021, 023, 025

CONTENTS

1. Safety Precautions 1 7. Rewind Starter 28 1. SAFETY

PRECAUTIONS
7.1 Routine Maintenance 28
2. Introduction 2
7.2 Rewind Spring 28
If the chainsaw is started up in the
7.2.1 Replacing 28
3. Specifications 3 course of repairs or maintenance
7.2.2 Tensioning 29
work, observe all local and country-
3.1 Engine 3
specific safety regulations as well
3.2 Fuel System 3 8. AV Handle System/
as the safety precautions and
3.3 Ignition System 4 Handle Housing 30
warnings in the owner’s manual.
3.4 Cutting Attachment 4
8.1 Annular Buffers 30
3.5 Special Accessories 4
8.2 Front Handle 31 Gasoline is an extremely flamm-
3.5.1 For User 4
8.3 Handle Housing 31 able fuel and can be explosive in
3.5.2 For Service 4
8.4 Switch Shaft 33 certain conditions.
3.6 Tightening Torques 5
8.5 Contact Spring 34
8.6 Throttle Trigger/ Improper handling may result in
4. Clutch, Chain Drive,

t
Interlock Lever 34 burns or other serious injuries.
Chain Brake and

rin
Chain Tensioner 6
9. Chain Lubrication 36 Warning! Do not smoke or bring
4.1 Clutch Drum/ any fire or flame near the fuel. All
9.1 Pickup Body 36

ep
Chain Sprocket 6 work with fuel must be performed
9.2 Connector/
4.2 Chain Catcher 7 outdoors only. Spilled fuel must be
Suction Hose 36
4.3 Clutch 7 wiped away immediately.
9.3 Vent Valve 37

rr
4.4 Chain Brake 8
9.4 Worm 38
4.4.1 Checking Function 8 Wash hands thoroughly after
9.5 Oil Pump 38
4.4.2 Disassembly 8 every contact with waste oil.
4.4.3
4.5
Assembly 10
Front Chain Tensioner 12
10. Fuel System fo 39
Do not pour waste oil down the
4.6 Side Chain Tensioner 12 10.1 Air Filter 39 drain or allow it to soak into the
ot
10.2 Carburetor 41 ground.
5. Engine 13 10.2.1 Leakage Test 41
10.2.2 Removing and Collect waste oil and take it to an
-n

5.1 Exhaust Muffler/Spark

Installing 42 official disposal site for environ-
Arresting Screen 13
10.2.3 Adjustment (except ment-friendly disposal.
5.2 Leaking Test 14
023 L and USA) 43
5.2.1 Preparations 14
10.2.4 Adjustment
n

5.2.2 Pressure Test 15

(023 L and USA) 44
5.2.3 Vacuum Test 15
sio

10.3 Tank Vent 45

5.3 Oil Seals 16
10.4 Pickup Body 46
5.4 Removing and
10.5 Suction Hose 46
Installing 18
10.6 Manual Fuel Pump 47
5.5 Cylinder 18
er

10.6.1 Fuel Hoses 47

5.6 Piston 20
10.7 Fuel Tank 48
5.7 Piston Rings 22
ev

5.8 Crankshaft 22
11. Special Servicing
5.9 Connecting Rod
Tools and Aids 50
(021 up to Serial No.
X 34 944 402) 23 11.1 Special Servicing Tools 50
lin

5.10 Decompression Valve 24 11.2 Servicing Aids 52

6. Ignition System 24
On

6.1 Spark Plug Boot 24

6.2 Ignition Lead 25
6.3 Ignition Module 25
6.3.1 Ignition Timing 26
6.3.2 Removing and
Installing 26
6.4 Flywheel 27

© 2000 Andreas Stihl AG & Co., Waiblingen

021, 023, 025 1

2. INTRODUCTION
This service manual contains
detailed descriptions of all the
repair and servicing procedures
specific to this power tool series.
There are separate handbooks for
servicing procedures for
standardized parts and
assemblies that are installed in
several STIHL power tool models.
Reference is made to these
handbooks in the appropriate
chapters in this manual.
As the design concept of model
021, 023 and 025 chainsaws is
almost identical, the descriptions
and servicing procedures in this
manual generally apply to all
three models. Differences are
described in detail.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual
components and assemblies.
Refer to the latest edition of the
relevant parts list to check the part
numbers of any replacement parts
needed.
Parts lists on microfiche and
CD-ROM are always more up to
date than printed lists.
A fault on the machine may have
several causes. To help locate the
fault, consult the troubleshooting
charts for all assemblies in the
"Standard Repairs, Troubleshoo-
ting" handbook.
ev
Refer to the "Technical Informa-
tion" bulletins for engineering
changes which have been intro-
duced since publication of this
lin
service manual. Technical informa-
tion bulletins also supplement the
parts list until a revised edition is
On
issued.
2 021, 023, 025
The special servicing tools mentio- outer 10 mm bore (3) in the
ned in the descriptions are assembly stand.
listed in the last chapter of this
manual.
Use the part numbers to identify
the tools in the "STIHL Special
Tools" manual.
The manual lists all special
servicing tools currently available
from STIHL.
Symbols are included in the text
and pictures for greater clarity. 1
The meanings are as follows:
t
In the descriptions:
rin
• = Action to be taken as
shown in the illustration
ep
135RA019 VA
(above the text)
- = Action to be taken that
rr
is not shown in the
illustration To service the underside of the
(above the text) machine (e.g. remove the oil
In the illustrations:
fo pump), turn the machine through
180 degrees and mount it so that
one clamp screw engages the
ot
= Pointer inner 10 mm bore (1) in the
assembly stand.
= Direction of movement
-n
Note: Pull the hand guard back
Service manuals and all technical against the front handle for this
information bulletins describing purpose.
engineering changes are intended
n
exclusively for the use of STIHL The powerhead can then be
sio
servicing dealers. They must not swivelled to the best position for
be passed to third parties. the ongoing repair and this leaves
both hands free.
er
Always use original STIHL
replacement parts.
They can be identified by the
STIHL part number,
the STIHL logo
and the
STIHL parts symbol (
The symbol may appear alone on
small parts.
Servicing and repairs are made
considerably easier if the clamp
(1) 5910 890 2000 is used to
mount the machine on assembly
stand (2) 5910 890 3100 so that
one clamp screw engages the
3. SPECIFICATIONS

3.1 Engine

STIHL single cylinder two-stroke engine with special impregnated cylinder bore

021 023 L 023 025

Displacement: 35.2 cm3 40.2 cm3 40.2 cm3 45.4 cm3

2.15 cu.in 2.45 cu.in 2.45 cu.in 1.8 cu.in
Bore: 40 mm 40 mm 40 mm 42 m 42,5 mm
1.57 in 1.57 in 1.57 in 1.7 in
Stroke: 28 mm 32 mm 32 mm 32 mm 32 mm
1.10 in 1.26 in 1.26 in 1.26 in
Power output to ISO 7293: 1.5 kW (2.0 bhp) 1.1 kW (1.5 bhp) 1.9 kW (2.6 bhp) 2.2 kW (3.0 bhp)
at 9,000 rpm at 6,500 rpm at 9,500 rpm at 10,000 rpm
Max. permissible engine speed
1)

t
(with bar and chain): 11,500 rpm 12,500 rpm 13,000 rpm

rin
Idle speed: 2,800 rpm
Bearings: Crankshaft supported in heavy-duty ball bearings, needle cages on
small and big ends
Cylindrical rollers on big end 2)

ep
Piston pin diameter: 10 mm (0.39 in)
Rewind starter: Pawl engagement

rr
Pawls: Single pawl system
Reserve pull on rope rotor: min. 1/2 turn
Starter rope: 3.0 mm (0.12 in) dia.
Clutch:
Clutch engages at: 3,600 rpm
fo
Centrifugal clutch without linings
4,100 rpm 3,500 rpm 3,500 rpm
Crankcase leakage
ot
test
at gauge pressure: 0.5 bar (7.25 psi)
under vacuum: 0.5 bar (7.25 psi)
-n

3.2 Fuel System

n

Carburetor: Diaphragm carburetor

sio

Standard setting on carburetors

with three adjusting screws
High speed screw H: Open approx. 1 turn
Low speed screw L: Open approx. 1 turn
er

Carburetor leakage test

at gauge pressure: 0.8 bar (11.6 psi)
ev

Function of tank vent

at gauge pressure: ≤ 0.3 bar (4.35 psi)
under vacuum: ≤ 0.05 bar (0.725 psi)
Fuel tank capacity: 0.47 l (1 US pt)
lin

Octane rating: min. 90 RON (US/CAN; pump octane min. 87)

Fuel mixture: Regular brand name gasoline
and two-stroke engine oil
On

Mix ratio: 50:1 with STIHL two-stroke engine oil

25:1 with other brand name two-stroke, air-cooled engine oils
Air filter:Box filter, fabric or fleece filter

1)
Not adjustable
2)
021 only up to serial number X 34 944 402

021, 023, 025 3

3.3 Ignition System Type: Electronic magneto
ignition (breakerless)
with integral trigger unit
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in)
Spark plug (suppressed): Bosch WSR 6F,
NGK BPMR 7 A,
Champion RCJ 6Y or
Autolite 2984
Electrode gap: 0.5 mm (0.020 in)

3.4 Cutting Attachment Chain lubrication: Fully automatic speed-controlled

oil pump with rotary piston

Oil deivery rate: approx. 7.5 cm3/min (0.25 fl.oz/min)

t
at 10,000 rpm

rin
Oil tank capacity: 0.20 l (0.4 US pt)

ep
3.5 Special Accessories

rr
3.5.1 For User STIHL repair kit 1123 900 5000
3/8" P, 8-tooth rim sprocket kit 1123 007 1001
.325", 7-tooth rim sprocket kit 1123 007 1003

1/4", 8-tooth spur sprocket

fo
.325", 8-tooth rim sprocket kit 1123 007 1002
1123 640 2010
3/8" P, 7-tooth spur sprocket 1123 640 2000
ot
.325", 7-tooth spur sprocket 1123 640 2015
.325", 8-tooth spur sprocket 1123 640 2020
Side chain tensioner kit 1123 007 1000
-n

3.5.2 For Service Carburetor parts kit 1123 007 1061

n
sio
er
ev
lin
On

4 021, 023, 025

3.6 Tightening Torques

DG screws are used in the polymer and light-alloy components. These screws form a permanent thread
when they are installed for the first time. They can be removed and installed as often as necessary without
detrimentally affecting the strength of the screwed assembly, providing the specified tightening torque is
observed. For this reason it is essential to use a torque wrench.

Fastener Thread For component Torque Remarks

size Nm lbf.ft

Spline screw IS-DG4x15 Chain brake cover 2.0 1.5

Spline screw IS-DG4x15 Handle molding 1.6 1.2
Spline screw IS-DG4x15 Connector 2.5 1.8
(engine/oil pump)
Spline screw IS-DG4x15 Ground wire 3.5 2.6

t
rin
(to cylinder)
Spline screw IS-DG5x24 Handle housing/ 3.5 2.6
front handle

ep
Spline screw IS-DG5x24 Hand guard 3.5 2.6
Spline screw IS-DG5x24 Hand guard 3.7 2.8 1)
Spline screw IS-DG5x24 Fan housing 3.5 2.6

rr
Spline screw IS-DG5x24 Buffer (to front handle) 3.5 2.6
Spline screw IS-DG5x24 Buffer (to engine) 3.5 2.6
Spline screw IS-DG5x24 Ignition module 4.0 3.0

Spline screw IS-DG5.3x40

(to engine housing)
Cylinder
fo 9.5 7.0
(to engine housing)
ot
Collar screw DG8x18 Guide bar mounting 16.0 11.8
Collar screw (rear) DG8x18 Guide bar mounting 8.0 5.9 3)
-n

M12x1L Carrier (clutch) 50.0 37.0

M14x1.25 Spark plug 25.0 18.5
Hexagon nut M5 Muffler 7.0 5.2
n

Hexagon nut M5 Filter housing/carburetor 2.7 2.0

Collar nut M8x1 Flywheel to crankshaft 28.0 21.0
sio

M12x1.5 Decompression valve 14.0 10.3 2)

Slotted nut M5 Filter base/carburetor 2.0 1.5 1)
Spline screw IS-DG5x16 Spiked bumper 3.7 2.8
er
ev

Use the following procedure to fit a DG screw in an existing thread:

– Place the DG screw in the hole and rotate it counterclockwise until drops down slightly.
– Tighten the screw clockwise to the specified torque.
lin

This procedure ensures that the screw engages properly in the existing thread and does not form a new thread,
which would weaken the assembly.
On

1) 023 L
2) On easy start version only
3) With quick chain adjuster

Note: Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm
DG screws max. 500 rpm

021, 023, 025 5

4. CLUTCH, CHAIN DRIVE, CHAIN BRAKE, CHAIN TENSIONER
4.1 Clutch Drum/Chain Sprocket
- Remove the chain sprocket
cover.
• Disengage the chain brake by
pulling the hand guard toward
the front handle.
• Remove the E-clip (1).
• Remove the washer (2).
ev
lin
On
- Remove the rim sprocket, if fitted.
• Pull off the clutch drum/chain
sprocket.
6 021, 023, 025
170RA005 VA
143RA007 VA
• Take the needle cage out of the • If the clutch drum/chain sprocket
sprocket. is still serviceable, use No. 120
emery paper or emery cloth
t
- Clean and inspect the clutch (grain size approx. 120µm) to
rin
drum/chain sprocket. clean and roughen its friction
surface.
ep
Reassemble in the reverse
sequence.
rr
- Clean stub of crankshaft.
Wash needle cage in clean white
spirit and lubricate with grease -
fo see 11.2.
- Replace damaged needle cage.
ot
100%
145RA006 VA
- Rotate clutch drum/chain
sprocket and apply slight
-n
80% ! pressure at the same same until
oil pump drive spring engages
Important: If there are noticeable properly.
wear marks on the inside diameter
n
of the clutch drum, check its wall - If rim sprocket was fitted, re-
sio
thickness. If it is less than 80% of install it with the cavities facing
the original wall thickness, fit a outward.
new clutch drum.
er
Note: If the clutch drum has to be
replaced, also check the brake
band - see 4.4.2.
4.2 Chain Catcher 4.3 Clutch

Troubleshooting chart - see

"Standard Repairs, Trouble-
shooting" handbook.

- Remove the clutch drum/chain

sprocket - see 4.1.

- Remove the air filter - see 10.1.

135RA023 VA
- On 023 L, remove the filter base -
see 10.2.2.

Sprocket cover with integrally • Unscrew clutch from the

molded chain catcher (1). crankshaft clockwise (left-hand
thread).

t
If the chain catcher has broken

rin
off (2), repair as follows: - Service the clutch - see
"Standard Repairs,
Trouble-shooting" handbook.

ep
rr
fo
ot
-n

• Pry the plug out of the front right- • Take out the shutter.
hand AV element.
n

- Pull boot off the spark plug and

sio

then unscrew the spark plug.

er
ev

1
lin
On

135RA022 VA

135RA024 VA

• Oil the cylindrical part (1) of the - Close the decompression valve, • Screw on the clutch and tighten
replacement chain catcher. if fitted. down to 50 Nm (37 lbf.ft).

• Push the chain catcher into the
AV element (2) and engage the
peg (3) in the housing bore (4) at
the same time.
021, 023, 025
• Push the locking strip (1) - Install the clutch drum/chain
0000 893 5903 into the cylinder. sprocket - see 4.1.
7

250RA008 VA
- Remove locking strip from
cylinder.
- Insert spark plug and tighten
down to 25 Nm (18.5 lbf.ft).
• If spark plug has a separate
terminal nut, make sure it is
properly tightened down.
- Fit boot on the spark plug.
ev
lin
On
• Fit the shutter so that its lugs
engage the recesses in the
handle housing.
- Install the air filter - see 10.1.
8 021, 023, 025
4.4 Chain Brake
4.4.1 Checking Function 4.4.2 Disassembly
The chain brake is one of the most - Remove the clutch drum/chain
important safety devices on the sprocket - see 4.1.
chainsaw. Its efficiency is
measured in terms of the chain - Release brake spring tension by
braking time, i.e. the time that pushing hand guard forward.
elapses between activating the
brake and the saw chain coming - Remove upper bumper strip from
to a complete standstill. The tensioner.
shorter the braking time, the better
the efficiency and protection
offered against being injured by
the rotating chain.
Contamination (with chain oil,
chips, fine particles of abrasion,
t
etc.) and smoothing of the friction
rin
surfaces of the brake band and
clutch drum impair the coefficient
of friction. This, in turn, reduces
ep
the frictional forces and thus
prolongs the braking time. A
fatigued or stretched brake spring
rr
has the same negative effect.
- Start the engine.
- With the chain brake activated
fo
(locked), open throttle wide for
ot
a brief period (max. 3 seconds) -
135RA026 VA
the chain must not rotate.
-n
- With the chain brake released,
open throttle wide and activate
the brake manually - the chain • Take out the screws.
must come to an abrupt
n
stop. - Remove the cover.
sio
Note: The braking time is in
order if deceleration of the
saw chain is imperceptible to
er
the eye.
• Carefully ease the brake spring
off the anchor pin and take it off
the bell crank.
 135RA028 VA
135RA027 VA

135RA031 VA
• Pry the brake band out of the • Take out the screw. • Remove the washer.
engine housing.

t
- Disconnect brake band from bell

rin
crank.

ep
rr
fo 1
ot
170RA014 VA

135RA032 VA
135RA029 VA

2
-n

Replace the brake band if: • Remove the E-clip. • Carefully pry the hand guard (1)
and bell crank (2) off their pivot
n

- there are noticeable signs of pins and lift away together.

sio

wear (large areas on inside

diameter and/or parts of outside - Pull the bell crank out of the
diameter) and hand guard.
er

- its remaining thickness is

< 0.6 mm (0.024").
ev

Important! Thickness of brake 2 1

band must not be less at any point.
1
• If the brake band is still
lin

serviceable, use No. 120 emery

paper or emery cloth (grain size
On

approx. 120µm) to clean and

135RA030 VA

roughen its entire friction surface

135RA033 VA

(inside diameter).
2

• Remove strap from bell crank • Up to serial number

pivot pin (1). X 28 310 254, remove the
spring (1).
• Push the strap sideways and lift
it off the hand guard pivot pin (2). • Pull out the cam lever (2).

021, 023, 025 9

 4.4.3 Assembly

- Lubricate sliding and bearing

1
points of chain brake with STIHL
multipurpose grease or,
preferably, Molykote grease -
see 11.2.

- From serial number

X 28 310 255, install the flat

135RA035 VA
spring.
3 2

• From serial number • Position the hand guard (1)

X 28 310 255, remove the flat against the pivot pin and fit the
spring. other side of the hand guard

t
over the housing.

rin
- Inspect parts and replace if
damaged. • Position the bell crank (2)
against the pivot pin.

ep
- Clean the entire housing recess
for the chain brake. • Press the cam lever (3) slightly
downward and push the hand

rr
- If the groove of the brake spring guard and bell crank onto their
anchor pin is worn, replace the pivot pins.
housing.
fo
ot
-n

- Up to serial number
X 28 310 254, fit the cam lever.
n

• Attach spring to cam lever (open

sio

side of spring hook facing

outwards) and slip it over the
pivot pin
er
ev
lin
On

1
135RA036 VA

2
135RA034 VA

• Insert the bell crank in the side of • Check that cam lever or flat
the hand guard so that the short spring (1) is properly located on
arm of the bell crank points to face (2) of hand guard bearing
top of hand guard. boss.

10 021, 023, 025

 1

135RA038 VA

135RA041 VA
135RA031 VA
2

• Fit the washer on the pivot pin. • Hook the brake spring onto the • Use the assembly (2)
bell crank. 1117 890 0900 to attach the
brake spring (1) to the anchor

t
pin.

rin
ep
1 2 3

rr
fo
1
ot
135RA037 VA

135RA039 VA

135RA042 VA
-n

• Fit strap on the pivot pin (1) • Position the brake band around - Fit the bushing in the hand guard.
and locate it in the pivot pin’s the clutch and push it into the
n

groove. engine housing. - Insert M5x24 screw and tighten

sio

down to 3.5 Nm (2.6 lbf.ft).

• Slip the other end of the strap
over the bell crank pivot pin (2). • On 023 L, push the rubber
bushing (1) into the hand guard
er

- Secure strap with E-clip. (2).

- Coat brake band with chain oil - Insert M5x32 screw (3) and
ev

(STIHL Bioplus), see 11.2, to tighten down to 3.7 Nm

protect it from corrosion and help (2.8 lbf.ft).
reduce "snatching" during the
lin

first few brake applications. - Fit the cover.

- Tighten screws to 2.0 Nm

On

(1.5 lbf.ft).
135RA040 VA

- Install clutch drum/chain

sprocket - see 4.1.

• Attach the brake spring to the - Check operation of chain brake -

bell crank. see 4.4.1.

021, 023, 025 11

4.5 Front Chain Tensioner 4.6 Side Chain Tensioner

135RA043 VA

135RA044 VA

135RA046 VA
- Remove the chain sprocket - Remove the chain sprocket • Pull the spur gear out of the
cover. cover. cover.

• Pull the cover out of the engine • Take out the screw.

t
rin
housing.
- Pull the complete tensioner
assembly out of the engine

ep
housing.

1 2 1 4 2 3

rr
fo
ot
135RA045 VA

135RA047 VA
143RA052 VA

-n

3
• Unscrew the nut (1) from the • Take the thrust pad (1) off the • Pull the tensioner slide off the
adjusting screw (2). adjusting screw (2). cover.
n

• Take the adjusting screw out of • Rotate the spur gear (3) until the
sio

- Take the adjusting screw out of

the cover (3). adjusting screw comes out of the the cover.
tensioner slide (4).
Reverse the above sequence to - Inspect the teeth on the spur
er

install the chain tensioner. gear and adjusting screw.

Replace both parts if necessary.
ev

Reverse the above sequence to

install the chain tensioner.
lin

- Coat teeth of adjusting screw

and spur gear with grease,
see 11.2, before refitting.
On

12 021, 023, 025

5. ENGINE
5.1 Exhaust Muffler/Spark Arresting Screen

This machine does not have a

conventional crankcase. The
engine consists of the cylinder,
piston, crankshaft and engine pan.

Troublehooting - see "Standard

Repairs, Troublehooting"
handbook.

135RA053 VA
135RA050 VA
1 2

• Remove spark arresting screen, • On 023 and 025, remove gasket

if fitted. (1) und heat shield (2).

t
- Clean the spark arresting screen

rin
or fit a new one if necessary.

ep
rr
fo
ot
135RA051 VA

135RA054 VA
135RA048 VA

-n

• Unscrew the nuts. • Remove the upper casing from • Remove the screws from the
the lower casing (not on 023 L). flange.
n

- Remove the muffler.

sio

Reassemble in the reverse

sequence.

- Use a new gasket.

er

- Fit new locknuts and torque

down to 7.0 Nm (5.2 lbf.ft).
ev
lin
On

135RA052 VA

• Pull away the cover plate. • If necessary, take the baffle out
of the lower casing.

021, 023, 025 13

5.2 Leakage Test 5.2.1 Preparations

Defective oil seals and gaskets or

cracks in castings are the usual
causes of leaks. Such faults allow
supplementary air to enter the
engine and upset the fuel-air
mixture.

This makes adjustment of the

prescribed idle speed difficult, if
not impossible.

Moreover, the transition from idle

speed to part or full throttle is not - Remove the muffler - see 5.1. • Fit the test flange (1)
smooth. 1118 850 4200 in place of the
• Fit the sealing plate (1) carburetor.

t
The engine housing can be 0000 855 8106 between the

rin
checked thoroughly for leaks with muffler and cylinder.
the carburetor and crankcase
tester and the vacuum pump. Note: The sealing plate must

ep
completely fill the space between
the two mounting screws.

• Slip the flange (2) 1123 855

rr
4200 over the screws.

• Fit the sleeves (3) 1123 851fo

8300 on the screws.

• Fit the nuts (4) and tighten down

ot
securely.
-n

- Remove the carburetor -

see 10.2.2.
• Pull out decompression valve
- Set the piston to top dead center button, if fitted.
n

(T.D.C.). This can be checked

sio

through the inlet port. - Check that spark plug is properly

tightened down.

- Check tester 1106 850 2905 and

er

vacuum pump 0000 850 3501 for

leaks.
ev
lin
On

135RA056 VA

• Inspect carburetor gasket and fit

new one if necessary.

14 021, 023, 025

5.2.2 Pressure Test 5.2.3 Vacuum Test

Oil seals tend to fail when sub-

jected to a vacuum, i.e. the sealing
lip lifts away from the crankshaft
during the piston’s induction stroke
because there is no internal
counterpressure.

An additional test can be carried

135RA060 VA
out with the vacuum pump to
detect this kind of fault.

- Carry out preparations -

- Carry out preparations - • However, if the indicated see 5.2.1.
see 5.2.1. pressure drops, the leak must
be located and the faulty part
• Connect pressure hose of tester

t
replaced.

rin
1106 850 2905 to nipple on test
flange. Note: To find the leak, coat the
suspect area with oil and

ep
pressurize the crankcase again.
Bubbles will appear if a leak exists.

rr
- If the decompression valve is
leaking, fit a new one - see 5.10.
1
fo
- Repeat the pressure test.

- Carry out the vacuum test -

ot
see 5.2.3.
143RA046 VA

- After finishing the test, open the

-n

vent screw and disconnect the

hose.
• Close the vent screw (1) on the • Connect suction hose of vacuum
rubber bulb. - Remove the test flange. pump 0000 850 3501 to test
n

flange nipple.
sio

- Pump air into the engine housing - Install the carburetor - see 10.2.2.
with the rubber bulb until the
gauge indicates a pressure of - Remove the flange.
0.5 bar (7.25 psi). If this pressure
er

remains constant for at least 20 - Remove the sealing plate.

seconds, the housing or
decompression valve, if fitted, is
ev

- Install the muffler - see 5.1.

airtight. 3
lin
On

2
135RA061 VA

• Close the vent screw (1) on the

pump.

• Operate lever (2) until pressure

gauge (3) indicates a vacuum of
0.5 bar (7.25 psi).

021, 023, 025 15


Note: If the vacuum reading
remains constant, or rises to no
more than 0.3 bar (4.25 psi) within
20 seconds, it can be assumed
that the oil seals are in good
condition.
However, if the pressure continues
to rise (reduced vacuum in the
engine housing), the oil seals must
be replaced.
- After finishing the test, open the
vent screw and disconnect the
hose.
- Remove the test flange.
- Install the carburetor - see 10.2.2.
- Remove the test flange.
- Remove the sealing plate.
- Install the muffler -
see 5.1.
ev
lin
On
16
5.3 Oil Seals
It is not necessary to disassemble - Clamp the puller arms.
the complete engine housing if
only the oil seals have to be - Pull out the oil seal.
replaced.
Important: Take special care not
to damage crankshaft stub.
t
Clutch side:
rin
- Remove the clutch - see 4.3.
ep
- Remove the oil pump - see 9.5.
1 2
rr
fo
ot
143RA064 VA
135RA062 VA
-n
• Ease the retaining ring out of the • If an oil seal with clamping ring
crankshaft. (1) is installed, use puller and
n
No. 3.1 jaws to remove the
sio
clamping ring. Pry the sealing
ring (2) out of the housing.
- Clean sealing face on crankshaft
er
stub with standard commercial,
solvent-based degreasant
containing no chlorinated or
halogenated hydrocarbons -
see 11.2.
Note: If the cylinder and engine
pan are assembled, only oil seals
1 9638 003 1581 (with clamping
ring) may be installed.
135RA063 VA
- Lubricate sealing lips of oil seal
with grease - see 11.2.
• Apply puller (1) 5910 890 4400 - Thinly coat the outside diameter
(jaws 0000 893 3711 with No. 6 of the oil seal with sealant -
profile). see 11.2.
021, 023, 025
 - Clamp the puller arms. • Screw the guide sleeve (2)
1123 894 7700 onto the
- Pull out the oil seal. crankshaft.

Important: Take special care not

to damage crankshaft stub.
1
Note: Remove the oil seal with

135RA064 VA
clamping ring as described for
clutch side.

- Clean sealing face on crankshaft

- Position the oil seal so that the stub with standard commercial,
clamping ring faces upwards. solvent-based degreasant
containing no chlorinated or
• Use the press sleeve (1)

t
halogenated hydrocarbons -

rin
1123 893 2400 to install the oil see 11.2.
seal.
Note: If the cylinder and engine

ep
- Wait about one minute, then pan are assembled, only oil seals
rotate the crankshaft. 9638 003 1581 (with clamping
ring) may be installed.

rr
- Fit a new retaining ring.
- Lubricate sealing lips of oil seal
- Install the oil pump - see 9.5. with grease - see 11.2.

- Install the clutch - see 4.3.

fo
- Thinly coat the outside diameter 1
of the oil seal with sealant -
ot
see 11.2.

135RA067 VA
-n

• Use the press sleeve (1)

1123 893 2400 to install the oil
n

seal.
sio

Starter side - Wait about one minute, then

rotate the crankshaft.
- Remove the flywheel -
er

see 6.4. - Install the flywheel - see 6.4.

ev
lin

1 2
On

1
135RA065 VA

135RA066 VA

• Apply puller (1) 5910 890 4400 • Position the oil seal (1) so that
(jaws 0000 893 3711 with No. 6 the clamping ring faces upwards.
profile).

021, 023, 025 17

5.4 Removing and Installing 5.5 Cylinder

Always check and, if necessary,

repair the fuel system, carburetor,
air filter and ignition system before
looking for faults on the engine.

- Remove the handle housing -

see 8.3.

135RA072 VA
135RA070 VA
- Remove the oil pump - see 9.5.

• Unscrew the engine pan - Remove the engine - see 5.4.

mounting screws.
- Take out the spark plug.

t
• Remove baffle plate.

rin
ep
rr
1
fo 2
ot
135RA068 VA

135RA073 VA
-n

• Pull off the worm with drive • Remove engine sideways from • Pull the manifold (1) off the
spring. housing. intake port.
n

• Disconnect the impulse hose (2).

sio

Install in the reverse sequence.

- Tighten down engine pan

mounting screws to 9.5 Nm
er

(7 lbf.ft) and ground wire

fastening screw to 3.5 Nm (2.6
lbf.ft).
ev
lin
On
135RA069 VA

135RA074 VA

• Take out ground wire fastening • Pull the engine pan off the
screw. cylinder.

18 021, 023, 025

 - If a new cylinder has to be
1
installed, always fit the matching
piston. Replacement cylinders
are only supplied complete with
piston for this reason.
1
- Thoroughly clean all residue of
sealant from the cylinder and

135RA080 VA
135RA075 VA
engine pan mating faces.

- Apply a thin coating of sealant 2

to the outer diameters of the oil
• Fit the clamp (1) 1123 893 9100 seals - see 11.2. • Line up the crankshaft so that
on connecting rod of 021 up to the long crankshaft stub (1) is on
serial number X 34 944 402 to - Lubricate piston and piston ring the same side as the exhaust

t
prevent it slipping off the with oil. port (2).

rin
crankshaft.
- Push piston home until ball
bearings are seated.

ep
- On 021 up to serial number
X 34 944 402, remove the clamp

rr
from the connecting rod.

fo
ot
-n

• Lift the crankshaft and pull the • Position the piston rings so that
piston out of the cylinder. the radii at the ring gap meet at
n

the fixing pin in the piston groove

sio

- Inspect ball bearings and oil when the rings are compressed.
seals and replace if necessary -
see 5.8.
er
ev
lin
On

135RA082 VA
135RA079 VA

- Inspect the cylinder and replace
it if necessary.
• On easy start version, unscrew
the decompression valve.
• Slide piston carefully into the • Apply a thin bead of sealant to
cylinder. the engine pan mating face -
see 11.2.
Note: The piston rings are
compressed by the inner taper of Note: Follow manufacturer’s
the cylinder. instructions for use of sealant.

021, 023, 025 19


• Fit the engine pan so that the
seat (1) for the oil pump is at the
same side as the long crankshaft
stub (2).
• On easy start version, unscrew
the plug, screw home the
decompression valve and tighten
it to 14 Nm (10.3 lbf.ft).
ev
lin
On
• Push the manifold on to the
intake port so that the straight
faces are in alignment.
Reassemble all other parts in the
reverse sequence.
20
5.6 Piston
135RA087 VA
135RA085 VA
- Pull the piston out of the cylinder • Inspect piston rings and replace
- see 5.5. if necessary - see 5.7.
• Ease the hookless snap rings
t
rin
out of the grooves in the piston
bosses.
ep
rr
fo a
ot
135RA088 VA
-n
• Use the assembly drift (2) Note: On 021, install new piston
1110 893 4700 to push the on crankshaft with fixed
n
piston pin (1) out of the piston. connecting rod; installed original
sio
piston on crankshaft with loose
Note: If the piston pin is stuck, tap connecting rod.
the end of the drift lightly with a
hammer. Important: Hold the • How to identify pistons:
er
piston steady during this process
to ensure that no jolts are Original piston "a" = 12.7 mm
transmitted to the connecting rod. New piston "a" = 12.2 mm
- Remove the piston from the
connecting rod.
- Inspect needle cage and replace
if necessary.
Note: If needle cage is press-
fitted, replace the crankshaft.
021, 023, 025
 Note: For instructions on how to
use installing tool, see "Standard
Repairs, Troublehooting" hand-
book.

• Fit needle cage in the small end. • Fit the piston pin (1) on the
assembly drift (2) and slide it
- Oil the needle cage. into the piston (the pin slides

t
home easily if the piston is

rin
warm).

ep
rr
fo
a

ot
b
135RA093 VA

982RA016 VA
-n

• To ease assembly, heat the • Modify the sleeve of the The ring gap must be on the
piston slightly and push it over installing tool 5910 890 2210 as piston’s vertical axis (point either
n

the connecting rod. shown. up or down).

sio

a = 16 mm (11/16")
• Installed position of piston: b = 8 mm (5/16") - Install the piston - see 5.5.
1 = Arrow
2 = Long stub of crankshaft
er
ev
lin
On

• Push the assembly drift, small - Use installing tool (1)

diameter first, through the piston 5910 890 2210 to fit the
and small end (needle cage) and hookless snap rings.
line up the piston.

021, 023, 025 21

5.7 Piston Rings 5.8 Crankshaft

- Pull the piston out of the cylinder

- see 5.6. 1

- Remove rings from piston.

170RA096 VA
135RA097 VA
2

• The crankshaft (1), connecting - Remove the piston - see 5.6.

rod (2) and needle bearing are
inseparable on models 023 and • Remove the retaining ring.

t
025 as well as model 021 from

rin
serial number X 34 944 403.
This means the crankshaft must
always be replaced as a

ep
complete unit.

rr
1

fo
ot
135RA095 VA

135RA098 VA

2
-n

• Use a piece of old piston ring to • On 021 up to serial number • Pull off the oil seals (1) and ball
scrape the groove clean. X 34 944 402, remove bearings (2).
n

connecting rod (1) from the

sio

crankshaft (2) - see 5.9.

- When fitting a replacement

crankshaft, always install new oil
er

seals and ball bearings.

ev
lin
On

135RA100 VA
135RA096 VA

• Install the new piston rings in the • Heat ball bearing to approx.
grooves so that the radii face 50°C (120°F) and, with closed
upward. side facing outwards, push it on
to the crankshaft stub as far as
- Install the piston - see 5.6. stop.

22 021, 023, 025

 5.9 Connecting Rod
(021 up to Serial No. X 34 944 402)

Note: If the crankshaft has been Note: Cylindrical rollers are

1
removed, the oil seals used in available in three different
production (9639 003 1585 with tolerance groups. Always replace
rigid housing) may be installed. cylindrical rollers in complete sets
of 14 to ensure that they are all
- Lubricate sealing lips of oil seals from the same tolerance group.
with grease - see 11.2.

135RA102 VA
2

- Remove the piston - see 5.6.

• Pull the oil seal (1) and ball

t
bearing (2) off the short stub of

rin
the crankshaft.

ep
rr
fo 1
ot
135RA103 VA

135RA105 VA
135RA101 VA

-n

• Slide oil seals over the • Remove th clamp (1) 1123 893 • Use grease, see 11.2, to stick
crankshaft stubs so that their 9100 from the connecting rod. the cylinrical rollers to the
n

open sides are facing the ball crankshaft.

sio

bearings.
- Slide connecting rod into position
- Install new retaining ring in and secure it with the clamp.
crankshaft groove.
er

- Install ball bearing and oil seal -

- Install the piston - see 5.6. see 5.8.
ev

- Install the piston - see 5.6.

lin
On

135RA104 VA

• Take the connecting rod off the

crankshaft.

- Remove the cylindrical rollers

from the crankshaft.

021, 023, 025 23

5.10 Decompression Valve 6. IGNITION SYSTEM 6.1 Spark Plug Boot

Warning! Exercise extreme - Remove the air filter - see 10.1.

caution when carrying out
maintenance and repair work on
the ignition system. The high
voltages which occur can cause
serious or even fatal accidents!
- On 023 L, remove the filter base -
see 10.2.2.
- Pull out the shutter - see 4.3.

Troubleshooting on the ignition - Pull boot off the spark plug.

system should always begin at
the spark plug. See "Standard
Repairs, Troubleshooting"
handbook.
- Remove the front handle -
see 8.2.

• Use standard commercial 13 mm

t
rin
socket to unscrew the
decompression valve.

ep
- Fit new decompression valve
and torque down to 14 Nm
(10.3 lbf.ft).

rr
- Fit the front handle.

fo
1
ot

135RA107 VA
135RA106 VA
-n

Note: The electronic (breakerless) • Use pliers to grip the leg spring
ignition system basically consists and pull it out of the spark plug
n

of an ignition module (1) and boot.

sio

flywheel (2).
- Unhook the leg spring from the
ignition lead.
er

- Pull spark plug boot off the

ignition lead.
ev

- Coat end of the ignition lead

(about 20 mm/3/4") with oil.
lin

- Fit spark plug boot over the

ignition lead.
On

- Use pliers to grip the end of the

ignition lead inside the spark
plug boot and pull it out.

24 021, 023, 025

 6.2 Ignition Lead 6.3 Ignition Module

135RA110 VA
135RA109 VA
135RA108 VA
• Pinch the hook of the leg spring - Pull the boot off the spark plug - The ignition module
into the center of the lead, i.e. see 6.1. accommodates all the
about 10 mm (3/8") from the end components required to control

t
of the lead. - Remove the ignition module - ignition timing. There are two

rin
see 6.3.2. electrical connections on the coil
body:
• Pull ignition lead out of the

ep
guide. 1. the high voltage output (1)

2. the connector tag (2) for the

rr
short circuit wire

Accurate testing of the ignition

fo module is only possible with
sophisticated test equipment. For
this reason it is only necessary to
ot
338RA142 VA
carry out a spark test in the work-
171RA146 VA

shop. A new ignition module must

be installed if no ignition spark is
-n

obtained (after checking that

wiring and stop switch are in good
• Pull the lead back into the - Cut new ignition lead to length condition).
boot so that the leg spring (see parts list or cut to same
n

locates properly inside it (as length as old lead).

sio

shown).
• Use pointed tool (awl or gimlet)
Important: If spark plug has a to pierce the center of the lead
separate terminal nut, make sure that is to be screwed into the
er

that it is properly tightened down. module.

- Fit boot on spark plug. - Pack the high voltage output with
ev

STIHL multipurpose grease -

- Fit the shutter - see 4.3. see 11.2.
lin

- On 023 L, fit the filter base. Important: Do not use graphite

grease (Molykote) or silicone
- Install the air filter - see 10.1. insulating paste for this job.
On

Reassemble all other parts in the

reverse sequence.

021, 023, 025 25

6.3.1 Ignition Timing 6.3.2 Removing and Installing

Ignition timing is not adjustable. • Pull the ignition module forward

a little further and turn it to
Since there is no mechanical wear unscrew the ignition lead (3)
in these systems, ignition timing from the contact pin.
cannot get out of adjustment.
However, an internal fault in the - Pull the ignition lead out of the
circuit can alter the switching point high voltage output.
in such a way that a spark test will

135RA111 VA
still show the system to be in order
although timing is outside the
permissible tolerance. This will
impair engine starting and running
behavior. - Remove the fan housing.

• Pull short circuit wire connector

t
off tag on ignition module.

rin
ep
rr
fo
ot

135RA114 VA
135RA112 VA
-n

• Take out the screws. - If necessary, ease peg of cable

retainer out of bore.
n

• Remove the cable retainer.

sio

- Pack high voltage output with

STIHL multipurpose grease -
er

see 11.2.

Important: Do not use graphite

ev

grease (Molykote) or silicone

insulating paste for this job.
lin

- Screw ignition lead into position.

- Fit short circuit wire in the

On

retainer.

- Pull the ignition module forward

a little.

• Take the short circuit wire (1) out

of the retainer (2).

26 021, 023, 025

 6.4 Flywheel

135RA116 VA
- Place the module in position, Removing the flywheel: Inspect the flywheel (1) and
insert the screws but do not magnet poles (2). If you find any
tighten them down yet. - Fit locking strip to block the damage, install a new flywheel.

t
piston - see 4.3.
• Secure ground wire (1) with

rin
outer screw. - Remove the fan housing. Installing the flywheel:

• Slide the setting gauge (1) • Unscrew the collar nut.

ep
Important: Clean the stub of the
1111 890 6400 between the crankshaft and the flywheel hub
arms of the ignition module and - Pull off the flywheel. bore with a standard commercial,

rr
the flywheel magnet poles. solvent-based degreasant which
contains no chlorinated or
- Press the ignition module halogenated hydrocarbons -
against the setting gauge and
tighten down the mounting
fo see 11.2.

screws to 4 Nm (3 lbf.ft). - Fit the flywheel.

ot
Reassemble all other parts in the Note: Check position of slot.
reverse sequence.
-n

Assemble all other parts in the

reverse sequence.

- Tighten flywheel nut to 28.0 Nm

n

(20.6 lbf.ft).
sio
er
ev
lin
On

135RA117 VA

Note: If the flywheel cannot be

removed by hand, screw on the
puller (1) 1116 893 0800 and tap
its end to release the flywheel.
Unscrew the puller.

021, 023, 025 27

7. REWIND STARTER
7.1 Routine Maintenance
If the action of the starter rope
becomes very stiff and the rope
rewinds very slowly or not com-
pletely, it can be assumed that
the starter mechanism is in order
but plugged with dirt. At very low
outside temperatures the lubri-
cating oil on the rewind spring may
thicken and cause the spring
windings to stick together. This
has a detrimental effect on the
function of the starter mechanism.
In such a case it is sufficient to
apply a few drops of paraffin
(kerosine) to the rewind spring.
Then carefully pull out the starter
rope several times and allow it to
rewind until its normal smooth
action is restored.
If clogged with dirt or pitch, the
entire starter mechanism, inclu-
ding the rewind spring, must be re-
moved and disassembled. Take
special care when removing the
spring.
Wash all parts in paraffin or white
spirit.
Lubricate the rewind spring and
starter post with STIHL special
lubricant, see 11.2, before
installing.
lin
On
28
7.2 Rewind Spring
7.2.1 Replacing
Troubleshooting chart - see
"Standard Repairs, Trouble-
shooting" handbook. a
- Remove the fan housing.
1
- Remove the rope rotor - see
"Standard Repairs, Trouble-shoo-
143RA121 VA
ting" handbook. Remove any
remaining pieces of spring from
the fan housing.
Note: The replacement spring co- • Position the anchor loop about
mes ready for installation and is 20 mm (3/4") (dimension ’a’)
secured with a frame. from the edge of the assembly
t
tool (1) 1116 893 4800.
rin
ep
rr
fo
ot
143RA122 VA
-n
- It should be lubricated with a few • Fit the rewind spring in the
drops of STIHL special lubricant counterclockwise direction,
n
before installation - see 11.2. starting from outside and
sio
working inwards.
• The frame (1) slips off as the
rewind spring is pushed into the - Place wooden assembly block
fan housing. Engage the anchor 1108 893 4800 over the spring
er
loop (2) in the recess in the fan housing to simplify this operation.
housing at the same time.
- Slip the assembly tool with
ev
Caution: The rewind spring rewind spring over the starter
may pop out and uncoil during post.
installation.
- If the rewind spring has popped
out, refit it as follows:
021, 023, 025
 7.2.2 Tensioning

- Hold the starter grip firmly to

keep the rope tensioned.

- Let go of the rope rotor and

slowly release the starter rope
so that it can rewind properly.

135RA119 VA
• Push the rewind spring into the • Make a loop in the starter rope.
fan housing and then remove the
assembly tool.

t
rin
- Install the rope rotor - see
"Standard Repairs and
Troubleshooting" handbook.

ep
- Tension the rewind spring -
see 7.2.2.

rr
fo
ot

135RA122 VA
135RA120 VA
-n

• Grip the rope close to the rotor Note: The rewind spring is
and use it to turn the rope rotor correctly tensioned when the
n

six times clockwise. starter grip sits firmly in the rope

sio

guide bush without drooping to

one side. If this is not the case,
tension the spring by one
additional turn.
er

When the starter rope is fully

extended, it must still be possible
ev

to rotate the rope rotor at least

another half turn before maximum
spring tension is reached. If this is
lin

not the case, pull the rope out,

hold the rope rotor steady and
take off one turn of the rope.
On

135RA121 VA

Do not overtension the rewind

spring as this will cause it to break.

- Fit the fan housing.

• Hold the rope rotor steady.

• Pull out the rope with the starter

grip and straighten it out.

021, 023, 025 29

8. AV HANDLE SYSTEM/HANDLE HOUSING
8.1 Annular Buffers

Rubber anti-vibration buffers are

installed between the handle and
engine housing, handle housing
and front handle.
Damaged rubber buffers (annular
buffers) must always be replaced.

135RA128 VA
135RA125 VA
Annular buffer in engine housing • Pry the annular buffer out of the
handle housing.
- Front handle abgebaut.

t
• Pry the annular buffer out of the

rin
engine housing.

ep
1

rr
fo
ot
135RA126 VA
135RA123 VA

135RA129 VA
-n

Annular buffers in front handle • Push annular buffer into the • Push the annular buffer into the
engine housing until its groove handle housing from outside until
n

- Remove the front handle - engages over the housing rib. its groove (1) engages over the
sio

see 8.2. edge of the housing (2).

- Fit the front handle.
• Pry both annular buffers out of - Install the handle housing -
the front handle. see 8.3.
er
ev
lin

1
On

135RA127 VA
135RA124 VA

• Push home the annular buffer Annular buffer in handle housing

from the inside the front handle
until its groove (1) engages over - Remove the handle housing -
the housing rib (2). see 8.3.

• Ease the plug out of the buffer.

30 021, 023, 025

8.2 Front Handle 8.3 Handle Housing

- Remove the front handle -

see 8.2.

- Remove the fan housing.

- Remove the muffler - see 5.1.

- Remove the carburetor -

135RA130 VA

135RA133 VA
see 10.2.2.

• Take the lower mounting screws • Pull the lower part of the handle
out of the front handle. housing out of the front handle.

t
- Remove the front handle.

rin
Reassemble in the reverse
sequence.

ep
- Tighten down screws in annular
buffers to 3.5 Nm (2.6 lbf.ft).

rr
fo
ot

135RA134 VA
135RA131 VA

-n

- Remove lower bumper strip from • Disconnect the tank vent from
the tensioner. the stub.
n

• Ease plugs out of the annular

sio

buffers.
er
ev

1
lin
On

135RA135 VA

• Take out the screws. • Pull the ground wire (1) off the
contact spring.

• Pull the short circuit wire’s

contact sleeve (2) out of the
switch shaft.

021, 023, 025 31

 - Remove the handle housing.

- To replace, remove the annular

buffers - see 8.1.

- Remove the switch shaft -

see 8.4.

135RA136 VA

135RA139 VA
- Remove the throttle trigger -
see 8.6.

- Remove the contact spring -

• Ease the plug out of the annular • Push the grommet out of the see 8.5.
buffer. handle housing.
- On easy start machines, remove

t
- Pull the ground and short circuit the manual fuel pump - see 10.6.

rin
wires out of the bore.
Reassemble in the reverse
sequence.

ep
rr
fo
ot
135RA140 VA

135RA142 VA
135RA137 VA

-n

• Pry the annular buffer out of the • Pull the impulse hose off the • To fit the manifold in the handle
engine housing. stub on the handle housing. housing intake opening, wind a
n

piece of string (about 15 cm / 6"

sio

long) around the back of the

manifold flange.
er
ev

4
lin

2
3
On

1
135RA141 VA
135RA138 VA

135RA143 VA

• Pull the handle housing slightly
forward and push the manifold
through the handle housing
opening at the same time.
• On easy start machines, pull
manual fuel pump hose out of
the fuel tank.
• Place the handle housing in
position and thread the string (1),
fuel hose (2), ground wire (3)
and short circuit wire (4) through
the openings.

32 021, 023, 025

 8.4 Switch Shaft

Note: The manifold flange is thus

pulled through the handle housing
intake opening without any
damage to the manifold.

135RA148 VA
• Push the grommet for the ground - Remove the carburetor box
and short circuit wires into the cover - see 10.1.
bore from inside.

t
- On 023 L, remove the filter base -

rin
see 10.2.2.

• Pull the contact sleeve out of the

ep
switch shaft.

rr
fo 3
ot

135RA149 VA
135RA147 VA
-n

• Connect the impulse hose to the • Push the annular buffer into the • Move the Master Control lever
stub on the handle housing. engine housing until its groove (1) until the slot in the choke
n

engages over the housing rib. shaft (2) and the choke rod (3)
sio

are in line.
er
ev
lin
On

135RA150 VA

• Pull the ends of the string • Pull the choke rod out of the
outward. switch shaft and the choke shaft.

021, 023, 025 33

 8.5 Contact Spring 8.6 Throttle Trigger/
Interlock Lever

135RA151 VA

135RA154 VA

135RA156 VA
• Set the Master Control lever to - Remove the carburetor - - Remove the carburetor box
the horizontal position and pry see 10.2.2. cover - see 10.1.
the switch shaft out of its pivot
• Pull the ground wire terminal off

t
mount. - On 023 L, remove the filter base -

rin
the contact spring. see 10.2.2.

• Take out the screw

ep
- Lift away the handle molding.

rr
fo
ot
135RA152 VA

135RA155 VA
-n

• Pull the switch shaft out of its • Pull the contact spring out its
bore. seat in the handle housing.
n
sio

Reassemble in the reverse Reassemble in the reverse

sequence. sequence.
er
ev
lin
On

135RA157 VA
135RA153 VA

• Lift the contact spring slightly to - Move Master Control lever to

install the switch shaft. "RUN" position.

• Pull the throttle interlock lever

out of its seat.

34 021, 023, 025

 - Fit the throttle trigger so that the
seat for the throttle rod points
upward.

- Fit the cylindrical pin.

- Push the throttle rod into the

throttle trigger.

135RA163 VA
• Remove throttle rod from throttle • Fit the handle molding so that
trigger. it engages behind the lugs as
shown.

t
rin
- Insert screw and tighten down
to 1.6 Nm (1.2 lbf.ft).

ep
- On 023 L, fit the filter base -
see 10.2.2.

rr
- Fit the carburetor box cover -
see 10.1.

fo
ot
135RA161 VA
-n

• Use a 4 mm (5/32") drift to drive • Press the interlock lever into the
out the cylindrical pin (1). slots. The torsion spring must be
n

under the interlock lever and

• Remove the throttle trigger (2)
sio

engage the notch.

and torsion spring (3).
er
ev
lin
On

135RA162 VA

2 1

• Take the torsion spring off the • Press the interlock lever (1)
throttle trigger. downward.

• Push the throttle trigger upward

and move the Master Control
lever (2) to the "Choke" position.

021, 023, 025 35

9. CHAIN LUBRICATION 9.2 Connector/
9.1 Pickup Body Suction Hose

Impurities gradually clog the fine

pores of the filter with minute
particles of dirt. This prevents the
oil pump from supplying sufficient
oil to the bar and chain. In the
event of problems with the oil
supply system, first check the oil
tank and the pickup body. Clean

135RA165 VA

135RA166 VA
the oil tank if necessary.

Troubleshooting chart - see

"Standard Repairs, Trouble-
shooting" handbook.
- Unscrew oil filler cap and drain
• Pull the pickup body out of the - Remove the front handle -
oil suction hose. see 8.2.
• Take out the screw.

t
the oil tank. - Wash the pickup body in white

rin
spirit and, if possible, blow out
Note: Collect chain oil in a clean with compressed air.
container or dispose of it properly

ep
at an approved disposal site. - Always replace a damaged
pickup body.
- Observe safety precautions -

rr
see 1. - Flush out the oil tank.

Reassemble in the reverse

sequence. fo
ot

135RA167 VA
-n

• Pull the connector out of the oil

pump and suction hose.
n
sio
er
ev
lin
On

135RA168 VA

• Use assembly hook (1) • Pull suction hose with pickup

5910 893 8800 to withdraw the body out of the oil tank.
pickup body from the oil tank.
- Remove the pickup body.
Note: Avoid stretching the oil hose.

36 021, 023, 025

 9.3 Vent Valve

There is a vent valve in the tank

wall which keeps the internal
pressure in the oil tank equal to
atmospheric pressure.

Cleaning the valve

145RA252 VA
- Unscrew the oil filler cap. a

- Drain the oil tank.

Reassemble in the reverse Note: Collect chain oil in a clean • Use a 7 mm (9/32") dia. drift to
sequence. container or dispose of it properly carefully push home the new
at an approved disposal site. valve until dimension ’a’ is about
• Fit new O-ring on connector

t
1 mm (3/64").

rin
(arrow). - Observe safety precautions -
see 1. - Fit the oil filler cap.
- Tighten down screw to 2.5 Nm

ep
(1.8 lbf.ft). - Use compressed air to blow
valve clear from the outside
inwards.

rr
- Flush the oil tank.

- Fit the oil filler cap. fo

ot
-n
n
sio

Relacing the valve

- Unscrew the oil filler cap.

er
ev
lin
On

135RA170 VA

• Use a 5 mm (3/16") dia. drift to

carefully drive the valve out of
the housing from inside the tank.

021, 023, 025 37

9.4 Worm 9.5 Oil Pump

3 2

- Remove the clutch - see 4.3.
• Pull the worm and drive spring
135RA176 VA
135RA173 VA
Removing • Swing lever (1) down into fork
head (2) and secure it with the
- Remove the connector - connecting pin (3).

t
off the crankshaft stub. see 9.2.

rin
• Push out the lower annular
buffer.

ep
rr
fo 1
ot

135RA177 VA
135RA174 VA
-n

• Take the drive spring off the • Fit lever (1) of installing tool • Swing lever upward to pull the
worm. 1123 890 2201 in the bore for oil pump out of the housing.
n

the annular buffer - from inside.

sio

Reassemble in the reverse - Unscrew the oil pump from the

sequence. fork head.
er
ev
lin

1
On

135RA178 VA
135RA175 VA

• Screw fork head (1123) with Installing

threaded stem (from installing
tool) into the oil pump. • Place the oil pump in position so
that its groove (1) lines up with
the square (2) on the housing.

38 021, 023, 025

 10. FUEL SYSTEM
10.1 Air Filter

Dirty and clogged air filters reduce

engine power, increase fuel
consumption and make starting
more difficult.

The air filter should always be

cleaned when there is a noticeable
loss of engine power.

135RA183 VA
- Close the choke shutter.

• Place the fork head (1123) with Box filter

the straight stem (from installing
tool) in the oil pump. • Unscrew the slotted nuts.

t
rin
- Fit lever in fork head and secure - Lift away the box filter.
in position.

ep
All models except 023 L

rr
2
fo 1
ot
135RA182 VA

135RA184 VA
-n

• Press the lever down until the • Turn twist lock (1) 90 degrees • Separate the two halves of the
fork head butts against the counterclockwise. filter.
n

engine housing. The oil pump is

• Lift off the carburetor box cover
sio

now installed at the right depth. - Wash both halves the filter in a
(2) vertically. fresh, non-flammable cleaning
- Remove the lever. solution (e.g. warm soapy water)
- Remove all loose dirt from and then dry.
er

around the filter.

Note: Replace a damaged air filter
immediately.
ev
lin
On

• Push the annular buffer into the

housing until its groove engages
over the housing rib.

- Fit the connector - see 9.2.

021, 023, 025 39

 Install only carburetor box covers
without ribs.

135RA199 VA
Foam filter Fabric/fleece filter

• Remove the foam filter from the • Place fingers behind the filter,

t
filter housing. press thumbs against housing,

rin
and swing filter toward rear
- Wash the foam filter in a fresh, handle.
non-flammable cleaning solution
(e.g. warm soapy water) and - Remove the filter.

ep
then dry.
- Use compressed to blow out
Note: Replace a damaged foam filter from the clean air side.

rr
filter immediately.
- If the mesh is caked with dirt or
Convert machines with foam filter
to fabric/fleece filter.
fo no compressed air is available,
wash the filter in a fresh,
non-flammable cleaning solution
ot
- Replace the filter housing - (e.g. warm soapy water) and
135RA201 VA

see 10.2.2. then dry.

-n

Note: Replace a damaged air filter

immediately.
• If an original carburetor box
cover with ribs has to be - Push air filter onto filter housing
n

installed, use side cutters to until it snaps into position.

sio

remove the ribs.

- Carburetor box cover anbauen.
- Carefully deburr the cover.
er

Important: Deburring is essential

to avoid damaging the filter mesh.
ev
lin
On
135RA200 VA

Note: The clearance between the

top edge of the air filter and the
carburetor box cover is only a few
millimeters.

40 021, 023, 025

 10.2 Carburetor
10.2.1 Leakage Test

Troubleshooting chart - see

"Standard Repairs,
Troubleshooting" handbook.

Important: If problems occur on

the carburetor or the fuel supply
system, always check and clean
the tank vent - see 10.3.

The carburetor can be tested for

leaks with the carburetor and
crankcase tester 1106 850 2905.
023 L • Push fuel line with nipple onto
- Remove the carburetor box co- carburetor elbow connector.
• Unscrew twist lock (1) several ver - see 10.1.

t
turns counterclockwise.

rin
- On 023 L, remove the filter base -
• Lift off the carburetor box cover see 10.2.2.
vertically.

ep
• Grip the tab and pull the air filter
(3) out of the carburetor box.

rr
- Knock it out or blow it out with
compressed air.

- If the mesh is caked with dirt,

fo
wash the filter in a fresh,
ot
non-flammable cleaning solution

135RA188 VA
(e.g. warm soapy water) and
then dry.
-n

Note: Replace a damaged air filter

immediately. - Check tester for leaks. • Connect the tester’s pressure
hose to the nipple.
n

• Fit the air filter in the carburetor • Pull fuel hose off the carburetor’s
sio

box cover. elbow connector.

• Fit the carburetor box cover.

er
ev

2 1
0,4 0,6

0,2
lin

0 1,0
3
On

1
143RA172 VA

135RA189 VA

• Push the fuel line (1) • Close the vent screw (1) on the
1110 141 8600 onto the nipple rubber bulb (2) and pump air into
(2) 0000 855 9200. the carburetor until the pressure
gauge (3) shows a reading of
approx. 0.8 bar (11.6 psi).

021, 023, 025 41

 10.2.2 Removing and Installing

If this pressure remains constant,

the carburetor is airtight. However,
if it drops, there are two possible
causes: 2

1. The inlet needle is not sealing

1
(foreign matter in valve seat or
sealing cone of inlet needle is

135RA190 VA

135RA192 VA
damaged or inlet control lever
sticking).

2. The metering diaphragm is

damaged. - Remove the air filter - see 10.1. • Unscrew the filter housing
locknuts.
- After completing test, open the On 023 L,
• unscrew the slotted nuts (1).

t
vent screw and pull the fuel line - Lift away the filter housing.

rin
off the elbow connector.
• Remove the filter base (2).
- Push the fuel hose onto the

ep
elbow connector.

- On 023 L, fit the filter base.

rr
- Fit the carburetor box cover.

fo 2
ot
1

135RA193 VA
3
-n

All models • Pull choke rod (1) out of choke

• Pull fuel hose off the carburetor’s shaft (2) and switch shaft (3).
n

elbow connector.
sio

- On easy start machines, ease

carburetor forward a little.
er
ev
lin
On

135RA191 VA

135RA194 VA

• Detach throttle rod from the • Disconnect fuel hose from the
throttle trigger. manual fuel pump.

42 021, 023, 025

 10.2.3 Adjustment
(except 023 L and USA)

H L
2

H=1
L=1

135RA205 VA

135RA208 VA

135RA210 VA
• Remove the carburetor. • Slip the gasket off the studs. Standard setting

To readjust the carburetor, start

t
with the standard setting.

rin
- Carefully screw both adjusting
screws until they are hard

ep
against their seats.

Then make the following

rr
adjustments:

H = High speed screw (1),

fo open 1 full turn
L = Low speed screw (2),
open 1 full turn
ot
135RA209 VA
135RA206 VA

A slight correction to this setting

may be necessary at high altitudes
-n

(mountains) or near sea level.

• Take the throttle rod off the • If necessary, remove the shim For corrections to high speed
throttle shaft. from the studs. screw (H):
n

Use a tachometer - do not

sio

Resassemble in the reverse exceed max. permissible

sequence. engine speed.
Engine can be damaged by lack
- Fit the shim with its flat side of lubricant and overheating.
er

facing outward.
Maximum engine speed with bar
- Install a new gasket.
ev

and properly tensioned chain:

11,500 rpm (021)
- Tighten down locknuts to 12,500 rpm (023, 025)
2.5 Nm (1.8 lbf.ft).
lin

Note: If no tachometer is
- On 023 L, fit a new gasket in the available, do not turn the high
filter base. speed and low speed screws
On

beyond the standard setting to

135RA207 VA

- On 023 L, tighten slotted nuts make the mixture leaner.

to 2 Nm (1.5 lbf.ft).

• Remove the grommet from the

adjusting screws.

021, 023, 025 43


- Check chain tension.
- Check air filter and clean
if necessary.
- Inspect the spark arresting sreen
and clean or replace if necessary.
- Start the saw -
warm up the engine.
- Adjust idle speed correctly
(chain must not rotate).
Turn high speed screw (H) and
low speed screw (L) clockwise for
leaner mixture at high altitudes or
counterclockwise for richer mixture
at sea level.
Turn screws very slowly and
carefully - even slight movements
produce a noticeable change in
engine running behavior.
Note the following when making
corrections to high speed screw:
The setting of the high speed
screw (H) affects the maximum
off-load engine speed.
If the setting is too lean, the
maximum permissible engine
speed will be exceeded and
increase the risk of engine
damage.
ev
lin
On
44
10.2.4 Adjustment
(023 L and USA)
L
1
135RA203 VA
135RA211 VA
3
Adjusting engine idle speed: This carburetor has a fixed jet in
A correction at the low speed place of the high speed adjusting
screw (L) usually necessitates a screw (H screw).
t
change in the setting of the idle
rin
speed screw (LA). Maximum engine speed is preset
and no longer adjustable. It is only
possible to correct idling speed
ep
Engine stops while idling: within certain limits.
Check standard setting.
The carburetor guarantees an
rr
Turn idle speed screw (LA) clock- optimum fuel-air mixture in all
wise until the chain begins to run - operating conditions.
then turn it back one quarter turn.
fo Standard setting
Chain runs while engine is id-
ot
ling: To readjust the carburetor, start
Check standard setting. with the standard setting.
-n
Turn the idle speed screw (LA)
counterclockwise until the chain Carefully screw down the low
stops running - and then turn it speed screw (L) clockwise until it
about another quarter turn in the is hard against its seat. Then open
n
same direction. it one full turn.
sio
- Check chain tension.
Erratic idling behavior,
poor acceleration - Check air filter and clean if
er
Idle setting too lean. necessary.
Turn the low speed screw (L) - Inspect the spark arresting
counterclockwise until the engine screen and clean or replace if
runs and accelerates smoothly. necessary.
- Start the saw -
warm up the engine.
- Adjust idle speed correctly
(chain must not rotate).
021, 023, 025
 10.3 Tank Vent

Correct operation of the carburetor

is only possible if atmospheric 1
pressure and internal fuel tank
pressure are equal at all times.
This is ensured by the tank vent.
2
Important: If problems occur on
the carburetor or the fuel supply

Adjusting engine idle speed
A correction at the low speed
screw (L) usually necessitates a
135RA214 VA
system, always check and clean
the tank vent. 1
Check function by performing
pressure and vacuum tests on • Use a 3 mm (1/8") dia. drift to
the tank via the fuel hose. push the grub screws (1) out
of the hose (2).

t
change in the setting of the idle - Remove the carburetor box

rin
speed adjusting screw (LA). cover - see 10.1. - Wash all parts in fresh white
spirit and blow clear with
Note: Turn screws very slowly and - On 023 L, remove the filter compressed air.

ep
carefully - even slight movements base - see 10.2.2.
produce a noticeable change in Reassemble in reverse sequence.
engine running behavior.

rr
Engine stops while idling:
Check standard setting. fo
Turn idle speed screw (LA) clock-
ot
wise until the chain begins to run -
then turn it back one quarter turn.
-n

Chain runs while engine is

idling:
Check standard setting.
n
sio

Turn the idle speed screw (LA)

counterclockwise until the chain
stops running - and then turn it
about another quarter turn in the
er

same direction.
ev

Erratic idling behavior, poor

acceleration -
even though low speed screw in
lin

one turn open

Idle setting too lean.
On

Turn the low speed screw (L)

135RA213 VA

135RA204 VA

counterclockwise until the engine

runs and accelerates smoothly. a

• Remove the vent from the stub • Use a drift to position the grub
on the fuel tank. screws as shown in the
illustration.
a = approx. 20 mm (3/4")

021, 023, 025 45

10.4 Pickup Body 10.5 Suction Hose

The diaphragm pump draws fuel

out of the tank and into the
carburetor via the fuel hose. Any
impurities mixed with the fuel are
retained by the pickup body (filter).
The fine pores of the filter
event-ually become clogged with
minute particles of dirt. This

135RA217 VA
135RA215 VA
restricts the passage of fuel and
results in fuel starvation. 1

Important: In the event of trouble

with the fuel supply system, • Use hook (1) 5910 893 8800 to - Remove the handle housing -
always check the fuel tank and pull the pickup body out through see 8.3.
the pickup body first. Clean the the filler opening.

t
fuel tank if necessary. - Remove the pickup body -

rin
Note: Do not stretch the suction see 10.4.
hose.
Cleaning the fuel tank: - Pry suction hose flange out of

ep
the fuel tank.
- Unscrew the filler cap and drain
the tank. • Pull the suction hose out of

rr
the tank.
Note: Observe safety precautions -
see 1. Reassemble in the reverse

- Pour a small amount of clean

fo sequence.

gasoline into the tank.

ot
135RA216 VA

- Close the tank and shake the

saw vigorously.
-n

- Open the tank again and drain it.

• Pull the pickup body off the fuel
Note: Dispose of fuel properly. hose.
n
sio

- Replace the pickup body.

Pickup body
Reassemble in the reverse
- Unscrew the fuel filler cap and sequence. - Coat the hose flange with a little
er

remove it together with the cap oil to simplify installation.

retainer, if fitted.
ev
lin
On

1
135RA218 VA

• Straight side (1) of hose

flange must be parallel to tank
joint (2).

46 021, 023, 025

10.6 Manual Fuel Pump 10.6.1 Fuel Hoses

Easy start machines only - Disconnect the hoses from the

fuel pump - see 10.6.
- Remove the air filter - see 10.1.
- Remove the filter housing -
- Take out the shutter - see 4.3. see 10.2.2.

- Pull boot off the spark plug. - Pull off the tank vent -
see 10.3.

135RA221 VA
• Carefully squeeze the retaining
tabs.

t
- Pull the fuel pump out of its seat

rin
in the handle housing.

Reassemble in the reverse

ep
sequence.

- Push home the fuel pump (short

rr
intake stub facing the air filter)
until retaining tabs snap into
position.
fo
- Connect carburetor suction hose
to the short stub.
ot
135RA219 VA

135RA223 VA
-n

• Carefully push cover, if fitted, • Pull the suction hose off the
with thumb in direction of arrow carburetor stub.
n

until it is released from its seat.

sio

- Pull the suction hose out of the

- Remove the cover. bore in the handle housing.

- If necessary, pull the helical

er

spring out of the suction hose.

Note: The helical spring must be

ev

fitted to prevent the hose bend

kinking and restricting its cross
section.
lin

2
1
On
135RA220 VA

135RA222 VA

• Disconnect hoses from the • Slide the cover (1) under the top
connectors. retaining tab (2) and fit the pin
(3) in the bore in the handle
housing.

021, 023, 025 47

 10.7 Fuel Tank

Fuel tank and engine housing are • Use hook (1) 5910 893 8800 to
2 1
a single unit. pull pickup body out of the fuel
tank.
- Remove the engine - see 5.4.
2 Note: Do not stretch the suction
- Remove the chain tensioner - hose.
see 4.5 and 4.6.

135RA224 VA
- Remove the chain brake -
3 see 4.4.2.

• Pull the return hose (1) out of

the retainers (2).

• Pull the return hose out of the

t
rin
grommet (3) and the bore in the
handle housing.

ep
- Check grommet and replace if
necessary.

rr
Note: Grommet is essential to
provide an effective seal.
2
Reassemble in the reverse
sequence.
fo2
1
ot

135RA227 VA
135RA225 VA
-n

• Disconnect the short circuit • Disconnect pickup body from the

wire (1). suction hose.
n

• Take out the screws (2).

sio

• Remove the ignition module (3).

er
ev
lin
On

135RA226 VA

135RA228 VA

- Unscrew the fuel filler cap and - Pry the suction hose flange out
remove with cap retainer, if fitted. of the fuel tank.

• Pull out the suction hose.

48 021, 023, 025

 • To install engine housing in a
machine with a quick chain
tensioner, use stud puller (1)
5910 893 0501 to slowly
unscrew the rear collar screw.

Note: Thread in engine housing

can be damaged if stud puller is

135RA230 VA

135RA232 VA
turned too fast.

• Pull out the oil pump suction Reassemble in the reverse

hose with pickup body. sequence.

• Position ground wires, short

t
rin
circuit wire and ignition lead in
the housing slots.

ep
- After assembling, set distance
between ignition module and
flywheel - see 6.3.2.

rr
- Coat the fuel hose flange with a
little oil to simplify installation.
fo
- Straight side of hose flange
must be parallel to tank joint.
ot
135RA233 VA

135RA231 VA
-n

• Remove the spiked bumper, if - Apply a little oil to the thread of

fitted. the new or original collar screw.
n

• Insert collar screw in the bore of

sio

the replacement engine housing

and turn it counterclockwise until
it engages the thread.
er

- Then screw it home clockwise

amd torque down to approx.
ev

8.0 Nm (5.9 lbf.ft).

- Tighten down mounting screws

lin

on spiked bumper to 3.7 Nm

(2.8 lbf.ft).
On
135RA229 VA

135RA234 VA

2 1 1

• On machines with quick chain Note: Replacement engine

tensioner, remove the stiffener housings are supplied with two
(1) and take out the rear collar collar screws of the same length.
screw (2).

021, 023, 025 49

11. Special Servicing Tools and Aids
11.1 Special Servicing Tools

No. Part Name Part No. Application Rem.

1 Locking strip 0000 893 5903 Blocking crankshaft

2 Press sleeve 1123 893 2400 Fitting oil seal
3 - Guide sleeve 1123 894 7700 - (ignition side only)
4 Puller 5910 890 4400 Removing oil seals 1)
5 - Jaws (No. 6) 0000 893 3711
6 Puller 1116 893 0800 Removing flywheel
7 Crimping tool 5910 890 8210 Attaching connectors to
electrical wires
8 Assembly drift 1110 893 4700 Removing and fitting
piston pin

t
9 Carburetor and crankcase 1106 850 2905 Testing carburetor and

rin
tester engine for leaks
10 - Nipple 0000 855 9200
11 - Fuel hose 1110 141 8600

ep
12 Vacuum pump 0000 850 3501 Testing engine for leaks
13 Sealing plate 0000 855 8106 Sealing exhaust port for

rr
leakage test
14 - Flange 1123 855 4200
15 - Sleeves 1123 851 8300
16 Test flange 1118 850 4200
fo
Leakage test
17 Setting gauge 1111 890 6400 Setting air gap between
ot
ignition module and flywheel
18 Socket, 13 mm 5910 893 5608 Flywheel nut
-n

19 Socket, 19 mm 5910 893 5612 Clutch

20 Torque wrench 5910 890 0301 0.5 - 18 Nm 2)

(0.4 - 13.5 lbf.ft)
n

5910 890 0302 3)

sio

21 Torque wrench 5910 890 0311 6 bis 80 Nm 2)

(4.4 - 60 lbf.ft)
5910 890 0312 3)
er

22 Spline screw socket T27x125 0812 542 2104 IS screws

23 Hook 5910 893 8800 Removing pickup bodies
ev

24 Installing tool 5910 890 2210 Installing hookless snap rings

in piston
25 Assembly tube 1117 890 0900 Attaching brake spring
26 T-handle screwdriver QI-T27x150 5910 890 2400 For all IS screws 4)
lin

27 Stud puller M8 5910 893 0501 Removing guide bar

mounting studs
On

50 021, 023, 025

No. Part Name Part No. Application Rem.

28 Clamp 1123 893 9100 Holding conrod bearing 5)

29 Installing tool 1123 890 2201 Removing/installing oil pump
30 Installing tool 1116 893 4800 Refitting rewind spring
31 Assembly stand 5910 890 3100 Holds chainsaw for
repairs
32 - Clamping bar 5910 890 2000

t
rin
Remarks:
1) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400.

ep
2) DG screws must always be tightened with a torque wrench
3) Wrench has optical/acoustic signal
4) Only use for releasing DG screws

rr
5) 021 up to serial No. X 34 944 402 only

fo
ot
-n
n
sio
er
ev
lin
On

021, 023, 025 51

11.2 Servicing Aids

No. Part Name Part No. Application

1 Lubricating grease 0781 120 1111 Oil seals, oil pump drive,
(370 g/13 oz tube) chain sprocket bearing, chain tensioner,
cylindrical rollers

2 Standard commercial, Cleaning crankshaft stub and

solvent-based degresant flywheel taper
containing no chlorinated
or halogenated hydrocarbons

3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor,

t
rewind spring in fan housing

rin
4 Ignition lead HTR, 0000 930 2251
10 m (33’)

ep
5 Dirko sealant, 0783 830 2120 Engine pan, oil seals (outside dia.)
(100 g/3 1/2 oz tube)

rr
6 Graphite grease fo
Peg on pawl

7 Molykote grease Sliding and bearing points on brake band

ot
-n

8 STIHL Bioplus 0781 516 3331 Protects brake band against corrosion
(1 l/34 fl.oz bottle)
n
sio
er
ev
lin
On

52 021, 023, 025