Beruflich Dokumente
Kultur Dokumente
7.1 Compression
2 Safety Precautions 3 Pressure 27 12 Special Servicing
7.2 Checking / Adjusting Tools 51
Valve Clearances 27
3 Specifications 4 7.3 Rocker Arms /
Pushrods 29
3.1 Engine 4 7.4 Cam Followers 30
3.2 Spark Plug 4 7.5 Cam Gear 30
3.3 Carburetor 4 7.5.1 Decompression
3.4 Tightening Torques 5 System 31
7.6 Muffler / Spark
Arresting Screen 31
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4 Troubleshooting 6 7.7 Clutch 32
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7.7.1 Removing and
4.1 Clutch 6 Disassembling 32
4.2 Rewind Starter 7 7.7.2 Assembling and
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4.3 Ignition System 8 Installing 33
4.4 Carburetor 9 7.7.3 Clutch Drum 34
4.5 Engine 11 7.7.4 Clutch Drum Bearing 35
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7.8 Flywheel 35
7.9 Crankshaft 36
5 Rewind Starter / 7.9.1 Replacing the Oil
Shroud 13
7.9.2
Seals fo
Crankcase, Lower
36
8 Ignition System 44
6 Fuel System 18
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This service manual contains Symbols are included in the text and
detailed descriptions of all repair pictures for greater clarity.
and servicing procedures specific to The meanings are as follows:
this powerhead.
In the descriptions:
You should make use of the
illustrated parts lists while carrying = Action to be taken as 1
out repair work. They show the shown in the illustration
249RA!63 VA
installed positions of the individual (above the text) 2
components and assemblies.
– = Action to be taken that is
Refer to the latest edition of the not shown in the illustration
relevant parts list to check the part (above the text) Servicing and repairs are made
numbers or any replacement parts. considerably easier if the machine
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In the illustrations: is mounted on assembly stand (2)
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Refer to the "Technical Information" 5910 890 3100 with the aid of clamp
bulletins for engineering changes Pointer (1) 5910 890 8800.
which have been introduced since The powerhead can then be
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publication of this service manual. Direction of movement swivelled to the best position for the
Technical information bulletins also ongoing repair. This leaves both
supplement the parts list until a Service manuals and all technical hands free.
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revised edition is issued. Information bulletins are intended
exclusively for the use of STIHL Always use original STIHL
The special servicing tools servicing dealers. They must not be replacement parts.
mentioned in the descriptions are
listed in the last chapter of this
passed to third parties. fo They can be identified by the
STIHL part number,
manual. Use the part numbers to the 67,+logo and the
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identify the tools in the "STIHL STIHL parts symbol
Special Tools" manual. This symbol may appear alone on
small parts.
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On
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Warning!
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Do not smoke or bring any fire,
flame or other source of heat near
the fuel. All work with fuel must be
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performed outdoors only. Spilled
fuel must be wiped away
immediately.
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On
3.1 Engine STIHL single cylinder four-stroke engine with gasoil mixture lubrication
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ball bearings, needle cages on
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small and big ends, plain bearings
on piston pin
Piston pin diameter: 8 mm
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Clutch: Centrifugal clutch, two clutch shoes
without linings
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Clutch engages at: 3,700 rpm
DG 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 Thread size For component Torque
Nm
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Collar nut M8 Filter housing/Carburetor 3.5
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Spline screw IS-M5x24 Shroud/Cylinder 6
Collar screw M5x16 Rocker lever collar screw/Cylinder 9
Spline screw IS-DG5x24 Engine pan/Cylinder 9
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Spline screw IS-M5x24 Fan housing/Shroud/Engine pan 6
Spline screw IS-M5x24 Fan housing/Engine pan 6
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Spline screw IS-DG5x24 Muffler/Cylinder 9
Nut M8x1 Flywheel/Crankshaft 17
Spline screw
Spline screw
IS-DG5x24
IS-DG5x24
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Starter cover/Cover/Engine pan
Starter cover/Tank/Engine pan
6
6
Nut M8x1 Starter cup/Crankshaft 17
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Spline screw IS-M5x30 Valve cover/Cylinder 3.5
Spline screw IS-D5x32 Spacer flange/Cylinder 9
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– Place the screw in the hole and rotate it counterclockwise until it drops down slightly.
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This procedure ensures that the screw engages properly in the existing thread and does not form a new
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Note:
Power screwdriver settings for polymer:
Tool stops at full throttle Clutch badly worn Fit new clutch
under load
Tool runs at idle speed Idle speed too high Readjust idle speed screw
(counterclockwise)
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Clutch springs stretched or Fit new clutch
fatigued
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Spring hooks broken Fit new clutch
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On
Starter rope broken Rope pulled out too vigorously as Fit new starter rope
far as stop or over edge, i.e. not
vertically
Rewind spring broken (starter rope Spring overtensioned – no reserve Fit new rewind spring
does not rewind) when rope is fully extended
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Very dirty or corroded Clean rewind spring or
fit a new one
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Starter rope can be pulled out Guide peg on pawl or pawl itself Fit new pawl
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almost without resistance is worn
(crankshaft does not turn)
Spring clip fatigued Fit new spring clip
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Starter rope is difficult to pull and Starter mechanism very dirty Thoroughly clean complete starter
rewinds very slowly (dusty conditions) mechanism
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Warning:
Exercise extreme caution while The high voltages which occur can
carrying out maintenance and cause serious or fatal injuries!
repair work on the ignition system.
Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug,
temporary low of power and fit a new leg spring if necessary
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Weak spark or no spark Faulty insulation on ignition lead or
short circuit wire. Use ohmmeter to
check ignition lead for break. If
break is detected or resistance is
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high, fit new ignition lead.
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Wrong air gap between ignition coil Reset air gap
and flywheel
Carburetor floods, engine stalls Inlet needle not sealing. Foreign Remove and clean or replace inlet
matter in valve seat or cone needle, clean fuel tank, pickup
damaged body and fuel line if necessary
Helical spring not located on nipple Remove inlet control lever and refit
of inlet control lever correctly
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Perforated disc on diamphragm is Fit new metering diaphragm
deformed and presses constantly
against inlet control lever
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Inlet control lever too high (relative Set inlet control lever flush with
to design position) upper face of housing or bottom of
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metering chamber
Poor acceleration Idle jet too lean Back off low speed screw slightly
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Main jet too lean Back off high speed screw slightly
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Inlet control lever too low (relative Set inlet control lever flush with
to design position) upper face of housing or bottom of
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metering chamber
Inlet needle sticking to valve seat Remove inlet needle and clean
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valve seat
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Engine will not idle, Throttle shutter opened too wide by Reset idle speed screw (LA)
idle speed too high idle speed screw
Engine stalls at idle speed Idle jet bores or ports blocked Clean jet bores and ports and blow
clear with compressed air
Idle jet too rich Screw dow low speed screw (L)
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slightly
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Setting of idle speed screw Set idle speed screw (LA) correctly
incorrect – throttle shutter
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completely closed
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Engine speed drops quickly under Air filter plugged Clean air filter
load – low power
Tank vent faulty
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necessary
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Leak in fuel line between tank and Seal or renew connections and fuel
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– Air filter
– Fuel system
– Carburetor
– Igniton system
Engine does not start easily, stalls Check compression Check combustion chamber
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at idle speed, but operates normally for excessive build-up of
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at full throttle combustion deposits, check
conditon of valves and valve
clearance
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Gasket on carburetor spacer flange Install new gasket
leaking
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Decompression lever sticking Install new cam gear
Muffler carbonized
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necessary
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Engine does not deliver full power Secondardy air seepage through Install new gaskets
or runs erratically faulty gaskets on spacer flange
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Engine overheating Insufficient cylinder cooling. Thoroughly clean all cooling air
Air inlets in fan housing passages and cooling fins
blocked or cooling fins on
cylinder very dirty
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On
249RA001 VA
and cause the spring windings to The spring will not be under tension
stick together. This has a if the starter rope is broken.
detrimental effect on the function of
the starter mechanism. In such a – Pull out the starter rope about
case it is sufficient to clean the Remove the screws (arrows) 20 cm (8") and hold the rope rotor
rewind spring with a standard from the rewind starter. steady.
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commercial cleaner and then coat it
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with resin-free oil. – Lift away the rewind starter.
Pull out the starter rope several
times and allow it to rewind until its Reassemble in the reverse
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normal smooth action is restored. sequence.
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6 Nm.
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249RA154 VA
1
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249RA141 VA
249RA025 VA
249RA027 VA
2
To remove the rope rotor, ease Installing: – Fit the pawl and washer. Engage
the spring clip (1) out of the spring clip in the groove on the
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groove in the starter post. Coat bore in rope rotor with STIHL starter post.
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special lubricant – see 11.
Remove the washer (2) and Note:
pawl (3). Fit the rope rotor on the starter The spring clip (1) must engage the
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post so that the driver (1) on the guide peg (2) on the pawl and point
rotor slips behind in the inner it counterclockwise.
spring loop (2).
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Handle the spring clip with care.
Note: The rewind starter may not function
Turn the rope rotor a little and let it properly if the spring clip is
1
go. It must spring back. fo deformed.
249RA028 VA
249RA029 VA
2
– Thread the other end of the rope Pull the rope back into the rotor
through the guide bush (2) from so that the knot locates in the
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outside. recess (1).
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– Thread the rope through the hole – Tension the rewind spring –
in the side of the rope rotor (1). see 5.4.1.
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Pull out the rope and secure it
with a simple overhand knot.
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249RA155 VA
249RA156 VA
Hold the rope rotor steady. Note:
The starter grip must sit firmly in the
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Pull out the rope with the starter rope guide bush without drooping to
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grip and straighten it out. one side. If this is not the case,
tension the spring by one additional
– Hold the starter grip firmly to keep turn.
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the rope tensioned.
When the starter rope is fully
– Let go of the rope rotor and extended, it must still be possible to
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slowly release the starter grip so rotate the rope rotor at least another
that the rope winds itself onto the half turn before maximum spring
rotor. tension is reached. If this is not the
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rope rotor steady and take off one
turn of the rope.
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249RA153 VA
249RA004 VA
249RA031 VA
Wear face protection and gloves to
reduce the risk of injury.
2
– Remove the spring housing and
Ease the spring clip (1) off the parts of the spring. – Remove the rewind starter –
starter post. see 5.2.
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– Lubricate the new spring with a
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Note: few drops of resin-free oil. Take out the screws (1 and 2).
Do not take the rope rotor off the
starter post. Carefully pull off the spark plug
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boot (3) vertically.
Pull the pawl (2) out of the rope
rotor.
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– Lubricate peg of new pawl with
graphite grease – see 11. 1
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249RA143 VA
249RA003 VA
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Position the new spring housing Take out the screw (1).
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(arrows) and push home. pull the spark plug boot through the
shroud at the same time.
– Install the rope rotor – see 5.3.
Install in the reverse sequence.
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Dirty and clogged air filters reduce Troubleshooting chart – see 4.4.
engine power, increase fuel 1 2
consumption and make starting Important:
more difficult. In the event of trouble with the
carburetor or the fuel supply
Note: system, always check and clean the
The air filter must be cleaned when tank vent – see 6.4.
there is a noticeable loss of engine
249RA007 VA
power. The carburetor can be tested for
leaks with the carburetor and
– Close the choke shutter. crankcase tester 1106 850 2905.
– Clean away any loose dirt from Take out the screws (1 and 2). – Remove the air filter – see 6.1.
around the filter and filter cover.
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– Remove the air filter housing. – Open the tank filler cap to relieve
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pressure.
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1
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249RA008 VA
249RA005 VA
249RA009 VA
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Loosen the slotted screw (1) and Remove the paper gasket (1) and Pull fuel hose (1) off carburetor’s
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lift away the filter cover. fit a new one. elbow connector.
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143RA172 VA
249RA006 VA
3 2
249RA012 VA
249RA010 VA
249RA013 VA
2 1
Push the fuel hose (1) with Close the vent screw (1) on the – Remove the air filter – see 6.1.
nipple (2) onto the carburetor rubber bulb.
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elbow connector. Pull the fuel hoses (1 and 2) off
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Pump air into the carburetor with the elbow connectors.
– Push the nipple into the tester's* the rubber bulb (2) until the
pressure hose (*carburetor and pressure gauge (3) shows a
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crankcase tester 1106 850 2905). reading of approx. 0.8 bar.
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the carburetor is airtight.
249RA014 VA
Reassemble all other parts in the
reverse sequence. 2
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there are two possible causes: (1) from slotted pin (2) on the
throttle lever.
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sticking).
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249RA016 VA
249RA017 VA
249RA108 VA
249RA110 VA
Pull carburetor off the studs. – Remove the shroud – see 5.7. Remove the flange.
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– Perform leakage test – see 6.2.1.
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Take out the screws (1).
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– Remove end cover with rubber
pump bulb (2).
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1
249RA111 VA
249RA018 VA
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sequence.
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On
249RA109 VA
1
1 1 2
2
249RA112 VA
249RA114 VA
249RA126 VA
– Remove the flange – see 6.3.1. Place the metering diaphragm (1) – Remove the metering diaphragm
on the gasket. – see 6.3.2.
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Remove metering diaphragm (1)
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and gasket (2) from the Note: Remove the round head
carburetor body. The cutout in the metering screw (1).
diaphragm (2) must line up with
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Note: the compensating bore in the
If the gasket and diaphragm are carburetor and the gasket.
stuck together, separate them
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carefully. To assemble all other parts –
see 6.3.1.
Check the diaphragm and gasket 1
and replace if necessary. fo
Note:
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The diaphragm is the most delicate
249RA127 VA
part of the carburetor. It is subjected
to continuous alternating stresses
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2 Important:
Make sure the inlet needle and
spring are properly seated.
On
249RA113 VA
Note:
The cutout in the gasket (2) must
line up with the compensating bore
in the carburetor.
2
1
1
1 1
2
249RA128 VA
249RA115 VA
249RA117 VA
– Remove the metering diaphragm – Remove the carburetor – Remove the gasket and pump
– see 6.3.2. see 6.2.2. diaphragm.
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Use a suitable screwdriver to Take out the screws (1). Note:
unscrew the fixed jet (1). If the gasket and diaphragm are
Remove the end cover (2). stuck together separate them
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Reassemble in the reverse carefully.
sequence.
Check diaphragm and gasket
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Important: and replace if necessary.
Take care not to damage the fixed
jet with the screwdriver during Note:
assembly and installation. 1
2
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part of the carburetor. It is subjected
to continuous alternating stresses
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and the material eventually shows
249RA116 VA
replaced.
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On
249RA118 VA
1
5
4
2 3
2
249RA024 VA
249RA121 VA
249RA119 VA
1 1
Remove the gasket (1) and pump Note: – Check the air filter and replace if
diaphragm (2). Gasket (1) and pump diaphragm (2) necessary.
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are held in place by the cast pegs on
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Reassemble in the reverse the end cover (5). – Clean the spark arresting screen
sequence. (if fitted) and replace if necessary.
Install the spring (4) and spring
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retainer (3) in the housing base – Start the engine and allow it to
(5). Fit the diaphragm (2) and warm up.
gasket (1) and screw the
Use the idle speed screw LA (1)
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assembly to the carburetor.
3 to adjust engine idle speed.
Note:
2
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The spring retainer’s integrally cast
spring guide points toward the
Turn clockwise to increase
engine speed.
spring (4).
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Turn counterclockwise to reduce
249RA120 VA
The pump diaphragm (1) and move. Then back off the screw
gasket (2) are held in position by the one quarter turn.
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Note:
If you use a tachometer, note that
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2
1 270°
249RA129 VA
249RA161 VA
249RA160 VA
1 2
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If the carburetor has to be adjusted against their seats. they are damaged during the
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from scratch, first carry out the removal process.
standard setting. Now make the following
adjustments: Fit new cap for high speed screw
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Push the puller 5910 890 4501 (H) so that is positioned against
(1), with the groove facing you, Open the high speed screw H (1) the stop (arrow).
between the limiter cap (2) and two full turns so that the limiter cap
Push cap home as far as the
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carburetor body and pry the cap can be fitted.
off. If the limiter cap is stuck on carburetor body.
the adjusting screw, turn the Open the low speed screw L (2)
puller over so that its groove
faces the carburetor body. Pry off
one full turn. fo
the limiter cap.
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Corrections using the high speed
screw:
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Note:
Corrections to the setting of the
high speed adjusting screw affect
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Note: Correct operation of the carburetor The diaphragm pump draws fuel out
It no tachometer is available, do not is only possible if atmospheric of the tank and into the carburetor
turn the high speed or low speed pressure and internal fuel tank via the fuel hose. Any impurities
screws beyond the standard setting pressure are equal at all times. This mixed with the fuel are retained by
to make the mixture leaner. is ensured by the tank vent. the pickup body. The fine pores of
the pickup body eventually become
– Check the air filter and replace if Important: clogged with minute particles of dirt.
necessary. In the event of trouble with the This restricts the passage of fuel
carburetor or the fuel supply and results in fuel starvation.
– Check the spark arresting screen system, always check and clean the
and clean or replace if necessary. tank vent. Check function by
performing pressure and vacuum
– Run the engine until it is warm. tests on fuel tank via the fuel hoses.
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– Adjust idle speed correctly (tool
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must not run) – see 6.3.6.
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clockwise for leaner mixture at
high altitudes or counter-
clockwise for richer mixture at
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sea level.
249RA033 VA
249RA032 VA
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Note:
A correction at the low speed screw
(L) usually necessitates a change in – Pull both fuel hoses off the Important:
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the setting of the idle speed screw carburetor. In the event of trouble with the fuel
(LA) – see 6.3.6. supply system, always check the
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– Seal one of the two fuel hoses fuel tank and the pickup body first.
with a suitable plug. Clean the fuel tank if necessary.
the tank. If the tank vent does not – Pour a small amount of clean
operate properly, replace it with gasoline into the tank and shake
the round gasket. the unit vigorously.
On
Note:
Dispose of fuel properly at approved
disposal site.
249RA035 VA
– Pull the fuel hoses off the
1 carburetor – see 6.2.2.
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Pry the grommet out of the fuel
tank.
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1
1 fo
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249RA159 VA
249RA036 VA
249RA038 VA
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2 3
Use the hook 5910 893 8800 (1) Remove the fuel hoses with the Pry the fuel hose (2) with pickup
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to pull the pickup body out pickup body. body out of the tank.
through the tank filler opening.
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Install in the reverse sequence. Remove the tank vent (1) with
Note: gasket.
Do not over-stretch the suction
hose. Unscrew the fuel filler cap (3) and
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249RA037 VA
– Pull the pickup off the suction Mark on fuel hose grommet must
hose. line up with mark on tank.
Note:
Check and adjust valve clearances
only when engine is cold.
249RA138 VA
249RA039 VA
2
1
Pull out the fuel tank with sleeves – Pull off the spark plug boot.
(1 and 2).
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– Unscrew the spark plug.
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Screw compression tester
5910 850 2000 (1) into the spark
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plug hole.
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– Set choke shutter to open.
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– Pull starter rope vigorously and
quickly several times.
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– Note compression pressure.
249RA040 VA
249RA041 VA
Note:
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sequence.
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2
On
249RA042 VA
1
2
249RA130 VA
249RA046 VA
249RA044 VA
1
Rotate the crankshaft until the – Rotate crankshaft counter- Rotate crankshaft clockwise until
arrow (1) is in line with the screw clockwise until the piston butts cam lobe points downward.
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(2) on the right-hand side of the against the locking screw.
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ignition module.
Remove the hex. nut (1).
Important:
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Check and adjust valves only when Remove the starter cup (2).
they are cold.
– Remove the locking screw.
2
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Note:
Observe rocker arms while rotating
the fanwheel up to the mark. If the
valves are operated by the rocker
arms in this position (valve overlap),
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rotate the crankshaft another turn
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until the valves are idle and the
249RA130 VA
arrow (1) lines up with the screw (2).
Make sure the valves are not
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adjusting instructions.
1 2 3 4
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1
On
249RA045 VA
249RA152 VA
249RA043 VA
Fit locking screw (1) Take out the screws (arrows). Marks (arrows) on (2 and 3) must
4180 890 2700 in spark plug line up with the notches (1 and 4)
hole. Carefully lift away the cam gear in the cylinder.
cover (1).
2 3 1
2
1
249RA048 VA
249RA053 VA
249RA049 VA
1
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before checking and adjusting valve Valve clearance is adjusted with the – see 7.2.
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clearances. locknuts (1 and 2).
Remove the locknut (1).
Insert feeler gauge To increase valve clearance: Turn
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4180 893 6400 (2) between nut counterclockwise
rocker arm and valve stem.
To reduce valve clearance: Turn nut
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Note: clockwise
The feeler gauge must slip through 1
with a certain resistance. – Turn engine over several times
249RA054 VA
sequence.
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Important:
Follow maker's instructions.
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4.5 Nm.
249RA055 VA
1 2
2 1
1
2
249RA056 VA
249RA057 VA
249RA058 VA
Take out the pushrod (1). – Remove the pushrods – – Remove the cam followers
see 7.3. – see 7.4.
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Reassemble in the reverse
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sequence. Pull out the pin (1). Pull out the pin (1).
Important: Remove the cam followers (2). Remove the cam gear (2).
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Make sure that the pushrod is firmly
seated in the rocker arm and cam Install in the reverse sequence. Install in the reverse
follower. sequence.
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Note:
– Adjust valves – see 7.2. Make sure the left-hand cam
follower is installed first. It controls
the inlet valve. fo
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1 2 3 4
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On
249RA152 VA
249RA050 VA
249RA059 VA
249RA140 VA
Install the pin (1). – Remove cam gear cover – Remove the rewind starter –
– see 7.2. see 5.2.
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Important:
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The marks must not move out of Check free movement and – Remove the shroud – see 5.7.
position while the cam gear is being function of decompression
fitted. system lever (arrow). Take out the screws (arrows).
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– Lever must project about 2 mm Remove the cover (1).
– Install cam followers – see 7.4. from cam.
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– Push decompression system
lever counterclockwise. The lever
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must move freely and retract fully.
Note:
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If the lever is difficult to move, worn
or not visible, install a new cam
gear.
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On
249RA051 VA
249RA052 VA
Use a screwdriver to lift up and Remove the exhaust gasket (1).
pull out the spark arresting
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screen (if fitted). Reassemble in the reverse
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sequence.
– Clean the spark arresting screen
or, if necessary, install a new one. – Use a new exhaust gasket.
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To remove the muffler, take out – Tighten down muffler mounting
the screws (arrows). screws to 9 Nm.
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– Tighten down cover screws to
4.5 Nm.
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249RA060 VA
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Caution:
Support engine while removing the
screw.
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On
100%
145RA006 VA
249RA061 VA
80% ! 1 3 2
Inspect the clutch drum. There Take out the clutch shoe screws Attach spring to clutch shoes.
should be no scores or signs of (1 and 2).
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excessive wear.
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Remove the cover plate (3).
Important:
If there are signs of serious wear on
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the inside diameter of the clutch
drum, check the remaining wall
thickness. If it is less than about
1
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80% of the original thickness, fit a
new clutch drum – see 7.7.3.
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249RA063 VA
249RA065 VA
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1 2
Remove the clutch shoes (1) Place cover plate (1), with "1"
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together with the spring (2) and facing up, on the flywheel.
lower cover plate.
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1 1
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2
On
249RA064 VA
249RA066 VA
Remove the spark plug. Fit the Tilt the clutch shoes and unhook Fit sleeves (1 and 2) on cover
locking screw 4180 890 2700. the spring. plate and press into the flywheel.
Rotate the crankshaft counter-
clockwise until the piston butts Important:
against the locking screw. Clutch shoes must always be
replaced in pairs.
1 1
2 1
2
249RA135 VA
249RA067 VA
249RA070 VA
Fit corrugated washers (1 and 2). Fit screws (1 and 2) and tighten – Remove the engine – see 7.7.1.
down to 12 Nm.
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Remove retaining ring (1) at tool
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end.
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249RA060 VA
249RA136 VA
249RA068 VA
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Fit clutch shoes with lettering – Marry engine to tool. Insert extension 4180 893 4400
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direction of engine.
249RA137 VA
249RA071 VA
hydrocarbons – see 11.
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Remove the hex. nut (1).
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Remove the retaining ring (1).
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ball bearing in the direction of the
engine.
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Reassemble in the reverse
sequence.
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249RA074 VA
249RA072 VA
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3 1 2
Mount puller (1) 4119 890 4501 Fit the flywheel in position.
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seated.
Key (1) in flywheel must engage
slot in crankshaft stub.
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On
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249RA073 VA
249RA071 VA
2 1
Flywheel (1) and magnet poles (2) Fit hex. nut (1) and torque down
must show no signs of cracks or to 17 Nm.
other damage.
If this is the case, install a new – Install the clutch – see 7.7.2.
flywheel.
249RA044 VA
– see 5.2. with grease – see 11.
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Remove the starter cup (2).
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249RA075 VA
249RA080 VA
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– Use combination wrench Apply puller 5910 890 4400 (1) Slip installing sleeve
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4180 890 3400 to remove the with No. 3.1 jaws and clamp the 4112 893 2400 (1) over the end
spark plug. arms. of the crankshaft.
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Important:
Take special care not to damage the
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crankshaft stub.
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On
249RA081 VA
Important:
Closed side of oil seal must face
rewind starter.
249RA082 VA
249RA076 VA
249RA083 VA
Press home the oil seal (1) with Apply puller 4112 890 4502 (1) Slip installing sleeve
press sleeve 1115 893 4600 (2) with No. 3.1 jaws (2) and clamp 4112 893 2400 (1) over the end
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so that it is flush with the the arms. of the crankshaft.
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crankcase.
Pull out the oil seal. – Lubricate sealing lips of oil seal
Remove the installing sleeve (2) with grease – see 11.
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and press sleeve (1).
Important: Apply thin coating of sealant to
Take special care not to damage the outside diameter of oil seal
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– Fit the starter cup on the crankshaft stub. – see 11.
crankshaft.
Flywheel side
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249RA084 VA
– see 7.7.1.
Important:
Closed side of oil seal must face
flywheel.
249RA085 VA
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so that it is flush with the
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crankcase.
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– Fit the flywheel – see 7.8.
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– Install the clutch – see 7.7.2.
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– Fit the shroud – see 5.7.
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crankcase – see 7.9.2.
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Tighten down screws (arrows) in – If one of these parts is damaged,
crosswise pattern to 9 Nm. install a new crankshaft
assembly.
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– Coat piston and piston rings with
oil.
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– Fit piston rings so that their gaps
are offset 120 degrees.
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– Lubricate sealing lips of oil seal
249RA086 VA
Important:
Wear safety glasses when working
with spring washers and snap rings.
249RA130 VA
249RA089 VA
1
– Carefully fit piston in the cylinder. Use the assembly drift (2)
1110 893 4700 to push the piston
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– Install the crankshaft with new oil pin (1) out of the piston.
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seals.
Note:
– Fit lower half of crankcase If the piston pin is stuck, tap the end
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– see 7.9.2. of the drift lightly with a hammer if
necessary. Hold the piston steady to
– Fit the flywheel – see 7.8. ensure that no jolts are transmitted
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to the connecting rod.
Rotate flywheel until mark (1) is in
line with screw head (2).
of the groove.
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249RA091 VA
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– Reassemble in the reverse Note: Push the large slotted diameter of
sequence. Use installing tool 5910 890 2206 to the sleeve over the magnet and
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fit the snap ring – see 12. snap ring. Position the sleeve so
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Indentation (arrow) in piston If installing tool 5910 890 2208 is that the inner pin (1) points
crown faces the spark plug hole. available, it can equipped with a towards the flat face (2) of the
new sleeve 5910 893 1703 and tool’s shank.
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used for this operation.
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249RA145 VA
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2 1
Attach the snap ring (1) to the Remove the sleeve and slip it
magnet (2) so that the snap ring onto the other end of the shank.
gad is on the flat side of the tool’s
shank. Note:
Inner pin must point towards flat
face.
249RA149 VA
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steady, center the tool shank
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exactly and press home until the
snap ring slips into the groove.
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249RA094 VA
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Fit the snap ring so that its gap is on scrape the grooves clean. Do not mix up the inlet and exhaust
the piston’s vertical axis (it must valves.
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hole.
– Remove the piston – see 7.9.4. – Install the piston – see 7.9.4.
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249RA022 VA
Inspect seats on valve heads (1 Remove gasket (1) from the
and 2) and replace parts as cylinder head.
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necessary.
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Reassemble in the reverse
– Inspect valve seats in cylinder sequence.
head and valve heads for any
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damage. Replace if necessary. – Use a new gasket.
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properly in groove of valve stem. 4
Reassemble in the reverse 1
sequence. fo 2
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3
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Take out the screws (1 and 2). Tighten down the screws (1 and
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2) to 9 Nm.
Remove spacer flange (3) and
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2
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249RA023 VA
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Troubleshooting on the ignition
system should always begin at the
spark plug – see 4.4.
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about 15 mm from the end of the
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lead.
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2 fo
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145RA170 VA
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Note: Use suitable pliers to pull the leg Pull the lead back into the boot so
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The electronic (breakerless) ignition spring out of the spark plug boot. that the leg spring locates
system basically consists of an properly inside it.
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ignition module (1) and flywheel (2). – Unhook the leg spring from the
ignition lead. Reassemble in the reverse
sequence.
– Push the spark plug boot back a
er
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still show the system to be in order
although timing is outside the 2
1 permissible tolerance. This will
impair engine starting and running
The ignition module accommodates behavior. – Remove the shroud – see 5.7.
all the components required to
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control ignition timing. Disconnect throttle cable nipple
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(1) from the slotted pin (2) on the
Three are three electrical throttle lever.
connections on the coil body:
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High voltage output with ignition
lead (1)
32 1
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Connector tag (2) for the short-
circuit wire
249RA097 VA
Accurate testing of the ignition
module is only possible with special
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test equipment.
For this reason it is only necessary
to carry out a spark test in the Pry the cable (1) out of the spacer
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workshop. flange.
A new ignition module must be
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2
3
249RA060 VA
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249RA099 VA
1
Take out screw (1) on fan housing Slide the setting gauge Insert screwdriver in slot (arrow),
and lift away the engine. 4118 890 6401 (2) between the press it down and push slide in
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arms of the ignition module (1) direction of engine.
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Important: and the flywheel (3).
Support the engine while removing
the screw. – Press the ignition module against
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the setting gauge.
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Reassemble all other parts in the
reverse sequence.
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Warning!
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handle is open.
2
On
249RA098 VA
Remove the torsion spring. Take tensioner out of guide and Remove the torsion spring.
remove the throttle cable.
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Reassemble in the reverse
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sequence.
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protective tube are correctly
positioned.
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1 – Tighten down screws to 1.0 Nm.
Remove throttle trigger (1) with Lift the interlock lever (1) a little
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attached throttle cable (2) from and turn it to the side until the
the pivot. torsion spring (2) is relieved of
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tension.
Note:
Throttle lever must butt against the
stop on the carburetor cover when
the throttle trigger is squeezed as
1 far as stop (full throttle), and butt
against the idle speed screw (LA)
when the throttle trigger is in the idle
position.
– Remove the carburetor – – Remove the shroud – see 5.7. – Remove the interlock lever –
see 6.2.2. see 9.1.
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– Adjust idle speed screw correctly.
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Swing tensioner (1) vertically Pull slide control off the handle
upwards and pull it off forwards. molding.
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Reassemble in the reverse
sequence.
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2
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3
249RA123 VA
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4
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249RA106 VA
2 1 1 2
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Take out the switch (1). – Remove the engine – see 7.7.1. Note:
Jaws must engage cutouts in the
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Reassemble in the reverse Take screw (1) out of fan housing. clamp (2).
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sequence.
– Remove the fan housing. Pull clamp (2) with rubber
Position wire for switch in element (1) out of fan housing.
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guide (2).
Note:
Coat rubber element and rubber
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1 mounting of sleeves with press fluid
– see 11.
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On
249RA133 VA
3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor,
rewind spring in rope rotor
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4 Dirko sealant (100 g tube) 0783 830 2120 Crankcase sealing faces
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5 Standard commercial, solvent- Cleaning crankshaft stub
based degreasant containing no
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chlorinated or halogenated
hydrocarbons
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On
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10 Vacuum pump 0000 850 3501 Testing crankcase for leaks
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11 Feeler gauge 4180 893 6400 Adjusting valve clearance
12 Puller 4119 890 4501 Removing fanwheel
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13 Puller 4112 890 4502 Universal puller
- Jaws (No. 2) Removing AV element
- Jaws (No. 3.1) Removing oil seals
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14 Installing sleeve 4112 893 2400 Installing oil seal
15 Press sleeve 4112 893 2401 Installing oil seals at starter side
16
17
Press sleeve
Wrench, 13mm
1115 893 4600
5910 893 5608
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Installing oil seal at clutch side
Removing starter cup / fanwheel
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18 Combination wrench 4180 890 3400 Spark plug
19 Assembly drift 1108 893 4700 Removing piston pin
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