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1. ZS 5910 007 2200 in two crankcase holes 034 036 036 QS 29 Unscrew the hexagon nuts Unscrew the spindle clockwise and take away the service tool Take out the two M5x72 screws 138RA074 VA 138RA077 VA Trim away any excess gasket Fit the installing sleeve 1 material in the area of the 1118 893 4602 over the clutch cylinder mounting face end of the crankshaft Slip the oil seal 2 open side facing the crankcase over the installing sleeve 138RA073 VA 138RA075 VA Drive home the two dowel pins f the crankshaft does not turn freely it is sufficient to tap the end of the stub with a plastic mallet to relieve axial stresses lt x lt x lt gt gt gt oO oO ee tT N oO oO oO lt lt lt ao ao oa CO cO eo m m oO Fit the five crankcase mounting Before installing oil seal coat Press home the oil seal with screws and tighten them down cavity between dust and sealing press sleeve 1 1118 893 2401 alternately in a diagonal pattern lips with grease see 13 2 see Tightening Torques Remove the installing sleeve 30 034 036 036 QS lt x gt O N O lt ao 0 Slide the oil seal open side facing the crankcase over the ignition end of the crankshaft Use press sleeve 1121 893 2400 to press home oil seal until sleeve butts against the crankcase Important It is essential to observe the correct installed depth of the oil
2. see Tightening Torques Securing screws see Tightening Torques Cleaning crankshaft stub Bearing bore in rope rotor rewind spring Electrical system Manifold crankcase gasket High speed and low speed adjusting screws Pawls in rewind starter Sliding and bearing points of brake levers 034 036 036 QS
3. If the rewind spring has popped out refit it in the spring housing as follows 034 036 036 QS Position anchor loop about 25 mm from the edge of the spring housing lt gt e lt oc o oe Refit the rewind spring in the spring housing in the counter clockwise direction starting outside and working inwards Fit the spring housing in the fan housing Engage the spring loop over the lug in the fan housing Install the rope rotor see 7 2 Tension the rewind spring see 7 4 7 3 2 Replacing the Rewind Spring 036 036 QS Remove the rope rotor see 7 2 Use suitable pliers to grip the anchor loop of the rewind spring and pull it out carefully Warning The rewind spring jumps out of its seat in the fan housing in this process Remove any remaining bits of spring from the fan housing Lubricate the rewind spring with STIHL special lubricant Engage the anchor loop over the lug in the fan housing and fit the rewind spring in the fan housing in the clockwise direction starting outside and working inwards Install the rope rotor see 7 2 Tension the rewind spring see 1 4 41 7 4 Tensioning the Rewind Spring Grip the rope between the guide bush and rotor pull it out and make a loop Hold the rope close to the rotor and use it to turn the rotor about five full turns clockwise Hold the rope rotor steady l
4. Remove the setting gauge and use a feeler gauge to check the air gap It should be 0 2 to 0 3 mm Fit the fan housing observe tightening torques see Tightening Torques 39 6 5 2 Ignition Timing Ignition timing on electronic breakerless magneto ignition systems is fixed at 2 5 mm B T D C at 8 000 rom and is not adjustable However in view of the permissible tolerances in the electronic circuitry it may vary between 1 8 and 2 6 mm B T D C at 8 000 rpm Since there is no mechanical wear in these systems ignition timing cannot get out of adjustment However an internal fault in the circuit can alter the switching point in such a way that a spark test will still show the system to be in order although timing is outside the permissible tolerance This will impair engine starting and running behavior 40 7 Rewind Starter 7 1 Routine Maintenance Troubleshooting chart see Standard Repairs Trouble shooting handbook If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not com pletely it can be assumed that the starter mechanism Is in order but plugged with dirt At very low outside temperatures the lubri cating 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 In such a case it is sufficient to apply a few drops of paraffin kerosine to the rewi
5. The carburetor comes from the factors with a standard setting This is the optimum setting of the high speed screw under the barometric pressure and climatic conditions at the factory 300 m above sea level It ensures the machine will deliver maximum power be fuel efficient and operate reliably Standard setting H High speed screw opened 1 full turn L Low speed screw opened 1 full turn If the carburetor has to be adjusted from scratch first carry out the standard setting If it is not possible to check the maximum permissible engine speed 13 000 rom with bar and properly tensioned chain do not turn the high speed screw beyond the standard setting to make the mixture leaner Caution The setting of the high speed adjusting screw affects not only the engine s performance but also its maximum off load speed If the setting is too lean adjusting screw turned too far clockwise the maximum permissible engine speed will be exceeded and increase the risk of engine damage due to a lack of lubricant and overheating If the saw is used at high altitudes mountains or near sea level it may be necessary to correct the setting Carry out the correction with the two adjusting screws Turn clockwise leaner at high altitudes Turn counterclockwise richer at sea level Caution Even slight changes to the adjusting screws have a noticeable effect on engine running behavior Adjusting idl
6. 890 8210 Attaching connectors to electric wires 9 Assembly drift 1110 893 4700 Fitting the piston pin 10 Clamping strap 0000 893 2600 Compressing piston rings 11 Wooden assembly block 1108 893 4800 Fitting piston 12 Carburetor and crankcase 1106 850 2905 Testing crankcase and carburetor tester for leaks 13 Vacuum pump 0000 850 3501 Testing crankcase for leaks 14 Nipple 0000 855 9200 15 Hose 1110 141 8600 16 Sealing plate 0000 855 8106 Sealing exhaust port for leakage test 17 Flange for leakage test 1128 850 4200 Leakage test 18 Setting gauge 1111 890 6400 Setting air gap between ignition module and flywheel 19 Socket 13 mm 5910 893 5608 Crankshaft nut 20 Socket 19 mm 5910 893 5612 21 Torque wrench 5910 890 0301 22 Torque wrench 5910 890 0311 23 Screwdriver bit T27x125 0812 542 2104 IS spline socket head screws 24 Assembly hook 5910 893 8800 Removing pickup bodies 25 Installing tool 5910 890 2210 Fitting hookless snap rings in piston 26 Press arbor 1120 893 7200 Removing crankshaft bearing at ignition side 27 Press arbor 1118 893 7200 Installing crankshaft bearings 28 Assembly hook 5910 890 2800 Detaching springs from clutch shoes 29 Installing tool 0000 890 2201 Flaring rope guide bush 30 Assembly tube 1117 890 0900 Attaching the brake spring 31 Centering tool 1118 893 3500 Centering the heating generator 32 Service tool AS set 5610 007
7. Cleaning the fuel tank Unscrew the filler cap and drain the tank Pour a small amount of clean gasoline into the tank Close the tank and shake the saw vigorously Open the tank again and drain it 68 S Hone oe 0 Gi oe 0 138RA225 VA Removing and installing the pickup body Use the hook 5910 893 8800 to pull the pickup body out through the fuel tank filler opening X A SAN 148RA044 VA Clr A Pull the pickup body off the fuel hose Replace the new type pickup body once piece lt x gt Te QI lt am ro Incase of original type pickup bodies remove the cap 4 from the pickup body 1 and take out the weight 3 lake the filter 2 out of the pickup body Caution The fine mesh strainer on the pickup body must not be damaged It can be washed in white spirit Note It is not advisable to clean the filter 2 always fit a new one The foam filter must be fitted without creases or twists Install in the reverse sequence lt x gt LO lt lt am Removing the suction hose Remove the carburetor see 12 3 Pull the pickup body off the suction hose Pull the suction hose out of the tank housing Install in the reverse sequence Note Coat the hose flange with a little oil to simplify installation The flat face of the hose flange must be seated on the tank housing 034 036 0
8. Take out screw 1 and remove the inner side plate 2 Take out screw 3 and remove the chain catcher 4 Reassemble in the reverse sequence 034 036 036 QS 4 3 Clutch Troubleshooting chart see Standard Repairs Trouble shooting handbook Remove clutch drum chain sprocket see 4 1 148RA064 VA Release twist lock 1 on carburetor box cover 2 and lift cover off vertically gt LO Ke lt oc 0 Note When reassembling check correct position of groove and guide 148RA066 VA Unscrew the slotted nut 1 Pull boot off the spark plug Remove the shroud 2 148RA067 VA On powerheads with a decompression valve 1 remove the cover and unscrew the decompression valve Unscrew the spark plug 2 148RA069 VA Push the locking strip 1 0000 893 5903 into the cylinder so that the words OBEN TOP face upward JS G AT Unscrew the clutch clockwise from the crankshaft left hand thread On 036 036 QS Remove cover washer from the crankshaft stub Disassemble and reassemble the clutch see Standard Repairs Troubleshooting handbook Reassemble in the reverse sequence Note Observe tightening torque for clutch see Tightening Torques 10 4 4 Chain Brake 034 036 4 4 1 Removing Troubleshooting chart see Standard Repairs Trouble shooting handbook Remove the chain sproc
9. if no ignition spark is obtained after checking that wiring and stop switch are in good condition 034 036 036 QS 6 5 1 Removing and Installing 138RA104 VA Remove the fan housing see 6 4 1 Use a screwdriver to disconnect the short circuit wire from the ignition module lt x gt Te lt am o oe lake out the two mounting screws and lift away the ignition module Note If the ignition module is faulty unscrew the ignition lead counterclockwise and transfer it along with the spark plug boot and cable retainer to the new ignition module To install the ignition module connect short circuit wire to tag On ignition module and then push the short circuit wire into the retainer Place the ignition module in the crankcase Coat threads of ignition module mounting screws with LOCTITE see 13 2 Use lower mounting screw to connect the ground wire to the ignition module Fit the two screws and tighten them down moderately Rotate the flywheel until the magnets are between the two arms of the ignition module lt x gt N oO lt am oe Slide the setting gauge 1111 890 6400 or 0 2 mm metal gauge between the arms of the ignition module and the flywheel magnets Press the ignition module against the flywheel and tighten down the mounting screws see Tightening Torques Important Tighten the upper screw first
10. installing tool 5910 890 2210 to fit the snap ring see Standard Repairs Troubleshooting handbook Fit new cylinder gasket on the crankcase Lubricate piston and piston rings with oil 22 138RA034 VA Slide the wooden assembly block between the piston and crankcase Rest the piston on the wooden assembly block 138RA035 VA Position the piston rings so that the radii at the ring gap meet at the fixing pin in the piston groove when the rings are compressed lt x gt Ko oP S lt aa ro Push the manifold on to the intake port so that its tab lines up with the rib on the cylinder 138RA037 VA Slide the hose clamp on to the manifold The screw head must point to the right The screw on the hose clamp must be below the manifold and at a right angle to the cylinder axis Tighten the screw until the gap a between the two ends of the hose clamp is 3 5 to 4 5 mm 138RA038 VA Note If a new cylinder is installed in an older machine it is necessary to shorten the seventh cylinder fin Use the edge of the eighth fin as a guide for the modification see arrow in illustration 034 036 036 QS Coat thread of setscrew in cylinder with LOCTITE see 13 2 Insert setscrew and tighten down firmly see Tightening Torques 138 RA 040VA Slide the cylinder over the piston Remove the wooden assembly block and clamping stra
11. make sure the grub screw is fitted squarely lt x gt Ko D e lt am On machines from serial number gt X 32 185 626 pull off the cap 3 and filter 2 vertically Inspect previous valve 1 ornew valve 4 for damage and if necessary replace as follows Pull the previous valve 1 out of the tank housing from outside and install it from outside In case of new valve 4 first drain the fuel tank Then pull the valve out of the tank housing from inside Install new valve from inside the fuel tank and carefully pull the stem from outside until the valve is properly seated Wash all parts in clean gasoline and blow clear with compressed alr Reassemble in the reverse sequence Note Overpressure may occur in the fuel tank e g due to heat build up or exposure to sunlight Always open the tank cap carefully so as to allow any pressure build up to release slowly 67 12 7 Fuel Filter and Fuel Hose The diaphragm pump draws fuel out of the tank and into the carburetor via the fuel hose Any impurities mixed with the fuel are retained by the pickup body filter The fine pores of the filter eventually become clogged with minute particles of dirt This restricts the passage of fuel and results in fuel starvation Important In the event of trouble with the fuel supply system always check the fuel tank and the pickup body first Clean the fuel tank if necessary
12. out of its seat Push back the rubber grommet a little and pull the connector sleeve out of the switch 034 036 036 QS 138RA138 VA Reassemble in the reverse sequence Note Check correct installed position of switch in its seat Switch seat in not symmetrical 10 3 Heating Element in Rear Handle 138RA131 VA Remove the handle molding see 10 1 Slide the insulating tubes off the two pin and socket connectors Separate the connectors lake the pressure pad out of the handle recess Release and remove the heating element lt x gt N N lt ao lt Important Make sure you install the heating element that matches the flywheel see 6 4 1 Previous heating element 2 New heating element 51 Before fitting the new heating element clean the surface inside the handle so that it is free from grease dirt and moisture Note The previous rear handle heating elements rectangular can still be used together with the previous front handles in the modified tank housing if they are bonded in position at an angle 138RA140VA Bond the rectangular heating element in the rear handle at an angle lt x gt lt am o oe Cut the previous version of the expanded rubber pressure pad as shown so that the lug arrow in the handle does not get in its way 52 lt x gt an lt am o ro Remove the backing pap
13. over the pivot pin secure it with the E clip and attach the spring 2 Install the chain tensioner 3 see 4 6 138RA066 VA Heat area of bearing seat on ignition side of crankcase to approx 120 C Use press arbor 1118 893 7200 to install the ball bearing open side up Important the ball bearing is closed at one side The open side must be on the inside of the crankcase to guarantee proper lubrication Note The ball bearing can be fitted by hand if the crankcase is heated as specified This operation must be carried out very quickly because the bearing absorbs heat immediately and begins to expand 28 138RA067 VA Push annular buffer into crankcase bore from outside until its groove 1 engages the inner rib 148RA093 VA Extend the spindle of service tool ZS 2 5910 007 2200 fully and then screw the threaded sleeve 1 5910 893 2420 onto the spindle as far as it will go lt x gt Q D ro lt aa Lubricate short crankshaft stub with oil and position it in the bearing from inside the ignition side of the crankcase Important The original crankshaft must not be installed in model 0348S 148RA091 VA Apply threaded sleeve 1 to thread 2 on crankshaft stub 148RA092 VA Hold the service tool and crankshaft steady and continue turning the spindle clockwise until the service tool butts against the crankcase 034 036 036 QS Push th
14. rear handle heating element Separate pin and socket connector of wire 1 from generator and wire 3 of rear handle heating element lt x gt t S2 lt am oe 47 Type of Reading in Condition heating element Q see 6 4 1 Previous version approx 2 5 OK No reading Break in circuit less than 2 5 Short circuit ina component New version 7 2 9 4 in Ordnung No reading Break in circuit less than 7 2 Short circuit in a component If the system is in order the ohmmeter should indicate in measuring range Q x 1 a value of about 2 5 Q on previous heating elements or between 7 2 Q and 9 4 Q on new heating elements see also 6 4 If no reading is obtained there is a break in the circuit If the onmmeter shows a value of less than 2 5 Q or 7 2 Q there is a short circuit in one of the components In either case it is necessary to check each component separately The generator wire remains disconneted from the heating element during this check 48 Remedy Check individual components see 10 1 2 Check individual components see 10 1 2 Check individual components see 10 1 2 Check individual components see 10 1 2 034 036 036 QS 10 1 1 Troubleshooting Chart ree Do both handles warm up ro s WIN ue Turn on yes Measure resistance of individual heating elements with ohmmeter On machines with carburetor heating pull connector pin of wire fr
15. speed screw 1 034 036 036 QS 138RA194 VA Fit the throttle shaft with torsion spring and secure with E clip Fit the idle speed screw and check that torsion spring is correctly positioned 138RA195 VA A Fit the throttle shutter round notch first in the throttle shaft Note Whole circumference of throttle shutter must locate against choke tube wall Coat the throttle shutter fastening screw with LOCTITE 270 see 13 2 and tighten down firmly Removing the choke shaft Unscrew the choke shutter fastening screw Ease the E clip off the choke 138RA196 VA 138RA197 VA shaft and pull the shaft out of the carburetor Remove the torsion spring After fitting the choke shaft check that torsion spring is correctly positioned Fit the E clip lt gt D lt aa o oe 65 O amp lt a o 138RA199 VA Fitthe choke shutter round notch first with the small bore facing the choke lever Note When choke shutter is closed its whole circumference must locate against choke tube wall Coat the fastening screw with LOCTITE 270 see 13 2 and tighten down firmly Install the carburetor see 12 3 66 12 5 Adjusting the Carburetor 138RA201 VA 1 Idle speed screw 2 Low speed screw 3 High speed screw Note Carry out carburetor adjustments only after warming up the engine and cleaning the air filter
16. the air filter see 12 1 Remove the carburetor see 12 3 lt x gt mM nN ro lt am oe Pull the washer 1 off the studs and remove the sleeve 2 from the manifold Remove the shroud spark plug and if fitted the decompression valve see 4 3 Remove the muffler see 5 1 Reassemble in the reverse sequence 20 5 3 Cylinder and Piston Removing 5 3 1 148RA089 VA Preparations see 5 2 Take out the four cylinder base Screws Pull the cylinder off the piston and at the same time push the manifold through the tank housing opening Caution Do not use pointed or sharp edged tools for this job 138RA025 VA Remove the cylinder gasket 138RA026 VA Release the hose clamp 1 on the manifold 2 Pull the manifold off the intake port Inspect the cylinder and replace it if necessary Note If a new cylinder has to be installed always fit the matching piston New cylinders are only supplied complete with piston for this reason 034 036 036 QS Important Hold the piston steady during this process to ensure that no jolts are transmitted to the connecting rod Remove piston and take the needle cage out of the connecting rod lt gt N N oO lt ao ap Important Before removing the piston decide whether or not the crankshaft has to be removed as well To remove the flywheel and clutch block the cran
17. 0 7 m s at 9 500 rpm with 7 tooth 3 8 sprocket Fully automatic soeed controlled reciprocating oil pump no oil feed at idle soeed Additional manual oil flow control Adjustable 5 5 15 5 cm min at 10 000 rom 320 cm 3 5 Tightening Torques 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 providing the specified tightening torque is observed For this reason it is essential to use a torque wrench Fastener Pan head screw Screw Self tapping screw Collar screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw screw assembly Spline screw Spline screw Spline screw Spline screw Screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Slotted nut Slotted nut Setscrew Setscrew Thread size For component M4x8 M7x12 5 M8x22 B3 9x13 M8sx21 5 IS M4x12 M10x1 M3 5x12 IS P6x21 5 IS P6x19 IS P6x32 5 IS P6x21 5 IS P4x19 M5x30 IS P6x19 IS M5x12 IS M5x20 IS M5x20 M12x1 L HL6x18 5 IS P6x19 IS M5x6 IS M5x25 IS M5x16 IS M5x25 IS M5x20 IS M5x22 M5 M5 M8x1 M5x8 5 M5x8 5 Chain tensioner cover plate Starter post to fan housing Brake band crankcase 036 QS II Br
18. 1 in rear handle lt x gt N lt am o oe Pull connector sleeves of short circuit wire 2 and ground wire 1 out of switch shaft and contact spring 54 Use pliers to pull the grommet out of the tank housing Remove the generator mounting SCrews Note The screws are secured with LOCTITE and may be difficult to remove 138RA151 VA Remove the generator Use pliers to pull the cable retainer out of the crankcase Pull the generator wire out of the rear grommet through the insulating tube and the retainer Note Inspect generator and poles for cracks or other damage If damage is found replace the generator Inspect magnet ring in flywheel for cracks or other damage If damage is found replace the flywheel 034 036 036 QS 10 5 2 Installing 138RA152 VA Thread the generator wire 1 through the retainer 4 the insulating tube 2 and rubber grommet 3 138RA153 VA Position the generator against the flange face The generator wire must locate in the crankcase recess arrow lt x gt t Te lt aa o oe Coat threads of screws with LOCTITE see 13 2 fit them in the generator and tighten down moderately 034 036 036 QS Fit centering tool 1118 893 3500 on the crankshaft so that its groove engages the Woodruff key Finally tighten the three generator mounting screws see Tightening To
19. 2205 Removing the crankshaft clutch side 33 Service tool ZS set 5910 007 2200 Removing the crankshaft ignition side 34 T handle screwdriver 5910 890 2400 For all IS screws QI 5x150 35 Stud puller MS 5910 893 0501 Removing bar mounting studs 36 Puller 1107 890 4500 Removing generator centering tool 37 Ohmmeter 38 Thrust piece sleeve 1107 894 1000 Protecting crankshaft thread 034 036 036 QS 71 13 2 Servicing Aids No Application 10 11 12 13 72 Lubricating grease Mobilplex Medium strength threadlocking adhesive LOCTITE 243 High strength threadlocking adhesive LOCTITE 270 High strength threadlocking adhesive up to 250 C LOCTITE 272 High strength threadlocking adhesive LOCTITE 649 Standard commercial solvent based degreasant containing no chlorinated or halogenated hydrocarbons STIHL special lubricant Electrician s repair kit Sealing paste Sealant LOCTITE 221 Graphite grease Molybdenum grease e g Molykote Ignition lead HTR 10 m 0781 120 1111 0786 110 0101 0786 110 0109 0786 110 0128 0786 110 0126 0781 417 1315 5910 007 1050 0783 810 1101 0000 930 2251 Oil seals oil pump drive chain sprocket bearing bearing and sliding points of throttle trigger switch lever brake lever and interlock lever Securing screws see Tightening Torques Securing screws see Tightening Torques Securing screws
20. 32 622 640 lt x gt t lt am o oe Remove the metering diaphragm and gasket from the carburetor body or the end cover Note If the gasket and diaphragm are stuck remove them very carefully 915RA042 VA Carefully separate the diaphragm and gasket Note The diaphragms are the most delicate parts of the carburetor They are subjected to continuous alternating stresses and the material eventually shows signs of fatigue i e the diaphragms distort and swell Check and replace if necessary The inlet needle valve is located in a recess in the metering diaphragm chamber Remove the round head screw 1 034 036 036 QS 138RA186 VA Remove the inlet control lever 1 with spindle 2 spring 3 and inlet needle 4 138RA175 VA f there is an annular indentation on the sealing cone of the inlet needle it will be necessary to replace the inlet needle because it will no longer seal properly lt gt N N N lt ao ap Use a suitable drift to press the valve jet out of its seat from outside in the direction of the venturi and wash it in white spirit 034 036 036 QS 148RA040 VA A part load fixed jet 2 is installed in addition to the valve jet 1 in machines from gt X 35 047 484 It helps prevent the mixture becoming over lean in the part load range As the part load fixed jet 2 cannot be removed blow it out with compress
21. 36 QS 12 8 Tank Housing 12 8 1 Removing and Installing 138RA206 VA Drain the tank housing Remove mounting screws from side of front handle 138RA023 VA 138RA210 VA Pull the washer 1 off the studs Remove the annular buffer and remove the sleeve 2 from mounting screw the manifold Remove the chain catcher see 4 2 138RA207 VA Remove mounting screws from underside of front handle Lift away the handle Note To remove front handle on machines with handle heating see 10 4 Remove the carburetor see 12 3 Remove the shroud see 4 3 034 036 036 QS Pull the connector sleeves of the Pry the plugs out of the annular short circuit wire 2 and ground buffers at the starter side wire 1 off the contact springs Remove annular buffer mounting SCrews f z lt oc se D Remove the fan housing see Pullthe grommet with ground and 6 4 1 short circuit wires out of the crankcase Pry the plug 1 out of the annular buffer at the ignition side 69 ae J y 138RA216 VA Pull the impulse hose off the nipple 138RA212 VA Pull the tank housing forward and push the manifold flange out of the tank housing intake opening at the same time lt x gt op N lt am o oe Pry out the rubber buffer on the inside of the crankcase Reassemble in the reverse sequence 70 138RA214 VA Note If a sc
22. Contents 1 4 1 4 2 4 3 4 4 1 4 4 2 4 5 1 4 5 2 4 5 3 4 5 4 4 5 5 4 6 4 9 5 2 5 6 5 6 1 5 6 2 5 6 3 Introduction 2 Safety Precautions 3 Specifications 4 Engine 4 Fuel System 4 Ignition System 5 Cutting Attachment 5 Tightening Torques 6 Special Accessories 7 For User 7 For Service 7 Clutch Chain Drive Chain Brake and Chain Tensioner 8 Clutch Drum and Chain Sprocket 8 Replacing the Chain Catcher 9 Clutch 9 Chain Brake 034 036 10 Removing 10 Installing 11 Chain Brake 036 QS 12 Removing 12 Installing 14 Checking Play 15 Adjusting Play 16 Checking Operation of Chain Brake 17 Chain Tensioner 17 Bar Mounting Studs 18 Engine 19 Removing and Installing Muffler 19 Exposing the Cylinder 20 Cylinder and Piston 20 Removing 20 Installing 21 Piston Rings 24 Crankcase 24 Removing the Crankshaft 24 Installing the Crankshaft 26 Crankcase Leakage Test 31 Preparations 31 Pressure Test 32 Vacuum Test 33 034 036 036 QS 5 7 6 1 6 2 6 3 6 4 1 6 4 2 6 5 1 6 5 2 7 1 7 2 7 3 7 3 1 7 3 2 7 4 8 1 9 1 9 2 9 3 9 4 10 10 1 10 1 1 10 1 2 Replacing the Oil Seals 33 Ignition System 34 Ignition Lead Spark Plug Boot 34 Short Circuit Wire Ground Wire 35 STOP Contact 37 Flywheel 38 Removing 38 Installing 38 Ignition Module 39 Removing and Installing 39 Ignition Timing 40 Rewind Starter 40 Routine Maintenance 40 Rope Rotor Pa
23. Take the adjusting screw out of the tensioner slide and replace the parts Install in the reverse sequence 18 034 036 036 QS 5 Engine 5 1 Removing and Installing Muffler Always check and if necessary repair the fuel system carburetor air filter and ignition system before looking for faults on the engine Troubleshooting chart see Standard Repairs Trouble shooting handbook 138RA021 VA Take out the screws and remove Install new gasket 1 so that its the lower casing bead points toward the muffler Note If the bores of the lower casing are not reinforced fit washers under the heads of the mounting screws Coat threads of mounting screws with LOCTITE see 13 2 Insert and tighten down the mounting screws firmly see Tightening Torques 138 RA 219VA 138RA021 VA 034 034 Take out the screws and remove Remove exhaust gasket 1 and the upper casing flange lt x gt N N rs lt am o oe 036 036 QS 036 036 QS Take out screws and remove the Remove heat shield 1 and upper casing gasket 2 from the upper casing 3 034 036 036 QS 19 5 2 Exposing the Cylinder Always check and if necessary repair the fuel system carburetor air filter and ignition system before looking for faults on the engine Troubleshooting chart see Standard Repairs Trouble shooting handbook Drain the fuel and oil tanks Remove
24. VA Removing the short circuit wire Disconnect short circuit wire from ignition module Pull short circuit wire out of retainer on ignition module Pull the short circuit wire through the insulating tube Install in the reverse sequence Note A ground wire is installed because the contact spring in the polymer tank housing is not connected to ground on the ignition module lt x gt cap D So lt am o ro Removing the ground wire Take out the screw 1 and remove the ground wire 2 Pull the ground wire out through the insulating tube Install the new ground wire in the reverse sequence Check that the insulating tube is properly located in the crankcase cable gland Important Use an ohmmeter to check correct operation of the ground and short circuit wires as well as the STOP contact _ T p 138RA094 VA Set the ohmmeter to measuring range Q x 1 Clip one of the two test leads to the contact spring 1 138RA095 VA Clip the other test lead to the ground wire terminal 034 036 036 QS The ohmmeter must now show a reading of 0 Q If no reading is obtained check the connection between the contact spring and connector sleeve Checking short circuit wire and STOP contact Leave one test lead clipped to the contact spring On machines with carburetor heating pull the thermostatic switch s flag connector of
25. ake cable retainer tank housing 036 QS II Guide bar Cover chain brake crankcase Decompression valve 036 036 QS Generator W version Front handle tank housing top right W version Front handle tank housing bottom W version Front handle tank housing top right polymer Front handle tank housing bottom polymer Handle molding Hand guard left Chain catcher Spiked bumber Crankcase Fan housing crankcase Carrier Annular buffer to rear left right of tank housing Annular buffer to front right of tank housing Muffler upper lower casing Muffler crankcase Muffler cylinder 036 036 QS Muffler crankcase 034 Muffler cylinder 034 Muffler cylinder 034 Z version Shroud Air filter Flywheel Setscrew l h side of cylinder Ssetscrew r h side of cylinder Torque Nm 3 0 12 0 10 0 1 5 23 0 3 0 14 0 2 0 7 0 7 0 5 0 5 0 1 6 7 0 2 8 7 9 9 0 7 0 90 0 5 0 5 0 6 5 10 0 10 0 10 0 10 0 10 0 3 3 2 0 33 0 1 4 1 4 034 036 036 QS Remarks NO N Rese ace a A D Fastener Thread size For component Torque Remarks Nm Hexagon nut M5 Carburetor initial 2 0 Hexagon nut M5 Carburetor final 3 5 Spline screw IS M5x20 Cylinder crankcase 036 036 QS 11 5 Spline screw IS M5x20 Cylinder crankcase 034 10 5 M14x1 25 Spark plug 25 0 Spline screw IS M5x20 Ignition module with washer 8 0 2 Spline screw IS M4x12 Oil pump crankcase 3 5 Micro encapsulated Threadlocking meth
26. ay Lock the setting with self tapping screw 1 Reassemble in the reverse sequence 034 036 036 QS 4 5 5 Check operation of the chain brake with the bar and chain mounted Note When starting the machine observe local safety regulations and the safety precautions in the owner s manual With the engine running open the throttle wide Release the rear handle The chain must come to a standstill in less than one second If the brake does not operate properly service the sliding and bearing points shown in the illustrations as follows If lightly contaminated Clean all parts with a brush and white spirit If heavily contaminated or clogged with resin Remove the parts concerned and clean in white spirit or a resin solvent Replace worn or damaged parts Before re installing parts the machine recesses and seats 034 036 036 QS Checking Operation of Chain Brake 148RA047 VA Lubricate bearing points with Mobilplex grease see 13 2 Lubricate these points 1 with Mobilplex grease see 13 2 Coat outside diameter of clutch drum 2 with chain oil Note If a biological chain oil is preferred STIHL recommends the use of rapidly biodegradable STIHL Bioplus To guarantee troublefree operation use only original STIHL replace ment parts as per the latest parts list 4 6 Chain Tensioner N 138RA004 VA Remove chain sprocket cove
27. carburetor is airtight However if it drops there are two possible Causes 1 The inlet needle is not sealing foreign matter in valve seat or sealing cone of inlet needle is damaged see 12 4 or inlet control lever sticking 2 The metering diaphragm is damaged In either of these cases the carburetor must be serviced After completing the test open the vent screw and pull the fuel hose off the carburetor Reassemble in the reverse sequence Repeat the leakage test after finishing repairs 034 036 036 QS 12 3 The all position diaphragm carburetor consists of a fuel pump and the actual carburetor Although the fuel pump shares a common housing with the carburetor it operates as a completely separate and independent unit Troubleshooting chart see Standard Repairs Trouble shooting handbook Remove the air filter see 12 1 138RA180 VA Lever the grommet off the carburetor adjusting screws Detach the throttle rod and choke lever 0 aa Pull the fuel hose off the carburetor s elbow connector 138RA17 Unscrew the carburetor mounting nuts 034 036 036 QS Removing and Installing the Carburetor elk N Gee Se 138RA222 VA Ne On machines with a carburetor heating system first pull the thermostatic switch s flag connector 1 off the contact spring and then remove heater plate 3 and heating element 2 fr
28. ck lever and locate in the notch arrow lt x gt lt oa o oe The choke shutter actuating lever is molded to the right hand end of the switch shaft It closes the choke shutter when the Master Control lever is set to CHOKE 44 138RA122 VA Detach throttle rod from the trigger Press the interlock lever 1 down pull the throttle trigger 2 up and move the Master Control lever 3 to CHOKE 034 036 036 QS 9 3 Throttle Trigger Interlock Lever Switch Lever 036 QS d Z E 138RA125 VA 148RA001 KV Fitthe handle molding so thatthe Remove the air filter see 12 1 lug at its front end engages properly under the seat on the tank housing Unscrew fastening screw 1 from handle molding 2 Lift away the handle molding Fit handle molding fastening screw see Tightening Torques 148RA099 VA Use a3 mm drift to drive the needle roller 2 out of the interlock lever 1 Remove the lever 148RA100 VA Use a 4 5 mm drift to drive the bushing 1 out of the interlock lever 2 and then remove the torsion spring 3 Install in the reverse sequence 034 036 036 QS 148RA054 To remove the switch lever 1 swing it back arrow 148RA055 VA Disconnect brake cable 1 from switch lever 2 Use a3 mm drift to drive the needle roller out of the switch Take out the switch lever Install in the reverse s
29. crankcase 034 036 036 QS See illustrated parts list for correct installed sequence and positions of crankcase components 138RA059 VA Pull the plastic plug out of the oil pump lt x gt o lt am o oe Position the oil pump against the crankcase Insert and tighten down the mounting screws Before heating the crankcase remove all rubber and polymer 034 036 036 QS components such as oil suction and delivery hoses grommets annular buffers and levers see 8 1 and 11 4 Inspect condition of all parts and replace as necessary Heat area of bearing seat on clutch side of crankcase to approx 120 C 138RA061 VA Place ball bearing in position and press it in until it locates against the oil pump Note The ball bearing can be fitted by hand if the crankcase is heated as specified This operation must be carried out very quickly because the bearing absorbs heat immediately and begins to expand Remove the oil pump and refit the plastic plug 138RA062 VA Push the two annular buffers tapered end first into position so that the groove 1 engages over the housing rib 138RA063 VA Push the oil suction hose into the crankcase bore lt gt st lt aa S Use a blunt tool to push the oil suction hose into the bore so that its tab locates in the bottom right recess 27 138RA065 VA Fit the lever 1
30. e new version Generator 50 32 VA Resistance Ohmmeter connection use either test lead Connector 0 25 on wire 4 0 25 Connector on wire 4 Connector on wire 3 1 Connector Ground 1 6 on wire 2 1 6 Stecker an Ground 7 Leitung 2 Ground Connector on wire 1 0 6 N approx approx approx approx approx If faulty Cause Switch Ground Switch faulty terminal Connector on wire 3 Heating element OK Break in wire heating element damaged Short circuit damaged insulation Heating element OK Break in wire Heating element damaged Short circuit damaged insulation Heating element OK Break in wire heating element damaged Short circuit durch damaged insulation Heating element OK Break in wire Heating element damaged Short circuit damaged insulation Generator OK Break in wire generator damaged Short circuit damaged insulation Remedy Replace switch Replace heating element Repair insulation Replace heating element Repair insulation Replace front handle Repair insulation Replace front handle Repair insulation Replace generator Repair insulation 034 036 036 QS 10 2 Heater Switch 138RA135 VA The front handle has to be removed for access to the heater switch see 12 8 1 Jake the ground wire ring terminal off the switch 138RA136 VA Pull the switch
31. e reverse sequence Note Coat the mounting screws for the upper and lower muffler casings with LOCTITE Insert and tighten down the screws see Tightening Torques 034 036 036 QS 5 6 3 Vacuum Test Oil seals tend to fail when subjected to a vacuum i e the sealing lip lifts away from the crankshaft during the piston s induction stroke because there is no internal counterpressure An additional test can be carried out with vacuum pump 0000 850 3501 to detect this kind of fault 148RA052 VA Connect suction hose of vacuum pump 0000 850 3501 1 to nipple of test flange 2 Close the vent screw 1 on the pump Operate lever 2 until pressure gauge 3 indicates a vacuum of 0 5 bar 034 036 036 QS Note If the vacuum reading remains constant or rises to no more than 0 3 bar within 20 seconds it can be assumed that the oil seals are in good condition However if the pressure continues to rise reduced vacuum in the crankcase the oil seals must be replaced even if no leaks were detected in the pressure test After finishing the test reassemble all parts in the reverse sequence Note Coat the mounting screws for the upper and lower muffler casings with LOCTITE Insert and tighten down the screws see Tightening Torques 5 7 Replacing the Oil Seals It is not necessary to disassemble the complete crankcase to replace the oil seals Remove the flywh
32. e press arbor 1118 893 7200 to press the ball bearing out of its seat 138RA055 VA Use a screwdriver or similar tool to knock the oil seal out of its seat at the ignition side From outside the crankcase use arbor 1120 893 7200 to press the ball bearing inwards and out of its seat 26 Pull the oil suction hose out of crankcase Inspect both halves of the crankcase for cracks and replace if necessary Note Always install new gaskets and ball bearings when replacing the crankcase The crankcase must be replaced as a complete unit even if only one half is damaged All other parts which are still serviceable can be transferred to the new crankcase after the new bearings have been fitted crankcase has to be heated Use the stud puller 5910 893 0501 to remove and install the bar mounting studs see 4 7 5 5 2 Installing the Crankshaft lf the original crankcase is used again remove all the gasket residue and clean the mating Surfaces Note Clean the mating surfaces thoroughly to ensure a perfect seal lt x gt Ye So lt am oe Note A new front chain tensioner is supplied with replacement crankcases 1 Tensioner slide 2 Adjusting screw 3 Thrust pad 4 Cover plate 5 Pan head screw Stamp the machine s serial number on the crankcase with 2 5 mm figure stamps Check that dowel pin is in position If necessary drive dowel pin into new
33. e speed Engine stops while idling Turn idle speed screw clockwise until the chain begins to move Then back off the screw one quarter turn Chain runs while engine is idling Turn idle speed screw counter clockwise until the chain stops running Then turn the screw about another quarter turn in the same direction 034 036 036 QS Erratic idling behavior poor acceleration Idle setting too lean Turn the low speed screw counterclockwise until the engine runs and accelerates smoothly Exhaust smokes at idle speed Idle setting too rich Turn the low speed screw clockwise until engine speed drops Then turn it back one quarter turn from that position Check that the engine accelerates smoothly when the throttle is opened 034 036 036 QS 12 6 Tank Vent Correct operation of the carburetor is only possible if atmospheric pressure and internal fuel tank pressure are equal at all times This is ensured by the tank vent Important In the event of trouble with the carburetor or the fuel supply system always check and clean the tank vent Remove the air filter see 12 1 138RA202 VA On older tank housings up to serial number gt iX 32 185 626 remove the original type tank vent arrow by pulling it upwards lt x gt m S N lt am o oe Take out the pan head screw 1 and the grub screw 2 When assembling the tank vent
34. ed air Note Owing to differences in calibration the old versions of valve jets high speed and low speed adjusting screws must not be installed in carburetors with a part load fixed jet see also parts list 138RA187 VA Remove the carburetor adjusting SCrews 138RA188 VA Use a drift to press the center of the sealing plate down until it buckles and can be removed Caution The sealing plug is destroyed during removal Remove it only if a replacement is available Wash the carburetor body and all serviceable parts in fresh white spirit and blow clear with compressed air paying special attention to the bores and ports Fit the new sealing plate curvature facing up in the bore and use a large diameter drift to carefully press it flat When inserting the valve jet make sure it is exactly vertical in the bore Press the jet home until it is flush with the metering chamber 63 915RA051 Fit the inlet needle 1 Fit spring 2 in bore Insert spindle 3 in the inlet control lever 4 Engage clevis in annular groove on head of the inlet needle Press the inlet control lever down and secure with the round head screw Note Make sure the helical spring locates on the control lever s nipple 138RA189 VA Important The upper edge of the inlet control lever must be flush with the top of the carburetor body If this is not the case install a new inlet cont
35. eel see 6 4 1 Remove the Woodruff key from the crankshaft stub lt x gt lt e lt am o oe On machines with handle or carburetor heating system take out the generator mounting screws lift the generator away and put it to one side Remove the clutch see 4 3 Remove the brake band see 4 4 1 and 4 5 1 Remove the oil pump see 11 4 Fit No 3 1 jaws 000 893 3706 in the universal oil seal puller 5910 890 4400 33 138RA083 VA Apply the puller at the clutch side and rotate the spindle clockwise to pull the oil seal out of the crankcase 138RA085 VA Apply the puller at the ignition side and rotate the spindle clockwise to pull the oil seal out of the crankcase Important When using the puller make sure it does not damage the crankcase surface or the ball bearing cages Install the oil seals as described under 5 5 2 Install the generator see 10 5 2 Reassemble all other parts in the reverse sequence 34 6 Ignition System Exercise extreme caution when carrying out maintenance and repair work on the ignition system The high voltages which occur can Cause serious or even fatal accidents Troubleshooting on the ignition system should always begin at the spark plug see Standard Repairs Troubleshooting handbook Note The electronic breakerless ignition system basically consists of an ignition module 1 and flywheel 2 which
36. emove wires from switch see 10 2 Take out the mounting screws at the side and bottom of the front handle Important The special screws used for polymer joints are secured with LOCTITE Always heat the screwed joint before loosening e g with a hair dryer Take care not to overheat the polymer 034 036 036 QS Heating Element in Front Handle 138RA145 VA Remove the front handle Pull the connecting wire out of the carburetor box through the grommet arrow 1125 791 1000 e 138RA144 VA Install the new front handle in the reverse sequence Note Mounting front handle without stiffener to original type tank housing up to and including index e Fita washer under each screw head Coat front handle mounting screws with LOCTITE insert and tighten down firmly see Tightening Torques 138RA146 VA Check that the wire of the front handle heating element and the generator wire are properly positioned in the rear handle 53 Generator Removing 10 5 10 5 1 Remove the air filter see 12 1 Remove the tank vent see 12 6 Remove the shroud see 4 3 Remove the handle molding and interlock lever disconnect the throttle rod see 9 2 Take out ignition module mounting screws see 6 5 1 and leave ignition module to one side Remove the flywheel see 6 4 138RA148 VA Disconnect generator wire see 10 1 fig 188 RA 132 VA wire
37. equence 45 148RA0 To remove the throttle trigger first remove the switch shaft see 9 4 Use a5 mm drift to drive out the cylindrical pin 3 and then remove the throttle trigger 2 with torsion spring 1 Take the torsion spring off the throttle trigger Install in the reverse sequence Note When installing make sure that short arm of torsion spring locates in the throttle trigger The long arm points toward the carburetor 46 9 4 Switch Shaft d A ANY se 138RA130 VA Remove the air filter see 6 4 Take out the handle molding fastening screw Lift away the handle molding 138RA090 VA 034 036 Remove the interlock lever see 9 2 Take short circuit wire 1 out of cam on switch shaft lt x gt co A lt am o oe Move the Master Control lever up to STOP Pry the switch shaft out of its mounting at the ignition side WAN 2 ISS lake the switch shaft out of its mounting 138RA127 VA Install in the reverse sequence 138RA128 VA Note When installing make sure that the throttle rod is above the switch shaft and the lug at the front end of the handle molding engages properly under the seat on the tank housing Note 034 036 When fitting the handle molding make sure that the torsion spring throttle rod and interlock lever are correctly positioned The torsion spring must pass under the interlock leve
38. er from the new heating element Press the heating element firmly and uniformly into position taking special care at the corners and along the edges Important Avoid creases If the heating element is not fitted perfectly flat heat transfer will be interrupted causing the element to overheat and fail The ambient temperature during installation should not be less than 15 C Fit anew expanded rubber pressure pad on top of the heating element The heating element must be completely covered Reconnect the wires and slide the insulating tubes back over the pin and socket connectors Reassemble all other parts in the reverse sequence Check operation of heating element Run the saw at maximum revs for no more than 30 seconds with the heating switched on Note The heat generated during this process also helps the element s adhesive set faster 034 036 036 QS 10 4 The heating element in the front handle is not replaceable A new handle must be fitted if the heating element is faulty To disassemble the front handle remove the carburetor box cover see 4 3 Remove the air filter see 12 1 Remove the handle molding and interlock lever see 9 2 Remove the carburetor see 12 3 138RA139 VA Separate pin and socket connector of wire 2 of front handle heating element and wire 4 of rear handle heating element Pull of the insulating tube R
39. es e T L Af its a O o lt ZA 7 lt lt Ve chy Fit the lever 2 and spring 1 Position the hand guard 1 First attach the brake band 2 to against the pivot pin and fit the the brake lever 3 and then push Fit the E clip 3 other side of the hand guard over it into the slot in the crankcase the fan housing Install screw 1 with LOCTITE Press the lever 1 slightly 243 and tighten down firmly see downward and push the hand Tightening Torques guard and brake lever 2 onto the pivot pins Insert screw with captive washer for hand guard and tighten down firmly see Tightening Torques Important Coat all sliding and bearing points with STIHL multipurpose grease see 13 2 or better with molybdenum grease e g Molykote see 13 2 Insert lever inthe side of the hand Do not lubricate the brake band guard as shown N N Ss DO 148RA071 VA lt gt l N O lt a vt 148RA075 VA _ Aitach brake cable 1 to hole Attach spring 1 to the pivot pin Hook the brake spring 1 to the arrow in brake lever 2 brake lever 2 14 034 036 036 QS 4 5 3 Checking Play Pull hand guard toward front handle Unscrew nut from chain sprocket cover and remove the cover see g 4 1 Remove the cutting attachment see 4 1 Use the assembly tool Press down interlock lever 1 all 1117 890 0900
40. f the contact spring Move the Master Control lever upwards to STOP Clip other lead to short circuit wire s terminal The ohmmeter must again show a reading of 0 Q If no reading is obtained check the connection between the connector sleeve in the switch shaft s cam and the contact spring On machines with carburetor heating push the thermostatic switch s flag connector onto the contact spring 034 036 036 QS 6 3 STOP Contact lt x gt Ko D e lt am oe Remove the air filter see 12 1 Remove the tank vent see 12 6 The short circuit system is in order if the short circuit wire makes contact with the connector sleeve when the Master Control lever is in the STOP position Replacing a bent or broken contact spring To avoid damaging the fuel hose pull it off the carburetor s elbow connector On machines with carburetor heating pull the thermostatic switch s flag connector off the contact spring lt x gt N D e lt am oe Pull the ground wire connector sleeve out of the contact spring Move Master Control lever to STOP position 138RA097 VA Squeeze the contact spring so that is disengages from the Master Control lever and at the same time use a screwdriver to pry it out of its seat in the crankcase Install the new contact spring Reconnect the ground wire connec
41. from piston tensioner slide butts against the Remove the oil pump see 11 4 thrust pad Use a piece of old piston ring to scrape the grooves clean Remove the flywheel see 6 4 1 Note Use service tools Warning Remove the ignition module see AS 5910 007 2205 and Do not install 1 2 mm rings in 6 5 1 ZS 5910 007 2200 to remove and pistons with 1 5 mm grooves install the crankshaft Follow the On machines with handle and or instructions supplied with the tools carburetor heating remove the generator see 10 5 1 Back off spindle on service tool AS all the way Remove the cylinder and piston see 5 3 1 Remove the tank housing see 12 8 1 Remove the spiked bumper Use a5 mm drift or other suitable tool to drive out the two dowel pins from the clutch side lt x lt x lt x gt gt gt Ko t t t ro ro lt lt lt ao oc oa o o o oe oe oe Install the new piston rings inthe Unscrew the five mounting Slip service tool grooves so that the radii at the screws which join the two halves AS 5910 007 2205 over the two ends of the rings face upward of the crankcase collar studs fit the hexagon nuts for sprocket cover and tighten Install the piston see 5 3 2 them down by hand 24 034 036 036 QS Note The tool s drilled plate must locate flat against the crankcase With the crankcase horizontal cylinder flange upright rotate service t
42. illed fuel must be wiped away immediately 034 036 036 QS 3 Specifications 3 1 Engine STIHL single cylinder two stroke engine with special impregnated cylinder bore Displacement Bore Stroke Compression ratio Engine power to ISO 8893 Max torque Max permissible engine speed with bar and chain Mean idle speed Crankshaft Main bearings Crankshaft journal diameter Big end bearing Piston pin diameter Small end bearing Connecting rod length Rewind starter Starter rope Clutch Diameter Clutch engages at Crankcase leakage test at gauge pressure under vacuum 3 2 Fuel System 034 56 5 cm 46 mm 34 mm 9 5 1 3 0 kW 4 1 bhp at 9 500 rom 3 5 Nm at 6 500 rom 13 000 rom 2 00 rom Two part drop forged Two deep groove ball bearings 14 4 mm Needle cage 10 mm Needle cage 58 mm Pawl engagement with automatic starter rope rewind mechanism 3 5 mm dia 960 mm Centrifugal clutch without linings 76mm approx 3 500 rom 0 5 bar 0 5 bar Carburetor Standard setting High speed screw H Low speed screw L Idle setting Carburetor leakage test at gauge pressure Fuel tank capacity Fuel mixture Mix ratio Air filter 036 036 QS 61 5 cm 48 mm 34 mm 9 5 1 3 4 kW 4 6 bhp at 9 500 rom 3 7 Nm at 6 500 rom 13 000 rom 2 00 rom Two part drop forged Two deep groove ball bearings 14 4 mm Needle cage 10 mm Needle cage 58
43. in the side of the hand guard so that short arm of lever points up Note Check correct installed position of lever lt gt io ro lt aa o ro Position the hand guard 1 against the pivot pin and fit the other side of the hand guard over the fan housing Vh 138RA014 VA Press the cam lever slightly downward and push the hand guard and lever onto the pivot pins Secure lever with E clip Insert hand guard mounting screw with captive washer at fan side and tighten down firmly see Tightening Torques Important Coat all sliding and bearing points with STIHL multipurpose grease see 13 2 or better with molybdenum grease e g Molykote see 13 2 Do not lubricate the brake band 138RA007 VA First attach the brake band 1 to the lever 2 and then push it into the crankcase recess arrow 11 Fit the inner side plate see 4 1 Install the clutch drum chain sprocket see 4 1 Fit the cutting attachment and chain sprocket cover see 4 1 138RA016 VA Check that protective tube is correctly positioned a 20 mm b 33 mm Hook the brake spring to the lever Er a4 CS Ic GAL iy Use the assembly tool 1117 890 0900 to attach the brake spring 1 to the anchor pin 138RA015 VA Fit cover over the chain brake 12 4 5 Chain Brake 036 QS 4 5 1 Removing Troubleshooting chart see Standard Repai
44. ket cover and cutting attachment see 4 1 Remove the clutch drum chain sprocket see 4 1 Cad O 138RA004 VA Remove mounting screw 1 from inner side plate 2 and lift side plate away Engage the chain brake by pushing the hand guard away from the front handle lt x gt Te 2 lt am o oe Remove mounting screws 1 from cover 2 and lift the cover away be Carefully pry the brake spring 1 off the anchor pin and disconnect it from the lever 2 138RA006 VA 138RA007 VA Ease the brake band 1 out of its seat in the crankcase and disconnect it from the lever 2 Remove screw with captive washer from the hand guard Note When installing tighten down the screw with captive washer firmly see Tightening Torques 034 036 036 QS 138RA009 VA Remove the E clip from the pivot pin Pull the hand guard and lever from the pivot pins lt gt o lt o 00 Pull the lever out of the hand guard Remove the E clip 3 from pivot pin of lever 2 and detach the spring 1 Remove the cam lever and spring Clean all disassembled parts in white spirit Replace any worn or damaged parts 034 036 036 QS 4 4 2 Installing i eNO 1 EANN E co 138RA011 VA ON N a7 s Fit the cam lever 2 and spring 1 Fit the E clip 138RA012 VA Insert lever
45. kshaft by sliding the wooden assembly block 1 1108 893 4800 between the piston and crankcase Use a scriber or similar tool to ease the hookless snap rings out of the grooves in the piston 138RA029 VA Inspect piston rings and replace if necessary see 5 4 lt x gt N e lt am o Sp Use the assembly drift 2 1110 893 4700 to push the piston pin 1 out of the piston Note lf the piston pin is stuck tap the end of the drift lightly with a hammer if necessary 034 036 036 QS 5 3 2 Installing 138RA030 VA Thoroughly clean the gasket seating surface on the cylinder Lubricate the needle cage with oil and fit it in the small end lt x gt cap S lt am ro Install a snap ring in the front piston boss 2 i e the piston boss facing you when the arrow 1 on the piston head is pointing to the right Note Use installing tool 5510 890 2210 to fit the snap ring see Standard Repairs Troubleshooting handbook Heat the piston on an electric heating plate to about 60 C 21 138RA032 VA Slip the piston over the connecting rod so that arrow on piston crown points to exhaust port Push the assembly drift 1110 893 4700 small diameter first from the clutch side through the piston and small end needle cage and line up the piston Fit piston pin on the end of the assembly drift and push it into the piston Use
46. lead into the ignition module Push the insulating tube right up the ignition module s high voltage output Install the ignition module see 6 5 1 Push ignition lead into seat in crankcase Fit the shroud see 4 3 Fit boot on the spark plug Fit the air filter see 12 1 6 2 Short Circuit Wire Ground Wire lt x gt N lt o oe Note lf the insulation of the short circuit wire 2 is damaged it can cause a short circuit to ground and upset or completely interrupt ignition To remove the short circuit wire 2 and ground wire 1 perform the following operations Remove the fan housing see 6 4 Remove the shroud see 4 3 Remove the air filter see 12 1 Remove the tank vent see 12 6 lt x gt o D lt am o oe Use a small screwdriver to ease the connector sleeve of the short circuit wire 1 out of its seat inthe switch shaft 35 138RA092 VA Pull ground wire connector sleeve out of contact spring lt gt N lt ao ro On machines with handle or carburetor heating disconnect the pin and socket connectors of the heating systems see 10 3 Pull grommet out of tank housing Slip grommet off the wires Pull the boot off the spark plug and remove the ignition lead from its seat in the crankcase Pull the insulating tube through the cable gland in the crankcase 36 138RA104
47. lled from machine serial number I gt X 20 239 583 This new oil pump can also be installed in older machines The adjustment range of the oil quantity control bolt 1 between minimum and maximum oil flow has been reduced from 720 degrees 2 turns to 90 degrees 1 4 turn lt x gt O N lt ao c ap Setting the oil pump to the E matic position E is the most economic position under normal operating conditions using a STIHL E matic guide bar 57 Install in the reverse sequence Note Pay special attention to the following points lt gt lt oc oO Cut new oil delivery hose to a length of 74 mm and coat the ends with oil Use modified flat nose pliers a 5 5 mm to fit the oil delivery hose on the oil pump nipple Push the oil delivery hose through the bore in the bar mounting flange from the inside outwards and allow it to project about 10 20 mm If the hose cannot be pushed through on older machines drill out the bore to a diameter of 6 2 mm and deburr carefully 58 lt gt N N lt am ap Hold the projecting end with the modified flat nosed pliers Now push home the sleeve with the modified carburetor screwdriver R 1 5 mm Place oil pump in installed position Use modified carburetor screwdriver to push hose into bar mounting flange so that it is recessed about 1 2 mm Insert oil pump mounting screws and tighten them d
48. mm Pawl engagement with automatic starter rope rewind mechanism 3 5 mm dia 960 mm Centrifugal clutch without linings 76mm approx 3 500 rom 0 5 bar 0 5 bar 034 036 036 QS All positon diaphragm carburetor with integral fuel pump approx 1 turn open approx 1 turn open starting with screws firmly against their seats 0 4 bar 625 cm Regular brand name gasoline and brand name two stroke engine oil 50 1 with STIHL two stroke engine oil 25 1 with other brand name two stroke air cooled engine oils Large area bisectional box filter with wire mesh 034 036 036 QS 3 3 3 4 Ignition System Cutting Attachment 034 036 036 QS Type Air gap Spark plug Suppressed Electrode gap Spark plug thread Thread length Heat range Guide bars Cutting lengths Oilomatic chain Chain sprockets Chain speed Chain lubrication Oil delivery rate Oil tank capacity 034 036 036 QS Transistorized magneto ignition breakerless 0 2 0 3 mm Bosch WSR 6 F 0 5 mm M14x1 25 9 5 mm 200 STIHL Rollomatic S bars with nose sprocket STIHL Duromatic bars with stellite tipped nose Both types with corrosion resistant finish and induction hardened rails Rollomatic 37 40 45 and 50 cm Duromatic 37 40 45 and 50 cm 9 32 mm 3 8 Rapid Micro Rapid Super Options 8 25 mm 0 325 Rapid Micro Rapid Super Topic Micro and Topic Super 7 tooth 3 8 rim sprocket 2
49. nd spring Then carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored If clogged with dirt or pitch the entire starter mechanism including the rewind spring must be removed and disassembled Take special care when removing the spring Wash all parts in paraffin kerosine or white spirit Lubricate the rewind spring and starter post with STIHL special lubricant see 13 2 before installing 7 2 Rope Rotor Pawls Starter Rope Rope Guide Bush Remove the fan housing see 6 4 1 Note For descriptions on removing and installing the rope rotor replacing the starter rope pawls or rope guide bush see Standard Repairs Troubleshooting handbook Observe tightening torques when refitting the fan housing see Tightening Torques 034 036 036 QS 7 3 Rewind Spring Replacing the Rewind Spring 034 7 3 1 Remove the rope rotor see 7 2 Use suitable pliers to grip the anchor loop of the rewind spring and lift it up Take the spring housing and rewind spring out of the fan housing Remove any remaining bits of spring from the fan housing Lubricate die rewind spring with STIHL special lubricant and fit it with the spring housing bottom plate facing up in the fan housing Engage the spring loop over the lug in the fan housing Warning The rewind spring may pop out and uncoil during installation
50. ng elements 1125 434 5000 may only be installed in machines with flywheel 1125 400 1207 Front handles and heating elements can be identified with the aid of the following resistances 148RA217 VA Rear handle heating element Old version 1 0 225 0 275 Q New version 2 0 9 1 1 Q Front handle heating element Old version 1 44 1 76 Q New version 6 3 7 7 Q 6 4 2 Installing Check correct position of Woodruff key a eel J X Oe Important Clean the stub of the crankshaft and the flywheel hub bore with a standard commercial solvent based degreasant containing no chlorinated or halogenated hydrocarbons see 13 2 138RA102 VA Fit the flywheel in position Fit and tighten down the flywheel nut see Tightening Torques Reassemble all other parts in the reverse sequence Observe tightening torques when refitting the fan housing see Tightening Torques 034 036 036 QS 6 5 Ignition Module 138RA103 VA The ignition module accommodates all the components required to control ignition timing Ignition module components and connections 1 Ignition lead with insulating tube 2 High voltage output 3 Ground wire 4 Connector tag for short circuit wire Accurate testing of the ignition module is only possible with special test equipment For this reason it is only necessary to carry out a spark test in the workshop A new ignition module must be installed
51. od medium strength adhesive e g LOCTITE 243 Threadlocking method high strength adhesive e g LOCTITE 649 Threadlocking method high strength adhesive up to 250 C e g LOCTITE 272 Threadlocking method high strength adhesive e g LOCTITE 270 Degrease taper with cleaning agent e g Somentor 33 i 2 3 4 5 6 N N NI S CU Use the following procedure when refitting a DG or P screw in an existing thread Place the screw in the hole and rotate 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 settings for polymer Plastoform screws max 600 rom DG screws max 500 rom 3 6 Special Accessories 034 036 036 QS 3 6 1 For User Intake air preheating kit 1125 007 1035 036 Intake air preheating kit 1125 007 1004 034 034S 325 8 tooth rim sprocket kit 1125 007 1000 325 7 tooth rim sprocket kit 1125 007 1001 3 8 7 tooth rim sprocket kit 1125 007 1002 3 8 7 tooth spur sprocket 1125 640 2000 325 7 tooth spur sprocket 1125 640 2005 3 6 2 For Service Gasket set 1125 007 1050 Carburetor parts kit 1128 007 1065 Gasket panel 0457 281 0604 034 036 036 QS 4 Clutch Chain Drive Chain Brake and Chain Tensioner Troubleshooting chart see Standard Repairs Trouble shooting handbo
52. ok 138RA002 VA Unscrew nuts 1 from chain sprocket cover 2 Remove the sprocket cover bar and chain 3 lt x gt t 2 lt aa P Disengage the chain brake by pulling the hand guard toward the front handle 4 1 Clutch Drum and Chain Sprocket 148RA061 VA Remove the E clip 1 and washer 2 If a rim sprocket 3 is fitted pull it off 148RA062 VA 036 QS Disengage the additional brake by pressing down the throttle trigger and interlock lever Remove the clutch drum 1 and needle cage 2 lt x gt isp ro lt am oe 034 036 Pull off the chain sprocket 1 or clutch drum 2 Take out the needle cage 148RA101 VA Inspect the clutch drum 1 There should be no scores or signs of excessive wear Important If there are signs of serious wear on the inside diameter of the clutch drum 1 check the remaining wall thickness If it is less than about 80 of the original thickness fit a new clutch drum Note Clean stub of crankshaft Wash needle cage examine it for damage and replace if necessary Lubricate needle cage with STIHL multi purpose grease see 13 2 Reassemble in the reverse sequence start by fitting the needle cage on the crankshaft stub 034 036 036 QS 4 2 Replacing the Chain Catcher AR j lo O81 7 ya O O S 148RA063 VA Remove chain sprocket cover see 4 1
53. om heating element out of the round plug Check rear handle heating element In good condition Bonding OK no Replace yes oe rear handle heating element Resistance Previous heating element approx 0 25 Q New heating element approx 1 Q see 10 1 and 10 3 yes Check generator Repl Resistance between generator no epilace connection 1 and engine ground generator approx 0 6 Q yes Fit new ground wire between heater switch Check ground wire between tank housing and crankcase ng Resistance between switch housing and crankcase approx 0 Q and crankcase yes Disconnect plug connection at heater switch Switch has to be partly removed for this purpose Check front handle heating element no Previous heating approx 1 6 Q New heating element approx 7 Q Replace front handle yes Check heater switch no Closed approx 0 Q Open high reading Fit new switch yes On machines with carburetor heating refit connector pin of wire from heating element in the round plug System in order 034 036 036 QS 10 1 2 Test Connections and Test Values The pin and socket connections of wires 1 to 4 must be disconnected to test the individual components see 10 1 fig 138 RA 1 Component Switch Heating element rear handle previous Heating element rear handle new version Heating element front handle previous Heating element in front handl
54. om the collar studs and leave them to one side Pull the carburetor off the collar studs Install in the reverse sequence Note The gasket is not fitted on machines from gt X 18 892 140 which are equipped with a Zama carburetor The gasket must still be installed on Tillotson carburetors 138RA023 VA Note Check that sleeve 2 in manifold and washer 1 are in place before fitting the carburetor new version Tighten down the mounting nuts see Tightening Torques 61 12 4 Servicing the Carburetor Remove the carburetor see 12 3 It is advisable to check the serviceability of the fuel pump whenever the carburetor is removed for repair Inspect pump diaphragm see Carburetors handbook chapter 7 3 Pump Diaphragm lt x gt N o lt am oe Note lf the fuel strainer arrow in the pump side of the carburetor body is dirty use a scriber to pry it out and then clean it Important lf the fuel strainer is damaged fit a new one If the strainer is dirty also check the fuel pickup body and replace it if necessary see 12 7 62 lt x gt op lt x oc ise To disassemble the carburetor take out the screws 1 of the metering chamber end cover 2 and lift away the cover Note There is no compensator stub 3 on the end cover 2 of older carburetors installed in model 034 I 1 45 945 205 and model 036 gt X
55. on above the text Action to be taken that is not shown in the illustration above the text gt Situation applies from serial number gt Situation applies up to serial number In the illustrations Pointer map Direction of movement Service manuals and all technical Information bulletins are intended exclusively for the use of STIHL servicing dealers They must not be passed to third parties servicing and repairs are made considerably easier if the powerhead is mounted on assembly stand 1 5910 890 3100 Remove the chain sprocket cover bar and chain first The powerhead can then be swivelled to the best position for the ongoing repair This leaves both hands free Always use original STIHL replacement parts They can be identified by the STIHL part number the STJAL ogo and the STIHL parts symbol amp 2 This symbol may appear alone on small parts 034 036 036 QS 2 Safety Precautions If the engine is started up in the course of repairs or maintenance work observe all local and country specific safety regulations as well as the safety precautions and warnings in the owner s manual Gasoline is an extremely flammable fuel and can be explosive in certain conditions Improper handling may result in burns or other serious injuries Warning Do not smoke or bring any fire flame or other source of heat near the fuel All work with fuel must be performed outdoors only Sp
56. ool until the number 7 on the plate is at the bottom 138RA048 VA lt x gt ou LO lt am o ro Turn the spindle of the service The crankshaft 1 connecting tool clockwise until the crankshaft is pressed out of the ball bearing The two halves of the crankcase separate during this process rod 2 and needle bearing form an inseparable unit This means that the crankshaft must always be replaced as a complete unit in the event of damage to any one of these parts When fitting a replacement crankshaft always install new oil seals and ball bearings Remove the gasket from the crankcase sealing face 138RA049 VA 138RA051 VA Fit thrust sleeve 1107 894 1000 from clutch puller 1107 890 4500 to protect the crankshaft thread during the following operation Secure the service tool to the crankcase with M5x72 mounting screws 9022 341 1190 Insert the screws in the holes marked 7 and tighten them down against the drilled plate Turn spindle counterclockwise left hand thread until it locates against the crankshaft Use a19 mm wrench to continue turning the spindle and push the crankshaft out of its bearing seat lt x gt cop LO lt am o ro Fit service tool ZS 5910 007 2200 against the outside of the crankcase Use a screwdriver to pry the oil seal out of the ball bearing at the clutch side 034 036 036 QS 25 138RA054 VA Us
57. or stub and carburetor box cover can only be installed in model 036 from serial number gt X 32 185 626 and only asa complete assembly Before removing the air filter close the choke shutter to prevent dirt falling into the carburetor lt x gt N lt a 0J Removing the main filter Remove the carburetor box cover Clean away any loose dirt from around the filter Unscrew the two slotted nuts so that the filter can be pulled off the collar studs lt x gt N N lt ao 0 m Removing the prefilter 034 036 Remove the carburetor box cover Remove grommet from carburetor box 034 036 036 QS Cleaning the prefilter and main filter Coarse dirt is retained by the wire mesh prefilter in the carburetor box cover Note The air filter consists of two parts 138RA179 VA Insert a screwdriver combination wrench in the slot at the side of the filter Twist the screwdriver to separate the two halves For daily cleaning it is sufficient to clean the two halves of the main filter and the prefilter with a soft brush If heavily plugged with dirt wash the prefilter and main filter in fresh white spirit and blow out with compressed air if available Note Do not clean flocked air filters with compressed air brushes or rags If the wire mesh or flocked coating is damaged immediately replace the part of the filter conce
58. own firmly see Tightening Torques 11 5 Servicing the Oil Pump Always check the suction hose and pickup body before disassembling the oil pump Remove the oil pump see 11 4 Use a2 mm drift to drive out the spring pin 6 Pull the control bolt 8 out of the housing 5 and remove the O rings 7 Note The previous pump has an adjusting screw which must be unscrewed clockwise Pry the plug 1 out of housing 5 and remove the pump piston 2 with spring 4 and washers 3 Wash all part in white spirit Inspect parts for damage and replace as necessary Reassemble in the reverse sequence Note Always install new O rings Coat pump piston and worm with grease see 13 2 before installing 034 036 036 QS 12 Fuel System 12 1 Air Filter Insert a screwdriver between the prefilter and carburetor box cover and lever the prefilter out of the retainer The air filter s function is to remove dust and dirt sucked in with the combustion air and thus help reduce wear on engine components to a minimum Pull the prefilter out of the guides Note in the carburetor box cover Older machines have a prefilter in the carburetor box cover which is not fitted in newer machines with compensator on carburetor Apart from the carburetor box cover the air filter was also modified on machines with compensator The components of the new air filter system air filter end cover with compensat
59. p 138 RA 039VA Lubricate the inside of the Wind a piece of string about cylinder with oil and line it up so 15 cm long around the back of that it is positioned as it will be in the manifold flange press the the installed condition manifold down and pass the ends of the string through the intake Use the clamping strap opening 0000 893 2600 to compress the rings around the piston Check correct installed position of rings once again Note To make cylinder installation easier apply clamping strap so that it is just below the piston crown lt x gt an t lt o oe Pull the ends of the string outward The manifold flange is pulled through the tank housing intake opening without damaging the manifold 034 036 036 QS Carefully line up the cylinder and gasket Fit cylinder base screws and torque down firmly in a diagonal pattern see Tightening Torques Important lt is essential to observe the specified tightening torque as the screws might otherwise work loose Assemble all other parts in the reverse sequence Always install new gaskets 23 5 4 Piston Rings 5 5 Crankcase 5 5 1 Removing the Crankshaft lt x lt x lt x gt gt gt isp LO Ko 8 lt lt lt z z z i o Remove the piston see 5 3 1 Remove the chain brake see 4 4 Use a screwdriver to rotate the and 4 5 spur gear clockwise until the Remove rings
60. r s pivot mount and engage the notch in the interlock lever arrow 034 036 036 QS 10 Electric Handle Heating System 034 036 10 1 Troubleshooting The entire handle heating system is maintenance free and subject to practically no wear Faults in the generator heating elements and wiring are generally caused by mechanical damage 138RA129 VA Important The heating element in the rear handle arrow may overheat and fail if it is not bonded firmly in position i e completely flat without creases There are two reasons for failures in the heating system a A break in the circuit due to a faulty wire or component b A short circuit resulting from damage to the insulation To trace the cause of a fault Remove the air filter see 12 1 034 036 036 QS 138RA130 VA 138RA133 VA Jake out handle molding Clip ohmmeter test leads to wires fastening screw and lift away 1 and 3 handle molding Remove the interlock lever 138RA132 VA 1 Wire from generator Set the heater switch to I 2 Wire to front handle heating element Note 3 amp 4 Wires of rear handle All electrical components of the heating element heating system are connected in series with the ohmmeter On machines with carburetor heating pull pin of wire from heating element out of round plug Slide back the insulating tube from pin and socket connector of wire 1 between generator and
61. r and cutting attachment see 4 1 Remove mounting screw 1 from inner side plate 2 and lift side plate away lt x gt Ko lt am Use a screwdriver to turn the spur gear clockwise until tensioner slide butts against the thrust pad Note Older machines are equipped with a front chain tensioner see 5 5 2 17 4 7 Bar Mounting Studs 148RA087 VA 138RA018 VA lt gt O lt oc oe oO Take out the cover plate Check that O ring is fitted in sour Remove chain sprocket cover mounting screw 1 gear and cutting attachment see 4 1 Remove the cover plate 2 with Lubricate O ring with a little oil Push stud puller 5910 893 0501 retainer 3 from the spur gear before fitting the spur gear over the collar stud as far as it will go Use a 15 mm wrench to Note unscrew the collar stud counter Coat teeth of adjusting screw and clockwise spur gear with grease see 13 2 before refitting Before installing coat thread of collar stud with LOCTITE see The adjusting screw and spur gear 13 2 must be replaced as a matching pair Install and tighten down the collar studs see Tightening Torques lt x gt ee lt o oo Pull out the spur gear 1 Take out the tensioner slide 3 with adjusting screw 4 and thrust pad 2 Inspect the teeth on the spur gear and adjusting screw remove thrust pad if necessary
62. readed sleeve over the crankshaft stub Hold the crankshaft steady and rotate the spindle counter clockwise to screw the threaded sleeve onto the crankshaft Release the crankshaft Hold the service tool 2 steady and continue turning the spindle until the tool locates against the guide lt lt gt gt O O g 5 lt L a Fs 8 Turn the spindle clockwise to pull Screw threaded sleeve 2 bar mounting face in the crankshaft until it locates 5910 893 2409 onto the spindle against the ball bearing of service tool AS 1 as far as it Fit the two hexagon nuts 3 on will go left hand thread the bar mounting studs and Important screw them down finger tight The connecting rod must point Lubricate crankshaft stub at toward the cylinder flange while the clutch side with oil crankshaft is being installed Fit crankcase gasket Remove service tool ZS First release the spindle counter Push the clutch side of the clockwise and then unscrew the crankcase over the crankshaft service tool ZS also counter stub as far as it will go clockwise Screw the spindle fully into service tool AS 5910 007 2205 in the clockwise direction lt x lt x gt gt a N ro ro lt lt am am o o ro oe Jo prevent the crankcase Turn the spindle counterclock and gasket twisting fit M5x72 wise until the crankshaft locates screws 1 from service tool against the ball bearing
63. requires no outside power source battery or dynamo A special flywheel with ring magnet for the generator is installed in models with handle or carburetor heating system 6 1 Ignition Lead Spark Plug Boot Remove the air filter see 12 1 Pull boot off the spark plug Remove the shroud see 4 3 Remove the ignition module see 6 5 1 Pull the ignition lead out of seat in crankcase 138RA087 VA Unscrew the ignition lead 1 from high voltage output on ignition module 2 Pull the insulating tube off the ignition lead Use a suitable pair of pliers to grip the leg spring and pull it out of the spark plug boot 034 036 036 QS Unhook the leg spring from the ignition lead and slip the spark plug boot off the lead Coat the end of the ignition lead and insulating tube about 20 mm with oil Fit spark plug boot over the lead Use a suitable pair of pliers to grip the end of the ignition lead inside the spark plug boot and pull it out lt x gt D oe So lt am oe Pinch the hook of the leg spring into the center of the lead i e about 15 mm from the end of the lead t Pull the lead back into the boot so that the leg spring locates properly inside it 366RA104 VA 034 036 036 QS Use a pointed tool to pierce the center of the other end of the ignition lead Slip the insulating tube over the ignition lead Screw the ignition
64. rew thread is stripped in one of the mounting holes for special self threading screws the tank housing can be repaired by installing a thread insert The stripped thread must be drilled out to a diameter of 8 5 mm and a depth of 15 mm Important Do not exceed the specified hole depth of 15 mm Fit M6x10 screw with washer in the thread insert 138RA215 VA Screw the thread insert into the tank housing Use an M6x18 pan head screw in place of the original special self threading screw In order not to damage the manifold when fitting it through the tank housing intake opening use the following procedure Wind a piece of string approx 15 cm long around the back of the manifold flange then press the manifold downward and pass the ends of the string through the intake opening 138RA042 VA Push the tank housing against the manifold and pull the ends of the string outward at the same time 034 036 036 QS 13 Special Servicing Tools and Aids 13 1 Special Servicing Tools No Application 1 Locking strip 0000 893 5903 Blocking the crankshaft 2 Press sleeve 1118 893 2401 Installing oil seal clutch side 3 Press sleeve 1121 893 2400 Installing oil seal ignition side 4 Puller 5910 890 4400 Removing oil seals 5 Jaws No 3 1 4 0000 893 3706 for clutch side only 6 Assembly sleeve 1118 893 4602 Oil seal clutch side 7 Puller 1110 890 4500 Removing flywheel 8 Crimping tool 5910
65. rned 59 Installing the prefilter 034 036 Slide the prefilter in the guides in the carburetor box cover and make sure its snaps into position Installing the main filter Assemble the two halves of the main filter Fit the filter over the two collar studs and tighten down the slotted nuts firmly see Tightening Torques Fit the carburetor box cover see also 4 3 and secure by turning the twist lock one quarter turn to the right 60 12 2 Troubleshooting chart see Standard Repairs Trouble shooting handbook Important In the case of problems with the carburetor or fuel supply system also check and clean the tank vent see 12 6 The carburetor can be tested for leaks with the carburetor and crankcase tester 1106 850 2905 148RA050 VA Remove the air filter see 12 1 Pull fuel hose off the carburetor s elbow connector lt gt N N lt aa op t Push fuel hose 1110 141 8600 1 onto one end of the nipple 0000 855 9200 2 Connect nipple to tester s pressure hose Leakage Testing the Carburetor lt gt N lt am o N Push fuel hose 1 with nipple 2 and tester 3 onto carburetor s elbow connector Close the vent screw on the rubber bulb Squeeze rubber bulb to pump air into the carburetor until the pressure gauge shows a reading of approx 0 4 bar If this pressure remains constant the
66. rol lever 64 138RA228 VA Place the gasket on the carburetor body Fit the metering gasket with the perforated plate 1 facing the inlet control lever Fit the end cover Note The gasket metering diaphragm and end cover are held in position by the pegs arrow on the carburetor body Insert the collar screws and tighten them down firmly 138RA182 VA Insert the fuel strainer at the pump side Fit the pump diaphragm gasket and end cover and tighten down firmly 138RA191 VA Note The pump diaphragm and gasket are held in position by the pegs arrow on the cover lt x gt D Te ro lt am Thoroughly clean the high speed screw 1 and low speed screw 2 Coat threads of screws not the first two or three turns with LOCTITE 221 see 13 2 Caution Do not apply adhesive to the first two or three turns of the screw threads Adhesive must not enter the carburetor Fit adjusting screws in the carburetor Carry out leakage test after installing carburetor 034 036 036 QS SS 138RA200 VA Removing the throttle shaft Unscrew the throttle shutter fastening screw and pull the shutter out of the throttle shaft 138RA192 VA Ease the E clip off the throttle shaft lt gt isp D lt am o oe Pull the throttle shaft out of the carburetor Remove the torsion spring Take out the idle
67. rques 138RA155 VA Remove the centering tool If necessary use the puller 1107 890 4500 to remove the centering tool from the crankshaft Install the ignition module see 6 5 1 Reassemble all other parts in the reverse sequence 11 Chain Lubrication 11 1 Pickup Body Impurities gradually clog the fine pores of the filter with tiny particles of dirt This prevents the oil pump from supplying sufficient oil to the bar and chain In the event of problems with the oil supply first check the oil tank and the pickup body Clean the oil tank if necessary 138RA156 VA Remove the oil filler cap and the cap retainer Drain the oil tank YNNN al W lt 4 138RA157 VA Use hook 5910 893 8800 to pull the pickup body out of the oil tank Note Do not stretch the oil hose too much during this operation 55 138RA158 VA Hold the oil hose steady and pull out the pickup body 138RA159 VA Use side cutters or similar tool to remove the strainer from the connector Important Always replace any damaged parts lt x gt o lt aa oe Flush out the oil tank Wash the strainer 2 and connector 1 in white spirit and blow out with compressed air Reassemble in the reverse sequence 56 11 2 Suction Hose 138RA161 VA Remove the pickup body see 11 1 Remove the oil pump see 11 4 Grip the tab of the suc
68. rs Trouble shooting handbook Remove the chain sprocket cover and cutting attachment see 4 1 Remove clutch drum chain sprocket see 4 1 lt gt O N O lt a 00 lt Remove mounting screw 1 from inner side plate 2 and lift side plate away Remove mounting screws 3 from cover 4 and lift the cover away Engage the chain brake by pushing the hand guard away from the front handle 034 036 036 QS Son RO J JTA N 148RA076 VA 148RA071 VA __ Carefully pry the brake spring 1 Carefully pry spring 1 off the Disconnect spring 1 from off the anchor pin and disconnect pivot pin lever 2 it from the lever 2 Pry the E clip 3 off the pivot pin and remove the lever with spring Clean all disassembled parts in white spirit Replace any worn or damaged parts Cy 148RA072 VA Remove the screw 1 Pull the hand guard 2 and brake lever 1 off the pivot pins Ease the brake band 2 out of its seat in the crankcase and disconnect it from the lever 3 lt x gt LO N O lt ao lt Remove screw with captive Disconnect brake cable 1 from washer from the hand guard the brake lever 2 Note Take the brake lever out of the When installing tighten down the hand guard screw with captive washer firmly see Tightening Torques 034 036 036 QS 13 4 5 2 Installing Tak S ns
69. seal to achieve a proper seal Always use the press sleeve for this operation Reassemble all other parts in the reverse sequence 5 6 Crankcase Leakage Test Defective oil seals and gaskets or cracks in castings are the usual causes of leaks Such faults allow supplementary air to enter the engine and thus upset the fuel air mixture This makes adjustment of the prescribed idle speed difficult if not impossible Moreover the transition from idle speed to part or full throttle is not smooth The crankcase can be checked thoroughly for leaks with the carburetor and crankcase tester 1106 850 2905 and the vacuum pump 0000 850 3501 5 6 1 Preparations Remove the shroud from the cylinder see 4 3 Take out the muffler upper casing mounting screws and remove the upper casing see 5 1 Loosen the muffler lower casing mounting screws about half way LALAN SAS U u n WNW Vaal lt x gt o So lt am o oe Fit sealing plate 0000 855 8106 from above and narrow end first between the muffler lower casing and cylinder exhaust port Note The sealing plate must completely fill the space between the two 034 036 036 QS 31 mounting screws Push the narrow end of the sealing plate home so that it is just below the lower casing Retighten the mounting screws moderately Remove the carburetor see 12 3 Set the piston to top dead cen
70. t x gt op lt oa o oe Pull out the rope with the starter grip and straighten it out Hold the starter grip firmly to keep the rope tensioned Let go of the rope rotor and slowly guide the starter grip back 42 so the starter rope can rewind properly Note The rewind spring is correctly tensioned when the starter grip sits firmly in the rope guide bush without drooping to one side If this is not the case tension the spring by one additional turn When the starter rope is fully extended it must still be possible to rotate the rope rotor at least another half turn before maximum spring tension is reached If this is not the case pull the rope out hold the rope rotor steady and take off one turn of the rope Do not overtension the rewind spring as this will cause it to break Fit the fan housing see 6 4 8 AV Handle System 8 1 Repair The crankcase and tank housing are connected by vibration damping rubber buffers Damaged rubber buffers annular buffers must always be replaced in sets Note When replacing annular buffers make sure you always install the latest type Annular buffers must be replaced in sets of the same hardness Harder buffers are installed for more accurate control but reduced vibration damping while softer butters provide better vibration damping To remove the annular buffers at the clutch side Remove the chain sprocket cover and cutting a
71. ter T D C This can be checked through the inlet port 148RA051 VA Remove screw 1128 855 9000 from test flange 1128 850 4200 Fit the test flange 1 number 1 facing up and flat side first on the carburetor studs While fitting the test flange make sure the impulse opening on the manifold flange is properly sealed see arrow Fit the two hexagon nuts 2 and tighten them down moderately 32 5 6 2 Pressure Test Preparations see 5 6 1 Check tightness of spark plug before starting leakage test If decompression valve is fitted make sure it is tight and closed Connect pressure hose 1 of tester 1106 850 2905 to nipple on test flange 2 148RA052 VA lt x gt Ke t i lt am SP Close the vent screw 1 on the rubber bulb Pump air into the crankcase with rubber bulb until the gauge indicates a pressure of 0 5 bar If this pressure remains constant for at least 20 seconds the crankcase is airtight However if the pressure drops the leak must be located and the faulty part replaced Then repeat the pressure test Note To find the leak coat the suspect area with oil and pressurize the crankcase Bubbles will appear if a leak exists Open the vent screw and disconnect the hose A pressure must always be followed by a vacuum test see 5 6 3 After finishing the tests reassemble all parts in th
72. the tank housing and is supported at two poinis The Master Control lever moves the switch shaft to select the required function The following positions can be selected with the Master Control lever lt x gt co lt oc oe STOP 1 closes short circuit contact and interrupts ignition RUN 2 normal operating position START 3 warm start Starting throttle choke shutter open CHOKE 4 cold start starting throttle choke shutter closed The cam on the left holds the connector sleeve of the short circuit wire and is also the stop for locking the Master Control lever in the RUN position 43 138RA096 VA In the STOP position the connector sleeve moves against the contact spring arrow 138RA117 VA The molded lever on the center of the switch shaft operates the throttle trigger when the START and CHOKE positions are selected 9 2 Throttle Trigger Interlock Lever 034 036 138RA120 VA Remove the air filter see 12 1 Take out the handle molding fastening screw Lift away the handle molding Move Master Control lever to RUN position Pull the throttle interlock lever out of its seat 138RA123 VA Use a5 mm drift to drive out the cylindrical pin 3 Take the throttle trigger 2 and torsion spring 1 out of the handle Install in the reverse sequence 138RA128 VA Note The torsion spring must be under the interlo
73. tion hose and pull it out of the crankcase 138RA162 VA Use a blunt tool to push the suction hose into the crankcase so that the tab locates it its seat at the bottom right Fit the pickup body see 11 1 Install the oil pump see 11 4 11 3 Vent Valve 148RA049 VA A valve 1 is installed in the tank wall to keep internal tank pressure equal to atmospheric pressure Remove the inner side plate see 4 2 Drain the oil tank Use a7 mm drift to carefully drive the vent valve 1 into the crankcase and take it out of the oil tank 1mm 138RA164 VA Carefully press in the new valve until it is about 1 mm below the face of the crankcase Fit the inner side plate see 4 2 034 036 036 QS 11 4 Removing and Installing the Oil Pump Remove the brake band see 4 4 1 and 4 5 1 Remove the clutch see 4 3 138RA165 VA Rotate the worm and drive spring clockwise and pull them off the crankshaft stub lt x gt Ko lt o oe Take out the oil pump mounting screws 034 036 036 QS Carefully pry the oil pump off its seat and lift it away 138RA168 VA Pull the ring 1 off the crankshaft stub and remove the washer 2 Note To remove the oil delivery hose it is necessary to pry the sleeve out of the bar mounting flange The hose is damaged in this process and must be replaced A new oil pump version is insta
74. to attach the the way and hold it in that brake spring 1 to the anchor pin position Fit cover over the chain brake see 4 5 1 Fit inner side plate see 4 5 1 Install the clutch drum chain sprocket see 4 1 Fit the cutting attachment and chain sprocket cover see 4 1 148RA070 VA Take out screw 1 and remove The brake band 1 must locate the side plate 2 without any play against the points A in the crankcase Take out screws 3 and remove the cover 4 gt SA IER lt lt x gt gt o gt N N co O O lt x lt x cc cc ee vt vt The brake cable 1 must hang Let go of the interlock lever 1 loosely in the crankcase when the brake is disengaged Check free travel by slowly squeezing the interlock lever 1 Play must be within the mark B at the front end of the interlock lever 034 036 036 QS 15 The brake lever must not move If it does adjust play see 4 5 4 Reassemble in the reverse sequence 16 4 5 4 Adjusting Play 148RA064 VA Open twist lock 1 and lift away the carburetor box cover 2 vertically 148RA084 VA Release and unscrew slotted nuts 1 Remove the air filter 2 lt gt To 00 So lt am Eo Loosen the self tapping screw 1 Use a 6mm open end wrench to adjust play with nut 2 Turn wrench to right to reduce play Turn wrench to left to increase pl
75. tor sleeve Important Check operation of the short circuit wire see 6 2 On machines with carburetor heating push the thermostatic switch s flag connector onto the contact spring Fit the tank vent see 12 6 Fit the air filter see 12 1 37 6 4 Flywheel Removing 6 4 1 138RA098 VA Take out mounting screws and remove the fan housing Rotate the flywheel so that the magnet poles are opposite the ignition module 138RA099 VA Use locking strip 0000 893 5903 to block the piston see 4 3 Unscrew the flywheel mounting nut from the crankshaft lt x gt 2 5 lt aa o oe Screw puller 1110 890 4500 into flywheel hub as far as stop Hold puller steady with a 24 mm wrench and use a 17 mm wrench to screw home the thrust bolt until the flywheel comes away from its seat on the crankshaft 38 Take off the flywheel Inspect the flywheel If you find any damage e g cracks broken fan blades fit a new flywheel Important If a new flywheel 1125 400 1208 is installed in a machine with heated handles X 31 813 247 the Original front handle must always be replaced by front handle 1125 790 1702 to take account of the higher power output In addition the new heating element 1128 434 5000 must be fitted in the rear handle since the heating elements may otherwise burn out The old front handle 1125 790 1707 and the old heati
76. ttachment see 4 1 Remove the chain catcher see 4 2 Use a screwdriver to remove the two plugs from the annular buffers 034 036 036 QS Take out the annular buffer mounting screws Use a screwdriver to pry the annular buffers out of their seats To remove the annular buffer at the ignition side Remove the carburetor box cover and shroud see 4 3 Installing new annular buffers Push the annular buffer washer first into the crankcase seat until groove 1 engages over the inner housing rib Insert the mounting screw and tighten it down firmly see Tightening Torques Lubricate the bead of the plug with oil and then push it into the annular buffer Reassemble all other parts in the reverse sequence Remove the fan housing see 6 4 Use a screwdriver to ease the plug 1 out of the annular buffer Take out the annular buffer mounting screw Use a screwdriver to pry the buffer out of its seat Note The tank housing has to be removed see 12 8 1 to replace the stop buffer Take out the stop buffer and fit a new one Install the tank housing see 12 8 1 034 036 036 QS 9 Master Control 9 1 Construction and Function The main part of the Master Control is the switch shaft with an integrally molded multi function operating lever a molded cam and a second lever The switch shaft located forward of the rear handle in
77. wls Starter Rope Rope Guide Bush 40 Rewind Spring 41 Replacing the Rewind Spring 034 41 Replacing the Rewind Spring 036 036 QS 41 Tensioning the Rewind Spring 42 AV Handle System 42 Repair 42 Master Control 43 Construction and Function 43 Throttle Trigger Interlock Lever 034 036 44 Throttle Trigger Interlock Lever Switch Lever 036 QS 45 Switch Shaft 46 Electric Handle Heating System 034 036 47 Troubleshooting 47 Troubleshooting Chart 49 Test Connections and Test Values 50 10 2 Heater Switch 51 10 3 Heating Element in Rear Handle 51 10 4 Heating Element in Front Handle 53 10 5 Generator 54 10 5 1 Removing 54 10 5 2 Installing 55 11 Chain Lubrication 55 Pickup Body 55 Suction Hose 56 Vent Valve 56 Removing and Installing the Oil Pump 57 11 5 Servicing the Oil Pump 58 12 Fuel System 59 12 1 Air Filter 59 12 2 Leakage Testing the Carburetor 60 12 3 Removing and Installing the Carburetor 61 12 4 Servicing the Carburetor 62 12 5 Adjusting the Carburetor 66 12 6 Tank Vent 67 12 7 Fuel Filter and Fuel Hose 68 12 8 Tank Housing 69 12 8 1 Removing and Installing 69 13 Special Servicing Tools and Aids 71 13 1 Special Servicing Tools 71 13 2 Servicing Aids 72 STIHL 2001 Andreas Stihl AG amp Co Waiblingen 1 1 Introduction This service manual contains detailed descriptions of all the repair and servicing procedures specific to this series of chain sa
78. ws There are separate handbooks for servicing procedures on standardized parts and assemblies that are installed in several STIHL power tool models Reference is made to these handbooks in the appropriate chapters of this manual You should make use of the illustrated parts lists while carrying out repair work They show the installed positions of the individual components and assemblies Refer to the latest edition of the relevant parts list to check the part numbers or any replacement parts Parts lists on microfiche and CD ROM are always more up to date than printed lists A fault on the machine may have several causes To help locate the fault consult the troubleshooting charts for all assemblies in the Standard Repairs Trouble shooting handbook Refer to the Technical Information bulletins for engineering changes which have been introduced since publication of this service manual Technical information bulletins also supplement the parts list until a revised edition is issued The special servicing tools mentioned in the descriptions are listed in the last chapter of this manual Use the part numbers to identify the tools in the STIHL Special Tools manual The manual lists all special servicing tools currently available from STIHL symbols are included in the text and pictures for greater clarity The meanings are as follows In the descriptions Action to be taken as shown in the illustrati

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