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Stihl TS 400 Cutquick, Manual

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Stihl TS 400 Cutquick Manual Download Page 46

STIHL TS 400                                                                                                                                                                   46

10.7

Impulse hose

• Unscrew the screws of the air

guide cover.

- Remove air guide cover.

Note: 

Secure a ground lead

between air guide cover and
housing.

•  Draw out fuel hose.

The parts are installed in reverse
order.

- Remove carburetor, see 10.2.2.

• Disconnect spark plug terminal (1)

from spark plug.

• Remove ignition lead and stop

switch lead from holder (2).

•  Draw impulse hose off connector.

Note: 

Installation is facilitated by

coating the hose flange with a little oil.

The straight edge of the flange
must rest against the web of the
tank housing.

The fuel hose must not be buckled or
damaged when it is pushed under the
carburetor.

• Press flange of impulse hose out of

the hole and pull out the impulse
hose.

The parts are installed in reverse
order.

Summary of Contents for TS 400 Cutquick

Page 1: ...pecial tools and service accessories 50 11 1 Special tools 50 11 2 Service accessories 52 TABLE OF CONTENTS 1 Introduction 2 2 Specifications 3 2 1 Engine 3 2 2 Fuel system 3 2 3 Ignition system 4 2 4...

Page 2: ...ement parts list until a new edition is published The special tools mentioned in the text are listed in the last chapter of this Manual The tools can also be identified in the manual of STIHL tools on...

Page 3: ...screw H Low speed adjusting screw L Leakage testing of the carburetor with excess pressure Fuel tank capacity Octane rating Fuel mix Mixing ratio Air filter 64 1 cm 3 49 mm 34 mm 9 5 1 3 2 kW 4 4 HP...

Page 4: ...achment for wet cutting V belt guard kit Bearing with guard D 300 Set of gaskets Set of carburetor parts Sealing panel Transistor controlled non contacting magneto ignition with integrated controller...

Page 5: ...8 Handle moulding handle 1 8 Retainer stop rods 1 8 Handle handle mount 8 0 Tank housing left right 7 5 Filter base carburetor 3 5 Cover clamp cast arm 4 5 Handle tank housing 8 0 Air guide cover cran...

Page 6: ...ew 1 in the thrust washer 2 Remove thrust washer Remove woodruff key 1 from groove in shaft Remove washer 2 from shaft Unscrew bearing screws 1 Remove guard 2 Remove axial clamping ring from shaft Rem...

Page 7: ...Remove flange Remove washer and rubber ring Press both deep groove ball bearings and the ring out of the bearing with drift pin 1 The parts are reassembled in reverse order Draw bearing out of rubber...

Page 8: ...ut with 37 5 Nm Position the deep groove ball bearing and press in with shaft until it rests against circlip Draw shaft out of deep groove ball bearings Insert second circlip in groove of bearing Impo...

Page 9: ...fastening screws Turn hexagon of clamp clockwise The clamp comes within range of the spring force after approx 1 8 of a turn It must be then be turned to the limit approx 1 8 of a turn Note The wrenc...

Page 10: ...ng faces not level parts are not original STIHL parts Spindle shaft damaged Tangible radial play in the bearing seat spindle bearing defective Possible causes Fastening screw loose during operation wr...

Page 11: ...elt from V belt pulley The parts are reassembled in reverse order Note The screws of the starter cover must be tightened with a torque of 6 Nm Remove circlip Note The ball bearing must be pressed in a...

Page 12: ...letely detensioned Remove the clamping lever from the housing slot The parts are installed in reverse order Insert both parts together Tighten the fastening nuts with a torque of 4 5 Nm Remove the cla...

Page 13: ...Troubleshootings standard repairs for troubleshooting procedures Remove V belt see chapter 3 4 Unscrew clutch and attachment from the crankshaft Important The clutch has a left hand thread Remove the...

Page 14: ...ht with the aid of the carburetor crankcase tester and the vacuum pump 5 2 1 Preparatory steps Draw out the spark arresting screen Clean the spark arresting screen fit new screen if necessary Remove s...

Page 15: ...no leaks in the crank case if this pressure is maintained for at least 20 seconds Install test flange 1 instead of the carburetor Important The pin must be inserted in the impulse hose 2 correctly whe...

Page 16: ...negative pressure in crankcase however the rotary shaft seals must be replaced even if the vacuum test did not reveal any leaks Reopen venting screw and remove hose after testing Remove test flange a...

Page 17: ...out rotary shaft seal Important The crankshaft stub must not be damaged Clean the sealing face with a conventional solvent based degreasing agent without CFCs and halogenated hydrocarbons as describe...

Page 18: ...rigger slightly and draw throttle rod out of trigger Remove spark plug terminal 1 from spark plug Remove ignition lead and stop switch lead from mount 2 Set choke lever to upward position Slide the ro...

Page 19: ...e air guide cover The parts are reassembled in reverse order Check that spout for decompres sion valve is located correctly on the shroud Set the slide control to I before assembling the shroud Unscre...

Page 20: ...ton pin 1 out of the piston with assembly pin 2 Note If the piston pin is stuck it can be released by lightly knocking against the assembly pin with a hammer The pin must be steadied in order not to t...

Page 21: ...t difficulty when the piston is warm Line up the piston rings the fixing pin must be engaged in the annular groove by the bevelled radii of the ring joint when compressed Slide the cylinder over the p...

Page 22: ...lopes at the ends facing towards the piston head Install piston see chapter 5 6 2 Screw in the cylinder base screws and alternately tighten them cross wise with a torque of 10 0 Nm Remove piston see c...

Page 23: ...until they rest against the drilled plate Unscrew the screws from the cast arm Unscrew the screws in the two halves of the housing Note Assembly devices without the holes marked 13 can be modified as...

Page 24: ...sing half Drive the deep groove ball bearing out with drift pin 1 Check the crankcase halves for cracks and replace if necessary Turn the spindle of the assembly tool counterclockwise until the cranks...

Page 25: ...driven into the housing half if necessary If the clutch side housing half can not be heated the deep groove ball bearing must be driven in as far as possible with drift pin 1 Screw the threaded sleeve...

Page 26: ...ning it counter clockwise too the crankshaft must be steadied at the same time Screw M5x72 screws from the set of assembly tools ZS into two holes of the crankcase connection to prevent the housing fr...

Page 27: ...ew the M5x72 screws fitted to prevent twisting Slide the rotary shaft seal over the assembly sleeve with the open side facing the crankcase Drive in with press sleeve 1 Remove the assembly sleeve afte...

Page 28: ...sion spring from the ignition lead Grasp ignition lead with pliers and draw it out of the spark plug terminal Draw spark plug terminal off ignition lead Remove cover from ignition lead Remove shroud s...

Page 29: ...d of the ignition lead which is to be turned into the ignition module Note Before turning in the ignition lead the high voltage output must be filled with STIHL multi purpose grease see 11 2 Caution G...

Page 30: ...g should therefore be limited solely to spark testing The complete ignition module must be replaced if the ignition spark fails although the leads and stop switch are intact Ignition in the transistor...

Page 31: ...switch lead out of wire harness 2 and mount 3 Disconnect spark plug terminal from spark plug Draw ignition lead out of retainers Remove stop switch lead from slot 1 and retainers 2 If necessary press...

Page 32: ...Unscrew the other two screws too Removing the flywheel Press the cap in at the bottom slide it upwards and remove it Press catch 1 down and draw contact sleeve 2 of stop switch lead out of the mount...

Page 33: ...here must not be any cracks or other signs of damage in the flywheel 1 and magnetic poles 2 otherwise the flywheel must be replaced Turn flywheel so that the magnetic poles are opposite the ignition m...

Page 34: ...d the starter no longer functions correctly In this case it is sufficient to apply a few drops of petroleum to the rewind spring Carefully pull the starter rope several times and let it rewind smoothl...

Page 35: ...on starter wheel Hold a short length of starter rope near the rope rotor and turn the rope rotor six times counterclockwise with it Note The rewind spring is correctly tensioned when the starter handl...

Page 36: ...ers out of rubber buffers Prise rubber buffers out of crankcase Press rubber buffers into cast arm until outer groove 1 engages chamfer 2 Tighten screws with a torque of 6 0 Nm Unscrew screws from rub...

Page 37: ...ve throttle trigger interlock from bearing Note The leaf spring 1 must be located in front of the slide control and the stop rod 2 below it Set the slide control to I Prise throttle rod 1 out of throt...

Page 38: ...tab 2 Remove torsion spring from rod The rod is installed in reverse order Unscrew the screws 1 in support 2 Remove support and handle 3 Remove shroud see 5 5 Unscrew the screw 1 on retainer 2 Remove...

Page 39: ...Handle mount Unscrew fastener for filter cover Remove filter cover Remove handle mount Unscrew the screw 1 in the rubber buffer Unscrew the screws 2 in the handle mount Press rubber buffer in until o...

Page 40: ...e parts are reassembled in reverse order Draw main filter out of filter housing Note The main filter must be replaced if soiled The auxiliary filter must be replaced at the same time Remove prefilter...

Page 41: ...rubber bulb 6 and pump air into the carburetor until an excess pressure of approx 0 8 bar is indicated on the pressure gauge There are no leaks in the carburetor if this pressure is maintained If it d...

Page 42: ...n hose 1 Compress and remove leaf spring 2 Draw choke lever off choke shaft The parts are reassembled in reverse order Unscrew nuts Remove air filter housing Draw carburetor off stud bolts Note Refer...

Page 43: ...g screws clockwise as far as possible They must then be adjusted as follows H High speed adjusting screw 1 1 turn open L Low speed adjusting screw 2 1 turn open Note If a tachometer is not available t...

Page 44: ...r 1 and valve Note The filter prevents dirt from entering the valve and compensator reservoir The cap 2 protects the filter against damage and contamination Remove shroud see 5 5 Prise out and remove...

Page 45: ...ivers sufficient fuel Important The fuel tank and pick up body must always be inspected first if any malfunctions develop in the fuel supply The fuel tank must be cleaned if necessary Remove tank vent...

Page 46: ...terminal 1 from spark plug Remove ignition lead and stop switch lead from holder 2 Draw impulse hose off connector Note Installation is facilitated by coating the hose flange with a little oil The st...

Page 47: ...er see 10 7 Remove sleeve from manifold Unscrew the screws in the left half of the housing Press flange of manifold out of the opening in the tank housing Remove manifold from intake port Position man...

Page 48: ...rubber buffers Press contact spring holder out of slot Remove holder Unscrew the screws 1 of handle 2 Unscrew the screws 3 on support 4 Remove support Remove that half of the housing Force out impulse...

Page 49: ...til the sloping edge 3 engages in slot 4 Use a new gasket Tighten the screws in the two housing halves with a torque of 7 5 Nm Unscrew filler cap Disconnect chain holding cap The parts are reassembled...

Page 50: ...850 6000 0000 890 9100 5910 893 8800 5910 850 3100 4110 893 7800 Use Rem Locking the crankshaft Sealing the exhaust during leakage tests Mounting the piston Tensioning the piston rings Leakage testing...

Page 51: ...crew connections 0 5 to 18 Nm 1 2 Screw connections 6 to 80 Nm 1 2 For all IS screws 3 Attaching plugs to electrical leads Extracting the flywheel Nut for flywheel Clutch Tightening the IS screws Driv...

Page 52: ...onventional solvent based degreasing agent without CFCs and halogenated hydrocarbons 3 HTR ignition lead 10 m 4 STIHL multipurpose grease Part No 0781 120 1111 0000 930 2251 0781 120 1109 Use Rotary s...

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