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Contents
232RA001 VA
described in the handbook edition is issued. 2
"Basic engine 4140".
Special servicing tools mentioned
There are separate handbooks for in the descriptions are listed in the
servicing procedures for last chapter of this manual. Use Servicing and repairs of power
standardized parts and the part numbers to identify the tools with shaft (FS, FC, HL) are
assemblies that are installed in tools in the "STIHL Special Tools" made considerably easier if the
several STIHL power tool models manual. The manual lists all machine is mounted on assembly
("Standard Repairs, special servicing tools currently stand (2) 5910 890 3100 with the
Troubleshooting", "Carburetors"). available from STIHL. aid of clamp (1) 5910 890 8800.
Reference is made to these
handbooks in the appropriate Symbols are included in the text Secure the clamp to the assembly
chapters in this manual. and pictures for greater clarity. stand with two washers and two
The meanings are as follows: M8 nuts. The complete unit can
You should make use of the then be swivelled to the best
q(
illustrated parts lists while carrying In the descriptions: position for the ongoing repair,
out repair work. They show the thus leaving both hands free.
installed positions of the individual • = Action to be taken as shown in
assemblies. the illustration (above the text) Always use original STIHL
replacement parts.
Refer to the latest edition of the - = Action to be taken that is not They can be identified by the
relevant parts list to check the part shown in the illustration (above STIHL part number,
numbers of any replacement parts the text) the logo and the
needed. Parts lists on microfiche STIHL parts symbol .
and CD-ROM are always more up In the illustrations: The symbol may appear alone on
to date than printed lists. small parts.
= Pointer
A fault in the machine may have
several causes. To help locate the = Direction of movement
fault, consult the troubleshooting
charts for all assemblies in the Service manuals and all technical
"Standard Repairs, information bulletins describing
Troubleshooting" handbook. engineering changes are intended
exclusively for the use of STIHL
servicing dealers. They must not
be passed on to third parties.
DG and P (Plastoform) screws are used in polymer and lightmetal 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, provided the specified tightening torque is
observed.
For this reason it is essential to use a torque wrench.
– Place the DG or P screw in the hole and turn it counterclockwise until it drops down slightly.
– Tighten the screw clockwise to the specified torque.
This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.
Note: Power screwdriver speed settings for polymer materials: Plastoform screws max. 600 rpm
DG screws max. 500 rpm
Important! Do not confuse screws with and without underhead locking teeth.
Removal
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9.2.2 or 9.3.2.
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1
• Undo fastening screws on • Press throttle cable out of • Remove screw of clutch drum
shroud (diagram shows machine clamping element at the sleeve. with insert (1) 0812 540 1112.
with bike handle).
Important: Do not buckle the - Remove clutch drum.
- Lift off shroud. strand.
2
1
2
1
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• Unplug short-circuit wire (1) and • Undo screws (1). • Examine clutch drum. It must not
ground wire (2) from ignition be scored or badly worn.
module. - Remove engine housing.
Important: The clutch drum must be
Note: Screw (2) should only be replaced if there are distinct wear
removed if damaged. Tighten new marks on the inside perimeter.
screw down with 4.5 Nm.
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always be replaced in pairs.
1
• Unscrew clutch.
1
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1 2
• If necessary, remove washer (1) Installation • Fit wrench (1) 4130 890 3600
and spacer sleeve (2) from and tighten clutch down with
crankshaft stub. • Hook clutch springs in so that 17.0 Nm.
they are located precisely under
the clutch shoes. The remaining parts are fitted in
the reverse order of steps.
Important: They must not
protrude at the sides.
3
1
2
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Note: Clutch shoes, carrier and • Position carrier obliquely, pull • Tighten inner screw of clutch
clutch springs are supplied as a clutch shoes slightly outwards and drum with 4.0 Nm using
complete part (clutch). Clutch press carrier in as far as possible. insert (1) 0812 540 1112.
springs can be replaced.
- Slide spacer sleeve and washer
onto crankshaft stub if they have
been removed.
Removal
• Remove circlip (1) from pinion • Insert wrench (1) 4133 893 1301
of clutch drum with pliers in carrier of clutch (2).
0811 611 8200.
• Unscrew clutch.
366RA016 VA
• Undo four screws securing gear • Press clutch drum (1) out with a • Unhook both clutch springs
housing to handle and remove standard commercial press. with assembly hook (1)
handle housing. 5910 890 2800.
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- Start engine.
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• Force ball bearing out with drift • Hook eyes of clutch springs into
pin (1) 1118 893 7200. clutch shoes.
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• If the brake band can be reused, - Remove clutch, see 4.1.
clean the entire friction surface
(inside of brake band) and • Undo screws.
roughen it with a coated abrasive,
grain size approx. 120 µm. - Remove muffler.
232RA021 VA
Important: A lower thickness
must not be measured at any point!
2
Refit the brake band in the reverse
• Swing lever (1) back to relieve order of steps. • Remove gasket.
the brake band (2).
• Remove lever (2) and lever (3). • Remove ignition module (2).
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• Lightly tap the front of the • Undo screws. - Use new gaskets. Note installed
crankshaft stub with a plastic position.
hammer to loosen the flywheel. - Remove adapter flange with
clamping element. • Insert screws in adapter flange
- Remove flywheel. to secure carburetor.
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232RA028 VA
932RA102 VA
- Remove starter cover, see 6.1. • Unplug short-circuit wire (1) and • Disconnect fuel hoses from the
ground wire (2) from ignition angled connector.
• Undo four screws securing gear module.
housing to handle.
• Undo screws (3) and remove
ignition module (4).
1 1
2
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- Unplug spark plug boot. • Unhook nipple of throttle • Undo screws and remove spiral
cable (1) from slotted bolt (2) on housing (snap-fitted).
- Unscrew spark plug. throttle lever.
- Remove engine from handle
• Fit locking strip (1) housing.
4221 893 5900.
Install parts in the reverse order of
steps.
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• Ensure that the carburetor • Undo screws and remove spiral
gasket is correctly positioned housing.
when fitting the engine and spiral
housing.
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• Unscrew collar nut (1) and Note: FS model illustrated,
remove flywheel (2). BG/SH are similar.
- Lightly tap the flywheel with a • Disconnect fuel hoses from the
plastic hammer to loosen it if angled connector.
necessary.
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Note: FS model illustrated, Note: FS model illustrated,
BG/SH are similar. BG/SH are similar.
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• Undo three screws and remove Spark arresting screen
engine from inner fan housing.
Note: FS model illustrated,
BG/SH and HS 45 are similar.
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Muffler Troubleshooting chart – see • BG/SH:
"Standard Repairs, Undo three IS DG5x20
Note: FS model illustrated, Troubleshooting" handbook. screws (1) and one IS P6x19
BG/SH and HS 45 are similar. screw (2). Remove fan housing
• FS model: with rewind starter.
• Undo screws. Undo three screws and remove
starter cover with rewind starter. • Remove antistatic wire if fitted.
- Remove muffler.
- Remove rope rotor, see
"Standard Repairs,
Troubleshooting" handbook.
Important! The rewind spring may - Fit rope rotor, see "Standard
pop out if it is not fitted with care. Repairs, Troubleshooting"
handbook.
If the rewind spring has popped
out, it must be refitted as follows: - Tension rewind spring, see 6.2.
232RA058 VA
it to the diameter of 55 mm
required for installation.
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• Then grasp rewind spring with • Hold the rope close to the rope
pointed pliers approx. 10 mm rotor and turn the rotor seven
from the end of the outer loop times counterclockwise.
and place it in the starter cover.
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232RA062 VA
Troubleshooting" handbook.
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Note: The starter grip must sit • Prise cap off starter grip.
firmly in the rope guide bush and
not droop to one side. If it does - Pull rope out of starter grip.
droop, the spring must be
tensioned by one additional turn.
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• Pull rope back until knot rests in • Introduce starter rope into hole in
starter grip. side of rope rotor.
- Press cap onto starter grip. - Secure starter rope with a simple
knot.
- Refit starter rope in rope rotor.
Starter grip
Troubleshooting" handbook.
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• Unplug short-circuit wire and
ground wire from stop switch.
1 2
2
1
2 1
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• Press trigger interlock (1) down. Install parts in the reverse order of • Unplug short-circuit wire ( 1) and
steps. ground wire (2) from ignition
• Pull holder (2) out of engine module.
housing. - Press trigger interlock down.
- Remove leads from engine
• Insert holder so that pegs (1) housing.
engage in holes (2).
2
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• Prise stop switch (3) out of • Ensure that leads are correctly
holder. pressed into guides in engine
housing.
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• Fit leads in mounts around - Remove holder for stop switch Throttle trigger
flywheel. and trigger interlock, see 7.1.
- Remove holder for stop switch
Trigger interlock and trigger interlock, see 7.1.
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1 2
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Install parts in the reverse order of - Remove throttle trigger,
steps. see 7.1.1.
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• Press throttle cable out of • Press flexible liner of throttle
clamping element at the sleeve. cable fully into front mount of
engine housing.
Important: Do not buckle the
strand.
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• Remove trigger interlock (1) from • Remove stop switch (1) from • Hook torsion spring into throttle
peg on left-hand housing half. left-hand housing half and trigger.
disconnect short-circuit wires (2).
- Hook throttle cable into throttle
trigger and slide throttle trigger
over peg on left-hand housing
half.
1
2
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• Position left-hand housing half • Position right-hand housing half - Remove shaft and shroud,
on shaft. so that peg (2) on lever engages see 4.1.
in hole (1) on trigger interlock.
Note: The housing halves must • Unhook nipple of throttle
rest in the groove of the handle - Turn in screws and tighten down cable (1) from slotted bolt (2) on
support. Ensure that the with 2.5 Nm. throttle lever.
short-circuit wires (1) and torsion
spring (2) are positioned correctly.
The throttle cable (3) must rest in
the mount of the left-hand housing
half.
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• Press throttle cable out of
clamping element at the sleeve.
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• Insert lever (1) and adjusting • Remove throttle cable from rear
spring (2) in right-hand housing part of engine housing.
half.
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• Press cable holder out from - Remove shaft and shroud,
below and remove throttle cable see 4.1.
from front part of engine housing.
• Unhook nipple of throttle
Install parts in the reverse order of cable (1) from slotted bolt (2)
steps. on throttle lever.
232RA075 VA
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• Fit flexible liner of throttle cable • Press throttle cable out of
in mounts. clamping element at the sleeve.
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1
1
932RA015 VA
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2
• Pull out cable holder (1) and Stop switch • Unplug short-circuit wire (1) and
remove liner with throttle ground wire (2) from ignition
cable (2) from front of engine • Prise stop switch (1) out of module.
housing. handle moulding with a flat
screwdriver. - Remove leads from handle
housing and spiral housing.
• Unplug (2) short-circuit and
ground wires from stop switch.
• Pull throttle cable out of liner. Install parts in the reverse order of
steps.
Install parts in the reverse order of
steps. • Ensure that leads are correctly
pressed into guides in handle
Short-circuit wire/ground wire housing and spiral housing.
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Trigger interlock Throttle trigger
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• Prise trigger interlock (1) out of • Disengage throttle trigger (1) • Press throttle cable out of
mounts in handle housing. from mounts in handle housing. clamping element at the sleeve.
• Remove and examine torsion • Unhook throttle cable from • Press throttle cable out of mount
spring, fit a new spring if throttle trigger. in handle housing and pull out
necessary. throttle cable.
Install parts in the reverse order of
Install parts in the reverse order of steps. Install parts in the reverse order of
steps. steps.
2 1
1
2
932RA073 VA
932RA101 VA
Stop switch • Unplug short-circuit wire (1) and Handle moulding
ground wire (2) from ignition
• Prise stop switch (1) out of module. • Undo screws and remove handle
handle moulding with a flat moulding.
screwdriver.
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Removal
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- Remove carburetor, see 8.2.2. FS models and HS 45 - Remove prefilter from filter
cover, if fitted.
• Force throttle cable (1) out of • Press tab on filter cover to side.
clamping element (2) and • Remove felt filter element.
remove throttle cable. • Swing filter cover aside and
remove from pegs on housing. - Clean felt filter element by
Install parts in the reverse order of tapping or blowing – do not
steps. wash – replace if severely fouled.
Installation
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supply.
- Fold filter cover over and press - Check that there are no leaks in
onto filter housing until it is heard tester.
to engage.
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BG/SH Note: Diagram shows FS model, • Slide pressure hose from tester
BG/SH and HS 45 are similar. onto connector.
• Fit filter cover (2) in pegs (1).
• Disconnect fuel hose from
• Fold filter cover over and press angled connector.
onto filter housing until it is heard
to engage.
2 1
2
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• Slide fuel line (1) 1110 141 8600 • Close vent screw (1) on rubber
onto connector (2) 0000 855 9200. bulb (2) and pump air into
carburetor until pressure
gauge (3) shows an excess
pressure of approx. 8 kPa
(0.8 bar).
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232RA085 VA
control lever sticking).
- After testing, open vent screw - Remove air filter, see 8.1. • Remove carburetor.
and disconnect fuel line from Note: Diagram shows FS model,
angled connector. BG/SH and HS 45 are similar.
- Slide fuel hose onto angled • Remove nuts with screwdriver
connector. 5910 890 2420.
- Remove filter housing.
- Fit filter cover.
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• Unhook nipple of throttle • Remove gasket.
cable (1) from slotted bolt (2) of
Install parts in the reverse order of
throttle lever.
steps.
- Use a new gasket.
- Ensure that fuel hoses are
routed without buckling.
932RA028 VA
232RA087 VA
• Disconnect fuel hoses from Note (FS model): Align fuel hose
angled connectors. on angled connector so that the
positioning strip on the hose points
towards the shaft.
Tighten nuts on filter housing
down with 3.5 Nm.
232RA090 VA
faults develop in the carburetor or
fuel supply.
Standard setting
Check correct functioning by
The standard setting must be Adjust idle speed performing pressure and vacuum
established first when adjusting tests on the tank via the fuel hose.
the carburetor. • Make standard setting.
232RA091 VA
run while engine is idling:
1 8 3 2 7 1
2
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6 5 4
Cleaning - Remove filter cover, see 8.1. • Pull out bush (1).
- Unscrew filler cap. • Disconnect fuel hoses from • Remove grommet (2) from tank.
angled connector.
• Prise cap (1) off valve body (2). - Remove fuel hoses, see 8.5.
- Remove starter cover, see 6.1.
• Remove sintered filter (3) from
cap.
232RA098 VA
- Clean valve body with fresh 2 1
petrol.
• Remove and replace valve (7). - Remove fuel tank. Install parts in the reverse order of
steps.
• Press new sintered filter (6) into • Remove inserts from fuel tank.
filler cap. • The inserts (1) must engage the
Note: Worn inserts must be pegs (2).
• Place sealing ring (8) over valve replaced.
body. - Ensure that throttle cable is not
jammed.
• Place spring washer (5) in filler
cap.
2 1
- Insert valve body in filler cap and
press home until it is heard to
engage.
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932RA028 VA
232RA101 VA
restricts the passage of fuel and
results in fuel starvation.
1 2
232RA100 VA
328RA219 VA
932RA102 VA
restricts the passage of fuel and
results in fuel starvation.
932RA058 VA
• Pull pickup body (1) out of fuel • Pull fuel hose (1) and vent
tank with assembly hook (2) hose (2) out with grommets.
5910 893 8800.
Install parts in the reverse order of
Note: Ensure that fuel hose is not steps.
overextended. If necessary, push
bottom end of hose into tank.
Fuel hoses
932RA096 VA
- Remove tank vent.
2
• Pull pickup body out of fuel tank Important: Note installed position
with assembly hook (1) of tank vent.
5910 893 8800.
• Pull out tank vent (1).
Note: Ensure that fuel hose is not
overextended. • Pull out grommet (2).
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2
232RA107 VA
1
232RA109 VA
932RA018 VA
- Grease clamping area. • Remove bar (1, if fitted), loop • Pull handle hose off handle
handle (2) and upper bracket (3). support.
• Slide shaft in until holes are
lined up. • Remove square nuts (4) from bar. Important: Do not warp angled
end of throttle cable when
Note: The shaft is illustrated removing hose.
beside the engine housing to show
which holes are meant.
932RA020 VA
2
- FS 45, 46 only:
Tighten down screw on deflector
• FS 45, 46 only: with 8.0 Nm and clamp on
Remove clamping screw (1) on deflector with 5.0 Nm.
deflector in order to replace shaft.
Note: Ensure that short-circuit
• Pull deflector (2) off to the front. wires and throttle cable are
correctly seated in handle support.
1
232RA109 VA
• FS 45, 46 only:
Remove screw (1).
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• Remove screw on carrying ring. • Pull flexible shaft out of rigid
shaft.
- Pull carrying ring apart and
remove it. Note: The flexible shaft must be
replaced if it has turned blue.
Install parts in the reverse order of
steps. - Before inserting the flexible
shaft, coat it with STIHL gear
lubricant for brushcutters
0781 120 1117, see 15.
392RA160 VA
232RA112 VA
1
2 1 3
392RA161 VA
Remove screws (1) and Deflector for all cutting tools
handlebar (2).
• Remove screws (1).
392RA164 VA
932RA029 VA
slightly so that square of drive 2
shaft engages in square socket
of drive pinion.
- Slide gear onto shaft as far as • Block output shaft with an arbor, • Remove clamping screws (1).
possible and align it. dia. 5 mm.
• Remove clamping element (2).
- Tighten clamping screw down • Unscrew collar lock nut in the
with 12.0 Nm. direction of the arrow (left-hand • Remove deflector (3) from gear.
thread).
- Refit deflector.
392RA165 VA
• Remove rubber skirt (3). • Slide bushes (2) and roller (3)
onto bolt.
392RA174 VA
• Unscrew bolts and remove roller • Slide gear onto shaft as far as
holder. possible and align it.
1
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932RA029 VA
932RA061 VA
25.0 Nm.
- Remove clutch drum, see 4.2. • Undo screws and remove gear
cover (1) with gasket.
• Note: The new gear housing is
supplied complete with fitted ball
bearings (1), bushes (2) and
straight pin (3).
• Remove gasket.
1
2
3
5 4
932RA063 VA
• Disconnect spark plug boot and • Unscrew hex nut (2). • Insert a screwdriver or similar
unscrew spark plug. implement in the recess on the
Note: Left-hand thread fan connector and press tab
upwards.
• SH only: Remove shredder
blade (3). - At the same time, turn blower
tube as far as possible
• Remove washer, counterclockwise (quarter turn).
fanwheel (1) and the washer
underneath it. - Remove blower tube from
connector.
- Examine all fan blades and
replace fanwheel if necessary. - To refit blower tube, insert it in
connector with peg.
Install parts in the reverse order of
steps. - Turn blower tube clockwise until
bayonet catch engages.
932RA094 VA
932RA099 VA
• Turn suction tube as far as possible • Undo upper screw at front.
counterclockwise (quarter turn).
• Insert a screwdriver or similar
- Remove suction tube from implement in the recess on the
connector. suction connector and press tab
upwards.
Open intake screen to fit suction
tube. - At the same time, turn manifold
as far as possible counterclockwise
(quarter turn).
Remarks:
1) Stop screw 4112 893 1200 can be used instead.
2) DG/P screws may only be tightened with a torque wrench.
3) This version includes visual / acousting signalling.
4) May only be used for unscrewing in the case of DG/P screws.
5) Only used for HS 45
Shoulder strap
Safety glasses
STIHL ElastoStart
- Starter rope (dia. 3 mm, 800 mm) with
starter grip (for FS, FC, HL, BG/SH 85) 0000 190 3400
- Starter rope (dia. 3 mm, 1060 mm) with
starter grip (for BG/SH 55, BG/SH 65, HS) 0000 190 3404
STIHL gear lubricant for brushcutters
- 80 g tube 0781 120 1117
- 225 g tube 0781 120 1118
STIHL gear lubricant for hedge trimmers
- 80 g tube 0781 120 1109
- 225 g tube 0781 120 1110
Bar handle (FS models) 4140 791 2300
Control handle (FS models) 4119 790 1302
Loop handle (FS models) 4130 790 1316
Vaccum attachment (BG models) 4229 007 1000
Roof gutter cleaning attachment
(BG models) 4229 007 1001
Round nozzle (BG 65) 4229 708 6300
Flat nozzle (BG 55) 4229 708 6301