STIH)

STIHL TS 410, 420 2007-09

 Contents

1. Introduction 3 7. Shortblock 33 10. Repairing the

AV system 67
7.1 Muffler / spark arresting
2. Safety precautions 5 screen 33 10.1 AV spring on the
7.2 Leak testing 34 handlebar 67
7.2.1 Preparatory steps 34 10.2 AV spring in the
3. Specifications 6 7.2.2 Vacuum test 34 support 68
7.2.3 Pressure test 35 10.3 AV spring at the bottom
3.1 Shortblock 6 7.3 Oil seals 36 of the crankcase 68
3.2 Fuel system 6 7.4 Removing and installing 10.4 AV spring on the
3.3 Ignition system 6 the shroud 37 carburetor 69
3.4 Cutting wheels 6 7.5 Cylinder 39 10.5 Handlebar 69
3.5 Tightening torques 7 7.6 Crankshaft 41 10.6 Rubber buffers /
7.6.1 Removal and support 71
installation 41
4. Troubleshooting 9 7.6.2 Grooved ball
bearing / crankcase 46 11. Actuating levers 73
4.1 Clutch 9 7.7 Piston 47
4.2 Cast arm with guard 10 7.7.1 Removal 47 11.1 Switch shaft /
4.3 Rewind starter 11 7.7.2 Installation 48 choke lever 73
4.4 Ignition system 12 7.8 Piston rings 50 11.1.1 Switch shaft, removal
4.5 Carburetor 14 7.9 Decompression valve 50 and installation 73
4.6 Engine 17 11.2 Throttle trigger /
trigger interlock, removal
8. Ignition system 51 and installation 74
5. Cast arm with guard 18 11.2.1 Choke lever / holder,
8.1 Ignition module 51 removal and
5.1 Water system 18 8.1.1 Removal and installation 76
5.2 Cast arm with guard 19 installation 51
5.3 Testing radial and axial 8.2 Ignition timing 53
truth of running 24 8.3 Testing the ignition
5.4 Test sequence 25 module 53
5.5 Ribbed poly V-belt 26 8.4 Spark plug boot 54
5.6 Tensioner 27 8.5 Flywheel 55
5.7 Starter cup 28 8.6 Short circuit wire /
switch 56
8.6.1 Testing 56
6. Clutch 30 8.6.2 Removal and
installation 56
6.1 Belt pulley / 8.7 Troubleshooting,
clutch drum 31 ignition system 58
6.2 Studs for securing the
cast arm with guard 32
9. Rewind starter 61

9.1 General 61
9.2 Removal and
installation 61
9.3 Pawl 61
9.4 Rope rotor 62
9.5 Starter rope /
starter grip 63
9.6 Tensioning the rewind
spring 64
9.7 Replacing the rewind
RA_370_00_01_03

spring 65

q
© ANDREAS STIHL AG & Co. KG, 2007

TS 410, TS 420 1
Contents

12. Fuel system 77

12.1 Air filter 77

12.2 Carburetor, removal and
installation 77
12.2.1 Leakage testing 79
12.3 Repairing the
carburetor 79
12.3.1 Metering diaphragm 79
12.3.2 Inlet needle 80
12.3.3 Fixed jet 81
12.3.4 Pump diaphragm 81
12.3.5 Air valve 83
12.3.6 Choke shaft /
choke shutter 85
12.3.7 Throttle shaft /
throttle shutter 87
12.3.8 Adjusting screws 89
12.4 Carburetor adjustment 90
12.4.1 Basic setting 90
12.4.2 Standard setting 91
12.5 Choke rod and
throttle rod 92
12.6 Intake elbow, removal
and installation 93
12.6.1 Impulse hose 94
12.7 Tank vent 95
12.7.1 Testing 95
12.7.2 Removal and
installation 96
12.7.3 Manual fuel pump 96
12.8 Fuel Intake 97
12.8.1 Pickup body 97
12.8.2 Fuel hoses 98
12.8.3 Fuel tank filler cap 99
12.9 Tank housing, removal
and installation 99

13. Special tools 101

14. Servicing
accessories 103

2 TS 410, TS 420
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1. Introduction

This service manual contains The special tools mentioned in the

detailed descriptions of all the descriptions are listed in the chapter 1
typical repair and servicing "Special Servicing Tools" of this 3
procedures for this power tool. manual. Use the part numbers to
identify the tools in the STIHL
Refer to the illustrated spare parts Special Tools manual. 2
lists during all repair work. These It lists all the special servicing tools
lists show the installation position currently available from STIHL.

219RA000 TG
and order in which the individual
parts and modules should be Symbols are included in the text and
assembled. pictures for greater clarity.
The meanings are as follows:
Refer to the latest edition of the Servicing and repairs are made
relevant parts list to check the part In the text: considerably easier by mounting the
numbers of any replacement parts machine on the assembly stand (3)
required. : = Action to be taken as shown in 5910 890 3100. For this purpose,
the illustration above the text secure the support (2)
A fault on the machine may be due 5910 850 1650 to the assembly
to several causes. To help locate – = Action to be taken but not stand with two screws (1) and
the fault, consult the chapter on shown in the illustration above washers.
"Troubleshooting" and the the text
"STIHL Service Training System" The screws must not protrude, as
for all function groups. they may damage the housing when
In the illustrations:
the machine is clamped, depending
Refer to the "Technical Information" on model.
A Item pointer (short arrow)
bulletins for engineering changes
which have been introduced since This step is not necessary when
aDirection of movement
publication of this service manual. using the new assembly stand
(long arrow)
Technical information bulletins also 5910 890 3101, as the support is
supplement the parts list and already mounted on it.
b 4.2 = Reference to another
service manual until an updated
chapter, i.e. to chapter 4.2
edition is issued.
in this case
3
Service manuals and technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
3
not be passed on to third parties.

1 2 370RA000 TG

The clamping plate (1)

4238 890 2100 is secured to
the support (2) with two M8x20
screws (3) and washers.

TS 410, TS 420 3
 370RA001 TG

The machine is secured to the

clamping plate by means of the two
front studs on the crankcase.

Guide the studs on the machine

through the bushings on the
clamping plate and secure them
with the nuts (arrows).

The cast arm with guard must be

removed first.

Always use original STIHL

replacement parts.
They can be identified by the STIHL
part number, the STIH) logo
and the parts symbol (
The symbol may appear alone on
small parts.

Storage and disposal of oil and

fuel

Lubricating oil and fuel must be

collected in a clean container and
disposed of in accordance with the
regulations and without harming the
environment.

4 TS 410, TS 420
2. Safety precautions

Specific national safety regulations

and the safety instructions in the
instruction manual must be
observed if the machine has to be
started up during maintenance or
repair work.

Gasoline is highly inflammable and

can also be explosive under certain
conditions.

Protective gloves must be worn

when components have to be
heated for assembly / removal
purposes.

Improper handling may result in

burns and other serious injuries.

Do not bring any fire, flame, spark or

other source of heat near the fuel.
All work with fuel must be performed
outdoors only. Spilled fuel must be
wiped away immediately.

Always test for leaks after working

on the fuel system and shortblock.

TS 410, TS 420 5
3. Specifications

3.1 Shortblock

TS 410 TS 420

Displacement: 66.7 cm3 66.7 cm3

Bore: 50 mm 50 mm
Stroke: 34 mm 34 mm
Engine power to ISO 7293: 3.2 kW (4.4 HP) 3.2 kW (4.4 HP)
at 9000 rpm at 9000 rpm
Permissible maximum speed: 10300 rpm 10300 rpm
Idle speed: 2500 rpm 2500 rpm
Clutch: Centrifugal clutch without
linings
Clutch engages at: 3800 rpm 3800 rpm
Crankcase leakage test
at gauge pressure: pü = 0.5 bar
under vacuum pu = 0.5 bar

3.2 Fuel system Carburetor leakage test at

gauge pressure: pü = 0.8 bar
Operation of tank vent at
gauge pressure: pü = 0.3 bar
Fuel: as specified in instruction
manual

3.3 Ignition system Air gap between ignition

module and flywheel: 0.15...0.35 mm
Spark plug (suppressed): Bosch WSR6F
Electrode gap: 0.5 mm

3.4 Cutting wheels

TS 410
Composite and diamond cutting wheels Diameter 300 mm
Cutting depth approx. 100 mm

TS 420
Composite and diamond cutting wheels Diameter 350 mm
Cutting depth approx. 125 mm

6 TS 410, TS 420
3.5 Tightening torques

DG and P screws are fitted in plastic and light alloy metal parts. These screws form a permanent thread when
they are installed for the first time. The material is permanently deformed. Screws can be removed and installed
as often as necessary without impairing the strength of the screwed assembly, provided that the specified
tightening torque is observed.
For this reason, it is essential to use a torque wrench.

Fastener Thread size For component Tightening Remarks

torque
Nm

Bolt M 6x28 Cast arm / flange 8.0

Nut M8 Cast arm / starter cover / stud 20.0
M 10x1 Decompression valve 14.0
Bolt M 5x20 Filter cover / tank housing 6.0
Bolt P 5x16 Handle molding / shroud 4.0
Bolt D 5x20 Rubber buffer / support 6.0
Bolt P 5x16 Holder / switch / shroud 3.0
Bolt P 6x19 Holder / water attachment / tank housing 6.0
Bolt P 6x19 Shroud / tank housing 6.0
Bolt M 5x17 Cap, spark plug cover / shroud 3.5
Nut M 10x1 L Poly V-belt pulley, front 38.0
Bolt P 6x40 Clamp / handlebar / tank housing 6.0
Bolt P 6x26 Clamp / tank housing 6.0
Bolt D 5x45 Clamp (AV system) / handlebar support 4.0
Bolt P 6x19 Crankcase / bearing plug (AV system) 6.0
Bolt M 5x32 Crankcase / cylinder 9.0
Bolt M 5x25 Crankcase fan side / drive side 10.0
M 12x1 L Driver 40.0
Bolt M 5x6 Bearing / rubber buffer 4.0 1)
Bolt P 5x16 Bearing plug AV system / tank housing 4.0
Bolt M 5x20 Fan cover / crankcase 6.0
Bolt P 6x19 Air baffle / tank housing 6.0
Bolt M 5x20 Air guide shroud / crankcase 3.0
Bolt M 5x20 Muffler / crankcase 10.0
Bolt M 5x20 Muffler / cylinder 10.0
Bolt M 5x30 Belt guard / cast arm 6.0
Nut M 8x1 Flywheel / crankshaft 33.0 2)
Bolt D 5x24 Clamping lever / cast arm 4.0
Bolt M 3x20 Hose clamp, manifold / cylinder 0.5
Nut M 8x1 Starter cup / crankshaft 33.0
Bolt M 8x53 Stud / crankcase 21.0
Bolt P 6x50 Support / clamp / handlebar / tank 6.0
housing

TS 410, TS 420 7
Bolt P 6x19 Support / bearing plug AV system 6.0
Bolt P 6x40 Support / tank housing 6.0
Bolt M 5x48x22 Tank housing / flange 3.5
Bolt M 10x18 Abrasive wheel 30.0
Bolt M 5x30 Adjusting lever / guard 6.0
Bolt M 8x24 Adjusting lever / guard / square nut, drive 3.0
side
Bolt M 8x17 Adjusting lever / guard / square nut, fan 3.0
side
M 14x1.25 Spark plug 28.0
Bolt M 5x20 Ignition module / crankcase 8.0
Bolt M 4x8 Pan head screw / banjo bolt 3.0

Remarks:

1) Loctite 243 medium strength

2) Connection between crankshaft and flywheel must be degreased and oil-free

When inserting DG and P screws into an existing screw thread:

Insert the DG or P screw in the hole and turn counterclockwise until it gently drops into the hole in axial
direction.
Tighten the screw clockwise to the specified torque.

DG screws must always be tightened with a torque wrench.

This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.

Coat micro-encapsulated screws with Loctite 243 medium strength before refitting them.

Screwdriver speed when used in plastic material: DG and P screws max. 500 rpm.
Do not use an impact wrench to release or tighten screw connections.

Screws with and without locking serration must not be confused.

8 TS 410, TS 420
4.2 Cast arm with guard

Problem Cause Remedy

Cutting wheel does not run Axial or radial runout Set axial or radial true running,
smoothly or vibrates replace cutting wheel if necessary

Ribbed poly V-belt is loose Check and tension ribbed poly

V-belt, replace ribbed poly V-belt or
tensioner if necessary

Grooved ball bearing of the front Replace grooved ball bearing

poly V-belt pulley is worn

Cutting wheel stops under load Clutch shoes badly worn Install new clutch
at full throttle

Clutch drum badly worn Install new clutch drum

Ribbed poly V-belt not properly Tension ribbed poly V-belt, replace
tensioned if necessary

Cutting wheel rotates at idle speed Idle speed too high Readjust with idle speed screw LA
(counterclockwise)

Clutch springs stretched or fatigued Replace tension springs, replace

clutch if necessary

Clutch spring hooks broken Replace tension springs

Cutting wheel runs dry although Shut-off cock or connector for hose Check and clean shut-off cock /
shutoff cock is open is clogged connector, replace if necessary

Nozzles are clogged Clean nozzles, replace if necessary

10 TS 410, TS 420
4.3 Rewind starter

Problem Cause Remedy

Starter rope broken Rope pulled out too vigorously as Replace starter rope
far as stop or over edge, i.e. not
vertically

Normal wear Replace starter rope

Starter rope does not rewind Very dirty or corroded Clean or replace rewind spring

Spring insufficiently tensioned Check rewind spring and increase

tension

Rewind spring broken Replace rewind spring

Starter rope cannot be pulled out Rewind spring overtensioned Check rewind spring and reduce
far enough tension

Starter rope can be pulled out Guide peg on pawls or pawls Replace pawls
almost without resistance themselves are worn
(crankshaft does not turn)

Spring clip fatigued Replace spring clip

Loose starter cup Tighten starter cup, replace if

necessary

Starter rope is difficult to pull or Starter mechanism is very dirty Thoroughly clean complete starter
rewinds very slowly mechanism

Lubricating oil on rewind spring Coat rewind spring with a little

becomes viscous at very low standard solvent-based degreasant
outside temperatures (spring (containing no chlorinated or
windings stick together) halogenated hydrocarbons), then
pull rope carefully several times
until normal action is restored

TS 410, TS 420 11
4.4 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.

Problem Cause Remedy

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

Ignition lead loose in ignition Secure ignition lead

module

Fuel/oil mixture contains too much Use a fuel mixture with the correct
oil mixing ratio

Incorrect air gap between ignition Set the correct air gap
module and flywheel

Flywheel cracked Install new flywheel

or has other damage 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

pole shoes have turned blue

Irregular spark Check operation of switch shaft /

contact spring, switch and ignition
module
Insulation damaged or break in
ignition lead or short circuit wire,
check ignition lead / ignition module,
replace if necessary
Check operation of spark plug
Clean the spark plug or replace if
necessary

If the engine runs roughly, this may also be due to problems in the carburetor or shortblock.

12 TS 410, TS 420
Problem Cause Remedy

No spark Spark plug defective Replace spark plug

Faulty insulation or short circuit in Check short circuit wire and switch,
short circuit wire or short circuit replace switch if necessary
switch

Break or damaged insulation in Check ignition lead, replace if

ignition lead necessary

Ignition module defective Replace ignition module

TS 410, TS 420 13
4.5 Carburetor

Problem Cause Remedy

Carburetor floods; engine stalls Inlet needle not sealing. Remove and clean inlet needle or
Foreign matter in valve seat or clean carburetor
cone

Inlet control lever sticking on Restore easy movement of inlet

spindle control lever

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

Perforated disc on diaphragm is Replace metering diaphragm

deformed and presses constantly
against the inlet control lever

Poor acceleration Low speed adjusting screw Check basic setting of carburetor,
"too lean" correct if necessary

High speed adjusting screw Check basic setting of carburetor,

"too lean" correct if necessary

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

Diaphragm gasket leaking Replace diaphragm gasket

Metering diaphragm damaged or Replace metering diaphragm

shrunk

Manifold damaged Replace manifold

Impulse hose damaged or kinked Straighten or replace impulse hose

14 TS 410, TS 420
Problem Cause Remedy

Engine will not idle, idle speed too Throttle shutter opened too wide by Set idle speed screw LA correctly
high idle speed screw LA

Oil seals / crankcase leaking Seal oil seals / crankcase, replace if

necessary

Air valve soiled Clean air valve, replace if

– air valve does not close necessary

Air valve moves stiffly Check air valve, replace if

necessary

Throttle rod moves stiffly Restore easy movement of throttle

– throttle shutter does not close rod

Engine stops when idling Idle jet bores or ports blocked Clean the carburetor

Low speed adjusting screw "too Correct setting of low speed

rich" or "too lean" adjusting screw L

Setting of idle speed screw Correct setting of idle speed

incorrect – throttle shutter screw LA
completely closed

TS 410, TS 420 15
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Problem Cause Remedy

Engine speed drops quickly under Air filter dirty Replace air filter
load – low power

Throttle shutter not opened fully Check linkage

Tank vent faulty Replace tank vent

Pickup body soiled Replace pickup body

Fuel strainer dirty Clean fuel strainer in carburetor,

replace if necessary

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

High speed adjusting screw H Check basic setting of carburetor,

"too rich" correct if necessary

Main jet bores or ports blocked Clean the carburetor

Pump diaphragm damaged or Replace pump diaphragm

fatigued

Impulse hose damaged or kinked Straighten or replace impulse hose

Engine runs extremely richly, lacks Air valve does not open Check lever and rod on air valve,
power and has very low final speed adjust or replace if necessary

Engine runs too richly, loses power, Air valve does not open completely Lever on air valve has been fitted
final speed is too low at full throttle incorrectly – the stamped number
must not be visible

Check lever, rod and air valve,

adjust, clean or replace if
necessary

Engine idles erratically – too lean Air valve does not close completely Check lever, rod and air valve,
adjust, clean or replace if
necessary

16 TS 410, TS 420
4.6 Engine

Always check and, if necessary,

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

- Air filter
- Fuel supply
- Carburetor
- Ignition system

Problem Cause Remedy

Engine does not start easily, stalls Oil seals in crankgear damaged Replace oil seals
at idle speed but operates normally
at full throttle

Crankcase leaking or damaged Seal / replace crankcase

(cracks)

Engine does not deliver full power Piston rings worn or broken Replace piston rings
or runs erratically

Muffler / spark arresting screen Clean muffler (inlet and outlet

carbonized openings), replace spark arresting
screen, replace muffler if necessary

Air filter dirty Replace air filter

Fuel / impulse hose severely bent, Fit new lines and ensure they are
kinked or damaged installed without kinking

Tank vent faulty Check tank vent and replace if

necessary

Air valve does not open Check air valve, adjust or replace if
necessary

Decompression valve does not Replace decompression valve

close

Engine overheating Insufficient cylinder cooling. Thoroughly clean all cooling air
Air inlet openings in fan cover openings and the cylinder fins.
clogged or cooling fins on cylinder
severely fouled.

TS 410, TS 420 17
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