Professional Documents
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STIH)
Contents
q
ANDREAS STIHL AG & Co. KG, 2005
This service manual contains Symbols are included in the text and If the engine is started up in the
detailed descriptions of all the pictures for greater clarity. course of repairs or maintenance
typical repair and servicing The meanings are as follows: work, observe all local and country-
procedures for this power tool. specific safety regulations as well
In the descriptions: as the safety precautions and
As the design concept of models warnings in the instruction manual.
BR 500, BR 550 and BR 600 is : = Action to be taken as
almost identical, the descriptions shown in the illustration Gasoline is an extremely flammable
and servicing procedures in this (above the text) fuel and can be explosive in certain
manual generally apply to all three conditions.
models. Differences are described = Action to be taken that is
in detail. not shown in the illustration Improper handling may result in
(above the text) burns or other serious injuries.
You should make use of the
illustrated parts lists while carrying In the illustrations: Warning!
out repair work. They show the Do not bring any fire, flame, spark or
installed positions of the individual A Pointer other source of heat near the fuel.
components and assemblies. All work with fuel must be performed
aDirection of movement outdoors only. Spilled fuel must be
Refer to the latest edition of the wiped away immediately.
relevant parts list to check the part b 4.2
numbers of any replacement parts. Reference to another chapter,
i.e. chapter 4.2 in this example.
A fault on the machine may have
several causes. To help locate the
fault, consult the chapter on Service manuals and technical
"Troubleshooting" in this manual information bulletins are intended
and the "STIHL Service Training exclusively for the use of properly
System" for all assemblies. equipped repair shops. They must
not be passed to third parties.
Refer to the Technical Information
bulletins for engineering changes Always use original STIHL
which have been introduced since replacement parts.
publication of this service manual. They can be identified by the
Technical information bulletins also STIHL part number,
supplement the parts list until an the STIH) logo and the
updated edition is issued. STIHL parts symbol (
This symbol may appear alone on
The special servicing tools small parts.
mentioned in the descriptions are
listed in the chapter "Special
Servicing Tools" of 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.
3. Specifications
Displacement: 64.8 cm3 (3.95 ci) 64.8 cm3 (3.95 ci) 64.8 cm3 (3.95 ci)
Bore: 50 mm (2.55 in) 50 mm (2.55 in) 50 mm (2.55 in)
Stroke: 33 mm (1.3 in) 33 mm (1.3 in) 33 mm (1.3 in)
Operating speed with nozzle: 5500 rpm 6100 rpm 7200 rpm
Idle speed: 2500 rpm 2500 rpm 2500 rpm
Crankcase leakage test
at gauge pressure: 0.5 bar 0.5 bar 0.5 bar
under vacuum: 0.5 bar 0.5 bar 0.5 bar
Air gap between ignition module and fanwheel: 0.15...0.3 mm 0.15...0.3 mm 0.15...0.3 mm
(0.006...0.012 in) (0.006...0.012 in) (0.006...0.012 in)
Spark plug: NGK CMR 6 H NGK CMR 6 H NGK CMR 6 H
Electrode gap: 0.7 mm (0.028 in) 0.7 mm (0.028 in) 0.7 mm (0.028 in)
Carburetor leakage test at gauge pressure: 0.8 bar 0.8 bar 0.8 bar
Operation of tank vent at gauge pressure: 0.3 bar 0.3 bar 0.3 bar
Fuel: as specified in as specified in as specified in
instruction manual instruction manual instruction manual
DG and P (Plastoform) screws 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 impairing the strength of the screwed assembly, providing the specified tightening torque is observed.
For this reason it is essential to use a torque wrench.
lbf.ft Nm
Remarks:
1) Install with high-strength Loctite 270
2) Do not lubricate with grease
3) Tighten in crosswise pattern
lbf.ft Nm
Place the screw in the hole and rotate it counterclockwise until it drops down slightly. Tighten the screw
clockwise to the specified torque.
This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.
Important:
Do not mix up screws with and without binding head
4. Troubleshooting
4.1 Rewind Starter
Starter rope broken Rope pulled out too vigorously as Fit new starter rope
far as stop or over edge, i.e. not
vertically
Starter rope does not rewind Rewind spring broken Fit new rewind spring
Starter rope can be pulled out Guide pegs on pawls or pawls Fit new pawls
almost without resistance themselves are worn
(crankshaft does not turn)
Starter rope is difficult to pull and Starter mechanism very dirty Thoroughly clean complete starter
rewinds very slowly mechanism
Exercise extreme caution while carrying out maintenance and repair work on the ignition system. The high
voltages which occur can cause serious or fatal injuries!
Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug,
temporary low of power and fit a new leg spring if necessary
4.3 Carburetor
Carburetor floods, engine stalls Inlet needle not sealing. Foreign Remove and clean or replace inlet
matter in valve seat or cone needle, clean fuel tank, pickup
damaged body and fuel line if necessary
Helical spring not located on nipple Remove inlet control lever and refit
of inlet control lever correctly
Inlet control lever too high (relative Set inlet control lever flush with
to design position) upper face of housing
Poor acceleration Idle jet too lean Turn low speed screw (L)
counterclockwise (richer) no further
than stop
Inlet control lever too low (relative Set inlet control lever flush with
to design position) upper face of housing
Engine will not idle, Throttle shutter opened too wide by Reset idle speed screw (LA), check
idle speed too high idle speed screw (LA), throttle throttle cable adjustment
cable adjustment incorrect
Engine stalls at idle speed Idle jet bores or ports blocked Clean jets and ports and blow clear
with compressed air
Idle jet too rich or too lean Set low speed screw (L) correctly
Setting of idle speed screw Set idle speed screw (LA) correctly
incorrect throttle shutter
completely closed
Small plastic disc in valve jet does Clean or renew valve jet
not close
Engine speed drops quickly under Air filter plugged Clean air filter
load low power
Leak in fuel line between tank and Seal or renew connections and fuel
fuel pump line
Setting of high speed screw (H) too Turn high speed screw (H)
rich clockwise (leaner), no further than
stop
4.4 Engine
Always check and, if necessary, repair the following parts before looking for faults on the engine:
Air filter
Fuel system
Carburetor
Ignition system
Engine does not start easily, stalls Check compression Check combustion chamber
at idle speed, but operates normally for excessive build-up of
at full throttle combustion deposits, check
condition of valves and valve
clearance
Engine does not deliver full power Piston rings worn or broken Install new piston rings
or runs erratically
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stick together. This has a
detrimental effect on the function of 2
the starter mechanism. In such a
case it is sufficient to apply a few : Take out the screws (arrows). Remove the starter cover with
drops of a standard solvent-based rewind starter, b 5.2
degreasant (containing no : Remove the starter cover with
chlorinated or halogenated rewind starter (1). : Ease the spring clip (1) off the
hydrocarbons) to the rewind spring. starter post starter post.
Install in the reverse sequence.
Carefully pull out the starter rope : Pull the pawls (2) out of the rope
several times and allow it to rewind rotor.
until its normal smooth action is
restored. Install in the reverse sequence.
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5 cm and hold the rope rotor
steady.
While still holding the rotor : Fit the washer and the pawls and
steady, take three turns of the engage the spring clip (1) in the
rope off the rotor. groove on the starter post (2).
Pull out the starter rope and then : Make sure the spring clip (1)
slowly let go of the rotor. engages the guide pegs (arrows)
on the pawls and points them
Remove the pawls, b 5.3 counterclockwise
1 Handle the spring clip with care.
The rewind starter may not function
properly if the spring clip is
deformed.
2
Tension the rewind spring, b 5.8
sequence.
1
2
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Inspect rope guide bushing in the : Pull the rope back into the rotor
starter cover for damage and so that the knot locates in the
replace if necessary, b 5.6 recess (arrow).
: Thread the starter rope through Tension the rewind spring, b 5.8
the bushing in the starter cover
from outside. Install all other parts in the reverse
sequence.
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: Thread the new rope through the : Thread the rope through the rope
top of the starter grip from above. rotor.
Pull the rope with knot into the Tie a simple overhand knot in the
starter grip. end of the rope.
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Remove the rope rotor, b 5.4
Use a suitable tool to pry the Fit the thrust sleeve (1), tapered
damaged bushing out of the end first, and screw on the hex
starter cover. nut.
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Place the new bushing in its seat : Use a suitable tool to carefully
in the starter cover. remove the rewind spring (1)
from the starter cover (2).
: Insert the screw spindle (1) of
installing tool 0000 890 2201 Remove any pieces of broken
through the bushing from inside spring from the starter cover,
the cover.
: With the spring housing facing
you, carefully clip the new rewind
spring into the starter cover,
making sure it is correctly
positioned (arrow).
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: Position the outer spring loop at : Place the special tool (1) with the Remove the starter cover with
distance a (30 mm) from the rewind spring on the spring rewind starter, b 5.2
edge of the special tool (1). housing.
: Make a loop in the starter rope.
The outer spring loop must line up
with the recess in the spring
housing (arrow).
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: Wind the rewind spring : Engage the rope in the notch
counterclockwise, from the (arrow) in the rotor. Grip the rope
outside inwards. close to the rotor and use it to
turn the rotor six full turns
To simplify this operation, place counterclockwise.
the assembly block
1108 893 4800 across the top of
the special tool.
5.9 Shroud
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spring as this will cause it to break.
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: Lay the unit on its back.
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6. Fuel System
6.1 Air Filter
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1 2 1 1
: Take out the screws (1). Coat new stop buffers (1) with
Press Fluid OH 723, b 13.
: Ease the engine in the direction
of the backplate until the stop Use pliers to grip end of stop
buffers (3) are clear of their seats buffer and pull it up until its
(arrows) and pull the shroud (2) groove (arrow) engages the
towards you at the same housing.
time.rauskommen.
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: Loosen the screws (arrows).
BR 500 only
1
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Remove the stop buffers (1). If the shroud is replaced, also : Remove the air filter (1).
bond a soundproofing liner (1) in
position. The filter element cannot be
washed and must be replaced if it is
Install all other parts in the reverse heavily loaded.
sequence.
1 1
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2 2
If the filter housing has to be : Pull off the carburetor (1). : Carefully pull out the hose (1).
replaced, remove the shroud and
rewind starter, b 5.9 : If necessary, remove the baffle : Carefully disconnect the hose (2)
(2). and pull it out of the housing bore
: Take out the screws (arrows) (arrow).
When installing, always fit a new
gasket between the carburetor and
filter housing.
1
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: Take out the screw (arrow). : Squeeze the tabs (arrows)
together and disengage the fuel
pump (1).
2
1 1
1
1
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: Pull the filter housing (1) off its : Carefully remove the hoses (1). : Pry the grommet (1) out to the
mounting (arrow). rear.
: Pull out the throttle cable (2).
Take the filter housing (1) out of Install in the reverse sequence.
the machine. Replace damaged hoses.
6.2 Carburetor
6.2.1 Leakage Test
Troubleshooting, b 4.3
1 2
In the event of trouble with the
carburetor or fuel supply system,
always check, clean or replace the
tank vent, b 6.5
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crankcase tester 1106 850 2905.
1 1 1 2
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2
: Clip the fuel pump in place so that : Disconnect the fuel hose (1) from : Connect hose (1) of tester
the longer stub (1) is at the the carburetor. 1106 850 2905 to the nipple (2).
bottom.
3 2 1
2
1
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1
: Close the vent screw (1) on the Remove the filter housing, b 6.1 Remove the carburetor, b 6.2.2
rubber bulb (2) and pump air into
the carburetor until the pressure : Disconnect the fuel hose (1). : Take out the screws (arrows).
gauge (3) shows a reading of
about 0.8 bar (80 kPa). : Disconnect the impulse hose (2). : Remove the end cover (1).
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2. Metering diaphragm is damaged,
replace if necessary, b 6.3.1 1
After completing the test, open : Disconnect nipple (1) from the : Remove the metering diaphragm
the vent screw (1) and pull the slotted pin (2) on the throttle and gasket (arrow) from the
hose off the carburetor. lever. carburetor body or end cover.
Push the fuel hose onto the Check flange for damage and
elbow connector. replace if necessary.
Install all other parts in the reverse Always install new gaskets.
sequence.
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Use a new gasket.
1
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: Place the gasket (1) on the : Place the end cover (1) in
carburetor body so that the hole position.
in the gasket lines up with the
bore in the carburetor body Make sure the bore in the end cover
(arrows). lines up with the hole in the
metering diaphragm (arrows).
3
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2
: Fit the inlet needle (1). : Take out the screws (arrows)
: Place the helical spring (2) in the : Remove the end cover (1).
bore.
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Make sure the helical spring locates
on the control levers nipple. 2
Check that the inlet control lever : Remove the spring (1). : Remove the pump cover (1).
moves freely.
: Remove the washer (2).
The upper edge of the inlet control
lever must be flush with the top of
the carburetor body.
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: Remove the gasket (1) with pump : Remove the gasket (1) with pump
diaphragm (2). diaphragm (2).
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and the inlet and outlet valves
eventually show signs of fatigue, i.e. 1
the diaphragm distorts and swells
and has to be replaced. : Fit the diaphragm (1) and Remove the carburetor, b 6.2.2
gasket (2) on the carburetor body
so that contours (arrow) match. Wear safety glasses.
Place the end cover on the : Take out the screw (1).
carburetor.
: Remove the throttle lever (2).
The pump diaphragm and gasket
are held in position by cast pegs on
1 the end cover.
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2 1
: Examine the fuel strainer (1) for : Carefully remove the spring (1).
contamination and damage. If
necessary, use a needle to pull it : Remove the sleeve (2).
out of the carburetor body and
clean or replace.
1
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1 2
Always cover the bore (arrow) with Install all other parts in the reverse
a finger to stop components sequence.
popping out.
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4 3 1 2
3
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Use a new screw and coat it with Check that the notch in the Standard setting
Loctite. throttle shutter lines up with the
bores (arrows) in the carburetor Do not remove the limiter caps to
: Fit the throttle shutter (1) and body. carry out the standard setting.
tighten it down moderately,
b 3.4 : Loosen the screw (1) slightly. With this carburetor it is only
possible to correct the setting of
Check that the stamped digits Center the throttle shutter so that the high speed screw (H) and low
(arrow) face up. it moves freely. speed screw (L) within fine limits.
Check that shutter still moves Turn the high speed screw (H)
freely. counterclockwise as far as stop.
Install all other parts in the reverse Turn the low speed screw (L)
sequence. counterclockwise as far as stop.
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screw is correct, poor
acceleration, idle speed too high
Idle setting is too lean. Turn the After removing the limiter caps it is
low speed screw (L) counter- necessary to carry out the basic
clockwise (no further than stop) setting.
until the engine runs and
accelerates smoothly. Screw both adjusting screws
down against their seats.
Idle setting is too rich. Turn the Open the high speed screw H (1)
low speed screw (L) clockwise 3 1/2 turns clockwise.
(no further than stop) until the
engine runs and accelerates Open the low speed screw L (2)
smoothly. 2 turns clockwise.
Check the standard setting. : Push the puller (1) If the air filter is dirty, install a new
5910 890 4501, with the open one do not clean.
Warm up the engine. side facing you, between the
limiter cap (2) and carburetor Check the spark arresting screen
Turn the high speed screw (H) body and pry the cap off. If the (if fitted) and clean or replace if
clockwise (leaner), but no further limiter cap is stuck on the screw, necessary.
than stop. turn the puller over so that its
open side faces the carburetor Warm up the engine.
If the setting is too lean, there is a body. Pry off the limiter cap.
risk of engine damage due to
insufficient lubrication and
overheating.
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2. Turn low speed screw (L) tank vent.
clockwise or counter-
clockwise to obtain Check function by performing
maximum engine speed. Do not re-stall used caps because pressure and vacuum tests on fuel
they may be damaged. Always tank via the fuel hoses.
If this speed is higher than install new limiter caps.
3,700 rpm, abort the procedure and Disconnect both hoses from the
start again with step 1. : Place the new limiter caps on the carburetor, b 6.2.2
adjusting screws (1+2) so that
3. Use the idle speed screw they are positioned against the Seal one of the two hoses with a
(LA) to set engine speed rich stop. suitable plug.
again to 3,300 rpm.
Connect the other hose to the
4. Set the engine speed to vacuum pump 0000 850 3501
2,500 rpm with the low and test fuel tank under vacuum.
speed screw (L).
a
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1
Equalization of pressure takes Remove the shroud with rewind The tab on the connector (arrow)
place via the tank vent (1). There starter, b 5.9 must locate in the fuel tanks recess.
must be no build-up of vacuum in
the tank. If the tank vent does not : Carefully pry the connector (1) Press home the connector as far
operate properly, replace it together with hoses and pickup body out as stop it must snap audibly into
with the O-ring. of its seat. position.
1 3 2
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Drain the fuel tank. Pull off the spark plug boot. : Connect spark plug boot to
terminal (1).
Remove the tank vent, b 6.5 Unscrew the spark plug.
: Attach the ground terminal (2) to
Remove the fuel hoses, b 6.6 : Screw compression tester the muffler.
5910 850 2000 (1) into the spark
: Take the screws (arrows) out of plug hole. : Set the spark gap to about 2 mm
the bottom of the backplate. with the adjusting knob (3).
The ZAT 3 ignition system tester
Remove the fuel tank. 5910 850 4520 must be fitted to
discharge the ignition voltage.
2
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1 1
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3
When using the ZAT 3, hold it only Check and adjust valve clearances : Take out the screw (1).
by the handle (4) or position it in a only when engine is cold.
safe place. Keep fingers or other Remove the sealing ring (arrow).
parts of body at least 1 cm away Remove the shroud with rewind
from the spark window (3), the high starter, b 5.9 Remove the valve cover (2) with
voltage connection (2), ground gasket.
connection (5) and the ground : Disconnect wires (1) and (2) from
terminal (1). the ignition module. Use combination wrench
4180 890 3400 to unscrew the
: Take the wires out of the air guide spark plug.
Crank the engine quickly with the shroud (arrow).
starter (min. 1,000 rpm).
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: Take out the screws (arrows) Rotate the crankshaft until the tip
(arrow) of the flywheel lines up
: Remove the air guide shroud (1). with the ignition module as
shown.
Observe rocker arms while rotating Remove the inner fan housing,
the fanwheel. If the valves are b 11.2
operated by the rocker arms in this
position (valve overlap), rotate the Take out the locking screw
crankshaft another turn until the 4282 890 2700.
valves are idle (ignition TDC). Turn
the crankshaft back and forth a little Remove the valve cover, b 7.2
to check again that the valves are
not operated in this position. Set the piston to ignition TDC,
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b 7.2
Adjusting valves
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2 Thoroughly clean the sealing
faces on the cylinder and cover.
: Insert feeler gauge : Remove the locknut (1).
4180 893 6400 (1) between Fit a new gasket.
rocker arm and valve stem.
1 452RA102 VA
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: Remove the rocker arm (1). Install in the reverse sequence. Remove the pushrods, b 7.3
Cam lobe on cam gear must point : Pull out the pin (1).
downward.
: Remove the cam followers (2)
Coat all parts with two-stroke and (3).
engine oil before installing.
Install in the reverse sequence.
Make sure the pushrod is properly
seated in the rocker arm and cam Coat all parts with two-stroke
follower. engine oil before installing.
1
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1 2 3 4
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Remove the cam followers, : Fit the cam gear so that the Remove cam gear cover, b 7.3
b 7.4 marks (2) and (3) and in
alignment with the notches (1) : Check free movement and
: Pull out the pin (1). and (4) in the cylinder. function of decompression
system lever (arrow).
: Remove the cam gear (2).
Lever must project about 2 mm
Install in the reverse sequence. from the cam.
2
1 1
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2 2
: Loosen the screws (1). : Remove the gasket (1). : Push the scoop (1) into place.
: Remove the scoop (2) to the left. Clean the sealing faces. : Tighten down the screws (2)
firmly.
Install in the reverse sequence.
Install all other parts in the reverse
Always install a new muffler gasket. sequence.
1
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1
1
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: Take out the screws (arrows) : Carefully fit the spark arresting
screen (1) in position.
: Remove the muffler (1).
Guide lug on spark arresting screen
must engage the scoop.
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based degreasant containing no impossible.
chlorinated or halogenated
hydrocarbons, b 13. Moreover, the transition from idle
Remove the shroud with rewind speed to part or full throttle is not
starter, b 5.9 Install in the reverse sequence. smooth.
: Unscrew the flywheel nut (1). After completing the tests, always
install a new muffler gasket.
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1
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The sealing plate must completely Oil seals tend to fail when subjected
fill the space between the screws. to a vacuum, i.e. the sealing lip lifts
2 away from the crankshaft during the
Set the piston to top dead center. piston's induction stroke because
there is no internal counterpressure.
Perform vacuum test, b 7.8.2
1 A test can be carried out with the
Perform pressure test, b 7.8.3 vacuum pump to detect this kind of
fault.
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1
3
1
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1 2
: Slide the sealing plate : Close the vent screw (1) on the
0000 855 8106 (1) between the pump.
muffler and cylinder exhaust port.
: Operate the lever (2) until the
Tighten the muffler mounting pressure gauge (3) indicates a
screws moderately. vacuum of 0.5 bar.
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appear if a leak exists.
After finishing the test, open the 1
vent screw and disconnect the If necessary, repeat the pressure
hose. Always carry out the vacuum test, test.
b 7.8.2, before this pressure
Carry out pressure test, b 7.8.3 test. After finishing the test, open the
vent screw and disconnect the
: Connect pressure hose (1) of hose.
tester 1106 850 2905 to nipple
(arrow) on test flange. Remove the test flange.
3 2
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7.9 Crankshaft
7.9.1 Oil Seals
Starter side
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punch.
452RA118 VA
b 13.
2 1
Install in the reverse sequence.
: Use the press sleeve (2) : Slip the installing sleeve (1)
1108 893 2405 to press home the 1118 893 4602 over the end of
oil seal (1) until it is flush with the the crankshaft.
crankcase.
1 1
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1
Thinly coat the outside diameter Remove the inner fan housing, : Fit the engine pan (1) in position.
of the oil seal with sealant, b 13. b 11.2
: Tighten down the screws
Slip the oil seal (1) over the : Take out the screws (arrows). (arrows) in a crosswise pattern.
crankshaft and up against the Observe sequence and
crankcase. : Lift away the engine pan (1). tightening torque, b 3.4
1
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1
: Lift the crankshaft (1) and pull the Apply thin coating of sealant to
piston out of the cylinder at the outer diameter of oil seals, b 13.
same time.
Carefully fit piston in the cylinder.
: Pull off the oil seals (2 and 3).
Install the crankshaft with new oil
Inspect cylinder running face for seals in the cylinder.
signs of damage and serious
scores. Install new cylinder with Fit lower half of crankcase,
1 2
piston if necessary, b 7.9.7 b 7.9.2
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2 1
: Use the assembly drift : Attach the snap ring (1) to the
1108 893 4700 to push the piston magnet (2) so that the snap ring
pin through the piston and gap is on the flat side of the tools
connecting rod. shank.
2 1
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: Inspect piston rings and replace if Use installing tool 5910 890 2212 : Push the large slotted diameter of
necessary, b 7.9.5 with sleeve 5910 893 1704 to fit the the sleeve over the magnet and
snap ring, b 12. snap ring. Position the sleeve so
Install in the reverse sequence. that the inner pin (1) points
: Remove the sleeve from the tool. towards the flat face (2) of the
tools shank.
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: Stand the installing tool, sleeve : Apply the installing tool to the Remove the piston, b 7.9.4
downward, on a flat surface piston boss, hold the piston
(wooden board) and press steady, center the tool shank Remove rings from piston.
vertically downwards until the exactly and press home until the
sleeve butts against the tools snap ring slips into the groove. Use a piece of old piston ring to
shoulder. scrape the grooves (arrows)
clean.
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pushrods, b 7.3
1
3
2
4
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3 1 2 3
: Check valve heads (1 and 2) for : Loosen the clamp (3) and remove
damage. the manifold (2) with flange (1).
: Check valve springs (3) for : Pull off the impulse hose (4).
damage.
8. Ignition System
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properly seated.
8.1 Ignition Module 8.2 Ignition Timing 8.3 Testing the Ignition
Module
Ignition timing is fixed and cannot To test the ignition module, use
be adjusted during repair or either the ZAT 4 ignition system
1 servicing work. tester 5910 850 4503 or the ZAT 3
3
2 ignition system tester
Since there is no mechanical wear 5910 850 4520.
in these systems, ignition timing
cannot get out of adjustment. The ignition test refers only to a
spark test, not to ignition timing.
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The ignition module accommodates
all the components required to
control ignition timing. There are
three electrical connections on the
coil body:
: Screw-mounted connector
tag (1) for the ground wire
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A new ignition module must be
installed if no ignition spark is 1 2 3
obtained (after checking that wiring
and stop switch are in good Using the ZAT 4 ignition tester
condition). 5910 850 4503
Warning!
The engine may start and
accelerate during the test.
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3
4
When using the ZAT 3, hold it only Remove the shroud with rewind
by the handle (4) or position it in a starter, b 5.9
safe place. Keep fingers and other
parts of body at least 1 cm away : Disconnect the ground wire (1).
from the spark window (3), the high
voltage connection (2), ground : Disconnect the short circuit
connection (5) and the ground wire (2).
terminal (1).
: Take out the screw (3) with
The high voltages that occur can washer.
cause an electric shock.
: Remove the screw (4) with
ZAT 3 Crank the engine quickly with the connector tag.
5910 850 4520 rewind starter (min. 1,000 rpm)
1 and check spark in the testers Remove the washers from
window (3). between the ignition module and
cylinder.
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Warning!
2 3 4 The engine may start and Check the ignition module and wires
accelerate during the test. for damage and replace as
Using ZAT 3 ignition system necessary.
tester 5910 850 4520 If a spark is visible, the ignition
system is in order. Install in the reverse sequence.
Before starting the test, install a
new spark plug in the cylinder If no spark is visible in the
and tighten it down firmly, b 3.4 window (3), check the ignition
system with the aid of the
: Pull the boot off the spark plug troubleshooting chart, b 8.7.
and connect it to terminal (2).
1 3 4 5
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6 2
: Fit screw (6) with ignition module : Rotate the flywheel until the Remove the shroud with rewind
(4), washer (2) and washer (5) in raised portion (arrow) is in line starter, b 5.2
position. with the ignition module.
Pull the boot off the spark plug.
: Fit screw (1) with ignition module
(4), connector tag (3) and : Use suitable pliers to pull the leg
washer (5) in position. spring out of the spark plug boot.
Pay attention to correct installed Unhook the leg spring from the
positions of the washers (5) and the ignition lead.
connector tag (3).
Slide the spark plug boot back a
Install all other parts in the reverse 2 little in the direction of the ignition
sequence. module
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: Check that the wires are correctly : Pinch the hook of the leg spring
positioned in the air guide into the center of the lead, i.e.
shroud (arrow). about 15 mm from the end of the
lead.
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: Pull the lead back into the boot so If the spark plug, ignition lead and
that the leg spring locates spark plug boot are in order, test the
properly inside it. resistance of the short circuit wire,
ground wire and contact spring.
Install in the reverse sequence.
Remove the shroud with rewind
starter, b 5.9
Powerful yes
spark?
no
Check flywheel:
Pole shoes have turned blue?
Install new flywheel
2 3
2 3
Check operation
of setting lever
Short circuit wire chafed?
Contact gap (contact springs)
If necessary, install new ignition lead
and/or contact springs
Re-connect short circuit wire
Powerful yes
spark?
no
Install new
ignition module
yes Engine no
runs
1
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3
: Take out the screw (arrow). : Swing the lever (1) sideways and Remove the interlock lever,
remove it upwards. b 9.1
Remove the control handle.
If necessary, take out the grub : Remove the torsion spring (1).
screw (arrow).
: Take out the screw (2) and
remove the cam (3).
1
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1 1
: Take out the screws (arrows) : Remove the interlock lever. : Remove the setting lever (1).
Remove the outer handle Install in the reverse sequence. Install in the reverse sequence.
molding (1).
Adjust the throttle cable, b 9.3.2
1
3
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: Remove the torsion spring (1). Make sure the teeth of the setting
lever mesh with those of the cam.
: Remove the throttle trigger (2)
with lever (3).
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ignition module, b 8.4
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: Carefully push the switch onto : Turn the grub screw (arrow) with
the fixing pins (arrows). a suitable tool until the throttle
lever butts against the carburetor
Adjust the throttle cable, b 9.3.2 cover.
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Take the powerhead off the Remove the shroud with rewind
backplate, b 10.2 starter, b 5.9
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11. Fan
11.1 Outer Fan Housing
1
1
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1 3 2
: Push the locking tabs (arrows) : Unclip the throttle cable (1) with : Take out the screws (arrows).
down and lift the protective grommet (3) from the hose
screen (1) upwards and away. clamp (2). : Remove the outer fan
housing (1).
Install in the reverse sequence. : Take out the screw (arrow).
: Remove the elbow (2).
: Remove the hose clamp (2) and
pleated hose. Install in the reverse sequence.
1 1
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Remove the antistatic wire,
b 11.4
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: Take out the screws (arrows) : When installing, check that the
groove in the manifold is properly
Remove the engine. seated in the fan housing (arrow).
Install in the reverse sequence. Check that the throttle cable and
fuel hoses are correctly
Do not lubricate the thread of the positioned.
fanwheel.
Install all other parts in the reverse
sequence.
1
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Remove the fanwheel, b 11.3 The machine may be operated only
with a properly installed antistatic
: Take out the screw (1). wire.
: Remove the antistatic wire (2). : Check that the hook on the
antistatic wire is always
Install in the reverse sequence. connected to the eye (arrow).
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: When installing, make sure the : Make sure the sleeve on the
crimping (arrow) on the cable lug antistatic wire is always clipped
faces outwards. into the retainer (arrow).
Install all other parts in the reverse Install all other parts in the reverse
sequence. sequence.
1 Compression tester 5910 850 2000 Testing valves and piston rings for
leaks
2 Locking screw 4282 890 2700 Blocking the crankshaft
3 Installing tool 5910 890 2212 Fitting snap ring in piston
with sleeve 5910 893 1704
4 Carburetor and crankcase tester 1106 850 2905 Testing crankcase and carburetor for
leaks
5 Hose 1110 141 8600 Testing carburetor for leaks
6 Nipple 0000 855 9200 Testing carburetor for leaks
7 Vacuum pump 0000 850 3501 Testing crankcase for leaks
8 Feeler gauge 4180 893 6400 Adjusting valve clearances
9 Socket, DIN 3124, 13 mm 5910 893 5608 Flywheel nut
10 Puller 1116 893 0800 Removing flywheel
11 Torque wrench 5910 890 0311 6 to 80 Nm; torque wrench
5910 890 0312 with optical/acoustic
signal may be used as an alternative
12 Torque wrench 5910 890 0301 0.5 to 18 Nm; torque wrench
5910 890 0302 with optical/acoustic
signal may be used as an alternative
13 Socket, 17 mm 5910 893 5610 Releasing fanwheel
14 Puller 5910 890 4400 Universal puller
15 Jaws (profile # 3.1) Removing oil seals
16 Installing sleeve 1118 893 4602 Installing oil seal
17 Press sleeve 1108 893 2405 Installing oil seal
18 Combination wrench 4180 890 3400 Spark plug
19 Assembly drift 1108 893 4700 Removing and installing piston pin
20 Setting gauge 4118 890 6401 Adjusting air gap between ignition
module and flywheel
21 Test flange 1119 850 4201 Leakage test
22 Bushing 0000 963 1008 For use with test flanges
1106 850 4201 and 1119 850 4201
23 Sealing plate 0000 855 8106 Sealing exhaust port
24 Ignition tester, ZAT 3 5910 890 4520 Testing the ignition system
25 Ignition tester, ZAT 4 5910 850 4503 Testing the ignition system
26 Puller 5910 890 4501 Removing limiter caps
27 Screwdriver, T 27 x 200 5910 890 2415
1 Lubricating grease (225 g tube) 0781 120 1111 Sliding and pivot points
2 Press Fluid OH 723 0781 957 9000 Rubber elements of AV system
3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor,
rewind spring in rope rotor
4 Dirko sealant (100 g tube) 0783 830 2120 Crankcase sealing faces
5 Standard commercial solvent- Cleaning crankshaft stub
based degreasant containing no
chlorinated or halogenated
hydrocarbons
6 Loctite 270 (50 ml bottle) 0786 111 1109 High-strength threadlocking adhesive
englisch / english
0455 452 0123. M7. C5. T. Printed in Germany