Service Manual - Stihl FS94 KM94 SP92 SP92T

STIH)
STIHL Series 4149 Powerhead 2014-10
FS 94
KM 94
SP 92, SP 92 T
Contents
1. Introduction and 6.4 Spark Plug Boot / 10. Fuel System 67

Safety Precautions 2 Ignition Lead 38
6.5 Flywheel 39 10.1 Air filter 67
1.1 Introduction 2 6.6 Short Circuit Wire 40 10.2 Filter Housing 67
1.2 Safety Precautions 3 6.6.1 Testing 40 10.3 Carburetor 68
6.6.2 Short Circuit Wire 10.3.1 Leakage Test 70
on Engine 10.4 Servicing the
2. Specifications 4 – Removing and Carburetor 71
Installing 41 10.4.1 Metering Diaphragm 71
2.1 Engine 4 6.6.3 Short Circuit Wire and 10.4.2 Inlet Needle 72
2.2 Fuel System 4 Contact Springs 10.4.3 Pump Diaphragm 73
2.3 Ignition System 4 on Control Handle 10.4.4 Control Valve 74
2.4 Tightening Torques 5 – Removing and 10.4.5 Adjusting Screws 75
Installing 42 10.5 Adjusting the
6.6.4 Ground Wire 44 Carburetor 76
3. Troubleshooting 7 6.6.5 Contact Springs 44 10.5.1 Basic Setting 76
6.7 Ignition System 10.5.2 Adjustments by User 78
3.1 Clutch 7 Troubleshooting 45 10.6 Spacer Flange 79
3.2 Rewind Starter 8 10.7 Tank Vent 80
3.3 Ignition System 10 10.7.1 Testing 80
3.4 Carburetor 11 7. Rewind Starter 48 10.7.2 Removing and
3.5 11 Installing 81
3.6 Engine 15 7.1 General 48 10.8 Fuel Intake 82
7.2 Rewind Starter 48 10.8.1 Pickup Body 82
7.3 Pawl / Carrier 49 10.8.2 Fuel Hose
4. Clutch 16 7.4 ErgoStart / on Carburetor 82
Rope Rotor 50 10.8.3 Fuel Suction Hose
4.1 Clutch Drum 16 7.5 Starter Rope / Grip 51 in Fuel Tank 83
4.2 Clutch 17 7.6 Tensioning 10.8.4 Fuel Hose / Fuel
the Rewind Spring 52 Return Hose and
7.7 Replacing Manual Fuel Pump 84
5. Engine 19 the Rewind Spring 53 10.9 Fuel Tank 86
10.9.1 Fuel Tank
5.1 Muffler / Spark Removing and
Arresting Screen 19 8. AV Elements 55 Installing 86
5.2 Leakage Test 20 10.9.2 Fuel tank
5.2.1 Preparations 21 8.1 Rubber Element 55 Replacing 87
5.2.2 Vacuum Test 21 10.9.3 Tank Guard (FS 94) 89
5.2.3 Pressure Test 22
5.3 Oil Seals 22 9. Control Levers 57
5.4 Shroud 24 11. Special Servicing
5.4.1 Air guide shroud 25 9.1 Control Handle Tools 90
5.5 Cylinder 26 on Drive Tube
5.6 Crankshaft 29 Removing and
5.6.1 Bearings / Installing 57 12. Servicing Aids 92
Crankcase 32 9.2 Control Handle for
5.7 Piston 34 Bike Handle
5.8 Piston Rings 35 Removing and
Installing 58
9.3 Throttle Trigger /
RA_593_00_01_03
6. Ignition System 36 Lockout Lever 59

9.4 Stop switch lever
6.1 Ignition Timing 36 (momentary contact
6.2 Install new switch): 62
ignition module 36 9.5 Adjusting Wheel 63
6.3 Testing the 9.6 Adjusting the
Ignition Module 38 Throttle Cable 65
6.3.1 Testing
Ignition Module q
with STIHL MDG 1 38 © ANDREAS STIHL AG & Co. KG, 2014
Series 4149 Powerhead 1

1. Introduction and Safety Precautions
1.1 Introduction The special tools mentioned in the Always use original STIHL
descriptions are listed in the chapter replacement parts.
on "Special Servicing Tools" in this They can be identified by the STIHL
This service manual contains
manual. Use the part numbers to part number,
detailed descriptions of all the repair
identify the tools in the the { logo and the
and servicing procedures specific to
"STIHL Special Tools" manual. The STIHL parts symbol K
this power tool.
manual lists all special servicing This symbol may appear alone on
tools currently available from small parts.
You should make use of the
STIHL.
illustrated parts lists while carrying
Storing and disposing of oils
out repair work. They show the
Symbols are included in the text and and fuels
installed positions of the individual
pictures for greater clarity.
components and assemblies.
The meanings are as follows: Collect fuel or lubricating oil in a
clean container and dispose of it
Refer to the latest edition of the
In the descriptions: properly in accordance with local
relevant parts list to check the part
environmental regulations.
numbers of any replacement parts.
N Action to be taken as shown in
the illustration above the text
A malfunction on the machine may
have several causes. To help locate
the problem, consult the chapter on – Action to be taken that is not
"Troubleshooting" and the shown in the illustration above
"STIHL Service Training System" the text
for all assemblies.
In the illustrations:
Refer to the “Technical Information”
bulletins for engineering changes A Pointer
which have been introduced since
publication of this service manual. a Direction of movement
Technical information bulletins also
supplement the parts list until a @ 4.2 =Reference to another
revised edition is issued. chapter, i.e. chapter 4.2
in this example.
Service manuals and all technical

information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed to third parties.
2 Series 4149 Powerhead

1.2 Safety Precautions The chapter on tightening torques
lists all machine components that
have to be tightened to a specific
If the machine is started up in the
torque or coated with threadlocking
course of repairs or maintenance
adhesive. The specifications must
work, observe all local and country-
be maintained when tightening
specific safety regulations as well
down screws, nuts and other
as the safety precautions and
fasteners in all the procedures
warnings in the instruction manual.
described in this service manual.
Gasoline is an extremely flammable
fuel and can be explosive in certain
Fuel system – hose barb
conditions.
connectors
Do not smoke or bring any fire,
Pull off or push on fuel hoses in line
flame or other source of heat near
with the connector, preferably by
the fuel. All work with fuel must be
hand, to ensure the tightness of the
performed outdoors only. Spilled
fuel system.
fuel must be wiped away
immediately.
Avoid damaging the hose barb
– do not use sharp-edged pliers,
Always perform leakage test after
screwdrivers, etc.
working on the fuel system and the
Do not cut open fuel hoses with a
engine.
knife or similar tool.
Exercise extreme caution while
Do not re-use fuel hoses after
carrying out maintenance and repair
removal. Always install new hoses
work on the ignition system. The
– fuel hoses can be overstretched
high voltages which occur can
during removal.
cause serious or fatal accidents.
Install new fuel hoses either dry or
Always wear suitable protective
with the aid of STIHL press fluid,
gloves for operations in which
b 12.
components are heated for
assembly or disassembly. Hot
Other press fluids are not approved
grease can cause burn injuries. The
and may result in damage to the fuel
lubricants in the components can
hoses.
become very hot.
Coat the ends of the hoses and the
Improper handling may result in
connectors with STIHL press fluid
burns or other serious injuries.
and then push the new hoses on to
the hose barbs, b 12.
Always replace damaged parts.
Check disassembled parts for wear
or damage before re-installing –
replace as necessary.
Run the machine only with the

shroud mounted in position – there
is otherwise a risk of injury from the
fanwheel and a risk of engine
damage due to overheating.

2. Specifications
2.1 Engine
SP 92, SP 92 T FS 94, KM 94
Displacement: 21.4 cm3 24.1 cm3

Bore: 33.0 mm 35.0 mm
Stroke: 25.0 mm 25.0 mm
Engine power to ISO 8893: 0.75 kW (1.0 bhp) 0.9 kW (1.2 bhp)
at 8,500 rpm at 8,500 rpm
Max. torque
at engine speed (rated): 1 Nm / 5,000 rpm 1.3 Nm / 5,000 rpm
Cut-off speed (rated): 9,800 rpm 1) 9,800 rpm 1)
Idle speed (rated): 2,800 rpm 2,800 rpm
Clutch: Centrifugal clutch without linings Centrifugal clutch without linings
Clutch engages at (rated): 3,850 rpm 3,850 rpm
Crankcase leakage test
at gauge pressure: 0.5 bar 0.5 bar
under vacuum: 0.5 bar 0.5 bar
2.2 Fuel System
Carburetor leakage test at gauge

pressure: 0.8 bar 0.8 bar
Operation of tank vent at gauge
pressure: 0.5 bar 0.5 bar
Fuel: as specified in instruction manual as specified in instruction manual
2.3 Ignition System
Air gap between ignition module and

fanwheel: 0.30 (+ 0.15/- 0.20) mm 0.30 (+ 0.15/- 0.20) mm
Spark plug (resistor type): NGK CMR 6 H NGK CMR 6 H
BOSCH USR 4 AC BOSCH USR 4 AC
Electrode gap: 0.5 mm 0.5 mm
1) The engine reaches its maximum RPM and maximum power after the break-in period (5 to 10 tank fillings) –
do not make any changes to the high speed screw (H) during the break-in period.

2.4 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.
Use the following procedure when refitting a DG or P screw in an existing thread:

Insert the screw in the hole and rotate it counterclockwise until it drops down slightly and engages in the existing
thread. 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.
Micro-encapsulated screws and screws coated with threadlocking adhesive:

Before re-installing, clean both threads (screw tap into female thread by hand and then blow out with
compressed air; clean male thread with brush), coat micro-encapsulated screws with medium-strength Loctite
242 or 243, and screws previously coated with threadlocking adhesive with Loctite (see list of screws below).
Power screwdriver setting for polymer: P and DG screws max. 500 rpm.
Do not use an impact wrench for releasing or tightening screws.
Do not mix up screws with and without binding heads.
Fastener Thread size For component Torque Remarks
Nm
Screw M 5x12 Cover / shroud 5.0 1), 2)

Screw D 5x24 Rewind starter / shroud / cylinder 6.0 1), 2)
Screw D 5x24 Rewind starter / tank housing / crankcase 6.0 1), 2)
Screw P 4x16 Control handle molding, outer / inner 1.3 1), 2)
Screw M 5x12 Control handle clamp/shaft 5.0 1), 2)
Screw P 4x10 Control handle, throttle set wheel / lever / 1.3
inner handle molding
Screw M 5x12 Filter cover / filter housing 5.0
Nut M5 Filter housing / carburetor 3.5
Screw D 5x12 Sleeve, anti-vibration / drive tube 5)
Screw M 5x20 Sleeve, anti-vibration clamp screw 5.5 1), 2)
Screw M 6x25 Clutch / flywheel 12.0
Screw D 5x24 Crankcase / cylinder 8.0 1), 2)
Screw D 5x24 Crankcase, flywheel side / crankcase, starter 8.0 1), 2)
side
Screw D 5x24 Fan housing / shroud / crankcase 6.0 1), 2)
Screw D 5x24 Fan housing / crankcase 6.0 1). 2)
Carrier M 8x1 Carrier / crankshaft 17,0
Screw D 5x20 Muffler / cylinder 8,0 1). 2)
Nut M6 Flywheel / crankshaft 12.0 4)
Nut M8 Flywheel / crankshaft 16.0 4)

Fastener Thread size For component Torque Remarks
Nm
Screw D 5x12 Carburetor / throttle cable 3.0

M 10x1 Spark plug / cylinder 12.0
Screw D 4x20 Ignition module / cylinder 4.0 1), 2)
Screw D 5x28 Spacer flange / cylinder 7.0 1), 2)
Remarks:
1) Screws with binding head

2) Waxed screws
3) Micro-encapsulated screws
4) Degrease crankshaft / flywheel and mount oil-free
5) Tighten down until head is seated

3. Troubleshooting
3.1 Clutch
Condition Cause Remedy
Working tool stops under full load Clutch shoes badly worn Install new clutch
Clutch drum badly worn Install new clutch drum
Working tool runs when engine Engine idle speed too high Readjust with idle speed screw LA
is idling
Clutch spring stretched Replace the clutch spring or install

new clutch
Clutch spring broken Replace the clutch spring
Loud noises Clutch spring stretched Replace clutch spring
Clutch drum bearing damaged Replace fan housing
Clutch screws loose Tighten down screws, replace

clutch if necessary and check
tapped holes in flywheel, replace
flywheel if necessary
Clutch shoes worn Install new clutch

3.2 Rewind Starter
Starter rope broken Rope pulled out too vigorously as Install new starter rope
far as stop or constantly over the
edge
Normal wear Install new starter rope
Starter rope does not rewind Rewind spring very dirty or Clean or replace rewind spring
corroded
Insufficient spring tension Check rewind spring and increase

tension
Rewind spring broken Install new rewind spring
Starter rope cannot be pulled out Spring overtensioned Check rewind spring and reduce
far enough tension
Starter rope can be pulled out Pegs on pawls broken or pawls Replace pawls
almost without resistance worn
(crankshaft does not turn)
Pawl springs fatigued Fit new springs and check pawls,

replace if necessary
Springs not installed correctly Install springs correctly
Lugs on carrier worn Fit new carrier, check pawls and

Spring loop in ErgoStart spring Attach ErgoStart spring loop to

housing not attached to carrier carrier

Starter rope is difficult to pull or Starter mechanism is very dirty Thoroughly clean complete starter
rewinds very slowly mechanism
ErgoStart spring in rope rotor Replace ErgoStart spring, check

fatigued carrier and rope rotor, replace if
necessary
At very low outside temperatures: Coat rewind spring with a small

Lubricating oil on rewind spring amount of standard solvent-based
becomes viscous (spring windings degreasant (containing no
stick together) or moisture has got chlorinated or halogenated
onto the rewind spring (spring hydrocarbons), then pull rope
windings frozen together) carefully several times until normal
action is restored

3.3 Ignition System
Exercise extreme caution while

carrying out maintenance and
repair work on the ignition system.
The high voltages which occur can
cause serious or fatal accidents.
Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug
temporary loss of power and fit new spring if necessary
Spark plug sooted, smeared with oil Clean the spark plug or replace if
necessary.
If sooting keeps recurring, check air
filter
Fuel/oil mixture Use correct mixture of fuel and oil

– too much oil
Incorrect air gap between ignition Set air gap correctly

module and flywheel
Flywheel cracked or Install new flywheel

damaged or pole shoes have
turned blue
Ignition timing wrong, flywheel out Install new flywheel

of adjustment
– key in flywheel has sheared off
Weak magnetization in flywheel Install new flywheel
Irregular spark Check operation of lever for stop

function (stop switch) / contact
spring and ignition module.
Damaged insulation or break in
ignition lead or short circuit. Check
ignition lead/module, replace
ignition module if necessary. Check
operation of spark plug, clean or
replace spark plug if necessary.

3.4 Carburetor
Carburetor floods; engine stalls Inlet needle not sealing Remove and clean the inlet needle,
– foreign matter in valve seat or clean the carburetor
cone
Inlet needle worn Fit new inlet needle
Inlet control lever sticking on Check the inlet control lever and
spindle replace if necessary
Helical spring not located on nipple Remove the inlet control lever and
of inlet control lever refit it correctly
Perforated disc on metering Fit new metering diaphragm

diaphragm is deformed and
presses constantly against the inlet
control lever
Metered diaphragm deformed Fit new metering diaphragm
Poor acceleration Setting of low speed screw too lean Check basic carburetor setting,
correct if necessary
Setting of high speed screw too Check basic carburetor setting,

lean correct if necessary
Inlet needle sticking to valve seat Remove inlet needle, clean and
refit
Metering diaphragm gasket leaking Fit new diaphragm gasket
Metering diaphragm damaged or Fit new metering diaphragm

shrunk
Tank vent faulty Fit new tank vent
Leak in fuel hose from tank to Seal connections or install new fuel
carburetor hose
3.5

Engine loses power during Jet on the Clean the carburetor

acceleration low speed screw L dirty –
insufficient volume of fuel, engine
running too lean
Fuel strainer dirty Clean fuel strainer and carburetor
Engine will not idle, idle speed too Control valve opened too wide by Reset idle speed screw (LA)
high idle speed screw (LA) correctly
Oil seals / crankcase leaking Seal oil seals / crankcase, replace if

necessary
Cylinder gasket leaking Perform leakage test, inspect

sealing faces and replace cylinder
gasket if necessary
Gaskets on spacer flange and Perform leakage test, replace

carburetor leaking, or crack in gaskets and spacer flange if
spacer flange necessary
Spring in control valve broken or Install new control valve, check and
fatigued – throttle lever is not replace carburetor if necessary
returned to original position
Engine stops while idling Setting of low speed screw (L) too Reset low speed screw (L)
rich or too lean correctly
Setting of idle speed screw LA Reset idle speed screw (LA)

incorrect – control valve completely correctly
closed
Control valve lever does not locate Open the throttle wide, the control
against valve lever returns to its original
idle speed screw LA position and locates against the idle
– control valve completely closed speed screw (LA), replace control
valve if necessary
Leak in fuel hose from tank to Install a new fuel suction hose.
carburetor

Working tool runs when engine is Engine idle speed too high Readjust idle speed screw
idling LA (counterclockwise)
Clutch spring stretched or fatigued Replace the clutch spring or install

new clutch
Clutch spring hooks broken Replace the clutch spring
Engine speed drops quickly under Air filter dirty Clean or replace fleece filter;
load – low power replace paper filter
Control valve not opened fully Check the throttle cable and re-
adjust if necessary.
Leak in fuel hose from tank to Seal connections or install new fuel
carburetor hose
Setting of high speed screw (H) too Check basic carburetor setting,
rich correct if necessary
Fuel pickup body dirty Fit new pickup body
Fuel strainer dirty Clean fuel strainer in carburetor,

Main jet bores or ports blocked Clean the carburetor
Pump diaphragm damaged or Fit new pump diaphragm

fatigued
Ignition timing wrong, flywheel out Install new flywheel

of adjustment
– key in flywheel has sheared off

Engine running extremely rich, has Cold start device of control valve Check and clean the control valve
no power and a very low maximum sticking or does not return to or replace if necessary
speed original position
Engine does not start No spark Replace spark plug, check ignition
module/control unit, replace if
necessary
Starter rope not pulled vigorously Remove and dry off the spark plug,
enough pull starter rope several times to
– fuel mixture too rich (flooded) clear combustion chamber, refit
and tighten down the spark plug,
repeat starting procedure
Jet on the Clean the carburetor or replace if
low speed screw L blocked necessary
– no fuel feed
Jet on the Install new carburetor

low speed screw L broken – engine
stalls

3.6 Engine
Always check and, if necessary,

repair the following parts before
looking for faults on the engine:
- Air filter
- Fuel system
- Carburetor
- Ignition system
Engine does not start easily, stalls Oil seals in engine damaged Install new oil seals
at idle speed, but operates normally
at full throttle
Crankcase leaking or damaged Seal crankcase, replace if

(cracks) necessary
Engine does not deliver full power Piston rings worn or broken Install new piston rings
or runs erratically
Muffler carbonized Clean the muffler (inlet and

exhaust), replace if necessary
Air filter dirty Clean or replace fleece filter;

replace paper filter
Fuel hose kinked or torn Fit new hose or position it free from
kinks
Engine overheating Insufficient cylinder cooling. Thoroughly clean all cooling air
Air inlets in fan housing or air slots openings and the cylinder fins
in shroud blocked.
Cylinder cooling fins heavily soiled.

4. Clutch
4.1 Clutch Drum Installing

3
– Troubleshooting, b 3.1
1
– Remove the rewind starter, 1
b 7.2
0208RA002 TG
– Remove the shroud, b 5.4
2
0208RA003 TG
– Remove the drive tube, b 9.1
: Place the fan housing (1) on 2
ring (2) 5910 893 7008 – this
ensures the fan housing (1) is – Heat inner race of ball bearing to
upright and securely supported. about 120°C (250°F).
: Position the ring (2) so that it : Position clutch drum (1) on ball
engages the projecting clutch bearing (2) and push it home as
drum. far as stop.
2
7022RA000 TG
: Use suitable press arbor (3) to This operation must be carried out
1 remove the clutch drum. quickly because the clutch drum
absorbs heat and begins to expand.
: Take out the screw (1) and

remove the fan housing (2)
– the two upper screws have
already been removed. 1
1
– Remove the sleeve and rubber
element, b 8.1
100%
0208RA396 TG
0208RA004 TG
80%
2
– Inspect the clutch drum (1) for
signs of wear. If it is not possible the heat the inner
1 bearing race, use a bench press to
install the cold clutch drum.
If there are signs of serious wear on
the inside diameter of the clutch
– Support the other side of the fan
0208RA001 TG
drum (1), check the remaining wall

housing with a suitable tube on
thickness. If it is less than about
the inner race of the ball bearing.
80% of the original thickness, install
a new clutch drum.
: Remove the retaining ring (1). : Position clutch drum (1) on ball
If square socket is worn or the stub bearing (2) and press it home as
damage, install a new clutch drum. far as stop.
– Inspect the ball bearing and

replace if necessary.

– Install the drive tube, b 9.1 4.2 Clutch
– Fit the shroud, b 5.4 – Remove the fan housing, b 4.1
1
1
1
0208RA001 TG
1
: Install circlip (1) at the other side.
0208RA007 TG
7022RA066 TG
– Remove the sleeve and rubber
element, b 8.1 2
: Fit screws (1), then tighten down : Pull boot (1) off the spark plug.
screw (2) and screws (1) firmly.
– Unscrew the spark plug.
– Install the rewind starter, b 7.2
3
1 4 1
2
7022RA001 TG
4 1
: Fit the fan housing (1) with clutch
7022RA067 TG
drum (2) over the clutch (3) and
0208RA008 TG
line it up so that the pins (4)

engage the holes (arrows) in the
crankcase.
: Insert locking strip (1)
: The throttle cable (1) must not be 0000 893 5904 in the cylinder.
under tension.
7022RA002 TG
: Tighten the screw (1) until the fan

housing is seated
– the upper screws are not fitted
and secured until the shroud is
installed – do not finally tighten
screw (1) yet.

Assembling
1
1
1
0208RA017 TG
0208RA013 TG
1
0208RA011 TG
: The locking strip (1) 2 : Fit upper cover washer (1) so that
0000 893 5904 must butt against the recesses (arrows) face up
the cylinder wall (arrow) : Fold the clutch shoes (1) and and the holes are in alignment.
– as shown in the illustration. unhook the spring (2).
Position the clutch shoes (1) so that Installing

Disassembling the markings (arrows) are visible.
The spring (2) must be hooked into

the back of the clutch shoes (1).
– Reassemble the clutch shoes in 2

1 the reverse sequence.
2
1
7022RA003 TG
1
0208RA009 TG
3
3
2 : Position clutch (1) with cover
: Take out the screws (1). washers on tapped holes
3
3 (arrows) in flywheel (2).
: Remove the clutch (2) with cover 1
0208RA012 TG
washers. : Insert and tighten down the

4
screws (3) firmly.
1
– Remove the locking strip from the
: Fit the washers (1) over the cylinder.
sleeves.
1 – Install the fan housing, b 4.1
: Position the clutch (2) so that the
marks (arrows) face up.
– Reassemble all other parts in the
reverse sequence.
: Push clutch (2) onto sleeves (3)
0208RA010 TG
of lower cover washer (4).
– Remove the upper cover washer.
: Pull the clutch (1) off the lower

cover washer.

5. Engine
5.1 Muffler / Spark Arresting Installing

Screen
Always check and, if necessary,
repair the fuel system, carburetor,
air filter and ignition system before
looking for faults on the engine.
– Troubleshooting, b 3
7022RA005 TG
2 1
7022RA006 TG
Before removing the muffler, set the : Remove the muffler gasket (1)
piston to top dead center to ensure and pull out the heat shield (2)
that no dirt falls into the cylinder. sideways – always install a new – Cover the exhaust port. Remove
muffler gasket. any dirt from around the cylinder
and exhaust port.
Spark arresting screen : Check and clean the sealing

(if fitted) faces (arrows) on the exhaust
port, heat shield and muffler,
1 remove any gasket residue –
1 make sure there is no gasket
residue or dirt in the exhaust port.
2
2 Always replace components with
7022RA073 TG damaged sealing faces.
1 3
1
: Take out the screw (1) and pull

out the spark arresting
screen (2). 1
2
1
7022RA007 TG
– Clean the spark arresting screen
1 or replace if necessary.
2
– Reassemble in the reverse
sequence. : Insert the screws (1).
: Fit new muffler gasket (2) over

7022RA004 TG
the screws (1) and against the

muffler (3).
: Take out the screws (1).
: Remove the muffler (2), check it

and replace if necessary.

5.2 Leakage Test
3
Defective oil seals and gaskets or
1 cracks in castings are the usual
2 2 causes of leaks. Such faults allow
2 supplementary air to enter the
1 engine and upset the fuel-air
7022RA007 TG mixture.
4 This makes adjustment of the

prescribed idle speed difficult, if not
: Push the upper edge of the heat impossible.
shield (1), tab (2) first, between
the wall of the air guide Moreover, the transition from idle
shroud (3) and cylinder and its speed to part or full throttle is not
lower edge between the hook (4) smooth.
and the cylinder.
Always perform the vacuum test
: Push the heat shield (1) home
1 first and then the pressure test.
until its holes line up with the 2 The engine can be checked
holes in the cylinder. 2
thoroughly for leaks under vacuum
and pressure with the pump
0000 850 1300.
7022RA009 TG
: Carefully fit the muffler (1) in

position and insert the screws (2)
– do not tighten down yet.
: Check that gasket and heat

shield are properly positioned.
: Insert and tighten down the

screws (2) firmly.

reverse sequence.

5.2.1 Preparations
1
– Remove the shroud, b 5.4 1
1 2
2
0208RA028 TG
7022RA010 TG
Make sure the gasket (1) is in place.
1
– Pull off the boot and unscrew the
spark plug. 1
– Set the piston to top dead center. 3

3
This can be checked through the
2
7022RA218 TG
spark plug hole. 2
2 2
: Fit the spark plug (1) and tighten
it down firmly.
7022RA011 TG : Line up the flange (1)
5910 850 4200 and fit it over the
– Remove the heat shield and studs (2).
gasket, fit muffler in position and
insert screws, b 5.1
: Fit the sealing plate (1) : Fit the nuts (3) and tighten them
0000 855 8106 between the down firmly.
cylinder exhaust port and muffler.
: Tighten the screws (2) 5.2.2 Vacuum Test

moderately.
Oil seals tend to fail when subjected
The sealing plate must completely to a vacuum, i.e. the sealing lip lifts
fill the space between the two away from the crankshaft during the
screws. piston's induction stroke because
there is no internal counterpressure.
– Remove carburetor with fuel
hoses still attached and put it to A test can be carried out with pump
one side, b 10.3 0000 850 1300 to detect this kind of
fault.

5.2.3 Pressure Test – Install the gasket, heat shield and
2 4 3 muffler, b 5.1
Carry out the same preparations as
for the vacuum test, b 5.2.2 – Reassemble all other parts in the
reverse sequence.
1
7022RA220 TG 1 3 2 5.3 Oil Seals
1 2
: Connect hose (1) of pump
0000 850 1300 to the nipple
(arrow).
7022RA219 TG
: Push ring (2) to the left
– vacuum test.
5904RA044 TG
: Push ring (1) to the right
: Operate the lever (3) until the – pressure test.
pressure gauge (4) indicates a
vacuum of 0.5 bar. : Operate the lever (2) until the When replacing oil seals, note that
pressure gauge (3) indicates a the 12x22x5 oil seal (1) must be
If the vacuum reading remains pressure of 0.5 bar. If this installed at the ignition side and the
constant, or rises to no more than pressure remains constant for at 10x20x4 oil seal (2) at the starter
0.3 bar within 20 seconds, it can be least 20 seconds, the engine is side.
assumed that the oil seals are in airtight.
good condition. It is not necessary to disassemble
If the pressure continues to rise – If the pressure drops, the leak the engine to replace the oil seals.
(reduced vacuum in engine), the oil must be located and the faulty
seals must be replaced, b 5.3. part replaced.
– After finishing the test, push the

To find the leak, coat the suspect
ring to the right to vent the pump.
area with soapy water and
pressurize the engine again.
– Continue with pressure test, Bubbles will appear if a leak exists.
b 5.2.3
– After finishing the test, push the
ring to the left to vent the pump –
disconnect the hose.
– Remove the flange

5910 850 4200 from the intake
manifold.
– Install the carburetor, b 10.3
– Remove the muffler and the

sealing plate 0000 855 8106.

Ignition Side – Reassemble all other parts in the
2 reverse sequence.
– Remove the clutch, b 4.2
– Remove the flywheel, b 6.5 Starter Side

1 – Remove the rewind starter,
b 7.2
0208RA141 TG
– Block the piston, b 4.2
1 : Fit the installing sleeve (1)

4149 893 4600.
: Slip the oil seal (2), sealing lip

0208RA018 TG
facing the crankcase, over the 1

installing sleeve.
Take care not to damage the – Remove the installing sleeve.

crankshaft stub.
0208RA073 TG
– Free off the oil seal in its seat by
tapping it with a suitable tube or a 2
punch. : Use hexagon (arrow) to loosen
and unscrew carrier (1)
: Apply puller (1) 5910 890 4400 counterclockwise.
with No. 6 jaws 0000 893 3711.
1
– Clamp the puller arms.
0208RA142 TG
– Pull out the oil seal.
To avoid the risk of engine damage,

Installing only use press sleeve (1)
4149 893 2400 to install the oil seal.
– Clean the sealing face, b 12
0208RA143 TG
: Fit the press sleeve (1)
– Lubricate sealing lips of new oil 4149 893 2400 with the smaller 1
seal with grease, b 12 diameter (22 mm) facing the
crankcase and press home the oil Take care not to damage the
seal (2). crankshaft stub.
The seating face must be flat and – Free off the oil seal in its seat by
free from burrs. tapping it with a suitable tube or a
punch.
– Degrease the crankshaft taper,
b 12 : Apply puller (1) 5910 890 4400
with No. 3.1 jaws 0000 893 3706.
– Clamp the puller arms and pull

out the oil seal.

Installing Installing
– Clean the sealing face.

1
– Lubricate sealing lips of new oil 1
seal with grease, b 12
0208RA146 TG
4 4
2
0208RA034 TG
: Use hexagon (arrow) to screw 3 2
carrier (1) into place clockwise,
1 then tighten it down firmly. : Fit the shroud (1) so that the tabs
(arrows) engage between the
– Reassemble all other parts in the crankcase (2) and fan
0208RA144 TG
reverse sequence. housing (3).

: Fit the installing sleeve (1) 5.4 Shroud screws (4) firmly.
1146 893 4600.
– Install the rewind starter, b 7.2
– Remove the rewind starter,
: Slip the oil seal (2), sealing lip b 7.2
facing the crankcase, over the
installing sleeve.
1
– Remove the installing sleeve. 2
2
2
1
0208RA035 TG
1
0208RA032 TG
1 : Push tab of cover (1) into

opening in shroud and fit cover in
: Take out the screws (1) and
0208RA145 TG
position.
remove the shroud (2).

: Fit the press sleeve (1) screw (2) firmly.
4149 893 2400 with the larger 2
diameter (25 mm) facing the
crankcase and press home the oil
seal (2).
1
The seating face must be flat and
free from burrs.
0208RA033 TG

remove the cover (2).

5.4.1 Air guide shroud : Line up the manual fuel pump (1)
1 so that the lug (2) points towards
the carburetor.
: Push the manual fuel pump (1)

into the retainer (3) on the air
guide shroud until the locking
– Remove the fan housing, b 4.1 tabs (arrows) snap into place
7022RA012 TG
below the retainer (3).
– Remove the ignition module,
b 6.2
– Unscrew the spark plug.
– Pull short circuit wire out of guide
in air guide shroud.
: Lift the air guide shroud (1) at the
starter side and remove it over
the cylinder.
0208RA155 TG
Installing
2
1
1
: Starting at the flag terminal, push
1 the short circuit wire (1) into the
0208RA054 TG
guide (arrow) so that it fits snugly

– if necessary, also push the
wires on the throttle cable
: Squeeze locking tabs (arrows) retainer fully into the guide.
7022RA013 TG
under the retainer (1) together

and push out the manual fuel – Reassemble all other parts in the
pump (2). reverse sequence.
: Position the air guide shroud (1)
: Remove the manual fuel at a slight angle and lower it in the
pump (2) with fuel hoses still direction of the starter side.
attached and put it to one side.
: Line up the air guide shroud (1)
so that it locates on the cylinder
and spacer flange and lines up
with the holes in the cylinder.
– Fit the spark plug and tighten it

down firmly.
– Install the ignition module, b 6.2
2
0208RA061 TG

5.5 Cylinder – Remove the ignition module and Versions with 0.75 kW engine
air guide shroud, b 6.2
Before removing the cylinder,
decide whether or not the – Remove the muffler, b 5.1
crankshaft has to be removed as
well. – Remove the fuel tank, b 10.9 2
3 1
Cylinder installed
To remove the clutch, flywheel or
carrier, block the.crankshaft by
0208RA335 TG
inserting the locking strip in the
spark plug hole. 1 1 4
Cylinder removed : Lift cylinder gasket (1) with
To remove the clutch, flywheel or tab (2) over the lug (3), detach it
carrier, block the crankshaft by 1
from the hook (4) and lift it over
resting the piston on the wooden
0208RA108 TG
1 the piston – always install a new
assembly block. cylinder gasket.
All sealing faces must be in perfect
condition. If the sealing faces are : Remove the screws (1) from the
damaged, replace the part underside of the crankcase.
concerned, b 3.6.

b 7.2
– Remove the shroud, b 5.4 1
0208RA337 TG
– Remove the filter cover, b 10.2
– Remove the throttle cable / short

0208RA109 TG
: Inspect and clean the sealing

circuit wire, b 6.6.2
face (arrow) – components with
damaged sealing faces must be
– Remove the drive tube, b 9.1 replaced, b 12
: Carefully lift the cylinder (1)
– Remove the fan housing, b 4.1 away.
– Pull off the boot and unscrew the

spark plug, b 4.2
– Pull off the carburetor and put it to

one side – there is no need to
remover the fuel hoses, b 10.3
– Remove the spacer flange,

b 10.6

Versions with 0.9 kW engine Versions with replaceable needle If the piston or the oil seals are
cage damaged, also inspect the inside of
– Remove the piston, b 5.7 the cylinder for signs of damage and
install a new cylinder if necessary.
2 1 Installing
1
Versions with 0.75 kW engine
0208RA112 TG
40208RA110 TG
1
: Pull out the needle cage (1),
inspect and clean it, replace if
: Lift cylinder gasket (1) with necessary.
0208RA338 TG
tab (2) over the lug (3), detach it
from the hook (4) and lift it over – Reassemble in the reverse
the connecting rod – always sequence. 3 2
install a new cylinder gasket.
: Fit the new cylinder gasket (1)
over the piston, attach it to the
All models
hook (2) and place it in position.
2 : Press down tabs (arrows) of new

cylinder gasket (1) until they
1 locate behind the lug (3).
1 – the cylinder gasket is now held
in position.
0208RA111 TG
0208RA113 TG

face (arrow) – components with The screws (1) and cover (2) must
damaged sealing faces must be not be removed at either side.
replaced, b 12
faces (arrows) and remove any
Versions with fixed needle cage gasket residue, b 12
The needle cage is permanently Always use a new cylinder gasket

connected to the small end and when re-installing the cylinder.
cannot be replaced separately.
– Inspect the piston and piston
– Inspect and clean the needle rings and replace if necessary,
cage, replace crankshaft if b 5.7, b 5.8
necessary, b 5.6

Versions with 0.9 kW engine
1 1
1
0208RA116 TG
0208RA118 TG
3
0208RA114 TG
– Lubricate the piston, piston rings While sliding the cylinder over the
and cylinder wall with oil, b 12 piston, hold the clamping strap
: Fit the new cylinder gasket (1) tightly around the piston so that the
over the piston, attach it to the – Check correct installed position rings do not project
hook (2) and place it in position. of rings, b 5.8 – they might otherwise break.
: Press down tabs (arrows) of new : Slide the cylinder (1) over the
: Use the clamping strap (1)
cylinder gasket (1) until they piston, the clamping strap moves
0000 893 2600 to compress the
locate behind the lug (3). downwards at the same time.
rings around the piston.
– the cylinder gasket is now held
in position. – Remove the clamping strap and
Apply the clamping strap (1) so that
wooden assembly block.
the piston rings do not project
– Install the piston, b 5.7 beyond the cylinder wall.
Make sure the cylinder gasket is
properly seated.
All models
1
0208RA117 TG
1 0208RA119 TG
0208RA115 TG
: Position the cylinder (1) so that

the rectangular ports (arrows) are
: Slide the wooden assembly in alignment. – Push cylinder on as far as stop
block (1) 1108 893 4800 and hold it steady, then turn
between the piston and cylinder and crankcase over.
crankcase.
: Fit screws (arrows) in underside
Take care not to damage the of crankcase and tighten them
cylinder gasket. down firmly in crosswise pattern.

reverse sequence.

5.6 Crankshaft Modifying an existing drilled
plate
– Remove the flywheel, b 6.5
1 1,4
– Remove the carrier, b 7.3
30
39
– Remove the cylinder, b 5.5
30
0208RA120 TG
– Remove the piston, b 5.7
34,4
30
0208RA122 TG
– Always install new bearings and : Inspect and clean the needle
oil seals after removing the 18,2
cage (1), replace crankshaft if
crankshaft, b 5.6.1 and b 5.3. necessary.
Drilled plate 5910 893 2103 without
holes marked "30" can be updated
Versions with replaceable needle All models with 5.5 mm holes as shown in the
cage illustration.
Starter side of crankcase
Dimensions are in millimeters.
The illustration shows the front of

the drilled plate.
1
0208RA112 TG
0208RA121 TG
: Pull out the needle cage (1),

inspect and clean it, replace if : Remove screws (arrows) from
0208RA343 TG
necessary. the ignition side.
Use the tools in the service tool set

Versions with fixed needle cage 5910 007 2201 to remove and
: Fit the deep bore of thrust
install the starter side of the
The needle cage is permanently piece (1) 4116 894 1000 over the
crankcase
connected to the small end and crankshaft stub at the starter side
– use drilled plate 5910 893 2103
cannot be replaced separately. to ensure that the length of the
and thrust piece 4116 894 1000.
screw sleeve in the service tool
set is sufficient to remove the
crankshaft.

Ignition side of crankcase Versions with replaceable needle
cage
The crankshaft, connecting rod and

1 needle bearing form an inseparable
3 2 unit. Always replace as a complete
unit.
0208RA123 TG
Versions with fixed needle cage
1 3
0208RA124 TG
The crankshaft, connecting rod with
needle cage and needle bearing
: Unscrew the spindle (1) form an inseparable unit. Always
clockwise until the drilled replace as a complete unit.
plate (2) butts against the starter : Rest the crankcase (1) on a
side of the crankcase suitable base so that it is secure
– left-hand thread. and the inbuilt guide sleeves
(arrows) are not damaged.
: Position the service tool with
drilled plate (2) 5910 893 2103 There must be sufficient space
so that the number "30" (arrow) is below to allow the crankshaft to be
at the bottom. removed.
The spindle (1) must engage the

center hole of the thrust piece
4116 894 1000. 2
: Insert two D 5 x 25 screws (3) 1

– or two screws from the rewind
starter – through the holes
marked "30", into the crankcase
at the starter side and tighten
0208RA125 TG
them down as far as stop.

3
: Turn the spindle (1)
counterclockwise until the : Fit the thrust piece (1)
crankshaft is pushed out of the 1107 894 1000 on the crankshaft
starter side of the crankcase. stub to protect it from damage.
– Take out the screws and remove : Apply a suitable press arbor (2)
the puller. to the crankshaft stub (ignition
side) and press out the
crankshaft (3).

All models Installing Starter side of crankcase
Ignition side of crankcase Take care not to damage the

1 crankshaft stub.
Take care not to damage the
crankshaft stub.
– Lubricate the crankshaft stub with

oil. 1
2
0208RA126 TG
0208RA128 TG
: Remove any gasket residue and
clean the sealing faces (arrows) 1
thoroughly (including the
peripheral groove in the starter
side of the crankcase) : Apply sealant (1) to peripheral
– sealing faces must be in good groove (arrows), b 12
0208RA127 TG
condition and clean.
: Check ignition side (1) and

starter side (2) of crankcase for : Position the tapered stub (arrow)
cracks and all sealing faces of the crankshaft (1) above the
(arrows) for damage. ball bearing at the ignition side.
a
– Replace damaged crankcase – Heat inner race of ball bearing to
halves, b 5.6.1. about 160°C (320°F).
938RA098 TG
If the original crankcase is used : Push the crankshaft home as far
again, replace the oil seals and ball as stop.
bearings.
This operation must be carried out : The bead of sealant should be
– If the original halves of the very quickly because heat is about 1 mm high (a).
crankcase are used again, absorbed by the crankshaft, and the
replace the ball bearings and oil inner bearing race shrinks. Make sure the sealant does not
seals, b 5.6.1 and b 5.3
project into the crankcase.
– Before installing, clean the – Lubricate the crankshaft stub with

crankshaft, b 12 oil.

pattern until the two halves of the – Check and install the cylinder,
crankcase are together. b 5.5
: Tighten down the screws (1) – Reassemble all other parts in the
firmly. reverse sequence.
0208RA129 TG Versions with replaceable needle 5.6.1 Bearings / Crankcase

cage
Inspect both halves of the
crankcase for cracks and all sealing
: Check that the guide sleeves faces for signs of damage.
(arrows) line up with the holes.
1 – See also Troubleshooting,
b 3.6
1 Each half of the crankcase can be
0208RA140 TG
replaced separately if it is damaged.
New crankcase halves are supplied

with the individual parts
2 2 : Lubricate the cleaned or preassembled – see the parts list.
replacement needle cage (1) with
0208RA130 TG
oil and push it into the connecting Parts not supplied with the new
rod, b 12 crankcase must be transferred from
the original crankcase – check the
parts and replace if necessary.
: Position starter side of crankcase
on straight crankshaft stub so Versions with fixed needle cage
If a new crankcase is installed, the
that the cylinder sealing faces
The needle cage is permanently machine's serial number must be
(arrows) are in alignment.
connected to the small end and stamped on it with 2.5 mm figure
cannot be replaced separately. stamps.
– Heat inner race of ball bearing to
about 160°C (320°F). If the original crankcase is used
– Lubricate the cleaned needle
cage with oil, b 12 again, replace the oil seals and ball
: Push the crankcase (1) into the bearings, remove any gasket
guide sleeves (2) as far as stop. residue and clean the sealing
surfaces thoroughly (including the
All models
This operation must be carried out peripheral groove in the starter side
very quickly because heat is of the crankcase). The sealing faces
– Check and install the piston, must be in good condition and clean
absorbed by the crankshaft, and the b 5.7
inner bearing race shrinks. to guarantee a perfect seal.
– Remove the crankshaft, b 5.6
1 1
0208RA131 TG
: Fit the screws (1) and tighten

them uniformly in a crosswise

Ignition side of crankcase : Push the ball bearing (1) home
as far as stop.
– Check that the bearing is properly

1
seated. If necessary, use
press arbor 4224 893 7200 to
press the bearing fully home.
0208RA137 TG
Starter side of crankcase
0208RA132 TG
– Heat area of bearing seat to
about 160°C (320°F).
: Use a punch to carefully drive out
the oil seal. This operation must be carried out
quickly because the bearing
– Check and clean the crankcase absorbs heat and begins to expand.
or replace if necessary.
: Push the ball bearing (1) home
0208RA135 TG
– If this half of the crankcase is in as far as stop.
order, install a new ball bearing.
– Check that the bearing is properly
– Heat area of bearing seat to : Use a punch to carefully drive out seated. If necessary, use
about 160°C (320°F). the oil seal. press arbor 4116 893 7205 to
press the bearing fully home.
The bearing drops out as soon as – Check and clean the crankcase
this temperature is reached. or replace if necessary. – Install the crankshaft, b 5.6
– If this half of the crankcase is in – Install the oil seals,

Installing order, install a new ball bearing. b 5.3
The ball bearing must not be press- – Heat area of bearing seat to The tapered crankshaft stub must
fitted in the cold condition. about 160°C (320°F). be free from grease.
The bearing drops out as soon as – Reassemble all other parts in the
this temperature is reached. reverse sequence.
1
Installing
The ball bearing must not be press-

fitted in the cold condition.
7022RA014 TG
– Heat area of bearing seat to

about 160°C (320°F).
This operation must be carried out

quickly because the bearing
absorbs heat and begins to expand.

5.7 Piston – Replace the cylinder gasket, – Lubricate the cleaned needle
inspect and clean the sealing cage with oil, b 12
faces, b 5.5
– Remove the cylinder, b 5.5
All models
The piston has only one snap ring. It
Installing
is fitted at the ignition side.
– Inspect the piston rings and
Versions with replaceable needle replace if necessary, b 5.8
cage
– Fit new cylinder gasket, b 5.5
1
1
0208RA138 TG
0208RA140 TG
2
: Use a suitable tool to grip the
0208RA216 TG
hookless snap ring at the recess
– Pull the needle cage out of the
(arrow) and ease it out.
small end, check it and replace if
necessary.
: Position the piston (1) as shown
so that the arrow (arrow) points in
: Lubricate the cleaned or the direction of the hook (2), or
replacement needle cage (1) with the side with the snap ring groove
2 oil and push it into the connecting is on the ignition side.
rod, b 12
: Place the piston (1) on the
1 connecting rod.
Versions with fixed needle cage
0208RA139 TG
The needle cage is permanently

connected to the small end and
cannot be replaced separately.
: Slide the assembly drift (1)
1130 893 4700, small diameter
first, through the side of the
piston opposite the snap ring
groove and push the piston pin 2)
out of the piston.
1
If the piston pin is stuck, release it
by tapping the end of the drift lightly
with a hammer.
0208RA120 TG
Hold the piston steady during this

process to ensure that no jolts are
transmitted to the connecting rod.
– Remove the piston. : Inspect and clean the needle

cage (1), replace crankshaft if
necessary.
– Inspect the piston rings and
replace if necessary, b 5.8

2
0208RA217 TG
0208RA219 TG
5904RA094 TG
: Slide the assembly drift (1) : Installing tool : Install the new piston rings in the
1130 893 4700, small diameter 5910 890 2208 with the sleeve’s grooves so that the radii face
first, through the side of the taper against the piston boss, upward (arrows).
piston opposite the snap ring hold the piston steady, center the
groove and the small end (needle tool shank exactly and press
cage) and line up the piston. home until the snap ring slips into
the groove.
– Lubricate the piston pin with oil.
Make sure the tool is held square on
: Fit the piston pin (2) on the the piston pin axis.
assembly drift (1) and slide it into
the piston. – Install the cylinder, b 5.5
0208RA220 TG
– Prepare snap ring for installation – Reassemble all other parts in the
with installing tool reverse sequence.
5910 890 2208.
– Carefully fit the piston rings over
5.8 Piston Rings the piston – they might otherwise
break.
– Remove the piston, b 5.7
: Install the piston rings so that the
– Remove the piston rings from the radii at the ring gap meet at the
piston. fixing pins in the piston grooves
(arrows).
1
– Use a broken piece of old piston
: Check correct installed position
0208RA218 TG
ring to scrape the grooves clean.

of the piston rings (arrows).
– Install the piston, b 5.7

Fit the snap ring (1) so that its gap
(arrow) points up. – Reassemble all other parts in the
reverse sequence.

6. Ignition System
Exercise extreme caution when Testing in the workshop is limited to

troubleshooting and carrying out a spark test. A new ignition module 1
maintenance or repair work on the must be installed if no ignition spark
ignition system. The high voltages is obtained (after checking that
which occur can cause serious or wiring and stop switch are in good
fatal accidents. condition).
2
Troubleshooting on the ignition
7022RA068 TG
system should always begin at the 6.1 Ignition Timing
spark plug, b 3.3
1
Ignition timing is fixed and cannot
be adjusted during repair work. : Take out the screws (1) with
washers and remove the ignition
– Remove the fan housing, b 4.1 Since there is no mechanical wear module (2).
in these systems, ignition timing
cannot get out of adjustment during
– Check ignition module and lead,
operation.
replace ignition module if
necessary
1 6.2 Install new ignition
module
Installing
2
2
7022RA015 TG
– Remove the fan housing, b 4.1

The electronic (breakerless) ignition
system basically consists of an 1
– Pull boot off the spark plug.
ignition module (1) and flywheel (2).
7022RA069 TG
The ignition module accommodates – Remove the drive tube, b 9.1
all the components required to 2
control ignition timing. There are
two electrical connections on the : Fit the ignition module (1) and
coil body: insert the screws (2) with
washers – do not tighten down
1. High voltage output with yet.
fixed ignition lead.
2. Fixed wire with

cable lug for the 1
0208RA148 TG
short circuit wire.

2
: Disconnect the flag terminal (1)

and pull the short circuit wire (2)
out of the guide (arrow).

3
1 1
3
2
0208RA151 TG
0208RA155 TG
7022RA071 TG
1
: Push the ignition module back : Press the ignition module (1) : Starting at the flag terminal, push
and slide the setting gauge (1) against the setting gauge (2) and the short circuit wire (1) snugly
0000 890 6400 between the tighten down the screws (3) into the guide (arrow).
arms of the ignition module and firmly.
the flywheel magnet poles.
: Remove the setting gauge (2).
Check operation
1
– Rotate the flywheel and make
sure it does not touch the ignition
module.
1
7022RA016 TG
7022RA070 TG
2 1
: Fit the boot (1) on the spark plug
and arrange it so that the ignition
The setting gauge is not shown in lead is positioned in the recess
the illustration. (arrows) in the air guide shroud
2
: Push the ignition module (1) back – Install the fan housing, b 4.1
0208RA154 TG
and hold it there.

The flywheel (2) must rotate freely. reverse sequence.
: Connect short circuit wire's flag
: Rotate the flywheel (2) until terminal (1) to the ignition
the "N / S" module (2) so that its crimped
magnets (arrows) are in line with side faces the cylinder.
the ignition module (1).

6.3 Testing the Ignition 6.4 Spark Plug Boot / Ignition
Module Lead
Install a new spark plug before The ignition module (1) and ignition
starting the test. lead (2) form a unit. If the ignition
lead is damaged, it may be
The engine may start and shortened no more than 5 mm in
accelerate during the test. order to reposition the leg spring.
0208RA280 TG
Do not shortened it any further –
– To test the ignition module, use install a new ignition module.
either the ZAT 4 ignition system
tester 5910 850 4503 or : Connect the MDG 1 between the – Remove the shroud, b 5.4
the ZAT 3 ignition system tester spark plug and spark plug boot
5910 850 4520. – ground clamps must engage – Pull boot off the spark plug.
hexagon on spark plug.
If a spark is visible, the ignition
system is in order. – To run diagnosis, select "Other
STIHL Products". Then start the
– If no spark is visible in the diagnostic function and follow the
window, check the ignition steps in the diagnostic software.
system with the aid of the
troubleshooting chart, b 6.7
To obtain an accurate result, pull the
starter rope briskly.
The test refers only to a spark test,
2310RA127 TG
not to ignition timing. The engine may start and
accelerate during the test.
6.3.1 Testing Ignition Module – In the event of a malfunction,
with STIHL MDG 1 : Use suitable pliers to pull the leg
check ignition system with the aid
spring out of the spark plug boot.
of the troubleshooting chart,
The ignition module can be tested b 6.7
simply, reliably and quickly with the – Unhook the leg spring from the
STIHL MDG 1. ignition lead.
The following points are checked – Pull the boot off the ignition lead.
during the test:
– Ignition voltage
– Ignition spark?
– Remove the cover and pull off the

spark plug boot, b 5.4
– Before starting the test, check the

spark plug and replace it if
necessary – use only spark plugs
recommended by STIHL.

Installing 6.5 Flywheel
– Remove the fan housing, b 4.1
– Use locking strip to block the
2310RA129 TG
piston, b 4.2
165RA188 TG
– Remove the clutch, b 4.2
: Make sure the leg spring (arrow)
locates properly inside the spark
– If the ignition module is new, use plug boot.
a pointed tool to pierce the center
of the ignition lead’s insulation,
about 15 mm from the end of the
lead.
1
: Pinch the hook of the leg spring 1
into the pierced hole in the center
0208RA157 TG
of the lead (arrow).
7022RA072 TG
: Unscrew the flywheel nut (1).
: Fit the boot (1) on the spark plug

and arrange it so that the ignition
lead is positioned in the recess
(arrows) in the air guide shroud
2
2310RA128 TG
– Reassemble all other parts in the 1

reverse sequence.
2
0208RA158 TG
– Coat the inside of the spark plug
boot with 3
STIHL press fluid, b 12
: Apply the puller (1)
: Hold the ignition lead and leg 4119 890 4501, insert screws (2)
spring together and push them from clutch and tighten them
into the spark plug boot. down firmly.
: Screw home the thrust bolt (3)

clockwise until the flywheel is
released. Remove the flywheel.
– Remove the puller (3)

4119 890 4501 from the flywheel.

6.6 Short Circuit Wire The resistance measured must be
infinitely high. If not, install a new
throttle cable, b 6.6.
S
The short circuit and ground wires
are combined with the throttle cable
Perform the contact and continuity
to form a unit. If either is damaged,
test on the ground wire too.
a new throttle cable must be
installed.
If the ground wire is damaged, the
N
throttle cable has to be replaced,

0208ra159
b 6.6
6.6.1 Testing
– If no fault can be found, check the
The flywheel and magnet poles If the spark plug, ignition lead and ignition system with the aid of the
(arrows) must not be damaged or spark plug boot are in order, check troubleshooting chart, b 6.7
have turned blue. Replace flywheel the short circuit wire.
if necessary.
– the magnet poles are marked – Remove the shroud, b 5.4 sequence.
"N / S".
Installing 2
The flywheel and crankshaft stub
must be free from grease before
assembly.
1
0208RA163 TG
: Disconnect flag terminal (1) of

the short circuit wire (2).
– Connect ohmmeter to ground

0208RA160 TG
and short circuit wire's flag

terminal.
Make sure the key (arrow) engages – Depress stop switch on control
the slot in the crankshaft. handle and hold it there.
– Push the flywheel into position, fit The resistance measured must be
the nut and tighten it down firmly. about 0 Ω. If it is much higher, the
reason is a break in the wire and the
– Set the air gap between the throttle cable has to be replaced,
ignition module and flywheel, b 6.6
b 6.2
– Release stop switch = start
– Reassemble all other parts in the position.
reverse sequence.

6.6.2 Short Circuit Wire : Check the cable holder (2),
on Engine replace throttle cable if
– Removing and
2 necessary.
Installing
– Remove the short circuit wire
– If necessary, remove the drive from the control handle, b 6.6.3
tube, b 9.1 1
0208RA037 TG
– Remove the shroud, b 5.4 Installing
– Fit the short circuit wire in the

– Pull boot off the spark plug.
: Disconnect ground wire control handle, b 6.6.3
terminal (1) and short circuit wire
terminal (2).
: Pull the ground and short circuit

3
wires out of the guides (arrows).
1
1 1
3
7022RA020 TG
1 2
: Fit the cable holder (1) on the

control valve (2) so that it and the
7022RA018 TG
protective tube fully engage the

2 seat (arrows).
: Turn the control valve lever (1) in : Insert and tighten down the
direction of full throttle, push the screw (3) firmly.
throttle cable (2) out of its seat
(arrow) and remove it.
3
1
2
1
7022RA017 TG
7022RA021 TG
: Take out the screws (1) or

2
7022RA019 TG
screw (2) and remove the filter

cover (3).
3 2 : Turn the control valve lever (1) in
direction of full throttle and
: Take out the screw (1) and engage the throttle cable (2) in its
remove the cable holder (2) with seat (arrow).
protective tube (3).

2 terminal (2) to the tag (3) so that
3 its crimped side faces the
carburetor.
1
reverse sequence.
0208RA042 TG
0208RA253 TG
6.6.3 Short Circuit Wire and 1
Contact Springs on
: Press the short circuit wire (1) Control Handle : Pull the contact spring (1) with
into the guide (arrow). – Removing and ground wire out of the guides
Installing (arrows).
terminal (2) to the ignition – Remove the throttle trigger and
module (3) so that its crimped lockout lever, b 9.3
side faces the engine. 1
– Remove stop switch lever, b 9.4
2 1
0208RA275 TG
2
1
: Disconnect contact springs (1, 2)
0208RA043 TG
from the ground and short circuit

0208RA254 TG
wires.
: Starting at the flag terminal, push – Inspect the contact springs,

the short circuit wire (1) snugly : Push the contact spring (1) replace if necessary – contact
into the guides (arrows). inwards in area of terminal (2) springs must not be twisted.
and lift it over the lug (arrow).
– Remove the throttle cable and
: Pull the contact spring (1) with short circuit wire from the engine,
short circuit wire out of the b 6.6.2
guides.
2
3
0208RA044 TG
: Push the ground wire (1) into the

guide (arrow).
– Ground wire must be under the
short circuit wire.

Installing
3 2 4 1
– Install throttle cable and short
circuit wire on engine, b 6.6.2
1 2
0208RA279 TG
0208RA278 TG
2 1 3
Do not twist the wire. Do not twist the wire.
: Position contact spring (1) with : Position contact spring (1) with
0208RA276 TG
ground wire so that the crimped short circuit wire so that the
side of the terminal (2) faces crimped side of the terminal (2)
away from the rib (3). faces away from the rib (3).
: Push terminal (1) of short circuit
wire onto the short contact : Push the contact spring (1) with : Push the contact spring (1) with
spring (2) so that its crimped side ground wire into the guides short circuit wire into the guides
faces away from the loop (arrow) (arrows). (arrows) until the contact
– the terminal must be pushed spring (1) is behind the lug (4).
fully home.
: Apply thin coating of STIHL
1 lubricating grease to radius of
contact spring (1)
1 2 – the contact face must remain
free from grease, b 12
0208RA270 TG
1
0208RA277 TG
: Press the ground wire (1) fully

into the guides (arrows).
: Push terminal (1) of ground wire
onto the long contact spring (2)
0208RA268 TG
so that its crimped side faces
away from the loop (arrow)
– the terminal must be pushed
fully home. : Push short circuit wire (1) fully
into the guides (arrows) – the
ground wire must be underneath
the short circuit wire.
– Install stop switch lever, b 9.4

Check operation
0208RA252 TG
: Depress stop switch lever (1), the

contact springs (arrows) must
touch each other
– the contact springs must be
free from grease.
– Install the throttle trigger / lockout

lever, b 9.3
– The travel of the throttle trigger in

the direction of full throttle is
limited by rotating the throttle set
wheel.
– Check throttle cable adjustment,

re-adjust if necessary, b 9.6

reverse sequence.
6.6.4 Ground Wire
Test and install the ground wire as

described for the short circuit wire.
– Perform contact and continuity

test and
replace throttle cable if
necessary, b 6.6, b 6.6.2,
b 6.6.3
6.6.5 Contact Springs
Test and install contact springs as

described in chapter on "Short
Circuit Wire on Control Handle –
Removing and Installing", b 6.6.3
0

6.7 Ignition System Troubleshooting
Engine does not run
Stop switch lever:

– Stop switch lever not depressed?
Check the spark plug:

– Smeared with oil, black?
– Sooted?
– Electrode gap correct?
– Contacts shorted?
– Clean, readjust or replace the spark plug,
b 6.3
Check the spark plug boot:

– Firmly seated on plug (leg spring)?
– Leg spring hook in center of ignition lead?
– Boot damaged?
– If necessary, install new spark plug boot and/
or leg spring,
b 6.4
Test ignition system:

with ZAT 3 or ZAT 4
(use ZAT 3 as main spark gap
see TI 32.1994), b 6.3

1
Ignition spark? yes
no
Air gap:
– Check ignition module/flywheel,
reset if necessary, b 6.2
Check the flywheel:

– Have pole shoes turned blue?
– Install new flywheel if necessary,
b 6.5
Check short circuit wire:

– Wire damaged?
– Connectors firmly seated?
– Check continuity, replace throttle cable if
necessary, b 6.6.1
Check the ignition lead:

– Severe chafing?
– Spark plug boot: Holes/cracks?
– Resistance: spark plug boot to ground:
spec. 1.5 – 12 kΩ
– Check resistance of ignition lead (spark plug
boot and ignition module removed):
spec.< 10 Ω,
If necessary, install new spark plug boot and/or
Install new ignition module,
b 6.4
2 3

2 3
Check operation of stop switch lever:

– Short circuit wire chafed?
– Function between contact springs on stop switch lever:
– Stop switch lever not depressed = no contact
– Stop switch lever depressed = contact
– If necessary, install new short circuit wire or contact springs,
b 6.6.2
Ignition spark? yes
no
Install new ignition module,

b 6.2
yes Machine runs no
Machine runs trouble-free, – Look for fault in fuel system or

no further action necessary carburetor.
– Check engine for leaks.
– Check position of flywheel on
crankshaft,
b 5.2, b 6.5

7. Rewind Starter
7.1 General 7.2 Rewind Starter Installing
If the action of the starter rope – Lubricate pegs on pawls with

becomes very stiff and the rope STIHL multipurpose grease,
b 12
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
1 2
oil on the rewind spring may thicken
and cause the spring windings to
stick together. This has a 1
detrimental effect on the function of
the starter mechanism.
2 2
In such a case it is sufficient to apply
a few drops of a standard solvent-
based degreasant (containing no
chlorinated or halogenated
hydrocarbons) to the rewind spring.
Carefully pull out the starter rope

several times and allow it to rewind
until its normal smooth action is
restored.
1
Before installing, lubricate the
rewind spring and starter post with
special lubricant, b 12. 2
7022RA022 TG
If clogged with dirt or pitch, the 1

entire starter mechanism, including
the rewind spring, must be removed
: Take out the screws (arrows) and 2
and disassembled. Take particular
remove the rewind starter (1).
7022RA023 TG
care when removing the rewind
spring.
2
– Clean all components.
The shroud must be in place.
: Place the rewind starter (1) in

ErgoStart position – insert and tighten down
the screws (2) firmly.
– Relieve tension of rewind spring,
b 7.4

7.3 Pawl / Carrier Installing
1 1
– Remove the rewind starter, 2 1
b 7.2
– Block the piston, b 4.2
0208RA077 TG
2
0208RA075 TG
: Push the pawls (1) into the bores
1 until they snap into place and
: Push the torsion springs (1) onto locate the ends of the springs
the pawls (2) so that the hooks (arrow) against the side of the
(arrow) locate against the carrier (2).
0208RA073 TG
pawls (2) as shown.
Check operation
: Apply tool to hexagon (arrow), – Swing pawls outwards towards
then loosen and unscrew edge of carrier and release – the
carrier (1) counterclockwise. 1 pawls must spring back
3 automatically as far as stop.
2
1
reverse sequence.
0208RA076 TG
2 2
: Position the pawls (1) so that the
retaining lugs on the pivots (2)
0208RA074 TG
engage the bores and the

pegs (3) locate in the openings
1 (arrows)
– the pegs (3) limit the range of
: Squeeze the retaining lugs on the movement of the pawls (1).
pivot (arrows) together and push
out the pawls (1) with torsion
springs (2).
: Remove the torsion springs (2).
– Inspect the torsion springs, pawls

and carrier and replace if
necessary.

7.4 ErgoStart / Rope Rotor
2
Relieving tension of rewind
spring
1
The system will not be under 1
tension if either the starter rope or
rewind spring is broken.
7022RA025 TG
7022RA029 TG
b 7.2
: Carefully release the rope Rewind spring must be relaxed.
rotor (1), while holding the starter
rope (2) in the notch (arrow), until : Carefully remove the rope
the rewind spring is relieved of rotor (1).
tension – the rewind spring may pop out
1 – do not completely let go of the and uncoil.
rope rotor (1) because it will
otherwise spin back and may – Remove the starter rope from the
2 damage the rewind spring. rotor and check it, replace if
necessary, b 7.5
7022RA024 TG
– Check the rope rotor and replace

if necessary.
: Pull out starter rope (1) all the
way until the notch (arrow) is next – Inspect bore in rope rotor, and
to the rope guide bushing, then 3 1 clean or replace if necessary.
hold the rope rotor (2) steady.
– Inspect the rewind spring and
0208RA081 TG
2 2
: Take out the retaining ring (1) and

1 remove the washer (2).
3 : Pull off the carrier (3).

0208RA079 TG
: Use hook (2) 5910 893 8800 to

pull out the starter rope (1)
between the notch and rope
guide bushing. 1
: Hold the starter rope in the

0208RA082 TG
notch (1) and allow the rope

rotor (3) to rotate slowly until the
rewind spring is no longer under
tension. : Pull out the spring (1).

Installing
– Lubricate full length of starter

post with STIHL special lubricant, 1
b 12
1
– Fit the starter rope on the rotor, 2
b 7.5
7022RA028 TG
7022RA030 TG
: Fit the carrier (1) in position so : Push the end of the starter
that the recess (arrow) engages rope (1) out a little and undo the
the spring's loop (2). knot.
– Fit the washer and retaining ring. – Pull the rope out of the rotor,
1 starter cover and grip.
7022RA026 TG
– Tension the rewind spring, b 7.6
2 – Lubricate pegs on pawls with Installing

STIHL multipurpose grease,
: Line up the inner spring loop b 12
(arrow) so that it locates against
the starter post (1).
reverse sequence.
: Fit the rope rotor (2) on the
starter post so that the inner
spring loop (arrow) engages the
7.5 Starter Rope / Grip
recess (1).
0208RA344 TG
The recess in the hub of the rope b 7.2
rotor is the anchor point for the
spring. : Tie special knot shown in end of
– Relieve tension of rewind spring,
b 7.4 rope.
The spring will not be under tension

1 if the starter rope is broken.
– Remove the ErgoStart / rope

rotor, b 7.4
2 – Remove any remaining rope from

7022RA027 TG
the rope rotor.

0208RA395 TG
Do not shorten the starter rope.

: Fit the spring (1) in the rope
rotor (2) so that its loop engages
: Thread the new starter rope
the lug (arrow).
through the top of the starter grip
until the knot is seated in the
recess (arrow).

2 1
1
3
7022RA031 TG
7022RA033 TG
7022RA035 TG
1 2
: Thread the rope (1) through the : Use hook (2) 5910 893 8800 to – Hold the starter grip firmly to keep
guide bushing and the rotor (2). pull out the starter rope (1) the rope tensioned.
between the notch (arrow) and
: Secure end of rope (1) with a rope guide bushing. : Let go of the rope rotor (1) and
simple overhand knot and pull it slowly release the starter rope so
back until the knot is against the : Engage the starter rope (1) in the that it can rewind properly.
rotor (2). notch (arrow) and hold it there.
Then turn the rotor (3) six turns
– Install the ErgoStart / rope rotor, counterclockwise.
b 7.4
The rewind spring is now tensioned. 1
– Tension the rewind spring, b 7.6
Hold the rope rotor steady since it
will otherwise spin back and may
damage the rewind spring.
reverse sequence.
0208RA093 TG
7.6 Tensioning the Rewind 1 2
Spring
The starter grip (1) must sit firmly in
the rope guide bushing (arrow)
without drooping to one side. If this
b 7.2
is not the case, tension the spring
by one additional turn.
7022RA034 TG
When the starter rope is fully

extended, it must still be possible to
rotate the rope rotor at least another
: Hold the rope rotor (1) steady, 1/2 to 1 1/2 turns before maximum
pull out the rope (2) with the spring tension is reached. If this is
1 starter grip and straighten it out. not the case, reduce spring tension
since there is otherwise a risk of
breakage.
7022RA032 TG
To reduce spring tension:

Pull the rope out, hold the rope rotor
steady and take off one turn of the
: Position the rope rotor (1) so that
rope.
the notch (arrow) points towards
the rope guide bushing.
reverse sequence.

7.7 Replacing the Rewind Installing new rewind spring
Spring
1
1
– The replacement spring comes 2
ready for installation and is
secured in a frame.
7022RA038 TG
7022RA036 TG
– Keep the frame in a safe place –
the frame can be used as an
assembly aid for installing a : Press the frame (1) against the
rewind spring that has popped rewind spring and, if necessary,
out and unwound. – Lubricate the rewind spring in the rotate it slightly until the spring is
frame with a few drops of STIHL properly seated.
special lubricant before installing,
– Wear a face shield and work
b 12 The rewind spring may pop out and
gloves
to protect your eyes and hands uncoil.
from injury. : Position the replacement spring
with frame in the starter cover so – Carefully remove the frame and
that the anchor loop (1) is above keep it in a safe place
the lug (2) and slips into its seat – the frame is used as an
b 7.2
(arrow). assembly tool for installing a
rewind spring that has popped
– Relieve tension of rewind spring if out and unwound.
necessary and remove the
ErgoStart / rope rotor, b 7.4
The spring will not be under tension

if it is broken.
If the rewind spring can no longer be

properly tensioned, install a new 1
7022RA037 TG
spring.
7022RA039 TG
– To reduce the risk of injury, place
suitable cover over the work area
when removing the rewind : Starting at the anchor loop, apply
spring. suitable tool to the recesses
(arrows) and push the rewind Make sure that the
spring into its seat in the starter rewind spring (1) is properly seated
cover – the frame slips off during and the outer anchor loop is
this process. engaged on the lug (arrow). If
necessary, push the rewind spring
fully into its seat in the starter cover.
: Secure the spring so that it

cannot pop out.
– Install the ErgoStart / rope rotor,

b 7.4

reverse sequence.

Installing unwound rewind spring
If the rewind spring has popped out,

refit it in the frame as follows:
1
0208RA098 TG
: Fit the anchor loop in its seat

(arrow) in the frame.
: Fit the rewind spring (1) in the

frame in the clockwise direction.
The procedure is otherwise the

same as that for installing a new
rewind spring.
– Install the ErgoStart / rope rotor,

b 7.4

reverse sequence.

8. AV Elements
The drive tube and fan housing are

connected by a vibration-damping 1
rubber element.
1
A damaged rubber element must
always be replaced. 3 2
2
0208RA069 TG
0208RA100 TG
8.1 Rubber Element

: Push 24 mm or 26 mm shaft of : Pull the rubber element (1) out of
– Remove the fan housing, b 4.1 installing tool (1) 4126 893 4900 the fan housing (2).
into the sleeve (2) as far as stop.
: Tighten down the screw (3) firmly

3 2 3
1
2 1
2
0208RA068 TG
0208RA101 TG
1
0208RA070 TG
: Stand fan housing (1) upright, : Loosen the screw (1) and pull the
then apply STIHL press fluid to sleeve (2) off the installing
profile (arrows) of rubber tool (3).
element (2) and allow it to act : Clamp square shank of installing
briefly, b 12 tool (1) with fan housing (2) in the – Examine the sleeve, rubber
vise. element and fan housing, replace
: Take out the screw (3). if necessary.
: Turn fan housing (2) back and
forth and pull it off at the same
time.
3
1
2
0208RA099 TG
: Press the retaining ring (1)

inwards through the slots
(arrows) in the fan housing (2)
and pry it out.
: Remove the retaining ring (1)
over the sleeve (3).

Installing
1 4 3 3 4
1 2
0208RA107 TG
0208RA106 TG
2 1 2
0208RA105 TG
3 : Coat outside of rubber : Insert the screw (1) – do not

element (4) with STIHL press tighten down yet.
– Clamp square shank of installing fluid – do not use oil or any other
tool in the vise. lubricant, b 12 : Loosen the screw (2) and pull off
the fan housing (3) complete with
: Push sleeve (1) onto 24 mm or : Position the fan housing (1) so rubber element and sleeve (4).
26 mm shaft of installing tool (2) that the lower bore (arrow) is in
4126 893 4900 as far as stop and line with the clamp screw (2) on – Reassemble all other parts in the
line it up so that the screw (3) is the sleeve (3) reverse sequence.
at the bottom. – the guide ribs in the fan
housing (1) seat must line up with
: Tighten down the screw (3) firmly the recesses in the rubber
element (4).
: Push the fan housing (1) onto the

2 rubber element (4) until the collar
4 is behind the lateral slots in the
fan housing (1).
0208RA102 TG
1
1 3
3
: Position the rubber element (1) 2
so that its collar (arrow) faces the
0208RA357 TG
vise and guide ribs on the

sleeve (2) are in line with the
recesses on the inside of the
rubber element (1).
: Fit the retaining ring (1) over the
: Push the rubber element (1) onto sleeve (2) so that the gap is on
the sleeve (2) as far as stop – the the same side as the clamp
lugs (3) must engage the screw (3).
openings (4).
: Push the retaining ring (1) into its
seat until it snaps into position in
the lateral slots (arrows).

9. Control Levers
9.1 Control Handle on Drive

Tube 4 2
Removing and Installing
3 1 1
0208RA232 TG
0208RA234 TG
OP
ST
2 3 1
0208RA223 TG
: Take out the screw (1) The clamps in the control handle on
– serves to fix the drive tube in the drive tube must be loose.
2 position.
: Push the control handle (1) onto
To avoid strain on the throttle cable, the end of the drive tube (2) with
This control handle (1) with
adjusting wheel (2) and stop hold the control handle (4) steady the plug or spring damper.
switch (3) is pushed onto the drive while pulling out the drive tube.
tube (24 mm or 25.4 mm diameter)
and secured with clamps. Loosen the screw (2) and pull the
drive tube (3) out of the fan housing 3 1
To replace the complete control and control handle (4).
handle (1), first remove the throttle
cable from the engine, b 6.6.2.
Installing
– Degrease area for clamp,
0208RA235 TG
b 12
2
: Push the drive tube (1) through

the sleeve (2) and into the fan
housing (3) while turning it back
and forth until the square end of
0208RA224 TG
the drive shaft engages the clutch

1 1 drum.
a
: Loosen the screws (1) on the
7022RA040 TG
The drive tube must be pushed

clamps. through the clamp as far as stop.
: The end of the drive tube with the

cross hole (arrow) must face the
engine – distance "a" from end of
drive tube to cross hole is 65 mm.

: Tighten down the screws (4) – Check the control levers and
2 firmly. replace if necessary,
– The control handle is now Throttle trigger and lockout lever,
clamped securely to the drive b 9.3,
tube. Stop switch lever (momentary
contact switch), b 9.4,
1 – Check instruction label on drive Adjusting wheel, b 9.5
0208RA236 TG tube for damage and legibility,
replace if necessary. – Check the throttle cable or short
circuit wire and replace if
necessary, b 6.6.1
: Position the drive tube so that the 9.2 Control Handle for
holes (arrow) in the drive tube Bike Handle
and sleeve (2) are in alignment. Removing and Installing Installing
: Fit the screw (1) as far as stop –

the drive tube is held in position 3 1
Label on drive tube must be visible

OP
ST
in working position. 1
2
0208RA228 TG
0208RA225 TG
3
2
: Position the throttle cable (1) with
This control handle (1) with
control handle (2) along the top of
adjusting wheel (2) and stop
the drive tube to the bike
switch (3) is pushed onto the bike
handle (3).
handle and secured with a screw.
0208RA237 TG
1 To replace the complete control

handle (1), first remove the throttle
: Insert and tighten down the cable from the engine, b 6.6.2.
screw (1) firmly – drive tube is
secured.
2
1
2 1
0208RA229 TG
a 2 3
1 : Line up the control handle (1) so

0208RA226 TG
that the throttle trigger (2) points

3 towards the gearbox.
0208RA238 TG
3 4 4 : Take out the screw and remove : Push the control handle (1) onto
the locknut (1) from the other side the handlebar (3), turning it back
– always install a new locknut. and forth until it engages the slots
: Position the control handle (1) so
(arrows).
that the lockout lever (2) faces up
and distance : Pull the control handle (2) off the
"a" between it and the sleeve (3) bike handlebar (3).
is 25 mm.

Version for bike handle
1 2
– Remove control handle from bike
handle, b 9.2
2 1
1 1
0208RA230 TG
0208RA207 TG
: Fit new locknut (1) in the recess : Disconnect the throttle cable (1)
and push the screw (2) through from the trigger (2).
the control handle and handlebar
0208RA205 TG
from the other side.
2 1
: Hold the locknut steady and 2 4 3
tighten down the screw firmly. : Take out the screws (1) and
carefully remove the handle
The control handle must be firmly molding (2).
seated on the handlebar and not
move.
All models
0208RA208 TG
9.3 Throttle Trigger / Lockout 1
Lever
: Take the lever (1) out of the
Version with control handle on throttle trigger (2).
drive tube
: Lift the torsion spring (3) clear of
– Remove control handle from the stop (4) and take it away.
drive tube, b 9.1
0208RA206 TG
1 2
1
1 1 : Take the throttle trigger (1) with
torsion spring (2) off the pivots
(arrows).
0208RA209 TG
0208RA204 TG
1 2 1
: Carefully lift the lockout lever (1)
: Take out the screws (1) and a little and turn it clockwise until
carefully remove the handle the torsion spring is relieved of
molding (2). tension, then pull it off.

1
1 1
0208RA210 TG
0208RA212 TG
0208RA215 TG
: Remove the torsion spring (1). : Turn the upper leg (1) of the : Push the lockout lever (1) onto
torsion spring counterclockwise the pivot pin and turn it
– Inspect the throttle trigger, lever, and push it behind the web counterclockwise until it engages
lockout lever and torsion springs, (arrow) the rib (arrow)
replace if necessary. – torsion spring is now – the lockout lever is now
pretensioned in its seat. pretensioned.
– Check the adjusting wheel and
3 4 2 1
– Inspect the stop switch lever and
1
– Check the throttle cable and
adjust or replace if necessary, 2
b 9.6
0208RA213 TG
0208RA241 TG
– Inspect the contact springs and
replace if necessary, b 6.6.3
: Push the lockout lever (1) onto : Push the straight leg (1) into the
– Check the handle moldings and the pivot pin (2) so that it fits past opening (arrow) and fit the torsion
the upper leg of the torsion spring (2) in position.
spring.
: Tension the hooked leg (3)
Installing
counterclockwise and fit it behind
the stop (4).
2
1
0208RA214 TG
0208RA211 TG
: Attach the torsion spring (arrow)

: Fit the torsion spring (1) on the to the lockout lever (1).
pivot pin (2) so that its lower, bent
leg butts against the web (arrow)
on the left.

Version with control handle on
3 2 drive tube
1
4 2 2
0208RA242 TG
0208RA245 TG
2
0208RA247 TG
: Fit the lever (1) in the throttle : Lift the lockout lever (1) slightly
trigger (2) so that the hooked and push the throttle trigger (2) 2 1 2
leg (3) projects from the opening into position until the lug (arrow)
(arrow) and the stop (4) is next to engages the lockout lever (1). : Fit the handle molding (1), insert
the adjusting screw. and tighten down the screws
(arrows) firmly.
1 – Install control handle on drive

1 2 tube, b 9.1
Version for bike handle
0208RA246 TG
2 2
0208RA243 TG
The wires must be properly seated

: Attach the throttle cable (1) to the in the right order in the guides.
trigger (2).
: Push throttle cable grommet (1)
0208RA342 TG
into its seat (arrow).
1 2

carefully remove the handle
molding (2).
– Install control handle on bike

handle, b 9.2
0208RA244 TG
1 2
: Fit the throttle trigger (1) on the

pivot pin (2) so that the hooked
leg (arrow) engages the pivot.

Check operation
1 2
1
OP
ST
0208RA249 TG
0208RA251 TG
2 1
0208RA248 TG
2 : Lift the stop switch lever (1) The contact spring (1) must be
slightly, pull the contact spring (2) located properly in the stop switch
The throttle trigger (2) must be out of the guide (arrow) and push lever (2).
locked in position when the lockout it to one side.
lever (1) is not depressed. : Push the contact spring (1)
: Pull off the stop switch lever (1), towards stop switch lever (2) and
– Turn adjusting wheel in direction check it and replace if necessary. into the guide (arrow).
of "+" up to stop.
– Inspect the contact springs and : Push stop switch lever (2) with
: Depress the throttle trigger (2) to replace if necessary, b 6.6.3 contact spring (1) into position –
full throttle position and let it go – press the wires fully into the
it must return to the stop. guides if necessary.
– Check the adjusting wheel and
re-adjust if necessary, b 9.6 Check operation
Installing
– Install control handle on drive
tube, b 9.1 1
Install control handle on bike 2 3
handle, b 9.2
9.4 Stop switch lever

(momentary contact
0208RA252 TG
switch):
0208RA250 TG
– Remove control handle from 1

drive tube, b 9.1 : Depress stop switch lever (1), the
Remove control handle from bike contact springs (arrows) must
: Push the contact spring (1) to
handle, b 9.2 touch each other
one side.
– the contact springs must be
free from grease.
– Remove the throttle trigger and : Push the stop switch lever (2)
lockout lever, b 9.3 onto the pivot pin (3) so that the
– Install the throttle trigger / lockout
contact spring loop (1) engages
lever, b 9.3
in its seat (arrow).


reverse sequence.

9.5 Adjusting Wheel Version with control handle on
drive tube
– Remove control handle from
drive tube, b 9.1
Remove control handle from bike 1
handle, b 9.2
2
– Remove the throttle trigger and
0208RA258 TG
lockout lever, b 9.3
0208RA255 TG
– Remove stop switch lever, b 9.4
: Reach through the opening
1 (arrow) and push the adjusting
wheel (1) off the pivot pin.
2 1 : Take out the screw (1) and
remove the clamp (2).
All models
2
1
0208RA254 TG
0208RA259 TG
2
: Push the contact spring (1)
inwards in area of terminal (2) 1
and lift it over the lug (arrow). 3
0208RA256 TG
: Remove the spring (1) from the

pivot pin (2).
: Pull the contact spring (1) with
short circuit wire out of the
guides. – Check the handle moldings and
: Take out the screw (1) and pull replace if necessary.
lever (2) off the pivot pin (3).
– Inspect the adjusting wheel, lever
and springs, replace if necessary.
1
2 Installing
0208RA253 TG
0208RA257 TG
1 2
: Pull the contact spring (1) with

ground wire out of the guides
: Lift the spring (1) a little until it
(arrows).
0208RA260 TG
slips past the lug (2), then pull it

out. 1
: Fit the spring (1) on the pivot

pin (2) so that its short leg locates
against the rib (arrow).

Version with control handle on
1 drive tube
2 1 3 1
0208RA261 TG
2
0208RA264 TG
2
0208RA266 TG
: Push the adjusting wheel (1) onto The peg (1) on lever (2) must
the pivot pin (2) so that the spiral engage the spiral groove (arrow) in
groove (arrow) is visible. the adjusting wheel (3).
: Fit clamp (1) in the handle
: Lubricate spiral groove (arrows) molding and position it against
in adjusting wheel (3) and slot the rabbet as shown (arrow).
(arrow) in lever (2) with STIHL
2 lubricant, b 12 : Insert the screw (2) – do not
tighten down yet.
5 All models
3
4
0208RA262 TG
3
1
1
: Leg (arrow) of spring (1) must be
2
0208RA265 TG
under tension and locate against

the adjusting wheel (2) – the
spring (1) must hold the adjusting
wheel (2) in the set position. If
0208RA279 TG
necessary, bend torsion spring to : Push the lever (1) onto the pivot
increase tension. pin (2) so that the spring (3) is 2 1
visible.
Do not twist the wire.
: Insert the screw (4) and tighten it
down – lever (1) and adjusting : Position contact spring (1) with
2 wheel (5) must move freely, ground wire so that the crimped
loosen the screw (4) a little if side of the terminal (2) faces
3 necessary. away from the rib (3).
: Lubricate end of spring (arrow) : Push the contact spring (1) with
with STIHL lubricant, b 12 ground wire into the guides
0208RA263 TG
(arrows).
1
: Line up the spring (1) so that its

hooked end (2) is next to the
lug (3).
: Push the spring (1) into the guide

(arrow) until it is behind the
lug (3).

9.6 Adjusting the Throttle
1 1 Cable
0208RA270 TG
0208RA268 TG
The throttle cable must be adjusted
to ensure the rotary piston of the
control valve on the carburetor
opens fully when the throttle is
: Press the ground wire (1) fully : Push short circuit wire (1) fully opened, and also closes properly.
into the guides (arrows). into the guides (arrows) – the
ground wire must be underneath The adjustments are the same on
the short circuit wire. all versions of the control handle.
2 4 1 – Install stop switch lever, b 9.4 Make sure the throttle cable sleeve
is properly seated in the guides and
butts against the stops
Check operation – the position of the throttle cable
sleeve affects the adjustment.
1
0208RA278 TG
Checking adjustment of throttle

cable
3
Do not twist the wire. 1
OP
ST
: Position contact spring (1) with
0208RA252 TG
short circuit wire so that the

crimped side of the terminal (2)
faces away from the rib (3).
: Depress stop switch lever (1), the
0208RA271 TG
: Push the contact spring (1) with contact springs (arrows) must
short circuit wire into the guides touch each other
(arrows) until the contact – the contact springs must be
2
spring (1) is behind the lug (4). free from grease.
: Turn adjusting wheel (1) in
direction of "+" up to stop.
: Apply thin coating of STIHL – Install the throttle trigger / lockout
lubricating grease to radius of lever, b 9.3
contact spring (1) : Squeeze the throttle trigger (2)
– the contact face must remain as far as stop and hold it there.
– The travel of the throttle trigger in
free from grease, b 12 the direction of full throttle is
limited by rotating the throttle set
wheel.


reverse sequence.

The throttle cable must not be under Engine does not return to idle
1 tension when the throttle trigger is speed – working tool runs in this
released since the control valve's position
rotary piston may not close properly
– the engine idle speed will then be – Shut off the engine.
too high.
7022RA041 TG
Engine speed increases when
throttle trigger alone is
depressed
: Turn the lever (1) on the rotary

piston. 1 3
OP
ST
If the throttle lever (1) can be turned
further in the full throttle direction, 1
the control valve's rotary piston will
not be wide open in the full throttle
position
0208RA397 TG
Adjusting the throttle cable 2
: Turn adjusting wheel (1) in

direction of "+" up to stop.
– Start the engine.
: Squeeze the throttle trigger (2) –

do not depress the throttle trigger
2
lockout (3).
0208RA273 TG
0208RA274 TG
If the engine speed increases
or if the working tool
runs, the throttle cable must be re-
3
: Squeeze the throttle trigger and
turn the grub screw (arrow) until adjusted.
: Squeeze throttle trigger (1) all the
the control valve's rotary piston is way and release it. The throttle
wide open. – Shut off the engine.
trigger (1) and lever (2) on the
control valve must automatically
– Turn the grub screw clockwise : Depress the lockout lever (3), return to their original positions.
= throttle cable is tensioned then squeeze the throttle
(rotary piston is opened more) trigger (2) as far as stop and hold
– Check freedom of movement of
it there.
throttle cable and re-adjust if
– Turn the grub screw necessary, b 6.6.2, b 6.6.3
counterclockwise : Turn grub screw (2) on throttle
= throttle cable is relaxed (rotary trigger 1/2 turn
– Check freedom of movement of
piston is opened less) counterclockwise.
lever on control valve, replace
control valve if necessary,
: Release the throttle trigger (2) b 10.4.4
and lockout lever (3).
– Fit the filter cover, b 10.1
– Start the engine and check the
adjustment, repeat procedure if
– Fit the shroud, b 5.4
necessary.

10. Fuel System
10.1 Air filter Fleece filter 10.2 Filter Housing
– See also Troubleshooting, 2 – Remove the air filter, b 10.1

b 3.4, b 3.6
Paper filter
1
2
2
0208RA045 TG
1
1
7022RA044 TG
remove the filter cover (2).
1
7022RA042 TG
: Unscrew the nuts (1) and remove

the filter housing (2).

remove the filter cover (2).
0208RA046 TG
1
7022RA045 TG
: Take out the air filter (1).
1
Check the air filter (fleece element)
7022RA043 TG
and clean or replace if necessary

: Pull the tank vent hose (1) off the
– see instruction manual. nipple (arrow) – always install a
new tank vent hose.
: Take out the air filter (1). – Reassemble in the reverse
sequence.
– Check the air filter and replace if 1
necessary.
– see instruction manual.
0208RA049 TG
: Remove the gasket (1) – always

install a new gasket.
– Examine sealing faces on

carburetor and filter housing and
clean if necessary, b 12

Installing : Fit the nuts (2) and tighten them
down to the specified torque.
Over-tightening may impair
1 freedom of movement or function
of carburetor.
1
0208RA050 TG reverse sequence.
10.3 Carburetor

: Fit the new gasket (1) so that the
tabs (arrows) point down.
– Remove the filter housing,
b 10.2
– Remove throttle cable (short

1 circuit wire) from engine,
b 6.6.2
– Open the fuel tank cap and drain 2

2 the fuel tank.
7022RA046 TG
– Collect the fuel in a clean

container, b 1
0208RA053 TG
Disconnect the fuel hose only when
– Use STIHL press fluid to ease
the tank cap is open.
installation, b 12 : Pry the fuel return hose (1) out of
the bore (arrow) in the tank
Remove the carburetor with the fuel
: Push the new tank vent hose (1) housing and pull off the elbow
hoses attached
fully onto the nipple (2). connector (2) of the fuel suction
– if fuel hoses are disconnected,
hose.
they must be replaced by new ones.
1 1
2
2
7022RA047 TG
0208RA049 TG
: Push the filter housing (1) over

the studs. : Remove the gasket (1) – always

1
2
1 1
3
2
0208RA054 TG
0208RA056 TG
0208RA186 TG
: Squeeze locking tabs (arrows) : Remove the gasket (1) – always – Use STIHL press fluid to make
under the retainer (1) together install a new gasket. installation easier, b 12
and push out the manual fuel
pump (2). – Inspect and clean the sealing : Fit the elbow connector (1) with
faces on the carburetor and fuel suction hose (3) under the
: Remove the manual fuel spacer flange, b 12 tank vent hose.
pump (2) with fuel hoses still
attached and put it to one side. – Check the carburetor and service : Push the elbow connector (1)
or replace if necessary, b 10.4 into the fuel suction hose (2) so
that fuel suction hose (3) locates
in the recess (arrow)
Installing – the elbow connector (1) must
be pushed fully into the fuel
suction hose (2).
1 1
2
0208RA055 TG
3 1
0208RA057 TG
: Remove the carburetor (1).
0208RA060 TG
: Check the fuel suction hose (2)
with elbow connector (3), replace : Fit the new gasket (1) so that the
if necessary, b 10.8.2 tabs (arrows) point down.
– Inspect the fuel hoses and – Use STIHL press fluid to simplify
manual fuel pump, replace if assembly, b 12
necessary, b 10.8.4
: Push the fuel return hose (1) fully
into the bore (arrow).
1
0208RA058 TG
: Push the carburetor (1) onto the

studs (arrows).

Check operation
3
– Check throttle cable and trigger
1 adjustments and re-adjust if
necessary, b 9.6
1
2 – Install the air filter, b 10.1
0208RA061 TG
0208RA165 TG
3 reverse sequence. 2
: Line up the manual fuel pump (1) – Push the pressure hose of pump
so that the lug (2) points towards 10.3.1 Leakage Test 0000 850 1300 onto the elbow
the carburetor. connector (1).
In the case of problems with the
: Push the manual fuel pump (1) carburetor or fuel supply system, : Push the ring (2) to the right and
into the retainer (3) on the air also check and clean or replace the pump air into the carburetor until
guide shroud until the locking tank vent, b 10.7 the pressure gauge (3) indicates
tabs (arrows) snap into place a pressure of about
below the retainer (3). The carburetor can be tested for 0.8 bar (80 kPa).
leaks with the pump
0000 850 1300. If this pressure remains constant
with the manual fuel pump attached,
1 – Remove carburetor with fuel the carburetor and manual fuel
hoses still attached and the pump are airtight. However, if the
manual fuel pump, b 10.3 pressure drops, the manual fuel
pump may be damaged.
– Check the fuel hoses on the
carburetor for signs of damage.
0208RA050 TG
Leakage test with manual

fuel pump
– Install the filter housing, b 10.2 1
– Fit throttle cable (short circuit

wire) on engine, b 6.6.2
2
0208RA164 TG
: Use a suitable plug (2) to seal the

fuel return hose (1).

Leakage test without manual – After completing the test, push
fuel pump the ring to the left to vent the 2
system and then pull the
pressure hose off the elbow
2 connector.
1 1
– Install the carburetor, b 10.3
0208RA282 TG
3 reverse sequence.
0208RA166 TG : Remove the complete flange (1)

10.4 Servicing the Carburetor with fuel hoses still attached.
: Pull the manual pump (1) off the – Inspect the pump diaphragm and
10.4.1 Metering Diaphragm
fuel hose (2). gasket, replace if necessary,
b 10.4.3
: Use a suitable plug (3) to seal the – Troubleshooting, b 3.4
fuel hose (1). – Inspect the fuel hoses, replace if
– Remove carburetor with fuel necessary, b 10.8.2, b 10.8.4
– Repeat the leakage test. hoses still attached and the
manual fuel pump, b 10.3
If the gasket and metering
If the pressure remains constant, diaphragm are stuck to the
the carburetor is airtight and the carburetor, remove them very
manual fuel pump has to be carefully.
2
replaced, b 10.8.4.
1 : Remove the metering
However, if it drops, there are three diaphragm (2) with gasket.
possible causes: 1
1
1. Metering diaphragm or gasket 1
damaged, replace as
0208RA281 TG
necessary,
b 10.4.1
2. The inlet needle is not sealing – Turn the carburetor over.

(foreign matter in valve seat,
sealing cone of inlet needle
is damaged or : Take out the screws (1) and
inlet control lever is sticking), remove the end cover (2).
remove to clean,
b 10.4.2
3. Pump diaphragm or
gasket damaged,
switch, b 10.4.3
– Test the tank vent if necessary,

b 10.7.1

2 1
2
1
1
1
1
1
0208RA285 TG
0208RA283 TG
0208RA287 TG
: Carefully separate the metering : Note installed positions of – Check that metering and pump
diaphragm (1) and gasket (2). gasket (1) and metering diaphragms with gaskets are
diaphragm (2). properly seated, re-position if
The diaphragm material is necessary.
subjected to continuous alternating : Fit the gasket (1) and metering
stresses and eventually shows diaphragm (2) so that the holes : Fit the screws (1) and tighten
signs of fatigue, i.e. the diaphragm line up with the pegs (arrows) and them down firmly in a crosswise
distorts and swells and has to be the holes in the carburetor. pattern.
replaced.
: Check metering diaphragm (1) reverse sequence.
and gasket (2) for signs of wear 2
or damage, replace if necessary.
10.4.2 Inlet Needle
Installing 1 – Remove the metering

diaphragm,
b 10.4.1
0208RA286 TG
– Check gaskets of metering and

pump diaphragms and replace if
2 : Hold the complete flange (1) and necessary, b 10.4.1, b 10.4.3
3 fit the end cover (2) so that it
engages the pegs (arrows).
0208RA284 TG
: Position the complete flange (1)

with fuel hoses attached against 1
the underside of the carburetor
body so that its peg (2) and the
projecting valve jet (3) engage
0208RA289 TG
the recesses.
– Check that the pump diaphragm

and gasket are properly seated. : Take out the screw (1)
– Hold the flange steady and turn it

over with the carburetor.

Installing 10.4.3 Pump Diaphragm
2 – Troubleshooting, b 3.4
1
1 hoses still attached and the
manual fuel pump, b 10.3
2
0208RA290 TG
– Remove the end cover, b 10.4.1
0208RA292 TG
: Take the inlet control lever (1)
with
spindle (2) out of the inlet : Fit the inlet needle (1).
needle’s groove.
: Fit the spring (2) in the bore.
The small spring under the inlet
control lever may pop out. 1
0208RA294 TG
1
3 2
: Remove the complete flange (1)
with fuel hoses still attached and
1 turn it over.
2 0208RA293 TG
: If the pump diaphragm and

0208RA291 TG
gasket are stuck, remove them

very carefully.
: Position the inlet control lever (1)
with spindle (2) on the spring
: Pull out the inlet needle (1) and (arrow) first, then slide the inlet
spring (2). control lever’s clevis into the
groove in the inlet needle (3).
– Check individual parts, replace if
necessary. Make sure the spring locates on the
control lever’s nipple.
– Press the inlet control lever down

and secure it with the screw.
– Check that the inlet control lever

moves freely.
– Install the metering diaphragm,

b 10.4.1
165RA348 TG
: If there is an annular indentation

(arrow) on the sealing cone of the
inlet needle, fit a new inlet
needle.

– Inspect the flange and replace if
necessary
– if a new flange is installed, the
attached fuel hoses must also be
1 replaced.
2
2 3
0208RA295 TG sequence.
0208RA284 TG
1
Installing
: Carefully separate the pump : Position the complete flange (1)
diaphragm (1) and gasket (2) with fuel hoses attached against
the underside of the carburetor
The diaphragm material is body so that its peg (2) and the
subjected to continuous alternating 2 projecting valve jet (3) engage
stresses and eventually shows the recesses.
signs of fatigue, i.e. the diaphragm
distorts and swells and has to be 1 – Check that the pump diaphragm
replaced. and gasket are properly seated.
0208RA297 TG
: Check pump diaphragm (1) and – Hold the flange steady and turn it
gasket (2) for signs of wear or over with the carburetor.
damage, replace if necessary. : Position the new gasket (1) and
pump diaphragm (2) so that the – Install the metering diaphragm
– Inspect the metering diaphragm tabs (arrows) are on the same and end cover, b 10.4.1
and gasket, replace if necessary, side.
b 10.4.1
reverse sequence.
– Inspect the fuel hoses, replace if
necessary, b 10.8.2, b 10.8.4
2
10.4.4 Control Valve
– Check fuel strainer for 4
contamination and damage.
Clean or replace if necessary. – Remove the carburetor, b 10.3
1 5
3 – Carburetor troubleshooting,
0208RA298 TG
b 3.4
1
: Fit the gasket (1) and pump

diaphragm (2) on the flange (3) 2
so that they engage the peg (4)
and projecting carburetor jet (5).
0208RA296 TG
2
0208RA300 TG
: Use a needle to remove the fuel

strainer (1) from the flange (2). 2 1
Clean or replace the fuel strainer.
: Set the lever (1) to the start
position and take out the
screws (2).

Check operation If the carburetor cannot be adjusted
properly, the problem may be the
adjusting screws.
The high speed screw H and low

1 speed screw L have a special hex
2 head and can only be adjusted with
screwdriver 5910 890 2311
0208RA301 TG
– no limiter caps are used.
0208RA303 TG
– See also carburetor
troubleshooting, b 3.4
: Carefully pull the control valve (1) 2 1
out of the carburetor (2).
The idle speed screw L is located in
: Turn lever (1) counterclockwise
the control valve lever. Exact
– Check the control valve and and push it home until it engages
adjustments are made difficult
replace if necessary. on and is held by lever (2) (arrow)
because the lever moves. Use
= cold start position.
sleeve 5910 893 1711 to hold the
The needle of the low speed lever steady while making
screw L in the control valve When lever (2) is turned in direction adjustments.
engages in the carburetor jet. of full throttle, lever (1) is
Remove the low speed screw L to disengaged and automatically Adjusting screws can be removed
reduce the risk of damaging the jet jumps back to its original position. and installed with the carburetor in
(small plastic tube) when installing When lever (2) is released, it position.
the automatically moves back until it
control valve. locates against idle speed
screw LA. Low speed screw
– Check the low speed screw L,
replace if necessary, b 10.4.5 – Install the carburetor, b 10.3

Installing reverse sequence.
1
10.4.5 Adjusting Screws
7022RA049 TG
2 1
3
: Use screwdriver (1)
4 2 5910 890 2311 to remove the low
0208RA302 TG
speed L (arrow) from the control

valve.
7022RA048 TG
: Line up the control valve (1) so 1

that the rabbet (2) engages over
the shoulder (3), then push it
carefully into the carburetor's (4) There are three adjusting screws on
bore (arrow) as far as stop. the carburetor:
H = high speed screw (1)
– Fit the screws and tighten them L = low speed screw (arrow)
down firmly. LA = idle speed screw (2)
– Install the low speed screw L,

b 10.4.5

: Insert screwdriver (2) 10.5 Adjusting the Carburetor
5910 890 2311 through the
sleeve (1) and locate it on the hex
The new carburetors are tuned at
head of the low speed screw L.
the factory so that the engine
receives an optimum fuel-air
: Hold the sleeve (1) steady and mixture in all environments and
screw home the low speed operating conditions.
0208RA306 TG screw L as far as stop.
The high speed screw H and low
1 – Continue with the high speed speed screw L can only be adjusted
screw H. with screwdriver 5910 890 2311.
: Check needle (arrow) for
damage or wear, replace low It is no longer necessary or possible
speed screw L (1) if necessary – High speed screw for the user to change the settings
the needle must be perfectly of these adjusting screws.
straight.
The user may adjust engine idle
speed with the idle speed screw LA.
10.5.1 Basic Setting
1 1 The basic setting is necessary only

7022RA052 TG
if the high speed screw H or low

speed screw L has to be replaced
or after cleaning the carburetor.
7022RA050 TG
: Use screwdriver (1) A basic setting and fine tuning are

5910 890 2311 to remove the necessary after removing and
high speed H (arrow). installing the adjusting screws.
: Carefully push the low speed
screw L (1) into the bore (arrow) The adjusting screws have to be
and screw it home – take care not preset before starting fine tuning.
to bend the needle. This can be performed while the
engine is stationary or on a
carburetor removed from the
machine.
Starting with the low speed and high

speed screws against their seats,
2
0208RA310 TG
turn them counterclockwise.
1 1
: Inspect the tip (arrow) for

7022RA051 TG
damage or wear and replace the

high speed screw H (1) if
necessary.
: Position sleeve (1)
5910 893 1711 on the control – Screw down the high speed
valve lever so that it engages the screw (H) as far as stop.
teeth (arrow).
– Carry out the basic setting,
b 10.5.1

Fine Tuning Preparations for adjusting idle
speed
The carburetor and air filter must be
installed.
1 – Mount the deflector and working 2

tool (mowing head) – see
4 0 2
instruction manual 10
14
8
– the working tool must run 3
4
12
1
12
6
6
14
freely, clean if necessary.
10 8
4
0
2
– Check the air filter (fleece

element) and clean or replace if
necessary
– see instruction manual, b 10.1
– Use screwdriver 5910 890 2311

3 to make adjustments.
10
8
Basic setting of
12
4
6
14
high speed screw Hand low speed

4
0
2
screw L must be in order.

2
– Start the engine and warm it up
for 1 minute at varying speeds.
3 0 2
14
4
– If necessary, turn the idle speed
7022RA053 TG
12
6
10
screw LA slowly clockwise until

8
the engine runs smoothly – the 2

working tool must not run.
7022RA054 TG
: Adjust the adjusting screws with
screwdriver (3) 5910 890 2311
and setting disk (4)
5910 893 6601. : Position sleeve (1)
5910 893 1711 on the control
: Open the high speed screw H (1) valve lever so that it engages the
1 1/4 turns and low speed teeth (arrow).
screw L (2)
1 1/2 turns from their seats. : Insert screwdriver (2)
5910 890 2311 with setting
This completes the basic setting of disk (3) 5910 893 6601 through
the high speed screw H and the low the sleeve (1) and locate it on the
speed screw L. hex head of the low speed
screw L.
– Continue with fine tuning.
: Hold the sleeve (1) steady and
adjust the low speed screw L to
the highest engine speed by
turning it counterclockwise or
clockwise.

Adjusting idle speed 10.5.2 Adjustments by User Engine stops while idling
– Adjust engine idle speed with a – Turn the idle speed screw LA
tachometer or the STIHL MDG 1. clockwise until the working tool
Adjust specified engine speeds starts running, then turn it back
within a tolerance of ± 100 rpm. 1 full turn.
1. Turn the low speed screw L

counterclockwise or clockwise Working tool runs when
to obtain the highest engine idle LA engine is idling
0208RA288 TG
speed.
– Turn the idle speed screw LA
If the engine speed is not between ) counterclockwise until the
3,100 rpm and 3,300 rpm, abort the working tool stops running, then
procedure, set the engine speed to The new carburetors ensure the turn it back 1 full turn.
3,200 rpm with idle speed screw LA engine receives an optimum fuel-air
and start again with step 1. mixture in all environments and
operating conditions. For this Erratic idling behavior, poor
2. Use the reason it is only possible to correct acceleration
idle speed screw LA the engine idle speed with the idle
) to set the engine speed to speed screw LA (arrow). – Check basic setting and fine
3,200 rpm. tuning of adjusting screws, re-
Always perform the following steps adjust if necessary or service the
3. Use the low speed screw L before carrying out any carburetor, b 10.5.1, b 10.4
to set the engine speed to adjustments:
2,800 rpm.
. – Troubleshooting, b 3.4
Fine Tuning for Operation at High
Altitude
– Check the working tool, adjust if
necessary. Motor does not run satisfactorily.
– Check the air filter (felt element) – Check basic setting and fine
and clean or replace if necessary tuning of adjusting screws, re-
– see instruction manual, b 10.1 adjust if necessary or service the
carburetor, b 10.5.1, b 10.4
Check running behavior:
The engine must accelerate
7022RA055 TG
1 smoothly when the throttle is

opened and run uniformly at idle
speed.
This completes fine tuning of the
high speed screw H (1) and low
speed screw L (arrow). Adjusting idle speed
The settings of the high speed Basic setting and fine tuning of
screw H and low speed screw L adjusting screws has been carried
cannot be changed by the user. out.
– Warm up the engine.

10.6 Spacer Flange Installing
1
– Troubleshooting, b 3.6 1 3
hoses still attached and put it to
one side, b 10.3
7022RA056 TG
2
0208RA065 TG
1
: Remove the gasket (1) – always 4
: Fit the new gasket (1) over the
– Inspect the spacer flange and peg (2) and lug (3) and against
replace it if necessary – even the spacer flange (4)
very minor cracks can result in – the holes (arrows) must be in
0208RA056 TG
engine running problems, b 3.4, alignment.

b 3.6
: Remove the gasket (1) – always 3 1

2
2
0208RA066 TG
1
0208RA064 TG
: Position the spacer flange (1)

0208RA062 TG
: Inspect and clean the sealing with gasket (2) against the
faces (arrows) on the cylinder cylinder intake port so the lug (3)
1 inlet port and spacer flange and engages the opening (arrow) in
remove any gasket residue, the intake port.
: Take out the screw (1) and b 12
remove the connector tag (2).
The sealing faces must be in perfect
: Remove the spacer flange (3). condition. If the sealing faces are
damaged, install a new cylinder and
/ or spacer flange.

10.7 Tank Vent
1
10.7.1 Testing
If problems occur on the carburetor

2 or the fuel supply system, also
check and clean the tank vent and
replace it if necessary. Check 1
0208RA067 TG
0208RA169 TG
function by performing pressure and
2 vacuum tests on the tank via the fuel
hose.
: Fit the connector tag (1) on the – Open the fuel tank cap and drain : Pull the fuel return hose (1) off
screw (2). the fuel tank, b 1. the nipple on the manual fuel
pump (arrow).
: Insert the screw (2) with – Close the tank cap.
connector tag (1) so that the
tag (1) locates in the recess – Remove the filter cover, b 10.1
(arrow) and points up, then fit the 2
lower screw (2).
: Tighten down the screws (2)

firmly – hold the connector tag (1)
in the recess (arrow) while 1
tightening the screw.
0208RA170 TG
1
7022RA057 TG
: Use a suitable plug (2) to seal the

fuel return hose (1).
1

nipple (arrow) on the filter
housing.
0208RA057 TG

– Push the carburetor with fuel

hoses attached into position,
b 10.3
7022RA058 TG

1 2
reverse sequence.
: Push the nipple (1)
0000 855 9200 into the fuel
hose (2).

Vacuum test – Operate the pump until the 10.7.2 Removing and Installing
pressure gauge indicates a
pressure of 0.5 bar. If this
2 – Remove the fuel tank, b 10.9
pressure remains constant for at
least 20 seconds, the tank,
including the tank vent, is airtight.
If the pressure drops, the leak
must be located and the faulty
part replaced. 2
7022RA059 TG
– If necessary, install a new tank
1 vent or tank, b 10.7 or b 10.9 1
0208RA173 TG
: Push the ring (1) to the left and – The fuel return hose and tank
connect the pump (2) vent may be re-used if they are
0000 850 1300 to the nipple still in order.
(arrow)
– create a vacuum in the fuel : Pry out the tank vent (1).
tank.
: Pull the tank vent (1) off the
Equalization of pressure takes hose (2), check and replace if
place via the tank vent. There must necessary.
be no buildup of vacuum in the tank.
– Remove the grommet.
– Clean the area around the tank
vent. Always install a new tank vent.
7022RA061 TG
– Always install a new fuel hose. 1

Installing
– If necessary, install a new tank – Use STIHL press fluid to make
vent or tank, b 10.7 or b 10.9 installation easier, b 12
: Push the tank vent hose (1) onto

Pressure test the nipple (arrow) on the filter 1
housing – the tank vent hose (1)
must be positioned above the fuel
2 suction hose.
0208RA174 TG
sequence.
: Position the grommet (1) so that

its taper points in the direction of
7022RA060 TG
the fuel tank.

1
– Use STIHL press fluid to make
: Push the ring (1) to the right and installation easier, b 12
connect the pump (2)
0000 850 1300 to the nipple : Fit the grommet (1) in the hole
(arrow) – pressurize the fuel tank. (arrow) and make sure it is
properly seated.

– Troubleshooting, b 3.4 or 10.8.2 Fuel Hose on Carburetor
b 3.6
2 – Open the tank cap.
Clean the fuel tank if necessary.
1 – Remove the shroud, b 5.4
– Open the tank cap and drain the
fuel tank.
0208RA175 TG
– Pour a small amount of clean

gasoline into the fuel tank. Close
the tank and shake the machine
– Use STIHL press fluid to make vigorously.
installation easier, b 12
– Open the tank again and drain it.
: Push nipple of new tank vent (1)
fully into the tank vent hose (2). – Dispose of fuel properly in
1
accordance with environmental
0208RA177 TG
: Position the tank vent (1) so that requirements, b 1.2
the nipple with tank vent hose (2)
locate in the recess (arrow).
2
– Open the tank cap.
: Pry out the elbow connector (1)
: Push the tank vent (1) with
with fuel suction hose (2).
hose (2) fully into the grommet.
The tank vent hose (1) must be

positioned above the fuel suction
hose and be pushed fully onto the
nipple on the filter housing.

0208RA176 TG
reverse sequence. 1 1
0208RA178 TG
10.8 Fuel Intake : Use hook 5910 893 8800 to
10.8.1 Pickup Body remove the pickup body (1) from
the fuel tank.
: Pull the fuel suction hose (1) with
The fine pores of the filter become elbow connector off the
clogged with minute particles of dirt. Do not overstretch the fuel hose. carburetor (arrow).
This restricts the passage of fuel
and results in fuel starvation. : Pull off the pickup body (1),
check it and replace if necessary. – Pull the elbow connector off the
fuel suction hose, check it and
In the event of problems with the replace if necessary.
fuel supply system, always check – Reassemble in the reverse
the fuel tank and the pickup body sequence.
Always use a new fuel suction hose.
first.

Installing
1
2
0208RA181 TG
0208RA177 TG
1 2
2 1 0208RA179 TG
: Position the fuel suction hose (1) : Pry out the elbow connector (1)
under the tank vent hose (2). with fuel suction hose (2).
installation easier, b 12 – Remove the tank housing,
b 10.9
: Push the elbow connector (1)
fully into the new fuel suction
hose (2) as far as stop. 2
1 1
0208RA182 TG
1
0208RA183 TG
2 : Push the fuel hose (1) onto the
carburetor's connector (2).
0208RA180 TG
– Reassemble all other parts in the : Pull the fuel suction hose (1) out
3 reverse sequence. of the fuel tank.
– Use STIHL press fluid to make Always use a new fuel suction hose.
installation easier, b 12 10.8.3 Fuel Suction Hose in Fuel
Tank
: Push the elbow connector (1) Installing
into the fuel suction hose (2) so
– Open the tank cap and drain the
fuel tank.
– the elbow connector (1) must
be pushed fully into the fuel – Remove the shroud, b 5.4
1
suction hose.
– Remove the pickup body,

0208RA184 TG
b 10.8.1
: Push the fuel suction hose (1)

through the bore (arrow) in the
fuel tank.

: Push the elbow connector (1)
1 into the fuel suction hose (2) so
1
– the elbow connector (1) must
suction hose (2).
0208RA185 TG
0208RA188 TG
– Use STIHL press fluid to make : Pry the fuel return hose (1) out of
installation easier, b 12 the bore (arrow) in the tank
housing.
: Push the fuel suction hose (1)
into the housing bore as far as
0208RA187 TG
stop so that pointed end of the
flange faces the recess (arrow).
1
– Install the tank housing, b 10.9
: Use hook 5910 893 8800 to pull 1
the end of the fuel suction
hose (1) out of the fuel tank.
0208RA189 TG
Do not overstretch the fuel suction
hose.
1 – Fit the pickup body, b 10.8.1

: Pull the fuel hose (1) off the
3
2 connector (arrow) on the
– Close the tank cap. carburetor.
0208RA186 TG

reverse sequence.
10.8.4 Fuel Hose / Fuel Return
Hose and Manual Fuel
2
: Fit the elbow connector (1) with 1
Pump
fuel suction hose (3) under the
tank vent hose.
– Open the tank cap.
0208RA054 TG
– Remove the filter cover, b 10.1 : Squeeze locking tabs (arrows)

pump (2).
– Remove manual fuel pump with

fuel hoses.

1
3 1
1 2
2
0208RA061 TG
0208RA192 TG
0208RA190 TG
3
: Pull off the fuel hose (1) and fuel : Line up the manual fuel pump (1) – Use STIHL press fluid to simplify
return hose (2). so that the lug (2) points towards assembly, b 12
the carburetor.
: Check the manual fuel pump (3) : Push the fuel return hose (1) fully
and fuel return hose (2) and : Push the manual fuel pump (1) into the bore (arrow) in the tank
replace if necessary. into the retainer (3) on the air housing.
guide shroud until the locking
: Install a new fuel hose (1). tabs (arrows) snap into place – Check operation
below the retainer (3). – fuel must flow when the fuel
pump is operated.
Installing
1
reverse sequence.
1 3
0208RA193 TG
0208RA191 TG
– Use STIHL press fluid to simplify

: Push the new fuel hose (1) onto assembly, b 12
the short nipple (2).
: Push the fuel hose (1) fully onto
: Push the fuel return hose (3) onto the carburetor's connector
the long nipple. (arrow).

10.9 Fuel Tank 10.9.1 Fuel Tank
Removing and Installing
– Drain the fuel tank, b 1
7022RA057 TG
b 7.2
1
1
– Remove the filter cover, b 10.1 nipple (arrow) on the filter
housing.
– Remove the tank guard if
necessary,
2
2
7022RA062 TG
2 1
: Pull the fuel tank (1) out of the

rubber mounts (2) and lift it away.
0208RA053 TG
: Pry the fuel return hose (1) out of

the bore (arrow) in the tank 1
housing and pull off the elbow
connector (2) of the fuel suction
hose.
0208RA198 TG
: Pull the rubber mounts (1) off the

stubs (arrows), check them and
– Test the tank vent, replace if

necessary, b 10.7

Installing
1
1 1
3
2
0208RA186 TG
0208RA060 TG
1 0208RA199 TG – Use STIHL press fluid to make – Use STIHL press fluid to simplify
installation easier, b 12 assembly, b 12
assembly, b 12 : Fit the elbow connector (1) with : Push the fuel return hose (1) fully
fuel suction hose (3) under the into the bore (arrow).
: Push the rubber mounts (1) fully tank vent hose.
onto the stubs (arrows). – Reassemble all other parts in the
: Push the elbow connector (1) reverse sequence.
into the fuel suction hose (2) so
2 in the recess (arrow) 10.9.2 Fuel tank
– the elbow connector (1) must Replacing
suction hose (2).
0208RA200 TG
1 2
2 1
0208RA054 TG
assembly, b 12
7022RA061 TG
: Push the fuel tank (1) with rubber

mounts (2) into the bores
1 : Squeeze locking tabs (arrows)
(arrows) in the crankcase until
seated.
pump (2).
– Remove manual fuel pump with
: Push the tank vent hose (1) onto
fuel hoses.
the nipple (arrow) on the filter
housing – the tank vent hose (1)
must be positioned above the fuel
suction hose.

Installing
1 2
2 1
0208RA189 TG
7022RA064 TG
1
0208RA199 TG
: Pull the fuel hose (1) off the : Pull the fuel tank (1) out of the 1
connector (arrow) on the rubber mounts (2) and lift it away.
carburetor. – Use STIHL press fluid to simplify
assembly, b 12
FS 94, KM 94
: Push the rubber mounts (1) fully
– Remove the tank guard, onto the stubs (arrows).
b 10.9.3
All models 2
7022RA057 TG
1 1
7022RA065 TG
nipple (arrow) on the filter 1
housing. 2
0208RA198 TG
– Remove the filter housing, – Use STIHL press fluid to simplify

b 10.2 1 assembly, b 12
: Pull the rubber mounts (1) off the : Push the fuel tank (1) with rubber
stubs (arrows), check them and mounts (2) into the bores
replace if necessary. (arrows) in the crankcase until
seated.
– If the rubber mounts are in order,
transfer them to the new fuel
1 tank. All other parts are included FS 94, KM 94
with the new fuel tank – see parts
list. – Install the tank guard, b 10.9.3
7022RA063 TG
: Pull the fuel suction hose (1) off

the connector (arrow) on the
carburetor.

All models
1
1
2
2
1
0208RA061 TG
7022RA221 TG
3 2
0208RA202 TG
2
: Line up the manual fuel pump (1) : Hold the fuel tank steady, lift the
so that the lug (2) points towards tank guard (1) at the starter side
– Use STIHL press fluid to make the carburetor. (arrow) and pull it off the lugs (2)
installation easier, b 12 at the same time.
: Push the manual fuel pump (1)
: Position the fuel suction hose (1) into the retainer (3) on the air – Inspect the tank guard and
under the tank vent hose (2) and guide shroud until the locking replace it if necessary.
push it onto the carburetor's tabs (arrows) snap into place
connector (arrow). below the retainer (3).
Installing
– Install the filter housing, b 10.2
1
1
3
0208RA193 TG
7022RA222 TG
2
7022RA061 TG
1 – Use STIHL press fluid to simplify : Position the tank guard (1) so
assembly, b 12 that the bulge (2) points in the
– Use STIHL press fluid to make directon of the filler neck.
installation easier, b 12 : Push the fuel hose (1) fully onto
the carburetor's connector : At the starter side (arrow), fit the
: Push the tank vent hose (1) onto (arrow). tank guard (1) over the fuel tank
the nipple (arrow) on the filter and push it home until the
housing – Reassemble all other parts in the lugs (3) snap into place in the
– the tank vent hose (1) must be reverse sequence. openings.
positioned above the fuel suction
hose. – Reassemble all other parts in the
10.9.3 Tank Guard reverse sequence.
(FS 94, KM 94)

b 7.2

11. Special Servicing Tools
New Special Tools
No. Part Name Part No. Application Rem.
1 Press sleeve 4149 893 2400 Installing oil seal

(ignition side / starter side)
2 Installing sleeve 4149 893 4600 Protecting oil seal at ignition side
3 Screwdriver 5910 890 2311 Adjusting the carburetor
– Screwdriver 5910 890 2307 Adjusting carburetor (without sleeve
and setting disk)
– Sleeve 5910 893 1711 Used as holder for adjusting
low speed screw L
– Setting disk 5910 893 6601 Adjusting the carburetor
4 Ring 5910 893 7008 Supporting fan housing, protecting
guide sleeves
Existing Special Tools
1 Carburetor and engine tester 0000 850 1300 Testing engine and carburetor for leaks
- Nipple 0000 855 9200 Testing carburetor for leaks
- Hose for leakage test 1110 141 8600 Testing carburetor for leaks
2 Sealing plate 0000 855 8106 Testing engine for leaks
3 Installing tool 0000 890 2201 Installing rope guide bushing
4 Setting gauge 0000 890 6400 Adjusting air gap between the ignition
module and flywheel
5 Clamping strap 0000 893 2600 Clamping rings around piston
6 Locking strip 0000 893 5904 Blocking the crankshaft
7 Screwdriver bit, T 27 x 125 0812 542 2104 Removing and installing spline socket
screws with electric or pneumatic
screwdrivers; tightening down screws
with torque wrench
8 Thrust piece 1107 894 1000 Protecting crankshaft stub at starter
side
9 Wooden assembly block 1108 893 4800 Supporting the piston
10 Assembly drift 1130 893 4700 Removing and installing piston pin
11 Installing sleeve 1146 893 4600 Protecting oil seal at starter side
12 Press arbor 4116 893 7205 Installing ball bearings hot and
pressing fully home if necessary
(starter side of crankcase)

13 Thrust piece 4116 894 1000 Extension for spindle of screw sleeve,
from service tool set ZS
14 Puller 4119 890 4501 Removing flywheel
15 Press arbor 4224 893 7200 Installing ball bearings hot and pressing
fully home if necessary (ignition side of
crankcase)
16 Installing tool 4126 893 4900 Rubber element, 1-point AV system
17 Combination wrench 4149 890 3400 Spark plug 1)
18 Service tool ZS (set) 5910 007 2201 Removing and installing the
crankshaft (starter side)
- Drilled plate 5910 893 2103 Removing and installing the

crankshaft (starter side)
- Instruction label 5910 967 3500 Adhesive label with latest hole circles
for screw sleeve 5910 893 2420
19 Flange 5910 850 4200 Crankcase leakage test
20 Ignition system tester, ZAT 4 5910 850 4503 Testing ignition system
21 Ignition system tester, ZAT 3 5910 850 4520 Testing ignition system
22 Torque wrench 5910 890 0302 0.5 to 18 Nm
23 Torque wrench 5910 890 0312 6 to 80 Nm
24 Installing tool 8 5910 890 2208 Installing hookless snap rings in piston
– Sleeve 5910 893 1708 Sleeve for installing tool 8
25 Screwdriver bit, T 27 x 150 5910 890 2400 IS-P screws (4 mm)
26 Hook 5910 890 2800 Removing the clutch spring
27 Assembly stand 5910 890 3101 Holding power tool for repairs
28 Puller 5910 890 4400 Removing oil seals
- Jaws (No. 3.1) 0000 893 3706 Removing oil seal(s)
- Jaws (No. 6) 0000 893 3711 Removing oil seal(s)
29 Clamp for assembly stand 5910 890 8800 Clamping drive tube of power tool to
assembly stand
30 Hook 5910 893 8800 Removing pickup body
Remarks:
1) Use for releasing only.

12. Servicing Aids
No. Part Name Part No. Application
1 STIHL multipurpose grease Control handle, carrier

- 80 g tube 0781 120 1109
- 225 g tube 0781 120 1110
2 STIHL lubricating grease Oil seals, sliding and bearing points

- 225 g tube 0781 120 1111
3 STIHL press fluid OH 723 0781 957 9000 Rubber elements, antivibration elements, fuel
hoses
4 Dirko HT red sealant 0783 830 2000 Sealing crankcase
5 Standard commercial solvent- Cleaning sealing faces and carburetor,

based degreasant containing no crankshaft stubs and flywheel taper
chlorinated or halogenated
hydrocarbons
6 Special plastic compatible, Bearing bore in rope rotor, rewind spring in

low temperature lubricating oil, starter
trade

englisch / english
0455 593 0123. VA2.J14.

Service Manual - Stihl FS94 KM94 SP92 SP92T

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Service Manual - Stihl FS94 KM94 SP92 SP92T

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STIH)

STIHL Series 4149 Powerhead 2014-10

1. Introduction and 6.4 Spark Plug Boot / 10. Fuel System 67

6. Ignition System 36 Lockout Lever 59

Series 4149 Powerhead 1

Service manuals and all technical

2 Series 4149 Powerhead

Run the machine only with the

Series 4149 Powerhead 3

Displacement: 21.4 cm3 24.1 cm3

2.2 Fuel System

Carburetor leakage test at gauge

2.3 Ignition System

Air gap between ignition module and

4 Series 4149 Powerhead

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

Micro-encapsulated screws and screws coated with threadlocking adhesive:

Do not mix up screws with and without binding heads.

Fastener Thread size For component Torque Remarks

Screw M 5x12 Cover / shroud 5.0 1), 2)

Series 4149 Powerhead 5

Screw D 5x12 Carburetor / throttle cable 3.0

1) Screws with binding head

6 Series 4149 Powerhead

Condition Cause Remedy

Clutch drum badly worn Install new clutch drum

Clutch spring stretched Replace the clutch spring or install

Clutch spring broken Replace the clutch spring

Loud noises Clutch spring stretched Replace clutch spring

Clutch drum bearing damaged Replace fan housing

Clutch screws loose Tighten down screws, replace

Clutch shoes worn Install new clutch

Series 4149 Powerhead 7

Condition Cause Remedy

Normal wear Install new starter rope

Insufficient spring tension Check rewind spring and increase

Rewind spring broken Install new rewind spring

Pawl springs fatigued Fit new springs and check pawls,

Springs not installed correctly Install springs correctly

Lugs on carrier worn Fit new carrier, check pawls and

Spring loop in ErgoStart spring Attach ErgoStart spring loop to

8 Series 4149 Powerhead

ErgoStart spring in rope rotor Replace ErgoStart spring, check

At very low outside temperatures: Coat rewind spring with a small

Series 4149 Powerhead 9

Exercise extreme caution while

Condition Cause Remedy

Fuel/oil mixture Use correct mixture of fuel and oil

Incorrect air gap between ignition Set air gap correctly

Flywheel cracked or Install new flywheel

Ignition timing wrong, flywheel out Install new flywheel

Weak magnetization in flywheel Install new flywheel

Irregular spark Check operation of lever for stop

10 Series 4149 Powerhead

Condition Cause Remedy

Inlet needle worn Fit new inlet needle

Perforated disc on metering Fit new metering diaphragm

Metered diaphragm deformed Fit new metering diaphragm

Setting of high speed screw too Check basic carburetor setting,

Metering diaphragm gasket leaking Fit new diaphragm gasket