Professional Documents
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232RA001 VA
2 and can be explosive in certain
Special servicing tools mentioned conditions.
in the descriptions are listed in the
last chapter of this manual. Use Improper handling may result in
the part numbers to identify the Servicing and repairs of power burns or other serious injuries.
tools in the "STIHL Special Tools" tools with shaft (FS, FC, HL) are
manual. The manual lists all made considerably easier if the Warning! Do not smoke or bring
special servicing tools currently machine is mounted on assembly any fire or flame near the fuel. All
available from STIHL. stand (2) 5910 890 3100 with the work with fuel must be performed
aid of clamp (1) 5910 890 8800. outdoors only. Spilled fuel must
Symbols are included in the text be wiped away immediately.
and pictures for greater clarity. Secure the clamp to the assembly
The meanings are as follows: stand with two washers and two
M8 nuts. The complete unit can
In the descriptions: then be swivelled to the best
position for the ongoing repair,
• = Action to be taken as shown in thus leaving both hands free.
the illustration (above the text)
Always use original STIHL
- = Action to be taken that is not replacement parts.
shown in the illustration They can be identified by the
(above the text) STIHL part number,
the T logo and the
In the illustrations: STIHL parts symbol .
The symbol may appear alone on
= Pointer small parts.
= Direction of movement
DG and P (Plastoform) screws are used in polymer and lightmetal components. These screws form a perma-
nent 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, provided the specified tightening torque is observed.
For this reason it is essential to use a torque wrench.
– Place the DG or P screw in the hole and turn 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.
Note: Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm
DG screws max. 500 rpm
Important! Do not confuse screws with and without underhead locking teeth.
Troubleshooting chart –
see "Standard Repairs,
Troubleshooting" handbook.
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- Remove housing parts, muffler,
ignition module and spacer
flange – see handbook
"Components, Basic • Unscrew cylinder base screws.
Engine 4140".
- Clamp puller in a vice.
- Unscrew the spark plug.
- Pull cylinder off piston.
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1 1
3
• Fit jaws (1) 0000 893 3700 with • Drive piston pin out of piston with
No. 2 profile on puller (2) a 7 mm drift.
5910 890 4400.
Note: If the piston pin is stuck,
• Fit screw bush (3) 1108 893 tap the end of the drift lightly with
4500 on spindle. a hammer if necessary. Hold the
piston steady during this process,
so that jolts are not transmitted to
the connecting rod.
• To ensure that the crankcase - Take snap ring (B8x0.7) out of - Inspect piston rings and replace
and engine pan do not come groove on starter cup side. if necessary, see 4.3.
apart when the cylinder is
removed, hold both parts
together with the puller.
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Thoroughly clean gasket seating Note: One (FS 45) or two
surface. (FS 45, 55) piston ring(s) is/are
used depending on the model in
- Lubricate needle cage in question.
connecting rod with oil.
• Position the piston rings so that
the radii at the ring gap meet at
• To simplify assembly, heat the
the fixing pin in the piston groove
piston and slip it over the
when the rings are compressed.
connecting rod.
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• Fit new cylinder gasket. • Use clamping strap (1)
0000 893 2600 to compress
piston ring around piston.
2
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• Fit the piston pin in position • Lubricate piston and piston rings
and use assembly drift (1) with oil. Rest piston (1) on
1114 893 4700 to push it as far wooden assembly block (2)
as possible against the hookless 1108 893 4800.
snap ring (the pin slides home
easily if the piston is hot).
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removed to ensure that residues
cannot fall into the crankcase
when installing the piston rings
and cleaning their grooves.
• Slide cylinder over piston – - Remove cylinder, see 4.1.
the clamping strap is pushed - Remove rings from piston.
downward as the piston rings • Remove flywheel (1),
slip into the cylinder. starter cup (2) and piston (3).
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• Use a piece of old piston ring to • Pull engine pan off crankcase.
scrape the grooves clean.
1 1
1
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• Use socket (1) 0812 542 2104 to • Install the new piston rings in the • Lift crankshaft out of crankcase.
tighten down cylinder base grooves so that the radii (1) face
screws to 9.0 Nm. the fixing pin (2). - Inspect ball bearings and oil
seals and replace if necessary.
Assemble all other parts in the - Install the piston, see 4.2.
reverse sequence.
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2
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- Grease sealing lips of oil seals, • Apply a thin bead of sealant to
see 10. mating face of engine pan,
see 10.
• Slide the oil seals over the ends
of the crankshaft, open side Important! Follow the
facing the ball bearings. manufacturer’s instructions.
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1 2 2 1 1 2
• Pull off the oil seals (1) and ball - Thoroughly clean sealing faces
bearings (2). on crankcase and engine pan to
remove all traces of sealant.
- Remove washers.
Starter side:
1 1
- Remove starter cup, see 8.2.
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- Remove housing parts, see
handbook "Components,
Basic Engine 4140".
• Slip assembly sleeve (1) Clutch side:
1129 893 4600 over the
crankshaft stub. - Remove flywheel, see 7.2.
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• Apply puller (1) 5910 890 4400 • Slide oil seal (1) over the - Grease sealing lips of oil seal,
(with No. 3.1 jaws crankshaft stub, open side facing see 10.
0000 893 3706). the crankcase.
see 10.
1
• Press fully home with press Leaks are usually caused by - Remove shroud, carburetor and
sleeve (2) 1120 893 2400. defective oil seals or gaskets and starter cover, see handbook
cracks in castings of the spacer "Machine components, 4140".
- Fit flywheel. flange. Such faults allow
supplementary air to enter the - Set piston to top dead centre
engine and thus upset the fuel-air (T.D.C.). This can be checked
mixture. through the inlet port.
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• Fit a new gasket on spacer
flange.
2
2
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0,4 0,6
0,2
0,8
0 1,0
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- Slacken muffler mounting screws - Carry out preparations, see 6.1. • If the indicated pressure drops,
half-way. the leak must be located and the
• Connect pressure hose of tester faulty part replaced.
• Slide sealing plate (1) 1106 850 2905 to nipple on test
0000 855 8106 between gasket flange. Note: To find the leak, coat
and cylinder exhaust port. the suspect area with oil and
Retighten screws moderately. pressurize the crankcase again.
Bubbles will appear if a leak exists.
Note: The sealing plate must
completely fill the space between - Repeat the pressure test.
the screws.
- Carry out vacuum test, see 6.3.
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- Remove test flange.
Oil seals tend to fail when Note: If the vacuum reading Warning! Exercise extreme
subjected to a vacuum, i.e. the remains constant or rises to no caution when carrying out
sealing lip lifts away from the more than 0.3 bar (3 kPa) within maintenance and repair work or
crankshaft during the piston’s 20 seconds, it may be assumed troubleshooting on the ignition
induction stroke because there that the oil seals are in good system. The high voltages which
is no internal counterpressure. condition. occur can cause serious or even
However, if the pressure continues fatal accidents!
An additional test can be carried to rise (reduced vacuum in the
out with the vacuum pump to crankcase), the oil seals must be Troubleshooting on the ignition
detect this kind of fault. replaced. system should always begin with
the spark plug. See "Standard
- Carry out preparations, see 6.1. - After testing, open vent screw Repairs, Troubleshooting"
and disconnect hose. handbook.
2
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• Connect suction hose of vacuum Note: The electronic
pump 0000 850 3501 to nipple (breakerless) ignition system
on test flange. basically consists of an ignition
module (1) and flywheel (2).
2
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still show the system to be in order
although timing is outside the
1 permissible tolerance. This will
impair engine starting and running
The ignition module accommo- behaviour. - Remove shroud or relevant
dates all the components required housing part, see handbook
to control ignition timing. "Machine components 4140".
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• Undo screws.
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hydrocarbons, see 10.
- Fit flywheel.
Note: The ignition lead is Removing the flywheel: Note: Check position of slot.
moulded to the ignition module.
- Remove clutch, - Install clutch,
- Place ignition module in position see handbook "Components, see handbook "Components,
and insert screws, but do not Basic Engine 4140". Basic engine 4140".
tighten them down yet.
• Lightly tap the end of the
• Secure connector tag (1) for crankshaft stub with a rubber
ground wire with upper screw. mallet to free the flywheel.
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setting gauge and tighten down
the mounting screws to a torque
of 4.5 Nm.
Assemble all other parts in the - Pull locking strip out of cylinder.
reverse sequence.
- Fit spark plug and torque down
to 20 Nm.
1
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may thicken and cause the spring
windings to stick together. This
has a detrimental effect on the
function of the starter mechanism.
In such a case, it is sufficient to - Remove starter cover, see
apply a few drops of paraffin handbook "Components,
(kerosine) to the rewind spring. Basic Engine 4140".
spirit.
Remarks:
1) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400.
2) Setting gauge 1111 890 6400 can be used instead.
3) Always use torque wrench to tighten DG/P screws.
4) Wrench includes visual/acoustic signal.
5) May only be used on GD/P screws for releasing.
Safety glasses
STIHL ElastoStart
(starter rope with grip) 0000 190 3400
STIHL gear lubricant for brushcutters
- tube 80 g 0781 120 1117
- tube 225 g 0781 120 1118
STIHL gear lubricant for
hedge trimmers
- tube 80 g 0781 120 1109
- tube 225 g 0781 120 1110