Stihl TS 700, TS 800 Service Manual Download

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STIH)

STIHL TS 700, 800

2012-06

Summary of Contents for TS 700, TS 800

Page 1: ...STIH STIHL TS 700 800 2012 06...

Page 2: ...53 9 2 Removal installation 53 9 3 Pawls 53 9 4 Rope rotor 54 9 5 Starter rope grip 55 9 6 Tension the rewind spring 56 9 7 Replacing the rewind spring 57 9 8 Starter rope guide bushing 58 10 Repairin...

Page 3: ...al tools of this manual Use the part numbers to identify the tools in the STIHL Special Tools manual It lists all the special servicing tools currently available from STIHL To help you use this manual...

Page 4: ...aintenance or repair work Petrol is highly inflammable and can also be explosive under certain conditions Improper handling may result in burns and other serious injuries Important Do not bring any fi...

Page 5: ...ithout linings Clutch engages at 3200 rpm Crankcase leakage test at excess pressure p 0 5 bar under vacuum pu 0 5 bar 3 2 Fuel system Carburetor leakage test at excess pressure p 0 8 bar Operation of...

Page 6: ...abrasive wheels Diameter 350 mm Cutting depth approx 123 5 mm TS 800 Composite and diamond abrasive wheels Diameter 400 mm Cutting depth approx 143 mm 3 5 Special accessories Cart FW 20 Cutting direct...

Page 7: ...M 5x35x12 Filter housing filter base 3 0 Screw IS P 5x19 Shroud tank housing 6 0 Screw M 10x1 L Belt pulley shaft 40 0 Screw IS M 5x20 Fan cover crankcase 6 0 Screw IS M 5x20 Starter cover crankcase...

Page 8: ...7 TS 700 TS 800 Remarks 1 Secure screw with Loctite 270 2 Place a washer under the screw head Note Screwdriver speed when used in plastic material Plastoform screws max 600 rpm...

Page 9: ...speed too high Readjust with idle speed screw LA anticlockwise Clutch springs stretched or fatigued Replace clutch springs or install new clutch Clutch spring hooks broken Replace clutch springs Loud...

Page 10: ...ensioned Check rewind spring and reduce tension Starter rope can be pulled out almost without resistance crankshaft does not turn Guide peg on pawls or pawls themselves are worn Fit new pawls Spring c...

Page 11: ...on 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 in flywheel h...

Page 12: ...st the inlet control lever Fit a new metering diaphragm Inlet control lever too high relative to correct installed position Set inlet control lever flush with top edge of housing Poor acceleration Idl...

Page 13: ...ls crankcase leaking Seal or replace oil seals crankcase Engine stops when idling Idle jet bores or ports blocked Clean the carburetor Idle jet too rich or too lean Set low speed screw L correctly Set...

Page 14: ...Clean the pick up body fit a new filter Fuel strainers dirty Replace the fuel strainers Leak in fuel line between tank and fuel pump Seal connections or install a new fuel line Setting of high speed s...

Page 15: ...gine does not deliver full power or runs erratically Piston rings worn or broken Replace piston rings Muffler spark arresting screen carbonized Clean the muffler inlet and exhaust replace spark arrest...

Page 16: ...ve screws 1 from bearing and remove guard 376RA004 TG 1 1 Unhook the ribbed V belt 1 from the belt pulley and remove the bearing with guard 1 376RA017 TG Remove screw 1 from the thrust washer 2 Remove...

Page 17: ...rubber ring 1 376RA014 TG Remove the washer 1 and rubber ring 2 1 2 376RA015 TG Remove the circlips in front of the deep groove ball bearings from the grooves on both sides Note Use pliers with short...

Page 18: ...ball bearing must not be damaged Lay the washer 1 over the bearing Insert the bearing in the rubber bearing from the outside 1 376RA008 TG Lay a washer over the flange Insert the flange from the insi...

Page 19: ...if the shaft diameter changes due to scoring etc it is sufficient to carefully inspect the shaft around the mount for the abrasive wheel The axial truth of running on the other hand depends on the con...

Page 20: ...30 mm diameter Axial runout 0 15 mm 0 15 mm Damage or unevenness in the mating faces of the thrust washers particularly the inner thrust washer mating faces are not plane use of parts which are not or...

Page 21: ...5 1 Remove cap and spark plug b 7 4 Push the locking strip 1 0000 893 5903 as far as possible into the cylinder Fit the piston 1 376RA102 TG Unscrew the nut arrow from the starter cup 376RA029 TG Pul...

Page 22: ...ive the ball bearing in as far as possible with the drift pin 1 4224 893 7200 1 376RA028 TG Note Do not use the assembly stand 5910 890 3100 for the following work Lay the machine on a suitable level...

Page 23: ...Tightening torques b 3 6 Note 1 376RA038 TG The tensioner must be in its pre tensioned position before installing the bearing with guard Turn the hexagon of the tensioner as far as possible anticlockw...

Page 24: ...shoes VA 208RA029 Slide the clutch shoes over the legs 1 on the carrier so that the type number 2 faces towards the longer hexagon 3 VA 146RA208 2 1 3 Clamp the clutch in a vice 212RA288 VA Hook one...

Page 25: ...spark arresting screen 2 Clean the spark arresting screen or fit a new screen if necessary 1 2 376RA046 TG Defective oil seals and gaskets or cracks in castings are the usual causes of leaks Such faul...

Page 26: ...s can be checked through the inlet port Check that the sleeve 1 is present in the manifold 1 376RA049 TG Check that the pin 1 and sealing ring 2 have been fitted on test flange 4224 890 1200 or fit th...

Page 27: ...finishing the test open the vent screw on the rubber bulb and disconnect the hose of tester 1106 850 2905 Vacuum test see b 7 2 3 Oil seals tend to fail when subjected to a vacuum In other words the...

Page 28: ...b 7 9 Reassemble remaining parts in reverse order It is not necessary to dismantle the complete power unit in order to replace the oil seals Clutch side Remove the clutch see b 6 Free off the oil sea...

Page 29: ...reasant not containing any chlorinated or halogenated hydrocarbons Lubricate the sealing lips of the new oil seal with grease Slip the oil seal with the open side facing the crankcase over the cranksh...

Page 30: ...ng see b 4 Remove shroud b 7 4 Remove muffler see b 7 1 Unplug the spark plug boot 1 from the spark plug 1 376RA067 TG Remove ignition lead 1 and short circuit wire 2 from the retainers arrows 1 2 376...

Page 31: ...Release hose clips arrows Note The hose clips must be unscrewed right up to the end of their screw threads for easy assembly 376RA072 TG Take out the screws through the holes arrows in the cylinder 3...

Page 32: ...The piston must be held steady during this process to ensure that jolts are not transmitted to the connecting rod Remove the piston from the connecting rod and take the needle cage out of the small e...

Page 33: ...tool on a suitable surface wooden board 376RA326 TG Remove the sleeve and push it as far as possible over the opposite end of the assembly tool s shank The inner pin must point towards the flat face 3...

Page 34: ...up as it will be in the installed condition Note When fitting the cylinder ensure that the clamping strap firmly encloses the piston and that none of the piston rings protrudes risk of breakage Carefu...

Page 35: ...plate is lined up with the groove 2 in the cylinder 1 2 376RA126 TG Insert the diaphragm and support plate with the cylindrical shoulder in the hole in the cylinder wall Insert and tighten down the sc...

Page 36: ...the starter cup b 5 4 Remove the clutch b 6 Remove the cylinder and piston b 7 6 Remove the screws from the recesses arrows in the two halves of the crankcase 376RA092 TG Remove the caps 1 from the ru...

Page 37: ...2 48 0 35 4 35 3 3 6 41 8 41 8 15 2 376RA097 TG Drive the crankshaft 1 out of the crankcase half on the clutch side 1 376RA101 TG The crankshaft 1 connecting rod 2 and needle bearing in between are a...

Page 38: ...e s serial number must be stamped on the crankcase with 2 5 mm figure stamps If the original crankcase is reused all gasket residues must be removed and the mating surfaces cleaned thoroughly The mati...

Page 39: ...r 1 4119 893 7205 to press home the deep groove ball bearing as far as the stop 1 376RA121 TG Heat the area of the ball bearing seat on the clutch side of the crankcase to approx 150 C 302 F Push the...

Page 40: ...h the assembly tool care must be taken to ensure that the small end always faces up towards the cylinder flange Grease the sealing lips of the oil seal b 14 Slide assembly sleeve 1 1107 893 4600 over...

Page 41: ...on the assembly tool until the drilled plate butts against the crankcase on the ignition side Screw the assembly tool in with two M5x72 screws arrows in the holes marked 19 on the drilled 1 376RA125 T...

Page 42: ...ecompression valve 1 1 376RA335 TG Fit insert 1 5910 893 2804 on the decompression valve then mount the extension 2 on the insert and unscrew the decompression valve 1 2 376RA336 TG Examine the sealin...

Page 43: ...lectrical connections on the coil body High voltage output 1 for the ignition lead 2 1 376RA140 TG Connector tag 2 for the short circuit wire Testing in the workshop is limited to a spark test A new i...

Page 44: ...flywheel Press the ignition module against the setting gauge 1 376RA143 TG Tighten down the screws arrows tightening torques b 3 6 Remove the setting gauge and use a feeler gauge to check the air gap...

Page 45: ...troubleshooting chart b 8 7 Using the ZAT 3 ignition system tester 5910 850 4520 Before starting the test install a new spark plug and tighten it down firmly Tightening torques b 3 6 376RA134 TG 1 2 3...

Page 46: ...pointed tool to pierce the centre of the lead s insulation about 15 mm from the end of the ignition lead Pinch the hook of the leg spring into the centre of the ignition lead arrow 376RA136 TG Coat th...

Page 47: ...1 376ET103 TG Push the locking strip 1 0000 893 5903 as far as possible into the cylinder Position the piston against the locking strip 1 1 376RA102 TG Unscrew the nut 1 376RA105 TG 1 Place the thrus...

Page 48: ...the spark plug and ignition lead with spark plug boot are in order Remove the fan cover b 7 5 Pull the short circuit wire 1 off the tag on the ignition module 1 376RA369 TG Connect the ohmmeter to gro...

Page 49: ...ble guides on the dismantled tank housing for clarity Remove the short circuit wire from the cable guides arrows 376RA194 TG So that the short circuit wire 1 can be guided better between cylinder and...

Page 50: ...hey are flush 376RA160 TG Pull the short circuit wire 1 in below the carburetor with the help of the string 1 376RA233 TG Use a deflector when pulling the wire through between cylinder and tank housin...

Page 51: ...e gap correct Contacts shorted Clean adjust or replace the spark plug b 8 3 Check spark plug boot Firmly seated on spark plug leg spring Leg spring hook in centre of ignition lead Spark plug boot dama...

Page 52: ...sary b 8 1 1 Check ignition lead Severe chafing Spark plug boot holes cracks Resistance of spark plug boot to ground required 1 5 12 k Check resistance of ignition lead value required 10 Replace spark...

Page 53: ...Look for fault in fuel or carburetor system Check power unit for leaks Check position of flywheel on crankshaft b 12 2 b 7 8 b 8 1 1 yes Stop switch Check correct operation Short circuit wire chafed...

Page 54: ...ow it to rewind until its normal smooth action is restored If clogged with dirt or pitch the entire starter mechanism including the rewind spring must be removed and disassembled Take particular care...

Page 55: ...e rope rotor off the starter post 1 376RA315 TG Remove the starter rope or remaining rope from the rope rotor Remove any remaining rope from the starter cover if necessary Install a new starter rope b...

Page 56: ...9 TG Thread the new rope 1 through the top of the starter grip 1 376RA320 TG Then thread the rope 1 through the opening arrow of the starter cover 1 376RA321 TG Finally draw the rope 1 into the rope r...

Page 57: ...rip firmly to keep the rope 1 tensioned Release the rotor and let go of the rope slowly so that it winds onto the rotor 1 376RA312 TG The rewind spring is correctly tensioned when the starter grip sit...

Page 58: ...special lubricant before installation b 14 Position the spring with spring housing 1 in the starter cover arrows If the rewind spring pops out during installation fit it in the spring housing as foll...

Page 59: ...tarter cover 1 376RA035 TG Insert the screw spindle 1 of the installing tool 0000 890 2201 through the guide bushing from inside the housing 1 376RA329 TG Fit the thrust sleeve 2 and hex nut 3 Tighten...

Page 60: ...and sleeve 376RA262 TG Note the installation sequence Reassemble remaining parts in reverse order Tightening torques b 3 6 376RA215 TG Damaged rubber buffers annular buffers must always be replaced Ru...

Page 61: ...3 6 Rubber buffer on clutch side Damaged rubber buffers annular buffers must always be replaced Prise the plug arrow out of the rubber buffer 376RA297 TG Remove the screw arrow from the rubber buffer...

Page 62: ...rew is being unscrewed press the tank housing against the spring until the screw is released Press the tank housing down slightly and unscrew the spring 1 from the upper bearing plug in anticlockwise...

Page 63: ...ress Fluid OH 723 b 14 Slide the new rubber buffer as far as possible into the T guide 376RA378 TG 1 arrow underneath the handle Stop buffer A stop buffer is installed between the tank housing and cra...

Page 64: ...he bearing 1 on the switch shaft Remove the bearing 1 376RA227 TG Pull the switch shaft 1 out of the left hand bearing arrow and remove it from the tank housing 1 376RA228 TG Prise the leaf spring 1 o...

Page 65: ...e remaining parts in reverse order Remove shroud b 7 4 Remove the air filter b 12 1 Remove the air filter base b 12 1 1 Removing the throttle trigger Push the throttle rod 1 down and out of the thrott...

Page 66: ...he tank housing 1 376RA190 TG Fix the interlock lever 2 with a suitable drift Position the pin 1 at the drift and push it into the hole 1 2 376RA175 TG Installing the throttle trigger Note the assembl...

Page 67: ...le loss of engine power Refer also to troubleshooting b 4 4 Remove the screw arrow from the filter cover 1 Remove the filter cover 376RA064 TG 1 Remove the screws arrows from the filter housing 1 Remo...

Page 68: ...Undo the screws 2 2 2 1 1 376RA146 TG Pull the air hose 1 off the filter base Disconnect the compensator hose 2 and fuel pump intake hose 3 from the carburetor 376RA147 TG 1 2 3 Disconnect the tank v...

Page 69: ...replace it if necessary 376RA149 TG Remove the carburetor gasket from the carburetor and replace it if necessary Reassemble parts in reverse order Tightening torques b 3 6 376RA151 TG Reassemble remai...

Page 70: ...6RA155 TG Note When fitting the choke lever 1 on the choke shaft 2 ensure that the flat side of the choke shaft is lined up with the semi circular recess in the choke lever 1 2 376RA156 TG Reassemble...

Page 71: ...carburetor is airtight However if the pressure drops there are two possible causes 1 The inlet valve is not sealing impurities in the valve seat sealing cone of the inlet needle is damaged or inlet c...

Page 72: ...w arrow 376RA269 TG Pull the inlet control lever 1 with spindle out of the groove in the inlet needle Note The spring under the inlet control lever may pop out 1 376RA270 TG Pull out the inlet needle...

Page 73: ...y 376RA207 TG 1 Carefully separate the pump diaphragm 1 and gasket 2 2 1 376RA208 TG The diaphragm material is subjected to continuous alternating stresses and eventually shows signs of fatigue In oth...

Page 74: ...or b 12 2 1 If actuation of the choke shaft is stiff and or the choke shutter cannot be opened or closed properly Remove the choke shaft then 376RA281 TG clean the shaft and shaft guides with a little...

Page 75: ...ctioning and easy movement 2 1 376RA287 TG Turn the choke shaft until the flat area is visible Slide the choke shutter 1 into the slot in the choke shaft with the recess 2 first Note 1 2 376RA286 TG E...

Page 76: ...the throttle shaft 1 376RA243 TG Undo screw arrow 376RA247 TG Turn the throttle shaft slightly Pull the throttle shutter 1 out of the slot in the throttle shaft 1 376RA244 TG Remove the circlip arrow...

Page 77: ...sting screw 1 376RA236 TG Slide the washer onto the throttle shaft and fit the circlip arrow 376RA238 TG Slide the throttle shutter 1 into the slot in the throttle shaft with the recess 2 first 1 2 3...

Page 78: ...b 12 2 1 Troubleshooting on the carburetor b 4 4 Remove the air flap shaft then clean the shaft and shaft guides with a little standard solvent based degreasant not containing any chlorinated or halog...

Page 79: ...ttle shutter side Note When fitting the air flap the marks arrow must be visible as an indentation and be located behind the bore Insert the screw on the flat side of the shaft and tighten it down mod...

Page 80: ...14 TG Pull off the upper lever 1 1 376RA243 TG Unhook and relax the torsion spring arrow 376RA216 TG Use a suitable tool to prise the lower lever 1 and torsion spring off the air flap shaft 2 1 376RA2...

Page 81: ...le shutter shaft and the lower lever 2 onto the air flap shaft 376RA380 TG 1 2 When fitting the upper lever ensure that the flat sides in the lever and throttle shaft are lined up with one another Do...

Page 82: ...376RA373 TG accordance with position A so that the rod 2 is vertical Press the lever 1 onto the ribbed part of the air flap shaft The air flap lever is now fixed in position Insert the screw 1 and ti...

Page 83: ...shaft b 12 3 7 Remove the sealing ring 2 b 12 3 7 The air flap shaft must be removed 2 1 376RA279 TG and cleaned b 12 3 7 if its guides are severely fouled Adjust the air flap rod if necessary b 12 3...

Page 84: ...e 1 2 376RA253 TG order Adjust the high speed screw b 12 4 Only necessary if the high speed screw H or low speed screw L has to be replaced or for cleaning and setting the carburetor Remove the limite...

Page 85: ...set the highest speed If this speed is more than 3700 rpm stop the adjustment and start again with step 1 3 Set the speed to 3300 rpm again with the idle speed adjusting screw LA 4 Set the speed to 2...

Page 86: ...another turn in the same direction Erratic idling behaviour poor acceleration Idle setting too lean e g at low ambient temperatures Give the low speed screw L a quarter turn anticlockwise until the e...

Page 87: ...ntake manifold and on the intake connector of the cylinder are lined up with one another 376RA368 TG To draw the manifold flange into the intake port of the tank housing wrap a piece of string 1 appro...

Page 88: ...w faces the cylinder Coat with Press Fluid OH 723 b 14 1 376RA374 TG Slip the hose clips onto the manifolds 1 Note the installed position of the hose clips arrows Install the manifolds in reverse orde...

Page 89: ...sing until the circumferential groove on the impulse hose engages the tapered end of the hole Draw the impulse hose through the hole in the tank housing Reassemble remaining parts in reverse order 376...

Page 90: ...lty part replaced Reassemble parts in reverse order Prise the tank vent 1 out of the grommet on the tank housing with a suitable tool Prise the rubber grommet off the tank vent with a suitable tool 1...

Page 91: ...y first if problems develop in the fuel supply Clean the fuel tank if necessary Clean the fuel tank Remove the filler cap 1 and empty the tank 1 376RA365 TG Fill a little clean petrol into the tank cl...

Page 92: ...order Remove the carburetor b 12 2 1 Remove the filler cap Use a suitable tool to remove the fuel hose 2 and elbow connector 1 2 1 376RA168 TG Check the fuel hose 1 and elbow connector 2 and replace...

Page 93: ...ank housing and line it up Reassemble remaining parts in reverse order 1 376RA196 TG Prise the cord of the filler cap out of its mount inside the tank Examine the filler cap cord and sealing ring and...

Page 94: ...Push the impulse hose out of the tank housing b 12 5 3 Unscrew the rubber buffers on the ignition and clutch sides b 10 1 and b 10 2 Remove the front handle b 10 5 Unscrew the spring b 10 3 The new t...

Page 95: ...seal s 14 Jaws No 6 0000 893 3711 Remove oil seal s 15 Press sleeve 4224 893 2400 Install oil seal ignition side 16 Press sleeve 4224 893 2401 Install oil seal clutch side 17 Assembly hook 5910 890 28...

Page 96: ...910 890 2415 IS P screws 4 mm 1 37 Screwdriver Q SW8x200 5910 890 2420 Carburetor nuts 38 Drift pin 1124 893 7200 Remove and install deep groove ball bearings clutch side 39 Drift pin 4119 893 7205 In...

Page 97: ...000 Rubber buffers in AV system 5 STIHL multi purpose grease 0781 120 1109 High voltage output on ignition module 6 Medium strength thread locking adhesive Loctite 242 0786 111 2101 7 High strength th...

Page 98: ...englisch english 0455 376 0123 VA0 F12 Printed in Germany...

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Summary of Contents for TS 700, TS 800

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