2 6. Rewind Starter...STIHL gear lubricant (80 g/3 oz tube) 0781 120 1117 2.5.2 For Service...

1. Introduction 2

2. Specifications 3

2.1 Engine 32.2 Fuel System 32.3 Ignition System 42.4 Gearhead 42.5 Special Accessories 42.5.1 For User 42.5.2 For Service 42.6 Tightening Torques 5

3. Clutch 7

3.1 Removing and Installing 73.2 Clutch Carrier 8

4. Engine 9

4.1 Exhaust Muffler/Spark Arresting Screen 9

4.2 Leakage Test 104.2.1 Preparations 104.2.2 Pressure Test 114.2.3 Vacuum Test 114.3 Oil Seals 124.4 Exposing the Cylinder 134.5 Cylinder and Piston 144.5.1 Removal 144.5.2 Installation 154.6 Piston Rings 174.7 Crankcase 174.7.1 Removing Crankshaft 174.7.2 Installing Crankshaft 204.8 Decompression Valve 23

5. Ignition System 23

5.1 Spark Plug Boot 235.2 Ignition Lead

(FS 400/450, FR 450) 245.3 Ignition Module 255.3.1 Ignition Timing 265.3.2 Removing and Installing

(FS 120...350, FR 350) 265.3.3 Removing and Installing

(FS 400/450, FR 450) 275.4 Flywheel 285.5 Short Circuit Wire 29

6. Rewind Starter 30

6.1 General 306.2 Rewind Spring 306.2.1 Replacing 306.2.2 Tensioning 316.3 Starter Rope/Starter

Grip (ElastoStart) 32

7. Throttle Control 33

7.1 Throttle Trigger/InterlockLever (Bike Handle) 33

7.2 Contact Springs/Detent Spring in Control Handle(Bike Handle) 34

7.3 Throttle Trigger/Interlock Lever (Loop Handle) 34

7.4 Slide Control (Loop Handle) 35

7.5 Throttle Cable 367.5.1 Replacing 367.5.2 Adjusting 37

8. Fuel System 38

8.1 Air Filter 388.2 Carburetor 398.2.1 Removing and Installing

(FS 120...350, FR 350) 398.2.2 Removing and Installing

(FS 400/450, FR 450) 408.2.3 Leakage Test 418.2.4 Adjusting

(three screws) 428.2.5 Adjusting

(one screw) 438.3 Tank Vent 448.4 Pickup Body 448.5 Fuel Tank/

Hoses 458.6 Manual

Fuel Pump 47

9. AV System 47

9.1 Repair (FS 120/200) 47

9.2 Repair (FS 300...450) 48

9.3 Repair (FR 350/450) 50

10. Shaft 51

10.1 Bike Handle (FS 120/200) 51

10.2 Bike Handle(FS 300...450) 51

10.3 Loop Handle 5210.4 Drive Shaft/

Flexible Liner 5210.5 Flexible Shaft

(FR 350/450) 5310.6 Drive Tube 5410.7 Housing

(FR 350/450) 56

11. Cutting Tool Drive 56

11.1 Gearhead 5611.2 Clutch Drum 57

12. Support Frame (FR 350/450) 58

12.1 Repair 58

13. Special Servicing Tools and Aids 59

13.1 Special Servicing Tools 5913.2 Servicing Aids 61

© 1997, Andreas Stihl, Waiblingen

CONTENTS

FS 120, 200, 300, 350, 400, 450, FR 350, 450 1

This service manual contains de-tailed descriptions of all the repairand servicing procedures specificto this power tool series.There are separate handbooks forservicing procedures for stand-ardized parts and assemblies thatare installed in several STIHL power tool models. Reference ismade to these handbooks in theappropriate chapters in this manual.

As the design concept of modelsFS 120, FS 200, FS 300, FS 350,FS 400, FS 450 and FR 350, FR450 is almost identical, the descrip-tions and servicing procedures inthis manual generally apply to allthree models. Differences are de-scribed in detail.

You should make use of the illustrated parts lists while carryingout repair work. They show the installed positions of the individualcomponents and assemblies.

Refer to the latest edition of the relevant parts list to check the partnumbers of any replacement partsneeded. Parts lists on microfiche and CD-ROM are always more up to datethan printed lists.

A fault on the power tool may haveseveral causes. Consult the troubleshooting charts for all as-semblies in the "Standard Repairs,Troubleshooting" handbook.

Refer to the "Technical Informa-tion" bulletins for engineering changes which have been intro-duced since publication of this service manual. Technical informa-tion bulletins also supplement theparts list until a revised edition is issued.

The special servicing tools men-tioned in the descriptions are listed in the last chapter of this manual. Use the part numbers to identifythe tools in the "STIHL SpecialTools" manual. The manual lists all special servicing tools currently availablefrom STIHL.

Symbols are included in the textand pictures for greater clarity. The meanings are as follows:

In the descriptions:

• = Action to be taken as shown in the illustration (above the text)

- = Action to be taken that is not shown in the illustration (above the text)

In the illustrations:

= Pointer

= Direction of movement

Service manuals and all technicalinformation bulletins describing engineering changes are intendedexclusively for the use of STIHLservicing dealers. They must notbe passed to third parties.

Servicing and repairs are madeconsiderably easier if the machineis mounted on assembly stand (2)5910 890 3100 with the aid ofclamp (1) 5910 890 8800.

Secure the clamp to the assemblystand with two washers and twoM8 nuts.

Servicing and repairs to the power-head are considerably easier if it ismounted on assembly stand (2)5910 890 3100 with the aid ofclamping plate (1) 5910 890 2101.

First remove the clutch housingand secure the powerhead to thestand with two M6x20 and twoM10x25 hex. head screws.

The machine or powerhead canthen be swivelled to the best posi-tion for the ongoing repair and thisleaves both hands free.

Always use original STIHL replacement parts. They can be identified by theSTIHL part number, the STIHL

and the STIHL parts symbol (The symbol may appear alone on small parts.

1. INTRODUCTION

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2 FS 120, 200, 300, 350, 400, 450, FR 350, 450

2.1 Engine

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

FS 120/300 FS 200/350 FS 400 FS 450FR 350 FR 450

Displacement: 30.8 cm3 36.3 cm3 40.2 cm3 44.3 cm3

1.88 cu.in 2.21 cu.in 2.45 cu.in 2.70 cu.inBore: 35 mm 38 mm 40.0 mm 42.0 mm

1.38 in 1.49 in 1.57 in 1.65 inStroke: 32 mm 32 mm 32 mm 32 mm

1.26 in 1.26 in 1.26 in 1.26 inPower output: 1.3 kW (1.8 bhp) 1.6 kW (2.2 bhp) 1.9 kW (2.6 bhp) 2.1 kW (2.8 bhp)

at 9,000 rpm Max. permissible engine speed without cutting tool (cut-off speed): 12,500 ± 1000 rpm 12,500 ± 800 rpmIdle speed: 2,800 rpmBearings: Crankshaft supported in heavy-duty ball bearings, needle cages on

small and big ends Piston pin diameter: 10 mm (0.39 in)Rewind starter: ElastoStartPawls: Single pawl systemReserve pull on rope rotor: min. 1/2 turnStarter rope: 3.0 mm (0.12 in) dia. x 800 mm (31.5 in)Clutch: Centrifugal clutch without liningsClutch engages at: 4,300 rpmCrankcase leakage test at gauge pressure: 0.5 bar (7.25 psi)under vacuum: 0.5 bar (7.25 psi)

2.2 Fuel System

Carburetor: Diaphragm carburetor Standard setting on carburetorswith three adjusting screwsHigh speed screw H: Open approx. 1 turnLow speed screw L: Open approx. 1 turnCarburetor leakage testat gauge pressure: 0.8 bar (11.6 psi)Function of tank ventat gauge pressure: ≤ 0.3 bar (4.35 psi)under vacuum: ≤ 0.05 bar (0.725 psi)Fuel tank capacity: 0.64 l (1.35 US pt) 0.68 l (1.44 US pt)Octane rating: min. 90 RON (US/CAN; pump octane min. 87)Fuel mixture: Regular brand name gasoline

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

25:1 with other brand name two-stroke, air-cooled engine oilsAir filter: Paper filter

2. SPECIFICATIONS

FS 120, 200, 300, 350, 400, 450, FR 350, 450 3

2.3 Ignition System Type: Electronic magneto ignition (breakerless)with integral trigger unitand electronic speed governor

Air gap: 0.2 - 0.5 mm (0.008 - 0.020 in)Length of ignition lead: 305 mm * (12 in)*Spark plug (suppressed): Bosch WSR 6F,

NGK BPMR 7 A orChampion RCJ 6Y

Electrode gap: 0.5 mm (0.020 in)Splark plug thread: M14x1.25Length of thread: 9.5 mm (0.37 in)

2.4 Gearhead Type: Spiral-toothed bevel gear drive

Gear ratio: 1:1.4 **1:1.235

Bearings: Deep groove ball bearings

Lubrication: STIHL gear lubricant 0781 120 1117(7 g / 0.25 oz)

2.5 Special Accessories

2.5.1 For User Full harnessSafety glassesTransport guard for metal cutting toolsSTIHL gear lubricant (80 g/3 oz tube) 0781 120 1109STIHL gear lubricant (80 g/3 oz tube) 0781 120 1117

2.5.2 For Service Carburetor parts kit 4134 007 1060Set of gasketsfor FS 120, 200, 300, 350, FR 350 4134 007 1050Set of gaskets for FS 400, 450, FR 450 4128 007 1050

* FS 400/450 only** FS 120, 200, 350 and 450

4 FS 120, 200, 300, 350, 400, 450, FR 350, 450

DG and P screws (Plastoform) are used in polymer and lightmetal components. These screws form a perma-nent thread when they are installed for the first time. They can be removed and installed as often as necessarywithout 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 Remarkssize Nm lbf.ft

Self-tapping screw IS-B3.5x6.5 Rewind spring/fan housing 1.5 1.1Self-tapping screw IS-B4.2x9.5 Muffler/spark arresting screen 2.5 1.8 1) 2)Spline screw IS-DG4x20 Ignition module/crankcase 4.5 3.3 3) 4) 5)Spline screw IS-DG5x24 Ignition module/crankcase 6.0 4.4 1) 2)Spline screw IS-DG5x12 AV sleeve/drive tube (fixing screw) 2.5 1.8 3)Spline screw IS-DG5x12 Guard ring/gear housing 5.0 3.7 1) 4)Spline screw IS-DG5x20 Fan housing/crankcase 6.0 4.4Spline screw IS-DG5x20 Fan housing/shroud/crankcase 6.0 4.4Spline screw IS-DG5x20 Carburetor housing/crankcase/

cylinder 6.0 4.4Spline screw IS-DG5x20 Filter housing/ground wire/

crankcase 6.0 4.4Spline screw IS-DG5x20 Ground wire/crankcase 6.0 4.4 1) 2)Spline screw IS-DG5x26 Fuel tank/crankcase 6.0 4.4Spline screw IS-DG5x24 Bracket/crankcase 6.0 4.4 1)Spline screw IS-DG5x20 Shroud/clutch housing 6.0 4.4Spline screw IS-DG5x26 Guard plate/fuel tank/

crankcase 6.0 4.4 1) 2)Spline screw IS-DG5x24 Cylinder/crankcase 8.5 6.3Spline screw IS-DG5x24 Muffler/crankcase 8.5 6.3Spline screw IS-DG5x24 Muffler/cylinder 8.5 6.3Spline screw IS-DG5x24 Crankcase 8.5 6.3Spline screw IS-DG5x24 Clutch housing/crankcase 8.5 6.3 1) 2) 4) 5)Spline screw IS-DG5x24 Clutch housing/crankcase 6.0 4.4 3)Spline screw IS-DG6x28 Clutch housing/drive tube 12.0 8.8 1) 6)Spline screw IS-DG5x24 Clutch housing/drive tube 8.5 6.3 4)Spline screw IS-DG5x24 Gear housing/drive tube 8.5 6.3 2) 3) 5)Spline screw IS-DG5x25 Gear housing/drive tube

Stage 1 1.5 1.1 1) 4) Stage 2 7.5 5.5 1) 4)

Collar nut M5 Filter housing/carburetor housing 3.5 2.6Collar screw M5/P6 Carburetor housing 4.0 3.0Spline screw IS-M5x12 Clamp/control handle/

drive tube (loop handle) 2.0 1.5 3) 4)Spline screw IS-M5x16 AV sleeve/drive tube (clamp screw) 5.5 4.0 3)Spline screw IS-M5x12 Clamp/control handle/drive tube 2.0 1.5 2) 5)Spline screw IS-M5x16 Clamp/drive tube (for harness) 4.5 3.3 3)Spline screw IS-M5x30 Control handle (bike handle) 2.0 1.5 6)

2.6 Tightening Torques

FS 120, 200, 300, 350, 400, 450, FR 350, 450 5

Fastener Thread For component Torque Remarkssize Nm lbf.ft

Spline screw IS-M6x25 Clamp/loop handle 4.5 3.3 3)Spline screw IS-M6x25 Support/drive tube 6.0 4.4 1) 4) 6)Spline screw IS-M6x35 Clamp moldings/support block

(handle support/bike handle) 4.5 3.3 3)M8 Carrier 24.0 17.7

Spline screw IS-M6x18 Clutch shoe/carrier 12.0 8.8M8 Flywheel 32.0 23.6M10 Decompression valve 14.0 10.3 1) 2) 4) 5)M14x1.25 Spark plug 20.0 15.0

Screw plug M11x10 Gearhead 8.5 6.3Spline screw IS-M5x14 Filter cover/filter housing 6.0 4.4 1) 2)Plastoform screw IS-P4x16 Control handle/handle moldings 1.0 0.75Collar screw IS-P3.5x10.6 Detent spring/slide control

(bike handle) 1.1 0.80 1) 3) 4)Nut M12x1.5 L Cutting tool 25.0 18.5Spline screw IS-M5x16 Cutting tool deflector/gearhead 4.3 3.2Spline screw IS-M6x14 Spring/support plate 10.0 7.5 2) 5)Spline screw IS-M6x25 Housing/shaft clamp screw 4.5 3.3 2) 5)Spline screw IS-M6x14 Bearing housing/support frame 10.0 7.5 2) 5)Spline screw IS-M10x20 Support plate/ball bearing/

support frame 20.0 15.0 2) 5)

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

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

This procedure ensures that the screw engages properly in the existing thread and does not form a new thread.

1) FS 400/4502) FR 4503) FS 120/2004) FS 300/3505) FR 3506) with washer

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

6 FS 120, 200, 300, 350, 400, 450, FR 350, 450

Removal

Troubleshooting chart - see"Standard Repairs, Trouble-shooting" handbook.

� Remove clutch housing - see 9.1 or 11.2.

All models• Inspect clutch drum. There

should be no scores or signs ofexcessive wear.

Important: If there are signs of serious wear on the inside diameter, fit a new clutch drum -see 11.2.

� Remove the shroud - see 4.1.

� Pull off the spark plug boot.

� Unscrew the spark plug.

FS 120...350, FR 350• Fit locking strip (1)

0000 893 5903.

FS 400/450, FR 450• Fit locking strip (1)

4221 893 5900.

• Take out screws (1).

• Remove cover (2).

• Remove clutch shoes with bushings.

• Take bushings out of the clutchshoes.

• Twist the clutch shoes and detach the springs.

Important: Clutch shoes andsprings must always be replacedin pairs.

3. CLUTCH 3.1 Removing and Installing

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Installation

• Fit clutch shoes with springs andbushings so that the arrows pointcounterclockwise.

• Fit cover in position.

• Insert screws and tighten down to 12 Nm (8.8 lbf.ft).

� Pull locking strip out of cylinder.

� Fit spark plug and tighten down to 20 Nm (15 lbf.ft).

Important: If the spark plug comes with a separate terminal nut, always fit the nut on the thread and tighten it down securely.

� Fit the boot on the spark plug.

� Fit the shroud - see 4.1.

� Fit clutch housing - see 9.1 or 11.2.

� Remove clutch - see 3.1.

• Unscrew carrier from end ofcrankshaft.

• Fit the carrier and tighten it down to 24 Nm (17.7 lbf.ft).

� Install the clutch - see 3.1.

3.2 Clutch Carrier

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Troubleshooting chart - see"Standard Repairs, Trouble- shooting" handbook.

Spark arresting screen

FS 120...350, FR 350• Pull spark arresting screen out of

the muffler.

� Clean or replace spark arrestingscreen if necessary.

FS 400/450, FR 450• Take out the screw (1).

• Pull spark arresting screen (2)out of the muffler.

� Clean or replace spark arrestingscreen if necessary.

� Tighten down screw to 2.5 Nm(1.8 lbf.ft).

Muffler

FS 400/450, FR 450� Remove air filter cover - see 8.1.

All models• Remove screws from clutch

housing.


• Press down the decompressionvalve (2).

• Remove the shroud (3).

• Take out the screws.

� Lift away the muffler.

• Remove the gasket.

Reassemble in the reversesequence.

� Use a new gasket.

� Tighten down screws to 8.5 Nm(6.3 lbf.ft).

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4. ENGINE 4.1 Exhaust Muffler/Spark Arresting Screen

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Defective oil seals, gaskets,cracks in castings or a faulty seal-ing ring between the carburetorhousing and cylinder are theusual causes of leaks. Such faultsallow air to enter the engine andthus upset the fuel-air mixture.

This makes adjustment of the prescribed idle speed difficult, ifnot impossible.

Moreover, the transition from idlespeed to part or full throttle is notsmooth.

The crankcase can be checkedthoroughly for leaks with the car-buretor and crankcase tester andthe vacuum pump.

� Remove the carburetor - see8.2.1 and 8.2.2.

� Set the piston to top dead center(T.D.C.). This can be checkedthrough the inlet port.

� Make sure the spark plug is properly tightened down.

• Slide a new gasket over the carburetor studs.

• Push the test flange (1) 1128 850 4200 into position.

• Fit and tighten down the nuts (2)firmly.

� Back off the muffler mountingscrews half-way.

• Slide the sealing plate (1) 0000 855 8106 between the gasket and cylinder exhaust port and retighten the mountingscrews moderately.

Note: The sealing plate must completely fill the space betweenthe two mounting screws.

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4.2 Leakage Test 4.2.1 Preparations

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� Carry out preparations - see 4.2.1.

• Connect pressure hose of tester1106 850 2905 to nipple on testflange.

• Close the vent screw (1) on the rubber bulb.

� Use rubber bulb to pump air intothe crankcase until the gauge indicates a pressure of 0.5 bar(7.25 psi). If this pressure re-mains constant for at least 20 seconds, the crankcase or de-compression valve, if fitted, is airtight.

• However, if the indicated press-ure drops, the leak must be located and the faulty part replaced.

Note: To find the leak, coat the suspect area with oil and pressurize the crankcase again.Bubbles will appear if a leak exists.

� If the decompression valve is notairtight, install a new one - see4.8.

� Repeat the pressure test.

� Carry out the vacuum test - see4.2.3.

� After finishing the test, open thevent screw and disconnect thehose.

� Remove the test flange.

� Slacken off the muffler mountingscrews.

� Pull out the sealing plate andtighten down the screws to 8.5 Nm (6.3 lbf.ft).

� Install carburetor - see 8.2.1 or8.2.2.

Oil seals tend to fail when sub-jected to a vacuum, i.e. the sealinglip lifts away from the crankshaftduring the piston’s induction strokebecause there is no internal counterpressure.

An additional test can be carriedout with the vacuum pump to detect this kind of fault.

� Carry out preparations - see 4.2.1.

• Connect the suction hose of vacuum pump 0000 850 3501 to test flange nipple.

• Close vent screw (1) on pump cylinder.

• Operate lever (2) until the gauge(3) indicates a vacuum of 0.5 bar(7.25 psi).

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4.2.2 Pressure Test 4.2.3 Vacuum Test

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Note: If the vacuum reading remains constant, or rises to nomore than 0.3 bar (4.25 psi) within20 seconds, it can be assumedthat the oil seals are in good condition.However, if the pressure continuesto rise (reduced vacuum in the crankcase), the oil seals must bereplaced.

� After finishing the test, open thevent screw and disconnect thehose.

� Remove the test flange.

� Sacken off the muffler screws.

� Remove the sealing plate tightenscrews to 8.5 Nm (6.3 lbf.ft).

� Install carburetor - see 8.2.1 and8.2.2.

It is not necessary to disassemblethe complete engine to replace theoil seals.

The FS 200 engine is shown in theillustrations.

Starter side:

� Remove the flywheel - see 5.4.

� Tap the oil seal with a suitablepiece of pipe or a punch to release it from its seat.

• Apply the puller (1) 5910 890 4400 (with No. 3.1jaws 0000 893 3706).

� Tension the arms.

� Pull out the oil seal.

Important: Take care not to damage crankshaft stub.

� Clean sealing surface with astandard solvent-based degreas-ant containing no chlorinated orhalogenated hydrocarbons - see13.2.

� Lubricate sealing lips of oil sealwith grease - see 13.2.

� Slide the oil seal, open side facing the crankcase, over theend of the crankshaft.

• Use the press sleeve (1) 4112 893 2401 to press it fullyhome.

� Install flywheel - see 5.4.

Clutch side:

� Remove carrier - see 3.2.

� Tap the oil seal with a suitablepiece of pipe or a punch to release it from its seat.

• Apply the puller (1) 5910 890 4400 (with No. 3.1jaws 0000 893 3706).

� Tension the arms.

� Pull out the oil seal.

Important: Take care not to dam-age crankshaft stub.

� Clean sealing surface with astandard solvent-based degreas-ant containing no chlorinated orhalogenated hydrocarbons - see13.2.

� Lubricate sealing lips of oil sealwith grease - see 13.2.

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4.3 Oil Seals

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• Slip installing sleeve (1) 4112893 2400 over the end of thecrankshaft.

� Push the oil seal, open side facing the crankcase, over the installing sleeve and press it home with the press sleeve.

• Press home with press sleeve(1) 1118 893 2401.

� Remove the installing sleeve.

� Install carrier - see 3.2.

Always check and, if necessary, repair the fuel system, carburetor,air filter and ignition system beforelooking for faults on the engine.


� Remove the muffler - see 4.1.

� Remove the carburetor - see8.2.1 and 8.2.2.


• Pull away the carburetor housing(2).

FS 400/450, FR 450• Disconnect hose from fuel pump

and pull it out of the guide.


• Pull away the carburetor hous-ing (2), ease grommet out of carburetor housing and pull theextended throttle cable out of thehousing opening.

Assemble in the reverse sequence.

• Fit stub (1) on carburetor hous-ing in the sealing ring (2) andthrottle cable (3) in the retainer(4).

� Tighten down screws to 6 Nm(4.4 lbf.ft).

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4.4 Exposing the Cylinder

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FS 400/450, FR 450• Fit throttle cable (1) and grom-

met (2) in opening in carburetorhousing.

• Insert stub (3) in the sealing ring (4).

� Secure lug of extended throttle cable between the raised marks and tighten down the screws to 6 Nm (4.4 lbf.ft).

� Preparations - see 4.4.

� Remove clutch housing - see 9.1 and 11.2.


� On FS 120...350, FR 350: Takeignition lead out of the retainerson the throttle cable holder.


� Unscrew the decompression valve, if fitted.

FS 400/450, FR 450• Take cable retainer out of

cylinder.

All models:Illustrations show the FS 200 engine.

• Pull out the sealing ring.

• Release and unscrew the four cylinder base screws.

� Pull the cylinder off the piston.

� Inspect the cylinder and replaceit if necessary.

� If a new cylinder has to be installed, always fit the matchingpiston. New cylinders are onlyavailable with piston.

� Before removing the piston, decide whether or not the crank-shaft has to be removed as well.To remove the clutch and carrier,block the crankshaft by slidingthe wooden assembly block between the piston and crank-case.

� Remove the cylinder gasket.

• Ease the hookless snap rings out of the grooves in the piston bosses.

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4.5 Cylinder and Piston 4.5.1 Removal

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• Now use the assembly drift (2)1110 893 4700 to push the pis-ton pin (1) out of the piston.

Note: If the piston pin is stuck, tapthe end of the drift lightly with ahammer if necessary. Hold the piston steady during this processto ensure that no jolts are trans-mitted to the connecting rod.

� Remove piston and take the needle cage out of the connect-ing rod.

• Inspect piston rings and replaceif necessary - see 4.6.

• Thoroughly clean the gasket seating surface (1).

• Check that adapter sleeves (2)are in place. Fit them if necess-ary.

• Lubricate the needle cage (3)with oil and fit it in the connectingrod.

• To simplify assembly, heat thepiston and slip it over the con-necting rod.

• Installed position of piston: 1 = Marking 2 = Flywheel

• Push the assembly drift, small diameter first, through the pistonand small end (needle cage) andline up the piston.

• Fit the piston pin (1) on the assembly drift (2) and slide it into the piston (the pin slideshome easily if the piston is hot).

• Modify sleeve of installing tool5910 890 2210 as shown indrawing.a = 30 degreesb = Ø 10 mm

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4.5.2 Installation

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• Use installing tool (1) 5910 890 2208 to fit the snaprings.

Note: For instructions on how touse the installing tool see "Standard Repairs, Trouble-shooting" handbook.

• Fit new cylinder gasket on thecrankcase.

• Lubricate piston and piston ringswith oil. Rest piston (1) on wooden assembly block (2) 1108 893 4800.

• Position the piston rings so thatthe radii at the ring gap meet atthe fixing pin in the piston groovewhen the rings are compressed.

• Use the clamping strap (1) 0000 893 2600 to compress thepiston rings around the pistonand check that the piston ringsare correctly positioned.

� Lubricate the inside of the cylinder with oil and line it up sothat it is positioned as it will be inthe installed condition. It is im-portant to observe this point asthe piston rings might otherwise break.

• Slide the cylinder over the piston- the clamping strap is pusheddownward as the piston ringsslip into the cylinder.

� Remove the clamping strap and wooden assembly block.

� Line up the cylinder and gasket.

• Use socket (1) 0812 542 2104 to tighten down cylinder basescrews to 8.5 Nm (6.3 lbf.ft).

Assemble all other parts in the reverse sequence.

250R

A04

2V

A25

0RA

041

1

2 VA

250R

A04

0V

A25

0RA

036

1

VA

250R

A04

3

1

VA

250R

A04

4V

A25

0RA

045

1

VA

�� )6��)5��

� Remove the piston - see 4.5.1.

Note: The piston must be re-moved to make sure that no residue can fall into the crankcasewhen installing the piston ringsand cleaning their grooves.

Illustrations show piston in model FS 200.

� Remove rings from piston.

• Use a piece of old piston to scrape the grooves clean.

• Install the new piston rings in thegrooves so that the radii (1) facethe fixing pin (2).

� Install the piston - see 4.5.2.

� Remove the ignition module -see 5.3.2 and 5.3.3.

� Remove the fuel tank - see 8.5.

� Remove the cylinder - see 4.5.1.

All models• Take out screw (1).

• Remove top of cable guide (2).

FS 120...350, FR 350

• Take throttle cable (1) out ofbase of guide (2).

• Take short circuit wire (3) out ofbase of guide and remove it fromthe retainers (4).

FS 400/450, FR 450• Remove short circuit wire from

the retainers.

• Ease the grommets out of thehousing and pull out the short circuit wire.

All models• Pull the base of the guide

off the housing.

� Remove the carrier - see 3.2.

250R

A04

9

1

3

2

4

VA

250R

A04

6V

A

250R

A04

8

2

1

VA

2

1

250R

A04

7

1

VA

250R

A05

0V

A25

0RA

051

VA

250R

A05

2V

A

4.6 Piston Rings 4.7 Crankcase 4.7.1 Removing Crankshaft

)6��)5��

� Remove the flywheel - see 5.4.

� Remove the piston - see 4.5.1.


• Place extension (1) 4116 8941000 on crankshaft stub at clutchside of crankcase.

• Back off spindle (left-handthread) of ZS installing tool (1)5910 890 2220 a little.

• Hold ZS installing tool againstclutch side of crankcase so thatthe notch marked "16" is at thebottom.

• Insert M6x20 screws (2) in holesmarked "17" and tighten themdown against the drilled plate.

Note: ZS installing tools withoutholes "16", "17" and "18" and notches "16" and "17" can be modified as shown in the illustration.

Holes "16" and "18" are needed atthe starter side of the crankcase.

The illustration shows the under-side of the drilled plate.

250R

A05

6V

A25

0RA

062

1

VA

17

250R

A06

3

217

16

2

1

VA

41.2

5

33.8

5

9.7

26.8

5

2.25

250R

A21

9

17.3

33.3 38.0

33.6

20.6

32.25

22.5

41.6

25.5

33.7

20.1

17.6

512

.6

24.7

5

17

19.9

18

16

18

1616

17

18

16

18

17

16

1

2.5

15.5

16 + 18 = 5,517 = 6,5

VA

�� )6��)5��

• Rotate spindle (1) counterclock-wise until the crankshaft comesout of the ball bearing. The twohalves of the crankcase are separated in this process.

• Puller (1) 4119 890 4600 can beused in place of the ZS installingtool. It is mounted to the clutchside of the crankcase wit M6x20screws (2).

• Turn thrust bolt (3) clockwise until the crankshaft is releasedfrom the ball bearing.

FS 120...350, FR 350� Back off spindle (left-hand

thread) of ZS installing tool 5910 890 2220 a little.

• Place extension (1) 4116 8941000 on crankshat stub and sleeve (2) 1123 851 8300 on bores at starter side of crank-case.

• Hold ZS installing tool (1) 5910 890 2220 against starterside of crankcase so that thenotch marked "16" is at the bottom.

• Insert screws (1) 9022 341 1190(from ZS installing tool kit) in holes marked "16", fit washers atother side and screw on nuts.

FS 400/450, FR 450� Hold ZS installing tool against

starter side of crankcase so thatthe notch marked "17" is at thebottom.

� Insert M5x60 screws in holesmarked "18", fit washers at otherside and screw on nuts.

All models

• Rotate spindle (1) counterclock-wise until the crankshaft comesout of the ball bearing.

• The crankshaft (1), connectingrod (2) and needle bearing forman inseparable unit. It must always be replaced as a com-plete unit.

250R

A06

1

1

VA

250R

A06

5

1

32

2

VA

250R

A05

8

2

1

2

VA

16

250R

A05

9

1

VA

250R

A06

0

116

1616

16

1

1

1

VA

250R

A06

4

1

VA

250R

A06

6

2

1

VA

)6��)5��

� When fitting a replacement crank-shaft always install new oil sealsand ball bearings.

• Carefully knock the oil seals outof the crankshaft.

• Use press arbor (1) 4119 8937200 to remove ball bearing.

• Use press arbor (1) 4119 8937200 to remove ball bearing.

� Inspect both halves of the crank-case for cracks and replace ifnecessary.

Each half of the crankcase may be replaced separately.

New crankcases come with factory-installed ball bearings.

If the original crankcase is usedagain, remove the gasket residueand clean the mating surfaces -they must be cleaned very thoroughly to ensure a perfect seal.

• Check that bushings are in posi-tion. If necessary, drive bushingsinto the crankcase.

� Heat area of bearing seat on starter side of crankcase to approx. 120°C (250°F).

• Fit ball bearing in crankcase byhand and push it home as far asstop.

Note: This operation must be carried out very quickly becausethe bearing absorbs heat immedi-ately and begins to expand.

• If it is not possible to heat thestarter side of the crankcase,use press arbor (1) 4119 8937200 to press in the ball bearingas far as stop.

� Heat area of bearing seat on clutch side of crankcase to approx. 120°C (250°F).

250R

A06

7V

A25

0RA

068

1

VA

250R

A06

9V

A

1

250R

A07

1V

A25

0RA

070

VA

250R

A07

2

1

VA

4.7.2 Installing Crankshaft

�� )6��)5��

• Fit ball bearing in crankcase byhand and push it home as far asstop.

Note: This operation must be carried out very quickly because the bearing absorbs heat immedi-ately and begins to expand.

• If it is not possible to heat theclutch side of the crankcase, usepress arbor (1) 4119 893 7200 topress in the ball bearing as faras stop.

• Position the straight stub of thecrankshaft in the bearing at theclutch side of the crankcase.

• Screw spindle (1) of installing tool 5910 890 2202 fully into thesleeve (2) (left-hand thread).

• Hold the crankshaft steady and screw the spindle (1) clockwiseonto the stub (2) as far as stop.

• Hold the spindle steady and rotate sleeve counterclockwiseuntil it butts against the ball bearing.

• Hold the sleeve steady and rotate spindle clockwise until thecrankshaft butts against the ballbearing.

Important: During this process theconnecting rod (without piston) must point towards the cylinder flange.

� Hold the crankshaft steady andunscrew spindle from the stub.

� Apply a thin coating of sealant tocrankcase mating face - see13.2.

Important: Follow manufacturer’sinstructions.

250R

A07

3V

A

250R

A07

7V

A

250R

A07

5V

A39

2RA

044

2 1

VA

250R

A07

8V

A

250R

A07

4

1

VA

250R

A07

6

21

VA

)6��)5��

• Fit starter side of crankcase overthe crankshaft stub.

• Hold crankshaft steady and screw the spindle (1) clockwiseonto the stub (2) as far as stop.

• Hold the spindle steady and rotate sleeve counterclockwiseuntil it butts against the ball bearing.

• Hold the sleeve steady and rotate spindle clockwise until thetwo halves of the crankcase aretogether.

� Remove the installing tool.

• Insert screws and use socket (1)0812 542 2104 to tighten themdown to 8.5 Nm (6.3 lbf.ft).

� Lubricate sealing lips of oil sealswith grease - see 13.2.

• Fit installing sleeve (1) 4112 8932400 over the clutch end of thecrankshaft.

� Slide the oil seal, open side facing the crankcase, over the installing sleeve.


� Remove the installing sleeve.

� Slide the oil seal, open side facing the crankcase, over thestarter end of the crankshaft.


Assemble as other parts in the reverse sequence.

� Adjust throttle cable - see 7.5.2.

250R

A08

2V

A

250R

A07

9V

A

250R

A08

5

1

VA

250R

A08

0

21

VA

250R

A08

3

1

VA

250R

A08

6

1

VA

250R

A08

4

1

VA

250R

A08

1V

A

�� )6��)5��


• Use standard commercial long-reach 13 mm socket to unscrewthe decompression valve.

� Install new decompression valveand tighten down to 14 Nm (10.3 lbf.ft).

� Fit the shroud.

Warning! Exercise extreme caution when carrying out maintenance and repair work onthe ignition system. The high voltages which occur can causeserious or even fatal accidents!

Troubleshooting on the ignition system should always begin at thespark plug. See "Standard Re-pairs, Troubleshooting" handbook.

Note: The electronic (breakerless)ignition system basically consistsof an ignition module (1) and flywheel (2).

The illustration shows the FS 200.



� On FS 400/450, FR 450, take cable holder off the cylinder.

• Use pliers to grip the leg springand pull it out of the spark plugboot.

� Unhook the leg spring from theignition lead.

� Pull spark plug boot off the ignition lead.

� Coat end of the ignition lead (about 20 mm/3/4") with oil.

� Fit spark plug boot over the ignition lead.

� Use pliers to grip the end of theignition lead inside the sparkplug boot and pull it out.

4.8 Decompression Valve 5. IGNITION SYSTEM 5.1 Spark Plug Boot

250R

A09

1V

A

250R

A08

7V

A

1

2 250R

A08

8V

A

)6��)5��

• Pinch hook of leg spring into thecenter of the lead, i.e. about 10 mm (3/8") from the end of the lead.

• Pull the lead back into the boot so that the leg spring locates properly inside it.

Important: If the spark plug comes with a separate terminal nut, always fit the nut on the thread and tighten it down securely.

� On FS 400/450, FR 450, attachthe cable retainer to the cylinder.

� Fit the boot on the spark plug.

� Fit the shroud - see 4.1.

� Remove the ignition module -see 5.3.3.

• Remove spark plug boot (1) -see 5.1.

• Pull off the cable retainer (2).

• Remove the retainer.

• Pull rubber boot (1) off the highvoltage output.

• Unscrew the ignition lead fromthe contact pin and pull it out ofthe high voltage output.

5.2 Ignition Lead (FS 400/450, FR 450)

250R

A08

9V

A

250R

A09

2

2 1

VA

250R

A09

0V

A

250R

A09

4

1

VA

250R

A00

8 V

A

250R

A05

3V

A

�� )6��)5��

� Slip the rubber boot off the ignition lead.

� Cut new ignition lead to length(see parts list or cut to samelength as old lead).

• Use a pointed tool (awl or gimlet)to pierce the center of the ignition lead that is to bescrewed into the module.

� Slip the rubber boot over thelead.

� Pack the high voltage output withSTIHL multipurpose grease - see13.2.

Important: Do not use graphitegrease (Molykote) or silicone insulating paste for this job.

� Screw home the ignition lead.

� Fit rubber boot on the high voltage output.

� Fit cable retainer and spark plugboot.

� Fit the ignition module - see5.3.3.

The ignition module accommo-dates all the components requiredto control ignition timing.

FS 120...350, FR 350There are two electrical connec-tions on the coil body:

1. the high voltage output (1) withignition lead (2)

2. the connector tag (3) for theshort circuit wire

A vibration damping pad is bondedto the side of the ignition module.

FS 400/450, FR 450There are two electrical connec-tions on the coil body:

1. the high voltage output (1)

2. the connector tag (2) for theshort circuit wire

Accurate testing of the ignition module is only possible with sophisticated test equipment. Forthis reason it is only necessary tocarry out a spark test in the work-shop. A new ignition module mustbe installed if no ignition spark isobtained (after checking that wiring and stop switch are in goodcondition).

5.3 Ignition Module

250R

A09

5

1

2

VA

338R

A14

2 V

A

250R

A05

4

21

3

VA

)6��)5��

Ignition timing is not adjustable.

Since there is no mechanical wearin these systems, ignition timingcannot get out of adjustment. How-ever, an internal fault in the circuitcan alter the switching point insuch a way that a spark test willstill show the system to be in orderalthough timing is outside the permissible tolerance. This will impair engine starting and runningbehavior.


� Pull the boot off the spark plug.

� Remove the fan housing - see6.2.

� Remove clutch housing - see 9.1.

• Remove ignition lead from the retainers.

• Pull short circuit wire connector(1) off tag on ignition module.


� Remove the ignition module.

� Remove the spark plug boot -see 5.1.

Note: The ignition lead is moldedto the ignition module.

Important: Before installing a newignition module, make sure areafor vibration damping pad is freefrom grease, dirt and moisture.

� Peel the backing off the new vibration damping pad.

• Place the pad on the ignition module and apply firm and uniform pressure.

250R

A09

8

1

2

3 VA

250R

A09

9V

A

250R

A09

6V

A

5.3.1 Ignition Timing 5.3.2 Removing and Installing (FS 120...350, FR 350)

250R

A09

7V

A

�� )6��)5��

� Place the module in position, insert the screws but do nottighten them down yet.

� Check that ignition lead is properly seated in grommet.

• Slide the setting gauge (1) 1127 890 6400 between thearms of the ignition module andthe flywheel magnet poles.

� Press the ignition moduleagainst the flywheel and tightendown the mounting screws to atorque of 4.5 Nm (3.3 lbf.ft).

Reassemble all other parts in thereverse sequence.



• Pull boot (1) off the spark plug.

• Pull cable retainer (2) out of cylinder.

• Take ignition lead out of guide.


• Lift ignition module away slightlyand disconnect short circuit wirefrom ignition module.

� Remove the ignition lead - see5.2.

� Connect the short circuit wire,place the module in position, insert the screws but do nottighten them down yet.

250R

A10

3V

A25

0RA

104

VA

250R

A10

2V

A

5.3.3 Removing and Installing (FS 400/450, FR 450)

250R

A10

1

1

2

VA

250R

A10

0

1

VA

)6��)5��

• Secure cable retainer (1) with outer screw.

• Slide the setting gauge (2) 1127 890 6400 between thearms of the ignition module andthe flywheel magnet poles.

� Press the ignition moduleagainst the flywheel and tightendown the mounting screws to atorque of 6.0 Nm (4.4 lbf.ft).

Reassemble all other parts in thereverse sequence.

Removing the flywheel:




FS 120...350, FR 350• Fit locking strip (1)

0000 893 5903.

FS 400/450, FR 450� Fit locking strip

4221 893 5900.

All models

• Unscrew the flywheel nut.

� Pull off the flywheel.

Note: If the flywheel cannot be removed by hand, screw on thepuller (1) 4133 893 0800 and tapits end to release the flywheel. Unscrew the puller.

Inspect the flywheel (1) and magnet poles (2). If you find anydamage, install a new flywheel.

Installing the flywheel:

Important: Clean the stub of thecrankshaft and the flywheel hubbore with a standard commercial,solvent-based degreasant whichcontains no chlorinated or halogenated hydrocarbons - see13.2.

� Fit the flywheel.

Note: Check position of slot.

Assemble all other parts in the reverse sequence.

� Fit flywheel nut. Tighten nut onFS 120 to 24 Nm (17.7 lbf.ft).Tighten nut on all other modelsto 32 Nm (23.6 lbf.ft).

5.4 Flywheel

250R

A11

0

2

1

VA

250R

A10

6

1

VA

250R

A10

9

1

VA

250R

A10

7V

A

225

0RA

105

1

VA

�� )6��)5��

� Remove the ignition module -see 5.3.2 and 5.3.3.


FS 120...350, FR 350

• Pull short circuit wire out of grommet.

• Remove short circuit wire from retainers.

FS 400/450, FR 450� Remove the fuel tank - see 8.5.

� Remove the muffler - see 4.1.

• Push out the outer grommet (1).

• Pull short circuit wire out of housing bore and remove grommet.

• Push out the grommet (1).

• Pull short circuit wire (2) out ofhousing bore, remove it from the retainers and pull off thegrommet.

All models• Take out the screw (1).


• Lift the throttle cable (1) a little.

• Remove short circuit wire connector (2) from base of cableguide.


� Check and adjust throttle cable - see 7.5.2.

5.5 Short Circuit Wire

250R

A11

3

1

VA

250R

A11

5V

A

1 2

250R

A11

41

2

VA

250R

A01

1V

A

250R

A11

6

2 1

VA

250R

A11

2V

A

)6��)5��

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 orderbut plugged with dirt. At very lowoutside temperatures the lubri-cating oil on the rewind spring maythicken and cause the spring windings to stick together. Thishas 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 starterrope several times and allow it torewind until its normal smooth action is restored.

If clogged with dirt or pitch, the entire starter mechanism, includ-ing the rewind spring, must be re-moved and disassembled. Takespecial care when removing thespring.

Wash all parts in paraffin or whitespirit.

Lubricate the rewind spring andstarter post with STIHL special lubricant, see 13.2, before installing.



• Remove fan housing with rewindstarter.

� Remove the rope rotor - see"Standard Repairs, Trouble-shooting" handbook.

• Take out the screw and removeany remaining pieces of springfrom the fan housing.

Note: The replacement spring comes ready for installation and is secured with a washer.

� It should be lubricated with a fewdrops of STIHL special lubricantbefore installation - see 13.2.

• The washer slips off the rewindspring as it is pushed into the fanhousing. Engage the outer spring loop in the recess in the fan housing at the same time.

Caution: The rewind spring maypop out and uncoil during installation.

� If the rewind spring has poppedout, refit it as follows:

250R

A11

9V

A

250R

A11

7V

A25

0RA

118

VA

6. REWIND STARTER 6.2 Rewind Spring6.1 General 6.2.1 Replacing

�� )6��)5��

• Engage outer spring loop in therecess and refit rewind spring infan housing in the counterclock-wise direction, starting outsideand working inwards.

• Check the position of the inner spring loop. It should be 2 mm (0.08") away from the hub.

� Fit screw and tighten it down to1.5 Nm (1.1 lbf.ft).

� Install the rope rotor - see Hand-buch "Standard Repairs, Trouble-shooting" handbook.

� Tension the rewind spring - see6.2.2.

• Make a loop in the starter rope.

• Grip the rope close to the rotorand use it to turn the rope rotorsix full turns counterclockwise.

• Hold the rope rotor steady.

• Pull out the rope with the startergrip and straighten it out.

� Hold the starter grip firmly tokeep the rope tensioned.

� Let go of the rope rotor and slowly release the starter rope so that it can rewind properly.

Note: The rewind spring is cor-rectly tensioned when the startergrip sits firmly in the rope guidebush without drooping to one side.If this is not the case, tension thespring by one additional turn.

When the starter rope is fully extended, it must still be possible to rotate the rope rotor at least another half turn before maximumspring tension is reached. If this isnot the case, pull the rope out,hold the rope rotor steady and take off one turn of the rope.

Do not overtension the rewindspring as this will cause it tobreak.

� Fit fan housing, insert screwsand tighten down to 6.0 Nm (4.4 lbf.ft).

250R

A12

1A

VA

250R

A12

3V

A

250R

A12

5V

A

250R

A12

2V

A

250R

A12

0V

A

250R

A12

4V

A

6.2.2 Tensioning

)6��)5��

� Remove fan housing with rewind starter - see 6.2.

Starter rope

� Remove rope rotor - see "Standard Repairs, Trouble-shooting" handbook.

� Remove the starter rope fromthe rotor.

• Pry cap out of starter grip.

� Pull rope out of starter grip.

� On FR 350/450, slip tube (75 mm/2.95") over the starterrope.

• Thread end of new starter ropethrough the underside of the star-ter grip.

� Secure end of rope with a simpleoverhand knot.

• Pull the rope back to locate theknot in the starter grip.

� Push cap into starter grip.

� Secure starter rope to rope rotor.

� Install the rope rotor.

Starter grip

The starter grip is supplied withstarter rope.

� Remove the rope rotor - see"Standard Repairs, Trouble-shooting" handbook.

� Pull the knot out of the recess inthe rope rotor.

� Undo the knot and pull the ropeout of the rotor and fan housing.

� On FR 350/450, slip tube (75 mm/2.95") over the starterrope.

• Thread the starter rope 0000 195 8200 through theguide bush from outside the fan housing.

• Thread rope through the hole inthe side of the rotor.

� Secure the starter rope with asimple overhand knot.

• Pull the rope back into thr rotorso that the knot locates in the recess.

� Install the rope rotor - see "Standard Repairs, Trouble-shooting" handbook.

� Tension the rewind spring - see6.2.2.

� Fit fan housing with rewind starter - see 6.2.2.

250R

A12

6V

A

250R

A12

7V

A25

0RA

128

VA

6.3 Starter Rope/Starter Grip (ElastoStart)

�� )6��)5��

• Take out screw and washer.

� Pull off the control handle.

Warning: To avoid risk of electricshock, do not start the unit whilethe control handle is open.

• Use screwdriver (1) 5910 8902301 to take out the screws.

� Separate the two halves of thehandle.

• Lift the interlock lever (1) slightlyand turn it to one side until thetorsion spring (2) is relaxed.

• Pull the interlock lever off thepeg.

• Remove the torsion spring.

• Take the throttle trigger (1) withtorsion spring (2) and throttle cable (3) off the peg.

• Disconnect throttle cable fromtrigger.


• Attach the throttle cable, then position torsion spring as shownand push its long arm into theslot.

• The interlock lever must be behind the throttle trigger.

• Check correct positions of throttle cable (1), contact spring(2), protective tube (3) and insulator (4).

7. THROTTLE CONTROL7.1 Throttle Trigger/Interlock Lever (Bike Handle)

)6��)5��

� Remove the throttle trigger - see7.1.

• Lift contact spring (1) a little andremove the throttle cable (2).

• Remove spring from seats (1)and peg (2).

• Remove contact spring from peg(1) and collar screw (2).

• Take out slide control’s collarscrew (1).

• Removedetent spring (2).

• Pull slide control out of handlemolding.


� Engage contact spring correctly in groove of collar screw.

FR 350/450• Use screwdriver (1) 5910 890

2301 to remove screw.

• Push guard (2) forward.

All models

Warning: To avoid risk of electricshock, do not start the unit whilethe control handle is open.

• Use screwdriver (1) 5910 8902301 to take out the screws.

� Remove handle molding.

• Remove torsion spring.

7.2 Contact Springs/Detent Spring in Control Handle 7.3 Throttle Trigger/Interlock(Bike Handle) Lever (Loop Handle)

�� )6��)5��

• Pull throttle trigger (1) with throttle cable (2) off the peg.

• Disconnect throttle cable fromtrigger.

• Lift contact spring (1) a little andremove the throttle cable (2).

• Pull interlock lever with contactspring off the peg.

• Remove contact spring from interlock lever.


• Check positions of throttle cable(1), contact spring (2), protectivetube (3) and insulator (4).

� Tighten screws to 1.0 Nm (0.75 lbf.ft).

� Remove the interlock lever - see7.3.

• Pull slide control off the handlemolding.

• Remove screws from clamps.

� Take handle molding off thedrive tube.

• Remove torsion spring from peg.

7.4 Slide Control (Loop Handle)

)6��)5��


� Tighten clamp screws to 2 Nm(1.5 lbf.ft).

• The groove (1) in the slide control must engage over the outer edge (2) of the handle molding.

• The torsion spring (3) must engage the recess (4) in the slide control.

• On FR 350/450, the distance "a"between the control handle andhousing must be 20 mm (0.8").

All models� Remove the shroud - see 4.1.


� Remove the air filter - see 8.1.

� Take throttle cable off the con-tact spring - see 7.2 and 7.3.

Note: On FS 120...350, FR 350,remove spark plug boot and takeignition lead out of retainers on topand base of cable guide.

• Take out the screw (1).


FS 120...350, FR 350• Remove screw (1) from

extended throttle cable (2).

• Disconnect throttle cable nipple(1) from slotted pin (2) on throttlelever.

• Take throttle cable (1) out ofbase of cable guide (2) and retainer (3) on carburetor housing.

FS 400/450, FR 450� Remove the air filter housing -

see 8.2.2.

• Remove screw (1) from extended throttle cable (2).

7.5 Throttle Cable7.5.1 Replacing

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• Disconnect throttle cable nipple(1) from slotted pin (2) on throttlelever.

• Pull grommet out of carburetorhousing.

• Take throttle cable (1) out ofbase of cable guide (2) and pull itout of opening (3) in carburetorhousing.

Reassemble in the reversesequence.

FS 400/450, FR 450• Make sure grommet is properly

located in the carburetor housing.

� Secure lug between the raisedmarks.

FS 120...350, FR 350� Place lug and extended throttle

cable in the corner of the filterhousing.

� Tighten screw of extended throttle cable to 6.0 Nm (4.4 lbf.ft).

� Adjust throttle cable - see 7.5.2.

• Throttle lever (1) must buttagainst the stop on the carbure-tor cover (2) when throttle triggeris squeezed (full throttle).

• On carburetors with an idlespeed screw: Throttle lever mustbutt against the idle speed screwwhen the trigger is in the idle position.

Note: The filter housing is notshown in the illustration.

Adjustment is effected by movingthe throttle cable in the holder.


� On FS 300...450, remove coverfrom AV housing - see 9.2.

� Check correct setting of idlespeed screw (if fitted).

Important: Note adjustment rangeof idle speed screw.

7.5.2 Adjusting

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No. Part Name Part No. Application Rem.

1 Locking strip for piston 0000 893 5903 Blocking crankshaft 1) 2) 2 Locking strip for piston 4221 893 5900 Blocking crankshaft 2) 3) 3 Press sleeve 4112 893 2401 Fitting oil seal

(starter side) 4 Press sleeve 1118 893 2401 Fitting oil seal

(clutch side) 5 Installing sleeve 4112 893 2400 Protecting oil seal

(clutch side) 6 Puller 5910 890 4400 Removing oil seals 4) 7 - Jaws (No. 3.1 + 4) 0000 893 3706 8 Puller 4133 893 0800 Removing flywheel 9 Crimping tool 5910 890 8210 Attaching connectors to

electrical wires10 Assembly drift 1110 893 4700 Removing and fitting piston pin

Removing and installing clutch drum 2) 3)

11 Clamping strap 0000 893 2600 Compressing piston rings12 Wooden assembly block 1108 893 4800 Fitting piston 13 Carburetor and 1106 850 2905 Testing carburetor

crankcase tester for leaks14 Vacuum pump 0000 850 3501 Testing crankcase for leaks15 - Nipple 0000 855 920016 - Fuel hose 1110 141 860017 Sealing plate 0000 855 8106 Sealing exhaust port for

leakage test18 Test flange 1128 850 4200 For leakage test19 Setting gauge 1127 890 6400 Setting air gap between ignition

module and flywheel 20 Socket, 13 mm 5910 893 5608 Clutch and flywheel nut,

decompression valve21 Torque wrench 5910 890 0301 0.5 - 18 Nm 5)

(0.4 - 13.5 lbf.ft)5910 890 0302 6)

22 Torque wrench 5910 890 0311 6 - 80 Nm 5)(4.4 - 60 lbf.ft)

5910 890 0312 6)23 Spline screw socket T27x125 0812 542 2104 IS screws24 Hook 5910 893 8800 Removing pickup bodies25 Installing tool 5910 890 2210 Installing hookless snap rings

in piston 26 Press arbor 4119 893 7200 Removing and installing ball bearings27 Service tool ZS 5910 890 2220 Removing crankshaft28 - Sleeve (4x) 1123 851 8300 1) 2)29 - Extension 4116 894 1000 1) 2)30 - Spline screw 9022 341 1190 1) 2)31 Puller 4119 890 4600 Removing crankshaft

(clutch side)

13. Special Servicing Tools and Aids13.1 Special Servicing Tools

FS 120, 200, 300, 350, 400, 450, FR 350, 450 59

No. Part Name Part No. Application Rem.

32 Installing tool 5910 890 2202 Installing crankshaft33 Installing tool 4126 893 4900 Removing rubber element

from AV sleeve34 Circlip pliers 0816 610 1495 External circlip on

clutch drum 35 Pliers C19 0811 641 8380 Internal circuit in

clutch housing 36 T-handle screwdriver QI-T27x150 5910 890 2400 For all IS screws 7)37 Screwdriver T20x100 5910 890 2301 Separating handle moldings38 Assembly drift 1108 893 4700 Removing and installing

clutch drum 1) 2)39 Vice jaws 5910 893 2700 Holding drive tube and bike

handle40 Press arbor 1120 893 7200 Removing ball bearing in

clutch housing 41 Press arbor 1118 893 7200 Installing ball bearing in

clutch housing,removing and installing ball bearing in bearing housing (support frame) 2)

42 Assembly stand 5910 890 3100 Holding FS and FR units43 - Clamp 5910 890 8800 Holds drive tube of FS units

for repairs (in conjunction with assembly stand)

44 - Clamping plate 5910 890 2101 Holds powerhead of FS and FR units for repairs(in conjunction with assembly stand)

Remarks:

1) FS 120...3502) FR 350/4503) FS 400/4504) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400.5) Always use torque wrench to tighten DG/P screws.6) Wrench has optical/acoustic signal.7) On DG/P screws, use for releasing only.

60 FS 120, 200, 300, 350, 400, 450, FR 350, 450

No. Part Name Part No. Application

1 Lubricating grease 0781 120 1111 Oil seals(225 g/0.79 oz tube)

2 Standard commercial, Cleaning crankshaft stubsolvent-based degreasant containing no chlorinated orhalogenated hydrocarbons

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

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

5 Dirko sealant 0783 830 2120 Crankcase sealing faces(100 g/3 1/2 oz tube)

6 STIHL gear lubricant Drive shaft and clamp screw on - 80 g/3 oz tube: 0781 120 1109 bike handle- 225 g/8 oz tube: 0781 120 1110

7 STIHL gear lubricant Gearhead lubrication- 80 g/3 oz tube: 0781 120 1117- 225 g/8 oz tube: 0781 120 1119

13.2 Servicing Aids

FS 120, 200, 300, 350, 400, 450, FR 350, 450 61

2 6. Rewind Starter...STIHL gear lubricant (80 g/3 oz tube) 0781 120 1117 2.5.2 For Service...

Documents

Transcript of 2 6. Rewind Starter...STIHL gear lubricant (80 g/3 oz tube) 0781 120 1117 2.5.2 For Service...