Ra 752 00 01 04 Zra 01 01

STIH)
STIHL FS 240, 260, 360, 410, 460 2011-09

Contents
1. Introduction and 6. Ignition system 39 7. M-Tronic 58

safety precautions 3
6.1 Ignition timing 39 7.1 Calibrating
1.1 Introduction 3 6.2 Ignition module 39 the control unit 58
1.2 Safety precautions 4 6.2.1 Control unit 7.2 Resetting the control
(ignition module) unit to factory defaults 58
M-Tronic 41 7.3 Testing 58
2. Specifications 5 6.3 Testing the 7.3.1 Test preparations 58
ignition module 42 7.3.2 Connect the test lead 58
2.1 Engine 5 6.4 Spark plug boot / 7.3.3 Check screwed and
2.2 Fuel system 5 ignition lead 43 plug connections as
2.3 Ignition system 5 6.5 Flywheel 45 well as switch 59
2.4 Gearbox 5 6.6 Short circuit wire 45 7.3.4 Checking the solenoid
2.5 Tightening torques 6 6.6.1 Testing 45 valve 59
6.6.2 Short circuit wire 7.3.5 Checking the start
on engine, detection function 60
3. Troubleshooting 8 removal and 7.3.6 Checking the wiring
installation 46 harness 60
3.1 Clutch 8 6.6.3 Short circuit wire 7.4 Removal and
3.2 Gearbox 9 with M-Tronic on installation 62
3.3 Drive tube assembly 10 engine, removal 7.5 Troubleshooting,
3.4 Starter 11 and installation 48 M-Tronic 65
3.5 Ignition system 13 6.6.4 Short circuit wire on 7.5.1 Engine does not start 65
3.6 Carburetor 14 control handle for 7.5.2 Engine does not start
3.7 Engine 18 loop handle, in position } 66
removal and 7.5.3 Engine speed drops
installation 51 under load
4. Clutch 19 6.6.5 Short circuit wire – low power 67
on control handle 7.5.4 Ignition – no ignition
4.1 Clutch drum 19 for bike handle, spark 68
4.1.1 Ball bearing 22 removal and 7.5.5 Engine stops
4.2 Clutch 23 installation 52 suddenly 69
6.6.6 Ground wire 54 7.5.6 Cut-off speed
6.6.7 Contact spring not reached 70
5. Engine 25 versions with control
handle for bike handle 54
5.1 Muffler 25 6.7 Troubleshooting, 8. Rewind starter 71
5.2 Leak testing 26 Ignition System 55
5.2.1 Preparations 26 8.1 General 71
5.2.2 Vacuum test 27 8.2 Starter 71
5.2.3 Pressure test 27 8.3 Pawls 71
5.3 Oil seals 28 8.4 ErgoStart/rope rotor 72
5.4 Shroud 29 8.5 Starter rope /
5.5 Cylinder 30 starter grip 73
5.6 Crankshaft 32 8.6 Tensioning
5.6.1 Ball bearing / the rewind spring 75
crankcase 35 8.7 Replacing
5.7 Piston 36 the rewind spring 75
RA_752_00_01_04
5.8 Piston rings 38
q
© ANDREAS STIHL AG & Co. KG, 2011
FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M 1

Contents
9. Antivibration 11. Fuel system 91 12. Drive tube assembly 112

elements 77
11.1 Air filter 91 12.1 Drive tube assembly
9.1 Rubber insert 11.2 Filter housing 91 with loop handle 112
1-point antivibration 11.3 Carburetor 93 12.2 Drive tube assembly
system 77 11.3.1 Leakage test 95 with control handle
9.2 Rubber buffers/ 11.4 Repairing for bike handle 113
springs 4-point the carburetor 96 12.2.1 Disassembling
antivibration system 78 11.4.1 Metering diaphragm 96 the drive tube
11.4.2 Inlet needle 97 assembly with a
11.4.3 Pump diaphragm 98 diameter of 25.4 mm 114
10. Actuating levers 82 11.4.4 Throttle shaft lever 99 12.2.2 Disassembling
11.4.5 Choke lever/choke the drive tube
10.1 Control handle for knob 100 assembly with a
loop handle 82 11.4.6 Adjusting screws, diameter of 28 mm 116
10.1.1 Throttle trigger / carburetor 12.2.3 Loop handle
throttle trigger without M-Tronic 102 with barrier bar 117
interlock 82 11.5 Carburetor 12.3 Deflector 118
10.1.2 Slide control 84 adjustment 12.3.1 Deflector for
10.2 Control handle with M-Tronic 103 gearbox with 25.4 mm
for bike handle 85 11.6 Carburetor drive tube assembly
10.2.1 Removal and adjustment diameter 118
installation 85 without M-Tronic 103 12.3.2 Deflector for gearbox
10.2.2 Throttle trigger / 11.6.1 Basic setting 103 with 28 mm drive tube
throttle trigger 11.6.2 User adjustment 104 assembly diameter 119
interlock 86 11.7 Spacer flange 105 12.3.3 One-piece
10.2.3 Lever for stop function 89 11.8 Tank vent 107 carrying ring 120
10.2.4 Adjusting 11.8.1 Testing 107 12.3.4 Support 120
the throttle cable 89 11.8.2 Removal 12.4 Gearbox for drive tube
10.2.5 Throttle rod 90 and installation 108 assembly 25.4 mm
11.9 Fuel intake 108 with square profile 120
11.9.1 Pickup body 108 12.4.1 Removal and
11.9.2 Fuel hose 109 installation 120
11.9.3 Fuel tank 110 12.4.2 Disassembly 121
12.5 Gearbox for drive tube
assembly 28 mm
with serration 124
12.5.1 Removal and
installation 124
12.5.2 Disassembly 124
13. Special tools 129
14. Service accessories 131
2 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

1. Introduction and safety precautions
1.1 Introduction The special tools mentioned in the Always use original STIHL
descriptions are listed in the chapter replacement parts.
This Service Manual contains "Special Servicing Tools" of this They can be identified by the STIHL
detailed descriptions of all the manual. The tools can be identified part number
typical repair and servicing according to part number in the the logo {
procedures for this machine. "STIHL Special Tools" manual. The and the
manual lists all tools supplied by STIHL parts symbol K
Refer to the illustrated spare parts STIHL. The symbol may appear alone on
lists during all repair work. These small parts.
lists show the installation position Symbols are included in the text and
and order in which the individual pictures for greater clarity. Storage or disposal of oil and fuel
parts and modules should be The meanings are as follows:
assembled. Collect fuel or lubricating oil in a
In the text: clean container and dispose of it in
Refer to the latest edition of the accordance with environmental
relevant spare parts list to check the N Action to be taken as shown in regulations.
part numbers of any spare parts the illustration above the text
required.
– Action to be taken that is not
A fault on the machine may be due shown in the illustration above
to several causes. To help locate the text
the fault, consult the chapter on
"Troubleshooting" and the In the illustrations:
"STIHL Service Training System"
for all functional groups. A Item pointer (short)
Refer to the "Technical Information" a Direction of

bulletins for engineering changes movement (long arrow)
which have been introduced since
publication of this Service Manual. @ 4.2 Reference to another
Technical information bulletins also chapter, in this case to
supplement the spare parts list and Chapter 4.2
Service Manual until an updated
edition is issued. Service Manuals and technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed on to third parties.

1.2 Safety precautions The chapter "Tightening Torques"
lists all components of this machine
Specific national safety regulations that must be tightened with the
and the safety instructions in the specified tightening torques or
instruction manual must be coated with thread-locking
observed if the machine has to be adhesive. These specifications
started up during maintenance or must be observed throughout the
repair work. Service Manual when tightening
screws and nuts as well as other
Gasoline is highly inflammable and fasteners.
can also be explosive under certain
conditions.
Fuel system – barbed
Do not bring any fire, flame, spark or connectors
other source of heat near the fuel.
All work with fuel must be performed Pull or push the fuel hoses, by hand
outdoors only. Spilled fuel must be whenever possible, in the direction
wiped away immediately. of the connector in order to ensure
leakproofness of the fuel system.
Test for leakage after all work on the
fuel system and engine. Avoid damaging the barbed
connectors
Exercise extreme caution while – sharp-edged pliers, screwdrivers,
carrying out maintenance and repair etc., may not be used.
work on the ignition system. The Also, do not cut open fuel hoses
high voltages which occur can with a knife or similar aids.
cause serious or fatal accidents.
Do not reuse fuel hoses after
Suitable protective gloves must be disassembly, but instead always
worn without fail if parts are heated replace them with new hoses
for assembly/disassembly – fuel hoses can be overstretched
purposes. Risk of burns from hot when being detached.
grease. Lubricants in the parts
become hot due to heating. Mount new fuel hoses dry or using
STIHL press fluid, b 14.
Improper handling may result in
burns and other serious injuries. Other press fluids are not permitted
and may lead to fuel hose damage.
Always replace damaged parts.
Check dismantled parts for wear When using STIHL press fluid,
and damage before installation, apply press fluid to the ends of the
replace if necessary. hose and the connectors and press
the new hoses onto the barbed
Only use the machine with the connectors, b 14.
shroud mounted – otherwise the
rotating fan wheel poses a risk of
injury and there is a risk of engine
damage due to overheating.

2. Specifications
2.1 Engine
FS 240 C, FS 360 C FS 260 C, FS 410 C FS 460 C
Displacement: 37.7 cm3 41.6 cm3 45.6 cm3

Bore: 40.0 mm 42.0 mm 44.0 mm
Stroke: 30.0 mm 30.0 mm 30.0 mm
Engine power to ISO 8893: 1.7 kW (2.3 HP) 2.0 kW (2.7 HP) 2.2 kW (3.0 HP)
at 8500 rpm at 9000 rpm at 9500 rpm
Cut-off speed
(Nominal value): 12500 rpm, FS 240 RC 12500 rpm, FS 260 RC 12300 rpm
10500 rpm 10500 rpm
Idling speed
(Nominal value): 2800 rpm 2800 rpm 2700 rpm
Clutch: Centrifugal clutch Centrifugal clutch Centrifugal clutch
without linings without linings without linings
Clutch engages at: 3600 rpm 3600 rpm 3600 rpm
Crankcase leakage test
at gauge pressure: pü = 0.5 bar pü = 0.5 bar pü = 0.5 bar
under vacuum: pu = 0.5 bar pu = 0.5 bar pu = 0.5 bar
2.2 Fuel system
Carburetor leakage test at

gauge pressure: pü = 0.8 bar pü = 0.8 bar pü = 0.8 bar
Operation of tank vent at
gauge pressure: pü = 0.5 bar pü = 0.5 bar pü = 0.5 bar
Fuel: as specified in instruction as specified in instruction as specified in instruction
manual manual manual
2.3 Ignition system
Air gap between ignition

module and fanwheel: 0.30 (+ 0.15/- 0.20) mm 0.30 (+ 0.15/- 0.20) mm 0.30 (+ 0.05/- 0.10) mm
Spark plug (suppressed): NGK CMR 6 H NGK CMR 6 H NGK CMR 6 H
Electrode gap: 0.5 mm 0.5 mm 0.5 mm
2.4 Gearbox
Quantity of gear
lubricant:
Drive tube assembly 9.5 g,

diameter STIHL gear lubricant for
25.4 mm/28.0 mm brushcutters

2.5 Tightening torques
DG and P screws are fitted in plastic and light alloy metal parts. These screws form a permanent thread when
they are installed for the first time. The material is permanently deformed. Screws can be removed and installed
as often as necessary without impairing the strength of the screwed assembly, provided that the specified
tightening torque is observed.
For this reason it is essential to use a torque wrench.
Fastener Thread size For component Tightening Comment

torque
Nm
Screw M 5x17 Cover/ shroud 6.0

Screw D 5x24 Cover/ clutch housing 6.0 1), 5)
Screw P 4x14 Cover/ starter cover 2.0
Screw P 6x14 Line limiting blade/ deflector 2.5
Screw D 5x24 Starter 6.0 1)
Screw P 5x32 Plugs for antivibration springs/ antivibration 3.0 6)
housing
Screw M 5x48x22 Control handle/ handlebar/ locknut 2.5
Screw P 4x16 Control handle moldings outside/ inside 1.3
Screw M 5x12 Control handle clamp/ drive tube assembly 5.0
Screw P 4x10 Diagnostic jack/ bushing 1.5 7)
Screw M 5x21 Filter cover 6.0
Collar nut M5 Filter housing 3.5
Screw M 6x35 Gearbox/ drive tube assembly 10.0 1)
Screw D 5x24 Gear housing/ drive tube assembly (1st stage) 4.0 1)
Screw D 5x24 Gear housing/ drive tube assembly (2nd stage) 9.0 1)
Screw M 5x10 Gear housing/ guard ring 8.0 2)
Screw M 5x48x22 Left handle/ handlebar/ locknut 2.5
Screw D 5x24 Shroud 6.0 1)
Screw P 4x14 Shroud/ slide 2.0
Screw P 4x10 Cable holder/ short circuit wire/ ignition 1.5
module
Screw M 6x30 Clamp/ drive tube assembly/ supports 8.0 1)
Screw M 5x16 Clamps handlebars 2.0 1)
Screw D 6x35 Clamping device clutch housing 8.0 1), 6)
Screw D 5x24 Fuel tank/ crankcase 6.0 1)
Screw M 6x25 Clutch/ flywheel 10.0
Screw D 5x24 Clutch housing/ crankcase 8.0 1)
Screw M 5x16 Crankcase fan side/ insert 6.0 2)
Screw D 5x24 Crankcase fan side/ starter side 8.0 1)
Screw P 3x6 Return spring/ fan housing 0.6
Screw M 5x16 Muffler / crankcase 9.0 2)
Screw M 5x16 Muffler/ cylinder/ first screw 2.0 2)
(1st stage)
Screw M 5x16 Muffler/ cylinder/ second screw 10.0 2)
(2nd stage)
Screw M 5x16 Muffler/ cylinder/ first screw 10.0 2)
(3rd stage)
Screw P 4x10 Switchgear/ bushing 1.5 7)

Fastener Thread size For component Tightening Comment
torque
Nm
Screw M 5x20 Clamp/ control handle for loop handle/ nut 4.5 1)
Screw M 5x20 Cutting attachment deflector/ gear housing 4.3 1)
Screw M 5x23 Cutting attachment deflector/ gear housing 10.0
Screw IS 5x14 Deflector/ antivibration housing 4.0 6)
Screw D 5x32 Protective hip plate/ crankcase 8.0 1)
Nut M 8x1 Flywheel/ crankshaft 28.0
Screw M 6x14 Clamp/ drive tube assembly harness anchor 4.5 1)
Screw D 6x32 Clamp/ drive tube assembly with washer 12.0 1)
Screw M 5x18 Clamp/ supports/ drive tube assembly 4.0 1), 6)
Nut M 8x1 Starter cup / crankshaft 17.0
Screw P 6x19 Supports/ plugs antivibration springs 6.0 6)
Screw M 14x1.25x7 Supports/ muffler with spark arresting screen 8.0
Screw P 4x14 Bushing choke/ filter housing 2.0
Screw P 4x10 Shim/ deflector 1.0
Screw M 11x10 Screw plug/ gearbox 9.5
M 10x1 Spark plug/ cylinder 12.0
Screw D 4x18 Ignition module/ cylinder 4.0 1)
Screw M 5x20 Spacer flange/ cylinder 8.0 2)
Screw D 5x32 Cylinder / crankcase 9.0 1)
Remarks:
1) Easy-slide coating with locking serration

2) Microencapsulated with locking serration
3) Microencapsulated with washer
4) Connection between crankshaft and flywheel must be degreased and oil-free
5) 1-point antivibration system
6) 4-point antivibration system
7) M-Tronic
When inserting DG and P screws into an existing screw thread:
Insert the DG or P screw in the hole and turn counterclockwise until it gently drops into the hole in axial direction.
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.
As a rule, microencapsulated screws must be replaced after removal.
Screwdriver speed when used in plastic material: max. 500 rpm for DG and P-type screws.
Do not use an impact wrench to release or tighten screw connections.
Screws with and without locking serration must not be confused.

3. Troubleshooting
3.1 Clutch
Problem Cause Remedy
Cutting attachment stops under Clutch shoes badly worn Install new clutch
load at full throttle
Clutch drum badly worn Install new clutch drum
Cutting attachment rotates at idle Idle speed too high Versions without M-Tronic:
speed Readjust idle speed screw LA
Versions with M-Tronic:
Carry out diagnosis
Tension springs of the clutch shoes Replace tension springs, replace

are stretched clutch if necessary
Tension springs of the clutch shoes Replace tension springs

are broken
Loud noises Tension springs stretched Replace all tension springs
Ball bearing of the clutch drum is Replace ball bearing

damaged
Screws of the clutch are loose Tighten screws, replace clutch if

necessary and check threaded
holes on the flywheel, replace
flywheel if necessary
Clutch shoes worn Install new clutch

3.2 Gearbox
Loud noises Ball bearings damaged or worn Replace ball bearings on the drive
side and non-drive side
Pinion damaged or worn Replace set of pinions on the drive

side and non-drive side
Too little or no gear lubricant in Gearbox drive tube assembly

gearbox 25.4 mm:
Add gear lubricant
Gearbox drive tube assembly
28 mm:
Remove drive pinion and add gear
lubricant
Gearbox becomes too hot Excessive friction due to damaged Replace ball bearings on the drive
or worn ball bearings side and non-drive side
Too little or no gear lubricant in Gearbox drive tube assembly

gearbox 25.4 mm:
Add gear lubricant
Gearbox drive tube assembly
28 mm:
Remove drive pinion and add gear
lubricant
Gearbox runs rough and stops Drive shaft does not fully engage Push gearbox onto drive tube
running under load drive pinion assembly until the drive shaft fully
engages the drive pinion
Square profile or serration in the Check drive pinion, drive shaft and
drive train is damaged or worn clutch drum, replace if necessary
Clutch worn Check clutch and clutch drum,

replace if necessary
Gearbox frozen Locking pin for changing tools not Remove locking pin
removed
Damaged or worn ball bearings Replace ball bearings on the drive

jammed and non-drive sides, also check
bearing seats in the gear housing,
replace gear housing if necessary
Serration damaged or broken – Replace set of pinions on the drive

fragments jammed side and non-drive side

3.3 Drive tube assembly
Drive tube assembly vibrates Flexible liner is worn Replace flexible liner
– Drive shaft is insufficiently
supported and can vibrate
Cutting attachment out of true Resharpen cutting attachment

evenly, replace if necessary
Drive tube assembly becomes very Drive shaft not sufficiently Lubricate drive shaft along its entire
warm lubricated length – the entire length of the
flexible liner must be lubricated
Bike handle does not clamp Clamps are greasy or oily Clean clamps and bike handle
Bike handle can no longer be Clamps are dirty Clean clamps and bike handle
adjusted

3.4 Starter
Starter rope broken Rope pulled out too vigorously as Replace starter rope
far as stop or over edge, i.e. not
vertically
Normal wear Replace starter rope
Starter rope does not rewind Heavy fouling or rust on rewind Clean or replace rewind spring
spring
Spring insufficiently tensioned Check rewind spring and increase

tension
Rewind spring broken Replace rewind spring
Starter rope cannot be pulled out Rewind spring overtensioned Check rewind spring and reduce
far enough tension
Starter rope can be pulled out Guide peg on pawls or pawls Replace pawls
almost without resistance themselves are worn
(crankshaft does not turn)
Spring clip fatigued Replace spring clip
Spring clip improperly installed Install spring clip properly
Lugs on starter cup worn Replace starter cup, check pawls,

Anchor loop in ErgoStart spring Hook ErgoStart anchor loop to

housing not hooked onto carrier carrier

Starter rope is difficult to pull or Starter mechanism is very dirty Thoroughly clean complete starter
rewinds very slowly mechanism
Spring in ErgoStart spring housing Replace ErgoStart

is fatigued
At very low outside temperatures: Coat rewind spring with a little

Lubricant oil on the rewind spring standard solvent-based degreasant
becomes viscous (spring winding (containing no chlorinated or
stick together) or moisture has halogenated hydrocarbons), then
penetrated the rewind spring pull rope carefully several times
(spring windings are frozen) until normal action is restored

3.5 Ignition system
Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug
temporary loss of power and fit new spring if necessary
Spark plug sooted, smeared with oil Clean the spark plug or replace if
necessary
In the event of repeated sooting,
check air filter
Fuel/oil mixture Use a fuel mixture with the correct

– contains too much oil mixing ratio
Incorrect air gap between ignition Set the correct air gap
module/control unit and flywheel
Flywheel cracked Install new flywheel

or has other damage or pole shoes
have turned blue
Incorrect ignition timing, flywheel Install new flywheel

out of adjustment
– Key in flywheel has sheared off
Weak magnetization in flywheel Install new flywheel
Irregular spark Check proper functioning of lever

for stop function/contact spring or
slide control/microswitch and
ignition module.
Damaged insulation or interruption
in ignition lead or short circuit wire.
Check ignition lead/ignition module,
replace ignition module if
necessary. Check operation of
spark plug, clean spark plug and
replace if necessary.
Versions with M-Tronic, carry out
diagnosis

3.6 Carburetor
Carburetor floods; engine stalls Inlet needle not sealing Remove and clean inlet needle or
– Foreign matter in valve seat or clean carburetor
cone
Inlet needle worn Replace inlet needle
Inlet control lever sticking on Examine control lever, replace if

spindle necessary
Helical spring not located on nipple Remove the inlet control lever and
of inlet control lever refit it correctly
Perforated disc on diaphragm is Replace metering diaphragm

deformed and presses constantly
against the inlet control lever
Metering diaphragm is deformed Replace metering diaphragm
Poor acceleration, version without Low speed screw "too lean" Check basic carburetor setting,
M-Tronic correct if necessary
High speed screw "too lean" Check basic carburetor setting,

correct if necessary
... All versions Inlet needle sticking to valve seat Remove inlet needle, clean and
refit
Diaphragm gasket leaking Replace diaphragm gasket
Metering diaphragm damaged or Replace metering diaphragm

shrunk
Tank vent faulty Replace tank vent
Leak in fuel line between tank and Seal connections or replace line
carburetor
... Versions with M-Tronic Parts in carburetor or M-Tronic Carry out M-Tronic diagnosis, if
wiring harness defective necessary, replace carburetor or
M-Tronic wiring harness

Power loss during acceleration, all Seal or spring of accelerator pump Replace carburetor
versions worn or damaged
Engine will not idle, idle speed too Throttle shutter opened too wide by Set idle speed screw LA correctly
high, versions without M-Tronic idle speed screw LA
... All versions Oil seals / crankcase leaking Seal oil seals / crankcase, replace if
necessary
Throttle shutter does not close Replace carburetor
Engine stops when idling, versions Idle speed screw "too rich" or Correct setting of low speed
without M-Tronic "too lean" screw L
Idle speed screw LA Set idle speed screw LA correctly

setting incorrect – throttle shutter
completely closed
... All versions Idle jet bores Clean the carburetor

or ports blocked
carburetor

Cutting attachment stops when Idle speed too high Readjust with idle speed screw
idling, versions without M-Tronic LA (counterclockwise)
... All versions Clutch springs stretched or fatigued Replace tension springs, replace
clutch if necessary
Clutch spring hooks broken Replace tension springs
Engine speed drops quickly under Air filter dirty Clean air filter, replace if necessary
load – low power,
all versions
Throttle shutter not opened fully Check throttle cable and rod
Fuel pick-up body dirty Replace pickup body
Fuel strainer dirty Clean fuel strainer in carburetor,

carburetor
Main jet bores or ports blocked Clean the carburetor
Pump diaphragm damaged or Replace pump diaphragm

fatigued
Incorrect ignition timing, flywheel Install new flywheel

out of adjustment
– Key in flywheel has sheared off
... Versions without M-Tronic High speed screw H "too rich" Check basic carburetor setting,
correct if necessary

Engine speed drops quickly under Parts in carburetor or M-Tronic Carry out M-Tronic diagnosis, if
load – low power, versions with M- wiring harness defective necessary, replace carburetor or
Tronic M-Tronic wiring harness
Engine runs extremely richly, lacks Choke shutter does not open Check carburetor and choke shaft,
power and has very low final speed if necessary, repair lever at the
choke shaft (choke lever) or
replace carburetor
Engine does not start No spark Replace spark plug, check ignition
module/control unit, replace if
necessary
Starter grip not pulled forcefully Remove and dry the spark plug,
enough crank the engine several times with
– Fuel/air mixture too rich (flooded) the starter to clear the combustion
chamber, reinsert and tighten spark
plug, repeat starting procedure

3.7 Engine
Always check and, if necessary,

repair the following parts before
looking for faults on the engine:
- Air filter
- Fuel supply
- Carburetor
- Ignition system/ M-Tronic
Engine does not start easily, stalls Oil seals in engine defective Replace oil seals
at idle speed but operates normally
at full throttle
Crankcase leaking or Reseal crankcase, replace if

damaged (cracks) necessary
Engine does not deliver full power Piston rings worn or broken Replace piston rings
or runs erratically
Muffler / spark arresting screen Clean muffler (inlet and outlet

carbonized openings), replace spark arresting
screen, replace muffler if necessary
Air filter dirty Clean or replace air filter
Fuel line kinked or cracked Fit new lines and ensure they are
installed without kinking
Engine is overheated Insufficient cylinder cooling. Thoroughly clean all cooling air
Air inlet openings in clutch housing openings and the cylinder fins
or air slits in shroud, cover or
antivibration housing are clogged.
Cooling fins on cylinder are
severely fouled.
Starter air intake fouled Clean starter air intake

4. Clutch
4.1 Clutch drum : Remove screws (2) and tilt

2 bushing (3) to the side
– Troubleshooting, b 3.1
– Detach short circuit wire and
– Remove drive tube assembly, 1 cable holder from engine,
1-point antivibration system, b 6.6.3
b 12.1, 4-point antivibration
5904RA002 TG
system, b 12.2
1
2
1
: Remove screws (1) 1
: Remove filter cover (2) with

screws
1
5904RA004 TG
1
1
5904RA000 TG
1
: Remove screws (1)
2 : Remove clutch housing (2)

: Pry out cable holder (1) on one
side
Versions with 4-point
antivibration system
5904RA003 TG
– Remove cable holder (1)
– Lay aside protective tube with 1 Removal and installation of the

clutch housing are the same as for
control handle
: Remove screws (1) 1-point antivibration systems.
– Do not kink protective tube
– Examine the rubber buffers,
: Remove bushing (2)
replace if necessary, b 9.2
1 – Detach short circuit wire and
cable holder from engine,
All versions
2 b 6.6.2
1
Versions with M-Tronic
5904RA001 TG
1
2
: Remove screws (1)
5904RA005 TG
: Remove cover (2) 3

2
1
5904RA290 TG
– Remove starter, b 8.2 : Remove the circlip (1)
– Remove shroud, b 5.4

: Remove the plug (1)
– Remove protective hip plate,
b 11.9.3

Installation
3 1
1
1
5904RA005 TG
5904RA006 TG
2 2
5904RA007 TG
: To protect the guide sleeves, set : Install circlip (1) on the opposite
clutch housing (1) on ring (2) side
5910 893 7005 – Heat the inner race of the ball
bearing to approx. 120 °C
: Orient ring (2) so that the clutch (250 °F)
housing rests evenly on it
: Position clutch drum (1) on ball
: Press out clutch drum using a bearing (2) and push it on as far 3
suitable punch (3) as it will go
This must be done quickly, as the 1

clutch drum absorbs heat and
5904RA009 TG
begins to expand. 2
1
: Guide clutch housing (1) with the
clutch drum (2) over the
clutch (3) and fasten with the
100% sleeves in the holes (arrows) of
5902RA018 TG
the clutch housing

! 1
80%
2
5904RA008 TG
– Examine the clutch drum (1) for

signs of wear 1
1
The remaining thickness must be
If it is impossible to heat the inner
measured if there are distinct signs
race, the clutch drum must be
of wear on the inside diameter of the
pressed on cold.
clutch drum (1). The clutch drum
must be replaced if the remaining
5904RA010 TG
– Support the clutch housing on

thickness is less than approx. 80 % 1
the opposite side with a suitable
of the original thickness.
pipe on the inner race of the ball 1
bearing
If the square socket is worn or the : Insert and tighten down the
pin is damaged, the clutch drum screws (1)
must be replaced. : Position clutch drum (1) on ball
bearing (2) and press it on as far
as it will go – Attach cable holder and short
circuit wire to engine, b 6.6.2

All versions
2
1
1
1
2
5904RA011 TG
5904RA014 TG
2
5904RA012 TG
2
: Position bushing (1) : Insert protective tube with control
handle in the guide
: Insert and tighten down the : Position filter cover (1) with groove (arrows)
screws (2) screws
: Position cable holder (1) and
: Insert and tighten down the slide it into the slits on the side
Versions with M-Tronic screws (2)
– Install drive tube assembly,
– Attach cable holder and short – Attach protective hip plate, 1-point antivibration system,
circuit wire to engine, b 6.6.3 b 11.9.3 b 12.1
– Refit the shroud, b 5.4

– Install starter, b 8.2 antivibration system
2
– Press on rubber buffers, b 9.2
1 antivibration system – Install drive tube assembly,
2 4-point antivibration system,
b 12.2
3
5904RA323 TG
3 2
1
: Position bushing (1)
: Insert and tighten down the

screws (2)
5904RA013 TG
: Insert plug (3) 3
: Orient cover (1) so that the guide

groove (arrow) faces the
protective tube (2)
: Position cover (1)

screws (3)

4.1.1 Ball bearing If it is impossible to heat the clutch Installation
housing, the ball bearing must be
– Remove the clutch drum, b 4.1 pressed out cold. Rubber insert or rubber buffers
must be removed.
3
1
5904RA017 TG
5904RA015 TG
5904RA018 TG
2
: To protect the guide sleeves, set

: Remove the circlip (1) clutch housing (1) on ring (2) – Heat the area around the bearing
5910 893 7005 seat to approx. 120 °C (250 °F)
– Remove rubber insert, b 9.1
: Orient ring (2) so that the clutch : Press the ball bearing (1) home
housing rests evenly on it as far as possible
4 -point antivibration system
: Press out ball bearing using a The ball bearing must be fitted
– Remove both rubber buffers suitable pipe (3) rapidly, as it absorbs heat and
– Replace ball bearing expands.
– Examine clutch housing, replace If it is impossible to heat the clutch

if necessary housing, the ball bearing must be
pressed in cold.
– Examine rubber insert and
clamp, install in new clutch
housing if necessary, b 9.1
1
5904RA016 TG
4 -point antivibration system

2
– Examine both rubber buffers, 1
– Heat the area around the bearing push onto new clutch housing, if
5904RA019 TG
seat to approx. 120 °C (250 °F) necessary, b 9.2
: The bearing (1) drops out on its – Examine clutch, replace if

own when this temperature is necessary, b 4.2
reached : Press the new ball bearing (1)
fully home with press arbor (2)
1118 893 7200

1
1 1
5904RA020 TG
5904RA022 TG
5904RA024 TG
: Install circlip (1) so that it is : Insert locking strip (1) : Remove clutch (1) from the lower
seated completely in the groove 0000 893 5904 in the cylinder cover washer
– Install the clutch drum, b 4.1

2 2
– Reassemble remaining parts in
reverse order 1
SM
1 1
4.2 Clutch SM
5904RA407 TG
5904RA025 TG
– Remove clutch housing, b 4.1
: Locking strip (1) 0000 893 5904 : Lift up clutch shoes (1) and
must rest against the cylinder unhook tension springs (2)
wall (arrow)
1 – Position as shown Clutch shoes must be oriented so
that the markings (arrows) are
visible.
1
5904RA021 TG
– Hook in new clutch springs
– Reassemble the clutch shoes in

reverse order
: Remove the spark plug boot (1)
2
– Unscrew spark plug
5904RA023 TG
: Remove bolts (1) SW 10
: Remove clutch (2) complete with

cover washers

3
SM
SM
2
2
1
1
5904RA026 TG
5904RA028 TG
3
1 3
: Position washers (1) on the pegs : Fit coupling (1) complete with
cover washers in the threaded
: Orient clutch (2) so that the holes (arrows) of the flywheel (2)
markings (arrows) are visible
: Slide clutch (2) onto the pegs on screws (3) SW 10
the lower cover washer (3)
– Pull the locking strip out of the
cylinder
– Install clutch housing, b 4.1

1
reverse order
SM
5904RA027 TG
SM
: Position upper cover washer (1)

so that the holes (arrows) match

5. Engine
5.1 Muffler
Check and if necessary repair the
fuel supply, carburetor, air filter and 1
ignition system before looking for 2
faults on the engine. 2
Troubleshooting, b 3
5904RA031 TG
5904RA033 TG
1
– Remove protective hip plate,
b 11.9.3 : Remove the exhaust gasket (1) : Position and orient exhaust
and cooling plate (2) gasket (1) on muffler (2)
To keep dirt particles from entering
the cylinder, move piston to top – Installing and removing the spark
dead center before removing the arresting screen, see Instruction
muffler. Manual 1 3
Installation 3
5904RA034 TG
2
5904RA029 TG
: Slide cooling plate (1) with the

lugs (arrows) into the recesses of
1 the muffler (2) and position
5904RA032 TG
: Remove screw (1) : Hold cooling plate (1) and insert

screws (3)
: Tilt insert (2) upward and out – Cover exhaust bore and remove – Position of the gasket and the
any fouling on the cylinder and cooling plate is secured
exhaust bore
: Examine and clean the mating

surfaces (arrows) on the exhaust
1 bore, cooling plate and muffler,
1 remove any gasket residues if
necessary – there must not be
2 any gasket residues or dirt
particles in the exhaust bore
5904RA030 TG
1
Parts with damaged mating
surfaces must be replaced.
: Remove screws (1)
: Take out and examine the

muffler (2), replace if necessary

5.2 Leak testing : Screw in spark plug (1) and
tighten it securely
2 Defective oil seals and gaskets or
2 cracks in housing are the usual – Remove cooling plate and gasket
causes of leaks. Such faults allow and position muffler with two
1 supplementary air to enter the screws, b 5.1
engine and upset the fuel-air
5904RA035 TG mixture.
3 This makes adjustment of the

1
prescribed idle speed difficult, if not
: Carefully position muffler (1) and impossible.
insert screws (2) – do not tighten
Moreover, the transition from idle 2
speed to part or full throttle is not 2
: Check gasket and cooling plate
smooth.
for proper position and fit lower
5904RA038 TG
screw (3)
Always start with the vacuum test
and then continue with the pressure
– Insert and tighten down all three test.
screws : Slide sealing plate (1)
The engine can be thoroughly 0000 855 8106 between cylinder
checked for leaks under vacuum exhaust port and muffler
and at gauge pressure using the
pump 0000 850 1300. : Tighten screws (2) lightly.
The sealing plate must fill the full

5.2.1 Preparations width between the screws.
– Remove shroud, b 5.4 – Remove the carburetor, b 11.3

1
5904RA036 TG
2
1 1
: Guide insert (1) behind the
muffler with tab (arrow) in front
and position
: Orient insert (1) parallel to muffler

5904RA039 TG
5904RA037 TG
: Screw in the screw (2) and

tighten
– Reassemble remaining parts in – Take off the spark plug boot and Gasket (1) must be in place.
reverse order remove the spark plug
– Set the piston to the top

dead center (this can be checked
through the spark plug hole)

: Operate lever (3) until the – If the pressure drops, the leak
1 pressure gauge (4) indicates a must be located and the defective
vacuum of 0.5 bar part replaced
If the vacuum reading remains To find the leak, coat the suspect
3 constant, or does not decrease by area with soapy water and
more than 0.3 bar within 20 pressurize the crankcase. Bubbles
3 seconds, it may be assumed that will appear if a leak exists.
5904RA040 TG
the oil seals are in good condition.
2 2 If the vacuum in the crankcase is – After testing, slide the ring on the
reduced further, the oil seals must pump to the left to vent the pump
be replaced, b 5.3. – disconnect the hose
: Orient flange (1) 5910 850 4201
and push it onto the studs (2)
– After testing, slide the ring on the – Remove flange 5910 850 4201
pump back to the right to vent the on intake elbow
: Tightly screw on nuts (3) pump.
– Install the carburetor, b 11.3
– Continue with pressure test,
5.2.2 Vacuum test b 5.2.3
– Remove muffler and remove
sealing plate 0000 855 8106
Oil seals tend to fail when subjected
to a vacuum. In other words, the 5.2.3 Pressure test
sealing lip lifts away from the – Install gasket, cooling plate and
crankshaft during the piston's muffler, b 5.1
The same preparatory steps are
induction stroke because there is no
required as for the vacuum test, – Reassemble remaining parts in
internal counterpressure.
b 5.2.2. reverse order
This kind of fault can be detected by
testing with pump 0000 850 1300.
3 2
4 3
1
5904RA042 TG
1
5904RA041 TG
2 : Slide ring (1) to the right

– Pressure test
: Push the hose (1) of pump
0000 850 1300 onto the : Operate the lever (2) until the
connector (arrow) pressure gauge (3) indicates a
pressure of 0.5 bar. If this
pressure remains constant for at
: Slide ring (2) to the left
least 20 seconds, the engine
– Vacuum test
crankcase is airtight

5.3 Oil seals – Free the oil seal in its seat by
tapping it with a suitable tube or a 1
punch.
1 2
: Apply the puller (1) 2
5910 890 4400 with jaws (profile
no. 3.1) 0000 893 3706
5904RA047 TG
– Clamp the puller arms
5904RA044 TG
– Pull out the oil seal

: Press the new oil seal (1) fully
home with press sleeve (2)
With new oil seals, oil seal (1) Installation 4238 893 2400
15x25x5 must be replaced on the
ignition side and oil seal (2) – Clean the mating surface, b 14 The seating face must be flat and
12x22x5 on the starter side. free from burrs.
– Grease the sealing lips of the
It is not necessary to dismantle the new oil seal, b 14 – Clean the cone of the crankshaft
complete engine if only the oil seals to ensure it is completely grease-
need to be replaced. free, b 14
2 – Reassemble remaining parts in

Ignition side reverse order
– Remove clutch, b 4.2

Starter side
– Remove the flywheel, b 6.5
– Remove starter, b 8.2
5904RA046 TG
1 1 – Block the piston, b 4.2
: Fit the installing sleeve (1)

1141 893 4600
2
: Slide the oil seal (2) over the
installing sleeve with the sealing
5904RA045 TG
lip facing the crankcase
– Remove the assembly sleeve

5904RA048 TG
Avoid damage to the crankshaft

stub. 1
: Unscrew the nut (1)
: Remove the starter cup (2)

: Slide the oil seal (2) over the 5.4 Shroud
1 installing sleeve with the sealing
lip facing the crankcase – Remove starter, b 8.2
– Remove the assembly sleeve
2 1
5904RA049 TG 2
Avoid damage to the crankshaft
stub.
1
5904RA053 TG
– Free the oil seal in its seat by 1
5904RA051 TG
tapping it with a suitable tube or a
punch.
: Remove screws (1)
: Apply the puller (1) : Orient press sleeve (1)
5910 890 4400 with jaws (profile 4147 893 2400 with the : Remove the shroud (2)
no. 3.1) 0000 893 3706 base (arrow) facing the
crankcase and press in the oil
– Clamp the puller arms seal (2)
2
– Pull out the oil seal The seating face must be flat and
free from burrs. 1
Installation
2
5904RA054 TG
– Clean the mating surface
– Grease the sealing lips of the

new oil seal, b 14
: Remove screw (1)
5904RA052 TG
: Remove cover (2)

1
1 – Check spacer (if present) and
slide for summer/winter operation
: Slide on the starter cup (2) and convert, if necessary, with a
2 new shroud
: Tightly screw on nuts (1)
5904RA050 TG

reverse order
: Fit the installing sleeve (1)

4119 893 4600

Installation 5.5 Cylinder – Remove the muffler, b 5.1
3 3 Before removing the cylinder,

decide whether or not the
crankshaft is to be removed. 1 1
1
With cylinder installed
The piston must be blocked through
the spark plug hole to prevent the
crankshaft turning in order to
5904RA055 TG
2 remove the clutch.

1
5904RA057 TG
With cylinder removed 1
: Fit shroud (1) so that the pins The crankshaft is blocked by
engage the holes (arrows) of the placing the piston on the wooden
assembly block in order to remove : Unscrew the pan head screws (1)
protective hip plate (2)
the clutch.
The mating surfaces must be in
screws (3)
perfect condition and without any 1
damage whatsoever. The cylinder
– Remove starter, b 8.2 must be replaced if the mating
surfaces are damaged b 3.7.
5904RA058 TG
1
2 – Remove drive tube assembly,
1-point antivibration system, : Carefully pull off the cylinder (1)
system, b 12.2
5904RA056 TG
: Slide cover (1) with the tab into – Take off the spark plug boot and
the slot (arrow) and position remove the spark plug, b 4.2
1
: Screw in the screw (2) and – Remove filter housing, b 11.2
tighten
5904RA059 TG
– Remove the carburetor, b 11.3
– Remove the spacer flange,

b 11.7 : Remove the cylinder gasket (1)
– Remove the ignition module,

b 6.2
Ignition module/control unit
M-Tronic, b 6.2.1

Installation
2 3
1
5904RA060 TG
5904RA064 TG
5904RA062 TG
: Examine and clean the mating – Coat piston, piston rings and
surface (arrow), b 14 inside of cylinder with oil, b 14
: Orient new cylinder gasket (1) so
that the tab (2) is located at the : Use the clamping strap (1)
ridge (3) 0000 893 2600 to compress the
– the openings must match with rings around the piston
the crankcase
– Ensure that piston rings are
: Guide cylinder gasket (1) over correctly positioned, b 5.8
the piston and lay it in the
sleeves (arrows)
The clamping strap (1) must be
– Cylinder gasket is secured
fitted in such a way that the piston
5904RA061 TG
rings do not protrude beyond the

piston sides.
1
: Examine and clean the mating
surfaces (arrows), and remove
any gasket residues, b 14
Always use a new cylinder gasket

after removing the cylinder.
5904RA063 TG
– Examine the piston rings and

replace if necessary, b 5.7,
b 5.8
: Place wooden assembly
If the piston or the piston rings are block (1) 1108 893 4800
damaged, then the inside of the between piston and crankcase
cylinder must also be inspected for
damage, replace cylinder if Avoid damage to the cylinder
necessary. gasket.

5.6 Crankshaft Starter-side half of the crankcase
– Empty the fuel tank in

1 accordance with regulations,
b 1.1
2 – Remove the starter cup, b 5.3

5904RA065 TG
– Remove the flywheel, b 6.5
5904RA068 TG
– Remove the cylinder, b 5.5
: Orient cylinder (1) so that the
intake duct (2) faces the filler
neck – Remove piston, b 5.7 : Take out the screws (arrows)
When fitting the cylinder over the – Remove insert, b 5.1

piston, ensure that the clamping
strap securely encloses the piston – Remove fuel tank, b 11.9.3
and that none of the piston rings
protrudes – Always fit new ball bearings and
– danger of breakage. oil seals when removing the
crankshaft, b 5.6.1 and b 5.3.
: Slide cylinder over piston; the
clamping strap is removed at the
5904RA069 TG
same time 2
1 1
– Remove clamping strap and
wooden assembly block
: Unscrew spindle (1) until it no
longer rests on the crankshaft
Ensure that the cylinder gasket is stub
correctly positioned.
: Position puller (2) 5910 890 4503
5904RA067 TG
so that the holes line up with the

threaded holes (arrows) of the
starter side half of the crankcase
: Take out the needle bearing (1),
examine and clean it, replace if
necessary
5904RA066 TG
– Push cylinder onto the guide

sleeves as far as it will go
– Cylinder gasket is secured
: Position the screws (arrows) and

tighten through the holes
crosswise

reverse order

– Replace ball bearings and oil
1 1 1 seals, b 5.6.1 and b 5.3
– Before installation, clean the

crankshaft, b 14
2
2
Installation
5904RA070 TG
5904RA072 TG
1
1 Ignition-side half of the
crankcase
: Insert and tighten down the : Position a suitable punch (1) on
screws (1) the cylinder side crankshaft stub Avoid damage to the crankshaft
and press out crankshaft (2) stub.
: Turn spindle (2) clockwise until
the crankshaft stub has been Crankshaft, con-rod and the needle
forced out of the ball bearing bearing between them form a
complete unit which must always be
The starter-side half of the replaced as such.
crankcase is pulled off by this
procedure.
– Undo the screws and remove the
5904RA074 TG
puller
– Replace ball bearings and oil

seals, b 5.6.1 and b 5.3
: Orient the crankshaft with the
conical crankshaft stub (arrow)
5904RA073 TG
facing the ignition-side ball

Ignition-side half of the
1 2 bearing
crankcase
: Examine ignition side (1) and – Heat only the inner race of the
1 starter side (2) halves of case for ball bearing to approx. 120 °C
cracks and check all mating (250 °F)
surfaces (arrows) for damage
: Press crankshaft stub fully home
If the original crankcase is reused,
the oil seals and ball bearings must The crankshaft must be fitted
be replaced, all gasket residues rapidly, as the heat is transmitted to
5904RA071 TG
removed and the mating surfaces the crankshaft stub and the inner
cleaned thoroughly (also in the bearing race contracts.
circumferential groove of the
ignition-side half of the case). The
: Position the crankcase half (1) on
mating surfaces must be absolutely
suitable surfaces so that it is held
flawless and clean to guarantee a
securely and the installed guide
perfect seal.
sleeves (arrows) are not
damaged
There must be sufficient clearance

downward so that the crankshaft
can be pressed out.

Starter-side half of the crankcase The crankcase must be fitted
rapidly, as the heat is transmitted to
1 Avoid damage to the crankshaft the crankshaft stub and the inner
stub. bearing race contracts.
5904RA075 TG
: Apply sealant (1) to the groove

on the circumference (arrows)
5904RA076 TG
5904RA068 TG
: Make certain that the guide : Fit screws (arrows) and tighten
sleeves (arrows) lineup with the evenly and alternately on
holes opposite sides until the halves of
the crankcase are completely
a
assembled
938RA098 TG
: Tighten screws (arrows)

1
– Examine and install the piston,
b 5.7
: Apply sealant so that a bead with
a height of a = 2 - 3 mm is formed
2 2
– Examine and install the cylinder,
b 5.5
5904RA077 TG
Sealant must not protrude into the

inside of the crankcase.
– Coat the cylindrical crankshaft reverse order
stub with oil : Position the clutch-side half of the
crankcase on the cylindrical
crankshaft stub so that the
cylinder mating surfaces (arrows)
match
– Heat only the inner race of the

ball bearing to approx.
120 °C (250 °F)
: Slide the crankcase half (1) on

until the guide sleeves (2) are in
as far as they will go

5.6.1 Ball bearing / crankcase Ignition-side half of the Installation
crankcase
The two halves of the crankcase
can be replaced individually if they 1
are defective.
New crankcases are delivered with

the relevant components pre-
assembled
– see spare parts list
5904RA080 TG
5904RA078 TG
Those parts which are not supplied
with the new crankcase must be
removed from the old crankcase – – Heat the area around the bearing
examine and replace, if necessary, : Carefully drive the oil seal out seat to approx. 120 °C (250 °F)
beforehand. with a punch
: Press the ball bearing (1) home
When fitting a new crankcase, the
: Examine and clean the as far as possible
machine's serial number must be
stamped on the crankcase with crankcase, replace if necessary.
2.5 mm figure stamps. The ball bearing must be fitted
– Replace ball bearings if the rapidly, as it absorbs heat and
If the original crankcase is reused, crankcase is in good condition expands.
the oil seals and grooved ball
bearings must be replaced, all – Check that the ball bearing is
gasket residues removed and the seated properly, if necessary, use
mating surfaces cleaned press arbor
thoroughly. The mating surfaces 1118 893 7200 to press the ball
must be absolutely flawless and bearing fully home
clean to guarantee a perfect seal.
Examine both halves of the

crankcase for cracks and check all
5904RA079 TG
mating surfaces for signs of

damage. 1
– Refer also to troubleshooting,

b 3.7 – Heat the area around the bearing
seat to approx. 120 °C (250 °F)
– Remove crankshaft, b 5.6
The bearing (1) drops out on its own
when this temperature is reached.

Starter-side half of the crankcase Installation
5904RA084 TG
5904RA081 TG
5904RA083 TG
: Use a suitable tool to pry the
hookless snap ring out at the
: Carefully drive the oil seal out – Heat the area around the bearing recess (arrow)
with a punch seat to approx. 120 °C (250 °F)
– Examine and clean the : Press the ball bearing (1)

crankcase, replace if necessary. home as far as possible 2 1
– Replace ball bearings if the The ball bearing must be fitted

crankcase is in good condition rapidly, as it absorbs heat and
expands.
– Check that the ball bearing is
5904RA085 TG
seated properly, if necessary, use
press arbor
4119 893 7200 to press the ball
bearing fully home
: Push the assembly drift (1)
1110 893 4700 stub end first
– Install crankshaft, b 5.6 through the installed snap ring
and press the piston pin (2) out of
5904RA082 TG
– Install the oil seals. the piston

1 b 5.3
If the piston pin is stuck, tap the end
– Heat the area around the bearing – Reassemble remaining parts in of the drift gently with a hammer to
seat to approx. 120 °C (250 °F) reverse order loosen it.
The piston must be held steady
during this process to ensure that
The bearing (1) drops out on its own
5.7 Piston jolts are not transmitted to the
when this temperature is reached.
connecting rod.
– Remove the cylinder, b 5.5 – Remove the piston
The assembly drift can be inserted – Examine the piston rings and
through the fitted snap ring, thus replace if necessary, b 5.8
only one snap ring must be
removed.

Installation
1 2
1
5904RA088 TG
165RA153 TG
2 1
5904RA086 TG
– Push assembly drift (2) into the : Attach the snap ring (1) to the
piston on the side with the magnet (2) and align it so that the
– Remove needle bearing from the installed snap ring snap ring gap is on the flat
rod eye, examine and clean it, side (arrow)
replace if necessary : Push the assembly drift (2)
1110 893 4700 with the stub end
: Coat the needle cage (1) with oil first through piston hole and rod
and insert it in the rod eye eye (needle cage) and secure 2 1
the piston
– Examine the piston rings and
replace if necessary, b 5.8 – Coat the piston pin with oil
: Fit the piston pin (1) on the stub

of the assembly drift (2) and slide
5904RA090 TG
1 it into the piston
: Push the slotted opening of the

sleeve over the magnet and snap
ring
5904RA087 TG
The inner pin (1) must point towards

the flat face of the
shaft (2).
: Orient the piston as illustrated so
5904RA089 TG
that the marking (arrow) faces

rearward and the starter cup (1) 2 1
is on the right
: Remove the sleeve (1)
– Position the piston on the rod eye 5910 893 1709 from the installing
tool (2) 5910 890 2211

5904RA091 TG
5904RA093 TG
5904RA094 TG
: Press the assembly tool down in : Position installing tool : Align the new piston rings so that
the sleeve until the magnet is at 5910 890 2211 with the taper the radiuses at the ends of the
the end of the guide slits. sleeve on the piston boss, hold ring (arrows) face upwards
the piston steady and press the
Stand the tool on a suitable surface. tool shank home until the snap
ring slips into the groove
The tool must be precisely aligned

in axial direction of the piston pin.
– Install new oil seals, b 5.3
– Install the cylinder, b 5.5
5904RA095 TG
216RA178 TG
reverse order
– Carefully slide the piston rings
over the piston
: Remove sleeve and fit it over the 5.8 Piston rings – danger of breakage
opposite shaft end of the
assembly tool, with the internal : Position the piston rings so that
– Remove piston, b 5.7
pin pointing towards the flat the radiuses at the ring gaps
surface. encircle the fixing pins in the
– Remove piston rings from piston
piston grooves (arrows)
– Use a piece of old piston ring to

: Check the correct installed
scrape the grooves clean
position of the piston rings
again (arrows)
– Install the piston, b 5.7

1
5904RA092 TG
reverse order
The snap ring (1) must be fitted so

that the gap in the ring (arrow)
points downwards in axial direction
of the piston.

6. Ignition system
Exercise extreme caution while Testing of the ignition module is – Detach short circuit wire and
carrying out maintenance and repair limited to a spark test. A new ignition cable holder from engine,
work on the ignition system. The module must be installed if no b 6.6.2
high voltages which occur can ignition spark is obtained (after
cause serious or fatal accidents. checking that the wiring and stop So that the air gap between ignition
switch are in good condition). module and flywheel can be set
Troubleshooting on the ignition using setting gauge 0000 890 6400
system should always start with the during installation, the clutch
spark plug, b 3.5 6.1 Ignition timing housing must be removed.
– Remove drive tube assembly, – Remove clutch housing, b 4.1

Ignition timing is fixed and cannot
1-point antivibration system, be adjusted during assembly work.
Alternatively, setting gauge
system, b 12.2
Since there is no mechanical wear 0000 890 6400 can be used to set
in these systems, ignition timing the air gap between ignition module
– Remove clutch housing, b 4.1 cannot get out of adjustment during and flywheel with the clutch housing
operation. installed. To do this, the gauge must
be bent one time.
6.2 Ignition module

1 a
1
2 – Unplug the spark plug boot

5904RA096 TG
– Remove drive tube assembly,

1-point antivibration system,
5904RA334 TG
system, b 12.2
The electronic ignition system
basically consists of an ignition
module (1) and flywheel (2). : Clamp the measuring
2 tongue (arrow) in a vise and bend
The ignition module accommodates the grip toward the measuring
all the components required to tongue until the grip (1) is at an
control ignition timing. There are angle of a = 30° relative to the
two electrical connections on the 1 measuring tongue
coil body:
1. High-voltage output with

5904RA097 TG
permanently installed ignition

lead.
2. Permanently installed lead with : Remove screw (1) and pull

lug for the short circuit wire lead (2) of the ignition module out
of the guides (arrows)

: Secure insulating element (1) Adjustment with clutch housing
with the stubs (arrows) on the installed
1 cylindrical bumps
2 1
1
5904RA102 TG 2
2
1 2
5904RA335 TG
: Remove screws (1) with washers
5904RA105 TG
: Remove the ignition module (2)
: Push back ignition module and
slide setting gauge (1)
: Fit ignition module (1) and insert 0000 890 6400 between the legs
screws (2) with washers – do not of the ignition module and the
tighten them down magnetic poles of the flywheel
1 : Slide setting gauge (1) in the

direction of the muffler until there
is enough space to tighten the
lower screw (2)
5904RA103 TG
1
: Remove the insulating
5904RA106 TG
element (1)
1
– Examine spark plug boot and
cable holder, replace if N S
necessary, b 6.4 : Push back ignition module and
5904RA107 TG
slide setting gauge (1)
0000 890 6400 between the legs
of the ignition module and the
magnetic poles of the flywheel
Shown without setting gauge for a
Installation better view.
– Push back and hold ignition

module (1)
– Flywheel must turn freely

2
: Turn the flywheel until the
pair of magnetic poles "N/ S"
(arrows) is at the ignition
5904RA104 TG
module (1) – not the pair of

1 magnetic poles "S/ N"
: Position insulating element (1) so

that the connection bar (2) faces
the carburetor

6.2.1 Control unit (ignition
3 module)
M-Tronic
1
1 3 – Remove shroud, b 5.4
S N 2
2 – Unplug the spark plug boot
5904RA108 TG
5904RA109 TG
: Press ignition module (1) against : Position ignition lead (1) and system, b 12.2
the setting gauge (2) and tighten press cable holder (2) into the
screws (3) hole of the cooling fin
: Remove the setting gauge (2) : Orient cable holder (2) so that it
aligns with the contour (arrows)
of the cooling fin
Adjustment with setting gauge 4
0000 890 6400 with clutch – Install clutch housing, b 4.1
housing installed
– Install cable holder and short
circuit wire, b 6.6.2
3
5904RA337 TG
2 1 2 3
1
1
3 The contactless electronic ignition
system basically consists of a
5904RA336 TG
3 control unit (1), flywheel (2),

switchgear (3) and solenoid
valve (4).
5904RA240 TG
: Press ignition module (1) against The ignition module accommodates

the setting gauge (2) and tighten 2 all the components required to
screws (3) control the ignition timing and fuel
: Press lead (1) of the ignition flow. There are only three electrical
: Remove the setting gauge (2) module with the lug (2) into the connections leaving the control unit:
mount
Checking operation 1. High-voltage output with
permanently installed ignition
: Starting at the lug (2), press the
– Turn the flywheel: it must not lead.
lead (1) of the ignition module
touch the ignition module into the guides (arrows) as far as
2. Permanently installed blue lead
it will go
with lug for the short circuit wire
: Screw in the screw (3) and 3. Permanently installed red lead

tighten with lug for the M-Tronic.

reverse order

Testing of the ignition module is not Using the ZAT 4 ignition system
limited to only a spark test. If no tester
ignition spark is obtained or other 1 5910 850 4503
functions do not work, a diagnosis
must be carried out according to the 2
troubleshooting chart; replace
control unit or M-Tronic wiring
3
harness if necessary.
5904RA136 TG
2
: Insert lead (red) of the ignition
165RA183 TG
module (1) with the lug (2) in the
1 mount – crimped side must face 1 2 3
cable holder
1 – Before starting the test, install a
: Insert lead (blue) of the ignition new spark plug in the cylinder
5904RA119 TG
module (1) with the lug (3) in the and tighten it down firmly.
mount – crimped side must face
3 cable holder : Connect the spark plug boot to
the input terminal (1). Push the
: Remove screws (1) tester's output terminal (3) onto
: Starting at the lug, press both
leads into the guides (arrows) as the spark plug
: Pull the red lead (2) and blue far as they will go
lead (3) out of the Danger! High voltage – risk of
guides (arrows) electrocution.
reverse order
– Remove throttle cable and short – Crank the engine quickly with the
circuit wire from engine, b 6.6.3 rewind starter and check
sparkover in the window (2) of
6.3 Testing the ignition
– Remove M-Tronic leads from the ignition system tester
module
cable holder and remove cable
holder, b 6.6.3 The engine may start and
To test the ignition module, use accelerate during the test.
either the ZAT 4 ignition system
Further removal of the control unit is
tester 5910 850 4503 or the If a spark is visible, the ignition
the same as for the ignition module ZAT 3 ignition system tester
without M-Tronic, b 6.2. system is in order.
5910 850 4520.
– If no spark is visible in the
The ignition test refers only to a window (2), check the ignition
Installation spark test, not to the ignition timing. system with the aid of the
Installation and adjustment of the troubleshooting chart, b 6.7
control unit is the same as for the
ignition module without M-Tronic,
b 6.2.
– Insert cable holder and insert M-

Tronic leads in the cable holder,
b 6.6.3
– Install throttle cable and short

circuit wire on engine, b 6.6.3

Using the ZAT 3 ignition system – Crank the engine quickly with the
tester 5910 850 4520 rewind starter and check 1
sparkover in the window (3) of
the ignition system tester
The engine may start and

accelerate during the test.
5904RA138 TG
If a spark is visible in the
1 window (3), the ignition system is in
order.
165RA184 TG
: Open and remove cable
2 3 4 – If no spark is visible in the
holder (1)
window (3), check the ignition
system with the aid of the
– Before starting the test, install a
troubleshooting chart, b 6.7
new spark plug and tighten it
down firmly.
6.4 Spark plug boot / ignition

: Connect the spark plug boot to
lead
the terminal (2)
: Attach ground terminal (1) to the Ignition module and ignition lead
spark plug form a complete unit. If the ignition
5904RA139 TG
lead is damaged, the ignition
module must be replaced.
: Use adjusting knob (4) to set
spark gap to approx. 2 mm,
see window (3) : Use suitable pliers to pull the
torsion spring out of the spark
– Unplug the spark plug boot
plug boot
– Unhook the torsion spring from

the ignition lead
5
– Pull the boot off the ignition lead
1
1
165RA185 TG
5904RA137 TG
2 3 4
While using the ZAT 3, hold it only

by the handle (4) or position it in a
safe place. Keep fingers or other : Pull out cable holder (1)
parts of your body at least 1 cm
away from the spark window (3),
high-voltage connection (2), ground
connection (5) and the ground
terminal (1).
Danger! High voltage – risk of

electrocution.

Installation
1
3
5904RA141 TG
5904RA144 TG
165RA188 TG
: Ensure that the torsion : Orient cable holder (1) so that it

spring (arrow) is located in the aligns with the contour (arrow) of
– With a new ignition module, use a recess the cooling fin
pointed tool to pierce the center
of the new lead's insulation : Run ignition lead (2) so that it is
approx. 15 mm from the end of not stretched against the ignition
the ignition lead 1 module and runs along the
cooling plate (3)
: Pinch the hook of the torsion
spring into the center of the – Reassemble remaining parts in
ignition lead (arrow) where it has reverse order
been pierced
5904R142 TG
: Position cable holder (1) around

the ignition lead and press
together
5904RA140 TG
– Coat the inside of the spark plug

boot with 1
STIHL press fluid, b 14
5904RA137 TG
: Push the ignition lead and torsion

spring into the spark plug boot
: Press cable holder (1)

completely into the hole on the
cooling fin
– Plug in the spark plug boot

6.5 Flywheel 6.6 Short circuit wire
– Remove shroud, b 5.4 The short circuit wire and ground

wire form a single unit together with
– Remove clutch housing, b 4.1 the throttle cable; the throttle cable
must be replaced if there is any sign
of damage.
– Block the piston with the locking
5904RA147 TG
strip, b 4.2
6.6.1 Testing
– Remove clutch, b 4.2
The flywheel and magnet
poles (arrows) must not display any 2
signs of damage or blue
discoloration; replace flywheel if
necessary.
1
1
Installation
5904RA241 TG
Flywheel and crankshaft stub must
5904RA145 TG
be free from grease for installation.
Check the short circuit wire if the

spark plug and ignition lead with
: Unscrew the flywheel nut (1) spark plug boot are in order.
: Unscrew screw (1) and remove

clamp (2) of the ignition module
5904RA148 TG
1
5904RA146 TG
Ensure that the machined key

(arrow) engages the slot in the
2 3 2 crankshaft.
: Position puller (1) – Set the air gap between ignition

5910 890 4503, screw in and coil and flywheel, b 6.2
tighten hexagon bolts (2) of the
clutch
reverse order
: Turn bolt (3) clockwise until the
flywheel come loose and remove
flywheel
– Detach puller (3) 5910 890 4503

from flywheel

– If no fault can be found, test the
ignition system in accordance
with flow chart, b 6.7
1 – Reassemble parts in reverse

order 1
5904RA242 TG
5904RA099 TG
6.6.2 Short circuit wire
2 on engine, 2
removal and installation
: Pull the lug (1) of the short circuit The blade receptacle is
wire (2) out of the mount – Remove shroud, b 5.4 permanently connected to the
connector tag and cannot be pulled
– Connect ohmmeter to off.
ground and the lug of the short
circuit wire : Remove screw (1)
– For versions with control handle : Remove ground wire (2) from the
for loop handle, move slide guides (arrows)
system, b 12.2
control to position STOP-0 and
hold it there
– Remove machine cover, b 4.1
– For versions with control handle
for bike handle, press and hold 2 1
lever for stop function
2
The resistance measured must be
approx. 0 Ω. If it is much higher, the
reason is a break in the wire and the
throttle cable must be replaced, 1
5904RA100 TG
b 6.6. 3
4
– Release slide control or lever for
5904RA097 TG
stop function = position "F"

: Remove screw (1)
The resistance measured must be

: Lift up cable holder (2) slightly,
infinitely high, otherwise replace the : Remove screw (1) and pull
pull out protective tube (3) by the
throttle cable, b 6.6, lead (2) of the ignition module out
tab (4) and out of the
of the guides (arrows)
guide (arrow)
The ground wire must also be
tested for contact and continuity.
If the ground wire is damaged, the 1

throttle cable must also be replaced. 2
1
5904RA098 TG
5904RA101 TG
: Remove short circuit wire (1)

: Pull throttle cable (1) out of the
from the guides (arrows)
mount (arrow) and unhook it from
the lever (2)

As strain relief, the protective tube is
1 clamped between the tab of the
2 cable holder and the guide of the
clutch housing.
1
1
5904RA243 TG
5904RA111 TG
: Take out and examine the cable : Hook throttle cable (1) onto
holder (1), replace if necessary lever (2) and press grommet into
5904RA245 TG
the mount (arrow)
2
– Remove short circuit wire on
control handle, control handle for
loop handle, b 6.6.4
Control handle for bike handle, : Screw in screw (1)
b 6.6.5 – do not tighten
: Check orientation and position of

3 the protective tube (2), align if
Installation
1 necessary, and tighten screw (1)
– Install short circuit wire on control 4
5904RA112 TG
handle, control handle for loop
2
handle, b 6.6.4
Control handle for bike handle,
b 6.6.5
: Orient throttle cable so that short
circuit wire (1) and ground
wire (2) face the cable holder
3
1 2 : Position Bowden cable (3) in the
5904RA115 TG
guide (arrow) and guide
protective tube under the tab (4)
2 1
: Place connector tag (2) of the

3 ground wire (1) in the recess and,
5904RA244 TG
starting at the recess, press into

the guides (arrows) as far as it
will go
: Position the cable holder (1) on
the clutch housing so that it : Screw in screw (3)
engages behind the – do not tighten
5904RA113 TG
groove (arrow) of the spacer 1

flange (2) and the tab (3) is
seated in the recess of the clutch
housing
: Position protective tube (1) of the
throttle cable in the guide of the
clutch housing so that it is aligned
with the edge (arrow) of the cable
holder

: Starting at the lug (2), press the
2 1 lead (1) of the ignition module 1
into the guides (arrows) as far as
it will go

tighten
5904RA246 TG
5904RA116 TG

reverse order 2 3
: Press short circuit wire (1) with : Pull the red lead (1) of the M-
the lug (2) into the mount 6.6.3 Short circuit wire Tronic out of the guides (arrows)
with M-Tronic on engine, up to the throttle cable (3)
: Starting at the lug (2), press the removal and installation
short circuit wire (1) into the : Remove blue lead (2) of the short
guides (arrows) as far as it will go – Remove shroud, b 5.4 circuit wire from the
guides (arrows)
1
– Remove drive tube assembly, 1 3
system, b 12.2
– Remove machine cover, b 4.1

5904RA117 TG
5904RA247 TG
2
2 2 4
To provide strain relief for the wires,
the short circuit wire (1) and ground The blade receptacles are
wire (2) must form small 1 permanently connected to the
loops (arrow) at the protective tube connector tags and cannot be
– Ensure that wires are not crossed. 1 pulled off.
5904RA119 TG
: Remove screw (1)

2 1 3 : Remove ground wire (2) of the
short circuit wire from the
: Remove screws (1) guides (arrows)
: Pull the red lead (2) and blue : Pull the ground wire (3) of the M-
3 lead (3) of the control unit Tronic out of the guides (arrows)
(ignition module) out of the up to the throttle cable (4)
5904RA118 TG
guides (arrows)
: Press lug (2) into the mount with

the crimped side facing the cable
holder

The leads of the M-Tronic are run
2 1 1 along the throttle cable guide of the
cable holder under the throttle cable
in the guides. So that the total length
of the leads installed is correct, they
must be completely routed in the
cable holder and secured in the
guides before installation of the
5904RA122 TG
5904RA249 TG
3 throttle cable.
4
: Remove screw (1) : Take out and examine the cable

holder (1), replace if necessary
: Lift up cable holder (2) slightly,
pull out protective tube (3) by the – Remove short circuit wire on
tab (4) and out of the control handle, control handle for 1
guide (arrow) loop handle, b 6.6.4
Control handle for bike handle,
5904RA251 TG
b 6.6.5
2
2 Installation
: Place ground wire (2) with
connector tag (1) in the recess
– Install short circuit wire on control
and, starting at the recess, press
handle, control handle for loop
into the guides (arrows) as far as
handle, b 6.6.4
1 Control handle for bike handle,
it will go
5904RA123 TG
b 6.6.5
1 2
: Pull throttle cable (1) out of the 1
mount (arrow) and unhook it from 2
the lever (2)
5904RA252 TG
1
3
5904RA250 TG
: Press red lead (2) of the M-Tronic

with the lug (1) into the mount
: Position the cable holder (1) on
and, starting at the mount, press
the clutch housing so that it
2 into the guides (arrows) as far as
5904RA248 TG
engages behind the

it will go
groove (arrow) of the spacer
flange (2) and the tab (3) is
seated in the recess of the clutch
: Pull red lead (1) and ground housing
wire (2) of the M-Tronic out of the
guides (arrows)

As strain relief, the protective tube is
clamped between the tab of the 2
2 cable holder and the guide of the
clutch housing.
1
– Hold the cable holder with throttle 3
cable in this position
5904RA128 TG
5904RA133 TG
– Pull the red and black lead of the
M-Tronic out of the guides 1
again up to the throttle cable
: Hook throttle cable (1) onto : Position ground wire (1) of the
lever (2) and press grommet into short circuit wire and ground
the mount (arrow) wire (2) of the M-Tronic with the
1 connector tags (arrows) in the
recess
: Screw in screw (3)

– do not tighten
5904RA132 TG
3 2
2 1 2
4
5904RA129 TG
: Screw in screw (1)

– do not tighten
3
: Orient throttle cable so that short : Check orientation and position of
circuit wire (1) and ground the protective tube (2), align if
5904RA134 TG
wire (2) face the cable holder necessary, and tighten screw (1)
1
: Position Bowden cable (3) in the
guide (arrow) and guide : Starting at the connector tags,
protective tube under the tab (4) press ground wire (1) of the short
circuit wire and ground wire (2) of
the M-Tronic into the
guides(arrows) as far as they will
go
: Tighten screw (3)

5904RA130 TG
: Position protective tube (1) of the

throttle cable in the guide of the
clutch housing so that it is aligned
with the edge (arrow) of the cable
holder

1 2 4 3 1
1
1
5904RA135 TG
5904RA259 TG
5904RA150 TG
2
: Insert lead (red) of the M-Tronic : Insert and tighten down the : Ease out microswitch (1)
with the lug (1) in the mount – screws (1)
crimped side must face cable : Pull out wiring harness (2) with
holder – Reassemble remaining parts in throttle cable (3) and slide (4)
reverse order
: Insert lead (blue) of the short – Remove throttle cable and short
circuit wire with the lug (2) in the circuit wire from engine,
mount – crimped side must face 6.6.4 Short circuit wire on without M-Tronic, b 6.6.2,
cable holder control handle for loop with M-Tronic, b 6.6.3
handle,
: Starting at the lug, press both removal and installation
leads into the guides (arrows) as Installation
far as they will go
– Remove throttle trigger and
trigger interlock, b 10.1.1
– Remove slide control, b 10.1.2

1
1
2
3
4902RA216 TG
5904RA136 TG
2
: Push the microswitch (1) onto the
1 pins (arrows) as far as possible
5904RA149 TG
: Insert lead (red) of the control

unit (ignition module) (1) with the
lug (2) in the mount – crimped
side must face cable holder
clamp (2)
: Insert lead (blue) of the control
unit (ignition module) (1) with the
lug (3) in the mount – crimped
side must face cable holder
: Starting at the lug, press both

leads into the guides (arrows) as
far as they will go

6.6.5 Short circuit wire
1 2 on control handle for bike
handle,
removal and installation
1 – Remove throttle trigger and

5904RA151 TG 2
5904RA153 TG
: Press short circuit wire (1) and : Position clamp (1) in the
ground wire (2) into the cable mount (arrow) and screw in 1
guide (arrows) as far as they will screw (2) – do not tighten
go – short circuit wire must be
routed under ground wire – Install slide control, b 10.1.2
5904RA155 TG
1 2 1 : Remove contact spring (1) from
the guides (arrows)
1 2
49022RA223 TG
5904RA154 TG
: Press throttle cable (1) into : Set slide control (1) to position
mount (arrow) of the slide (2) STOP-0 , the contact
5904RA156 TG
until it snaps into place spring (arrow) must actuate the
microswitch – this can be heard
as a clicking noise
2 : Remove short circuit wire (1) with

– Install throttle trigger and trigger contact spring (2) from the
interlock, b 10.1.1 guide (arrows)
– Install control handle for loop

handle, b 10.1
1
5904RA152 TG
– Install throttle cable and short

circuit wire on engine,
1 without M-Tronic, b 6.6.2,
with M-Tronic, b 6.6.3
: Push slide (1) with throttle
cable (2) into the middle of the – Adjust throttle cable on control
5904RA157 TG
serrated mount (arrow) handle for loop handle, b 10.2.4

reverse order : Relieve and remove torsion
spring (1)

Installation
1 1
1
5904RA158 TG
5904RA164 TG
2
5904RA161 TG
: Push lever (1) in the direction of : Press ground wire (1) as far as it
the post (2) of the throttle trigger will go into the guide (arrows)
and remove from post (arrow) : Slide eyelet (1) onto the post (2)
of the lever so that the eyelet
opening faces the stop (arrow)
2 1
1
2
5904RA165 TG
5904RA159 TG
1 5904RA162 TG
The ground wire (1) must not be

: Remove ground wire (1) with stretched between lever (2) and
lever (2) from the guide (arrow) guide (arrow).
: Twist eyelet (1) as far as it will go
into the locking groove (arrow).
2 2
1
1
3
5904RA166 TG
5904RA160 TG
1
5904RA163 TG
: Twist eyelet (1) as far as it will 2 : Push blade receptacle (1) of the
go (arrow) and remove from the short circuit wire onto the contract
post of the lever (2) : Push lever (1) with ground spring (2) as far as it will go –
wire (2) onto the post (3) and turn crimped side must face
in the opening (arrow) curvature (arrow) of the contact
– Remove throttle cable and short
spring
circuit wire from engine,
without M-Tronic, b 6.6.2,
with M-Tronic, b 6.6.3

6.6.6 Ground wire
2 4 1
Testing and installation of ground
3 wire is the same as for the short
circuit wire
5
– Check contacts and operation,
5904RA167 TG replace throttle cable if
5904RA169 TG
necessary, b 6.6
1 2 3
: Press contact spring (1) with : Slide torsion spring (1) onto the 6.6.7 Contact spring versions
short circuit wire (2) into the axle (2) so that the hook (arrow) with control handle for
guides (arrows) as far as it will engages in the lever (3) bike handle
go, in the process slightly lifting
the contact point (3) : Turn torsion spring (4) Testing and installation of the
counterclockwise and position on contact spring is described in the
stop (5) chapter "Short circuit wire control
handle for bike handle", b 6.6.5.
1
Torsion spring is tensioned and can
pop out.
Checking operation
5904RA168 TG
: Press short circuit wire (1) as far

as it will go into the
guide (arrows)
5904RA170 TG
Eyelet of the ground wire must

touch the contact spring in STOP
position (arrow)
– Install throttle trigger and trigger

interlock, b 10.2.2
– Install control handle for bike

handle, b 10.2.1
– Adjust throttle cable on control

handle for bike handle, b 10.2.4

reverse order

6.7 Troubleshooting, Ignition System
Engine does not run
Slide control or lever for stop function:

– Set to position "F" or not pressed?
Check spark plug:

– Smeared with oil, black?
– Sooted?
– Electrode gap correct?
– Contacts shorted (threads)?
– Clean, adjust or replace spark plug,
b 6.3
Check spark plug boot:

– Firmly seated on spark plug (torsion
spring)?
– Torsion spring hook in center of ignition
lead?
– Spark plug boot damaged?
– Replace spark plug boot and/or torsion
spring if necessary,
b 6.4
Check ignition:
with ZAT 3 or ZAT 4
(use ZAT 3 as main spark gap
see TI 32.94),
b 6.3

1
Powerful spark? yes
no
Air gap:
– Check ignition module / flywheel,
– Adjust if necessary, b 6.2
Check flywheel:
– Have pole shoes turned blue?
– Replace flywheel if necessary,
b 6.5
Check short circuit wire:

– Wire damaged?
– Plug connections firmly seated?
– Check continuity, replace switch if
necessary, b 6.6.1
Check ignition lead:

– Severe chafing?
– Spark plug boot: Holes / cracks?
– Resistance of spark plug boot to ground:
Required 1.5...12 kΩ
– Check resistance of spark plug lead to
ground, (spark plug boot and ignition module
have been removed)
Value: Required < 10 Ω,
Replace spark plug boot and/or ignition module
if necessary,
b 6.4
2 3

2 3
Check that the slide control or lever for stop function is working properly:
– Short circuit wire chafed?
Control handle for loop handle
– Function between slide control and contact spring of the microswitch:
– Position "F" = microswitch not pressed
– Position "0" = microswitch pressed
Control handle for bike handle
– Function between lever for stop function and contact spring:
– Lever for stop function not pressed = no connection
– Lever for stop function pressed = connection
– Replace short circuit wire if necessary,
b 6.6.2
Powerful spark? yes
no
Ignition module
needs to be replaced
b 6.2
yes Does engine run? no
Engine runs smoothly, – Look for fault in fuel or carburetor

troubleshooting procedure completed system
– Check engine for leaks
– Check position of flywheel on
crankshaft,
b 5.2, b 6.5

7. M-Tronic
– Let the engine warm up for 7.3 Testing

approx. 120 seconds at full
7.3.1 Test preparations
throttle; during this time, carry out
several short load changes (let
engine idle – then accelerate The following steps must be carried
again to full throttle) out before testing.
– Let the engine idle for approx. 5
seconds – Carry out troubleshooting
5904RA274 TG
according to troubleshooting
– Let the machine run four or five chart, b 7.5
times for approx. 30 seconds at
full throttle in the cut-off range.
Let the engine idle for periods of – Remove shroud, b 5.4
The fully electronic M-Tronic engine
management system controls the approx. 5 seconds each between
ignition timing and fuel flow, taking the full-throttle phases. – Remove coarse dirt from around
all external conditions into account. the screwed connections, control
unit, switchgear, solenoid valve
A basic or standard setting of the 7.2 Resetting the control unit and diagnostic jack
carburetor is no longer required. to factory defaults
The M-Tronic electronically adjusts – Remove the air filter cover,
the fuel-air mixture in the carburetor. b 11.1
If the control unit and/or the
carburetor is replaced in customer
The M-Tronic controls all operating
service, the M-Tronic must be reset
states such as start, idle, part 7.3.2 Connect the test lead
to the factory defaults.
throttle and full throttle while
accounting for the external
– Set choke lever to position }
conditions, e.g., use at varying
attitudes, as well as changing – Start engine – do not blip the
temperatures or fuel quality – the throttle trigger!
carburetor does not have any – Let engine run in this start
adjusting screws. position for at least 90 seconds 1
– Actuate the stop switch –
Troubleshooting and test calibration is completed
procedures are described in the
5904RA275 TG
following chapters, Testing, b 7.3,
The control unit is adjusted to the
Troubleshooting, b 7.5.
carburetor while the engine runs in
the position Start}. The control
unit saves the information when the : Remove the plug (1)
7.1 Calibrating the control
engine is switched off immediately.
unit
Calibration of the control unit may

be necessary if the outstanding
running behavior and usual
performance of the engine can no
longer be attained. 1
Sequence of operations for
5904RA276 TG
calibration:
– Remove cutting attachment, all

mounting hardware for the
cutting attachment and the thrust : Connect M-Tronic test lead (1)
plate 5910 840 0903 to the diagnostic
jack (arrow)

After ending the test procedure, 7.3.4 Checking the solenoid
disconnect the test lead and reseal valve
the diagnostic jack with the plug.
– Carry out test preparations,
b 7.3.1
7.3.3 Check screwed and plug 1
connections as well as
switch – Check contacts and operation,
5904RA278 TG
b 7.3.3
– Carry out test preparations,

– Move choke lever to position "F"
b 7.3.1
Plug (1) must be seated completely
– Connect the test lead, b 7.3.2
There must be a reliable connection and firmly in the recess of the
for communication between control solenoid.
unit, switching device and solenoid
valve. If communication between : If necessary, remove plug (1) and Measuring resistance
control unit and solenoid valve is check contacts
interrupted or faulty, the control unit
does not initiate an ignition spark.
1
– In the event of a malfunction or if

there is no ignition spark, first
check the plug connections and
wiring harness between control
device and solenoid valve
5904RA280 TG
1
2 2
5904RA279 TG
: Measure resistance between

plugs (1) and (2) of the M-Tronic
test lead
1 : Set choke lever (1) to
position }; the cam on the
1 lever (2) must actuate the Target value: between 28 and
microswitch (arrow) 42 ohms
5904RA277 TG
– Clicking noise
– If the target value is not attained,
check electrical leads for
interruption, e. g., due to cable
Screws (1) must be tight. breakage between solenoid
valve and diagnostic jack
Leads (arrows) must be seated
completely and firmly in the cable
lugs.

7.3.5 Checking the start 7.3.6 Checking the wiring
detection function 2 harness
– Carry out test preparations, – Carry out test preparations,

b 7.3.1 b 7.3.1
– Check contacts and operation, – Check contacts and operation,
5904RA284 TG
b 7.3.3 b 7.3.3

1 3 – Move choke lever to position "F"
– Connect M-Tronic test lead to

multimeter
Checking the ground connection
: Insert black plug (1) in the "com"

/ "ground" jack and the red
plug (2) in the "volt" / "ohm" jack
2 2
– Set multimeter to "diode test"
5904RA282 TG
: Test diode on switchgear (3)

1 (microswitch) in accordance with
5904RA287 TG
multimeter instruction manual
: Disconnect the plug (1) from the 1
solenoid valve (2) If the switchgear (microswitch) is
intact and the choke lever is set to : Measure the resistance between
the "}" position, the following blade receptacle (1) and
target values will be attained: screw (2) at the control unit
3 (ignition module)
– Measurement in direction of flow,
target value: 0.3 volts to 0.7 volts Target value: < 10 ohms.
1
– Move choke lever to position "F" If the target values are not
1
– slide control or lever for stop attained
function on control handle is not
5904RA283 TG
pressed – Check electrical leads for

interruption, e. g., cable
2 breakage – if necessary, replace
– Reverse-biased measurement
Target value: 1.2 volts to infinity M-Tronic wiring harness, b 7.4.
: Remove screws (1)
– If target values are not attained,
: Pull out the blue lead (2) and red replace M-Tronic wiring harness,
lead (3) b 7.4
– Move choke lever to

position "}" – slide control or
lever for stop function on control
handle is not pressed

Check leads between control unit – Check continuity between blade
and diagnostic jack receptacle and angled terminal
socket
– Connect the test lead, b 7.3.2 – Blade receptacle and angled
terminal socket must be firmly 1
connected with one another; in
the event of contact problems,
1 2 the M-Tronic wiring harness must
5904RA289 TG
be replaced, b 7.4.
2
Check leads between solenoid
: Measure the resistance between
valve and diagnostic jack
black lead (1) at the plug of the
solenoid and red plug (2) of the
5904RA286 TG

diagnostic cable
Target value: < 10 ohms

red lead (1) and black plug (2) of If the target values are not
the diagnostic cable attained
Target value: < 10 ohms. 2 – Check contact surfaces between

lug and screw and check leads
for interruptions, e. g., cable
breakage – the leads must be
5904RA282 TG
12 firmly seated in the blade
1 receptacle and in the lug.
: Disconnect the plug (1) from the

solenoid valve (2)
5904RA547 TG
1
black lead (1) and red plug (2) of
the diagnostic cable
5904RA288 TG
Target value: < 10 ohms.
If the target values are not 2

attained
– Check that screw on control unit red lead (1) at the plug of the
(ignition module) and screw on solenoid and black plug (2) of the
angled terminal socket are firmly diagnostic cable
seated, if necessary, remove
screws and clean with angled Target value: < 10 ohms
terminal socket, then reinsert and
tighten

7.4 Removal and installation Installation
With a new switchgear, first the thin

leads must be inserted in the guides
1 of the switchgear.
– Remove the air filter cover,
b 11.1 Leads and plug connections must
not be damaged.
5904RA173 TG
– Check M-Tronic, b 7.3
– Detach M-Tronic leads from

cable holder and remove wiring
2 1
harness with throttle cable on
switchgear
engine, b 6.6.3
3
5904RA541 TG
4
Leads with plug (1) to solenoid

2 5904RA174 TG
valve of the carburetor.
5904RA171 TG
1 : Press red lead (2) and black

lead (3) into the guides (arrows)
of the switchgear (4) so that they
: Pull leads out of the form a loop
: Remove the plug (1)
guides (arrows) – see illustration
: Remove screws (2)
3
2
1
1
5904RA175 TG
5904RA542 TG
2 3 1 4
5904RA172 TG
2
: Unscrew screw (1) and remove Leads with diagnostic plug (1).
diagnostic connector (2) from the
: Remove the plug (1) mount of the bushing (3) : Press red lead (2) and black
lead (3) completely into the
: Pull leads out of the guides (arrows) of the
guides (arrows) switchgear (4)
– see illustration
: Remove bushing (2) with M-
Tronic

2
1 1
5904RA176 TG
5904RA178 TG
5904RA180 TG
2 1
: Orient diagnostic connector (1) Insert the thin leads of the : Insert switchgear (1) with the
so that the tab faces the switchgear first. pegs in the mounts (arrows)
recess (arrow)
: Press red lead (1) and black – Insert and tighten down the screw
: Push the diagnostic lead (2) as far as they will go into
connector (1) into the bushing (2) the guides (arrows) on the plug
as far as it will go
1 2
2 1
5904RA181 TG
5904RA179 TG
5904RA177 TG
Run the thick leads to the ignition

1 module over the thin leads.
Run the black lead under the red
: Insert and tighten screw (1) – firm lead – for left guide, see illustration : Press red lead (1) and black
seating of the diagnostic lead (2) as far as they will go into
connector is ensured : Press black lead (1) and red the guides (arrows) on the plug
lead (2) as far as they will go into
the guide that is offset by
90° (arrows)

1
1 2
1 2
1
5904RA182 TG
5904RA184 TG
5904RA186 TG
2
Run the black lead under the red : Insert and tighten down the Do not expose plug to tensile loads,
lead – for right guide, see illustration screws (1) thus run leads so that they form a
90° loop at the plug.
: Press black lead (2) and red : Press plug (2) into the diagnostic
lead (1) as far as they will go into connector (arrow) as far as it will : Press black lead (1) as far as it
the guide that is offset by go will go into the guides (arrows),
90° (arrows) starting at the plug
: Press red lead (2) as far as it will

go into the guides (arrows),
2 starting at the plug
1
– Install wiring harness and throttle
2 cable on engine, install
1 M-Tronic leads in cable holder,
b 6.6.3
5904RA185 TG
5904RA183 TG

reverse order
: Orient plug (1) so that the
– Move choke lever to position "F" lug (arrow) aligns with the groove
in the mount (2)
: Orient bushing (1) so that the
scale (arrow) faces the cylinder – Push plug into the mount as far
as it will go
: Guide bushing (1) over the choke
lever (2) and position

7.5 Troubleshooting, M-Tronic
7.5.1 Engine does not start
Engine does not start
Can engine yes

– Move choke lever to be started? Troubleshooting completed
position }
no
– Test ignition system
according to flow chart
"Ignition system
troubleshooting", b 7.5
no
– Check ignition (spark yes yes

Ignition spark
plug, spark plug boot, Is it possible to start
present?
ignition spark), b 6 the engine?
no
– Mechanically check start

detection system; is the
Mechanically no – Examine switch gear,
switchgear (microswitch)
actuated by the cam of the OK? clean or replace if
choke lever? necessary, b 7.4
– Clicking noise, b 11.4.5 yes
– Check start detection and Are target values no

– Replace switchgear,
wiring harness electrically, attained?, b 7.3 b 7.4
b 7.3.5, b 7.3.6
yes
Are target values no

– Check solenoid valve, – Replace switchgear and/
attained? b 7.3.4 or carburetor, b 11.3
b 7.3.4
yes
– Look for a fault in the fuel

path, check engine for
leaks, b 11

7.5.2 Engine does not start in
position }
Engine does not start in

position } – engine floods.
Can the flooded engine be
started in position F? yes
Is it possible to start Troubleshooting completed
the engine?
no
– Check start detection no – Examine switch gear,

Mechanically
(microswitch actuation) clean or replace if
OK?
clean if necessary necessary, b 7.4
yes
no
– Check start detection and Are target values – Replace switchgear,
wiring harness, b 7.3 attained? b 7.4
yes

path (inlet needle, lever,
spring, membrane),
check engine for leaks,
b 11.4, b 5.2

7.5.3 Engine speed drops
under load
– low power
Engine speed drops under load –

low power
– Examine the air filter, replace if

necessary, b 11.1
– Calibrate control unit, b 7.1
yes no
Cut-off speed =
12300 rpm?
Troubleshooting completed – Look for a fault in the fuel

leaks,
b 11.4, b 5.2

7.5.4 Ignition – no ignition
spark
No ignition spark
Can engine yes Troubleshooting

– Move choke lever to be started? completed
position }
no
no
– Check the flywheel, Combination Establish correct control unit/
(two pairs of poles?) b 6.5 OK? flywheel combination
yes
Air gap no
– Check air gap between – Set correct air gap,
OK?
control unit and flywheel, b 6.2
b 6.2
yes
– Test ignition system

according to flow chart
"Ignition system
troubleshooting",
b 6.7

7.5.5 Engine stops suddenly
Engine stops suddenly Machine yes Troubleshooting

OK? completed
no
– Check fuel path (fuel pick-up no

Fuel path – Repair fuel
body, tank vent, fuel hoses),
OK? system
b 11.9.1, b 11.8, b 11.9.2
yes
– Push plug on all the way

– Check screwed connection on Connection and tighten screwed
no
control unit (are leads firmly and firm seat of the connections, b 7.3.3,
seated in the lugs?) lugs OK? replace switchgear if
necessary, b 7.4
yes
– Check start detection no

Mechanically – Replace switchgear,
(actuation of switchgear)
OK? b 7.4
clean if necessary
yes
– Check start detection, wiring no

harness and plug and screwed Are target values – Replace switchgear,
connections, b 7.3 attained? b 7.4
yes
– Replace switchgear and/

Are target values no or carburetor, b 11.3
– Check solenoid valve, attained?
b 7.3.4
yes
– Check engine for leaks,
b 5.2

7.5.6 Cut-off speed not
reached
Maximum speed less than

11500 rpm
– Check air filter and spark arrestor screen

(if present) in muffler, clean or replace if
necessary, b 11.1, b 5.1
– Check cutting attachment for easy
movement, clean or replace if necessary,
see Instruction Manual
– Calibrate control unit, Cut-off speed greater yes Troubleshooting

b 7.1 than 12300 rpm? completed
no
– Tighten screwed
Connection connections and push
no
– Check screwed and firm seat in the plug on all the way, if
connections of the control lug necessary, replace
unit leads, b 6.2.1 OK? switchgear or control unit,
b 7.4, b 6.2.1
yes
– Check start detection, no

Are target values – Replace switchgear,
wiring harness and plug
attained? b 7.4
connections, b 7.3
yes

leaks,
b 11, b 5.2

8. Rewind starter
8.1 General 8.2 Starter 8.3 Pawls
If the action of the starter rope – Remove starter,

becomes very stiff and the rope b 8.2
rewinds very slowly or not
completely, it may be assumed that
the starter mechanism is in order
but plugged with dirt. At very low
outside temperatures, the 1
lubricating oil on the rewind spring
5904RA187 TG
may thicken and cause the spring
windings to stick together. This has 1
a detrimental effect on the function
of the starter mechanism.
: Take out the screws (arrows) and
5904RA189 TG
To clean the rewind spring, it is remove the starter (1)
sufficient to apply a few drops of a
standard solvent-based degreasant
not containing any chlorinated or Installation : Carefully ease the spring (1) off
halogenated hydrocarbons to the the starter post
rewind spring.
2 2
– Remove pawls
Carefully pull out the starter rope
several times and allow it to rewind
until its normal smooth action is
Installation
restored.
1
Before installing, lubricate the
5904RA188 TG
rewind spring and starter post with 2

STIHL special lubricant, b 14.
2 1
If clogged with dirt or pitch, the 1
entire starter mechanism, including The shroud must be attached.
the rewind spring, must be removed
and disassembled. Take particular : Position starter (1) and insert and
5904RA190 TG
care when removing the rewind tighten screws (2)
spring.
– Clean all components : Press new pawls into

holes (arrows) and grease the
pegs (1), b 14
ErgoStart
– Relieve the tension of the rewind

spring, b 8.4

8.4 ErgoStart/rope rotor
2
Relieve tension of rewind spring
The system will not be under 1 3

1
tension if the starter rope or rewind
spring is broken.
5904RA191 TG
5904RA194 TG
– Remove pawls, b 8.3

: Position spring (1) so that its : Remove the circlip (1)
anchor loops engage the pegs of
the pawls and the curved part of : Remove the washer (2)
the spring (arrow) is located in 2 3
the groove of the rope rotor post
: Remove carrier (3)
: Then slide the straight part of the

spring over the starter post until it 1
engages in the groove
5904RA193 TG
1
: Pull out the starter rope (1)
between rope rotor and starter
5904RA195 TG
cover with assembly hook (3)
5910 893 8800, then hold rope
rotor (2) tight
5904RA192 TG
The rewind spring must be relieved.

– Take all turns off the rope rotor
: Pull off the rope rotor (1)
– Pull out the rope with the starter
The guide loops of the springs must grip and carefully release the – Remove the starter rope; remove
run along the pawls (arrows). rope rotor any remaining scraps of rope,
b 8.5
Checking operation
– Pull starter rope, the rope rotor – Examine the return spring and
turns, and the pegs of the pawls replace if necessary, b 8.7
move in the direction of the
anchor loops – the pawls move
outward

reverse order

Installation 8.5 Starter rope / starter grip
– Lubricate the entire length of the – Remove starter, b 8.2

starter post with STIHL gear
lubricant, b 14 – Relieve the tension of the rewind
spring,
– Install starter rope in rope rotor, 2 b 8.4
b 8.5
5904RA198 TG
The rewind spring will not be under
1 tension if the starter rope is broken.
: Insert the carrier (1) in the spring – Remove ErgoStart/rope rotor,

housing so that the recess b 8.4
(arrow) engages the anchor loop
1 (2) – Remove any remaining rope from
the rope rotor if necessary
The starter rope must not be

5904RA196 TG
2 shortened.
2
: Orient inner anchor loop (arrow)

so that it rests against the base of 1
the starter post
: Orient rope rotor (1) so that the 5904RA199 TG
recess (2) engages the inner

anchor loop (arrow)
5904RA231 TG
: Fit washer (1)
The recess in the hub of the rope
rotor acts as carrier for the anchor : Slide circlip (2) into the lower
loop. groove (arrow) of the starter post
: Make the illustrated knot in the
end of the rope at the rope rotor
– Install pawls and spring, b 8.3
– Tension the rewind spring, b 8.6
– Grease the pegs of the pawls,

b 14
1
5904RA197 TG
reverse order
: Fit the rope rotor (1) on the starter

post so that the recess of the
rope rotor engages the anchor
loop

1
1
2
5904RA200 TG
4903RA132 TG
5904RA203 TG
: Push starter rope (1) out a short : Pull the rope through the grip until : Insert starter rope (1) in the
distance and undo the knot the knot at the end of the rope is recess (arrow) and press the
in the recess (arrow) knot into the depression (2) as far
– Pull the starter rope out of the as it will go
rope rotor, starter cover and
starter grip – Install ErgoStart/rope rotor,
b 8.4
Installation
– Tension the rewind spring, b 8.6

reverse order
5904RA201 TG
: Then thread the rope (1) through

5904RA230 TG
the opening (arrow)
: Make the special knot illustrated

in the end of the rope at the
starter grip 1
5904RA202 TG
: Thread starter rope (1) into rope

rotor
4903RA131 TG
– Secure the rope (1) with a simple

overhand knot
: Thread the new starter rope into
the starter grip from above

8.6 Tensioning the rewind 8.7 Replacing the rewind
spring spring
– Remove starter, b 8.2 1 – Troubleshooting, b 3.4
The replacement spring is supplied

ready for installation and secured in
2 1
5904RA206 TG
a spring housing.
– Wear face shield and protective

gloves
– Hold the starter grip firmly to – risk of injury
keep the rope (1) tensioned
5904RA204 TG
: Let go of the rope rotor and let the

starter rope rewind slowly – Relieve the rewind spring if
necessary and remove the
: Pull out part of the starter rope (1) ErgoStart/rope rotor, b 8.4
and insert it in the notch (arrow)
1 The rewind spring will not be under
: Turn rope (1) with rope rotor (2) tension if it is broken.
six times counterclockwise
If the rewind spring no longer
produces sufficient tension, it must
The rewind spring is now tensioned.
be replaced.
5904RA207 TG
Hold the tensioned rope rotor firmly,
– When removing the rewind
as the rewind spring will be
spring, lay a blanket over the
damaged if it jumps back suddenly.
assembly area
The rewind spring is correctly
tensioned when the starter grip (1)
2 1 sits firmly in the rope guide
bushing (arrow) without drooping to
one side. If this is not the case, the
rewind spring must be tensioned by
one additional turn.
When the starter rope is fully

5904RA205 TG
extended, it must still be possible to

rotate the rope rotor at least another
full turn before the the max. spring
tension is reached. If not, the spring
– Hold the rope rotor (2) steady tension must be reduced, otherwise
it will break.
: Pull out the twisted starter
rope (1) with the starter grip and Reduce spring tension
straighten it out Pull the rope out, hold the rope rotor
steady and take off one turn of the
rope.

reverse order

– Carefully press the spring Reinstalling a rewind spring that
housing into the mount in the has popped out
starter cover as far as it will go
1 If the rewind spring pops out during
The rewind spring may pop out. installation, fit it in the spring
housing as follows:
5904RA208 TG
1
1
: Remove screws (1) and carefully

remove the spring housing with 1
rewind spring
–The rewind spring may pop out 1
5904RA210 TG
5904RA212 TG
A worn or broken rewind spring may
still be under tension while installed.
– Remove any fragments of the old screws (1) : Insert anchor loop in the recess
spring (arrow) of the spring housing
: Fit the rewind spring (1) in the

Install new rewind spring spring housing in a circular
fashion, working in clockwise
direction
1 The further course of action is the

1 same as for "Installing a new rewind
spring".
5904RA211 TG
– Install the rope rotor, b 8.4

5904RA209 TG

: Make certain that the
reverse order
inner anchor loop (1) protrudes at
the spring housing; orient if
– Lubricate rewind spring with a necessary – anchor loop must
few drops of STIHL special engage the carrier on the rope
lubricant before installing it, rotor
b 14
: Orient the spring housing with

rewind spring in the starter cover
so that the outer anchor loop (1)
is positioned over the mount for
the loop (arrow)

9. Antivibration elements
The vibration damping connection

between drive tube assembly and 2 1 2 3
clutch housing is made via a rubber
insert (1-point antivibration system)
or via rubber buffers, annular
buffers and springs (4-point
antivibration system).
5904RA214 TG
5904RA217 TG
Damaged rubber inserts, rubber
buffers, annular buffers or springs
must always be replaced.
1
: Clamp square profile of installing : Loosen bolt (1) and remove

9.1 Rubber insert tool (1) with clutch housing (2) in clamp (2) from installation
1-point antivibration system the vise tool (3)
– Move the clutch housing back – Examine clamp, rubber insert

– Remove the drive tube assembly,
and forth while apply sufficient and clutch housing, replace if
b 12.1
STIHL press fluid between clamp necessary
and rubber insert, b 14
– Remove the clutch housing and
clutch drum, b 4.1
: Pull off clutch housing (2) Installation
2 3
O 25,4
2
O2
1 5,4
5904RA218 TG
5904RA213 TG
5904RA216 TG
1
2
1
– Clamp square profile of installing
: Insert installing tool (1) tool in vise
: Pull off rubber insert (1) from
4126 893 4900 with the 25.4 mm
clamp (2)
shaft into the clamp (2) as far as
: Slide clamp (2) onto installing
it will go
tool (3) 4126 893 4900 with the
25.4 mm shaft as far as it will go
: Tighten bolt (3)
: Tighten bolt (1)

9.2 Rubber buffers/springs
1 3 4-point antivibration
system
5904RA215 TG
5904RA219 TG
2 1 3 2
: Orient rubber insert (1) so that – Apply STIHL press fluid to the
5904RA222 TG
the clamping area (2) of the outside of the rubber insert,
clamp engages the b 14 1
opening (arrow) and the guide
ribs (3) line up with the : Orient the clutch housing (1) so : Remove screw (1)
depressions in the rubber insert that the clamping device (2) of
the clamp is aligned with the : Push protective shell (2) toward
middle of the opening (arrow)
engine and remove
– the guide ribs in the clutch
2 housing must line up with the
depressions in the rubber insert
1
: Slide on the clutch housing (1) 2
until the rubber insert (3) is
completely inside the clutch
housing
5904RA220 TG
1 3
5904RA223 TG
2 3
– Apply STIHL press fluid to the
3
inside of the rubber insert, b 14
: Remove clamping screw (1) and
: Push the rubber insert (1) onto
remove control handle for bike
the clamp (2) until the groove (3) handle (2)
is completely seated in the 4
– remove spring
opening on the opposite side of
5904RA221 TG
the rubber insert (arrow) 1

: Pull throttle cable (3) out of the
guide (arrows) and set aside bike
handle with control handle
: Loosen bolt (1) and remove
clutch housing (2) with rubber
insert (3) and clamp (4) – If handlebar adjustment is stiff,
disassemble clamps and guides
and clean the bike handle, b 14
reverse order

Installation
2
1
2
1
5904RA224 TG
5904RA227 TG
1
1 2
5904RA549 TG
: Loosen screw (1) on underside of : Remove screws (1) and pull out
the antivibration housing (2) support (2)
– Insert screwdriver through the
: Pull out drive tube assembly with holes in the plugs of the large
antivibration housing (2) at the anitvibration spring (1) and small
clutch housing 2 2 antivibration spring (2)
: Screw the screw into the
1 antivibration housing and fasten
antivibration springs
1 3
5904RA228 TG
1 2
– Examine clamp, annular buffers

5904RA225 TG
and support, replace if necessary

3 2
1
5904RA233 TG
: Pull annular buffers (1) over the
: Loosen screw (1) and remove spring nuts (2) and remove
complete antivibration
housing (2) from drive tube : Lever off the clamp (3)
assembly (3) : Push the clamp (1) on so that the
head of the screw (2) points
toward the recess (arrow)
1 1 – Coat inside of annular buffer with

2
5904RA550 TG
5904RA226 TG
1
– Insert screwdriver through the
: Remove rubber buffers (1) from holes in the plugs of the large
clutch housing (2) anitvibration spring (1) and small
antivibration spring (2
: Remove the screws and
antivibration springs

2 1
1 2
1
5904RA237 TG
5904RA234 TG
5904RA239 TG
1
2 2
: Push annular buffers (1) over the : Press the rubber buffers (1) onto – Apply STIHL press fluid to the
spring nuts (2) the plugs (2) of the clutch outside of the rubber buffer,
– Annular buffers must be housing as far as they will go b 14
completely behind the spring nuts
: Insert the drive tube assembly (1)
in the hole (arrow) of the clutch
2 1 housing as far as it will go
3
2
1
1 5904RA238 TG
5904RA235 TG
3
3
: Orient antivibration housing (1)
5904RA260 TG
: Orient support (1) so that the so that the support (2) faces the
large spring recess engages the drive tube assembly (3)
large antivibration spring (2) and
the annular buffers (3) align with : Push the antivibration : Orient drive tube assembly and
the holes (arrows) housing (1) onto the end of the tighten screw (1)
drive tube assembly (3) with the – Drive tube assembly is
built-in shakeproof washer until clamped and secured
the drive tube assembly (3)
protrudes a little on the opposite
side
2
1
5904RA236 TG
: Press on the support (1) and hold

it in place – the bearing plugs are
seated in the serrations and can
no longer twist

screws (2)

1 a
1 2
4
3
5904RA253 TG
5904RA255 TG
5904RA257 TG
1
: Push the antivibration : Orient bike handle (1) so that the : Starting at the engine, insert the
housing (1) into the rubber control handle (2) is on the throttle cable (1) in the
buffer, so that a circumferential muffler side guide (arrows)
gap (arrows) of a = 6 mm
between it and the shroud/ : Slide spring (3) into the mount on
protective hip plate results the clamp (4)
2
– Hold the antivibration housing (1) Throttle cable must be routed under
in this position the drive tube assembly.
– Through the gap, check that the

rubber buffers are seated
properly 1
5904RA258 TG
2 1
1 : Position fairing (1) with the hooks
in the openings (arrows) and
slide toward support (2)
5904RA256 TG
– Insert and tighten down the screw
2 : Position bike handle (1) on profile

5904RA254 TG
of the antivibration housing and

insert clamping screw (2) in the
thread (arrow) and tighten it
: Tighten screw (1) through the
opening in the support (2)
– Antivibration housing is
clamped and secured
– Position bike handle on

antivibration housing so that the
throttle cable is routed under the
drive tube assembly – narrow
side of the support and clamping
screw must face the cutting
attachment

10. Actuating levers
10.1 Control handle for loop

handle 3 2
1
1
5904RA263 TG
5904RA498 TG
2 1
5904RA261 TG
: Remove torsion spring (1) from : Thread out the throttle cable (1)
the guide (2) and pull out under on throttle trigger (2)
the throttle cable (3)
The control handle for the loop
handle (1) with slide control (arrow)
is pushed directly onto the drive 1
tube assembly (diameter 25.4 mm)
and clamped down with clamps.
– Installing and removing the

control handle for the loop
handle, b 10.1
5904RA265 TG
5904RA264 TG
10.1.1 Throttle trigger / throttle 1

trigger interlock : Carefully pull out trigger
: Remove throttle trigger (1) interlock (1) – tension on the
torsion spring is released
1 suddenly
1
5904RA262 TG
5904RA496 TG
: Take out the screws (arrows) 2

5904RA266 TG
: Remove handle molding (1) : Rotate throttle trigger (1) by 90° 1

clockwise until the hook (2) rests
against the surface (arrow) : Remove torsion spring (1)
–The slide control may pop out

Installation
1
2 2
1
5904RA269 TG
5904RA271 TG
1 2
5904RA267 TG
: Slide throttle interlock (1) onto : Slide throttle trigger (1) onto the
the post (2) post (2)
Shown without drive tube assembly
for a better view. – Release upper end of the torsion
spring
: Push torsion spring (1) onto the 2
post (2) so that the end that is
angled downward rests against
the ridge (arrow) on the left
5904RA272 TG
1
5904RA270 TG
: Orient throttle trigger (1) so that

1 the lug (2) engages the trigger
interlock (arrow)
5904RA268 TG
: Torsion spring (1) must lie in the

notch (arrow)
2
: Use a suitable tool to press the
upper end (arrow) of the torsion 2
spring toward the handlebar and
hold it there
1
1
5904RA273 TG
5904RA393 TG
: Push torsion spring (1) under the

throttle cable (2)
: Thread throttle cable (1) into
throttle trigger (2)
– Turn throttle trigger by 90°

counterclockwise

10.1.2 Slide control
1
– Remove control handle for loop
handle, b 10.1
2
– Remove throttle trigger / throttle
3 4902RA125 TG
5904RA294 TG
1
: Push the torsion spring (1) into : Short end (1) must lie between
the mount (2) as far as it will go the ridges (arrows)
1
The bent end (arrow) must rest
against the peg (3).
5904RA291 TG
1
1
: Remove slide control (1)
5904RA295 TG
4902RA126 TG
: Orient slide control (1) so that the

cam (arrow) faces downward
1
: Push slide (1) into the mount so
that engages the middle of the
5904RA292 TG
serration (arrow)
1
1 : Remove torsion spring (1)
2
5904RA296 TG
Installation
3
5904RA262 TG
: Position slide control (1) so that

the cam (2) is seated to the left of
the contact spring (3)
: Position handle molding (1),

insert and tighten down the 1
5904RA293 TG
screws (arrows) 2
Checking operation
– Check throttle cable setting, : Slide torsion spring (1) onto the
adjust if necessary, b 10.2.4 post (2) so that the angled
end (arrow) faces upward

10.2 Control handle for bike 1-point antivibration system
1 handle
1
1
2
5904RA297 TG
5904RA301 TG
5904RA299 TG
: The torsion spring (1) must be
seated in the mount (2)
: Remove protective tube (1) from
The control handle for bike the guide (arrow)
handle (1) with lever for stop
function (arrow) is pushed directly
1 onto the bike handle (diameter 4-point antivibration system
25.4 mm or 22 mm) and secured
with a transverse screw.
2
2
10.2.1 Removal and installation
5904RA298 TG
5904RA222 TG
: Check installation position of
torsion spring (2) and slide
control (1) 1
2
– see illustration
: Remove screw (1), push
For the throttle trigger to be seated fairing (2) toward engine and
5904RA300 TG
correctly, the torsion spring (2) must 1 remove

be pushed onto the post (3) over the 3
ribbed base
– Torsion spring is completely inside : Unscrew and remove the
the handle molding. screw (1), remove nut on the
opposite side
Checking operation
– Set slide control to position : Remove control handle (2) from

STOP-0 , the contact spring must bike handle (3)
actuate the microswitch – this
5904RA257 TG
can be heard as a clicking noise

1
– Install throttle trigger / throttle
: Remove protective tube (1) from
the guide (arrows)
– Check throttle cable setting,
adjust if necessary, b 10.2.4
– Examine throttle cable or short
circuit wire and replace if
– Reassemble remaining parts in necessary, b 6.6
reverse order
– Examine actuating lever, replace
if necessary, b 10.2

Installation 1-point antivibration system – Insert and tighten down the screw
1 1
10.2.2 Throttle trigger / throttle
trigger interlock
2
– Remove control handle for bike
5904RA302 TG
handle, b 10.2
5904RA304 TG
3 2 2 1 1
: Orient control handle for bike : Press protective tube (1) into the
handle (1) so that the throttle guides (arrow) so that the
trigger (2) faces toward the protective tube (1) lies against
cutting attachment the drive tube assembly (2) and
does not form any kinks
5904RA305 TG
: Push control handle for bike
handle (1) onto handlebar (3)
and twist it gently back and forth 4-point antivibration system
1
until it is aligned with the
openings (arrows) : Unscrew screws (1) and carefully
remove handle molding (2) –
trigger interlock can pop out
2
5904RA257 TG
1 1
5904RA303 TG
: Press protective tube (1) into the 3
5904RA306 TG
2 guide (arrows) as far as it will go
– protective tube must lie tight
: Push bolt (1) through control against the machine
handle for bike handle and
handlebar : Lift and relieve tension on the end
of the torsion spring (1) at the
2 stop (2)
: Push new hexagon nut (2) in the
mount on the opposite side, then
screw in the bolt and tighten it : Remove torsion spring (3)
The control handle must be

clamped firmly onto the handlebar
and must be immovable.
5904RA258 TG
: Press fairing (1) with the hooks in

the openings (arrows) and slide
toward support (2)

2 1
1
1
5904RA307 TG
5904RA310 TG
5904RA312 TG
: Remove throttle trigger (1) and – Stud (1) must be present, install : Push on the trigger interlock (1)
unhook throttle cable (2) from new stud if necessary and hook on the torsion spring
throttle trigger (arrow) (arrow)
A new throttle trigger is supplied
with a pre-installed stud.
1 – With a new throttle trigger or after 2

the position of the stud has been
changed, the throttle cable must
be readjusted, b 10.2.4
2
1
5904RA308 TG
5904RA313 TG
1
: Carefully pull out trigger – Turn the angled end of the torsion
interlock(1) – tension on the spring (1) clockwise until it is
torsion spring (2) is released aligned behind the rib (arrow)
suddenly 2
5904RA311 TG
: Push trigger interlock (2) on as

– Remove torsion spring far as it will go and make certain
that the angled end (1) rests
: Slide torsion spring (1) onto the behind the ridge (arrow)
post (2) so that the angled end
(arrow) faces the handle housing – Trigger interlock may pop out
1
2
5904RA309 TG
2
5904RA 314 TG
: Remove the lever (1) from the

throttle trigger (2)
1
– Examine trigger interlock, lever
and torsion springs, replace if : Press nipple (1) of the throttle
necessary cable into the hole of the lever (2)
and guide it into the slot (arrow)

1
2
3
5904RA315 TG
5904RA318 TG
5904RA321 TG
1
: Slide throttle trigger (1) onto : Turn torsion spring clockwise and – Carefully fit handle molding (1)
post (3) hook it into the lever (arrow) until it snaps into place
– Levers may pop out
: Slide lever (2) into the throttle
trigger (1) so that the lever : Insert and tighten down the
(arrow) rests against the stud screws (arrows)
Checking operation
1
1
5904RA319 TG
Ground wire and short circuit wire

5904RA316 TG
must be inserted completely in the

guides (arrows).
5904RA322 TG
: Turn the trigger interlock (1) 2
slightly and push the throttle
2 1
trigger on further until it engages When the trigger interlock (1) is not
the trigger interlock pressed, the throttle trigger (2) is
blocked and must not move.
: Release throttle trigger (2) – the

throttle trigger must return
completely to the stop
5904RA320 TG
1 : Route throttle cable (1) and

protective tube (2) in the guides
5904RA317 TG
(arrows) and hold in place
: Slide torsion spring (1) onto

throttle trigger and secure it with
the anchor loop on the cylindrical
raised part (arrow)

10.2.3 Lever for stop function

handle, b 10.2.1
– Remove throttle trigger and

5904RA325 TG
5904RA327 TG
Removal and installation are
described in the chapter "Short 1
circuit wire on control handle for
bike handle", b 6.6.5 : Push the lever (1) onto the : Release throttle trigger (arrow) –
throttle shaft the throttle trigger must return
completely to the stop in the initial
10.2.4 Adjusting the throttle If it is possible to continue turning position
cable the lever (1) in the direction of full
throttle, then the throttle shutter is
– Remove shroud, b 5.4 not completely open in the full- Adjusting throttle cable on
throttle position. control handle for loop handle
The throttle trigger must be adjusted With the control handle for the loop
in order for the throttle shutter of the Adjusting throttle cable on handle, the throttle cable grommet
carburetor to open and close control handle for bike handle is snapped into a slide and the
completely when the throttle is throttle cable is adjusted by moving
opened. the slide.
The adjustment tasks vary for the
control handles for the loop handle
and bike handle.
With both versions, make certain

that the throttle cable grommets are
seated in the guides and are
5904RA326 TG
inserted as far as possible

– Position of the throttle cable
grommets influences the throttle
cable adjustment. : Press throttle trigger and turn
screw (arrow) until the throttle
shutter is open completely
Checking throttle cable setting
– Turn the stud clockwise
= Throttle cable is tensioned
(throttle shutter opens more)
1 – Turn the stud counterclockwise

= Throttle cable is relieved
(throttle shutter opens less)
5904RA324 TG
: Press throttle trigger (1) as far as

it will go and hold it there

When the throttle trigger is not Installation
actuated, the throttle cable must not
be under tension, otherwise the
throttle shutter may no longer close
completely, which would result in a
high idle speed.
– Reassemble parts in reverse

5904RA328 TG
order 1
5904RA332 TG
10.2.5 Throttle rod
: Position screwdriver at the
notch of the slide (arrow) and
press in – Remove the shroud, b 5.4 : Push throttle rod (1) into
– Slide is unlocked hole (arrow) and hook it in
: Press throttle trigger and move

slide (arrow) until the throttle
shutter is open completely 1
1
– Push slide (arrow) in direction of
the protective tube
3
= Throttle cable is tensioned 3
(throttle shutter opens more)
5904RA330 TG
5904RA333 TG
– Push slide (arrow) in direction of 2
the trigger interlock 2
= Throttle cable is relieved : Hold lever (1) and press lever (2)
(throttle shutter opens less) of the throttle shaft in the : Hold lever (1) and push lever (2)
direction of full-throttle until the of the throttle shaft in the
throttle rod (3) slides out of the direction of full-throttle
lever (2)
: Hook throttle rod (3) into
groove (arrow) and release
lever (2)
2
Checking operation
5904RA329 TG
– When the throttle trigger on the

1 control handle is pressed all the
way, the lever of the throttle shaft
5904RA331 TG
: Release throttle trigger (arrow) – must move as far as it can go in

the throttle trigger must return the direction of full-throttle, adjust
completely to the stop in the initial throttle cable if necessary,
position b 10.2.4
: Unhook the throttle rod (1) from
the lever (2)
reverse order
– Check lever (2), replace if
necessary, b 11.7

11. Fuel system
11.1 Air filter 11.2 Filter housing All versions
– Refer also to troubleshooting, – Remove the air filter, b 11.1 1

b 3.6, b 3.7
5904RA395 TG
1
1 : Remove tank vent hose (1) at the

1
5904RA390 TG
connector (arrow) – always use a
5904RA394 TG
new tank vent hose
: Remove screws (1)

: Remove plug (1) on diagnostic 1 1
: Remove the filter cover (2) connector (arrow)
2
All versions
5904RA396 TG
1
2
: Unscrew nuts (1) and pull off filter
5904RA391 TG
housing (2)
5904RA003 TG
: Remove the air filter (1)

1
: Remove screws (1)

– Examine air filter, clean or
replace if necessary 1
– see Instruction Manual In versions with M-Tronic, the
grommet (2) is not removed
because it is connected to the
5904RA397 TG
switchgear.
order
: Remove grommet (2)
: Press out grommet (1) in the

direction of the carburetor
– For versions with M-Tronic:

check the plug of the diagnostic
connector, replace if necessary

: Press grommet (1) into Versions with M-Tronic
1 hole (arrow) on the back of the air
filter housing until it encloses the
hole completely
5904RA398 TG
2
5904RA403 TG
: Remove gasket (1) – always use 1 1
a new gasket
: Press plug (1) into the diagnostic
5904RA401 TG
– Check mating surfaces on connector (arrow) as far as it will
carburetor and filter housing, go
clean if necessary, b 14
– To simplify installation, coat the
inside of the grommet with STIHL All versions
Installation press fluid, b 14
: Slide filter housing (1) onto the

2
1 studs so that the support of the
carburetor engages the
grommet (2)
– Fit nuts and screw them tight. 1
5904RA404 TG
5904RA399 TG
2
2 1
: Push the grommet (1) into the
: Push on new gasket (1) mounts (arrows)

screws (2)
1
5904RA402 TG

reverse order
– Use STIHL press fluid to simplify

assembly, b 14
5904RA400 TG
: Push the new tank vent hose (1)

completely onto the
connector (2)
– To simplify installation, coat the
outside of the grommet with
: Orient grommet (1) so that the

cone faces the hole

11.3 Carburetor All versions
– Remove filter housing, b 11.2 1

1
– Open filler cap and drain fuel tank
– Collect fuel in a clean container, 2
5904RA410 TG
b1 3
3
5904RA330 TG
The fuel hose may only be removed
when the tank filler cap is open. 2 : Remove carburetor (1)
: Hold lever (1) and press lever (2) : Examine the fuel hose (2), with
of the throttle shaft in the connector (3), replace if
direction of full-throttle until the necessary, b 11.9.2
Leads and plug connections must
throttle rod (3) slides out of the
not be damaged.
lever (2)
1
1
5904RA411 TG
5904RA405 TG
1
5904RA408 TG
: Remove gasket (1) – always use

: Remove plug (1) on solenoid a new gasket
valve of the carburetor : Pull off the fuel return line (1) at
the connector (arrow)
– Check and clean mating surfaces
: Pull leads out of the on carburetor and spacer flange,
guides (arrows) b 14
– Examine the carburetor and

repair or replace it if necessary.
– Replace removed fuel hoses,

2 b 11.9.2
1
5904RA409 TG
1
5904RA406 TG
: Pry out connector (1) with fuel

hose (2)
: Pull bushing (1) with switchgear
over the choke lever (2) and lay it
aside

Installation Versions with M-Tronic
2
1
1
5904RA415 TG
1
5904RA412 TG
5904RA185 TG
: Push the new fuel return line (1)
completely onto the
: Push on new gasket (1) connector (2) : Orient plug (1) so that the
lug (arrow) aligns with the groove
in the mount (2)
– Push plug into the mount as far
1 Leads and plug connections must as it will go
not be damaged.
1
5904RA413 TG
1 2
: Press carburetor (1) over the

studs (arrows)
5904RA186 TG
5904RA416 TG
2
Do not expose plug to tensile loads,
: Orient bushing (1) with thus run leads so that they form a
switchgear so that the 90° loop at the plug.
scale (arrow) faces the cylinder
: Press black lead (1) as far as it
1 : Guide bushing (1) with will go into the guides (arrows),
switchgear over the choke starting at the plug
5904RA414 TG
lever (2) and position

2 3 : Press red lead (2) as far as it will
– Install filter housing, b 11.2 go into the guides (arrows),
starting at the plug
: Push connector (1) with fuel
hose (2) into the fuel suction
hose (3) so that it between the
ribs (arrows) – fuel hose is
secured

All versions 11.3.1 Leakage test : Push ring (1) to the right and
pump air into the carburetor until
The tank vent must also be checked the pressure gauge (2) shows a
and replaced if problems develop pressure of approx.
1 0.8 bar (80 kPa)
with the carburetor or fuel supply,
b 11.8
If this pressure remains constant,
3 The carburetor can be tested for the carburetor is airtight. However, if
leaks with the pump the pressure drops, there are two
0000 850 1300. possible causes:
5904RA333 TG
2 – Remove the carburetor, b 11.3 1. Metering diaphragm or gasket is
damaged, replace if necessary,
b 11.4.1
: Hold lever (1) and push lever (2)
of the throttle shaft in the
1 2. The inlet valve is not sealing
direction of full-throttle
(foreign objects in the valve
seat,
: Hook throttle rod (3) into sealing cone of the inlet needle
groove (arrow) and release is damaged or
lever (2) inlet control lever is sticking),
remove to clean,
b 11.4.2
5904RA338 TG
Checking operation
2 3. Pump diaphragm or
– When the throttle trigger on the gasket damaged,
control handle is pressed all the : Push the fuel line (1) replace if necessary, b 11.4.3
way, the lever of the throttle shaft 1110 141 8600 onto the double
must move as far as it can go in connector (2) – Check tank vent if necessary,
the direction of full-throttle, adjust 0000 855 9200. b 11.8.1
throttle cable if necessary, control
handle for loop handle, b 10.1 : Push the fuel line with double – After completing the test, slide
control handle for bike handle, ring (1) to the left and vent the
connector onto the fuel
b 10.2 port (arrow) system, then disconnect fuel line
from elbow connector of
– Install air filter, b 11.1 carburetor
– Reassemble remaining parts in 2 – Install filter housing, b 11.2

reverse order
reverse order
5904RA339 TG
– Push pressure hose of the pump

0000 850 1300 onto the double
connector

11.4 Repairing the carburetor Installation
2 1
11.4.1 Metering diaphragm 2
1
– Remove the carburetor, b 11.3 3
5904RA342 TG
3
5904RA345 TG
: Carefully separate the metering
diaphragm (1) and gasket (2).
– Note the order in which the
The diaphragm material is metering diaphragm (2) and
subjected to continuous alternating gasket (1) are installed
stresses and eventually shows
signs of fatigue. In other words, the : Align the gasket (1) and metering
5904RA340 TG
diaphragm distorts and swells and diaphragm (2) so that the small
must be replaced. holes (arrows) align with the
pins (3)
: Take out the screws (arrows) – Examine the metering diaphragm
for signs of damage and wear, fit : Position gasket (1) and metering
a new gasket diaphragm (2) on the pins (3)
1
1
1
5904RA341 TG
5904RA343 TG
: Remove the complete flange (1) 5904RA346 TG
If the gasket and diaphragm are : Remove the end cover (1) : Position cap (1) in the circular
stuck to the carburetor, they must groove (arrow)
be removed very carefully
– Position end cover
– Remove metering
diaphragm with gasket
1
5904RA344 TG
: Remove cap (1)

11.4.2 Inlet needle
3
– Remove the metering
diaphragm,
1 b 11.4.1 1
2
2
5904RA347 TG
5904RA351 TG
1
: Orient flange (1) so that : Pull out the inlet needle (1)
connector (2) is on the same side
as the choke shutter and position : Take out and examine the
it so that it engages the pins on spring (2), replace if necessary
5904RA349 TG
the carburetor
: Orient end cover (3) so that the

bulges (arrows) face in the
: Remove screw (1)
direction of the idle speed
screw LA
2 1
165RA348 TG
1 1
1
: The inlet needle must be
5904RA350 TG
replaced if a circular
5904RA348 TG
indentation (arrow) is visible on

the tip of its sealing cone
: Pull the inlet control lever (1) with
spindle (2) out of the groove in
: Fit and tighten screws (1) the inlet needle Installation
– Check that the metering

The spring under the inlet control
diaphragm and gasket are lever may pop out.
correctly seated, then tighten
down the screws crosswise
1
– Reassemble remaining parts in 2
reverse order
5904RA352 TG
: Fit the inlet needle (1)
: Fit spring (2) in bore

: Remove the end cover (2)
1 2 3 1
If the gasket and pump diaphragm
are stuck to the carburetor, they
must be removed very carefully.
5904RA353 TG
5904RA356 TG
2
: First fit the spindle (2) of the inlet 3 : Pull fuel strainer (1) with needle
control lever (3) at the conical out of the carburetor housing and
seat (arrow) of the spring, then clean or replace it
slide the clevis on the inlet control
5904RA354 TG
lever into the groove on the inlet 1
needle (1) order
Ensure that the spring locates on : Carefully remove the pump

the nipple of the inlet control lever. diaphragm with gasket from the Installation
end cover (1)
– Press the inlet control lever down
and secure it with the screw. : Carefully separate the pump 2
diaphragm (2) and gasket (3)
– Check that the inlet control lever
moves easily The diaphragm material is
subjected to continuous alternating
– Install the metering diaphragm, stresses and eventually shows
b 11.4.1 signs of fatigue. In other words, the
5904RA357 TG
diaphragm distorts and swells and 1
must be replaced.
11.4.3 Pump diaphragm
– Examine the pump diaphragm for
: Orient new gasket (1) and pump
– Troubleshooting, b 3.6 signs of damage and wear, fit a
diaphragm (2) so that the
new gasket
tabs (arrows) match
– Examine fuel strainer for
contamination and damage,
clean or replace if necessary
1
2
5904RA354 TG
: Remove screw (1)

Installation
2
2
1
4
1
3
5904RA358 TG
5904RA360 TG
4
5904RA362 TG
: Position gasket (1) with pump – Check that the pump diaphragm 3 2 1
diaphragm (2) on the end and gasket are correctly seated
cover (3) so that the : Orient lever (2) so that the hook
protrusions (arrows) match and : Hold end cover (1) in position, engages the choke
are secured via the pins (4) screw in and tighten screw (2) lever (arrows)
– Reassemble remaining parts in : Slide the lever (2) onto the

reverse order throttle shutter shaft so that it
aligns with the flat faces (3)
11.4.4 Throttle shaft lever : Screw in the screw (1) and

tighten
Checking operation
5904RA359 TG
– Troubleshoot carburetor, b 3.6

1
2
– Position the end cover (1) on the
carburetor housing from below so
1
that the gasket and pump
diaphragm remain secured to the
end cover
5904RA363 TG
: Orient end cover (1) so that the
protrusion (arrow) is on the same 1
5904RA361 TG
side as the idle speed screw LA

and fit until the pins of the end 2 In the "warm start" position,
cover align with the holes in the lever (1) must engage the
carburetor housing : Remove screw (1) notch (arrow) of lever (2) and align
with the contact surface of the cam.
: Remove lever (2)

Checking operation, versions Installation
with M-Tronic
All versions
5904RA366 TG
1
5904RA364 TG
5904RA369 TG
: Remove spring (1)
1
1
Lever (1) must align with the contact
surface (arrows) on the cam of 2 : Orient the torsion spring (1) so
lever (2). that the angled end points toward
the carburetor
reverse order : Slide torsion spring (1) onto the
choke shaft and slide the angled
5904RA367 TG
end into the hole (arrow) – torsion
11.4.5 Choke lever/choke knob spring is secured
1
Versions without M-Tronic
: Push out circlip (1)
: Pull out lever (2) with torsion 3 1

spring (arrow)
– Remove torsion spring
5904RA370 TG
5904RA365 TG
1 2
2
: Orient the lever (1) so that the flat
: Remove choke knob (1) with a
surface aligns with the choke
firm tug
– choke knob is held in place by shaft (2) and the cam (3) faces
the depression on the shaft the throttle shaft lever
5904RA368 TG
: Slide lever (1) onto choke

1 shaft (2), turn torsion spring
counterclockwise and hook it into
: Push out circlip (1) lever (arrow)
: Pull out lever (2) with torsion

spring (arrow)
– Remove torsion spring

Versions with M-Tronic Checking operation without M-
2 Tronic
3
2
5904RA373 TG
1
5904RA371 TG
5904RA363 TG
1 2 : Push the spring (1) onto the
choke shaft (2) 1
: Orient the lever (1) so that the flat
surface aligns with the choke In the "warm start" position,
shaft (2) and the cam (3) faces lever (1) must engage the
the throttle shaft lever notch (arrow) of lever (2) and align
with the contact surface of the cam.
: Slide lever (1) onto choke
shaft (2), turn torsion spring
counterclockwise and hook it into Checking operation with M-
lever (arrow) Tronic
5904RA392 TG
2
All versions
1 When pressing on the choke knob,

the choke shaft must be held in
place.
5904RA364 TG
: Place the opposite end (arrow) of
the choke shaft on a solid surface
1
5904RA372 TG
Lever (1) must align with the contact

surface (arrows) on the cam of
lever (2).
– Slide on the lever as far as it will
– Install the carburetor, b 11.3
go – the groove for the circlip
must be visible
– Install filter housing and
grommet, b 11.2
: Push circlip (1) into place
5904RA374 TG
: Press the choke knob (1) firmly

onto the choke shaft until it snaps
into place – spring must rest
against the base (arrow) of the
black lever

The high speed screw H and the low High speed screw
speed screw L have a special
hexagonal head and can only be
adjusted with screwdriver 1
5910 890 2307
– no limiter caps are used.
1
2 5904RA279 TG
– See also Troubleshooting on the
5904RA381 TG
carburetor, b 3.6
: Set choke lever (1) to
position }; the cam on the
lever (2) must actuate the Low speed screw : Unscrew high speed
microswitch (arrow) screw H (arrow) with
– clicking noise screwdriver (1) 5910 890 2307
1
reverse order
1
11.4.6 Adjusting screws, 5904RA379 TG
carburetor without M-
Tronic
5904RA382 TG
1 2 : Unscrew low speed
screw L (arrow) with
screwdriver (1) 5910 890 2307
: Examine the tip (arrow) for signs
of damage or wear. Fit a new high
speed screw H (1) if necessary
1
3
5904RA378 TG
– Turn the high speed screw H in

as far as possible
Grommet not shown for a better – Make the basic setting, b 11.6.1
view.
5904RA380 TG
There are three adjusting screws on

the carburetor:
H = High speed adjusting
screw (1) : Examine the tip (arrow) for signs
L = Low speed adjusting of damage or wear. Fit a new low
screw (2) speed screw L (1) if necessary
LA = Idle speed adjusting screw (3)
– Turn the low speed screw L in as
If the carburetor setting can no far as possible
longer be adjusted, this may also be
due to the adjusting screws. – Continue with the high speed
screw H

11.5 Carburetor adjustment The idle speed screw LA remains Now the basic setting of the high
with M-Tronic unchanged and can still be set by speed screw H and the low speed
the user to adjust the idle speed. screw L has been established.
The carburetor is adjusted by the M-
– Continue with fine adjustment
Tronic, thus no manual adjustments
11.6.1 Basic setting
to the carburetor are necessary or
possible.
Only necessary if the high speed Fine adjustment
screw H or low speed screw L has
to be replaced or for cleaning and Carburetor and air filter must be
setting the carburetor. installed.
Basic setting and fine adjustment – Attach deflector and cutting

2 are required after the adjusting attachment (mowing head), see
screws have been removed and Instruction Manual
installed. – Cutting attachment must rotate
freely, clean if necessary
5904RA383 TG
1 Before the start of the fine

adjustment, the adjusting screws – Examine the spark arresting
must be pre-set; this can not be screen (if installed); clean or
done if the engine is running or if the replace it if necessary, b 3.7 or
Position of the screw (1) must not carburetor has been removed from b 5.1
be changed the machine.
– changing the factory default
– Examine air filter, replace if
setting leads to impaired engine With the low speed and high speed necessary
performance. screws in their seats, turn them – a dirty air filter may not be
Solenoid valve (2) is pre-set at the counterclockwise. cleaned, b 11.1
factory and must not be
disassembled. – Set adjusting screws using
3 screwdriver 5910 890 2307
– In case of malfunctions, check M-
Tronic, b 7.5
Basic setting of the
high speed screw H and low speed
screw L must have been
11.6 Carburetor adjustment established.
without M-Tronic
5904RA384 TG
– Let the engine warm up

The new carburetors have been
1 2
adjusted for optimum performance
and fuel efficiency in all operating
states at the factory. : Set adjusting screws using
screwdriver (3) 5910 890 2307
The high speed screw H and low
speed screw L can only be adjusted : Turn high speed adjusting
with screwdriver 5910 890 2307. screw H (1)
1 3/4 turns Turn low speed
It is no longer necessary or possible screw L (2)
for the user to adjust these adjusting 1 1/4 turns
screws.

Setting idle speed – Check cutting attachment, adjust
1 2 if necessary
– Examine the spark arresting

screen (if installed); clean or
replace it if necessary, b 3.7 or
b 5.1
5904RA386 TG
– Examine air filter, replace if
necessary
5904RA385 TG
– a dirty air filter may not be

1 The fine adjustment of the high cleaned, b 11.1
speed screw H (1) and low speed
: Position screwdriver (1) screw L (2) is now complete. Check running behavior:
5910 890 2307 in low speed The engine must accelerate well
screw L and high speed screw H The settings of the high speed when the throttle is opened and idle
screw H and the low speed screw L smoothly.
– Set idle speed with a speed can no longer be changed by the
tester. Set the specified speeds user.
within the tolerance range of Setting the idle speed
± 200 rpm
11.6.2 User adjustment The basic and fine adjustment of the
adjusting screws must be set.
1. Using the
idle speed screw LA
– Let the engine warm up
set speed to 3300 rpm
2. Turn the
low speed screw L Engine stops when idling
left or right to set the highest.
speed – Turn the idle speed screw LA
clockwise until the cutting
5904RA387 TG
If this speed is more than attachment begins to turn, then

3700 rpm, stop the adjustment and back off 1 turn
start again with step 1.
3. With the The new carburetors provide an Cutting attachment rotates

idle speed screw LA optimum fuel-air mixture in all during idling
set the speed again to environments and operating states,
3300 rpm thus all that is eventually necessary – Turn the idle speed screw LA
or possible is correction of the idle counterclockwise until the cutting
4. With the low speed screw L speed using the idle speed screw attachment stops turning, then
set the speed to 2800 rpm LA. back off 1 turn
To avoid problems, the following
Fine adjustment of the cut-off speed steps must be performed for all
is not required. settings:

Erratic idling behavior, poor
acceleration
2
– Check basic and fine setting of
the adjusting screws, adjust them
or service carburetor, if 1
necessary, b 11.6.1, b 11.4
5904RA418 TG
5904RA421 TG
Correcting the carburetor setting
for use at high altitudes
: Unhook the throttle rod (1) from : Examine and clean the mating
Engine not running satisfactorily
the lever (2) surfaces (arrows), remove any
gasket residues if necessary.
– Check basic and fine setting of
b 14
the adjusting screws, adjust them
or service carburetor, if
1 The mating surfaces must be in
necessary, b 11.6.1, b 11.4
perfect condition and without any
damage whatsoever. If the mating
11.7 Spacer flange 2 surfaces are damaged, the cylinder
or spacer flange must be replaced.
5904RA419 TG
: Unhook throttle cable (1) at 1

1 lever (2) and remove it from the 2
mount (arrow)
5904RA422 TG
1 : Press out the circlip (1) and
5904RA417 TG
remove the lever (2)

2
1
: Remove gasket (1) – use a new
5904RA420 TG
gasket
1
: Unscrew screws (1) and remove

spacer flange (2)
– Remove gasket – use a new

gasket
– Check spacer flange, replace if

necessary – even tiny cracks can
lead to impaired engine
performance, b 3.6, b 3.7

Installation
1 3 2
2 1 1
4
3
5904RA425 TG
5904RA418 TG
5904RA423 TG
2 : Orient lever (1) so that the : Hook the throttle rod (1) onto the
pins (arrows) face the spacer lever (2)
: Align the new gasket (1) so that flange and push it onto the
the tab (2) faces downward and post (2)
the holes (arrows) match
2
: Insert two screws (3) and affix
gasket to spacer flange (4)
5904RA427 TG
2
5904RA426 TG
1 1
2 : Orient gasket (1) so that the
holes (arrows) match and the
: Push circlip (1) into place openings engage the ridge (2)
5904RA424 TG
2 : Press gasket (1) over the studs
: Position spacer flange (1) with 1

gasket on cylinder intake port reverse order
: Insert and tighten down the 2

screws (2)
5904RA419 TG
: Hook throttle cable (1) onto

lever (2) and press it into the
mount (arrow)

11.8 Tank vent Testing with gauge pressure
11.8.1 Testing 2
2
If problems develop in the
carburetor or fuel supply, the tank 1
vent must always also be tested and
replaced if necessary. Correct
5904RA430 TG
functioning is determined by testing
the fuel tank under vacuum or at
5904RA432 TG
gauge pressure via the fuel hose.
– Open filler cap and drain fuel : Pull off the fuel return line (1) at 1
tank, b 1 the connector of the carburetor
and seal with a suitable : Slide ring (1) to the right and
– Close the filler cap stopper (2) connect the pump (2)
0000 850 1300 to the double
nipple (arrow)
– Remove filter housing, b 11.2 – Create excess pressure in fuel
Testing with negative pressure
tank
2 – Actuate the pump until the

pressure gauge shows a
pressure of 0.5 bar. If this
pressure remains constant for at
least 20 seconds, the tank and
tank vent are airtight. If the
pressure drops, the leak must be
5904RA431 TG
located and the defective part

5904RA428 TG
replaced.
1
2 1
– Replace the tank vent or tank if
: Slide ring (1) to the left and
: Pull out connector (1) with fuel necessary, b 11.8 or b 11.9.3
connect the pump (2)
hose (2) 0000 850 1300 to the double
nipple (arrow) – Always use a new fuel hose
– Pull connector off of fuel hose – Create vacuum in fuel tank
Pressure is equalized via the tank order
vent. A negative pressure must not
build up inside the tank.
– Clean the area around the tank

vent
– Always use a new fuel hose

5904RA429 TG
– Replace the tank vent or tank if

1 necessary, b 11.8 or b 11.9.3
: Push the connector (1)

0000 855 9200 into the fuel
suction hose (arrow)

11.8.2 Removal and installation – Troubleshooting, b 3.6 or
b 3.7
Clean the fuel tank if necessary.
1
– Open the filler cap and drain the
2 tank.
5904RA435 TG
– Fill a little clean gasoline into the
tank, close the tank and shake it
1 thoroughly.
– Coat mounting surface of tank
vent with STIHL press fluid, – Reopen the tank and empty it.
5904RA433 TG
b 14
– Ensure that the fuel is disposed
– Push new tank vent into hose of correctly and without harming
: Pry out the tank vent (1) via the the environment, b 1
mounting rib (arrow) : Orient tank vent (1) so that the
connector with hose lines up with – Open the filler cap
– Remove tank vent (1) from hose the opening (arrow)
(2), examine and replace if
necessary : Press tank vent (1) with hose
completely into the grommet
– Remove the grommet
Hose must be pressed completely
Always fit a new tank vent. onto the connectors of the tank vent
and the filter housing and run so
that it is free of kinks.
Installation 1
5904RA436 TG
reverse order
: Use hook 5910 893 8800 to pull

11.9 Fuel intake the pickup body (1) out of the fuel
1 tank
11.9.1 Pickup body
Impurities which are entrained into Take care not to overextend the fuel
hose.
5904RA434 TG
the fuel tank with the fuel are

trapped by the pick-up body. With
time, the fine pores in the pick-up : Pull off pickup body (1) and
body become clogged with very fine examine it, replace if necessary
: Orient grommet (1) so that the dirt particles. This reduces the
cone faces the fuel tank intake diameter and fuel can no – Reassemble parts in reverse
longer be delivered in sufficient order
– Coat outside of grommet with quantities.
Always check the fuel tank and pick-
up body first if problems develop in
: Press grommet (1) into
the fuel supply.
hole (arrow) until it encloses the
hole completely

11.9.2 Fuel hose
– Open the filler cap
– Remove filter housing, b 11.2 1 1
5904RA439 TG
5904RA450 TG
: Pull the fuel suction hose (1) out – Use STIHL press fluid to simplify
of the inside of the tank assembly, b 14
2
: Orient the fuel suction hose (1)
1
5904RA409 TG
and press it into the hole in the

housing as far as it will go – the
flange must be flush with the
guide (arrow)
: Pull out connector (1) with fuel 1
hose (2)
5904RA440 TG
1
: Pull off the fuel return line (1) at
the connector (arrow)
5904RA451 TG
1 Always use new fuel hoses.
5904RA437 TG
Installation : Push the new fuel return line (1)

completely onto the
connector (arrow)
: Pull off fuel hose (1) with

connector at the
carburetor (arrow) 1
– Pull connector off of fuel hose

5904RA449 TG
– Remove the pickup body,

b 11.9.1
: Push fuel suction hose (1) into

hole (arrow) in fuel tank

11.9.3 Fuel tank
1
– Empty the fuel tank, b 1
2 3
1 5904RA452 TG
2 – Remove filter housing, b 11.2
5904RA455 TG
: Connect the fuel hose (1) to the – Coat connector with STIHL press
connector (2) fluid, b 14 2
1
– Slide carburetor onto stud bolts : Push connector (1) into the fuel 1
suction hose (2) so that the fuel
hose (3) is between the
5904RA456 TG
ribs (arrows) 1
1 – Connector must be pushed all
the way into the fuel suction hose 1
: Remove screws (1)
: Remove the protective hip

plate (2)
5904RA453 TG
: Push the fuel return line (1)

5904RA537 TG
completely onto the

connector (arrow)
2
: Use hook 5910 893 8800 to pull
the fuel suction hose (1) out of 1
5904RA409 TG
the fuel tank
2 Take care not to overextend the fuel

1 suction hose. : Pull out connector (1) with fuel
3 hose (2)
– Fit the pickup body, b 11.9.1
5904RA454 TG
– Close the filler cap
: Press connector (1) onto fuel – Reassemble remaining parts in

hose (2) so that the second reverse order
connector (3) faces the
hole (arrow) of the fuel suction
hose
– Connector must be pushed all
the way into the fuel hose

Installation
1
1 3
3
5904RA457 TG
5904RA455 TG
5904RA459 TG
: Pull off the fuel return line (1) at 2 1 : Push connector (1) into the fuel
the connector (arrow) suction hose (2) so that the fuel
: Insert the engine unit (1) in the hose (3) is between the
Always use a new fuel return line. fuel tank (2) so that the ribs (arrows)
domes (arrows) on the starter – Connector must be pushed all
and ignition side engage the the way into the fuel suction hose
recesses of the fuel tank
1
tighten
1
5904RA458 TG
2
2 1
5904RA438 TG
1
fuel tank (2) downward
5904RA460 TG
1 : Push the new fuel return line (1)

Only reuse those parts of the old completely onto the
fuel tank which are not supplied with
1 connector (arrow)
the new fuel tank – see spare parts
list. : Fit protective hip plate (2) so that – Reassemble remaining parts in
the bulge is at the tank filler port reverse order
– Check tank vent, replace if
necessary : Insert and tighten down the
screws (1)

12. Drive tube assembly
12.1 Drive tube assembly with

loop handle 2 2
Before removing the drive tube

assembly, the control handle for the
loop handle must be detached.
5904RA442 TG
5904RA444 TG
1 3 1 1
: Undo the screw (1) The clamps in the control handle for
the loop handle must be loosened.
: Pull the drive tube assembly (2)
out of the clutch housing and : Push the control handle for the
control handle for loop handle (3) loop handle (1) onto the side of
5904RA441 TG
the drive tube assembly (2), with

1 the stopper installed
– Examine the drive tube
assembly, repair or replace if
: Undo the screws (1) necessary, b 12.2.1
2 1
With a new drive tube assembly, the
installed parts or components must
be converted.
Installation
1
5904RA445 TG
– Degrease clamping area,
b 14 3
5904RA000 TG
: Push the drive tube assembly (1)

through the cover (2) in the clutch
housing with gentle twisting
: Ease out the cable holder (1)
motions until the square
profile (3) of the drive shaft
engages the clutch drum
The drive tube assembly must be

seated in the clamp as far as it will
5904RA443 TG
go.
Loop handle and carrying ring must

be installed, b 12.2.3, b 12.3.3.
: Orient end of drive tube

assembly (arrow), with stopper
installed, so that it faces the
engine

: Tighten screws (3) : Pull drive tube assembly with
1 – Control handle for loop handle antivibration housing (2) out of
is clamped and secured the clutch housing
– Check instruction label on drive – Examine the drive tube

tube assembly for damage and assembly, repair or replace if
legibility, replace if necessary necessary, b 12.2.2
5904RA446 TG
With a new drive tube assembly, the
2 12.2 Drive tube assembly with installed parts or components must
control handle for bike be converted.
: Orient drive tube assembly (1) handle
and tighten screw (2) through the
opening (arrow) Installation
– Drive tube assembly is handle and remove protective
clamped and secured – Degrease clamping area,
tube from guides. b 10.2
b 14
The sticker on the drive tube
assembly must be visible when
using the machine. 2
2 4 1
1
5904RA388 TG
5904RA389 TG
1
2 3
5904RA447 TG
: Undo the screw (1)

Throttle cable support and carrying
ring must be installed, b 12.3.4,
: Pull the drive tube assembly (2) b 12.3.3.
out of the clutch housing
: Insert protective tube (1) in the
guide (arrows) and install cable : Orient end of drive tube
holder (2) assembly with stopper
Versions with antivibration installed (4) so that it faces the
housing engine
1 2 2 : Push the drive tube assembly (1)

through the cover (2) in the clutch
housing with gentle twisting
motions until the square
profile (3) of the drive shaft
engages the clutch drum, if
necessary, turn the square profile
5904RA448 TG
of the drive shaft or the drive shaft

5904RA224 TG
at the gearbox on the opposite

3 3 1 end
: Orient control handle for loop – The drive tube assembly must be
handle (1) so that the trigger seated in the clamp as far as it
interlock (2) faces up will go.

Drive tube assembly with 28 mm 12.2.1 Disassembling the drive
diameter for 4-point antivibration 1 2 tube assembly with a
system diameter of 25.4 mm
– Degrease clamping area,

b 14
b 12.1
5904RA464 TG
– If necessary, install bike handle
with control handle, b 9.2
3
– If necessary, install carrying ring
: Push the drive tube assembly (1) and throttle cable support,
into the clutch housing (2) with b 12.3.3, b 12.3.4
gentle twisting motions until the
serration (3) of the drive shaft
engages the clutch drum
5904RA462 TG
1 1
The drive tube assembly must be 3
seated in the clutch housing as far
: Orient end of drive tube assembly as it will go.
with shakeproof washer
installed (arrow) so that it faces
the engine
1
5904RA466 TG
2
: Undo the screws (1)

1
: Pull gearbox (2) off of drive tube
5904RA465 TG
assembly (3)
2
5904RA463 TG
: Orient drive tube assembly (1)

and tighten screw (2) through the
opening (arrow)
Antivibration housing (1) must be – Drive tube assembly is
pushed on and clamping clamped and secured
screw (arrow) must be loosened.
The sticker on the drive tube
5904RA467 TG
using the machine.

1
– Secure antivibration housing,
b 9.2 : Pull drive shaft (1) with square
profile out of the drive tube
– install bike handle with control assembly
handle, b 9.2
If the shaft has blue tarnish on it, it
– Check instruction label on drive must be replaced.
tube assembly for damage and
legibility, replace if necessary

– Apply lubricant to the drive shaft
1 evenly
– Only pressing lubricant into the
hole of the flexible liner and
pushing in the unlubricated drive
shaft does not ensure sufficient
lubrication
5904RA468 TG
5904RA471 TG
a : Push drive shaft (1) with square
1 profile into opening (arrow) of the
flexible insert
: Pry out plug (1) : Push flexible liner (1) inside the
drive tube assembly until depth a
= 30 mm
3
1
2
3
5904RA474 TG
5904RA469 TG
5904RA472 TG
: Slide on the gearbox (1) on the
1 opposite end of the installed
: Pull flexible liner (1) out of the
stopper as far as it will go
drive tube assembly
: Press plug (1) into the drive tube
assembly as far as it will go : Orient drive tube assembly (2) so
that the sticker aligns with the
Assembly
dome (arrow) on the gear
housing, then tighten screws (3)
1 – The sticker on the drive tube
using the machine
– With gentle twisting motions,

push the drive shaft into the
gearbox as far as it will go, turn
5904RA470 TG
5904RA473 TG
output shaft on gearbox, if

necessary
1
Checking operation
: Push flexible liner (1) into drive The drive shaft is supported by the
tube assembly flexible insert in the drive tube – Turn the square profile of the
assembly. drive shaft; the output shaft on
the gearbox must also turn
must be replaced.
– Coat the drive shaft with STIHL order
gear lubricant for brushcutters
before installation,
b 14

12.2.2 Disassembling the drive
tube assembly with a 1
diameter of 28 mm

b 12.2
5904RA477 TG
5904RA480 TG
– Remove bike handle, if a
necessary, b 9.2
1
– Remove 4-point antivibration
system, if necessary, b 9.2 : Pry out shakeproof washer (1) : Push flexible liner (1) inside the
– Replace shakeproof washer drive tube assembly until depth a
after removal = 25 mm
3
1 1
1
a
5904RA475 TG
2
5904RA478 TG
5904RA481 TG
: Pull flexible liner (1) out of the : Push new shakeproof washer (1)
drive tube assembly inside the drive tube assembly
assembly (3)
until depth a = 6 mm
Assembly
1
5904RA476 TG
5904RA479 TG
: Pull drive shaft (1) with serration

out of the drive tube assembly
: Push flexible liner (1) into drive
tube assembly
must be replaced.

: Orient drive tube assembly (2) so
that the sticker aligns with the
2
housing, then tighten screw (3)
– The sticker on the drive tube
using the machine
5904RA482 TG
545RA263 TG
– With gentle twisting motions,
1 push the drive shaft into the 1
gearbox as far as it will go, turn
output shaft on gearbox, if
The drive shaft is supported by the – Undo and remove the screw
necessary
flexible insert in the drive tube
assembly. : Pull the clamp (1) out of the loop
Checking operation
handle (2)
must be replaced. – Turn the serrated end of the drive
shaft; the output shaft on the
– Coat the drive shaft with STIHL gearbox must also turn
gear lubricant for brushcutters
before installation, – Reassemble parts in reverse
b 14 order
– Apply lubricant to the drive shaft

evenly 12.2.3 Loop handle with barrier
5904RA484 TG
– Only pressing lubricant into the bar
hole of the flexible liner and
pushing in the unlubricated drive 1 2
shaft does not ensure sufficient
lubrication – Unscrew screw (1) and remove
2 with washer
: Push drive shaft (1) with serration
into opening (arrow) of the : Remove barrier bar (2)
flexible insert
– Check the various parts and
545RA262 TG
2 1
– Reassemble the parts in reverse
order
b 12.1
3
5904RA483 TG
– Slide loop handle (2) off of drive

1 tube assembly
: Push gearbox (1) onto the end

without the shakeproof washer
until it rests against the drive tube
assembly (2)

Installation 12.3 Deflector
12.3.1 Deflector for gearbox

with 25.4 mm drive tube
2
assembly diameter
2
To preserve the threads in the
5904RA489 TG
plastic parts, screw the screws into
the existing threads and tighten
1
5904RA485 TG
carefully.
1 : Unscrew the bolt (1)
: Insert clamp (1) in loop handle (2) 11 : Slide line limiting blade (2) down
slightly and remove
– Fit screw
– do not tighten 1
1 – Examine line limiting blade,
resharpen or replace if necessary
5904RA487 TG
a
3 2 2
: Remove screws (1)
1
: Remove plate (2) and deflector
(3)
5904RA543 TG
5904RA490 TG
1
– Install drive tube assembly,

b 12.1 : Press tab (1) and slide out
strip (2)
: Orient loop handle (1) at a 1
distance of approx. a = 35 cm – Examine gearbox, repair or
from control handle and tighten replace if necessary, b 12.4.2
screw (arrow)
5904RA488 TG

reverse order
: Unscrew the bolt (1)
– Push out mount with line limiting

blade

Installation 12.3.2 Deflector for gearbox
1 with 28 mm drive tube
assembly diameter
Installation and removal of the

deflector for metal tools and the
1 shredder deflector are the same as
described in this chapter.
5904RA493 TG
2
5904RA491 TG
2 1 1
: Orient the mount (1) with the line
limiting blade so that the head of
: Position line limiting blade (1) and the bolt (2) faces the deflector
slide it into the mount (arrow) and slide it into upper
guide (arrow) as far as the tab
: Carefully screw in the screw (2)
and tighten – Insert and carefully tighten down
5904RA495 TG
the bolt
– Threads in plastic can strip 2 1
2 : Remove screws (1)
33 : Remove deflector (2)

1
3
3
3
2
5904RA492 TG
5904RA494 TG
: Orient the strip (1) so that the 1 2

1
recess (2) faces the tab (3) and
slide it onto the deflector with the : Position deflector (1) and fit
5904RA497 TG
lower guide (arrow) until the plate (2)
tab (3) snaps into place
screws (3) : Unscrew the screw (1)
– Slide out and examine line

limiting blade (2), resharpen or

Installation 12.3.3 One-piece carrying ring 12.4 Gearbox for drive tube
assembly 25.4 mm with
square profile
1
2 – Removing cutting attachment

5904RA499 TG
545RA271 TG
1 1
1 3
: Push the line limiting blade (1) : Unscrew screw (1) and bend
into the mount (arrow) open and remove clamp (2)
– Insert and tighten down the screw – Install parts in reverse order
5904RA466 TG
To preserve the threads in the 2
plastic housing, screw the screws 12.3.4 Support
into the existing threads and tighten
carefully. : Undo the screws (1)
– Examine gearbox, repair or b 12.1 : Pull gearbox (2) off of drive tube
replace if necessary – see assembly (3)
"Kombi-Tools" Service Manual
– Examine gearbox, repair or
1 replace if necessary, b 12.4.2
2 2
5904RA540 TG
5904RA500 TG
1 2 : Remove throttle cable holder (1)
: Position the deflector (1) on the – Install parts in reverse order

gearbox

screws (2)

Installation : Position set of pinions on the
outer race of the ball bearing (2)
and use a suitable tool to press
3 out the drive pinion (3)
2
3
1
5904RA376 TG
1 5904RA375 TG 1
: Remove the circlip (1)
Drive tube assembly is installed on
5904RA377 TG
the machine.
– Degrease clamping area, b 14

: Orient gearbox (1) so that the
sticker on the drive tube
assembly aligns with the
5904RA501 TG
housing 1
: With gentle twisting motions,

slide the gearbox (1) onto the 1
– Heat gearbox in the area (arrows)
drive tube assembly (2) as far as
of the bearing seats of the drive
it will go, until the drive shaft
tube assembly connection to
5904RA503 TG
aligns with the square profile of
approx.
the drive pinion, turn the output
120 °C (250 °F)
shaft on the gearbox if necessary
: Once this temperature is – Heat the output end of the

: Tighten screws (3)
reached, the entire drive side set gearbox to 120 °C (250 °F)
of pinions (1) can be pulled out
: Once this temperature is
Checking operation
reached, the entire output side
set of pinions (1) can be pulled
– Unplug the spark plug boot and
out
turn the engine; the output shaft
on the gearbox must also turn
– Check gearbox, clean and
1 replace if necessary
12.4.2 Disassembly
2
5404RA502 TG
– Removing cutting attachment 3
– Remove gearbox, b 12.4.1

Always use new ball bearings.
– Observe safety instructions when
heating parts, b 1 : Remove the circlip (1)

– Fit new ball bearings if the set of
pinions is in good condition
If a pinion is damaged, the complete

set of pinions (drive pinion and
output pinion) must be replaced.
5904RA504 TG
5904RA509 TG
Assembly
2 1 1 2
Always use new ball bearings. : Using a suitable tool on the inner
race, press the new ball bearing
: Position ball bearing (1) on the 2 (1) onto the long stub of the drive
outer race of the bearing (arrow) shaft (2) as far as it will go
1
out the drive shaft (2) 3
5904RA507 TG
2
: Using a suitable tool on the inner

race, press the new ball bearing
(1) onto the stub of the drive
pinion (3) as far as it will go
5904RA510 TG
: Position the new ball bearing (2) 1 3
5904RA505 TG
so that the closed side faces

2 1 outward, using a suitable tool on
– Sparingly lubricate the serrations
the inner race, press it onto the
and collar on the short stub of the
stub of the drive pinion (3) as far
Always use new ball bearings. drive shaft with STIHL gear
as it will go
lubricant, b 14
: Pull ball bearing (1) off of the
drive shaft (2) : Orient spur bevel gear (1) so that
the serrations (arrow) face the
drive shaft and slide it onto the
1 short stub of the output shaft (2)
: Press the new ball bearing (3) on

as far as possible
5404RA508 TG
5904RA506 TG
2 1
: Fit the circlip (1)
: Pull spur bevel gear (1) off of the
drive shaft (2)
– Clean and examine all parts,

replace set of pinions if
necessary

2
2 1
1
5904RA511 TG
5904RA513 TG
5904RA515 TG
1
– Coat serrations of the spur bevel – Coat serrations of the drive pinion : Remove the screw plug (1)
gear with STIHL gear lubricant, with STIHL gear lubricant, b 14
b 14 – STIHL gear lubricant should be
: Heat the gearbox (1) on the drive pressed into the hole, b 14
: Heat the gearbox (1) on the end in the area of the bearing
output end (arrow) to approx. seats (arrows) to approx. – Use specified quantity of
120 °C (250 °F) 120 °C (250 °F) lubricant, b 2.4
: Position set of pinions so that the : Position drive pinion (2) so that : Insert and tighten down the screw
spur bevel gear (2) faces the gear the bevel gearing faces the gear plug (1)
housing housing
: Push set of pinions into the gear : Press in the drive pinion (2) as far Checking operation
housing (1) as far as they will go as it will go
The set of pinions must be fitted – If necessary, turn the output shaft 1
rapidly, as the ball bearing absorbs until the drive pinion engages the
heat and expands. output shaft
The drive pinion must be inserted

quickly, as it absorbs heat and
begins to expand.
5904RA516 TG
1
: Turn output shaft (1); the square
profile of the drive pinion (arrow)
5904RA512 TG
must also turn

– Gearbox must turn easily
1 – Install gearbox, b 12.4.1

5904RA514 TG

12.5 Gearbox for drive tube : With gentle twisting motions,
assembly 28 mm with slide the gearbox (1) onto the
serration drive tube assembly (2) as far as
it will go, until the drive shaft
aligns with the serrations of the
drive pinion, turn the output shaft
on the gearbox if necessary 1
– Removing cutting attachment
5904RA518 TG
: Tighten bolt (3)
3
Checking correct functioning – Heat gearbox in the area of the
bearing seats of the drive tube
– Unplug the spark plug boot and assembly connection to
1 turn the motor; the output shaft approx.120 °C (250 °F)
on the gearbox must also turn
: Once this temperature is
5904RA475 TG
reached, the entire drive side set

12.5.2 Disassembly of pinions (1) can be pulled out
2
– Removing cutting attachment
: Undo the screw (1) Cold removal of the drive side set
– Remove gearbox, b 12.5.1 of pinions
assembly (3)
– Observe safety instructions when 2 3
heating parts, b 1
– Examine gearbox, repair or 1
replace if necessary, b 12.5.2
Installation
5904RA538 TG
1
2 4
: Remove punch (1) from puller (2)

5904RA517 TG
3 5910 890 4408
: Twist nut (3) as far as the

locknuts and push the puller (2)
5904RA483 TG
: Unscrew the stud (1)

with the insert (4) first into the
1 inner serrations of the drive
pinion until it engages
Drive tube assembly is installed on
the machine.
– Degrease clamping area, b 14
: Orient gearbox (1) so that the

sticker on the drive tube
assembly (2) aligns with the
dome on the gear
housing (arrow)

1 2 4 1
3
1
2
5904RA539 TG
5904RA520 TG
5904RA545 TG
1
3 1 2
: Push the punch (1) into puller (2) : Unscrew screws (1) and remove : Orient the ring (1) of puller
5910 890 4408 as far as it will go guard ring (2) 5910 890 4407 so that the
– Insert is spread behind the narrow collar (2) faces away from
drive pinion the gearbox
: Position washer (4) on the gear 1 : Push locking pin (3) into the hole
housing, hold locknuts in place as far as the indentation (arrow)
and twist nut (3) until the drive
pinion set is pulled out of the
bearing seats
– Pull out the punch and remove
5904RA521 TG
the drive pinion set from the 1
puller 2
: Pry out the guard plugs (1)
5904RA546 TG
1 1 : Screw in the clamping screw (1)
until it rests against the
indentation (arrow) of the locking
2 pin (2)
5404RA519 TG
3
: Tighten clamping screw (1)
5904RA544 TG
Always use new ball bearings.

The locking pin (1) of puller
5910 890 4407 must engage the
: Position set of pinions on the hole (arrow) – puller is secured
outer race of the ball bearing (2) against twisting with the locking pin.
out the drive pinion (3)

– Withdraw the puller with the drive – Fit new ball bearings if the set of
3 4 side pinion set from the gearbox, pinions is in good condition
unscrew the nut and remove the
puller If a pinion is damaged, the complete
set of pinions (drive pinion and
– Check gearbox, clean and output pinion) must be replaced.
5904RA547 TG
2 Assembly
1
3
: Fit thrust washer (1) onto ring (2)
so that it extends over the narrow
collar (3) and engages the
hole (arrow) in the locking pin (4)
5904RA523 TG
5904RA525 TG
3 2 1
1 1 2
4 Always use new ball bearings.
: Using a suitable tool on the inner
2 : Pull ball bearing (1) off of the race, press the new ball bearing
drive shaft (2) (1) onto the stub of the drive
1 pinion (2) as far as it will go
5904RA522 TG
: Slide on spacer sleeve (3) and

1 press the second ball bearing (1)
on the inner race home as far as
: Push the ring (1) with the thrust
it will go
washer (2) over the drive
shaft (3) so that the locking pin
engages the hole in the gear
housing
1
5904RA524 TG
: Tighten the nut (4)

– Left-hand thread 3 2
– Heat gearbox in the area of the Always use new ball bearings.
bearing seats on the output end
5404RA526 TG
to 120 °C (250 °F) : Position ball bearing (1) on the

outer race of the bearing (arrow)
: Once this temperature is and use a suitable tool to press
reached, turn the washer (4) out the drive shaft (2)
counterclockwise until the output : Fit the circlip (1)
side pinion set is pulled out of the : Remove washer (3)
bearing seat
– Clean and examine all parts,
replace set of pinions if
necessary

3
5904RA527 TG
5904RA529 TG
5904RA531 TG
3 1 2 1 2 2 1
: Slide washer (1) onto long – Coat serrations of the spur bevel : Position guard ring (1) so that the
stub of the drive shaft (2) and, gear with STIHL gear lubricant, groove (2) faces the output
using a suitable tool on the inner b 14 shaft (3) and all four
race, press the new ball holes (arrows) match
bearing (3) home as far as it will : Heat the gearbox (1) in the
go location of the bearings on the
output end (arrow) to approx.
120 °C (250 °F) 1
4 : Position set of pinions so that the
spur bevel gear (2) faces the gear 1
housing
: Push set of pinions into the gear
5904RA532 TG
housing (1) as far as they will go
1
5904RA528 TG
The set of pinions must be fitted

3 2 1 rapidly, as the ball bearing absorbs : Insert and tighten down new
heat and expands. screws (1)
– Sparingly lubricate the collar on
the short stub of the output shaft
with STIHL gear lubricant, b 14
1
: Push the new ball bearing (1)
onto the short stub (2) as far as it
will go
: Apply gear lubricant (arrows)

between the serrations of the
5904RA530 TG
spur bevel gear (3) and the ball

bearing (4), b 14
– Use specified quantity of : Press plug (1) into the mount as

lubricant, b 2.4 far as it will go

2
1
1
5904RA534 TG
5904RA535 TG
: Heat the gearbox (1) in the : Insert and tighten down the stud
location of the bearings on the (1)
drive end (arrows) to approx.
120 °C (250 °F)
Checking operation
: Position drive pinion (2) so that
the bevel gearing faces the gear
housing 1
: Press in the drive pinion (2) as far

as it will go
– If necessary, turn the output shaft

until the drive pinion engages the
5904RA536 TG
output shaft
The drive pinion must be inserted

quickly, as it absorbs heat and : Turn output shaft (1); the inner
begins to expand. serration of the drive
pinion (arrow) must also turn
– Gearbox must turn easily
– Install gearbox, b 12.5.1

13. Special tools
New special tools
No. Designation Part No. Use Re-

marks
1 Setting gauge 0000 890 6400 Setting the air gap between ignition
module and flywheel / control unit
2 Installing sleeve 1141 893 4600 Protection of the oil seal
(Ignition side)
3 Press sleeve 4147 893 2400 Pressing in oil seal (Starter side)
4 Press sleeve 4238 893 2400 Pressing in oil seal (Ignition side)
5 Test lead 5910 840 0903 M-Tronic diagnostic and testing tasks
6 Flange 5910 850 4201 Sealing the cylinder exhaust port for
leakage test
7 Screwdriver 5910 890 2307 Adjusting carburetors without M-Tronic
8 Puller 5910 890 4503 Removing the flywheel and the starter-
side half of the crankcase
9 Puller 5910 890 4407 Pulling out the drive pinion for
gearboxes with a drive tube assembly
diameter of 28 mm
10 Puller 5910 890 4408 Pulling out the drive pinion for
gearboxes with a drive tube assembly
diameter of 28 mm
11 Sleeve 5910 893 1709 Sleeve for installing tool 11
12 Ring 5910 893 7005 Support for clutch housing (protection
of guide sleeves)
Existing special tools

marks
1 Carburetor and crankcase tester 0000 850 1300 Testing crankshaft in engine and
carburetor for leakage
- Connector 0000 855 9200 Testing carburetor for leaks
- Hose for leakage test 1110 141 8600 Testing carburetor for leaks
2 Sealing plate 0000 855 8106 Testing crankshaft in engine and
carburetor for leakage
3 Installing tool 0000 890 2201 Installation of starter rope guide bushing
4 Clamping strap 0000 893 2600 Stretching piston rings on piston
5 Locking strip 0000 893 5904 Blocking crankshaft
6 Bit T 27 x 125 0812 542 2104 Removing and installing spline socket
head screws with electric or pneumatic
screwdrivers; tightening down screws
with torque wrench
7 Wooden assembly block 1108 893 4800 Positioning piston
8 Press arbor 1118 893 7200 Cold forcible insertion of ignition side
ball bearing

marks
9 Assembly drift 1110 893 4700 Removing and installing piston pins
10 Combination wrench 1129 890 3401 Spark plug 1)
11 Installing sleeve 4119 893 4600 Protection of the oil seal
(Starter side)
12 Press arbor 4119 893 7200 Cold forcible insertion of starter side
ball bearing
13 Installing tool 4126 893 4900 Rubber element 1-point antivibration
system
14 Clamping device for assembly 5910 890 8800 Clamping drive tube assembly of
stand machine to assembly stand
15 ZAT 4 ignition tester 5910 850 4503 Test ignition system
16 ZAT 3 ignition tester 5910 850 4520 Test ignition system
17 Torque wrench 5910 890 0302 Screw connections (0.5 to 18 Nm)
18 Torque wrench 5910 890 0312 Screw connections (6 to 80 Nm)
19 Installing tool, 11 5910 890 2211 Fit hookless snap rings in piston
20 Bit T 27 x 150 5910 890 2400 IS-P screws (4 mm)
21 Assembly stand 5910 890 3101 Holding machine for repairs
22 Puller 5910 890 4400 Extracting the oil seal
- Jaws (with profile no. 3.1) 0000 893 3706 Extracting oil seal(s)
23 Assembly hook 5910 893 8800 Remove pick-up body
Remarks:
1) Use only for releasing.

14. Service accessories
No. Designation Part No. Use
1 STIHL multi-purpose grease 0781 120 1109
2 Grease (225 g tube) 0781 120 1111 Oil seals, sliding and bearing points
8 STIHL gear lubricant for Gearbox, drive shaft

trimmers
80 g tube 0781 120 1117
225 g tube 0781 120 1118
3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in
starter
4 STIHL press fluid OH 723 0781 957 9000 Rubber elements antivibration elements
5 Tube of sealant Dirko HT red 0783 830 2000 Sealing the crankcase
6 Standard solvent-based Cleaning mating surfaces and the carburetor,

degreasant not containing any cleaning the crankshaft stub and tapers in
chlorinated or halogenated flywheel
hydrocarbons

englisch / english
0455 752 0123. M0,15. A12. FST. Printed in Germany

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STIH)

STIHL FS 240, 260, 360, 410, 460 2011-09

1. Introduction and 6. Ignition system 39 7. M-Tronic 58

5.8 Piston rings 38

FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M 1

9. Antivibration 11. Fuel system 91 12. Drive tube assembly 112

13. Special tools 129

14. Service accessories 131

2 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

Refer to the "Technical Information" a Direction of

FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M 3

4 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

FS 240 C, FS 360 C FS 260 C, FS 410 C FS 460 C

Displacement: 37.7 cm3 41.6 cm3 45.6 cm3

2.2 Fuel system

Carburetor leakage test at

2.3 Ignition system

Air gap between ignition

Drive tube assembly 9.5 g,

FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M 5

Fastener Thread size For component Tightening Comment

Screw M 5x17 Cover/ shroud 6.0

6 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

1) Easy-slide coating with locking serration

When inserting DG and P screws into an existing screw thread:

As a rule, microencapsulated screws must be replaced after removal.

Screws with and without locking serration must not be confused.

FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M 7

Problem Cause Remedy

Clutch drum badly worn Install new clutch drum

Tension springs of the clutch shoes Replace tension springs, replace

Tension springs of the clutch shoes Replace tension springs

Loud noises Tension springs stretched Replace all tension springs

Ball bearing of the clutch drum is Replace ball bearing

Screws of the clutch are loose Tighten screws, replace clutch if

Clutch shoes worn Install new clutch

8 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

Problem Cause Remedy

Pinion damaged or worn Replace set of pinions on the drive

Too little or no gear lubricant in Gearbox drive tube assembly

Too little or no gear lubricant in Gearbox drive tube assembly

Clutch worn Check clutch and clutch drum,

Damaged or worn ball bearings Replace ball bearings on the drive

Serration damaged or broken – Replace set of pinions on the drive

FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M 9

Problem Cause Remedy

Cutting attachment out of true Resharpen cutting attachment

10 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

Problem Cause Remedy

Normal wear Replace starter rope

Spring insufficiently tensioned Check rewind spring and increase

Rewind spring broken Replace rewind spring

Spring clip fatigued Replace spring clip

Spring clip improperly installed Install spring clip properly

Lugs on starter cup worn Replace starter cup, check pawls,

Anchor loop in ErgoStart spring Hook ErgoStart anchor loop to

FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M 11

Spring in ErgoStart spring housing Replace ErgoStart

At very low outside temperatures: Coat rewind spring with a little

12 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M

Problem Cause Remedy

Fuel/oil mixture Use a fuel mixture with the correct

Flywheel cracked Install new flywheel