Service Manual - Troy-Bilt
Contents
1. Figure 41 Cable Assembly Figure 42 Wire Leads Notice Routing 14 12 Using a small screwdriver pry the rubber seal from above the flex conduit Set it aside See Figure 43 14 13 Using a small screwdriver pry the flex conduit from the carburetor pulse inlet See Figure 44 Figure 43 Rubber Seal Figure 44 Flex Conduit 14 14 14 Using a T 25 Torx driver remove the two screws attaching the carburetor to the intake housing See Figure 45 NOTE You will need to flex the carburetor upward at the rear to access the screws 14 15 Slip the carburetor up and out of the housing See Figure 46 14 16 Using a small flat bladed screwdriver remove the fuel line See Figure 46 14 17 As you remove the carburetor remove the choke assembly and note the orientation of the small wire connector going from the choke to the car buretor Set the choke assembly and connector wire aside See Figure 47 14 18 Slip the throttle cable from its seat and remove the Z fitting from the throttle lever 14 19 Remove the air cleaner boot and two screws from the carburetor 14 20 Remove the lower black primer hose from the carburetor See Figure 48 Figure 45 Torx Screws Figure 46 Fuel Line Figure 47 Choke Assembly Choke Wire Figure 48 Primer Hose 15 14 21 The carburetor can now be rebuilt or replaced See Figure 49 14 22 Install the carburetor in the reverse order of dis assembly Fi2. 2 6 Reconnect fuel hose to carburetor fitting 2 7 Replace air filter and air box cover 3 CHAIN OIL FILTER NOTE If the chain oiler fails to work properly the cause may be a clogged filter Drain oil tank before changing filter NOTE Make sure you have a new filter and a length of hose before beginning this procedure 3 1 Using a T 25 Torx driver remove the two screws securing the lower heat shield to the crankcase See Figure 5 Figure 3 Figure 4 Fuel Filter Figure 5 Torx Screws 3 3 2 Using a small screwdriver or needlenose pliers disconnect oil hose from the pump fitting See Figure 6 3 3 Using a side cutter cut the hose as close to the side of the oil reservoir as possible See Figure 7 3 4 Using a small screwdriver push the end of the tube into the oil reservoir Figure 6 Oil Hose Figure 7 3 5 Tip the saw over the oil filler or use a wire with a hook to remove the oil filter from tank See Fig ure 8 3 6 Insert a long length of new hose into the tank from the crankcase side and push it into the tank 3 7 Use a hook to fish the end of the hose through filler opening 3 8 Install a new filter on the hose end and pull hose back into tank so the filter is positioned in the bottom of tank 3 9 On the crankcase side put a loose bend in the hose and cut it so that it fits on the end of the oil pump fitting without kinking 4 SPARK ARRESTER SCREEN NO
3. 8 CHAIN OILER REMOVAL 8 1 Perform all steps to remove the clutch drum sprocket assembly Refer to CLUTCH REMOVAL Section NOTE There is an adjustment screw for chang ing the flow of chain oil accessible from under the saw near the drum sprocket See Figure 17 8 2 Using a T 15 Torx driver remove the small screw securing the flange plate and bar plate to the housing Set the screw plate flange plate and bar plate aside See Figure 18 Figure 16 Clutch Drum Stamped Washer Tangs Clutch Figure 17 Adjustment Screw Figure 18 Screw Flange Plate 7 8 3 Using a T 25 Torx driver remove the 3 screws securing the pump assembly to the housing See Figure 19 NOTE The top right screw is longer then the other two 8 4 Pull the pump slightly away from the housing The upper oil feed should release from the slot in the housing See Figure 20 Figure 19 Pump Screws Figure 20 Upper Oil Feed 8 5 Secure the clear oil feed tube going to the pump with some form of clamp or tie to keep it from dropping into the oil reservoir when you remove the tube from the pump See Figure 21 8 6 Remove the tube from the pump assembly 8 7 Remove the chain oiler pump from the unit See Figure 22 Figure 21 Rubber Band Figure 22 8 8 8 Remove the foam plug at the rear of the pump See Figure 23 8 9 Remove the flow set screw from the pump 8 10 You can now slide the pump assembly compo n
4. NOTE If the cover plate is reversed on the assembly the pawls won t move out and the starter will not work properly Figure 26 Screw Pawls Figure 27 Cord Pulley Washer Spring Plate Do not reverse 10 3 Inspect componants See Figure 28 10 4 Remove the accumulator spring cover and inspect the spring See Figure 29 10 5 During assembly feed the pull cord through the housing cover knot the cord as shown in the pic ture and wind the cord around the starter pulley Place the pulley under spring tension for the last two turns 11 FLYWHEEL REMOVAL 11 1 Remove the starter assembly following the STARTER ASSEMBLY REMOVAL Section Figure 28 Cord Return Spring Figure 29 Accumulator Spring Spring Slot 10 11 2 Using a 13 mm socket loosen but do not remove the nut securing the flywheel to the drive shaft See Figure 30 11 3 Loosen the nut until the threads are flush with the end of the drive shaft 11 4 Place a pry bar between the flywheel and the case 11 5 Put pressure on the flywheel while tapping the nut with a brass drift and a hammer See Figure 31 11 6 The flywheel is keyed to the tapered drive shaft See Figure 32 NOTE Make sure you do not displace the key during assembly 11 7 Assemble in reverse order of disassembly NOTE Use a feeler guage to properly gap the distance between the coil and flywheel It should be between 08 010 tolerence See Figure 33
5. 12 HANDLE REMOVAL NOTE If the throttle cable breaks it will be nec essary to remove the handle to service it NOTE It will also be necessary to remove the handle in order to remove the caruretor from the unit Figure 30 Figure 31 Brass Drift Pry Bar Figure 32 Keyway Key in tapered Shaft Figure 33 Feeler Guage 11 12 1 Using a T 25 Torx driver remove the lower left handle mounting screw See Figure 34 12 2 Remove the mounting screw at the left side of the baseplate See Figure 35 Figure 34 Mounting Screw Figure 35 Mounting Screw 12 3 Remove the screw at the top right side of the kick back lever Remove the handle from the unit See Figure 36 NOTE Note any different length or type of screws used during disassembly NOTE Note the routing of the throttle cable and electrical wires 12 4 To service the throttle control power switch or other handle componants remove the five screws securing the handle halves together See Figure 37 NOTE Note any different length of screws used during disassembly Figure 36 Mounting Screw Figure 37 Mounting Screws 12 12 5 Separate the handle halves Note the orientation on all componants of the handle during diassem bly See Figure 38 NOTE During handle assembly be sure to place the wire cable assemblies in front of the springs 13 CARBURETOR ADJUSTMENT The carburetor was pre set at the factory for optimum perf
6. Flywheel Removal 9 Handle Removal 10 Carburetor Adjustment 12 Carburetor Removal 12 1 TROY BILT CHAIN SAW MODEL FS55 TB 4920CC GENERAL INFORMATION 55cc Displacement Family 4MHXS 0555AA EM The Troy Bilt models are all AV Anti Vibration This engine conforms to 2004 U S EPA PH 2 Emission Regulations 20 Blade w INTENZ by Oregon Incorporates chain tension adjustment on the blade bar Bar 9040 31B203 Chain 9220 31B203 20 78DL THIS SAW FEATURES OUR SPRING ASSIST STARTING SYSTEM The system allows the customer to pull the recoil rope at any pace they please yet still generate enough force to start the engine The system is simple it consists of a recoil pul ley assembly which includes an accumulator spring As the rope is pulled the accumulator spring winds up When the force on the accumu lator spring over comes the engine compres sion it releases its accumulated energy spinning the crankshaft rapidly This Service Manual is a supplement to the Opera tor s Manual Read understand and follow a
7. Service Manual MTD Products LLC Product Training and Education Department FORM NUMBER 769 01423 9 2004 TROY BILT CHAIN SAW MODEL FS55 TB 4920CC NOTE These materials are for use by trained technicians experienced in the service and repair of outdoor power equipment of the kind described in this publication and are not intended for use by untrained or inexperienced individuals These materials are intended to provide supplemental information to assist the trained technician Untrained or inexperienced individuals should seek the assistance of an experienced and trained professional Read understand and follow all instructions and use common sense when working on power equipment This includes the contents of the product s Operators Manual supplied with the equipment No liability can be accepted for any inaccuracies or omission in this publication although care has been taken to make it as complete and accurate as possible at the time of publication However due to the variety of outdoor power equipment and continuing product changes that occur over time updates will be made to these instructions from time to time Therefore it may be necessary to obtain the latest materials before servicing or repairing a product The company reserves the right to make changes at any time to this publication without prior notice and without incurring an obligation to make such changes to previously published versions Instructions photographs and illust
8. TE A clogged spark arrester screen will dra matically reduce engine performance Figure 8 Oil Filter 4 4 1 Using a screwdriver or drift punch and hammer flatten the tabs on the lock plate of the muffler assembly See Figure 9 4 2 Using a 10mm socket remove the two muffler retaining nuts lock plate and muffler cover 4 3 Remove the spark arrester screen from the metal baffle Replace the screen with a new one See Figure 10 4 4 Reassemble the muffler components and tighten nuts securely 4 5 Bend the tabs on the lock plate to secure the hex nuts 5 SPARK PLUG NOTE For efficient operation of the engine the spark plug must be kept clean and properly gapped 5 1 Push STOP switch up 5 2 Remove top Cover 5 3 Disconnect the wire connector from the spark plug by pulling and twisting at the same time 5 4 Using a scrench remove the spark plug DO NOT USE ANY OTHER TOOL See Figure 11 5 5 Check electrode gaps with wire feeler gauge and set gaps to 025 635mm if necessary or install a new spark plug NOTE A resistor spark plug must be used for replacement part no 9295 320001 NOTE This spark ignition system meets all requirements of the Canadian Interterence Causing Equipment Regulations Figure 9 Tabs Figure 10 Muffler Spark Arrester Baffle Figure 11 Scrench 5 6 BAR AND CHAIN REMOVAL 6 1 Using a scrench or 5 8 socket remove the two nuts se
9. curing the Chain Brake Assembly to the unit Remove the assembly See Figure 12 6 2 Use the scrench or a screwdriver to loosen the chain tension adjustment turn counterclock wise to take tension off the chain See Figure 13 6 3 Remove the chain from around the bar and slide the bar and chain guide plate from the mounting studs 7 CLUTCH REMOVAL 7 1 Remove the chain brake assembly bar and chain See BAR AND CHAIN REMOVAL Sec tion 7 2 Remove the air filter cover Figure 12 Hex Nuts Figure 13 Chain Adjustment 7 3 Remove the spark plug 7 4 Place a length of starter cord in the spark plug opening to ease removal of the clutch drum assembly See Figure 14 7 5 Using a 13mm socket remove the compression nut securing the Clutch Drum assembly to the crankshaft See Figure 15 NOTE The nut is left hand threaded Turn the socket clockwise to loosing it Figure 14 Starter Cord Figure 15 Compression Nut 6 7 6 Remove the clutch drum sprocket assembly from the crankshaft NOTE There is a needle bearing on the crank shaft the may stay on the shaft or come out with the clutch See Figure 16 NOTE There is a stamped washer between the drum sprocket assembly and the housing Note the orientation of this washer The cupped side faces in and the tangs mate with the chain sprocket See Figure 16 NOTE The notches in the sprocket need to mate with the tabs on the chain oiler pump
10. ents from the pump housing Notice how the set screw affects the depth of the pump piston and adjusts the oil quantity See Figure 23 NOTE Replace the O ring and felt washer dur ing service of the pump 9 STARTER ASSEMBLY REMOVAL 9 1 Using a T 25 Torx driver remove the four screws securing the starter assembly to the housing See Figure 24 NOTE The upper screw is a machine screw and uses locktite to secure it 9 2 Remove the starter assembly from the unit See Figure 25 10 SERVICING THE SPRING ASSIST STARTER The spring assist starting system contains two coiled torsion springs The standard recoil spring is used strictly to retract the starter rope In addition to the recoil spring there is an accumulator spring located between the starter rope pulley and the clutch dog assembly When the starter rope is pulled the clutch dogs engage the flywheel The flywheel resists turning because of engine compression As tension in the accumulator spring increases it overcomes the engine compression and rapidly turns the crank and starts the engine Figure 23 Adjustment Screw Pump Piston Gear Pump Housing Foam Plug O Ring Washer Spring Figure 24 Torx Screws Figure 25 9 10 1 To service the starter use a T 25 Torx driver to remove the screw securing the pawl mechanism and starter cord pulley to the housing cover See Figure 26 10 2 Note the orientation of the parts See Figure 27
11. gure 49
12. ll safety procedures before operating or servicing this chain saw Refer to the Owners Manual for pro cedures for proper setup and operation IMPORTANT Prior to servicing the chain saw remove the spark plug wire from the spark plug WARNING Never perform maintenance when the engine is hot to avoid any chance of burning hands or fingers 1 AIR FILTER 1 1 Using a T 25 Torx Driver loosen the cover retaining screws Lift off the cover See Figure 1 1 2 Remove the air filter See Figure 2 Figure 1 Cover Screws Figure 2 Filter Troy Bilt Chain Saw Model FS55 TB4920CC 2 1 3 Wash filter in clean warm soapy water Rinse in clear cool water Air dry completely See Figure 3 NOTE It is advisable to have a supply of spare filters 1 4 Install air filter 1 5 Install engine air filter cover Make sure cover fits properly 1 6 Tighten the cover retaining screws securely 2 FUEL FILTER 2 1 Remove air box cover and air filter 2 2 Disconnect fuel hose from the carburetor fitting NOTE You may not need to disconnect the fuel hose to gain access to the filter 2 3 Pull fuel filter out of tank with a bent wire or long needle nosed pliers See Figure 4 2 4 Disconnect filter and discard NOTE Do not pull hose completely out of tank 2 5 Install a new fuel filter on hose and pull hose fil ter assembly back into tank so filter is positioned in front right corner
13. ormance Only qualified technicians should adjust the fuel air mixture If the carburetor becomes gummed up or fails in any way it can be replaced or rebuilt 14 CARBURETOR REMOVAL 14 1 Remove air filter cover 14 2 Remove starter assembly cover 14 3 Disconnect spark plug wire 14 4 Remove the air filter 14 5 Remove the spark plug 14 6 Using a T 25 Torx driver remove the three screws securing the cover assembly to the fuel oil tank assembly Remove the cover See Fig ure 39 14 7 Using a T 25 Torx driver remove the screw securing the ground wire to the cylinder body See Figure 40 14 8 Using a T 25 Torx driver remove the cable guide attached to the cylinder body See Figure 40 14 9 Disconnect the lead attached to the ignition assembly See Figure 40 14 10 Using a T 25 Torx driver remove the 3 screws securing the handle assembly to the unit See HANDLE REMOVAL Section NOTE On the right handle and rear handle there is a cable assembly that attaches between Figure 38 Throttle Cable Trigger Safety Figure 39 Torx Screws Figure 40 Ground Wire Ignition Lead Cable Guide 13 the handle and the spring Be sure to assemble correctly See Figure 41 14 11 Remove the two wire leads from the housing groove as you separate the handle from the housing See Figure 42 NOTE The throttle cable will still be attached to the carburetor at this time It will be discon nected later
14. rations used in this publication are for reference use only and may not depict actual model and component parts Copyright 2005 MTD Products Inc All Rights Reserved 0 Table of Contents General Information 1 Air Filter 1 Fuel Filter 2 Chain Oil Filter 2 Spark Arrester Screen 3 Spark Plug 4 Bar and Chain Removal 5 Clutch Removal 5 Chain Oiler Removal 6 Starter Assembly Removal 8 Servicing the Spring Assist Starter 8
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