STIH)

STIHL Series 4140 Components

BG, SH 2005-01
Contents

1. Introduction 2 8. Throttle Control 18 10. Blower and Vacuum

Attachment 35
8.1 Throttle Trigger 18
2. Safety Precautions 3 8.2 Setting Lever 10.1 Fanwheel 35
(BG 85, SH 85 only) 19 10.2 Protective Screen
8.3 Stop Switch 19 (all except BG 45) 35
3. Specifications 4 8.3.1 Version up to 2001 19 10.3 Protective Screen
8.3.2 Version from 2001 20 (BG 45 only) 35
3.1 Fuel System 4 8.4 Short Circuit Wire/ 10.4 Blower Tube
3.2 Tightening Torques 5 Ground Wire 20 (BG only) 36
8.5 Throttle Cable 21 10.5 Suction Tube
8.6 Throttle Rod 21 (SH only) 36
4. Troubleshooting 7 10.6 Elbow (SH only) 36

4.1 Rewind Starter 7 9. Fuel System 21

4.2 Fuel System 8 11. Special Servicing
4.3 Engine 10 9.1 Air Filter 21 Tools 37
9.1.1 Removing and
Installing 22
5. Housing 11 9.1.2 Choke Shutter 22 12. Servicing Aids 38
9.2 Carburetor 23
5.1 Handle Molding 11 9.2.1 Leakage Test 23
5.2 Handle and Feet 9.2.2 Removing and
(BG 85, SH 85) 11 Installing 24
9.2.3 Spacer Flange 24
9.3 Servicing
6. Engine 12 the Carburetor 25
9.3.1 Manual Fuel Pump
6.1 Removing with Oval End Cover 25
and Installing 12 9.3.2 Manual Fuel Pump
6.2 Muffler/Spark with Square
Arresting Screen 13 End Cover 26
6.2.1 Without Cat 13 9.3.3 Metering Diaphragm 26
6.2.2 Muffler with 9.3.4 Inlet Needle 27
Catalytic Converter 13 9.3.5 Fixed Jet 28
9.3.6 Pump Diaphragm
and Fuel Strainer 28
7. Rewind Starter 14 9.4 Adjusting
the Carburetor 29
7.1 General 14 9.4.1 Carburetor
7.2 Removing and with LD Screw 29
Installing 14 9.4.2 User Adjustment of
7.3 Starter Cup 15 Carburetor with H, L
7.4 Rope Rotor 15 and LA Screws 29
7.5 Replacing the 9.4.3 Basic Setting on
Rewind Spring 16 Carburetor with H, L
7.5.1 Tensioning the and LA Srews 31
Rewind Spring 17 9.5 Tank Vent 32
7.6 Starter Rope 17 9.5.1 General 32
7.7 Pawl 18 9.5.2 Replacing 33
9.6 Fuel Tank 33
9.6.1 General 33
9.6.2 Pickup Body 34
9.6.3 Fuel Hoses 34

q
© ANDREAS STIHL AG & Co. KG, 2005

Series 4140 Components BG, SH 1

1. Introduction
This service manual contains
detailed descriptions of all typical
repair and servicing procedures for
models BG 45, 46, 55, 65, 85,
SH 55, 85, which are based on the
series 4140 powerhead.
You will find detailed descriptions of
procedures for servicing and
repairing engine components in the
service manual for the “Series 4140
Powerhead“.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual
components and assemblies.
Refer to the latest edition of the
relevant parts list to check the part
numbers of any replacement parts.
A fault on the machine may have
several causes. To help locate the
fault, consult the chapter on
"Troubleshooting" in this manual
and the "STIHL Service Training
System" for all assemblies.
Refer to the "Technical Information"
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list until a
revised edition is issued.
2 Series 4140 Components BG, SH
The special servicing tools Always use original STIHL
mentioned in the descriptions are replacement parts.
listed in the chapter "Special They can be identified by the
Servicing Tools" of this manual. STIHL part number,
Use the part numbers to identify the the STIH) logo and the
tools in the "STIHL Special Tools” STIHL parts symbol (
manual. The manual lists all special This symbol may appear alone on
servicing tools currently available small parts.
from STIHL.
Symbols are included in the text and
pictures for greater clarity.
The meanings are as follows:
In the descriptions:
: = Action to be taken as
shown in the illustration
(above the text)
– = Action to be taken that is
not shown in the illustration
(above the text)
b 4.2
Reference to another chapter, i.e.
chapter 4.2 in this example.
In the illustrations:
A Pointer
a Direction of movement
Service manuals and technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed to third parties.
2. Safety Precautions

If the engine is started up in the

course of repairs or maintenance
work, observe all local and country-
specific safety regulations as well
as the safety precautions and
warnings in the instruction manual.

Gasoline is an extremely flammable

fuel and can be explosive in certain
conditions.

Improper handling may result in

burns or other serious injuries.

Warning!
Do not bring any fire, flame, spark or
other source of heat near the fuel.
All work with fuel must be performed
outdoors only. Spilled fuel must be
wiped away immediately.

Series 4140 Components BG, SH 3

3. Specifications

3.1 Fuel System Carburetor: Diaphragm carburetor

Carburetor leakage test
at gauge pressure: 0.8 bar (8 kPa)
Operation of tank vent
at gauge pressure: 0.3 bar (3 kPa)
under vacuum: 0.05 bar (0.5 kPa)
Fuel: see instruction manual
Octane number: min. 90 RON
Fuel mixture: Regular brand-name gasoline and
STIHL 50:1 two-stroke engine oil or
brand-name two-stroke engine oil
Mix ratio: 50:1 with STIHL 50:1 two-stroke
engine oil

Fuel mix for units with catalytic

converter: Use only STIHL 50:1 two-
stroke engine oil with unleaded
gasoline.

4 Series 4140 Components BG, SH

3.2 Tightening Torques

DG and P (Plastoform) screws are used in polymer and light metal 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.

Fastener Thread size For component Torque Remarks

Nm

Screw IS-DG5x60 Muffler/cylinder 9.0

Screw IS-DG5x24 Muffler/cylinder (version with catalytic 9.0
converter)
M14x7 Stub/muffler (version with spark 10.0
arresting screen in muffler)
Screw IS-DG5x24 Spacer flange/cylinder 6.0 1)
Collar screw P6x15/49 Collar screw/inner blower housing 4.0 2)
Screw IS-DG5x24 Inner blower housing/crankcase 8.0
Screw IS-DG5x24 Inner blower housing/engine pan 8.0
Screw IS-P6x26.5 Outer/inner blower housings 5.0
Nut M8x1LH-06 Fanwheel/crankshaft 17.0
(SH with shredder blade)
Screw IS-P6x19 Handle/inner blower housing 5.0 3)
Screw IS-P6x19 Handle molding/inner blower housing 4.0 4)
Screw IS-P6x19 Fan housing/inner blower housing 6.0
Screw IS-DG5x20Z Fan housing/spiral housing 6.0
Screw IS-DG5x24 Spiral housing/crankcase 6.0
Screw IS-DG5x24 Spiral housing/engine pan 6.0
Screw IS-P6x19 Protective screen/outer blower housing 5.0 5)
M14x1.25 Spark plug 20.0

Remarks:

1) with binding head

2) SH 55, 85 only
3) BG 85, SH 85 only
4) BG 65, 85, SH 85 only
5) BG 45 only

Series 4140 Components BG, SH 5

Use the following procedure when refitting a DG or P screw in an existing thread:

– 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.

Power screwdriver settings for Plastoform screws max. 600 rpm

polymer:
DG screws max. 500 rpm

Important:
Do not mix up screws with and without binding head

6 Series 4140 Components BG, SH

4. Troubleshooting
4.1 Rewind Starter
Condition Cause
Starter rope broken Rope pulled out too vigorously as
far as stop or over edge, i.e. not
vertically
Normal wear
Rewind spring broken Spring overtensioned – no reserve
when rope is fully extended
Very dirty or corroded
Starter rope can be pulled out Guide peg on pawl or pawl itself
almost without resistance is worn
(crankshaft does not turn)
Spring clip fatigued
Starter rope is difficult to pull and Starter mechanism very dirty
rewinds very slowly (dusty conditions)
Lubricating oil on rewind spring
becomes viscous at very low
outside temperatures (spring
windings stick together)
Series 4140 Components BG, SH
Remedy
Fit new starter rope
Fit new starter rope
Fit new rewind spring
Fit new rewind spring
Fit new pawl
Fit new spring clip
Thoroughly clean complete starter
mechanism
Coat rewind spring with a standard
solvent-based degreasant
(containing no chlorinated or
halogenated hydrocarbons). Then
pull rope carefully as often as
necessary until normal action is
restored
7
4.2 Fuel System

Condition Cause Remedy

Engine stalls at idle speed Idle jet bores or ports blocked Clean jet bores and ports and blow
clear with compressed air

Idle jet too rich or too lean Reset low speed screw (L) correctly

Setting of idle speed screw (LA) Reset idle speed screw (LA)
incorrect – throttle shutter correctly
completely closed

Engine speed drops quickly under Air filter plugged Clean the air filter or replace if
load – low power necessary

Tank vent faulty Fit new tank vent

Leak in fuel line between tank and Seal or renew connections and fuel
fuel pump line

Pump diaphragm damaged or Fit new pump diaphragm

fatigued

Main jet bores or ports blocked Clean the bores and ports

Fuel pickup body dirty Install new pickup body

Setting of high speed screw (H) too Reset high speed screw (H)
rich correctly

Throttle shutter not opened fully Check linkage

8 Series 4140 Components BG, SH

Condition Cause Remedy

Poor acceleration Idle jet too lean Turn low speed screw (L) counter-
clockwise (richer), no further than
stop

Main jet too lean Turn high speed screw (H) counter-
clockwise (richer), no further than
stop

Inlet control lever too low Set inlet control lever flush with top
(relative to correct installed of carburetor body
position)

Inlet needle sticking to valve seat Remove inlet needle, clean and
refit

Connecting bore to atmosphere Clean the bore

blocked

Diaphragm gasket leaking Fit new diaphragm gasket

Metering diaphragm damaged or Fit new metering diaphragm

shrunk

Engine will not idle – Throttle shutter opened too wide by Reset idle speed screw (LA)
idle speed too high idle speed screw (LA) correctly

Carburetor floods, Inlet needle not sealing. Foreign Remove and clean or replace inlet
engine stalls matter in valve seat or cone needle, clean fuel tank, pickup
damaged body and fuel line if necessary

Inlet control lever sticking on Free off inlet control lever

spindle

Helical spring not located on nipple Remove inlet control lever and refit
of inlet control lever correctly

Perforated disc on diaphragm is Fit new metering diaphragm

deformed and presses constantly
against inlet control lever

Inlet control lever too low Fit new inlet control lever
(relative to correct installed
position)

Series 4140 Components BG, SH 9

4.3 Engine

Always check and, if necessary,

repair the following parts before
looking for faults on the engine:

– Air filter
– Fuel system
– Carburetor
– Ignition system1)

Condition Cause Remedy

Engine does not start easily, stalls Oil seals in crankcase faulty Install new oil seals 1)
at idle speed, but operates normally
at full throttle

Crankcase leaking / damaged Seal / replace the crankcase 1)

(cracks)

Muffler leaking Seal / replace the muffler

Engine does not deliver full power Piston rings worn or broken Install new piston rings 1)
or runs erratically

Muffler / spark arresting screen Clean muffler (inlet and

carbonized exhaust openings), replace
spark arresting screen

Air filter element dirty Fit new air filter element

Fuel / impulse line kinked or Fit new lines or position

cracked without kinks

Engine overheating Insufficient cylinder cooling. Thoroughly clean all cooling air
Air inlets in fan housing passages and cooling fins
blocked or cooling fins on
cylinder very dirty

1)
see "Series 4140 Powerhead" service manual

10 Series 4140 Components BG, SH

5. Housing 5.2 Handle and Feet
5.1 Handle Molding (BG 85, SH 85)

Remove fan housing with rewind

starter, b 7.2 2

– Remove the spark plug.

1

932RA172 VA

932RA262 VA
: If necessary, replace the setting : Take out the screws (arrows).
lever (1), b 8.2
– Remove the handle.
: If necessary, remove the grip
molding (2) as follows:

2 1 1

1
1
932RA170 VA

932RA261 VA

932RA263 VA
1

BG 45, 55, SH 55 only
: Take out the screws (1) and
remove the handle molding (2).
: Pull the grip molding (1) out of the : Pull the feet (1) upwards and out
guides (arrows) and lift it away. of the handle.
Install in the reverse sequence. Reassemble in the reverse
sequence.

2 1

1
932RA171 VA

BG 65, 85, SH 85 only

: Take out the screws (1) and

remove the handle molding (2).

Note:
BG 65 has no setting lever.

Series 4140 Components BG, SH 11

6. Engine
6.1 Removing and Installing

– Remove fan housing with rewind

starter, b 7.2
2
– Remove the fanwheel, b 10.1
1
– Remove the filter housing,
b 9.1

932RA175 VA

932RA176 VA
– Remove the handle molding, b
5.1

: On machines with a throttle : Remove the engine.

cable, disconnect the throttle
cable (1) from slotted pin (2) on
the throttle lever and push the
throttle cable out of the tensioner
(arrow). If necessary, remove the
carburetor first. Avoid kinking the
throttle cable in this process.

3 – On machines with a throttle rod,

remove the throttle rod, b 8.6
1
2

932RA177 VA
932RA173 VA

: Disconnect the short circuit Install in the reverse sequence.

wire (1) and ground wire (2) from Observe correct tightening torques,
the ignition module. b 3.2.

: Remove the retainers (3). : When installing the engine in the

inner fan housing, check that the
gasket (arrow) is in front of the
inner fan housing.

2
1
932RA174 VA

932RA092 VA

: Take engine mounting screws

: Pull the fuel hoses (1 and 2) off (arrows) out of inner fan housing.
the elbow connectors on the
carburetor.

12 Series 4140 Components BG, SH

6.2 Muffler/Spark Arresting 6.2.2 Muffler with Catalytic
Screen Converter
6.2.1 Without Cat
Troubleshooting, b 4.3 Install in the reverse sequence. Troubleshooting, b 4.3

– Remove the fan housing with
rewind starter, b 7.2
– Clean the sealing faces before
installation.
– Install a new exhaust gasket.
– Apply sealant to the underside of
the screw head, b 12.
– Tighten down the screws firmly,
b 3.2
The catalytic converter integrated in
the muffler is a device that helps
reduce the amount of noxious
emissions in the exhaust gas by
initiating chemical reactions without
being consumed in the process.
The catalytic converter is
maintenance-free. Never attempt to
carry out repairs on the catalytic
converter.

1 1

932RA207 VA
932RA205 VA

932RA208 VA
1

Muffler Spark arresting screen Muffler

: Take out the screws (1). : On machines with a removable – Remove the fan housing with the
stub (1) (with and without spark rewind starter, b 7.2
arresting screen), use a 15 mm
wrench to unscrew the stub. : Take the screws (1) out of the
muffler.
– Clean the spark arresting screen
or install a new stub if necessary.
2 2
– Clean the thread of the stub and
coat it with sealant, b 12.
1
Follow the sealant manufacturer’s
instructions.
932RA201 VA

932RA209 VA

– Screw home the stub and tighten

it down firmly, b 3.2
1 3

: Remove the muffler (1) and : Remove the muffler (1) with
exhaust gasket (2). exhaust gaskets (2) and
flange (3).

Series 4140 Components BG, SH 13


Install in the reverse sequence.
– Clean the sealing faces before
installation.
– Install new exhaust gaskets.
1 until its normal smooth action is
2 and disassembled. Take particular
932RA210 VA
Spark arresting screen
– Remove the fan housing with
rewind starter, b 7.2
: Take out the screw (1).
: Pull the spark arresting
screen (2) out of the muffler.
– Clean the spark arresting screen,
replace it if necessary.
Install in the reverse sequence.
14
7. Rewind Starter 7.2 Removing and Installing
7.1 General
Troubleshooting, b 4.1
If the action of the starter rope
becomes very stiff and the rope
rewinds very slowly or not
completely, it can be assumed that
the starter mechanism is in order
but plugged with dirt. At very low
outside temperatures the lubricating
oil on the rewind spring may thicken
and cause the spring windings to
stick together. This has a
detrimental effect on the function of : Take out the screws (1+2).
the starter mechanism. In such a
case it is sufficient to apply a few – Remove the fan housing with
drops of a standard solvent-based rewind starter.
degreasant (containing no
chlorinated or halogenated : If necessary, remove the
hydrocarbons) to the rewind spring. antistatic wire (arrow).
Carefully pull out the starter rope
several times and allow it to rewind
restored.
If clogged with dirt or pitch, the
entire starter mechanism, including
the rewind spring, must be removed
care when removing the spring.
Clean all parts, b 12.
Lubricate the rewind spring and
starter post with STIHL special
lubricant, b 12, before installing.
Series 4140 Components BG, SH
7.3 Starter Cup
Machines with starter cup
integrated in flywheel: For servicing
information see the chapter on
“Flywheel” in the “Series 4140
Powerhead” service manual.
Series 4140 Components BG, SH
7.4 Rope Rotor
Remove the rewind starter,
b 7.2
Relieving tension of rewind 3 1
spring 2
The rewind spring will not be under
tension if the starter rope is broken.
932RA181 VA
– Pull out the starter rope about
10 cm and hold the rope rotor
steady.
Removing
– While still holding the rotor
steady, take three turns of the The rewind spring must not be
rope off the rotor. under tension.
– Pull out the starter rope a little : Remove the spring clip (1) from
further and then let go of the the starter post.
rotor.
: Remove the washer (2) and
The rotor spins back so that the pawl (3).
rewind spring is no longer under
tension. – Carefully pull the rope rotor off
the starter post.
– Replace the broken or worn
starter rope, b 7.6
Installing
– Coat the bore in the rope rotor
with STIHL special lubricant,
b 12.
1
2
932RA182 VA
: Fit the rotor on the starter post
so that the driver (1) on the rope
rotor slips behind the inner spring
loop (2).
15

– Check that the spring loop has
engaged by turning the rope rotor
a little and letting it go. It must
spring back.
– Coat pawl with special lubricant
and install, b 12.
2 1
932RA183 VA
: Fit the washer and engage the
spring clip (1) in the groove in the
starter post.
: Make sure the spring clip (1) den
engages the guide peg (arrow)
on the pawl (2) and points
clockwise.
Handle the spring clip with care.
The rewind starter may not function
properly if the spring clip is
deformed.
– Tension the rewind spring,
b 7.5.1
– Install the rewind starter,
b 7.2
16
7.5 Replacing the Rewind
Spring
– Remove the rope rotor, b 7.4
– Remove the pieces of broken
spring from the rope rotor and
starter cover.
– Before installing, lubricate the
new spring with a few drops of
STIHL special lubricant, b 12.
: Then grip the rewind spring with
pointed nose pliers about 10 mm
from the end of the outer loop and
place it in the starter.
932RA184 VA
: Position the rewind spring in the : Check the distance of the inner
starter and press the outer spring spring loop from the hub and
loop over the lug (arrow). correct if necessary. Dimension
"A" must not be more than 2 mm.
The rewind spring may pop out and
uncoil if the rope rotor is not – Install the rope rotor, b 7.4
installed very carefully.
– Tension the rewind spring,
If the rewind spring has popped out, b 7.5.1
refit it as follows:
– Hold the spring in your hand and
wind from the inside outwards
and tension it to a diameter of
55 mm.
Series 4140 Components BG, SH
7.5.1 Tensioning the
Rewind Spring
932RA187 VA
: Make a loop in the unwound
starter rope. Grip the rope close
to the rotor and use it to turn the
rotor six full turns clockwise.
932RA188 VA
: Hold the rope rotor steady.
: Pull out the rope with the starter
grip and straighten it out.
– Hold the starter grip firmly to keep
the rope tensioned.
– Let go of the rope rotor and
slowly release the starter grip so
that the rope winds itself onto the
rotor.
Series 4140 Components BG, SH
7.6 Starter Rope
– Remove the rewind starter,
b 7.2
– If the starter rope is broken,
remove the remaining rope from
the rope rotor and starter grip.
– If the starter rope is worn, relieve
932RA189 VA
tension of rewind spring, b 7.4.
Pull the end of the rope out of the
rotor and undo the knot. Then pull
the worn rope out of the starter
The starter grip must sit firmly in the grip, housing and rotor.
rope guide bush without drooping to
one side. If this is not the case,
tension the spring by one additional
turn.
When the starter rope is fully
extended, it must still be possible to
rotate the rope rotor at least another
half turn before maximum spring
tension is reached. If this is not the
case, pull the rope out, hold the
rope rotor steady and take off one
turn of the rope.
Do not overtension the rewind
932RA190 VA
spring as this will cause it to
break.
– Place the rewind starter in
position, insert the screws and : Thread one end of the new rope
tighten them down firmly, b 3.2 through the rotor and housing.
Tie a simple overhand knot in the
end of the rope.
– Pull the rope back into the rotor
until the knot locates in the
recess.
– Thread the other end of the rope
through the starter grip. Tie a
simple overhand knot in the end
of the rope.
17

380RA065 VA
1 2
: On machines with "ElastoStart":
Thread end of new starter rope
through the grip (1) and the
spring element (2). Tie a simple
overhand knot in the end of the
rope. Pull the rope and spring
element into the grip and then fit
the cap (3).
– Tension the rewind spring,
b 7.5.1
– Install the rewind starter,
b 7.2
18
7.7 Pawl 8. Throttle Control
8.1 Throttle Trigger
2 1
932RA183 VA
– Remove the rewind starter, – Remove the handle molding,
b 7.2 b 5.1
: Ease the spring clip (1) off the : On machines with a throttle
starter post and pull the pawl (2) cable, remove the throttle
out of the rope rotor. trigger (1) and disconnect it from
the throttle cable.
Do not pull the rope rotor off the
starter post.
– Coat the new pawl with special 2
lubricant, b 12, and fit it in
position.
: Push the spring clip (1) into the 1
groove in the starter post.
932RA268 VA
: Make sure the spring clip (1)
engages the guide peg (arrow)
on the pawl (2).
: On machines with a throttle
The spring clip must point rod (1), remove the throttle
clockwise. trigger (2) and disconnect it from
the throttle rod.
Handle the spring clip with care.
The rewind starter may not function Install in the reverse sequence.
properly if the spring clip is
deformed.
– Install the rewind starter,
b 7.2
Series 4140 Components BG, SH
8.2 Setting Lever (BG 85, 8.3 Stop Switch
SH 85 only) 8.3.1 Version up to 2001

8 7 6 1
4 3
1
2
2

932RA226 VA

932RA227 VA

932RA073 VA
54 3 2 1

– Remove the handle molding, : Fit the cam (1) on the setting
b 5.1 lever’s stub so that it lines up with
the marking on the handle
: Ease the E-clip (8) off the setting housing.
lever’s stub.
: Push the E-clip (2) in the groove
: Remove the cam (7). on the setting lever’s stub.
: Use a flat screwdriver to ease the
stop switch (1) out of the handle
molding.
: Pull the connectors (2) (short
circuit and ground wires) off the
stop switch.

: Pull the setting lever (1) with Assemble all other parts in the Install in the reverse sequence.
washers (2, 5) and cup springs reverse sequence.
(3, 4) out of the handle Check correct positions of wires.
molding (6).

Reassemble in the reverse

sequence.

– Slip the washers (2, 5) and cup

springs (3, 4) over the stub of the
setting lever (1) and push it into
the handle molding (6).

Note the correct installed position of

the two cup springs (3 and 4).

Series 4140 Components BG, SH 19

8.3.2 Version from 2001 8.4 Short Circuit Wire/
Ground Wire

1
2
1
3
1
932RA223 VA
2

932RA101 VA

– Remove the handle molding,
b 5.1
: Use a flat screwdriver to ease the
stop switch (1) and protective
cap (2) out of the handle molding.
: Pull the connectors (3) (short
circuit and ground wires) off the
stop switch.
932RA225 VA
– Remove the handle molding, b BG 65, 85, SH 85 from 2001 only
5.1
: Remove the wire (1) from the
– Remove the stop switch, housing peg.
b 8.3
: Pull the connectors of the short
circuit wire (1) and ground
wire (2) off the ignition module.

Install in the reverse sequence.

Check correct positions of wires.

932RA075 VA
1

All BG/SH units

: Pull the retainers (1) off the

ignition lead.

: Take the wires out of the guides

(arrows) in the inner fan housing.

Reassemble in the reverse

1 sequence.

– Push home the wires so that they

are properly seated in the guides
in the inner fan housing.
2
932RA224 VA

BG 45, 55, SH 55 only, from 2001

– Remove the throttle trigger,

b 8.1

: Remove the wire (1) from the

throttle trigger’s pivot pin (2).

20 Series 4140 Components BG, SH

8.5 Throttle Cable 8.6 Throttle Rod 9. Fuel System
9.1 Air Filter

Dirty air filters reduce engine power,

increase fuel consumption and
2 make starting more difficult.

If there is a noticeable loss of

engine power, check to see if the
1 air filter is plugged with dirt.

– Remove the handle molding,
b 5.1
: Disconnect the throttle cable (1)
from the throttle trigger (2),
b 8.1
932RA268 VA
– Before removing the air filter,
close the choke shutter and
remove all loose dirt from around
the filter.
– Remove the handle molding,
b 5.1 – Wash the foam filter in a standard
solvent-based degreasant
: Remove the throttle trigger (2) containing no chlorinated or
and disconnect the throttle halogenated hydrocarbons and
rod (1). then dry. Replace if necessary.

: Take the throttle cable out of the
guides (arrows) in the inner fan
housing.
– Remove the carburetor, b 9.2.2
: Disconnect the throttle rod (1)
from the carburetor.
Install in the reverse sequence.
– Replace the felt filter. As a
temporary measure, knock the
filter out on the palm of your hand
or blow clear with compressed
air. Do not wash.

– Replace multi-ply felt filter. As a

temporary measure, knock the
filter out on the palm of your hand
or blow clear with compressed
air. Do not wash

If a felt filter is replaced by a multi-

ply filter, do not re-install the foam
filter.

Always replace a damaged air filter

immediately.

: Push the throttle cable (1) out of

the tensioner (2). Remove the
throttle cable.

Install in the reverse sequence.

Series 4140 Components BG, SH 21

9.1.1 Removing and Installing 9.1.2 Choke Shutter

– Knock the filter out on the palm of

your hand or blow clear with 3
compressed air. Do not wash.
Replace if heavily loaded. 1
2
Always replace a damaged air filter
immediately.
932RA211 VA

932RA229 VA
: Squeeze retainers together. – Remove the air filter, b 9.1.1

: Remove the push nut (1).

: Pull the choke shutter (2) out of

the lever (3).

– When installing, make sure the

choke shutter is properly located
in the lever’s guide.
1 Use a new push nut.
2
Install in the reverse sequence.
932RA212 VA

932RA216 VA

: Swing the filter cover (1) to the Machines with catalytic converter
side and pull the lugs out of the
guides (arrows). : Remove the gasket (1) and heat
shield (2).

Use new gaskets.

Install in the reverse sequence.

2

1
932RA217 VA

: Pull the filter (1) out of the filter

housing (3).

: Unscrew the nuts (2) and remove

the filter housing.

22 Series 4140 Components BG, SH

9.2 Carburetor
9.2.1 Leakage Test

If you suspect a fault in the fuel If this pressure remains constant,

system, see b 4.2. the carburetor is airtight. However, if
In the case of problems with the it drops, there are two possible
carburetor or fuel supply system, causes:
also check or clean the tank vent,
b 9.5 1. The inlet needle is not sealing
The carburetor can be tested for (foreign matter in valve seat or
leaks with the carburetor and sealing cone of inlet needle is

232RA082 VA
crankcase tester 1106 850 2905.
– Remove the air filter, b 9.1.1
: Push the fuel line with nipple onto
the carburetor’s elbow connector
(arrow).
damaged or inlet control lever
sticking).
2. Metering diaphragm is damaged.
In either of these cases the
carburetor has to be serviced.

– After completing the test, open

the vent screw and pull the fuel
line off the carburetor.

– Push the fuel hose onto the

carburetor’s elbow connector.

Assemble all other parts in the

reverse sequence.

Always install a new gasket.

232RA083 VA
932RA215 VA

: Disconnect the fuel hose from the : Connect the tester's pressure
carburetor’s elbow connector. hose to the nipple.

2 1

2
143RA172 VA

232RA084 VA

: Push the fuel line (1) : Close the vent screw (1) on the
1110 141 8600 onto the rubber bulb (2) and pump air into
nipple (2) 0000 855 9200. the carburetor until the pressure
gauge (3) shows a reading of
approx. 0.8 bar.

Series 4140 Components BG, SH 23

9.2.2 Removing and Installing 9.2.3 Spacer Flange

Remove the air filter, b 9.1.1

1
2

932RA234 VA
: Remove the carburetor (1) and – Remove the carburetor, b 9.1.1
gasket (2).
: On machines with throttle cable,
Install in the reverse sequence. pull the throttle cable (1) out of
the spacer flange (2).
Always install the carburetor with
new gaskets.

Position the fuel hoses so that they

are not kinked.

Observe tightening torques, b 3.2

1
2

932RA253 VA
932RA233 VA

: Disconnect the fuel hoses from : On machines with throttle cable,

from the elbow connectors on the take out the screws (1) and
carburetor. remove the spacer flange
together with the hex head
screws (2).

2
2
1
1
932RA239 VA

932RA252 VA

: On machines with throttle : On machines with throttle rod,

cable (1), disconnect throttle take out the screws (1) and
cable from slotted pin (2) on remove the spacer flange
carburetor’s throttle lever. together with the hex head
screws (2).
– On machines with throttle rod,
remove the throttle rod, b 8.6

24 Series 4140 Components BG, SH

 9.3 Servicing the Carburetor
9.3.1 Manual Fuel Pump with Oval End Cover

– Carry out leakage test, b 9.2

– Remove the carburetor, b 9.2.2

932RA254 VA

936RA258 VA
: Pull the gasket (1) out of the : Take the cap out of the end cover.
guides (arrows) on the spiral
housing.

Install in the reverse sequence.

Always install new gaskets.

Observe tightening torques,

b 3.2 1

936RA223 VA

936RA025 VA
: Take out the M3x12 screws (1). : Inspect the metering diaphragm
and gasket and replace if
: Remove the end cover with necessary, b 9.3.3
cap (2).
Reassemble in the reverse
sequence.

Additional holes in the gasket and

diaphragm (if there are any) must
1 line up with those in the carburetor
and flange.

2
936RA224 VA

: Take out the M3x8 screws (1).

: Remove the flange (2).

Series 4140 Components BG, SH 25

9.3.2 Manual Fuel Pump with Square End Cover 9.3.3 Metering Diaphragm

1
1

936RA023 VA

936RA025 VA

936RA026 VA
: Take out the screws (1). : Inspect the metering diaphragm – Remove flange from manual fuel
and gasket and replace if pump with oval end cover,
– Remove the end cover with cap. necessary, b 9.3.3 b 9.3.1

Reassemble in the reverse – Remove flange from manual fuel

sequence. pump with square end cover,
b 9.3.2

: Remove the metering

diaphragm (1) and gasket (2)
from the carburetor body.

If the gasket and diaphragm are

stuck together, remove and
separate them very carefully.
932RA285 VA

: Inspect the diaphragm and

gasket and replace if necessary.

The diaphragm is a very delicate

: Take the cap out of the end cover. component. As a result of the
alternating stresses the material
eventually shows signs of fatigue,
i.e. the diaphragm distorts and
swells and has to be replaced.

Reassemble in the reverse

sequence.
936RA024 VA

: Remove the flange.

26 Series 4140 Components BG, SH

 9.3.4 Inlet Needle

Reassemble in the reverse

1 1 sequence.

– Engage clevis in annular groove

2 on head of the inlet needle.

Make sure the helical spring locates

on the control lever’s nipple.

936RA027 VA

936RA029 VA
– Check that inlet control lever
moves freely.

: Fit the gasket (1) on the – Remove the metering Important:

carburetor body.
Line up the hole in the gasket (2)
with the compensating bore in the
carburetor.
diaphragm, b 9.3.3 The upper edge of the inlet control
lever must be flush with the top of
: Take out the screw (1). the carburetor body.
– Install the metering diaphragm,
b 9.3.3

1 4 3

1
936RA028 VA

932RA260 VA

: Place metering diaphragm (1) on : Remove the inlet control

the gasket. lever (4), spindle (3), spring (2)
and inlet needle (1).
Line up the hole in the metering
diaphragm (1) with the Take care with the spring (2)
compensating bore in the because it may pop out during
carburetor and gasket. disassembly.

Assemble all other parts,

b 9.3.1 and 9.3.2.
372RA120 VA

: If there is an annular indentation

(arrow) on the sealing cone of the
inlet needle, it will be necessary
to replace the inlet needle
because it will no longer seal
properly.

Series 4140 Components BG, SH 27

9.3.5 Fixed Jet 9.3.6 Pump Diaphragm and
Fuel Strainer

Take care not to damage the fixed The diaphragm is a very delicate
jet when removing. 1 component. As a result of the
alternating stresses the material
– Remove the metering eventually shows signs of fatigue,
diaphragm, b 9.3.3 2 i.e. the diaphragm distorts and
swells and has to be replaced.

– Inspect the diaphragm and

936RA032 VA
gasket and replace if necessary.

– Remove the carburetor, b 9.2.2

: Take out the screw (1).

: Remove the end cover (2).

1 1

1
936RA225 VA

936RA033 VA

936RA086 VA
C1Q-S48, C1Q-S50, C1Q-S55 : Remove the gasket (1). : Examine the fuel strainer (1) for
carburetors only contamination and damage and
replace if necessary.
: Unscrew the fixed jet (1).

1 1
2
936RA034 VA
936RA031 VA

932RA259 VA

C1Q-S64, C1Q-S73 carburetors : Remove the pump Reassemble in the reverse

only diaphragm (1). sequence.

: Unscrew the fixed jet (1). If the gasket and pump diaphragm : The pump diaphragm (1) and
are stuck together, remove and gasket (2) are held in position by
Reassemble in the reverse separate them very carefully. the pegs (arrows) on the end
sequence. cover (3).

28 Series 4140 Components BG, SH

9.4 Adjusting the Carburetor 9.4.2 User Adjustment of
9.4.1 Carburetor with LD Carburetor with H, L and
Screw LA Screws
The carburetor with idle speed
screw (LD) has no adjusting screws L
for maximum engine (H screw) or
idle mixture (L screw).
LD

The carburetor is tuned so that the

engine receives an optimum fuel-air H
mixture under all operating

232RA090 VA

932RA303 VA
conditions.
LA
Standard setting

When adjusting from scratch, first
carry out the standard setting.
Adjusting idle speed Standard setting
– Carry out standard setting. The limiter cap must not be
removed from the high speed screw
– Start the engine and warm it up. (H) to carry out the standard setting.

With this carburetor it is only

Engine stops while idling: possible to correct the setting of the
high speed screw (H) within fine
: Turn the idle speed screw (LD) limits.
(arrow) slowly clockwise until the
engine runs smoothly. – Check the air filter and replace if
LD necessary, b 9.1.1
Erratic idling behavior, poor
acceleration: – Check the spark arresting
screen, clean or replace it if
232RA090 VA

: Turn the idle speed screw (LD) necessary, b 6.2

slowly no more than half a turn
counterclockwise.

: Carefully turn the idle speed

screw (LD) (arrow)
counterclockwise (left-hand
thread) down onto its seat.

: Then turn the idle speed

screw (LD) two full turns
clockwise.

– Check the air filter and replace if

necessary, b 9.1

– Check the spark arresting

screen, clean or replace as
necessary, b 7.2

Series 4140 Components BG, SH 29


L the high speed screw (H)
H smoothly.
932RA303 VA
LA
Now make the following
adjustments:
: Turn the high speed screw (H)
counterclockwise as far as stop
(no more than 3/4 turn)
: Carefully turn the low speed
screw (L) clockwise until it is
against its seat, then open it one
full turn counterclockwise.
– Start the engine and allow it to
warm up.
Fine tuning
A minor correction may be
necessary when operating at high
altitude or at sea level. Note that
even very slight corrections to the
high speed screw (H) produce a
noticeable change in engine
running behavior.
– Carry out the standard setting.
– Start the engine and allow it to
warm up.
– Open the throttle wide.
30
– At high altitude (mountains): Turn Erratic idling behavior
clockwise (leaner), but no further – Idle setting is too rich. Turn the
than stop, until there is no low speed screw (L) clockwise
noticeable increase in engine (about a quarter turn) until the
speed. engine runs and accelerates
– At sea level: Turn the high speed
screw (H) counterclockwise It is usually necessary to change the
(richer), but no further than stop, setting of the idle speed screw (LA)
until there is no noticeable after every correction to the low
increase in engine speed. speed screw (L).
It is possible that the standard
setting produces the highest engine
rpm in both the above cases.
Adjusting idle speed
– Open the low speed screw (L)
one full turn.
– Allow the engine to warm up.
Engine stops while idling
– Turn the idle speed screw (LA)
slowly clockwise until the engine
runs smoothly.
Erratic idling behavior, poor
acceleration
– Idle setting is too lean. Turn the
low speed screw (L) counter-
clockwise (about a quarter turn)
until the engine runs and
accelerates smoothly.
Series 4140 Components BG, SH
9.4.3 Basic Setting on
Carburetor with H, L
and LA Srews
The limiter cap has to be removed Adjusting idle speed
from the high speed screw (H) only
if it is necessary to replace the high – Check the air filter and clean or
speed screw (H), clean the replace as necessary.
carburetor or adjust it from scratch.
– Warm up the engine.
After removing the limiter cap it is
1
necessary to carry out the basic Adjust idle speed with a tachometer.

932RA315 VA
setting. Adjust specified engine speeds
within a tolerance of +/- 200 rpm.

1. Adjust engine speed with idle

: On carburetors with a long limiter speed screw (LA) to 3,300 rpm.
cap (1):
Use suitable pliers to pull off the 2.Turn low speed screw (L)
limiter cap. clockwise or counterclockwise
to obtain maximum engine
– Screw down both adjusting screw speed.
(H and L) clockwise until they are
against their seats. If this speed is higher than
3,700 rpm, abort the procedure and
Now make the following start again with step 1.
adjustments:
3. Use the idle speed screw (LA)
to set engine speed again to
3,300 rpm

4. Set the engine speed to

932RA316 VA

2,800 rpm with the low speed

screw (L).
2 1
5. Set maximum engine speed to
: On carburetors with a short 10,500 rpm with the high speed
limiter cap (1): Push the puller (2) screw (H).
5910 890 4501, with the groove
facing you, between the limiter Do not re-install used caps because
cap (1) and carburetor body and they may be damaged during the
pry the cap off. If the limiter cap is removal process. Always install a
stuck on the screw, turn the puller new limiter cap.
over so that its groove faces the
carburetor body. Pry off the
limiter cap.

H L
932RA317 VA

– Open the high speed screw (H)

1 1/2 turns counterclockwise.

– Open the low speed screw (L)

one full turn counterclockwise.

Series 4140 Components BG, SH 31


270°
249RA129 VA
: On carburetors with a short
limiter cap:
Line up the new cap for the high
speed screw (H) against the rich
stop and press it on only as far as
the second noticeable detent
position.
The stop limits the adjustment
range of the high speed screw (H) to
a 3/4 turn. Do not press the cap
against the carburetor body as it will
otherwise be damage.
– Carry out standard setting,
b 9.4.2
32
270
392RA318 VA
: On carburetors with a long
limiter cap:
Line up the new cap for the high
speed screw (H) against the rich
stop so that the high speed
screw (H) can only be rotated a
3/4 turn clockwise.
: Push on the limiter cap until it
butts against the carburetor body.
Carry out standard setting, b 9.4.2
9.5 Tank Vent
9.5.1 General
Correct operation of the carburetor
is only possible if atmospheric
pressure and internal fuel tank
pressure are equal at all times. This
is ensured by the tank vent.
In the event of trouble with the
carburetor or the fuel supply
system, always check the tank vent
and replace it if necessary.
Testing the tank vent
– Open the tank cap slowly and
drain the tank. Refit the tank cap,
making sure it is tight.
– Disconnect the fuel hoses from
the carburetor, b 9.2.2
– Seal one of the fuel hoses with a
suitable plug.
– Connect vacuum pump
0000 850 3501 to the other fuel
hose and produce a vacuum in
the fuel tank by operating the
pump quickly.
– If the vacuum remains
unchanged, install a new tank
vent, b 9.5.2
If the vacuum slowly disappears,
the tank vent is in order.
Series 4140 Components BG, SH
9.5.2 Replacing 9.6 Fuel Tank
9.6.1 General

If no equalization of pressures takes
place, replace the tank vent.
– Remove the filter housing,
b 9.1.1
Note installed position of tank vent.
Always use a new sealing ring.
Install in the reverse sequence.
Fuel tank
The fuel tank is part of the inner fan
housing and cannot be replaced
separately.
If the fuel tank is damaged, replace
the complete inner fan housing.

The diaphragm pump draws fuel out

of the tank and into the carburetor
via the fuel hose. Any impurities
mixed with the fuel are retained by
the pickup body (filter). The fine
pores of the filter eventually become
clogged with minute particles of dirt.
This restricts the passage of fuel
and results in fuel starvation.

Always observe all safety

precautions when working on the
fuel system, b 2.

In the event of trouble with the fuel

supply system, always check the
fuel tank and the pickup body first.
Clean the fuel tank if necessary.
1
932RA096 VA

Cleaning the fuel tank

2 – Unscrew the fuel filler cap and
drain the tank.
Machines up to 2002
– Pour a small amount of clean
: Pull out the tank vent (1). gasoline into the tank.

: Pull out the grommet (2). – Close the tank and shake the
machine vigorously.
Install in the reverse sequence.
– Open the tank again and drain it.

Dispose of fuel properly.

1
932RA321 VA

Machines from 2002

: Carefully pry out the tank vent (1)

with sealing ring (2).

Series 4140 Components BG, SH 33

9.6.2 Pickup Body
– Unscrew the fuel filler cap and
drain the tank.
: Use hook (1) 5910 893 8800 to
pull the pickup body out of the
fuel tank.
: Pull the pickup body (1) off the
fuel hose and check it for
contamination, replace if
necessary.
Install in the reverse sequence.
34
9.6.3 Fuel Hoses
– Unscrew the fuel filler cap and
drain the tank.
– Remove the fan housing with
rewind starter,
b 7.2
– Remove the carburetor, b 9.2.2
– Remove the pickup body.
– Pull off the tank vent,
b 9.5.2
: Pull out the fuel hoses (arrow).
Note installed position.
Install in the reverse sequence.
– Unscrew the spark plug.
– Use locking strip 4221 893 5900
to block the piston.
– Remove the blower tube and
elbow, b 10.4 and
b 10.6
932RA164 VA
BG 55, 65, 85 only
: Take out the screws and lift away
the outer fan housing.
932RA162 VA
: On BG 45, take out the screws
and lift away the outer fan
housing.
Series 4140 Components BG, SH
10. Blower and Vacuum 10.2 Protective Screen 10.3 Protective Screen
Attachment (all except BG 45) (BG 45 only)
10.1 Fanwheel

1 1 1

932RA163 VA

932RA161 VA

932RA166 VA
SH 55, 85 only SH units only : Take out the screws (1).

: Unscrew the star nut (1), take out
the screws and lift away the outer
fan housing.
– Remove suction tube, b 10.5
: Press down the retaining tab (1)
on the protective screen and
swing the screen open.
: Lift the right-hand side of the
protective screen so that it comes
out of the guide (2)

1 1

2
3
4
932RA165 VA

: Unscrew the nut (1) clockwise : Use a screwdriver or similar tool
(left-hand thread). to press down the retaining
tabs (1) on the outer fan housing
: On SH 55, 85, remove the and lift away the protective
shredder blade (2). screen (2).
932RA167 VA
– Remove the protective screen.
: Before reinstalling, check the
seal (1) for damage and make
sure it is properly seated.

: Remove the washer (3), Install in the reverse sequence.

fanwheel (4) and the washer
behind it. – Make sure the protective screen
engages in the guide.
– Inspect all blades and replace
fanwheel if necessary.

Install in the reverse sequence.

: Remove the torsion spring

(arrow).

Install in the reverse sequence.

Series 4140 Components BG, SH 35

10.4 Blower Tube (BG only)
: Insert a screwdriver or similar tool
in the recess (arrow) on the
blower stub and push the
retaining tab up.
– At the same time, turn the blower
tube counterclockwise as far as
stop (1/4 turn).
– Pull the blower tube off the stub.
– Fit by inserting blower tube with
lug in the stub.
– Rotate the blower tube clockwise
until the bayonet coupling
engages.
36
10.5 Suction Tube (SH only)
932RA094 VA
: Turn the suction tube
counterclockwise as far as stop
(1/4 turn).
– Pull the suction tube off the stub.
To fit, open the protective screen.
: Insert suction tube so that its
guide slots (arrow) engage the
lugs (arrow) on the stub.
– Rotate the suction tube clockwise
until the bayonet coupling
engages.
10.6 Elbow (SH only)
932RA168 VA
: Loosen the star nut (1).
: Insert a screwdriver or similar tool
in the recess (arrow) on the
blower stub and push the
retaining tab up.
– At the same time, turn the elbow
counterclockwise as far as stop
(1/4 turn).
– Pull the elbow off the stub.
– Fit by inserting blower tube with
lug in the stub.
932RA169 VA
: Check that rubber sealing ring
(arrow) is properly seated.
– Rotate elbow clockwise until the
bayonet coupling engages.
Series 4140 Components BG, SH
11. Special Servicing Tools

No. Part Name Part No. Application Rem.

1 Locking strip 4221 893 5900 Blocking crankshaft

2 Socket 0812 540 1112 Installing and removing spline socket
head screws with electric or pneumatic
screwdrivers
3 Vacuum pump 0000 850 3501 Testing crankcase and carburetor for
leaks, testing tank vent
4 Carburetor and crankcase tester 1106 850 2905 Testing crankcase and carburetor for
leaks
5 Nipple 0000 855 9200 Testing carburetor for leaks
6 Hose for leakage test 1110 141 8600 Testing carburetor for leaks
7 Screwdriver 5910 890 2420 Carburetor nuts
Q-SW 8 x 200
8 Crimping tool 5910 890 8210 Attaching connectors to electrical wires
9 Torque wrench 5910 890 0301 0.5 to 18 Nm 1) 2)
10 Torque wrench 5910 890 0311 6 to 80 Nm 1) 3)
11 Socket, T 27 x 125 0812 524 2104 Installing and removing spline socket
head screws with electric or pneumatic
screwdrivers, tightening with torque
wrench
12 T-handle screwdriver 5910 890 2400 IS screws 4)
Q - T 27 x 150
13 Hook 5910 893 8800 Removing pickup body

Remarks:

1) Always use torque wrench for tightening DG or P screws.

2) Alternative: Torque wrench 5910 890 0302 with optical/acoustic signal.
3) Alternative: Torque wrench 5910 890 0312 with optical/acoustic signal.
4) Only use for releasing/removing DG or P screws.

Series 4140 Components BG, SH 37

12. Servicing Aids

No. Part Name Part No. Application

1 Dirko gray sealant (100 g tube) 0783 830 2120 Guard on muffler

2 STIHL special lubricating oil 0781 417 1315 Bearing bore in rope rotor, rewind spring

3 Standard commercial, solvent- Cleaning sealing faces

based degreasant containing no
chlorinated or halogenated
hydrocarbons

38 Series 4140 Components BG, SH

Series 4140 Components BG, SH 39
40 Series 4140 Components BG, SH
englisch / English
0455 295 0123. M7. A5. Sä. Printed in Germany