STIH) STIHL FS 240, 260, 360, 410, 460 2011-09
Contents 1. 1.1 1.2 Introduction and safety precautions 3 Introduction Safety precautions 3 4 6. Ignition system 39 7. M-Tronic 6.1 6.2 6.2.
Contents 9. 9.1 9.2 Antivibration elements Rubber insert 1-point antivibration system Rubber buffers/ springs 4-point antivibration system 10. Actuating levers 10.1 Control handle for loop handle Throttle trigger / throttle trigger interlock Slide control Control handle for bike handle Removal and installation Throttle trigger / throttle trigger interlock Lever for stop function Adjusting the throttle cable Throttle rod 10.1.1 10.1.2 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 11. Fuel system 91 12.
1. Introduction and safety precautions 1.1 Introduction This Service Manual contains detailed descriptions of all the typical repair and servicing procedures for this machine. Refer to the illustrated spare parts lists during all repair work. These lists show the installation position and order in which the individual parts and modules should be assembled. Refer to the latest edition of the relevant spare parts list to check the part numbers of any spare parts required.
1.2 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. 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.
2. Specifications 2.1 Engine Displacement: Bore: Stroke: Engine power to ISO 8893: Cut-off speed (Nominal value): Idling speed (Nominal value): Clutch: Clutch engages at: Crankcase leakage test at gauge pressure: under vacuum: 2.2 FS 460 C 37.7 cm3 40.0 mm 30.0 mm 1.7 kW (2.3 HP) at 8500 rpm 41.6 cm3 42.0 mm 30.0 mm 2.0 kW (2.7 HP) at 9000 rpm 45.6 cm3 44.0 mm 30.0 mm 2.2 kW (3.
2.5 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 torque Nm Comment Screw Screw Screw Screw Screw Nut Screw Screw Screw Nut Screw Screw Screw Screw Screw M 5x20 M 5x20 M 5x23 IS 5x14 D 5x32 M 8x1 M 6x14 D 6x32 M 5x18 M 8x1 P 6x19 M 14x1.
3. Troubleshooting 3.
3.2 Gearbox Problem Cause Remedy Loud noises Ball bearings damaged or worn Replace ball bearings on the drive side and non-drive side Pinion damaged or worn Replace set of pinions on the drive side and non-drive side Too little or no gear lubricant in gearbox Gearbox drive tube assembly 25.
3.
3.4 Starter Problem Cause Remedy Starter rope broken Rope pulled out too vigorously as far as stop or over edge, i.e.
Problem Cause Remedy Starter rope is difficult to pull or rewinds very slowly Starter mechanism is very dirty Thoroughly clean complete starter mechanism Spring in ErgoStart spring housing is fatigued Replace ErgoStart At very low outside temperatures: Lubricant oil on the rewind spring becomes viscous (spring winding stick together) or moisture has penetrated the rewind spring (spring windings are frozen) Coat rewind spring with a little standard solvent-based degreasant (containing no chlorinated
3.
3.
Problem Cause Remedy Power loss during acceleration, all versions Seal or spring of accelerator pump worn or damaged Replace carburetor ... Versions with M-Tronic Parts in carburetor or M-Tronic wiring harness defective Carry out M-Tronic diagnosis, if necessary, replace carburetor or M-Tronic wiring harness Engine will not idle, idle speed too high, versions without M-Tronic Throttle shutter opened too wide by idle speed screw LA Set idle speed screw LA correctly ...
Problem Cause Remedy Cutting attachment stops when idling, versions without M-Tronic Idle speed too high Readjust with idle speed screw LA (counterclockwise) ... All versions Clutch springs stretched or fatigued Replace tension springs, replace clutch if necessary Clutch spring hooks broken Replace tension springs ...
Problem Cause Remedy Engine speed drops quickly under load – low power, versions with MTronic Parts in carburetor or M-Tronic wiring harness defective Carry out M-Tronic diagnosis, if necessary, replace carburetor or M-Tronic wiring harness Engine runs extremely richly, lacks Choke shutter does not open power and has very low final speed Check carburetor and choke shaft, if necessary, repair lever at the choke shaft (choke lever) or replace carburetor Engine does not start No spark Replace spark p
3.
Clutch 4.1 Clutch drum : Remove screws (2) and tilt bushing (3) to the side 2 – Troubleshooting, b 3.1 – Remove drive tube assembly, 1-point antivibration system, b 12.1, 4-point antivibration system, b 12.2 1 2 1 1 : Remove screws (1) 1 – Detach short circuit wire and cable holder from engine, b 6.6.
3 Installation 1 1 : Orient ring (2) so that the clutch housing rests evenly on it 5904RA005 TG – Heat the inner race of the ball bearing to approx. 120 °C (250 °F) : Position clutch drum (1) on ball bearing (2) and push it on as far as it will go : Press out clutch drum using a suitable punch (3) : Install circlip (1) on the opposite side 3 1 This must be done quickly, as the clutch drum absorbs heat and begins to expand.
All versions 2 1 1 1 2 : Position bushing (1) : Insert and tighten down the screws (2) : Position filter cover (1) with screws Versions with M-Tronic : Insert and tighten down the screws (2) – Attach cable holder and short circuit wire to engine, b 6.6.3 – Attach protective hip plate, b 11.9.
4.1.1 Ball bearing – Remove the clutch drum, b 4.1 If it is impossible to heat the clutch housing, the ball bearing must be pressed out cold. Installation Rubber insert or rubber buffers must be removed. 3 1 1 : Remove the circlip (1) – Remove rubber insert, b 9.
1 5904RA022 TG 5904RA020 TG : Install circlip (1) so that it is seated completely in the groove : Insert locking strip (1) 0000 893 5904 in the cylinder 5904RA024 TG 1 1 : Remove clutch (1) from the lower cover washer – Install the clutch drum, b 4.1 – Reassemble remaining parts in reverse order 2 2 1 SM 1 1 Clutch – Remove clutch housing, b 4.
3 SM 5904RA026 TG 2 : Position washers (1) on the pegs : Orient clutch (2) so that the markings (arrows) are visible : Slide clutch (2) onto the pegs on the lower cover washer (3) 1 3 5904RA028 TG SM 1 3 1 2 : Fit coupling (1) complete with cover washers in the threaded holes (arrows) of the flywheel (2) : Insert and tighten down the screws (3) SW 10 – Pull the locking strip out of the cylinder – Install clutch housing, b 4.
5. Engine 5.1 Muffler Check and if necessary repair the fuel supply, carburetor, air filter and ignition system before looking for faults on the engine. 1 2 2 1 – Remove protective hip plate, b 11.9.3 : Remove the exhaust gasket (1) and cooling plate (2) To keep dirt particles from entering the cylinder, move piston to top dead center before removing the muffler. 5904RA033 TG – Remove shroud, b 5.
5.2 2 3 5904RA035 TG 1 : Carefully position muffler (1) and insert screws (2) – do not tighten : Check gasket and cooling plate for proper position and fit lower screw (3) – Insert and tighten down all three screws : Screw in spark plug (1) and tighten it securely Defective oil seals and gaskets or cracks in housing are the usual causes of leaks. Such faults allow supplementary air to enter the engine and upset the fuel-air mixture.
: Operate lever (3) until the pressure gauge (4) indicates a vacuum of 0.5 bar – If the pressure drops, the leak must be located and the defective part replaced If the vacuum reading remains constant, or does not decrease by more than 0.3 bar within 20 seconds, it may be assumed that the oil seals are in good condition. If the vacuum in the crankcase is reduced further, the oil seals must be replaced, b 5.3. To find the leak, coat the suspect area with soapy water and pressurize the crankcase.
5.3 Oil seals 1 – Free the oil seal in its seat by tapping it with a suitable tube or a punch. 2 2 5904RA047 TG : Apply the puller (1) 5910 890 4400 with jaws (profile no. 3.1) 0000 893 3706 1 5904RA044 TG – Clamp the puller arms – Pull out the oil seal : Press the new oil seal (1) fully home with press sleeve (2) 4238 893 2400 Installation With new oil seals, oil seal (1) 15x25x5 must be replaced on the ignition side and oil seal (2) 12x22x5 on the starter side.
: Slide the oil seal (2) over the installing sleeve with the sealing lip facing the crankcase 1 5.4 Shroud – Remove starter, b 8.2 – Remove the assembly sleeve 1 5904RA049 TG 2 1 : Apply the puller (1) 5910 890 4400 with jaws (profile no. 3.1) 0000 893 3706 – Clamp the puller arms 5904RA051 TG – Free the oil seal in its seat by tapping it with a suitable tube or a punch.
5.5 3 – Remove the muffler, b 5.1 Before removing the cylinder, decide whether or not the crankshaft is to be removed. 3 5904RA055 TG 1 2 Cylinder : Fit shroud (1) so that the pins engage the holes (arrows) of the protective hip plate (2) : Insert and tighten down the screws (3) With cylinder installed The piston must be blocked through the spark plug hole to prevent the crankshaft turning in order to remove the clutch.
Installation 1 : Examine and clean the mating surface (arrow), b 14 5904RA061 TG : Orient new cylinder gasket (1) so that the tab (2) is located at the ridge (3) – the openings must match with the crankcase – Coat piston, piston rings and inside of cylinder with oil, b 14 : Use the clamping strap (1) 0000 893 2600 to compress the rings around the piston – Ensure that piston rings are correctly positioned, b 5.
5.6 Crankshaft Starter-side half of the crankcase – Empty the fuel tank in accordance with regulations, b 1.1 2 – Remove the starter cup, b 5.3 5904RA068 TG – Remove the flywheel, b 6.5 – Remove the cylinder, b 5.5 : Orient cylinder (1) so that the intake duct (2) faces the filler neck – Remove piston, b 5.7 When fitting the cylinder over the piston, ensure that the clamping strap securely encloses the piston and that none of the piston rings protrudes – danger of breakage.
1 – Replace ball bearings and oil seals, b 5.6.1 and b 5.3 1 1 – Before installation, clean the crankshaft, b 14 : Insert and tighten down the screws (1) 5904RA072 TG 1 5904RA070 TG 2 2 1 : Position a suitable punch (1) on the cylinder side crankshaft stub and press out crankshaft (2) : Turn spindle (2) clockwise until the crankshaft stub has been forced out of the ball bearing Installation Ignition-side half of the crankcase Avoid damage to the crankshaft stub.
Starter-side half of the crankcase 1 5904RA076 TG : Apply sealant (1) to the groove on the circumference (arrows) : Apply sealant so that a bead with a height of a = 2 - 3 mm is formed 1 2 2 Sealant must not protrude into the inside of the crankcase.
5.6.1 Ball bearing / crankcase Installation Ignition-side half of the crankcase The two halves of the crankcase can be replaced individually if they are defective. 1 When fitting a new crankcase, the machine's serial number must be stamped on the crankcase with 2.5 mm figure stamps. If the original crankcase is reused, the oil seals and grooved ball bearings must be replaced, all gasket residues removed and the mating surfaces cleaned thoroughly.
Starter-side half of the crankcase Installation : Carefully drive the oil seal out with a punch – Heat the area around the bearing seat to approx. 120 °C (250 °F) – Examine and clean the crankcase, replace if necessary. : Press the ball bearing (1) home as far as possible – Replace ball bearings if the crankcase is in good condition The ball bearing must be fitted rapidly, as it absorbs heat and expands.
Installation 1 2 – Remove needle bearing from the rod eye, examine and clean it, replace if necessary : Coat the needle cage (1) with oil and insert it in the rod eye – Examine the piston rings and replace if necessary, b 5.
Stand the tool on a suitable surface. : Position installing tool 5910 890 2211 with the taper sleeve on the piston boss, hold the piston steady and press the tool shank home until the snap ring slips into the groove 5904RA094 TG 5904RA093 TG 5904RA091 TG : Press the assembly tool down in the sleeve until the magnet is at the end of the guide slits.
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. Troubleshooting on the ignition system should always start with the spark plug, b 3.5 – Remove drive tube assembly, 1-point antivibration system, b 12.1, 4-point antivibration system, b 12.2 Testing of the ignition module is limited to a spark test.
: Secure insulating element (1) with the stubs (arrows) on the cylindrical bumps 1 2 Adjustment with clutch housing installed 1 2 1 2 2 5904RA335 TG 5904RA102 TG 1 : Fit ignition module (1) and insert screws (2) with washers – do not tighten them down 5904RA103 TG 1 : Slide setting gauge (1) in the direction of the muffler until there is enough space to tighten the lower screw (2) 1 5904RA106 TG : Remove the insulating element (1) – Examine spark plug boot and cable holder, replace if necessar
6.2.1 3 1 1 3 S 2 2 N Control unit (ignition module) M-Tronic – Remove shroud, b 5.
Using the ZAT 4 ignition system tester 5910 850 4503 1 2 3 2 : Insert lead (red) of the ignition module (1) with the lug (2) in the mount – crimped side must face cable holder 1 3 5904RA119 TG 1 : Remove screws (1) : Pull the red lead (2) and blue lead (3) out of the guides (arrows) – Remove throttle cable and short circuit wire from engine, b 6.6.3 – Remove M-Tronic leads from cable holder and remove cable holder, b 6.6.
Using the ZAT 3 ignition system tester 5910 850 4520 – Crank the engine quickly with the rewind starter and check sparkover in the window (3) of the ignition system tester 1 3 4 – Before starting the test, install a new spark plug and tighten it down firmly. If a spark is visible in the window (3), the ignition system is in order. 6.4 : Connect the spark plug boot to the terminal (2) : Attach ground terminal (1) to the spark plug : Use adjusting knob (4) to set spark gap to approx.
Installation 1 3 – With a new ignition module, use a pointed tool to pierce the center of the new lead's insulation approx.
Flywheel 6.6 – Remove shroud, b 5.4 The short circuit wire and ground wire form a single unit together with the throttle cable; the throttle cable must be replaced if there is any sign of damage. – Remove clutch housing, b 4.1 5904RA147 TG – Block the piston with the locking strip, b 4.2 – Remove clutch, b 4.2 The flywheel and magnet poles (arrows) must not display any signs of damage or blue discoloration; replace flywheel if necessary. 1 Short circuit wire 6.6.
– If no fault can be found, test the ignition system in accordance with flow chart, b 6.7 : Pull the lug (1) of the short circuit wire (2) out of the mount – Connect ohmmeter to ground and the lug of the short circuit wire – For versions with control handle for loop handle, move slide control to position STOP-0 and hold it there – For versions with control handle for bike handle, press and hold lever for stop function The resistance measured must be approx. 0 Ω.
1 2 : Orient throttle cable so that short circuit wire (1) and ground wire (2) face the cable holder : Position Bowden cable (3) in the guide (arrow) and guide protective tube under the tab (4) 1 5904RA113 TG : Position the cable holder (1) on the clutch housing so that it engages behind the groove (arrow) of the spacer flange (2) and the tab (3) is seated in the recess of the clutch housing 3 2 1 : Place connector tag (2) of the ground wire (1) in the recess and, starting at the recess, press into
2 : Starting at the lug (2), press the lead (1) of the ignition module into the guides (arrows) as far as it will go 1 1 : Press short circuit wire (1) with the lug (2) into the mount – Reassemble remaining parts in reverse order 6.6.
1 4 : Remove screw (1) The leads of the M-Tronic are run along the throttle cable guide of the cable holder under the throttle cable in the guides. So that the total length of the leads installed is correct, they must be completely routed in the cable holder and secured in the guides before installation of the throttle cable.
5904RA128 TG 1 – Hold the cable holder with throttle cable in this position 2 3 – Pull the red and black lead of the M-Tronic out of the guides again up to the throttle cable : Hook throttle cable (1) onto lever (2) and press grommet into the mount (arrow) 5904RA133 TG 2 As strain relief, the protective tube is clamped between the tab of the cable holder and the guide of the clutch housing.
1 2 4 3 1 1 : Insert lead (red) of the M-Tronic with the lug (1) in the mount – crimped side must face cable holder : Insert lead (blue) of the short circuit wire with the lug (2) in the mount – crimped side must face cable holder : Starting at the lug, press both leads into the guides (arrows) as far as they will go : Insert and tighten down the screws (1) : Ease out microswitch (1) – Reassemble remaining parts in reverse order 6.6.
6.6.5 2 2 : Position clamp (1) in the mount (arrow) and screw in screw (2) – do not tighten 1 – Install slide control, b 10.1.2 1 : Remove contact spring (1) from the guides (arrows) 1 : Press throttle cable (1) into mount (arrow) of the slide (2) until it snaps into place – Install throttle trigger and trigger interlock, b 10.1.1 : Push slide (1) with throttle cable (2) into the middle of the serrated mount (arrow) 5904RA152 TG – Install control handle for loop handle, b 10.
Installation 1 1 1 5904RA161 TG : Push lever (1) in the direction of the post (2) of the throttle trigger and remove from post (arrow) : Slide eyelet (1) onto the post (2) of the lever so that the eyelet opening faces the stop (arrow) 5904RA164 TG 2 5904RA158 TG 2 : Press ground wire (1) as far as it will go into the guide (arrows) 2 1 1 1 5904RA162 TG 5904RA159 TG 5904RA165 TG 2 : Remove ground wire (1) with lever (2) from the guide (arrow) The ground wire (1) must not be stretched betw
2 6.6.6 1 4 Testing and installation of ground wire is the same as for the short circuit wire 3 : Press contact spring (1) with short circuit wire (2) into the guides (arrows) as far as it will go, in the process slightly lifting the contact point (3) 1 2 3 5904RA169 TG 5904RA167 TG 5 1 Ground wire – Check contacts and operation, replace throttle cable if necessary, b 6.6 : Slide torsion spring (1) onto the axle (2) so that the hook (arrow) engages in the lever (3) 6.6.
6.7 Troubleshooting, Ignition System Engine does not run Slide control or lever for stop function: – Set to position "F" or not pressed? Check spark plug: – Smeared with oil, black? – Sooted? – Electrode gap correct? – Contacts shorted (threads)? – Clean, adjust or replace spark plug, b 6.3 Check spark plug boot: – Firmly seated on spark plug (torsion spring)? – Torsion spring hook in center of ignition lead? – Spark plug boot damaged? – Replace spark plug boot and/or torsion spring if necessary, b 6.
1 Powerful spark? yes no Air gap: – Check ignition module / flywheel, – Adjust if necessary, b 6.2 Check flywheel: – Have pole shoes turned blue? – Replace flywheel if necessary, b 6.5 Check short circuit wire: – Wire damaged? – Plug connections firmly seated? – Check continuity, replace switch if necessary, b 6.6.1 Check ignition lead: – Severe chafing? – Spark plug boot: Holes / cracks? – Resistance of spark plug boot to ground: Required 1.5...
2 3 Check that the slide control or lever for stop function is working properly: – Short circuit wire chafed? Control handle for loop handle – Function between slide control and contact spring of the microswitch: – Position "F" = microswitch not pressed – Position "0" = microswitch pressed Control handle for bike handle – Function between lever for stop function and contact spring: – Lever for stop function not pressed = no connection – Lever for stop function pressed = connection – Replace short circuit
M-Tronic A basic or standard setting of the carburetor is no longer required. The M-Tronic electronically adjusts the fuel-air mixture in the carburetor. The M-Tronic controls all operating states such as start, idle, part throttle and full throttle while accounting for the external conditions, e.g., use at varying attitudes, as well as changing temperatures or fuel quality – the carburetor does not have any adjusting screws.
After ending the test procedure, disconnect the test lead and reseal the diagnostic jack with the plug. 1 Check screwed and plug connections as well as switch 5904RA278 TG – Carry out test preparations, b 7.3.1 There must be a reliable connection for communication between control unit, switching device and solenoid valve. If communication between control unit and solenoid valve is interrupted or faulty, the control unit does not initiate an ignition spark.
Checking the start detection function 7.3.6 2 Checking the wiring harness – Carry out test preparations, b 7.3.1 – Check contacts and operation, b 7.3.3 – Check contacts and operation, b 7.3.3 – Connect the test lead, b 7.3.2 1 3 5904RA284 TG – Carry out test preparations, b 7.3.
– Connect the test lead, b 7.3.2 1 2 – Check continuity between blade receptacle and angled terminal socket – Blade receptacle and angled terminal socket must be firmly connected with one another; in the event of contact problems, the M-Tronic wiring harness must be replaced, b 7.4. 1 2 5904RA286 TG Check leads between solenoid valve and diagnostic jack – Connect the test lead, b 7.3.
7.4 Removal and installation – Remove shroud, b 5.4 Installation With a new switchgear, first the thin leads must be inserted in the guides of the switchgear. 1 5904RA173 TG – Remove the air filter cover, b 11.1 – Check M-Tronic, b 7.3 – Detach M-Tronic leads from cable holder and remove wiring harness with throttle cable on engine, b 6.6.3 Leads and plug connections must not be damaged.
: Orient diagnostic connector (1) so that the tab faces the recess (arrow) : Push the diagnostic connector (1) into the bushing (2) as far as it will go 1 5904RA180 TG 1 2 5904RA178 TG 2 5904RA176 TG 1 Insert the thin leads of the switchgear first.
1 1 2 1 2 2 Run the black lead under the red lead – for right guide, see illustration : Insert and tighten down the screws (1) : Press black lead (2) and red lead (1) as far as they will go into the guide that is offset by 90° (arrows) : Press plug (2) into the diagnostic connector (arrow) as far as it will go 2 Do not expose plug to tensile loads, thus run leads so that they form a 90° loop at the plug.
7.5 Troubleshooting, M-Tronic 7.5.1 Engine does not start Engine does not start – Move choke lever to position } Can engine be started? yes no Troubleshooting completed – Test ignition system according to flow chart "Ignition system troubleshooting", b 7.
7.5.2 Engine does not start in position } Engine does not start in position } – engine floods. Can the flooded engine be started in position F? Is it possible to start the engine? yes Troubleshooting completed no – Check start detection (microswitch actuation) clean if necessary Mechanically OK? no – Examine switch gear, clean or replace if necessary, b 7.4 yes – Check start detection and wiring harness, b 7.3 Are target values attained? no – Replace switchgear, b 7.
7.5.3 Engine speed drops under load – low power Engine speed drops under load – low power – Examine the air filter, replace if necessary, b 11.1 – Calibrate control unit, b 7.1 yes Cut-off speed = 12300 rpm? Troubleshooting completed FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M no – Look for a fault in the fuel path, check engine for leaks, b 11.4, b 5.
7.5.4 Ignition – no ignition spark No ignition spark – Move choke lever to position } Can engine be started? yes Troubleshooting completed no – Check the flywheel, (two pairs of poles?) b 6.5 Combination OK? no Establish correct control unit/ flywheel combination yes – Check air gap between control unit and flywheel, b 6.2 Air gap OK? no – Set correct air gap, b 6.2 yes – Test ignition system according to flow chart "Ignition system troubleshooting", b 6.
7.5.5 Engine stops suddenly Engine stops suddenly Machine OK? yes Troubleshooting completed no – Check fuel path (fuel pick-up body, tank vent, fuel hoses), b 11.9.1, b 11.8, b 11.9.2 Fuel path OK? no – Repair fuel system yes – Check screwed connection on control unit (are leads firmly seated in the lugs?) Connection and firm seat of the lugs OK? no – Push plug on all the way and tighten screwed connections, b 7.3.3, replace switchgear if necessary, b 7.
7.5.6 Cut-off speed not reached Maximum speed less than 11500 rpm – Check air filter and spark arrestor screen (if present) in muffler, clean or replace if necessary, b 11.1, b 5.1 – Check cutting attachment for easy movement, clean or replace if necessary, see Instruction Manual – Calibrate control unit, b 7.1 Cut-off speed greater than 12300 rpm? yes Troubleshooting completed no – Check screwed connections of the control unit leads, b 6.2.
If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not completely, it may be assumed that the starter mechanism is in order but plugged with dirt. At very low outside temperatures, the lubricating oil on the rewind spring may thicken and cause the spring windings to stick together. This has a detrimental effect on the function of the starter mechanism.
8.4 ErgoStart/rope rotor 2 Relieve tension of rewind spring 5904RA191 TG 1 3 5904RA194 TG The system will not be under tension if the starter rope or rewind spring is broken. 1 – Remove starter, b 8.2 – Remove pawls, b 8.
Installation 8.5 – Lubricate the entire length of the starter post with STIHL gear lubricant, b 14 – Remove starter, b 8.2 – Relieve the tension of the rewind spring, b 8.
1 1 : Push starter rope (1) out a short distance and undo the knot : Pull the rope through the grip until the knot at the end of the rope is in the recess (arrow) – Pull the starter rope out of the rope rotor, starter cover and starter grip 5904RA203 TG 4903RA132 TG 5904RA200 TG 2 : Insert starter rope (1) in the recess (arrow) and press the knot into the depression (2) as far as it will go – Install ErgoStart/rope rotor, b 8.4 Installation – Tension the rewind spring, b 8.
8.6 Tensioning the rewind spring 8.7 – Remove starter, b 8.2 1 2 5904RA206 TG 1 5904RA204 TG – Hold the starter grip firmly to keep the rope (1) tensioned : Pull out part of the starter rope (1) and insert it in the notch (arrow) – Troubleshooting, b 3.4 The replacement spring is supplied ready for installation and secured in a spring housing. – Wear face shield and protective gloves – risk of injury – Remove starter, b 8.
Reinstalling a rewind spring that has popped out If the rewind spring pops out during installation, fit it in the spring housing as follows: 5904RA208 TG The rewind spring may pop out. : Remove screws (1) and carefully remove the spring housing with rewind spring –The rewind spring may pop out 1 1 1 5904RA210 TG 1 A worn or broken rewind spring may still be under tension while installed.
Antivibration elements 2 1 2 Damaged rubber inserts, rubber buffers, annular buffers or springs must always be replaced. 9.1 Rubber insert 1-point antivibration system – Remove the drive tube assembly, b 12.1 – Remove the clutch housing and clutch drum, b 4.1 3 5904RA217 TG The vibration damping connection between drive tube assembly and clutch housing is made via a rubber insert (1-point antivibration system) or via rubber buffers, annular buffers and springs (4-point antivibration system).
1 9.
Installation : Loosen screw (1) on underside of the antivibration housing (2) 1 2 – Insert screwdriver through the holes in the plugs of the large anitvibration spring (1) and small antivibration spring (2) : Screw the screw into the antivibration housing and fasten antivibration springs 2 1 5904RA225 TG 1 2 5904RA228 TG 3 3 : Lever off the clamp (3) 1 2 – Examine clamp, annular buffers and support, replace if necessary : Pull annular buffers (1) over the spring nuts (2) and remove : Loosen
2 2 1 1 2 : Push annular buffers (1) over the spring nuts (2) – Annular buffers must be completely behind the spring nuts 1 2 : Press the rubber buffers (1) onto the plugs (2) of the clutch housing as far as they will go 2 3 5904RA239 TG 5904RA234 TG 1 5904RA237 TG 1 – Apply STIHL press fluid to the outside of the rubber buffer, b 14 : Insert the drive tube assembly (1) in the hole (arrow) of the clutch housing as far as it will go 1 2 1 2 : Push the antivibration housing (1) onto the end
1 a 1 2 4 : Orient bike handle (1) so that the control handle (2) is on the muffler side – Hold the antivibration housing (1) in this position Throttle cable must be routed under the drive tube assembly.
Control handle for loop handle 2 3 1 1 5904RA261 TG 2 : Remove torsion spring (1) from the guide (2) and pull out under the throttle cable (3) The control handle for the loop handle (1) with slide control (arrow) is pushed directly onto the drive tube assembly (diameter 25.4 mm) and clamped down with clamps. 1 : Thread out the throttle cable (1) on throttle trigger (2) 1 5904RA264 TG 1 10.1.
Installation 1 : Push torsion spring (1) onto the post (2) so that the end that is angled downward rests against the ridge (arrow) on the left : Slide throttle interlock (1) onto the post (2) 1 2 : Slide throttle trigger (1) onto the post (2) – Release upper end of the torsion spring 2 5904RA272 TG Shown without drive tube assembly for a better view.
10.1.2 Slide control 1 – Remove control handle for loop handle, b 10.1 2 4902RA125 TG 3 5904RA294 TG – Remove throttle trigger / throttle trigger interlock, b 10.1.1 1 : Push the torsion spring (1) into the mount (2) as far as it will go : Short end (1) must lie between the ridges (arrows) 1 5904RA291 TG The bent end (arrow) must rest against the peg (3).
10.2 1 Control handle for bike handle 1-point antivibration system 1 1 : The torsion spring (1) must be seated in the mount (2) The control handle for bike handle (1) with lever for stop function (arrow) is pushed directly onto the bike handle (diameter 25.4 mm or 22 mm) and secured with a transverse screw.
Installation 1-point antivibration system – Insert and tighten down the screw 1 1 10.2.
2 1 : Remove throttle trigger (1) and unhook throttle cable (2) from throttle trigger (arrow) – Stud (1) must be present, install new stud if necessary 5904RA312 TG 5904RA307 TG 1 5904RA310 TG 1 : Push on the trigger interlock (1) and hook on the torsion spring (arrow) A new throttle trigger is supplied with a pre-installed stud.
1 2 : Slide throttle trigger (1) onto post (3) : Turn torsion spring clockwise and hook it into the lever (arrow) : Slide lever (2) into the throttle trigger (1) so that the lever (arrow) rests against the stud 5904RA321 TG 5904RA318 TG – Carefully fit handle molding (1) until it snaps into place – Levers may pop out : Insert and tighten down the screws (arrows) Checking operation 5904RA316 TG 5904RA319 TG 1 Ground wire and short circuit wire must be inserted completely in the guides (arrows).
10.2.3 Lever for stop function – Remove control handle for bike handle, b 10.2.1 1 : Push the lever (1) onto the throttle shaft 10.2.4 Adjusting the throttle cable If it is possible to continue turning the lever (1) in the direction of full throttle, then the throttle shutter is not completely open in the fullthrottle position. – Remove shroud, b 5.4 The throttle trigger must be adjusted in order for the throttle shutter of the carburetor to open and close completely when the throttle is opened.
– Reassemble parts in reverse order Installation 1 5904RA332 TG 5904RA328 TG When the throttle trigger is not actuated, the throttle cable must not be under tension, otherwise the throttle shutter may no longer close completely, which would result in a high idle speed. 10.2.5 Throttle rod : Position screwdriver at the notch of the slide (arrow) and press in – Slide is unlocked – Remove the shroud, b 5.
11. Fuel system 11.1 Air filter 11.2 Filter housing All versions – Remove the air filter, b 11.1 – Refer also to troubleshooting, b 3.6, b 3.
: Press grommet (1) into hole (arrow) on the back of the air filter housing until it encloses the hole completely 1 1 5904RA401 TG – Check mating surfaces on carburetor and filter housing, clean if necessary, b 14 – To simplify installation, coat the inside of the grommet with STIHL press fluid, b 14 : Press plug (1) into the diagnostic connector (arrow) as far as it will go All versions 2 : Slide filter housing (1) onto the studs so that the support of the carburetor engages the grommet (2) 1 1
11.3 Carburetor All versions 1 – Remove filter housing, b 11.2 1 – Collect fuel in a clean container, b1 The fuel hose may only be removed when the tank filler cap is open. Versions with M-Tronic Leads and plug connections must not be damaged.
Installation Versions with M-Tronic 2 1 : Push on new gasket (1) 2 1 : Push the new fuel return line (1) completely onto the connector (2) 5904RA185 TG 5904RA415 TG 5904RA412 TG 1 : Orient plug (1) so that the lug (arrow) aligns with the groove in the mount (2) Versions with M-Tronic 2 : Orient bushing (1) with switchgear so that the scale (arrow) faces the cylinder 3 : Push connector (1) with fuel hose (2) into the fuel suction hose (3) so that it between the ribs (arrows) – fuel hose is se
All versions 11.3.1 Leakage test 1 2 5904RA333 TG 3 The tank vent must also be checked and replaced if problems develop with the carburetor or fuel supply, b 11.8 The carburetor can be tested for leaks with the pump 0000 850 1300. – Remove the carburetor, b 11.
11.4 Repairing the carburetor 2 Installation 1 11.4.1 Metering diaphragm 2 – Troubleshooting, b 3.6 1 3 3 5904RA345 TG 5904RA342 TG – Remove the carburetor, b 11.3 5904RA340 TG : Carefully separate the metering diaphragm (1) and gasket (2). The diaphragm material is subjected to continuous alternating stresses and eventually shows signs of fatigue. In other words, the diaphragm distorts and swells and must be replaced.
11.4.2 Inlet needle 3 1 – Remove the metering diaphragm, b 11.4.
1 : Remove the end cover (2) 2 3 1 Ensure that the spring locates on the nipple of the inlet control lever. – Press the inlet control lever down and secure it with the screw. – Check that the inlet control lever moves easily – Install the metering diaphragm, b 11.4.1 11.4.
Installation 2 2 1 4 – Check that the pump diaphragm and gasket are correctly seated 3 2 1 5904RA362 TG : Position gasket (1) with pump diaphragm (2) on the end cover (3) so that the protrusions (arrows) match and are secured via the pins (4) 5904RA360 TG 4 1 5904RA358 TG 3 : Orient lever (2) so that the hook engages the choke lever (arrows) : Hold end cover (1) in position, screw in and tighten screw (2) – Reassemble remaining parts in reverse order : Slide the lever (2) onto the throttle sh
Checking operation, versions with M-Tronic Installation All versions 5904RA364 TG 1 1 Lever (1) must align with the contact surface (arrows) on the cam of lever (2). 5904RA369 TG 5904RA366 TG 2 : Remove spring (1) 1 2 : Orient the torsion spring (1) so that the angled end points toward the carburetor 5904RA367 TG – Reassemble remaining parts in reverse order 11.4.5 Choke lever/choke knob 1 – Remove the carburetor, b 11.
Versions with M-Tronic Checking operation without MTronic 2 3 5904RA373 TG : Push the spring (1) onto the choke shaft (2) 5904RA363 TG 2 1 1 : Orient the lever (1) so that the flat surface aligns with the choke shaft (2) and the cam (3) faces the throttle shaft lever In the "warm start" position, lever (1) must engage the notch (arrow) of lever (2) and align with the contact surface of the cam.
The high speed screw H and the low speed screw L have a special hexagonal head and can only be adjusted with screwdriver 5910 890 2307 – no limiter caps are used. : Set choke lever (1) to position }; the cam on the lever (2) must actuate the microswitch (arrow) – clicking noise – Remove the carburetor, b 11.3 – See also Troubleshooting on the carburetor, b 3.
Carburetor adjustment with M-Tronic The idle speed screw LA remains unchanged and can still be set by the user to adjust the idle speed. The carburetor is adjusted by the MTronic, thus no manual adjustments to the carburetor are necessary or possible. 5904RA383 TG 2 1 Position of the screw (1) must not be changed – changing the factory default setting leads to impaired engine performance. Solenoid valve (2) is pre-set at the factory and must not be disassembled.
Setting idle speed 1 – Check cutting attachment, adjust if necessary 2 1 : Position screwdriver (1) 5910 890 2307 in low speed screw L and high speed screw H – Set idle speed with a speed tester. Set the specified speeds within the tolerance range of ± 200 rpm 5904RA386 TG 5904RA385 TG – Examine the spark arresting screen (if installed); clean or replace it if necessary, b 3.7 or b 5.1 The fine adjustment of the high speed screw H (1) and low speed screw L (2) is now complete.
Erratic idling behavior, poor acceleration 2 – Check basic and fine setting of the adjusting screws, adjust them or service carburetor, if necessary, b 11.6.1, b 11.4 Correcting the carburetor setting for use at high altitudes : Unhook the throttle rod (1) from the lever (2) Engine not running satisfactorily – Check basic and fine setting of the adjusting screws, adjust them or service carburetor, if necessary, b 11.6.1, b 11.4 11.7 1 2 Spacer flange – Remove the carburetor, b 11.
Installation 2 3 1 2 4 2 : Align the new gasket (1) so that the tab (2) faces downward and the holes (arrows) match 5904RA425 TG 5904RA423 TG 3 1 : Orient lever (1) so that the pins (arrows) face the spacer flange and push it onto the post (2) 5904RA418 TG 1 : Hook the throttle rod (1) onto the lever (2) 2 1 2 : Position spacer flange (1) with gasket on cylinder intake port 5904RA424 TG 1 2 5904RA426 TG 2 1 : Push circlip (1) into place 5904RA427 TG : Insert two screws (3) and affix
Tank vent Testing with gauge pressure 11.8.1 Testing 2 1 5904RA430 TG If problems develop in the carburetor or fuel supply, the tank vent must always also be tested and replaced if necessary. Correct functioning is determined by testing the fuel tank under vacuum or at gauge pressure via the fuel hose.
11.8.2 Removal and installation – Troubleshooting, b 3.6 or b 3.7 – Remove the carburetor, b 11.3 Clean the fuel tank if necessary. 1 – Open the filler cap and drain the tank. 5904RA435 TG 2 : Pry out the tank vent (1) via the mounting rib (arrow) – Remove tank vent (1) from hose (2), examine and replace if necessary – Remove the grommet – Reopen the tank and empty it.
11.9.2 Fuel hose – Open the filler cap 1 : Pull the fuel suction hose (1) out of the inside of the tank – Use STIHL press fluid to simplify assembly, b 14 : Orient the fuel suction hose (1) and press it into the hole in the housing as far as it will go – the flange must be flush with the guide (arrow) 5904RA409 TG 1 5904RA450 TG 2 1 5904RA439 TG – Remove filter housing, b 11.2 1 : Pull out connector (1) with fuel hose (2) 5904RA440 TG – Remove the carburetor, b 11.
11.9.3 Fuel tank 1 – Empty the fuel tank, b 1 2 : Connect the fuel hose (1) to the connector (2) – Coat connector with STIHL press fluid, b 14 – Slide carburetor onto stud bolts : Push connector (1) into the fuel suction hose (2) so that the fuel hose (3) is between the ribs (arrows) – Connector must be pushed all the way into the fuel suction hose 1 – Remove filter housing, b 11.2 2 1 1 1 1 5904RA456 TG 1 – Remove shroud, b 5.
Installation 1 3 1 2 : Pull off the fuel return line (1) at the connector (arrow) Always use a new fuel return line.
12. Drive tube assembly 12.1 Drive tube assembly with loop handle 2 2 1 1 5904RA441 TG : Undo the screw (1) : Undo the screws (1) 5904RA000 TG 1 The clamps in the control handle for the loop handle must be loosened. : Pull the drive tube assembly (2) out of the clutch housing and control handle for loop handle (3) – Examine the drive tube assembly, repair or replace if necessary, b 12.2.1 With a new drive tube assembly, the installed parts or components must be converted.
2 : Orient drive tube assembly (1) and tighten screw (2) through the opening (arrow) – Drive tube assembly is clamped and secured The sticker on the drive tube assembly must be visible when using the machine.
Drive tube assembly with 28 mm diameter for 4-point antivibration system 12.2.1 Disassembling the drive tube assembly with a diameter of 25.4 mm 2 1 – Degrease clamping area, b 14 : Orient end of drive tube assembly with shakeproof washer installed (arrow) so that it faces the engine : Push the drive tube assembly (1) into the clutch housing (2) with gentle twisting motions until the serration (3) of the drive shaft engages the clutch drum – If necessary, install bike handle with control handle, b 9.
– Apply lubricant to the drive shaft evenly – Only pressing lubricant into the hole of the flexible liner and pushing in the unlubricated drive shaft does not ensure sufficient lubrication : Pry out plug (1) a 5904RA471 TG : Push flexible liner (1) inside the drive tube assembly until depth a = 30 mm 1 3 5904RA469 TG 2 3 1 5904RA472 TG 1 : Pull flexible liner (1) out of the drive tube assembly : Press plug (1) into the drive tube assembly as far as it will go Assembly 1 5904RA473 TG 5904RA47
12.2.2 Disassembling the drive tube assembly with a diameter of 28 mm 1 1 – Remove 4-point antivibration system, if necessary, b 9.2 : Pry out shakeproof washer (1) – Replace shakeproof washer after removal a 5904RA480 TG – Remove bike handle, if necessary, b 9.2 5904RA477 TG – Remove the drive tube assembly, b 12.
The drive shaft is supported by the flexible insert in the drive tube assembly. If the shaft has blue tarnish on it, it must be replaced.
1 5904RA485 TG 2 Deflector 12.3.1 Deflector for gearbox with 25.4 mm drive tube assembly diameter To preserve the threads in the plastic parts, screw the screws into the existing threads and tighten carefully. 1 : Unscrew the bolt (1) 11 : Insert clamp (1) in loop handle (2) – Fit screw – do not tighten 2 5904RA489 TG 12.
12.3.
Installation 12.3.3 One-piece carrying ring 12.4 1 Gearbox for drive tube assembly 25.4 mm with square profile 12.4.1 Removal and installation – Removing cutting attachment 1 : Push the line limiting blade (1) into the mount (arrow) : Unscrew screw (1) and bend open and remove clamp (2) – Insert and tighten down the screw – Install parts in reverse order To preserve the threads in the plastic housing, screw the screws into the existing threads and tighten carefully. 12.3.
Installation : Position set of pinions on the outer race of the ball bearing (2) and use a suitable tool to press out the drive pinion (3) 2 3 1 5904RA375 TG 1 5904RA376 TG 3 1 : Remove the circlip (1) 5904RA377 TG Drive tube assembly is installed on the machine. – Degrease clamping area, b 14 : Tighten screws (3) – Heat gearbox in the area (arrows) of the bearing seats of the drive tube assembly connection to approx.
– Fit new ball bearings if the set of pinions is in good condition 1 Always use new ball bearings.
2 – Coat serrations of the spur bevel gear with STIHL gear lubricant, b 14 – Coat serrations of the drive pinion with STIHL gear lubricant, b 14 5904RA515 TG 5904RA513 TG 1 1 1 5904RA511 TG 2 : Remove the screw plug (1) – STIHL gear lubricant should be pressed into the hole, b 14 : Heat the gearbox (1) on the output end (arrow) to approx. 120 °C (250 °F) : Heat the gearbox (1) on the drive end in the area of the bearing seats (arrows) to approx.
Gearbox for drive tube assembly 28 mm with serration 12.5.1 Removal and installation – Removing cutting attachment : With gentle twisting motions, slide the gearbox (1) onto the drive tube assembly (2) as far as it will go, until the drive shaft aligns with the serrations of the drive pinion, turn the output shaft on the gearbox if necessary 1 5904RA518 TG 12.
1 2 1 4 3 1 : Push the punch (1) into puller (2) 5910 890 4408 as far as it will go – Insert is spread behind the drive pinion 2 : Unscrew screws (1) and remove guard ring (2) 1 : Position washer (4) on the gear housing, hold locknuts in place and twist nut (3) until the drive pinion set is pulled out of the bearing seats : Orient the ring (1) of puller 5910 890 4407 so that the narrow collar (2) faces away from the gearbox : Push locking pin (3) into the hole as far as the indentation (arrow) 59
– Withdraw the puller with the drive side pinion set from the gearbox, unscrew the nut and remove the puller 4 2 1 5904RA547 TG – Check gearbox, clean and replace if necessary – Fit new ball bearings if the set of pinions is in good condition If a pinion is damaged, the complete set of pinions (drive pinion and output pinion) must be replaced. Assembly 3 1 4 Always use new ball bearings.
: Slide washer (1) onto long stub of the drive shaft (2) and, using a suitable tool on the inner race, press the new ball bearing (3) home as far as it will go 4 1 2 – Coat serrations of the spur bevel gear with STIHL gear lubricant, b 14 1 : Position set of pinions so that the spur bevel gear (2) faces the gear housing 5904RA528 TG 1 – Sparingly lubricate the collar on the short stub of the output shaft with STIHL gear lubricant, b 14 : Position guard ring (1) so that the groove (2) faces the out
2 : Heat the gearbox (1) in the location of the bearings on the drive end (arrows) to approx. 120 °C (250 °F) 5904RA535 TG 1 5904RA534 TG 1 : Insert and tighten down the stud (1) Checking operation : Position drive pinion (2) so that the bevel gearing faces the gear housing 1 : Press in the drive pinion (2) as far as it will go The drive pinion must be inserted quickly, as it absorbs heat and begins to expand.
13. Special tools New special tools No. Designation Part No.
No. Designation Part No. Use 9 10 11 Assembly drift Combination wrench Installing sleeve 1110 893 4700 1129 890 3401 4119 893 4600 12 Press arbor 4119 893 7200 13 Installing tool 4126 893 4900 14 Clamping device for assembly stand ZAT 4 ignition tester ZAT 3 ignition tester Torque wrench Torque wrench Installing tool, 11 Bit T 27 x 150 Assembly stand Puller - Jaws (with profile no. 3.
14. Service accessories No. Designation Part No.
132 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
englisch / english 0455 752 0123. M0,15. A12. FST.
