Professional Documents
Culture Documents
STIH)
2003-04
CONTENTS
1.
Introduction
2.
Specifications
2.1
2.2
2.3
2.4
2.5
2.5.1
2.5.2
2.6
Engine
Fuel System
Ignition System
Gearhead
Special Accessories
For User
For Service
Tightening Torques
3
3
4
4
4
4
4
5
6.
Rewind Starter
30
10.
Shaft
6.1
6.2
6.2.1
6.2.2
6.3
General
Rewind Spring
Replacing
Tensioning
Starter Rope/Starter
Grip (ElastoStart)
30
30
30
31
10.1
Bike Handle
(FS 120/200)
Bike Handle
(FS 300...450)
Loop Handle
Drive Shaft/
Flexible Liner
Flexible Shaft
(FR 350/450)
Drive Tube
Housing
(FR 350/450)
Clutch
3.1
3.2
7.
7.1
7
7.3
7.4
4.
Engine
4.1
Exhaust Muffler/
Spark Arresting Screen 9
Leakage Test
10
Preparations
10
Pressure Test
11
Vacuum Test
11
Oil Seals
12
Exposing the Cylinder 13
Cylinder and Piston
14
Removal
14
Installation
15
Piston Rings
17
Crankcase
17
Removing Crankshaft 17
Installing Crankshaft
20
Decompression Valve 23
4.2
4.2.1
4.2.2
4.2.3
4.3
4.4
4.5
4.5.1
4.5.2
4.6
4.7
4.7.1
4.7.2
4.8
5.
Ignition System
5.1
5.2
5.3
5.3.1
5.3.2
5.3.3
5.4
5.5
23
10.3
10.4
10.5
7.2
3.
32
10.2
7.5
7.5.1
7.5.2
Throttle Control
33
Throttle Trigger/Interlock
Lever (Bike Handle)
33
Contact Springs/Detent
Spring in Control Handle
(Bike Handle)
34
Throttle Trigger/Interlock
Lever (Loop Handle) 34
Slide Control
(Loop Handle)
35
Throttle Cable
36
Replacing
36
Adjusting
37
8.
Fuel System
8.1
8.2
8.2.1
Air Filter
38
Carburetor
39
Removing and Installing
(FS 120...350, FR 350) 39
Removing and Installing
(FS 400/450, FR 450) 40
Leakage Test
41
Adjusting
(three screws)
42
Adjusting
(one screw)
43
Tank Vent
44
Pickup Body
44
Fuel Tank/
Hoses
45
Manual
Fuel Pump
47
8.2.2
8.2.3
8.2.4
8.2.5
8.3
8.4
8.5
8.6
9.
AV System
9.1
Repair
(FS 120/200)
Repair
(FS 300...450)
Repair
(FR 350/450)
9.2
9.3
38
10.6
10.7
11.
51
51
51
52
52
53
54
56
Cutting Tool
Drive
56
11.1
11.2
Gearhead
Clutch Drum
56
57
12.
Support Frame
(FR 350/450)
58
12.1
Repair
58
13.
Special Servicing
Tools and Aids
59
13.1
13.2
47
47
48
50
qS
2000, Andreas Stihl AG & Co., Waiblingen
INTRODUCTION
= Action to be taken as
250RA227VA
In the illustrations:
= Pointer
= Direction of movement
Service manuals and all technical
information bulletins describing
engineering changes are intended
exclusively for the use of STIHL
servicing dealers. They must not
be passed to third parties.
2
1
250RA228 VA
1.
2.
SPECIFICATIONS
2.1
Engine
STIHL single cylinder two-stroke engine with special impregnated cylinder bore
Displacement:
Bore:
Stroke:
Power output:
Max. permissible engine speed
without cutting tool
(cut-off speed):
Idle speed:
Bearings:
Piston pin diameter:
Rewind starter:
Pawls:
Reserve pull on rope rotor:
Starter rope:
Clutch:
Clutch engages at:
Crankcase leakage
test
at gauge pressure:
under vacuum:
2.2
FS 200/350
FR 350
FS 400
FS 450
FR 450
30.8 cm3
1.88 cu.in
35 mm
1.38 in
32 mm
1.26 in
1.3 kW (1.8 bhp)
at 9,000 rpm
36.3 cm3
2.21 cu.in
38 mm
1.49 in
32 mm
1.26 in
1.6 kW (2.2 bhp)
40.2 cm3
2.45 cu.in
40.0 mm
1.57 in
32 mm
1.26 in
1.9 kW (2.6 bhp)
44.3 cm3
2.70 cu.in
42.0 mm
1.65 in
32 mm
1.26 in
2.1 kW (2.8 bhp)
Fuel System
Carburetor:
Standard setting on carburetors
with three adjusting screws
High speed screw H:
Low speed screw L:
Carburetor leakage test
at gauge pressure:
Function of tank vent
at gauge pressure:
under vacuum:
Fuel tank capacity:
Octane rating:
Fuel mixture:
Mix ratio:
Air filter:
FS 120/300
Diaphragm carburetor
Open approx. 1 turn
Open approx. 1 turn
0.8 bar (11.6 psi)
0.3 bar (4.35 psi)
0.05 bar (0.725 psi)
0.64 l (1.35 US pt)
0.68 l (1.44 US pt)
min. 90 RON (US/CAN; pump octane min. 87)
Regular brand name gasoline
and two-stroke engine oil
50:1 with STIHL two-stroke engine oil
25:1 with other brand name two-stroke, air-cooled engine oils
Paper filter
2.3
Ignition System
Type:
Electronic magneto
ignition (breakerless)
with integral trigger unit
and electronic speed
governor
0.2 - 0.5 mm (0.008 - 0.020 in)
305 mm * (12 in)*
Bosch WSR 6F,
NGK BPMR 7 A or
Champion RCJ 6Y
0.5 mm (0.020 in)
M14x1.25
9.5 mm (0.37 in)
Air gap:
Length of ignition lead:
Spark plug (suppressed):
Electrode gap:
Splark plug thread:
Length of thread:
2.4
Gearhead
Type:
Spiral-toothed
bevel gear drive
Gear ratio:
1:1.4 **
1:1.235
Bearings:
Lubrication:
2.5
Special Accessories
2.5.1
For User
Full harness
Safety glasses
Transport guard for
metal cutting tools
STIHL gear lubricant (80 g/3 oz tube) 0781 120 1109
STIHL gear lubricant (80 g/3 oz tube) 0781 120 1117
2.5.2
For Service
* FS 400/450 only
** FS 120, 200, 350 and 450
2.6
Tightening Torques
DG and P screws (Plastoform) are used in polymer and lightmetal components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary
without detrimentally affecting the strength of the screwed assembly, providing the specified tightening torque is
observed. For this reason it is essential to use a torque wrench.
Fastener
Thread
size
For component
Self-tapping screw
Self-tapping screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
IS-B3.5x6.5
IS-B4.2x9.5
IS-DG4x20
IS-DG5x24
IS-DG5x12
IS-DG5x12
IS-DG5x20
IS-DG5x20
IS-DG5x20
Spline screw
IS-DG5x20
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
IS-DG5x20
IS-DG5x26
IS-DG5x24
IS-DG5x20
IS-DG5x26
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
IS-DG5x28
IS-DG5x24
IS-DG5x24
IS-DG5x24
IS-DG5x24
IS-DG5x24
IS-DG6x28
IS-DG5x24
IS-DG5x24
IS-DG5x25
Collar nut
Collar screw
Spline screw
M5
M5/P6
IS-M5x12
Spline screw
Spline screw
Spline screw
Spline screw
IS-M5x16
IS-M5x12
IS-M5x16
IS-M5x30
Torque
Nm
lbf.ft
Remarks
1.5
2.5
4.5
6.0
2.5
5.0
6.0
6.0
1.1
1.8
3.3
4.4
1.8
3.7
4.4
4.4
6.0
4.4
6.0
6.0
6.0
6.0
6.0
4.4
4.4
4.4
4.4
4.4
6.0
10.5
8.5
8.5
8.5
8.5
6.0
12.0
8.5
8.5
4.4
7.5
6.3
6.3
6.3
6.3
4.4
8.8
6.3
6.3
1) 2)
1.5
7.5
3.5
4.0
1.1
5.5
2.6
3.0
1) 4)
1) 4)
2.0
5.5
2.0
4.5
2.0
1.5
4.0
1.5
3.3
1.5
3) 4)
3)
2) 5)
3)
6)
1) 2)
3) 4) 5)
1) 2)
3)
1) 4)
1) 2)
1)
1) 2) 4) 5)
3)
1) 6)
4)
2) 3) 5)
Fastener
Thread
size
For component
Spline screw
Spline screw
Spline screw
IS-M6x25
IS-M6x25
IS-M6x35
Clamp/loop handle
Support/drive tube
Clamp moldings/support block
(handle support/bike handle)
Carrier
Clutch shoe/carrier
Flywheel
Decompression valve
Spark plug
Gearhead
Filter cover/filter housing
Control handle/handle moldings
Detent spring/slide control
(bike handle)
Cutting tool
Cutting tool deflector/gearhead
Spring/support plate
Housing/shaft clamp screw
Bearing housing/support frame
Support plate/ball bearing/
support frame
Screw plug
Spline screw
Plastoform screw
Collar screw
M8
IS-M6x18
M8
M10
M14x1.25
M11x10
IS-M5x14
IS-P4x16
IS-P3.5x10.6
Nut
Spline screw
Spline screw
Spline screw
Spline screw
Spline screw
M12x1.5 L
IS-M5x16
IS-M6x14
IS-M6x25
IS-M6x14
IS-M10x20
Spline screw
Torque
Nm
lbf.ft
Remarks
4.5
6.0
3.3
4.4
3)
1) 4) 6)
4.5
24.0
12.0
32.0
14.0
20.0
8.5
6.0
1.0
3.3
17.7
8.8
23.6
10.3
15.0
6.3
4.4
0.75
3)
1.1
25.0
4.3
10.0
4.5
10.0
0.80
18.5
3.2
7.5
3.3
7.5
1) 3) 4)
20.0
15.0
2) 5)
1) 2) 4) 5)
1) 2)
2) 5)
2) 5)
2) 5)
FS 400/450
FR 450
FS 120/200
FS 300/350
FR 350
with washer
Note: Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm
DG screws
max. 500 rpm
3.
3.1
CLUTCH
Removing and Installing
Removal
250RA230 VA
250RA001 VA
FS 120...350, FR 350
bushings.
FS 400/450, FR 450
250RA005 VA
250RA003 VA
250RA002 VA
shoes.
250RA004 VA
250RA229 VA
3.2
Clutch Carrier
250RA234 VA
250RA231 VA
Installation
250RA235 VA
250RA232 VA
250RA233 VA
4.
4.1
ENGINE
Exhaust Muffler/Spark Arresting Screen
250RA011 VA
250RA006 VA
FS 400/450, FR 450
- Remove air filter cover - see 8.1.
250RA012 VA
250RA009 VA
All models
housing.
250RA007 VA
FS 400/450, FR 450
250RA010 VA
1 2
Leakage Test
4.2.1
Preparations
250RA015 VA
4.2
250RA013 VA
250RA014 VA
10
4.2.2
Pressure Test
4.2.3
Vacuum Test
250RA017 VA
250RA016 VA
Oil seals tend to fail when subjected to a vacuum, i.e. the sealing
lip lifts away from the crankshaft
during the pistons induction stroke
because there is no internal
counterpressure.
250RA016 VA
143RA046 VA
250RA018 VA
11
4.3
250RA020 VA
Oil Seals
Starter side:
- Remove the flywheel - see 5.4.
250RA021 VA
250RA019 VA
Clutch side:
12
250RA022 VA
250RA026 VA
4.4
250RA024 VA
250RA023 VA
FS 400/450, FR 450
250RA027 VA
250RA025 VA
Fit stub (1) on carburetor housing in the sealing ring (2) and
throttle cable (3) in the retainer
(4).
- Tighten down screws to 6 Nm
(4.4 lbf.ft).
13
4.5
4.5.1
250RA031 VA
250RA028 VA
ring (4).
- Secure lug of extended throttle
cable between the raised marks
and tighten down the screws
to 6 Nm (4.4 lbf.ft).
250RA029 VA
FS 400/450, FR 450
All models:
Illustrations show the
FS 200 engine.
250RA032 VA
250RA030 VA
cylinder.
14
1110 893 4700 to push the piston pin (1) out of the piston.
250RA038 VA
250RA033 VA
Installation
250RA035 VA
4.5.2
250RA039 VA
250RA057 VA
250RA037 VA
250RA034 VA
To simplify assembly, heat the piston and slip it over the connecting rod.
1 = Marking
2 = Flywheel
FS 120, 200, 300, 350, 400, 450, FR 350, 450
15
250RA044 VA
250RA041 VA
250RA036 VA
16
250RA045 VA
250RA043 VA
250RA040 VA
4.6
Piston Rings
4.7
4.7.1
Crankcase
Removing Crankshaft
FS 400/450, FR 450
All models
250RA051 VA
250RA046 VA
250RA048 VA
FS 120...350, FR 350
1
250RA052 VA
250RA049 VA
250RA047 VA
All models
Pull the base of the guide
off the housing.
- Remove the carrier - see 3.2.
17
38.0
33.3
32.25
33.6
17.3
20.6
15.5
250RA062 VA
17
17
12.6
18
16
41.25
9.7
26.85
18
16
17
2.25
16
16
17.65
24.75
20.1
33.85
41.6
18
18
17
16
16
18
16 + 18 =
17
=
5,5
6,5
19.9
22.5
33.7
1
250RA219 VA
17
250RA063 VA
2.5
25.5
1
2
250RA058 VA
250RA061 VA
FS 400/450, FR 450
- Hold ZS installing tool against
starter side of crankcase so that
the notch marked "17" is at the
bottom.
- Insert M5x60 screws in holes
marked "18", fit washers at other
side and screw on nuts.
All models
250RA059 VA
250RA065 VA
250RA064 VA
16
1
16
16
16
16
1
250RA060 VA
250RA066 VA
FS 120...350, FR 350
- Back off spindle (left-hand thread) of ZS installing tool
5910 890 2220 a little.
19
4.7.2
Installing Crankshaft
Note: This operation must be
carried out very quickly because
the bearing absorbs heat immediately and begins to expand.
250RA067 VA
250RA071 VA
250RA070 VA
250RA068 VA
250RA069 VA
250RA071 VA
- Inspect both halves of the crankcase for cracks and replace if necessary.
20
250RA077 VA
250RA075 VA
250RA073 VA
250RA078 VA
392RA044 VA
250RA076 VA
250RA074 VA
21
250RA085 VA
250RA079 VA
250RA082 VA
250RA086 VA
250RA083 VA
1 2
250RA080 VA
250RA081 VA
22
250RA084 VA
4.8
Decompression Valve
5.
IGNITION SYSTEM
5.1
250RA091 VA
250RA087 VA
250RA088 VA
23
5.2
Ignition Lead
(FS 400/450, FR 450)
250RA092 VA
250RA089 VA
250RA053 VA
250RA090 VA
24
250RA094 VA
250RA008 VA
5.3
- Slip the rubber boot off the
ignition lead.
Ignition Module
250RA054 VA
338RA142 VA
FS 400/450, FR 450
There are two electrical connections on the coil body:
250RA095 VA
25
5.3.1
Ignition Timing
5.3.2
250RA096 VA
26
250RA098 VA
250RA099 VA
5.3.3
250RA103 VA
250RA101 VA
250RA100 VA
cylinder.
250RA104 VA
250RA102 VA
27
5.4
Flywheel
1
1
outer screw.
250RA109 VA
250RA106 VA
250RA105 VA
FS 120...350, FR 350
250RA110 VA
250RA107 VA
28
5.5
250RA115 VA
250RA113 VA
All models
FS 400/450, FR 450
- Remove the fuel tank - see 8.5.
FS 120...350, FR 350
250RA111 VA
250RA116 VA
grommet.
1
2
250RA114 VA
250RA112 VA
29
REWIND STARTER
General
6.2
6.2.1
Rewind Spring
Replacing
Note: The replacement spring
comes ready for installation and is
secured with a washer.
- It should be lubricated with a few
drops of STIHL special lubricant
before installation - see 13.2.
250RA117 VA
6.
6.1
250RA119 VA
250RA118 VA
30
6.2.2
Tensioning
250RA120 VA
250RA122 VA
250RA125 VA
250RA123 VA
250RA121 VA
31
6.3
250RA127 VA
362RA097 VA
250RA128 VA
362RA095 VA
250RA126 VA
362RA096 VA
7.
7.1
THROTTLE CONTROL
Throttle Trigger/Interlock Lever (Bike Handle)
trigger.
Assemble in the reverse
sequence.
peg.
FS 120, 200, 300, 350, 400, 450, FR 350, 450
33
7.2
7.3
screw (1).
Throttle Trigger/Interlock
Lever (Loop Handle)
FR 350/450
34
7.4
Slide Control
(Loop Handle)
interlock lever.
35
7.5
7.5.1
Throttle Cable
Replacing
All models
- Remove the shroud - see 4.1.
- Remove clutch housing see 9.1 and 11.2.
- Take throttle cable off the contact spring - see 7.2 and 7.3.
Assemble in the reverse sequence.
- Tighten clamp screws to 2 Nm
(1.5 lbf.ft).
250RA143 VA
250RA141 VA
250RA144 VA
FS 120...350, FR 350
250RA145 VA
250RA142 VA
250RA237 VA
FS 400/450, FR 450
- Remove the air filter housing see 8.2.2.
36
7.5.2
Adjusting
250RA148 VA
250RA146 VA
250RA239 VA
FS 400/450, FR 450
250RA149 VA
250RA238 VA
FS 120...350, FR 350
- Place lug and extended throttle
cable in the corner of the filter
housing.
- Tighten screw of extended
throttle cable to 6.0 Nm
(4.4 lbf.ft).
- Adjust throttle cable - see 7.5.2.
housing.
250RA147 VA
37
8.
8.1
FUEL SYSTEM
Air Filter
250RA150 VA
FS 120...350, FR 350
250RA153 VA
250RA151 VA
All models
Remove the filter.
250RA152 VA
2
1
FS 400/450, FR 450
38
8.2
8.2.1
Carburetor
Removing and Installing
FS 120...350, FR 350
250RA159 VA
250RA156 VA
throttle cable.
filter housing.
250RA158 VA
250RA161 VA
250RA155 VA
250RA160 VA
250RA154 VA
250RA157 VA
39
FS 400/450, FR 450
250RA166 VA
250RA013 VA
250RA163 VA
8.2.2
250RA167 VA
250RA164 VA
250RA165 VA
250RA168 VA
from carburetor.
connector.
40
8.2.3
Leakage Test
250RA171 VA
250RA169 VA
250RA170 VA
250RA172 VA
FS 400/450, FR 450
- Remove the shroud - see 4.1.
pressure hose.
FS 120...350, FR 350
- Remove the carburetor - see
8.2.1.
2
1
250RA173 VA
143RA172 VA
41
8.2.4
LA
3
Standard setting
FS 400/450, FR 450
- Push the fuel hose onto the
elbow connector.
H
1
LD
250RA221 VA
1 2
250RA220 VA
Adjusting
(three screws)
42
8.2.5
Turn the idle speed screw (LD)
counterclockwise until cutting tool
stops rotating and then turn it
about another one full turn in the
same direction.
Note:
If the engine does not reach
6,000 rpm in starting throttle
position, readjust the throttle
cable, see 7.5.
Adjusting
(one screw)
Note:
If the engine does not reach
6,000 rpm in starting throttle
position, readjust the throttle
cable, see 7.5.
1
+
LD
250RA222 VA
43
Tank Vent
8.4
3
7
5
4
250RA225 VA
8.3
Cleaning
- Unscrew the fuel filler cap.
Pickup Body
body (2).
cap (4).
filler cap.
250RA223 VA
filler cap.
- Unscrew the filler cap and remove it together with the retainer.
body.
- Fit valve body in filler cap and
press it home until it snaps into
position.
- Fit new sintered filter in the cap.
250RA224 VA
44
8.5
Fuel Tank/
Hoses
All models
- Drain the fuel tank.
250RA174 VA
FS 120...350, FR 350
- On FR 350, remove powerhead
from support frame - see 9.3.
FS 400/450, FR 450
- On FR 450, remove powerhead
from support frame - see 9.3.
- Remove the carburetor - see
8.2.2.
250RA178 VA
250RA176 VA
250RA175 VA
250RA177 VA
250RA179 VA
FS 400/450 only
Take out the screws.
45
250RA184 VA
250RA180 VA
250RA181 VA
1
A
250RA185 VA
250RA182 VA
250RA226 VA
tank.
- Remove fuel hoses if necessary.
Reassemble in the reverse
sequence.
2
1
250RA183 VA
46
8.6
9.
9.1
AV SYSTEM
Repair (FS 120/200)
250RA192 VA
250RA186 VA
clutch housing.
- On FS 120...350, FR 350,
remove the air filter - see 8.1.
250RA190 VA
250RA187 VA
3
250RA193 VA
tabs.
250RA191 VA
250RA189 VA
47
9.2
Repair
(FS 300...450)
392RA136 VA
250RA194 VA
installing tool.
250RA196 VA
250RA195 VA
392RA134 VA
Rubber buffers
48
250RA197 VA
392RA135 VA
250RA198 VA
250RA199 VA
250RA201 VA
250RA202 VA
250RA203 VA
250RA200 VA
clutch housing.
49
9.3
- Inspect rubber buffers, replace if
necessary.
- Adjust gap after fitting the AV
housing and support.
Repair
(FR 350/450)
250RA162 VA
1
2
1
2
250RA242 VA
50
10.
10.1
SHAFT
Bike Handle (FS 120/200)
10.2
Bike Handle
(FS 300...450)
3
5
250RA205 VA
51
10.3
Loop Handle
10.4
Drive Shaft/
Flexible Liner
52
10.5
Flexible Shaft
(FR 350/450)
362RA177 VA
250RA241 VA
250RA240 VA
250RA243 VA
Flexible liner
53
10.6
Drive Tube
FS 120/200
- Remove the drive shaft - see
10.4.
392RA129 VA
362RA174 VA
drive tube.
the AV sleeve.
392RA156 VA
362RA175 VA
250RA206 VA
54
for harness.
250RA249 VA
392RA139 VA
FR 350/450
- Remove the drive shaft - see
10.4.
250RA208 VA
FS 300...450
- Remove the AV housing - see
9.2.
250RA207 VA
55
11.
11.1
250RA210 VA
250RA243 VA
10.7
250RA244 VA
250RA209 VA
FS 300...450
Remove retainer (1) - if fitted and thrust washer (2) from the
output shaft.
56
Clutch Drum
FS 120/200
- Take rubber element (AV
system) out of clutch housing see 9.1.
1
2
FS 300...450
- Remove the control handle see 10.1.
250RA214 VA
250RA250 VA
11.2
FR 350/450
- Remove the powerhead from the
support frame - see 9.3.
250RA211 VA
250RA215 VA
250RA216 VA
250RA213 VA
250RA212 VA
57
12.
12.1
250RA254 VA
250RA217 VA
250RA251 VA
250RA255 VA
250RA218 VA
250RA252 VA
250RA253 VA
58
13.
13.1
No.
Part Name
Part No.
Application
Rem.
1
2
3
1) 2)
2) 3)
Press sleeve
Installing sleeve
6
7
8
9
Puller
- Jaws (No. 3.1 + 4)
Puller
Crimping tool
Blocking crankshaft
Blocking crankshaft
Fitting oil seal
(starter side)
Fitting oil seal
(clutch side)
Protecting oil seal
(clutch side)
Removing oil seals
Assembly drift
10
11
12
13
14
15
16
17
Clamping strap
Wooden assembly block
Carburetor and
crankcase tester
Vacuum pump
- Nipple
- Fuel hose
Sealing plate
18
19
Test flange
Setting gauge
20
Socket, 13 mm
21
Torque wrench
22
Torque wrench
23
24
25
26
27
28
29
30
31
Press arbor
Service tool ZS
- Sleeve (4x)
- Extension
- Spline screw
Puller
Removing flywheel
Attaching connectors to
electrical wires
Removing and fitting piston pin
Removing and installing
clutch drum
Compressing piston rings
Fitting piston
Testing carburetor
for leaks
Testing crankcase for leaks
4)
2) 3)
5)
6)
5)
6)
IS screws
Removing pickup bodies
Installing hookless snap rings
in piston
Removing and installing ball bearings
Removing crankshaft
1) 2)
1) 2)
1) 2)
Removing crankshaft
(clutch side)
59
No.
Part Name
Part No.
Application
Rem.
32
33
Installing tool
Installing tool
34
Circlip pliers
35
Pliers C19
36
37
38
39
Vice jaws
40
Press arbor
41
Press arbor
42
43
Assembly stand
- Clamp
44
- Clamping plate
Installing crankshaft
Removing rubber element
from AV sleeve
External circlip on
clutch drum
Internal circlip in
clutch housing
For all IS screws
7)
Separating handle moldings
Removing and installing
clutch drum
1) 2)
Holding drive tube and bike
handle
Removing ball bearing in
clutch housing
Installing ball bearing in
clutch housing,
removing and installing
ball bearing in bearing
housing (support frame)
2)
Holding FS and FR units
Holds drive tube of FS units
for repairs
(in conjunction with assembly stand)
Holds powerhead of FS and
FR units for repairs
(in conjunction with assembly stand)
Remarks:
1) FS 120...350
2) FR 350/450
3) FS 400/450
4) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400.
5) Always use torque wrench to tighten DG/P screws.
6) Wrench has optical/acoustic signal.
7) On DG/P screws, use for releasing only.
60
13.2
Servicing Aids
No.
Part Name
Part No.
Application
Lubricating grease
(225 g/0.79 oz tube)
Oil seals
Standard commercial,
solvent-based degreasant
containing no chlorinated or
halogenated hydrocarbons
Dirko sealant
(100 g/3 1/2 oz tube)
Gearhead lubrication
61
englisch/English
0455 250 0123. M0,75. C1. T. Printed in Germany