1
1. . IInnttrroodduuccttiioonn 11
2.
2. SaSafefety ty pprrececauautitioonnss 22
3
3. . SSppeecciifificcaattiioonnss 33 3
3..1 1 EEnnggiinne e 33 3
3..2 2 IIggnniittiioon n ssyysstteem m 33 3
3..3 3 TTiigghhtteenniinng g ttoorrqquuees s 44
4
4. . CCyylliinnddeer r aannd d ppiissttoonn 55 4
4..1 1 RReemmoovvaal l 55 4
4..2 2 IInnssttaallllaattiioon n 66 4
4..3 3 PPiissttoon n rriinnggs s 77
5 5. . CCrraannkksshhaafft t / / ball bearings ball bearings 77 5 5..1 1 OOiil l sseeaalls s 99 6 6 LLeeaakkaagge e tteesstt 1010 6
6..1 1 PPrreeppaarraattiioonns s 1100 6
6..2 2 PPrreessssuurre e tteesst t 1111 6
6..3 3 VVaaccuuuum m tteesst t 1122
7
7. . IIggnniittiioon n ssyysstteemm 1212 7
7..1 1 IIggnniittiioon n mmoodduulle e 1133 7
7..11..1 1 IIggnniittiioon n ttiimmiinng g 1133 7.
7.1.1.2 2 ReRemomovaval l anandd
iinnssttaallllaattiioon n 1133 7
7..2 2 FFllyywwhheeeel l / / ffaan n wwhheeeel l 1144 8
8. . RReewwiinnd d ssttaarrtteerr 1515 8
8..1 1 GGeenneerraal l 1155 8
8..2 2 SSttaarrtteer r ccuup p 1155
9
9. . SSppeecciiaal l sseerrvviicciinngg tools
tools 1616
1
100. . SSeerrvviicce e aaiiddss 1717
11
11. . SpSpececiaial l acaccecessssororieiess for the user
for the user 1717
The "basic engine 4140" is used to The "basic engine 4140" is used to drive a number of power tools: drive a number of power tools: FS 45, 46, 55; FC 55; FS 45, 46, 55; FC 55; BG 45, 55, 65, 85; SH 55, 85; BG 45, 55, 65, 85; SH 55, 85; HS 45; HL 45. HS 45; HL 45.
Servicing procedures for specific Servicing procedures for specific machine components are
machine components are described in the handbook described in the handbook "Machine components 4140". "Machine components 4140". There are separate handbooks There are separate handbooks for servicing procedures for for servicing procedures for standardized parts and standardized parts and
assemblies that are installed in assemblies that are installed in several STIHL power tool models several STIHL power tool models ("Standard Repairs, ("Standard Repairs, Trouble-shooting", "Carburetors"). shooting", "Carburetors").
Reference is made to these Reference is made to these handbooks in the appropriate handbooks in the appropriate chapters in this manual. chapters in this manual. You should make use of the You should make use of the
illustrated parts lists while carrying illustrated parts lists while carrying out repair
out repair work. work. They show They show thethe installed positions of the individual installed positions of the individual components and assemblies. components and assemblies. Refer to the latest edition of the Refer to the latest edition of the relevant parts list to check the part relevant parts list to check the part numbers of any replacement parts numbers of any replacement parts needed. Parts lists on microfiche needed. Parts lists on microfiche and CD-ROM are always more up and CD-ROM are always more up to date than printed lists.
to date than printed lists.
A fault in the machine may have A fault in the machine may have several caus
several causes. es. To helTo help locatep locate the fault, consult the the fault, consult the trouble-shooting charts for all
shooting charts for all assembliesassemblies in the "Standard Repairs,
in the "Standard Repairs, Troubleshooting" handbook. Troubleshooting" handbook. Bas
Basicic enenginginee 41441400 Contents
Refer to the "Technical Refer to the "Technical information" bulletins for information" bulletins for engineering changes which engineering changes which have been introduced since have been introduced since publication of this service
publication of this service manual.manual. Technical information bulletins Technical information bulletins also supplement the parts list until also supplement the parts list until a revised edition is issued.
a revised edition is issued.
Special servicing tools mentioned Special servicing tools mentioned in the descriptions are listed in the in the descriptions are listed in the last chapter
last chapter of this mof this manual. anual. UseUse the part numbers to identify the the part numbers to identify the tools in the "STIHL Special Tools" tools in the "STIHL Special Tools" manual. The manual lists all manual. The manual lists all special servicing tools currently special servicing tools currently available from STIHL.
available from STIHL.
Symbols are included in the text Symbols are included in the text and pictures for greater clarity. and pictures for greater clarity. The meanings are as follows: The meanings are as follows: In the descriptions:
In the descriptions:
•
•= = Action to Action to be taken be taken as shown as shown inin
the illustration (above the text) the illustration (above the text) - =
- = ActiAction to on to be tabe taken tken that ihat is nots not shown in the illustration shown in the illustration (above the text)
(above the text) In the illustrations: In the illustrations:
=
= PoinPointerter =
= Direction Direction of of movementmovement Service manuals and all technical Service manuals and all technical information bulletins describing information bulletins describing engineering changes are intended engineering changes are intended exclusively for the use of STIHL exclusively for the use of STIHL servicing d
servicing dealers. ealers. They mThey must notust not be passed on to third parties. be passed on to third parties.
Servicing and repairs of power Servicing and repairs of power tools with shaft (FS, FC, HL) are tools with shaft (FS, FC, HL) are made considerably easier if the made considerably easier if the machine is mounted on assembly machine is mounted on assembly stand (2) 5910 890 3100 with the stand (2) 5910 890 3100 with the aid of clamp (1) 5910 890
aid of clamp (1) 5910 890 8800.8800. Secure the clamp to the assembly Secure the clamp to the assembly stand with two washers and two stand with two washers and two M8 nuts. The complete unit can M8 nuts. The complete unit can then be swivelled to the best then be swivelled to the best position for the ongoing repair, position for the ongoing repair, thus leaving both hands free. thus leaving both hands free. Always use original STIHL Always use original STIHL replacement parts.
replacement parts.
They can be identified by the They can be identified by the STIHL part number,
STIHL part number, the
the logo logo and and thethe STIHL parts symbol
STIHL parts symbol ..
The symbol may appear alone on The symbol may appear alone on small parts.
small parts.
If the machine is started up in the If the machine is started up in the course of repairs or maintenance course of repairs or maintenance work, observe all local and specific work, observe all local and specific national safety regulations, as well national safety regulations, as well as the safety precautions and as the safety precautions and warnings in the owner’s manual. warnings in the owner’s manual. Petrol is a highly inflammable fuel Petrol is a highly inflammable fuel and can be explosive in certain and can be explosive in certain conditions.
conditions.
Improper handling may result in Improper handling may result in burns or other serious injuries. burns or other serious injuries. Warning!
Warning! Do not smoke Do not smoke or bringor bring any fire or fla
any fire or flame near the fueme near the fuel. l. AllAll work with fuel must be performed work with fuel must be performed outdoors only
outdoors only. . Spilled fuSpilled fuel musel mustt be wiped away
be wiped away immediately.immediately. 2
2. . SSaaffeettyy pprreeccaauuttiioonnss
V V A A 2 2 3 3 2 2 R R A A 0 0 0 0 1 1 2 2 1 1 q q ( (
3
3..1 1 EEnnggiinnee STIHL STIHL single-cylinder single-cylinder two-stroke two-stroke engine engine with with special special impregnatedimpregnated cylinder bore cylinder bore D Diissppllaacceemmeenntt: : 2277..2 2 ccmm33 B Boorree: : 334 4 mmmm S Sttrrookkee: : 330 0 mmmm E
Ennggiinne e ppoowweer r tto o IISSO O 8888993 3 00..775 5 kkW W ((1 1 HHPP)) at 7000 rpm:
at 7000 rpm:
Max. permissible engine speed Max. permissible engine speed without cutting tool
without cutting tool
((ccuutt--oofff f ssppeeeedd)): : 9955000 0 + + 88000 0 rrppmm IIddlle e ssppeeeedd: : 2828000 0 + + 33000 0 rrppmm B
Beeaarriinnggss: : CCrraannkksshhaafft t ssuuppppoorrtteed d iinn heavy-duty deep-groove ball heavy-duty deep-groove ball bearings, needle cages on bearings, needle cages on small and big ends
small and big ends P
Piissttoon n ppiin n ddiiaammeetteerr: : 8 8 mmmm C
Clluuttcchh: : CCeennttrriiffuuggaal l cclluuttcch h wwiitthhoouut t lliinniinnggss C
Clluuttcch h eennggaaggees s aatt: : 3388000 0 rrppmm Crankcase leakage test
Crankcase leakage test a
at t ggaauugge e pprreessssuurree: : ppü ü = = 00..5 5 bbaar r ((5 5 kkPPaa)) u
unnddeer r vvaaccuuuumm: : ppu u = = 00..5 5 bbaar r ((5 5 kkPPaa))
3.
3.2 2 IIgngnititioion n sysyststemem TTyyppee: : EElleeccttrroonniic c mmaaggnneetto o iiggnniittiioonn (breakerless) with integral (breakerless) with integral trigger unit
trigger unit Air
Air gap: gap: 0.15 0.15 ... ... 0.45 0.45 mmmm S
Sppaarrk k pplluug g ((ssuupppprreesssseedd)): : BBoosscch h WWSSR R 66FF NGK BPMR 7 A NGK BPMR 7 A Champion RCJ 6Y Champion RCJ 6Y E Elleeccttrroodde e ggaapp: : 00..5 5 mmmm 3
DG and P (Plastoform) screws are used in polymer and lightm
DG and P (Plastoform) screws are used in polymer and lightmetal components. etal components. These screws form a perma-These screws form a perma-nent thread when they are installed for the first time.
nent thread when they are installed for the first time. They can be removed and installed as often as necessaryThey can be removed and installed as often as necessary without impairing the strength of the screwed assembly, provided the specified tightening torque is
without impairing the strength of the screwed assembly, provided the specified tightening torque is observed.observed. For this reason it is
For this reason it is essential to use a torque wrench. essential to use a torque wrench.
F
Faasstteenneer r TThhrreeaad d ssiizze e FFoor r ccoommppoonneennt t TTiigghhtteenniinng g ttoorrqquue e RReemmaarrkkss (Nm)
(Nm) S
Spplliinne e ssccrreew w IISS--DDGG55xx660 0 EEnnggiinne e ppaan n / / ccrraannkkccaasse e / / ccyylliinnddeer r 99,,0 0 22)) S
Spplliinne e ssccrreew w IISS--DDGG55xx660 0 MMuufffflleer r / / ccyylliinnddeer r 99,,0 0 22)) M
M8 8 SSttaarrtteer r ccuup p 1177,,00 M
M1144xx11,,225 5 SSppaarrk k pplluug g 2200,,00 S
Spplliinne e ssccrreew w IISS--DDGG44xx220 0 IIggnniittiioon n mmoodduulle e / / ccyylliinnddeer r 44,,5 5 22))
Proceed as follows to fit a DG or P screw in an existing thread: Proceed as follows to fit a DG or P screw in an existing thread: –
– Place the DG or P screw in the hole and turn it counterclockwise until it drops down slightly.Place the DG or P screw in the hole and turn it counterclockwise until it drops down slightly. –
– Tighten the scTighten the screw clockwise to rew clockwise to the specified torqthe specified torque.ue. This procedure ensures that the screw engages properly in
This procedure ensures that the screw engages properly in the existing thread and does not the existing thread and does not form a new threadform a new thread and weaken the assembly.
and weaken the assembly. Note:
Note: Power Power screwscrewdrivedriver r speed speed settisettings ngs for for polympolymer: er: PlastPlastoform oform screwscrews s max. max. 600 600 rpmrpm D
DG G ssccrreewws s mamaxx. . 55000 0 rrppmm Important!
Important! Do not confuse screws with and without underhead locking teeth.Do not confuse screws with and without underhead locking teeth. 1)
1) With With locking teeth locking teeth 2)
2) Without Without locking teeth locking teeth 3.
Always check and, if necessary, Always check and, if necessary, repair the fuel system, carburetor, repair the fuel system, carburetor, air filter and ignition system before air filter and ignition system before looking for faults on the engine. looking for faults on the engine. Troubleshooting chart –
Troubleshooting chart – see "Standard Repairs, see "Standard Repairs, Troubleshooting" handbook. Troubleshooting" handbook. - Remove housing parts, muffler, - Remove housing parts, muffler,
ignition module and spacer ignition module and spacer flange – see handbook flange – see handbook "Components, Basic "Components, Basic Engine 4140".
Engine 4140".
- Unscrew the spark plug. - Unscrew the spark plug.
•
•Fit jaws (1) 0000 893 3700 Fit jaws (1) 0000 893 3700 withwith
No. 2 profile on puller (2) No. 2 profile on puller (2) 5910 890 4400.
5910 890 4400.
•
•Fit screw bush (3) 1108 893Fit screw bush (3) 1108 893
4500 on spindle. 4500 on spindle.
•
•To ensure that the crankcaseTo ensure that the crankcase
and engine pan do not come and engine pan do not come apart when the cylinder is apart when the cylinder is removed, hold both parts removed, hold both parts together with the puller. together with the puller.
•
•Unscrew cylinder base screws.Unscrew cylinder base screws.
- Clamp puller in a vice. - Clamp puller in a vice. - Pull cylinder off piston. - Pull cylinder off piston.
- Inspect cylinder and replace it if - Inspect cylinder and replace it if
necessary. necessary.
- If a new cylinder has to be - If a new cylinder has to be
installed, always fit the
installed, always fit the matchingmatching piston as
piston as well. well. New cyliNew cylindersnders are only available with piston. are only available with piston. - Remove cylinder gasket. - Remove cylinder gasket.
- Take snap ring (B8x0.7) out of - Take snap ring (B8x0.7) out of
groove on starter cup side. groove on starter cup side.
Note:
Note: The hookless snap ring The hookless snap ring onon the flywheel side
the flywheel side remains remains in the in the groove.
groove.
•
•Drive piston pin out of piston Drive piston pin out of piston withwith
a 7 mm drift. a 7 mm drift. Note:
Note: If the piston pin is stucIf the piston pin is stuck,k, tap the end of the drift
tap the end of the drift lightly lightly with with a hammer if necessary.
a hammer if necessary. Hold the Hold the piston steady
piston steady during this process, during this process, so that jolts are not
so that jolts are not transmitted totransmitted to the connecting rod.
the connecting rod. -
- Remove piston from connectinRemove piston from connectingg rod.
rod.
- Inspect needle cage and
- Inspect needle cage and replace replace crankshaft if necessary,
crankshaft if necessary, see 5.1. see 5.1.
Note:
Note: One (FS 45) One (FS 45) or twoor two (FS 45, 55) piston ring(s) is/are (FS 45, 55) piston ring(s) is/are used depending on the model in used depending on the model in question.
question. - Inspect pisto
- Inspect piston rings ann rings and replaced replace if necessary
if necessary,, see 4.3.see 4.3.
4
4. . CCyylliinnddeerr aanndd ppiissttoonn 4 4..1 1 ReRemmoovvaall V V A A 2 2 3 3 2 2 R R A A 1 1 1 1 5 5 V V A A 2 2 3 3 2 2 R R A A 1 1 1 1 7 7 V V A A 2 2 3 3 2 2 R R A A 1 1 1 1 4 4 V V A A 2 2 3 3 2 2 R R A A 1 1 1 1 6 6 V V A A 2 2 3 3 2 2 R R A A 1 1 1 1 8 8 1 1 3 3 1 1 2 2
Thoroughly clean gasket seating Thoroughly clean gasket seating surface.
surface.
- Lubricate needle cage in - Lubricate needle cage in
connecting rod with oil. connecting rod with oil.
•
•To simplify assembly, heat theTo simplify assembly, heat the
piston and slip it over the piston and slip it over the connecting rod.
connecting rod.
•
•Installed position of piston:Installed position of piston:
1 = Marking = exhaust side 1 = Marking = exhaust side 2 = Flywheel
2 = Flywheel
•
•Fit the piston pin in positionFit the piston pin in position
and use assembly drift (1) and use assembly drift (1) 1114 893 4700 to push it as far 1114 893 4700 to push it as far as possible against the hookless as possible against the hookless snap ring (the pin
snap ring (the pin slides homeslides home easily if the piston is hot). easily if the piston is hot).
- Fit snap ring (B8x0.7) so that its - Fit snap ring (B8x0.7) so that its gap is on the vertical axis of the gap is on the vertical axis of the piston (pointing up or down). piston (pointing up or down).
•
•Fit new cylinder gasket.Fit new cylinder gasket.
•
•Lubricate piston and piston ringsLubricate piston and piston rings
with oil.
with oil. Rest piston Rest piston (1) on(1) on wooden assembly block (2) wooden assembly block (2) 1108 893 4800.
1108 893 4800.
Note:
Note: One (FS 45) or One (FS 45) or twotwo (FS 45, 55) piston ring(s) is/are (FS 45, 55) piston ring(s) is/are used depending on the model in used depending on the model in question.
question.
•
•Position the piston rings so thatPosition the piston rings so that
the radii at the ring gap meet at the radii at the ring gap meet at the fixing pin in the
the fixing pin in the piston groovepiston groove when the rings are compressed. when the rings are compressed.
•
•Use clamping strap (1)Use clamping strap (1)
0000 893 2600 to compress 0000 893 2600 to compress piston ring around piston. piston ring around piston. - Check that piston rings are - Check that piston rings are
correctly positioned. correctly positioned.
- Lubricate inside of cylinder with - Lubricate inside of cylinder with
oil and line it up in its subsequent oil and line it up in its subsequent position when installed. The position when installed. The piston rings may break if this piston rings may break if this point is disregarded. point is disregarded. V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 0 0 1 1 4
4..2 2 IInnssttaallllaattiioonn
V V A A 1 1 2 2 3 3 2 2 R R A A 1 1 1 1 9 9 2 2 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 2 2 1 1 2 2 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 1 1 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 4 4 1 1 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 3 3
•
•Slide cylinder over piston –Slide cylinder over piston –
the clamping strap is pushed the clamping strap is pushed downward as the piston rings downward as the piston rings slip into the cylinder.
slip into the cylinder.
- Remove clamping strap and - Remove clamping strap and
wooden assembly block. wooden assembly block. - Line up cylinder and cylinder - Line up cylinder and cylinder
gasket. gasket.
•
•Use socket (1) 0812 542 2104 toUse socket (1) 0812 542 2104 to
tighten down cylinder base tighten down cylinder base screws to 9.0 Nm.
screws to 9.0 Nm.
Assemble all other parts in the Assemble all other parts in the reverse sequence.
reverse sequence.
- Remove piston,
- Remove piston, see 4.1. see 4.1.
Note:
Note: One (FS 45) oOne (FS 45) or twor two (FS 45, 55) piston ring(s) is/are (FS 45, 55) piston ring(s) is/are used depending on the model in used depending on the model in question.
question. Note:
Note: The piston mThe piston must beust be removed to ensure that residues removed to ensure that residues cannot fall into the crankcase cannot fall into the crankcase when installing the piston rings when installing the piston rings and cleaning their grooves. and cleaning their grooves. - Remove rings from piston. - Remove rings from piston.
•
•Use a piece of old piston ring toUse a piece of old piston ring to
scrape the grooves clean. scrape the grooves clean.
•
•Install the new piston rings in theInstall the new piston rings in the
grooves so that the radii (1) face grooves so that the radii (1) face the fixing pin (2).
the fixing pin (2). - Install the piston,
- Install the piston, see 4.2. see 4.2.
- Remove cylinder,
- Remove cylinder, see 4.1. see 4.1.
•
•Remove flywheel (1),Remove flywheel (1),
starter cup (2) and piston (3). starter cup (2) and piston (3).
•
•Remove puller (4).Remove puller (4).
•
•Pull engine pan off crankcase.Pull engine pan off crankcase.
•
•Lift crankshaft out of crankcase.Lift crankshaft out of crankcase.
- Inspect ball bearings and oil - Inspect ball bearings and oil
seals and replace if necessary. seals and replace if necessary. 4
4..3 3 PPiissttoon rn riinnggs s 5. 5. CCrraannkksshhaafft / t / ball
ball bearbearingsings
V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 0 0 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 7 7 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 9 9 2 2 1 1 4 4 3 3 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 5 5 V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 1 1 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 8 8 2 2 1 1 11 V V A A 2 2 3 3 2 2 R R A A 1 1 2 2 6 6 1 1
•
•Crankshaft (1), connectingCrankshaft (1), connecting
rod (2) and needle bearing form rod (2) and needle bearing form an inseparable unit and must an inseparable unit and must always be replaced as a always be replaced as a complete unit.
complete unit. -
- New oil seals and ball bearingsNew oil seals and ball bearings must always be installed when must always be installed when fitting a replacement crankshaft. fitting a replacement crankshaft.
•
•Pull off the oil seals (1) Pull off the oil seals (1) and balland ball
bearings (2). bearings (2). - Remove washers. - Remove washers.
•
•Slip washers (1) onto right andSlip washers (1) onto right and
left crankshaft stubs. left crankshaft stubs.
•
•Heat ball bearings (2) to approx.Heat ball bearings (2) to approx.
50 °C and push them home as 50 °C and push them home as far as possible.
far as possible.
- Grease s
- Grease sealing lips of oil seals,ealing lips of oil seals, see 10.
see 10.
•
•Slide the oil seals over the endsSlide the oil seals over the ends
of the crankshaft, open side of the crankshaft, open side facing the ball bearings. facing the ball bearings.
- Thoroughly clean sealing faces - Thoroughly clean sealing faces on crankcase and engine pan to on crankcase and engine pan to remove all traces of sealant. remove all traces of sealant.
•
•Place crankshaft in crankcase soPlace crankshaft in crankcase so
that connecting rod (1) points to that connecting rod (1) points to cylinder side and the short cylinder side and the short
crankshaft stub (2) is on the wide crankshaft stub (2) is on the wide side (arrow) of the crankcase. side (arrow) of the crankcase.
•
•Apply a thin bead of sealant toApply a thin bead of sealant to
mating fa
mating face of engine pan,ce of engine pan, see 10.
see 10.
Important!
Important! Follow the Follow the manufacturer’s instructions. manufacturer’s instructions. - Fit engine pan and cla
- Fit engine pan and clamp it tomp it to crankcase with puller,
crankcase with puller, see 4.1. see 4.1.
Assemble all other parts in the Assemble all other parts in the reverse sequence. reverse sequence. V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 7 7 V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 5 5 V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 4 4 2 2 2 2 11 V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 2 2 1 1 2 2 V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 6 6 1 1 22 V V A A 2 2 3 3 2 2 R R A A 1 1 3 3 3 3 2 2 1 1 22 11
It is not necessary to
It is not necessary to disassembledisassemble the complete engine in order to the complete engine in order to replace the oil seals.
replace the oil seals.
Starter side: Starter side:
- Remove starter cup,
- Remove starter cup, see 8.2. see 8.2.
- Remove housing parts, see - Remove housing parts, see
handbook "Components, handbook "Components, Basic Engine 4140". Basic Engine 4140".
•
•Apply puller (1) 5910 890 4400Apply puller (1) 5910 890 4400
(with No. 3.1 jaws (with No. 3.1 jaws 0000 893 3706). 0000 893 3706). - Tension the arms. - Tension the arms. - Pull out oil seal. - Pull out oil seal. Important:
Important: Take care not to Take care not to damage the crankshaft stub. damage the crankshaft stub. - Clean sealing surface with a - Clean sealing surface with a
standard solvent-based standard solvent-based
degreasant containing neither degreasant containing neither chlorinated nor
chlorinated nor halogenat halogenateded hydrocarbons,
hydrocarbons, see 10.see 10.
-- Grease se Grease sealing lips of oil seal,aling lips of oil seal, see 10.
see 10.
•
•Slip assembly sleeve (1)Slip assembly sleeve (1)
1129 893 4600 over the 1129 893 4600 over the crankshaft stub.
crankshaft stub.
•
•Slide oil seal (1) over theSlide oil seal (1) over the
crankshaft stub, open side facing crankshaft stub, open side facing the crankcase.
the crankcase.
•
•Press fully home with pressPress fully home with press
sleeve (2) 1114 893 4601. sleeve (2) 1114 893 4601. - Fit housing parts.
- Fit housing parts. - Install starter cup. - Install starter cup.
Clutch side: Clutch side:
- Remove flywheel,
- Remove flywheel, see 7.2.see 7.2.
•
•Apply puller (1) 5910 890 4400Apply puller (1) 5910 890 4400
(with No. 3.1 jaws (with No. 3.1 jaws 0000 893 3706). 0000 893 3706). - Tension the arms. - Tension the arms. - Pull out oil seal. - Pull out oil seal. Important:
Important: Take care not to Take care not to damage the crankshaft stub. damage the crankshaft stub. - Clean sealing surface with a - Clean sealing surface with a
standard solvent-based standard solvent-based
degreasant containing neither degreasant containing neither chlorinated nor
chlorinated nor halogena halogenatedted hydrocarbons,
hydrocarbons, see 10. see 10.
-
- Grease sealing lips of oil seal,Grease sealing lips of oil seal, see 10.
see 10.
•
•Slide oil seal (1) over assemblySlide oil seal (1) over assembly
sleeve with open side facing sleeve with open side facing crankcase. crankcase. 5 5..1 1 OOiill sseeaallss V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 0 0 2 2 1 1 V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 8 8 1 1 V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 1 1 1 1 V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 9 9 1 1 V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 2 2 2 2 1 1
•
•Press fully home with pressPress fully home with press
sleeve (2) 1120 893 2400. sleeve (2) 1120 893 2400. - Fit flywheel.
- Fit flywheel.
Leaks are usually caused by Leaks are usually caused by defective oil seals or gaskets and defective oil seals or gaskets and cracks in castings of the spacer cracks in castings of the spacer flange.
flange. Such Such faults faults allowallow supplementary air to enter the supplementary air to enter the engine and thus upset the fuel-air engine and thus upset the fuel-air mixture.
mixture.
This makes adjustment of the This makes adjustment of the prescribed idle speed difficult, if prescribed idle speed difficult, if not impossible.
not impossible.
Moreover, the transition from idle Moreover, the transition from idle speed to part or full throttle is not speed to part or full throttle is not smooth.
smooth.
The crankcase can be checked The crankcase can be checked thoroughly for leaks with the thoroughly for leaks with the carburetor and crankcase tester carburetor and crankcase tester and the vacuum pump.
and the vacuum pump.
- Remove shroud, carburetor and - Remove shroud, carburetor and
starter cover, see handbook starter cover, see handbook "Machine components, 4140". "Machine components, 4140". - Set piston to top dead centre - Set piston to top dead centre
(T.D.C.).
(T.D.C.). This cThis can be an be checkedchecked through the inlet port.
through the inlet port.
- Check that the spark plug is - Check that the spark plug is
properly tightened down. properly tightened down.
•
•Fit a new gasket on spacerFit a new gasket on spacer
flange. flange.
•
•Fit test flange (1) 1128 850 4200.Fit test flange (1) 1128 850 4200.
Fit nuts (2) and tighten down to Fit nuts (2) and tighten down to 3.5 Nm.
3.5 Nm. 6
6. . LLeeaakkaagge te teesst t 66..1 1 PPrreeppaarraattiioonnss
V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 2 2 V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 3 3 1 1 2 2 2 2
-
- Slacken muffler mounting screwSlacken muffler mounting screwss half-way.
half-way.
•
•Slide sealing plate (1)Slide sealing plate (1)
0000 855 8106 between gasket 0000 855 8106 between gasket and cylinder exhaust port. and cylinder exhaust port. Retighten screws moderately. Retighten screws moderately. Note:
Note: The sealing pThe sealing plate mustlate must completely fill the space between completely fill the space between the screws.
the screws.
- Carry out preparations
- Carry out preparations,, see 6.1.see 6.1.
•
•Connect pressure hose of testerConnect pressure hose of tester
1106 850 2905 to nipple on test 1106 850 2905 to nipple on test flange.
flange.
•
•Close vent screw (1) on rubberClose vent screw (1) on rubber
bulb. bulb.
- Use rubber bulb to pump air - Use rubber bulb to pump air
into the engine until the gauge into the engine until the gauge indicates a pressure of 0.5 bar indicates a pressure of 0.5 bar (5 kPa).
(5 kPa). If this prIf this pressure remainessure remainss constant for at least 20 seconds, constant for at least 20 seconds, the crankcase is airtight.
the crankcase is airtight.
•
•If the indicated pressure drops,If the indicated pressure drops,
the leak must be located and the the leak must be located and the faulty part replaced.
faulty part replaced. Note:
Note: To find the To find the leak, coatleak, coat the suspect area with oil and the suspect area with oil and pressurize the crankcase again. pressurize the crankcase again. Bubbles will appear if a leak exists. Bubbles will appear if a leak exists. - Repeat the pressure test.
- Repeat the pressure test. - Carry out vacuum test,
- Carry out vacuum test, see 6.3.see 6.3.
- After testing, open vent screw - After testing, open vent screw
and disconnect hose. and disconnect hose. - Remove test flange. - Remove test flange. -
- Slacken muffler mounting screSlacken muffler mounting screws.ws. - Pull out sealing plate and tighten - Pull out sealing plate and tighten
down the screws to 9.0 down the screws to 9.0 Nm.Nm. - Refit starter cover, carburetor - Refit starter cover, carburetor
and shroud, see handbook and shroud, see handbook "Machine components 4140". "Machine components 4140". 6
6..2 2 PPrreessssuurree tteesstt
V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 5 5 V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 4 4 1 1 1 1 4 4 3 3 R R A A 0 0 4 4 6 6 V V A A 1 1 2 2 3 3 2 2 R R A A 0 0 3 3 6 6 0 0 0 0,,22 0 0,,44 00,,66 0 0,,88 1 1,,00 V V A A
Oil seals tend to fail when Oil seals tend to fail when subjected to a vacuum, i.e. the subjected to a vacuum, i.e. the sealing lip lifts away from the sealing lip lifts away from the crankshaft during the piston’s crankshaft during the piston’s induction stroke because there induction stroke because there is no internal counterpressure. is no internal counterpressure. An additional test can be carried An additional test can be carried out with the vacuum pump to out with the vacuum pump to detect this kind of fault. detect this kind of fault. - Carry out preparations,
- Carry out preparations, see 6.1.see 6.1.
•
•Connect suction hose of vacuumConnect suction hose of vacuum
pump 0000 850 3501 to nipple pump 0000 850 3501 to nipple on test flange.
on test flange.
•
•Close vent screw (1) on Close vent screw (1) on pumppump
cylinder. cylinder.
•
•Operate lever (2) until theOperate lever (2) until the
gauge (3) shows a vacuum of gauge (3) shows a vacuum of 0.5 bar (5 kPa).
0.5 bar (5 kPa).
Note:
Note: If the vacuum If the vacuum readingreading remains constant or rises to no remains constant or rises to no more than 0.3 bar (3 k
more than 0.3 bar (3 kPa) withinPa) within 20 seconds, it may be assumed 20 seconds, it may be assumed that the oil seals are in
that the oil seals are in goodgood condition.
condition.
However, if the pressure continues However, if the pressure continues to rise (reduced vacuum in the to rise (reduced vacuum in the crankcase), the oil seals must be crankcase), the oil seals must be replaced.
replaced.
- After testing, open vent screw - After testing, open vent screw
and disconnect hose. and disconnect hose. - Remove test flange. - Remove test flange. -
- Slacken muffler mounting screwSlacken muffler mounting screws.s. - Pull out sealing plate and tighten - Pull out sealing plate and tighten
down the screws to 9.0 Nm. down the screws to 9.0 Nm. - Refit carburetor and shroud, - Refit carburetor and shroud,
see handbook "Machine see handbook "Machine components 4140". components 4140".
Warning!
Warning! Exercise extreme Exercise extreme caution when carrying out caution when carrying out maintenance and repair work or maintenance and repair work or troubleshooting on the ignition troubleshooting on the ignition system.
system. The high The high voltages whvoltages whichich occur can cause serious or even occur can cause serious or even fatal accidents!
fatal accidents!
Troubleshooting on the ignition Troubleshooting on the ignition system should always begin with system should always begin with the spark
the spark plug. plug. See "StandaSee "Standardrd Repairs, Troubleshooting" Repairs, Troubleshooting" handbook.
handbook.
Note:
Note: The electronic The electronic
(breakerless) ignition system (breakerless) ignition system basically consists of an ignition basically consists of an ignition module (1) and flywheel (2). module (1) and flywheel (2). 6
6..3 3 VVaaccuuuumm tteesst t 77. . IIggnniittiioonn ssyysstteemm
V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 5 5 V V A A 2 2 3 3 2 2 R R A A 0 0 3 3 7 7 1 1 2 2 3 3 V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 3 3 2 2 1 1
The ignition module The ignition module accommo-dates all the components required dates all the components required to control ignition timing.
to control ignition timing. There are two electrical There are two electrical connections on the coil body: connections on the coil body: A. The high-voltage output (1) A. The high-voltage output (1)
with ignition lead (2) with ignition lead (2)
B. The connector tag (3) for the B. The connector tag (3) for the
short-circuit wire short-circuit wire
Accurate testing of the ignition Accurate testing of the ignition module is only possible with module is only possible with sophisticated
sophisticated test equipmtest equipment. ent. ForFor this reason, it is only necessary to this reason, it is only necessary to carry out a spark test in the
carry out a spark test in the workshop.
workshop. A new A new ignition ignition modulemodule must be installed if an ignition must be installed if an ignition spark is not obtained (after spark is not obtained (after checking that wiring and stop checking that wiring and stop switch are in good condition). switch are in good condition).
Ignition timing is
Ignition timing is not not adjustable. adjustable. Since there is no mechanical wear Since there is no mechanical wear in these systems, ignition timing in these systems, ignition timing cannot get out of adjustment. cannot get out of adjustment. However, an internal fault in the However, an internal fault in the circuit can alter the switching point circuit can alter the switching point in such a way that a spark test will in such a way that a spark test will still show the system to be in still show the system to be in orderorder although timing is outside the although timing is outside the permissible
permissible tolerance. tolerance. This wThis willill impair engine starting and running impair engine starting and running behaviour.
behaviour. - - Remove Remove shroud shroud or or relevantrelevant housing part, see handbook housing part, see handbook "Machine components 4140". "Machine components 4140".
•
•Disconnect short-circuit wire (1)Disconnect short-circuit wire (1)
and ground wire (2) from ignition and ground wire (2) from ignition module.
module.
- Pull boot off spark plug. - Pull boot off spark plug.
•
•Undo screws.Undo screws.
- Remove ignition module. - Remove ignition module. 7
7..1 1 IIggnniittiioon mn moodduulle e 77..11..1 1 IIggnniittiioonn ttiimmiinng g 77..11..2 2 RReemmoovvaall aannd id innssttaallllaattiioonn
V V A A 2 2 3 3 2 2 R R A A 0 0 0 0 5 5 2 2 1 1 V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 4 4 3 3 2 2 1 1 V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 5 5
Note:
Note: The ignition lThe ignition lead isead is moulded to the ignition
moulded to the ignition module.module. -
- Place ignition module in positiPlace ignition module in positionon and insert screws, but do not and insert screws, but do not tighten them down yet.
tighten them down yet.
•
•Secure connector tag (1) forSecure connector tag (1) for
ground wire with upper screw. ground wire with upper screw.
•
•Slide setting gauge (2)Slide setting gauge (2)
1127 890 6400 between arms 1127 890 6400 between arms of ignition module and flywheel of ignition module and flywheel magnet poles.
magnet poles. -
- Press ignition module againstPress ignition module against setting gauge and tighten down setting gauge and tighten down the mounting screws to a torque the mounting screws to a torque of 4.5 Nm.
of 4.5 Nm.
Assemble all other parts in the Assemble all other parts in the reverse sequence.
reverse sequence.
Removing the flywheel: Removing the flywheel: - Remove clutch,
- Remove clutch,
see handbook "Components, see handbook "Components, Basic Engine 4140".
Basic Engine 4140".
•
•Lightly tap the end of theLightly tap the end of the
crankshaft stub with a rubber crankshaft stub with a rubber mallet to free the flywheel. mallet to free the flywheel. - Pull off the flywheel.
- Pull off the flywheel.
Note:
Note: There must not There must not be anybe any cracks or other signs of damage cracks or other signs of damage visible in the flywheel (1) and visible in the flywheel (1) and magnet poles (2), otherwise the magnet poles (2), otherwise the flywheel must be replaced. flywheel must be replaced.
Installing the flywheel: Installing the flywheel: Important:
Important: Degrease the Degrease the stub ofstub of the crankshaft and bore of the the crankshaft and bore of the flywheel hub with a standard flywheel hub with a standard commercial solvent-based commercial solvent-based degreasant containing neither degreasant containing neither chlorinated no
chlorinated nor halogenr halogenatedated hydrocarbons,
hydrocarbons, see 10. see 10.
- Fit flywheel. - Fit flywheel. Note:
Note: Check position of Check position of slot.slot. - Install clutch,
- Install clutch,
see handbook "Components, see handbook "Components, Basic engine 4140".
Basic engine 4140".
- Pull locking strip out of cylinder. - Pull locking strip out of cylinder. - Fit spark plug and torque down - Fit spark plug and torque down
to 20 Nm. to 20 Nm.
•
•If the spark plug comes with aIf the spark plug comes with a
separate terminal nut, always separate terminal nut, always check that the nut is securely check that the nut is securely tightened down on the thread tightened down on the thread and retighten if necessary. and retighten if necessary. - Fit boot on spark plug. - Fit boot on spark plug. 7
7..2 2 FFllyywwhheeeell // ffaann wwhheeeell
V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 6 6 2 2 1 1 2 2 3 3 2 2 R R A A 0 0 4 4 7 7 V V A A V V A A 2 2 5 5 0 0 R R A A 0 0 0 0 8 8 V V A A 2 2 3 3 2 2 R R A A 0 0 4 4 8 8 1 1 2 2
If the action of the starter rope If the action of the starter rope becomes very stiff and the becomes very stiff and the rope rewinds very slowly or rope rewinds very slowly or incompletely, it may be assumed incompletely, it may be assumed that the starter mechanism is in that the starter mechanism is in order but
order but plugged wiplugged with dirt. th dirt. AtAt very low outside temperatures, the very low outside temperatures, the lubricating oil on the rewind spring lubricating oil on the rewind spring may thicken and cause the spring may thicken and cause the spring windings
windings to stick to stick together. together. ThisThis has a detrimental effect on the has a detrimental effect on the function of the starter mechanism. function of the starter mechanism. In such a case, it is sufficient to In such a case, it is sufficient to apply a few drops of paraffin apply a few drops of paraffin (kerosine) to the rewind spring. (kerosine) to the rewind spring. Then carefully pull out the starter Then carefully pull out the starter rope several times and allow it to rope several times and allow it to rewind until its normal smooth rewind until its normal smooth action is restored.
action is restored.
If clogged with dirt or pitch, the If clogged with dirt or pitch, the entire starter mechanism, entire starter mechanism,
including the rewind spring, must including the rewind spring, must be removed and
be removed and disassembled.disassembled. Take particular care when Take particular care when removing the spring. removing the spring.
Wash all parts in paraffin or Wash all parts in paraffin or whitewhite spirit.
spirit.
Lubricate the rewind spring and Lubricate the rewind spring and starter p
starter post with STIost with STIHL specialHL special lubricant
lubricant,, see 10see 10, be, before installing.fore installing.
- Remove starter cover, see - Remove starter cover, see
handbook "Components, handbook "Components, Basic Engine 4140". Basic Engine 4140". - Unscrew spark plug. - Unscrew spark plug.
•
•Fit locking strip (1)Fit locking strip (1)
4221 893 5900. 4221 893 5900.
•
•Unscrew starter cup.Unscrew starter cup.
•
•Fit starter cup and torque downFit starter cup and torque down
to 17.0 Nm. to 17.0 Nm.
Install all other parts in the
Install all other parts in the reversereverse sequence.
sequence. 8
8. . RReewwiinndd ssttaarrtteerr 8
8..1 1 GGeenneerraal l 88..2 2 SSttaarrtteerr ccuupp
V V A A 2 2 3 3 2 2 R R A A 0 0 6 6 5 5 V V A A 2 2 3 3 2 2 R R A A 0 0 6 6 4 4 1 1 V V A A 2 2 3 3 2 2 R R A A 0 0 6 6 6 6
N
Noo. . PPaarrt t nnaamme e PPaarrt t NNoo. . AApppplliiccaattiioon n RReemmaarrkkss 1
1 Locking Locking strip strip for for piston piston 4221 4221 893 893 5900 5900 Blocking Blocking crankshaftcrankshaft 2
2 Puller Puller 5910 5910 890 890 4400 4400 Removing Removing oil oil seals seals 1)1) 3
3 - - JJaawws s ((pprrooffiille e NNoo. . 33..1 1 + + 44) ) 0000000 0 88993 3 33770066 4
4 - - JJaawws s ((pprrooffiille e NNoo. . 22) ) 0000000 0 88993 3 3377000 0 CCllaammppiinng g eennggiinne e ppaan n aanndd crankcase
crankcase 5
5 - - SSccrreew w bbuussh h 1111008 8 88993 3 44550000 6
6 CCaarrbbuurreettoor r aannd d 1111006 6 88550 0 2299005 5 TTeessttiinng g ccaarrbbuurreettoor r aanndd c
crraannkkccaasse e tteesstteer r crrac annkkccaasse e ffoor r lleeaakkss 7
7 VVaaccuuuum m ppuummp p 0000000 0 88550 0 3355001 1 TTeessttiinng g ccrraannkkccaasse e ffoor r lleeaakkss 8
8 SSeeaalliinng g ppllaatte e 0000000 0 88555 5 8811006 6 SSeeaalliinng g eexxhhaauusst t ppoorrt t ffoorr leakage test
leakage test 9
9 TTeesst t ffllaanngge e 1111228 8 88550 0 4422000 0 LLeeaakkaagge e tteesstt 1
10 0 AAsssseemmbblly y sslleeeevve e 1111229 9 88993 3 4466000 0 PPrrootteeccttiinng g ooiil l sseeaall (starter side) (starter side) 1
11 1 PPrreesss s sslleeeevve e 1111114 4 88993 3 4466001 1 IInnssttaalllliinng g ooiil l sseeaall (starter side) (starter side) 1
12 2 PPrreesss s sslleeeevve e 1111220 0 88993 3 2244000 0 IInnssttaalllliinng g ooiil l sseeaall (clutch side) (clutch side) 13
13 Setting Setting gauge gauge 1127 1127 890 890 6400 6400 Setting Setting air air gap gap between between 2)2) ignition module and flywheel
ignition module and flywheel 1
14 4 CCrriimmppiinng g ttooool l 5599110 0 88990 0 8822110 0 AAttttaacchhiinng g ccoonnnneeccttoorrss to electrical wires to electrical wires 15
15 Torque Torque wrench wrench 5910 5910 890 890 0301 0301 Screw Screw connections connections 3)3) (0.5 to 18 Nm)
(0.5 to 18 Nm) 5910
5910 890 890 0302 0302 4)4)
16
16 Torque Torque wrench wrench 5910 5910 890 890 0311 0311 Screw Screw connections connections 3)3) (6 to 80 Nm)
(6 to 80 Nm) 5910
5910 890 890 0312 0312 4)4)
17
17 SpSpllinine e sscrcreew w sosockcket et TT2727x1x125 25 0810812 2 54542 2 212104 04 TTiighghtetenining ng hhexexagagononalal socket-head screws socket-head screws 18
18 Screwdriver Screwdriver 5910 5910 890 890 2400 2400 For For all all hexagonal hexagonal 5)5) Q
Q--TT2277xx11550 0 ssoocckkeett--hheeaad d ssccrreewwss 1
19 9 AAsssseemmbblly y ssttaannd d 5599110 0 88990 0 3311000 0 HHoollddiinng g FFS S uunniittss 2
20 0 - - CCllaammp p 5959110 0 88990 0 8888000 0 HHoollddiinng g FFS S uunniitts s bby y ddrriivve e ttuubbee for servicing (in conjunction for servicing (in conjunction with assembly stand)
with assembly stand) 2
21 1 AAsssseemmbblly y ddrriifft t 1111114 4 88993 3 4477000 0 IInnssttaalllliinng g ppiissttoon n ppiinn 2
22 2 WWooooddeen n aasssseemmbblly y bblloocck k 1111008 8 88993 3 4488000 0 FFiittttiinng g ppiissttoonn 2
23 3 CCllaammppiinng g ssttrraap p 0000000 0 88993 3 2266000 0 CCoommpprreessssiinng g ppiissttoon n rriinngg
Remarks: Remarks: 1)
1) Equivalent to puller 0000 890 44Equivalent to puller 0000 890 4400, but with longer spindle 5900, but with longer spindle 5910 890 8400.10 890 8400. 2)
2) Setting gauge 1111 Setting gauge 1111 890 6400 can b890 6400 can be used instead.e used instead. 3)
3) Always use torque Always use torque wrench to tighten wrench to tighten DG/P screws.DG/P screws. 4)
4) Wrench includeWrench includes visual/acoustic s visual/acoustic signal.signal. 5)
5) May only be May only be used on GD/P used on GD/P screws for releasiscrews for releasing.ng. 9
N
Noo. . PPaarrt t nnaamme e PPaarrt t NNoo. . AApppplliiccaattiioonn 1
1 LLuubbrriiccaattiinng g ggrreeaasse e 0077881 1 11220 0 1111111 1 OOiil l sseeaallss (370 g tube)
(370 g tube) 2
2 SSttaannddaarrd d ccoommmmeerrcciiaal l ssoollvveenntt- - CClleeaanniinng g ccrraannkksshhaafft t ssttuubb based degreasant containing
based degreasant containing neither chlorinated nor
neither chlorinated nor halogenated hydrocarbons halogenated hydrocarbons 3
3 SSTTIIHHL L ssppeecciiaal l lluubbrriiccaannt t 0077881 1 44117 7 1133115 5 BBeeaarriinng g bboorre e iin n rrooppe e rroottoorr,, rewind spring in rope rotor rewind spring in rope rotor 4
4 EElleeccttrriiccaal l rreeppaaiir r kkiit t 5599110 0 00007 7 1100550 0 EElleeccttrriiccaal l ssyysstteemm 5
5 DDiirrkko o sseeaallaannt t 0077883 3 88330 0 2211220 0 SSeeaalliinng g eennggiinne e ppaan n / / ccyylliinnddeerr
1
11. 1. SpecSpeciaiall acaccecessssoorriieses ffoorr tthhee uusserer
P
Paarrt t nnaamme e PPaarrt t NNoo.. Safety glasses
Safety glasses STIHL ElastoStart STIHL ElastoStart
((ssttaarrtteer r rrooppe e wwiitth h ggrriipp) ) 0000000 0 11990 0 33440000 STIHL gear lubricant for brushcutters
STIHL gear lubricant for brushcutters -
- ttuubbe e 880 0 g g 0077881 1 11220 0 11111177 -
- ttuubbe e 22225 5 g g 0077881 1 11220 0 11111188 STIHL gear lubricant for
STIHL gear lubricant for hedge trimmers hedge trimmers - - ttuubbe e 880 0 g g 0077881 1 11220 0 11110099 - - ttuubbe e 22225 5 g g 0077881 1 11220 0 11111100 1
