 0002RA366 TG 0002RA104 TG Position the piston rings so that the radii at the ring gap meet at the fixing pin in the piston groove arrows Check correct installed position of the piston rings arrows Install the piston b 4 8...

Page 31: ...ignition timing cannot get out of adjustment during operation 0002RA064 TG 1 2 5 2 Ignition Module The ignition module accommodates all the components required to control ignition timing There are two electrical connections on the coil body High voltage output 1 with ignition lead Connector tag 2 for the short circuit wire Testing in the workshop is limited to a spark test A new ignition module mu...

Page 32: ...talling Hold the wiring harness 1 in the direction of the carburetor so that it cannot be pinched Position the ignition module 1 so that the ignition lead 2 points towards the carburetor Fit the screw 3 with washer do not tighten down yet 0002RA000 TG 1 0002RA070 TG 2 1 3 Fit the connector tag 1 and insert the screw 2 with washer do not tighten down yet Push the ignition module 1 back Slide the se...

Page 33: ...oot onto the spark plug Reassemble all other parts in the reverse sequence 5 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 ignition system tester 5910 850 4520 The ignition test refers only to a spark test not to ignition timing 0002RA033 TG 1 2 Using ZAT 4 ignition system 5910 850 4503 Before starting the test inst...

Page 34: ... a spark is visible 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 5 7 5 4 Spark Plug Boot The ignition module 1 and ignition lead 2 form a unit A new ignition module must be installed if the ignition lead is damaged Pull off the spark plug boot vertically Remove the shroud b 4 4 Use suitable pliers to pu...

Page 35: ... 1 5910 893 0801 clockwise on to the crankshaft as far as stop then back it off a 1 4 turn Tap the end of the puller to release the flywheel Take care not to damage the crankshaft stubs and ball bearings Unscrew the puller and remove the flywheel 0002RA079 TG 0002RA080 TG 1 The flywheel and magnet poles arrows must not be damaged or have turned blue Replace flywheel if necessary Before assembly de...

Page 36: ... 0002RA083 TG 1 To locate the fault test the wires for continuity and check insulation for damage If the wires are in order check operation of stop switch b 5 7 If no fault can be found check the ignition system with the aid of the troubleshooting chart b 5 7 Check ground wire for continuity Reassemble in the reverse sequence 5 6 2 Removing and Installing The short circuit wire black ground wire b...

Page 37: ... the stop switch 2 Pull the ground and short circuit wires out of the guides arrows Remove the wires with the stop switch Pull the protective tube 1 out of its seat arrow in the handle molding 0002RA089 TG 1 2 0002RA090 TG 0002RA091 TG 1 Pull the wires and throttle cable out of the guides The stop switch is permanently connected to the short circuit wire If any part is damaged the entire throttle ...

Page 38: ...cam b 8 Fit the handle molding 1 in position Insert the screws arrows and tighten them down firmly Position the protective tube 1 so that the throttle cable 2 is under the wiring harness 3 in the direction of the blower housing 0002RA096 TG 1 0002RA097 TG 1 0002RA098 TG 1 2 3 Push the protective tube 1 into its guides arrows as far as stop The protective tube is now held in position Attach the thr...

Page 39: ... fuel hoses 1 into the guides arrows Reassemble all other parts in the reverse sequence 5 6 3 Ground Wire A faulty ground wire may impair or prevent operation of the short circuit wire The short circuit wire black ground wire blue and throttle cable are in a protective tube and form an assembly If any part is damaged the entire throttle cable must be replaced Check for contact and continuity and r...

Page 40: ...Sooted Electrode gap correct Contacts shorted Clean or replace the plug b 5 3 Check 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 b 5 4 Test ignition system with ZAT 3 or ZAT 4 use ZAT 3 as main spark gap see TI 32 94 b 5 3 1 ...

Page 41: ...heck the ignition lead Severe chafing Spark plug boot Holes cracks Resistance spark plug boot to ground spec 1 5 12 kΩ If necessary install new spark plug boot and or ignition lead with module b 5 2 Check ground and short circuit wires Wire damaged Connectors firmly seated Check continuity replace wires or wiring harness if necessary b 5 6 2 1 3 yes no 2 Powerful spark ...

Page 42: ...for fault in fuel system or carburetor Check engine for leaks Check position of flywheel on crankshaft b 4 2 b 5 5 yes Check operation of stop switch Function of stop switch Setting lever on F no connection Setting lever on 0 connection Install new throttle cable if necessary b 5 6 b 5 6 2 2 3 Powerful spark Machine runs ...

Page 43: ...gloves when working on the rewind spring risk of injury Carefully 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 If clogged with dirt or pitch the entire starter mechanism including the rewind spring must be removed and disassembled Take particular ...

Page 44: ...ds Reassemble all other parts in the reverse sequence 6 4 Rope Rotor Relieving tension of rewind spring Remove the starter cover b 6 2 Pull out the starter rope 1 about 5 cm and hold the rope rotor 2 steady 0002RA111 TG 0002RA112 TG 1 2 Take three full turns of the rope off the rope rotor Pull out the rope with the starter grip and slowly release the rope rotor Remove the starter rope or remaining...

Page 45: ...ip Do not shorten the starter rope Remove the rope rotor b 6 4 0002RA114 TG 1 Push the end of the starter rope 1 out a little and undo the knot Pull the starter rope out of the rotor Use a suitable tool to pry the cap 1 out of the starter grip 0002RA115 TG 1 0002RA117 TG 1 Pull the sleeve washers spring and remaining rope arrow out of the grip Pull the remaining rope out of the sleeve Do not short...

Page 46: ... the starter cover b 6 2 6 6 Tensioning the Rewind Spring Remove the starter cover b 6 2 Pull out a short length of starter rope 1 Use the starter rope 1 to rotate the rope rotor 2 six turns clockwise The pawls and spring clip must be installed The rewind spring is now tensioned 0002RA122 TG 0002RA123 TG 1 2 Hold the rope rotor steady since it will otherwise spin back and may damage the rewind spr...

Page 47: ... replacement spring comes ready for installation in a spring housing Remove the starter cover b 6 2 Relieve tension of rewind spring if necessary and remove the rope rotor b 6 4 Remove any remaining pieces of old spring Lubricate the spring with a few drops of STIHL special lubricant before installing b 13 Line up the replacement spring and spring housing the anchor loop 2 must be above the lug 1 ...

Page 48: ...t the rewind spring with housing in position Take care to ensure the rewind spring is not pushed out of the spring housing by the starter post The rewind spring may pop out and unwind Push the rewind spring with spring housing 1 into its seat in the starter cover Make sure that the spring housing 1 is properly seated Install the rope rotor b 6 4 Install the pawls b 6 3 Lubricate pegs on pawls with...

Page 49: ...AV springs 2 steady in their seats and take out the screws 1 Remove the AV springs 2 0002RA130 TG 2 2 1 1 Unscrew the bearing plugs 1 and 2 from the AV springs Screw home the bearing plugs 1 and 2 as far as stop Installing Line up the preassembled AV springs 1 so that the face arrow is parallel to the blower wheel Push the AV springs home as far as stop 0002RA131 TG 1 2 0002RA132 TG 1 Hold the AV ...

Page 50: ...r housing SR 430 b 10 7 SR 450 b 10 8 Reassemble all other parts in the reverse sequence 7 3 AV Springs on Backplate Metering Unit SR 450 Remove the metering unit b 10 3 Unscrew the anti vibration springs from the bearing plugs arrows 0002RA136 TG 0002RA433 TG Unscrew the bearing plugs 1 from the anti vibration springs Screw the bearing plugs 1 into the springs as far as stop Installing Screw the ...

Page 51: ...he bore Install the filter housing b 9 4 Reassemble all other parts in the reverse sequence 0002RA139 TG 1 0002RA140 TG 1 7 5 Stop Buffer on Shroud Remove the shroud b 4 4 Pull off and replace the stop buffer 1 Installing Use STIHL press fluid to simplify assembly b 13 Push the stop buffer 1 tapered end first into the bore arrow as far as stop the tapered end must slide fully home and engage the b...

Page 52: ...full throttle b half throttle to disengage the lock return the setting lever to the run position F On the carburetor The rotary knob returns to the run position when the throttle trigger is operated Position e normal run position Position t warm start warm engine is started in this position Position c cold start cold engine is started in this position 0002RA503 TG a b 0002RA144 TG 8 2 Setting Leve...

Page 53: ...versions Pull off the cam 1 Pull the detent spring 1 slightly apart and lift it out over the guides arrows do not overstretch the detent spring Check the cam 2 and detent spring 1 and replace if necessary 0002RA499 TG 1 0002RA149 TG 1 0002RA150 TG 1 2 Push the detent spring 1 into the guides arrow until it snaps into position do not overstretch the detent spring Disconnect the leg arrow from the l...

Page 54: ...ort circuit wires must be properly seated in the guides arrows Push the lever 1 into the throttle trigger so that it fits snugly against the throttle trigger arrow Push the throttle cable nipple 1 into the lever and engage it in the slot arrow 0002RA157 TG 0002RA158 TG 1 1 0002RA159 TG 1 Version with throttle limiter Push the throttle trigger 1 onto the pivot pin Version with throttle lock Push th...

Page 55: ...lock lever 1 until it is properly seated Position the cam 1 so that the lug 2 points towards the throttle trigger Push the cam 1 past the throttle trigger and onto the setting lever s pivot pin short arrow Make sure the contact spring is not bent 0002RA165 TG 1 2 0002RA166 TG 1 2 Version with throttle lock Turn the cover 1 clockwise until it is between the edge of the housing and stop arrow Push h...

Page 56: ...68 TG 8 4 Valve Lever Remove the interlock lever and throttle trigger b 8 3 Hold the valve to prevent it popping out Pull off the valve lever 1 Turn the valve lever 1 clockwise and disconnect it from the rod 2 0002RA178 TG 0002RA179 TG 1 0002RA180 TG 2 1 Installing Position the valve lever 1 so that the guide arrow points in the direction of the handle housing Push the valve lever 1 onto the rod 2...

Page 57: ...2RA184 TG 1 2 0002RA185 TG 1 2 3 Disconnect the cable 3 Installing Push the cable 1 into the metering lever and engage it in the slot arrow Position the metering lever 2 with cable 3 against the handle housing Fit the cable 2 in the guide arrow 0002RA186 TG 1 0002RA187 TG 1 2 Insert and tighten down the screw 1 firmly Fit the cover 1 Insert and tighten down the screw 2 firmly Check operation Rotar...

Page 58: ...metering lever 2 setting shutter to closed 0002RA184 TG 1 2 0002RA470 TG 1 2 Push the cable with knurled nut 2 into the seat arrow and hold it there Turn the metering lever 1 as far as stop in direction of blower tube shutter fully open Turn the metering lever 1 as far as stop in direction of pleated hose shutter fully closed Fit the cover 1 Insert and tighten down the screw 2 firmly Check operati...

Page 59: ... and air filter element 2 1 0002RA428 TG 0002RA190 TG 1 2 Installing Fit the filter cover 1 in position Insert the screws arrows and tighten them down firmly 9 2 Baffle Remove the filter cover b 9 1 Use screwdriver 5910 890 2420 to unscrew the nuts arrows Remove the baffle 1 1 0002RA326 TG 0002RA191 TG 1 Installing Check the gasket 1 and replace it if necessary Make sure the gasket 1 is properly s...

Page 60: ...gages the slot in the spacer flange Engage the end 2 in the guide arrow Fit and tighten down the screws 1 firmly 0002RA197 TG 1 1 2 0002RA198 TG 2 1 0002RA199 TG 1 1 Starting at the ignition module attach the ignition lead 1 to the guides arrows Position the ignition lead so that it is not kinked at the ignition module and not under tension Reassemble all other parts in the reverse sequence 9 4 Fi...

Page 61: ...RA201 TG 1 0002RA202 TG 1 0002RA203 TG 2 1 Pull the filter housing 1 off the boss arrow Remove the gasket 1 Check and clean the sealing faces arrows on the carburetor and filter housing b 13 Always replace components with damaged sealing faces 0002RA204 TG 1 0002RA205 TG 1 0002RA206 TG Push out the grommet 1 Check the gasket 1 and replace if necessary Make sure the gasket 1 is properly seated Inst...

Page 62: ...ure the wiring harness 2 and fuel hoses are not pinched Push the filter housing 1 onto the studs Insert and tighten down the screw 1 firmly 0002RA215 TG 1 2 0002RA217 TG 1 0002RA219 TG 1 Insert and tighten down the screw 1 firmly Starting at the ignition module attach the ignition lead 1 to the guides arrows Position the ignition lead so that it is not kinked at the ignition module and not under t...

Page 63: ... fuel hoses only when the tank cap is open Always install new fuel hoses 0001RA469 TG 1 1 Pull the fuel hoses 1 out of the guides arrows Pull the throttle cable 1 and wiring harness 2 out of the guides arrows Press down the throttle lever until the nipple arrow projects Take the throttle cable 1 out of the pin 2 0002RA085 TG 1 1 0002RA221 TG 1 2 1 2 0002RA087 TG Pull the fuel hose 1 off the nipple...

Page 64: ...ow the fuel hose must be pushed fully home Take care not to damage the new fuel hoses Reassemble all other parts in the reverse sequence 0002RA471 TG 1 0002RA229 TG 1 9 5 1 Leakage Test In the case of problems with the carburetor or fuel supply system also check and clean or replace the tank vent b 9 10 The carburetor can be tested for leaks with the pump 0000 850 1300 Install new fuel hoses after...

Page 65: ...off the carburetor s nipple Install the carburetor b 9 5 Reassemble all other parts in the reverse sequence 0002RA231 TG 1 2 9 6 Servicing the Carburetor 9 6 1 Metering Diaphragm Remove the carburetor b 9 5 Take out the screws arrows Remove the end cover 1 If the gasket and diaphragm are stuck to the carburetor remove them very carefully Carefully separate the metering diaphragm 1 and gasket 2 The...

Page 66: ...ing 2 If there is an annular indentation arrow on the sealing cone of the inlet needle fit a new inlet needle 0002RA238 TG 1 2 0002RA239 TG 1 2 533RA309 TG Installing 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 3 Make sure the sp...

Page 67: ...gm from the end cover Carefully separate the pump diaphragm 1 and gasket 2 The diaphragm material is subjected to continuous alternating stresses and eventually shows signs of fatigue i e the diaphragm distorts and swells and has to be replaced 0002RA244 TG 1 0002RA245 TG 0002RA246 TG 1 2 Check fuel strainer for contamination and damage Clean or replace if necessary Reassemble in the reverse seque...

Page 68: ...its pegs engage the holes in the carburetor body 0002RA249 TG 1 2 2 0002RA250 TG 1 2 Check that diaphragm and gasket are properly seated Insert and tighten down the screw 1 firmly Reassemble all other parts in the reverse sequence 9 6 5 Throttle Lever Remove the carburetor b 9 5 Take out the screw arrow Pull off the throttle lever 1 0002RA251 TG 1 0002RA252 TG 1 Installing Hold the throttle lever ...

Page 69: ...eated in the guide sleeve 2 Fit the spring 1 on the choke shaft Position the rotary knob 2 so that the holes arrows are in alignment Push the rotary knob 2 onto the choke shaft until it engages and hold it in that position 0002RA258 TG 1 0002RA259 TG 1 2 Insert screw arrow and tighten it down firmly Check operation Press the rotary knob the knob can be rotated 2 notches clockwise Turn the rotary k...

Page 70: ... the carburetor removed from the machine See also carburetor troubleshooting b 3 4 0002RA261 TG 1 2 3 Low Speed Screw L Take out the low speed screw L 1 Inspect the tip arrow for damage or wear and replace the low speed screw L if necessary Installing Carefully turn the low speed screw L clockwise as far as stop Check the high speed screw H and replace it if necessary Carry out the basic setting b...

Page 71: ...rclockwise Turn the high speed screw H 1 1 1 2 turns Turn the low speed screw L 2 1 full turn This completes the basic setting of the high speed screw H and the low speed screw L The air filter must be clean and installed Start and warm up the engine 0 1 4 12 1 0 8 6 4 2 0 1 4 12 1 0 0002RA266 TG 1 2 Insert the screwdriver 1 5910 890 2305 into the adjusting screws arrow Adjust idle speed with a ta...

Page 72: ... the spark arresting screen if fitted and clean or replace it if necessary b 4 1 Check the air filter and clean or replace if necessary b 9 1 Check operation of throttle cable and readjust if necessary b 9 8 1 Turn the high speed screw H slowly counterclockwise as far as stop but no more than a 3 4 turn 0002RA269 TG Turn the low speed screw L slowly clockwise as far as stop then open it 1 full tur...

Page 73: ... must be adjusted to ensure the throttle shutter opens and closes properly Remove the shroud b 4 4 Checking adjustment of throttle cable Squeeze the throttle trigger 1 as far as stop and hold it there Press down the throttle lever 1 If the throttle lever 1 can be turned further the throttle shutter is not wide open Adjusting the throttle cable The throttle lever butts against the idle speed screw ...

Page 74: ...k and clean the sealing faces arrows on the cylinder and spacer flange b 13 The sealing faces must be clean and in perfect condition Always replace components with damaged sealing faces 0002RA274 TG 1 0002RA275 TG Fit the new gasket 1 over the guide arrows on the spacer flange Position the spacer flange 1 with gasket against the cylinder intake port so the guide engages the opening arrow Fit the s...

Page 75: ...nipple arrow 0002RA085 TG 1 1 0002RA223 TG 1 Pull the fuel return hose 1 off the manual fuel pump arrow Take out the screws 1 and remove the fuel tank 2 Seal one fuel hose arrow with a plug 0002RA294 TG 1 0002RA310 TG 2 1 1 0002RA280 TG Push the nipple 1 0000 855 9200 into the fuel hose arrow Vacuum test Push the ring 1 to the left and connect the pump 2 0000 850 1300 to the nipple arrow subject t...

Page 76: ...and Installing Remove the shroud b 4 4 Pry the tank vent 1 out of its seat arrow Always install a new tank vent Installing Coat sealing ring of new tank vent with STIHL press fluid b 13 Position the tank vent so that the shoulder arrow is not near the recess used for removing the vent Push home the tank vent by hand until it snaps into position Test the tank vent b 9 10 1 Reassemble all other part...

Page 77: ... 4 4 0002RA290 TG 2 1 3 0002RA291 TG 1 9 11 Fuel Intake 9 11 1 Pickup Body Any impurities mixed with the fuel are retained by the pickup body filter The fine pores of the filter eventually become clogged with minute particles of dirt This restricts the passage of fuel and results in fuel starvation In the event of problems with the fuel supply system always check the fuel tank and the pickup body ...

Page 78: ... shroud b 4 4 Remove the filter housing b 9 4 Before removing the fuel hoses check them to see if they need to be replaced Disconnect the fuel hoses only when the tank cap is open Pull the fuel hoses 1 out of the guides arrows 0002RA293 TG 0002RA085 TG 1 1 Pull the fuel return hose 1 off the manual fuel pump arrow Pull the fuel hose 1 off the carburetor arrow Take out the screws 1 and remove the f...

Page 79: ...he lower nipple arrow Push the fuel suction hose 1 onto the upper nipple arrow Push the fuel return hose 1 onto the nipple arrow 0002RA297 TG 1 0002RA298 TG 1 0002RA300 TG 1 Press the fuel return hose 1 into the guide arrow Reassemble all other parts in the reverse sequence Push the fuel suction hose 1 onto the nipple arrow Press the fuel suction hose 1 into the guide arrow Lay the fuel hoses para...

Page 80: ...1 9 11 3 Connector Remove the fuel hoses b 9 11 2 Pry out the connector 1 at the recess arrow Pull the connector 1 with fuel hose and pickup body out of the fuel tank 0002RA303 TG 1 0002RA304 TG 1 Pull the pickup body 1 and connector 2 off the fuel hose 3 Installing Coat nipple with STIHL press fluid b 13 Push the fuel hose 1 onto the nipple so that the loop arrow faces away from the tab 2 The fue...

Page 81: ...using Always install new fuel hoses Take care not to damage the new fuel hoses Connect the new fuel hoses to the nipples on the connector 1 and install the carburetor b 9 5 Reassemble all other parts in the reverse sequence Check for leaks 0002RA309 TG 1 9 12 Fuel Tank Drain the fuel tank b 1 1 Remove the shroud b 4 4 If the fuel hoses and connector are in order pry out the connector with the fuel...

Page 82: ...l tank 1 so that the holes arrows are in alignment Fit and tighten down the screws 2 firmly Position the fuel hoses 1 kink free on the fuel tank Reassemble all other parts in the reverse sequence 0002RA311 TG 2 1 2 0001RA469 TG 1 1 9 12 1 Fuel Tank Cap See instruction manual Open the tank cap Disconnect the tank cap cord s nipple from the slot arrow inside the tank Inspect the tank cap Install new...

Page 83: ...screws 1 0002RA489 TG 1 1 0002RA314 TG 1 1 Disengage the locking tabs arrow on both sides of protective screen 1 Lower the bracket 1 Pull the bracket 1 out of the guides arrows Take the container 1 out of the bracket 1 0002RA475 TG 1 0002RA315 TG 1 0002RA319 TG 1 2 Unscrew the cap Pull the hose 1 off the nipples arrows Rotate the strainer 1 45 counterclockwise and lift it out 0002RA317 TG 1 0002RA...

Page 84: ...s with long back padding Fit and tighten down the screws 1 firmly All versions Push the protective screen 1 into position until the locking tabs arrow at both sides snap into place Install the blower housing b 10 7 0002RA314 TG 1 1 0002RA489 TG 1 1 0002RA321 TG 1 10 2 Container SR 450 Drain the container Squeeze the retaining tabs arrows together and unlock the clamping lever 1 Remove the containe...

Page 85: ...R 450 Remove the container b 10 2 Version without pressure pump Use a screwdriver to ease the hose clamp arrow open Loosen the hose clamp 3 Pull off the hose 1 and plug 2 Version with pressure pump Loosen the hose clamps 2 Pull off the hoses 1 0002RA327 TG 1 2 3 0002RA328 TG 1 1 2 2 Versions with long back padding Take out the screws 1 SR 450 versions with and without pressure pump Take out the sc...

Page 86: ...move the felt ring 2 from the groove in the lever 1 Push the rotary shutter 1 in the direction of the AV spring 2 Ease the rotary shutter 1 out of the hole arrow Remove the rotary shutter 1 0002RA331 TG 1 2 0002RA332 TG 2 1 0002RA333 TG 1 Pull out the gasket 1 Disengage the locking tab arrow Remove the lever 1 downwards Installing Position the lever 1 so that the retaining tabs arrows engage the w...

Page 87: ...into the hole arrow Fit the lever 1 into the hole so that it engages the teeth Push the lever 1 fully home Check operation the rotary shutter must open and close when the lever is turned Insert and tighten down the screw 1 firmly 0002RA340 TG 1 0002RA341 TG 1 0002RA363 TG 1 Install the cable b 10 4 Make sure that the gasket 1 is properly seated Position the metering unit 1 with AV springs in the s...

Page 88: ...ntil they engage Fit and tighten down the hose clamp 3 Version with pressure pump Push home the hoses 1 as far as stop Fit and tighten down the hose clamps 2 Reassemble all other parts in the reverse sequence 0002RA327 TG 1 2 3 0002RA328 TG 1 1 2 2 10 4 Cable SR 450 Remove the metering unit b 10 3 Remove the cable from the metering lever b 8 5 Take out the screw 1 and lift the cover 2 Disconnect t...

Page 89: ...sition Engage the cable 1 in the guide arrow Engage the cover s retaining tab 1 on the housing arrow 0002RA347 TG 1 0002RA350 TG 1 Place the cover 1 in position Insert and tighten down the screw 2 firmly Install the metering unit b 10 3 Reassemble all other parts in the reverse sequence Check operation Shutter in metering unit must open and close completely when the lever on the control handle is ...

Page 90: ...ump 1 0002RA353 TG 1 1 1 1 2 2 2 0002RA354 TG 1 Remove the strainer 1 Installing Position the strainer 1 so that the recess arrows point in the direction of the container and blower tube see illustration The strainer is not shown in the illustration Push the pressure pump 1 coupling 2 first into the bore arrow 0002RA355 TG 1 0002RA357 TG 1 0002RA358 TG 1 2 Position the pressure pump 1 so that the ...

Page 91: ...eassemble all other parts in the reverse sequence 10 6 Blower Wheel Remove the blower housing SR 430 b 10 7 SR 450 b 10 8 Remove the metering unit SR 450 b 10 3 Take out the screws arrows Remove the outer blower housing 1 on versions with a pressure pump leave the pump mounted in position Remove the blower tube see instruction manual 0002RA435 TG 1 0002RA365 TG 1 Use locking strip 1 0000 893 5904 ...

Page 92: ...st be properly seated in the outer blower housing Place the outer blower housing 1 in position Insert the screws arrows and tighten them down firmly Reassemble all other parts in the reverse sequence 10 7 Blower Housing SR 430 Remove the filter housing b 9 4 Remove the fuel tank b 9 12 Pull the fuel hoses out of the guides Remove the short circuit wire from the blower housing b 5 6 2 0002RA380 TG ...

Page 93: ...se a screwdriver to ease the hose clamp arrow open Pull off the hose 1 and molded hose 2 Version with pressure pump Loosen the hose clamps 3 Pull off the hoses 1 and molded hose 2 0002RA376 TG 2 1 0002RA377 TG 2 1 1 3 3 SR 430 versions with and without pressure pump Pull off the blower housing 1 The lower AV springs are pulled out of their seats at the same time Pull the hose 1 off the pressure pu...

Page 94: ... 1 and replace it if necessary Inspect other components and transfer if necessary Transfer the pressure pump if fitted b 10 5 Transfer the molded hose Transfer the AV springs b 7 Pull out the molded hose 1 0002RA383 TG 1 0002RA384 TG 1 Installing Place the elbow 1 in position Use STIHL press fluid b 13 Push the molded hose 1 tab facing edge of housing arrow into the hole Push the molded hose 1 ful...

Page 95: ... on the underside of the machine Version without pressure pump Pull off the hose 1 and molded hose 2 Squeeze the tabs arrow of the hose clamp together until they engage Version with pressure pump Fit the hoses 1 and molded hose 2 0002RA374 TG 1 1 0002RA388 TG 2 10002RA389 TG 2 1 1 3 3 Fit and tighten down the hose clamps 3 SR 430 versions with and without pressure pump Push the blower housing 1 wi...

Page 96: ... metering unit b 10 3 Remove the short circuit wire b 5 6 2 Remove the filter housing b 9 4 Remove the fuel tank b 9 12 Pull the fuel hoses out of the guides Remove the short circuit wire from the blower housing b 5 6 2 Versions with long back padding Take out the screws arrows Remove the back padding 1 Take out the screws 1 0002RA487 TG 1 0002RA490 TG 1 1 Versions with short back padding Fold dow...

Page 97: ...0002RA481 TG 1 0002RA395 TG 1 Remove the gasket 1 Take out the screw 1 Remove the antistatic wire 2 and chain 3 Take out the screws arrows Remove the outer blower housing 1 0002RA396 TG 1 0002RA397 TG 1 3 2 0002RA365 TG 1 Remove the elbow 1 with blower tube Check the sealing ring arrow and replace it if necessary Check the inner blower housing 1 and replace it if necessary Inspect other components...

Page 98: ...tion the air guide 1 on the guides arrows and push it home Place the elbow 1 in position Place the outer blower housing 1 in position Insert the screws arrows and tighten them down firmly 0002RA402 TG 1 0002RA398 TG 1 0002RA365 TG 1 Fit the antistatic wire 2 and chain 3 Insert and tighten down the screw 1 firmly Fit the hose 1 in the guide arrow Push the gasket 1 fully home its lips must locate sn...

Page 99: ... 0002RA374 TG 1 1 0002RA482 TG 1 Versions with long back padding Fit and tighten down the screws 1 firmly Fit the back padding 1 in position Insert the screws arrows and tighten them down firmly 0002RA490 TG 1 1 0002RA487 TG 1 Versions with short back padding Fold down the back padding 1 Fit and tighten down the screws 2 firmly Reassemble all other parts in the reverse sequence 10 9 Nozzle Valve 1...

Page 100: ... and 1 0 2 3 must be used in machines with a pressure pump Pull off the metering knob 1 Inspect the nozzle 1 metering knob 2 and sealing ring 3 and replace if necessary Reassemble in the reverse sequence 1 0002RA411 TG 0002RA412 TG 1 2 3 10 9 2 Valve Use a screwdriver to ease the hose clamps arrows open Pull off the hoses 1 Remove the throttle trigger and interlock lever b 8 3 Remove the valve lev...

Page 101: ... if necessary The tubes have lugs of different widths to make them non interchangeable Lubricate the O rings with grease b 13 before installing the piston Reassemble in the reverse sequence Place the valve 1 with spring in its seat arrow 0002RA418 TG 0002RA421 TG 1 Push the valve 1 in the direction of the spring seat until it engages the guides arrows in the handle housing Hold the valve 1 in the ...

Page 102: ...See instruction manual Counting from the elbow fit the hose clamp 1 over the sixth pleat in the hose Lift the hose clamp 1 a little and fit the hoses arrows do not cross the hoses over Straighten the hoses and close arrow the hose clamp 1 0002RA423 TG 0002RA425 TG 1 0002RA426 TG 1 10 10 2 Elbow Remove the pleated hose see instruction manual Remove the blower housing SR 430 b 10 7 SR 450 b 10 8 SR ...

Page 103: ...e hose clamp 2 open Pull off the hose 1 Push the hose clamp onto the new hose Push the hose 1 onto the stub as far as stop Fit the hose clamp 2 and squeeze the tabs arrow together until they they engage Reassemble all other parts in the reverse sequence 1 0002RA431 TG 2 1 0002RA492 TG 1 2 SR 430 SR 450 versions with pressure pump Loosen the hose clamp 2 Pull off the hose 1 Push the hose clamp 2 on...

Page 104: ... lugs of protective screen into the slots arrows Place the protective screen 1 in position so that the lugs arrow engage the guides 2 Push the spring seats 1 into the seats arrow 0002RA438 TG 0002RA444 TG 1 2 0002RA445 TG 1 Push top of protective screen 1 into position until it snaps into place Install the blower housing b 10 7 Reassemble all other parts in the reverse sequence 11 2 Backplate SR 4...

Page 105: ...nstalling Pass the clamping strap 1 around the seat and through the loop arrow Push lugs into the slots arrows Place the protective screen 1 in position so that the lugs arrow are above the first web 0002RA484 TG 1 0002RA438 TG 0002RA439 TG 1 Push the spring seats 1 into the seats arrow Push the protective screen 1 into position until it snaps into place Install the blower housing b 10 8 Reassembl...

Page 106: ...7 TG 1 0002RA448 TG 1 2 Ease the ring 1 out of the retainer 2 and pull it out of the opening arrow Installing Thread the loop 1 of the harness strap through the backplate Fit the pin 1 through the loop 0002RA449 TG 1 2 0002RA450 TG 1 0002RA451 TG 1 Center the pin 1 between the guides arrows Position the pin 1 behind the retainers arrows Push the pin 1 home until it snaps into place 0002RA452 TG 1 ...

Page 107: ...6 SR 430 SR 450 11 4 Back Padding Take out the screws arrows Remove the back padding 1 Take out the screws arrows Remove the back padding 1 Reassemble in the reverse sequence 0002RA364 TG 1 0002RA487 TG 1 ...

Page 108: ...3 4602 Protects oil seal at fan side 8 Setting gauge 4118 890 6401 Adjusting air gap between the ignition module and flywheel 9 Combination wrench 4119 890 3400 Releasing nuts and screws 1 10 Test flange 5910 850 4200 Leakage Test 11 Ignition system tester ZAT 4 5910 850 4503 Testing ignition system 12 Ignition system tester ZAT 3 5910 850 4520 Testing ignition system 13 Torque wrench 5910 890 030...

Page 109: ...108 SR 430 SR 450 No Description Part No Application Rem 24 Hook 5910 893 8800 Removing pickup body Remarks 1 Use for releasing only ...

Page 110: ...rewind spring in fan housing 3 STIHL press fluid OH 723 0781 957 9000 Rubber elements fuel hoses etc 4 STIHL multipurpose grease 0781 120 1109 High voltage output on ignition module 5 Dirko HT red sealant 0783 830 2000 Engine pan oil seals outside 6 Standard commercial solvent based degreasant containing no chlorinated or halogenated hydrocarbons Cleaning sealing faces and carburetor crankshaft st...

Page 111: ...englisch english 0455 454 0123 M3 8 J09 FST Printed in Germany ...

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Stihl SR 430, Manual

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