STIH)

STIHL Series 4140 Components BG, SH

2005-01

Contents

1. 2. 3. 3.1 3.2 4. 4.1 4.2 4.3 5. 5.1 5.2

Introduction Safety Precautions Specifications Fuel System Tightening Torques Troubleshooting Rewind Starter Fuel System Engine Housing Handle Molding Handle and Feet (BG 85, SH 85) Engine Removing and Installing Muffler/Spark Arresting Screen Without Cat Muffler with Catalytic Converter Rewind Starter General Removing and Installing Starter Cup Rope Rotor Replacing the Rewind Spring Tensioning the Rewind Spring Starter Rope Pawl

2 3 4 4 5 7 7 8 10 11 11 11

8. 8.1 8.2 8.3 8.3.1 8.3.2 8.4 8.5 8.6 9. 9.1 9.1.1 9.1.2 9.2 9.2.1 9.2.2 9.2.3 9.3

Throttle Control Throttle Trigger Setting Lever (BG 85, SH 85 only) Stop Switch Version up to 2001 Version from 2001 Short Circuit Wire/ Ground Wire Throttle Cable Throttle Rod Fuel System Air Filter Removing and Installing Choke Shutter Carburetor Leakage Test Removing and Installing Spacer Flange Servicing the Carburetor Manual Fuel Pump with Oval End Cover Manual Fuel Pump with Square End Cover Metering Diaphragm Inlet Needle Fixed Jet Pump Diaphragm and Fuel Strainer Adjusting the Carburetor Carburetor with LD Screw User Adjustment of Carburetor with H, L and LA Screws Basic Setting on Carburetor with H, L and LA Srews Tank Vent General Replacing Fuel Tank General Pickup Body Fuel Hoses

18 18 19 19 19 20 20 21 21 21

10. 10.1 10.2 10.3 10.4 10.5 10.6 11.

Blower and Vacuum Attachment 35 Fanwheel Protective Screen (all except BG 45) Protective Screen (BG 45 only) Blower Tube (BG only) Suction Tube (SH only) Elbow (SH only) Special Servicing Tools Servicing Aids 35 35 35 36 36 36

21 22 22 23 23 24 24 25 25 26 26 27 28 28 29 29 29 31 32 32 33 33 33 34 34 12.

37 38

6. 6.1 6.2 6.2.1 6.2.2

12 9.3.1 12 13 13 13 14 14 14 15 15 16 17 17 18 9.5 9.5.1 9.5.2 9.6 9.6.1 9.6.2 9.6.3 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4 9.4.1 9.4.2 9.4.3

7. 7.1 7.2 7.3 7.4 7.5 7.5.1 7.6 7.7

q
ANDREAS STIHL AG & Co. KG, 2005

Series 4140 Components BG, SH

1.

Introduction

This service manual contains detailed descriptions of all typical repair and servicing procedures for models BG 45, 46, 55, 65, 85, SH 55, 85, which are based on the series 4140 powerhead. You will find detailed descriptions of procedures for servicing and repairing engine components in the service manual for the Series 4140 Powerhead. 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. A fault on the machine may have several causes. To help locate the fault, consult the chapter on "Troubleshooting" in this manual and the "STIHL Service Training System" for all assemblies. Refer to the "Technical Information" bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list until a revised edition is issued.

The special servicing tools mentioned in the descriptions are listed in the chapter "Special Servicing Tools" of this manual. Use the part numbers to identify the tools in the "STIHL Special Tools manual. The manual lists all special servicing tools currently available from STIHL. Symbols are included in the text and pictures for greater clarity. The meanings are as follows: In the descriptions: : = Action to be taken as shown in the illustration (above the text) = Action to be taken that is not shown in the illustration (above the text) b 4.2 Reference to another chapter, i.e. chapter 4.2 in this example. In the illustrations: A Pointer a Direction of movement Service manuals and technical information bulletins are intended exclusively for the use of properly equipped repair shops. They must not be passed to third parties.

Always use original STIHL replacement parts. They can be identified by the STIHL part number, the STIH) logo and the STIHL parts symbol ( This symbol may appear alone on small parts.

Series 4140 Components BG, SH

2.

Safety Precautions

If the engine is started up in the course of repairs or maintenance work, observe all local and countryspecific safety regulations as well as the safety precautions and warnings in the instruction manual. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. Improper handling may result in burns or other serious injuries. Warning! Do not bring any fire, flame, spark or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately.

Series 4140 Components BG, SH

3.

Specifications

3.1

Fuel System

Carburetor: Carburetor leakage test at gauge pressure: Operation of tank vent at gauge pressure: under vacuum: Fuel: Octane number: Fuel mixture:

Diaphragm carburetor 0.8 bar (8 kPa) 0.3 bar (3 kPa) 0.05 bar (0.5 kPa) see instruction manual min. 90 RON Regular brand-name gasoline and STIHL 50:1 two-stroke engine oil or brand-name two-stroke engine oil 50:1 with STIHL 50:1 two-stroke engine oil Fuel mix for units with catalytic converter: Use only STIHL 50:1 twostroke engine oil with unleaded gasoline.

Mix ratio:

Series 4140 Components BG, SH

3.2

Tightening Torques

DG and P (Plastoform) screws are used in polymer and light metal components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary without impairing the strength of the screwed assembly, providing the specified tightening torque is observed. For this reason it is essential to use a torque wrench. Fastener Thread size For component Torque Nm Screw Screw Muffler/cylinder Muffler/cylinder (version with catalytic converter) M14x7 Stub/muffler (version with spark arresting screen in muffler) IS-DG5x24 Spacer flange/cylinder P6x15/49 Collar screw/inner blower housing IS-DG5x24 Inner blower housing/crankcase IS-DG5x24 Inner blower housing/engine pan IS-P6x26.5 Outer/inner blower housings M8x1LH-06 Fanwheel/crankshaft (SH with shredder blade) IS-P6x19 Handle/inner blower housing IS-P6x19 Handle molding/inner blower housing IS-P6x19 Fan housing/inner blower housing IS-DG5x20Z Fan housing/spiral housing IS-DG5x24 Spiral housing/crankcase IS-DG5x24 Spiral housing/engine pan IS-P6x19 Protective screen/outer blower housing M14x1.25 Spark plug IS-DG5x60 IS-DG5x24 9.0 9.0 10.0 6.0 4.0 8.0 8.0 5.0 17.0 5.0 4.0 6.0 6.0 6.0 6.0 5.0 20.0 1) 2) Remarks

Screw Collar screw Screw Screw Screw Nut Screw Screw Screw Screw Screw Screw Screw

3) 4)

5)

Remarks: 1) with binding head 2) SH 55, 85 only 3) BG 85, SH 85 only 4) BG 65, 85, SH 85 only 5) BG 45 only

Series 4140 Components BG, SH

Use the following procedure when refitting a DG or P screw in an existing thread: Place the screw in the hole and rotate it counterclockwise until it drops down slightly. Tighten the screw clockwise to the specified torque. This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly.

Power screwdriver settings for polymer:

Plastoform screws DG screws

max. 600 rpm max. 500 rpm

Important: Do not mix up screws with and without binding head

Series 4140 Components BG, SH

4. 4.1

Troubleshooting Rewind Starter

Condition Starter rope broken

Cause Rope pulled out too vigorously as far as stop or over edge, i.e. not vertically Normal wear

Remedy Fit new starter rope

Fit new starter rope Fit new rewind spring

Rewind spring broken

Spring overtensioned no reserve when rope is fully extended Very dirty or corroded

Fit new rewind spring Fit new pawl

Starter rope can be pulled out almost without resistance (crankshaft does not turn)

Guide peg on pawl or pawl itself is worn Spring clip fatigued

Fit new spring clip Thoroughly clean complete starter mechanism Coat rewind spring with a standard solvent-based degreasant (containing no chlorinated or halogenated hydrocarbons). Then pull rope carefully as often as necessary until normal action is restored

Starter rope is difficult to pull and rewinds very slowly

Starter mechanism very dirty (dusty conditions) Lubricating oil on rewind spring becomes viscous at very low outside temperatures (spring windings stick together)

Series 4140 Components BG, SH

4.2

Fuel System

Condition Engine stalls at idle speed

Cause Idle jet bores or ports blocked

Remedy Clean jet bores and ports and blow clear with compressed air Reset low speed screw (L) correctly

Idle jet too rich or too lean

Setting of idle speed screw (LA) incorrect throttle shutter completely closed Engine speed drops quickly under load low power Air filter plugged

Reset idle speed screw (LA) correctly

Clean the air filter or replace if necessary Fit new tank vent Seal or renew connections and fuel line Fit new pump diaphragm

Tank vent faulty Leak in fuel line between tank and fuel pump Pump diaphragm damaged or fatigued Main jet bores or ports blocked Fuel pickup body dirty Setting of high speed screw (H) too rich Throttle shutter not opened fully

Clean the bores and ports Install new pickup body Reset high speed screw (H) correctly Check linkage

Series 4140 Components BG, SH

Condition Poor acceleration

Cause Idle jet too lean

Remedy Turn low speed screw (L) counterclockwise (richer), no further than stop Turn high speed screw (H) counterclockwise (richer), no further than stop Set inlet control lever flush with top of carburetor body

Main jet too lean

Inlet control lever too low (relative to correct installed position) Inlet needle sticking to valve seat

Remove inlet needle, clean and refit Clean the bore

Connecting bore to atmosphere blocked Diaphragm gasket leaking Metering diaphragm damaged or shrunk Engine will not idle idle speed too high Carburetor floods, engine stalls Throttle shutter opened too wide by idle speed screw (LA) Inlet needle not sealing. Foreign matter in valve seat or cone damaged Inlet control lever sticking on spindle Helical spring not located on nipple of inlet control lever Perforated disc on diaphragm is deformed and presses constantly against inlet control lever Inlet control lever too low (relative to correct installed position)

Fit new diaphragm gasket Fit new metering diaphragm

Reset idle speed screw (LA) correctly Remove and clean or replace inlet needle, clean fuel tank, pickup body and fuel line if necessary Free off inlet control lever

Remove inlet control lever and refit correctly Fit new metering diaphragm

Fit new inlet control lever

Series 4140 Components BG, SH

4.3

Engine

Always check and, if necessary, repair the following parts before looking for faults on the engine: Air filter Fuel system Carburetor Ignition system1)

Condition Engine does not start easily, stalls at idle speed, but operates normally at full throttle

Cause Oil seals in crankcase faulty

Remedy Install new oil seals 1)

Crankcase leaking / damaged (cracks) Muffler leaking Engine does not deliver full power or runs erratically Piston rings worn or broken

Seal / replace the crankcase 1)

Seal / replace the muffler Install new piston rings 1)

Muffler / spark arresting screen carbonized

Clean muffler (inlet and exhaust openings), replace spark arresting screen Fit new air filter element Fit new lines or position without kinks Thoroughly clean all cooling air passages and cooling fins

Air filter element dirty Fuel / impulse line kinked or cracked Engine overheating Insufficient cylinder cooling. Air inlets in fan housing blocked or cooling fins on cylinder very dirty

1)

see "Series 4140 Powerhead" service manual

10

Series 4140 Components BG, SH

5. 5.1

Housing Handle Molding

5.2

Handle and Feet (BG 85, SH 85)

Remove fan housing with rewind starter, b 7.2 Remove the spark plug.

2 1

: If necessary, replace the setting lever (1), b 8.2 : If necessary, remove the grip molding (2) as follows:

: Take out the screws (arrows). Remove the handle.

1 1

1
932RA170 VA 932RA261 VA 932RA263 VA

BG 45, 55, SH 55 only : Take out the screws (1) and remove the handle molding (2).

: Pull the grip molding (1) out of the guides (arrows) and lift it away. Install in the reverse sequence.

: Pull the feet (1) upwards and out of the handle. Reassemble in the reverse sequence.

1
932RA171 VA

BG 65, 85, SH 85 only : Take out the screws (1) and remove the handle molding (2). Note: BG 65 has no setting lever. Series 4140 Components BG, SH 11

932RA262 VA

932RA172 VA

6. 6.1

Engine Removing and Installing

Remove fan housing with rewind starter, b 7.2 Remove the fanwheel, b 10.1 Remove the filter housing, b 9.1
932RA175 VA

2 1

Remove the handle molding, b 5.1

: On machines with a throttle cable, disconnect the throttle cable (1) from slotted pin (2) on the throttle lever and push the throttle cable out of the tensioner (arrow). If necessary, remove the carburetor first. Avoid kinking the throttle cable in this process.

: Remove the engine.

3 1 2
932RA173 VA

On machines with a throttle rod, remove the throttle rod, b 8.6

: Disconnect the short circuit wire (1) and ground wire (2) from the ignition module. : Remove the retainers (3).

Install in the reverse sequence. Observe correct tightening torques, b 3.2. : When installing the engine in the inner fan housing, check that the gasket (arrow) is in front of the inner fan housing.

2
932RA174 VA 932RA092 VA

: Pull the fuel hoses (1 and 2) off the elbow connectors on the carburetor.

: Take engine mounting screws (arrows) out of inner fan housing.

12

Series 4140 Components BG, SH

932RA177 VA

932RA176 VA

6.2

Muffler/Spark Arresting Screen 6.2.1 Without Cat Troubleshooting, b 4.3 Remove the fan housing with rewind starter, b 7.2

6.2.2

Muffler with Catalytic Converter

Install in the reverse sequence. Clean the sealing faces before installation. Install a new exhaust gasket. Apply sealant to the underside of the screw head, b 12. Tighten down the screws firmly, b 3.2

Troubleshooting, b 4.3 The catalytic converter integrated in the muffler is a device that helps reduce the amount of noxious emissions in the exhaust gas by initiating chemical reactions without being consumed in the process. The catalytic converter is maintenance-free. Never attempt to carry out repairs on the catalytic converter.

932RA205 VA

932RA207 VA

1
Spark arresting screen

Muffler : Take out the screws (1).

Muffler Remove the fan housing with the rewind starter, b 7.2 : Take the screws (1) out of the muffler.

: On machines with a removable stub (1) (with and without spark arresting screen), use a 15 mm wrench to unscrew the stub. Clean the spark arresting screen or install a new stub if necessary. Clean the thread of the stub and coat it with sealant, b 12. Follow the sealant manufacturers instructions.
932RA201 VA

2 1

1
: Remove the muffler (1) and exhaust gasket (2).

Screw home the stub and tighten it down firmly, b 3.2

3
: Remove the muffler (1) with exhaust gaskets (2) and flange (3).

Series 4140 Components BG, SH

13

932RA209 VA

932RA208 VA

7. 7.1 Install in the reverse sequence. Clean the sealing faces before installation. Install new exhaust gaskets.

Rewind Starter General

7.2

Removing and Installing

Troubleshooting, b 4.1 If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not completely, it can be assumed that the starter mechanism is in order but plugged with dirt. At very low outside temperatures the lubricating 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 a standard solvent-based degreasant (containing no chlorinated or halogenated hydrocarbons) to the rewind spring. Carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored. If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed and disassembled. Take particular care when removing the spring. Clean all parts, b 12. Lubricate the rewind spring and starter post with STIHL special lubricant, b 12, before installing.

: Take out the screws (1+2). Remove the fan housing with rewind starter. : If necessary, remove the antistatic wire (arrow).

2
932RA210 VA

Spark arresting screen Remove the fan housing with rewind starter, b 7.2 : Take out the screw (1). : Pull the spark arresting screen (2) out of the muffler. Clean the spark arresting screen, replace it if necessary. Install in the reverse sequence.

14

Series 4140 Components BG, SH

7.3

Starter Cup

7.4

Rope Rotor

Machines with starter cup integrated in flywheel: For servicing information see the chapter on Flywheel in the Series 4140 Powerhead service manual.

Remove the rewind starter, b 7.2 Relieving tension of rewind spring The rewind spring will not be under tension if the starter rope is broken. Pull out the starter rope about 10 cm and hold the rope rotor steady. Removing While still holding the rotor steady, take three turns of the rope off the rotor. Pull out the starter rope a little further and then let go of the rotor. The rotor spins back so that the rewind spring is no longer under tension. The rewind spring must not be under tension. : Remove the spring clip (1) from the starter post. : Remove the washer (2) and pawl (3). Carefully pull the rope rotor off the starter post. Replace the broken or worn starter rope, b 7.6 Installing Coat the bore in the rope rotor with STIHL special lubricant, b 12.
932RA181 VA

1 2

1 2
932RA182 VA

: Fit the rotor on the starter post so that the driver (1) on the rope rotor slips behind the inner spring loop (2).

Series 4140 Components BG, SH

15

7.5

Replacing the Rewind Spring

Check that the spring loop has engaged by turning the rope rotor a little and letting it go. It must spring back. Coat pawl with special lubricant and install, b 12.

Remove the rope rotor, b 7.4 Remove the pieces of broken spring from the rope rotor and starter cover. Before installing, lubricate the new spring with a few drops of STIHL special lubricant, b 12.

: Then grip the rewind spring with pointed nose pliers about 10 mm from the end of the outer loop and place it in the starter.

932RA183 VA

: Fit the washer and engage the spring clip (1) in the groove in the starter post. : Make sure the spring clip (1) den engages the guide peg (arrow) on the pawl (2) and points clockwise. Handle the spring clip with care. The rewind starter may not function properly if the spring clip is deformed. Tension the rewind spring, b 7.5.1 Install the rewind starter, b 7.2

: Position the rewind spring in the starter and press the outer spring loop over the lug (arrow). The rewind spring may pop out and uncoil if the rope rotor is not installed very carefully. If the rewind spring has popped out, refit it as follows: Hold the spring in your hand and wind from the inside outwards and tension it to a diameter of 55 mm.

932RA184 VA

: Check the distance of the inner spring loop from the hub and correct if necessary. Dimension "A" must not be more than 2 mm. Install the rope rotor, b 7.4 Tension the rewind spring, b 7.5.1

16

Series 4140 Components BG, SH

7.5.1

Tensioning the Rewind Spring

7.6

Starter Rope

Remove the rewind starter, b 7.2 If the starter rope is broken, remove the remaining rope from the rope rotor and starter grip. If the starter rope is worn, relieve tension of rewind spring, b 7.4. Pull the end of the rope out of the rotor and undo the knot. Then pull the worn rope out of the starter grip, housing and rotor.
932RA187 VA

: Make a loop in the unwound starter rope. Grip the rope close to the rotor and use it to turn the rotor six full turns clockwise.

The starter grip must sit firmly in the rope guide bush without drooping to one side. If this is not the case, tension the spring by one additional turn. When the starter rope is fully extended, it must still be possible to rotate the rope rotor at least another half turn before maximum spring tension is reached. If this is not the case, pull the rope out, hold the rope rotor steady and take off one turn of the rope.

932RA188 VA

: Hold the rope rotor steady. : Pull out the rope with the starter grip and straighten it out. Hold the starter grip firmly to keep the rope tensioned. Let go of the rope rotor and slowly release the starter grip so that the rope winds itself onto the rotor.

Place the rewind starter in position, insert the screws and tighten them down firmly, b 3.2

: Thread one end of the new rope through the rotor and housing. Tie a simple overhand knot in the end of the rope. Pull the rope back into the rotor until the knot locates in the recess. Thread the other end of the rope through the starter grip. Tie a simple overhand knot in the end of the rope.

Series 4140 Components BG, SH

17

932RA190 VA

Do not overtension the rewind spring as this will cause it to break.

932RA189 VA

7.7

Pawl

8. 8.1

Throttle Control Throttle Trigger

380RA065 VA

: On machines with "ElastoStart": Thread end of new starter rope through the grip (1) and the spring element (2). Tie a simple overhand knot in the end of the rope. Pull the rope and spring element into the grip and then fit the cap (3). Tension the rewind spring, b 7.5.1 Install the rewind starter, b 7.2

932RA183 VA

Remove the rewind starter, b 7.2 : Ease the spring clip (1) off the starter post and pull the pawl (2) out of the rope rotor. Do not pull the rope rotor off the starter post. Coat the new pawl with special lubricant, b 12, and fit it in position. : Push the spring clip (1) into the groove in the starter post. : Make sure the spring clip (1) engages the guide peg (arrow) on the pawl (2). The spring clip must point clockwise. Handle the spring clip with care. The rewind starter may not function properly if the spring clip is deformed. Install the rewind starter, b 7.2

Remove the handle molding, b 5.1 : On machines with a throttle cable, remove the throttle trigger (1) and disconnect it from the throttle cable.

1
932RA268 VA

: On machines with a throttle rod (1), remove the throttle trigger (2) and disconnect it from the throttle rod. Install in the reverse sequence.

18

Series 4140 Components BG, SH

8.2

Setting Lever (BG 85, SH 85 only)

8.3 8.3.1

Stop Switch Version up to 2001

8 7

6 4 3

1
1 2

2
932RA226 VA 932RA227 VA

54 3 2 1
Remove the handle molding, b 5.1

: Ease the E-clip (8) off the setting levers stub. : Remove the cam (7). : Pull the setting lever (1) with washers (2, 5) and cup springs (3, 4) out of the handle molding (6). Reassemble in the reverse sequence. Slip the washers (2, 5) and cup springs (3, 4) over the stub of the setting lever (1) and push it into the handle molding (6). Note the correct installed position of the two cup springs (3 and 4).

: Fit the cam (1) on the setting levers stub so that it lines up with the marking on the handle housing. : Push the E-clip (2) in the groove on the setting levers stub. Assemble all other parts in the reverse sequence.

: Use a flat screwdriver to ease the stop switch (1) out of the handle molding. : Pull the connectors (2) (short circuit and ground wires) off the stop switch. Install in the reverse sequence. Check correct positions of wires.

Series 4140 Components BG, SH

19

932RA073 VA

8.3.2

Version from 2001

8.4

Short Circuit Wire/ Ground Wire

2 1 3 1
932RA223 VA 932RA101 VA

Remove the handle molding, b 5.1 : Use a flat screwdriver to ease the stop switch (1) and protective cap (2) out of the handle molding. : Pull the connectors (3) (short circuit and ground wires) off the stop switch. Install in the reverse sequence. Check correct positions of wires.

Remove the handle molding, b 5.1 Remove the stop switch, b 8.3 : Pull the connectors of the short circuit wire (1) and ground wire (2) off the ignition module.

BG 65, 85, SH 85 from 2001 only : Remove the wire (1) from the housing peg.

All BG/SH units : Pull the retainers (1) off the ignition lead. : Take the wires out of the guides (arrows) in the inner fan housing.

Reassemble in the reverse sequence. Push home the wires so that they are properly seated in the guides in the inner fan housing.

2
932RA224 VA

BG 45, 55, SH 55 only, from 2001 Remove the throttle trigger, b 8.1 : Remove the wire (1) from the throttle triggers pivot pin (2). 20 Series 4140 Components BG, SH

932RA075 VA

932RA225 VA

8.5

Throttle Cable

8.6

Throttle Rod

9. 9.1

Fuel System Air Filter

Dirty air filters reduce engine power, increase fuel consumption and make starting more difficult. If there is a noticeable loss of engine power, check to see if the air filter is plugged with dirt.
932RA268 VA

Before removing the air filter, close the choke shutter and remove all loose dirt from around the filter. Wash the foam filter in a standard solvent-based degreasant containing no chlorinated or halogenated hydrocarbons and then dry. Replace if necessary. Replace the felt filter. As a temporary measure, knock the filter out on the palm of your hand or blow clear with compressed air. Do not wash. Replace multi-ply felt filter. As a temporary measure, knock the filter out on the palm of your hand or blow clear with compressed air. Do not wash If a felt filter is replaced by a multiply filter, do not re-install the foam filter. Always replace a damaged air filter immediately.

Remove the handle molding, b 5.1 : Disconnect the throttle cable (1) from the throttle trigger (2), b 8.1 : Take the throttle cable out of the guides (arrows) in the inner fan housing. Remove the carburetor, b 9.2.2

Remove the handle molding, b 5.1 : Remove the throttle trigger (2) and disconnect the throttle rod (1). : Disconnect the throttle rod (1) from the carburetor. Install in the reverse sequence.

: Push the throttle cable (1) out of the tensioner (2). Remove the throttle cable. Install in the reverse sequence.

Series 4140 Components BG, SH

21

9.1.1

Removing and Installing

9.1.2

Choke Shutter

Knock the filter out on the palm of your hand or blow clear with compressed air. Do not wash. Replace if heavily loaded. Always replace a damaged air filter immediately.
932RA211 VA

3 1 2

: Squeeze retainers together.

Remove the air filter, b 9.1.1 : Remove the push nut (1). : Pull the choke shutter (2) out of the lever (3). When installing, make sure the choke shutter is properly located in the levers guide.

1 2

Use a new push nut. Install in the reverse sequence.

932RA212 VA

1
: Swing the filter cover (1) to the side and pull the lugs out of the guides (arrows).

Machines with catalytic converter : Remove the gasket (1) and heat shield (2). Use new gaskets. Install in the reverse sequence.

2 1

3
: Pull the filter (1) out of the filter housing (3).

: Unscrew the nuts (2) and remove the filter housing.

22

932RA217 VA

932RA216 VA

Series 4140 Components BG, SH

932RA229 VA

9.2 9.2.1

Carburetor Leakage Test If this pressure remains constant, the carburetor is airtight. However, if it drops, there are two possible causes: 1. The inlet needle is not sealing (foreign matter in valve seat or sealing cone of inlet needle is damaged or inlet control lever sticking). 2. Metering diaphragm is damaged. In either of these cases the carburetor has to be serviced. After completing the test, open the vent screw and pull the fuel line off the carburetor. Push the fuel hose onto the carburetors elbow connector. Assemble all other parts in the reverse sequence. Always install a new gasket.
932RA215 VA

Remove the air filter, b 9.1.1

: Push the fuel line with nipple onto the carburetors elbow connector (arrow).

: Disconnect the fuel hose from the carburetors elbow connector.

: Connect the tester's pressure hose to the nipple.

2
143RA172 VA

: Push the fuel line (1) 1110 141 8600 onto the nipple (2) 0000 855 9200.

: Close the vent screw (1) on the rubber bulb (2) and pump air into the carburetor until the pressure gauge (3) shows a reading of approx. 0.8 bar.

Series 4140 Components BG, SH

232RA084 VA

232RA083 VA

232RA082 VA

If you suspect a fault in the fuel system, see b 4.2. In the case of problems with the carburetor or fuel supply system, also check or clean the tank vent, b 9.5 The carburetor can be tested for leaks with the carburetor and crankcase tester 1106 850 2905.

23

9.2.2

Removing and Installing

9.2.3

Spacer Flange

Remove the air filter, b 9.1.1

1
932RA234 VA

: Remove the carburetor (1) and gasket (2). Install in the reverse sequence. Always install the carburetor with new gaskets. Position the fuel hoses so that they are not kinked. Observe tightening torques, b 3.2

Remove the carburetor, b 9.1.1 : On machines with throttle cable, pull the throttle cable (1) out of the spacer flange (2).

1
932RA233 VA

2
932RA253 VA

: Disconnect the fuel hoses from from the elbow connectors on the carburetor.

: On machines with throttle cable, take out the screws (1) and remove the spacer flange together with the hex head screws (2).

2 2 1 1
932RA239 VA 932RA252 VA

: On machines with throttle cable (1), disconnect throttle cable from slotted pin (2) on carburetors throttle lever. On machines with throttle rod, remove the throttle rod, b 8.6 24

: On machines with throttle rod, take out the screws (1) and remove the spacer flange together with the hex head screws (2).

Series 4140 Components BG, SH

9.3 9.3.1

Servicing the Carburetor Manual Fuel Pump with Oval End Cover

Carry out leakage test, b 9.2 Remove the carburetor, b 9.2.2

932RA254 VA

: Pull the gasket (1) out of the guides (arrows) on the spiral housing. Install in the reverse sequence. Always install new gaskets. Observe tightening torques, b 3.2

: Take the cap out of the end cover.

936RA223 VA

: Take out the M3x12 screws (1). : Remove the end cover with cap (2).

: Inspect the metering diaphragm and gasket and replace if necessary, b 9.3.3 Reassemble in the reverse sequence. Additional holes in the gasket and diaphragm (if there are any) must line up with those in the carburetor and flange.

2
936RA224 VA

: Take out the M3x8 screws (1). : Remove the flange (2).

Series 4140 Components BG, SH

25

936RA025 VA

936RA258 VA

9.3.2

Manual Fuel Pump with Square End Cover

9.3.3

Metering Diaphragm

1 2

936RA023 VA

936RA025 VA

: Take out the screws (1). Remove the end cover with cap.

: Inspect the metering diaphragm and gasket and replace if necessary, b 9.3.3 Reassemble in the reverse sequence.

Remove flange from manual fuel pump with oval end cover, b 9.3.1 Remove flange from manual fuel pump with square end cover, b 9.3.2 : Remove the metering diaphragm (1) and gasket (2) from the carburetor body. If the gasket and diaphragm are stuck together, remove and separate them very carefully.

932RA285 VA

: Inspect the diaphragm and gasket and replace if necessary. The diaphragm is a very delicate component. As a result of the alternating stresses the material eventually shows signs of fatigue, i.e. the diaphragm distorts and swells and has to be replaced. Reassemble in the reverse sequence.

: Take the cap out of the end cover.

: Remove the flange.

26

936RA024 VA

Series 4140 Components BG, SH

936RA026 VA

9.3.4

Inlet Needle

Reassemble in the reverse sequence. Engage clevis in annular groove on head of the inlet needle. Make sure the helical spring locates on the control levers nipple. Check that inlet control lever moves freely. Important: The upper edge of the inlet control lever must be flush with the top of the carburetor body. Install the metering diaphragm, b 9.3.3

936RA027 VA

: Fit the gasket (1) on the carburetor body. Line up the hole in the gasket (2) with the compensating bore in the carburetor.

Remove the metering diaphragm, b 9.3.3 : Take out the screw (1).

4 3 1

2
: Remove the inlet control lever (4), spindle (3), spring (2) and inlet needle (1). Take care with the spring (2) because it may pop out during disassembly.

: Place metering diaphragm (1) on the gasket. Line up the hole in the metering diaphragm (1) with the compensating bore in the carburetor and gasket. Assemble all other parts, b 9.3.1 and 9.3.2.

: If there is an annular indentation (arrow) on the sealing cone of the inlet needle, it will be necessary to replace the inlet needle because it will no longer seal properly.

Series 4140 Components BG, SH

372RA120 VA

932RA260 VA

936RA028 VA

936RA029 VA

27

9.3.5

Fixed Jet

9.3.6

Pump Diaphragm and Fuel Strainer

Take care not to damage the fixed jet when removing. Remove the metering diaphragm, b 9.3.3

1 2

The diaphragm is a very delicate component. As a result of the alternating stresses the material eventually shows signs of fatigue, i.e. the diaphragm distorts and swells and has to be replaced. Inspect the diaphragm and gasket and replace if necessary.

Remove the carburetor, b 9.2.2 : Take out the screw (1). : Remove the end cover (2).

1 1

936RA032 VA

936RA225 VA

936RA033 VA

C1Q-S48, C1Q-S50, C1Q-S55 carburetors only : Unscrew the fixed jet (1).

: Remove the gasket (1).

: Examine the fuel strainer (1) for contamination and damage and replace if necessary.

3
1
936RA031 VA

2 1
932RA259 VA

C1Q-S64, C1Q-S73 carburetors only : Unscrew the fixed jet (1). Reassemble in the reverse sequence. 28

: Remove the pump diaphragm (1). If the gasket and pump diaphragm are stuck together, remove and separate them very carefully.

936RA034 VA

Reassemble in the reverse sequence. : The pump diaphragm (1) and gasket (2) are held in position by the pegs (arrows) on the end cover (3). Series 4140 Components BG, SH

936RA086 VA

Adjusting the Carburetor Carburetor with LD Screw The carburetor with idle speed screw (LD) has no adjusting screws for maximum engine (H screw) or idle mixture (L screw).
LD

9.4 9.4.1

9.4.2

User Adjustment of Carburetor with H, L and LA Screws

232RA090 VA

Standard setting When adjusting from scratch, first carry out the standard setting. Adjusting idle speed Carry out standard setting.

LA
Standard setting

Start the engine and warm it up. Engine stops while idling: : Turn the idle speed screw (LD) (arrow) slowly clockwise until the engine runs smoothly.
LD

The limiter cap must not be removed from the high speed screw (H) to carry out the standard setting. With this carburetor it is only possible to correct the setting of the high speed screw (H) within fine limits. Check the air filter and replace if necessary, b 9.1.1 Check the spark arresting screen, clean or replace it if necessary, b 6.2

Erratic idling behavior, poor acceleration:

232RA090 VA

: Turn the idle speed screw (LD) slowly no more than half a turn counterclockwise.

: Carefully turn the idle speed screw (LD) (arrow) counterclockwise (left-hand thread) down onto its seat. : Then turn the idle speed screw (LD) two full turns clockwise. Check the air filter and replace if necessary, b 9.1 Check the spark arresting screen, clean or replace as necessary, b 7.2

Series 4140 Components BG, SH

29

932RA303 VA

The carburetor is tuned so that the engine receives an optimum fuel-air mixture under all operating conditions.

At high altitude (mountains): Turn the high speed screw (H) clockwise (leaner), but no further than stop, until there is no noticeable increase in engine speed. At sea level: Turn the high speed screw (H) counterclockwise (richer), but no further than stop, until there is no noticeable increase in engine speed. It is possible that the standard setting produces the highest engine rpm in both the above cases. Adjusting idle speed Open the low speed screw (L) one full turn. Allow the engine to warm up.
932RA303 VA

Erratic idling behavior Idle setting is too rich. Turn the low speed screw (L) clockwise (about a quarter turn) until the engine runs and accelerates smoothly. It is usually necessary to change the setting of the idle speed screw (LA) after every correction to the low speed screw (L).

H LA
Now make the following adjustments: : Turn the high speed screw (H) counterclockwise as far as stop (no more than 3/4 turn) : Carefully turn the low speed screw (L) clockwise until it is against its seat, then open it one full turn counterclockwise. Start the engine and allow it to warm up.

Engine stops while idling Fine tuning A minor correction may be necessary when operating at high altitude or at sea level. Note that even very slight corrections to the high speed screw (H) produce a noticeable change in engine running behavior. Carry out the standard setting. Start the engine and allow it to warm up. Open the throttle wide. Turn the idle speed screw (LA) slowly clockwise until the engine runs smoothly. Erratic idling behavior, poor acceleration Idle setting is too lean. Turn the low speed screw (L) counterclockwise (about a quarter turn) until the engine runs and accelerates smoothly.

30

Series 4140 Components BG, SH

Basic Setting on Carburetor with H, L and LA Srews The limiter cap has to be removed from the high speed screw (H) only if it is necessary to replace the high speed screw (H), clean the carburetor or adjust it from scratch. After removing the limiter cap it is necessary to carry out the basic setting.

9.4.3

Adjusting idle speed Check the air filter and clean or replace as necessary.

1
932RA315 VA

Warm up the engine. Adjust idle speed with a tachometer. Adjust specified engine speeds within a tolerance of +/- 200 rpm. 1. Adjust engine speed with idle speed screw (LA) to 3,300 rpm. 2.Turn low speed screw (L) clockwise or counterclockwise to obtain maximum engine speed. If this speed is higher than 3,700 rpm, abort the procedure and start again with step 1. 3. Use the idle speed screw (LA) to set engine speed again to 3,300 rpm

: On carburetors with a long limiter cap (1): Use suitable pliers to pull off the limiter cap. Screw down both adjusting screw (H and L) clockwise until they are against their seats. Now make the following adjustments:

932RA316 VA

4. Set the engine speed to 2,800 rpm with the low speed screw (L). 5. Set maximum engine speed to 10,500 rpm with the high speed screw (H). Do not re-install used caps because they may be damaged during the removal process. Always install a new limiter cap.

: On carburetors with a short limiter cap (1): Push the puller (2) 5910 890 4501, with the groove facing you, between the limiter cap (1) and carburetor body and pry the cap off. If the limiter cap is stuck on the screw, turn the puller over so that its groove faces the carburetor body. Pry off the limiter cap.

Open the high speed screw (H) 1 1/2 turns counterclockwise. Open the low speed screw (L) one full turn counterclockwise.

Series 4140 Components BG, SH

932RA317 VA

31

9.5 9.5.1

Tank Vent General

270
249RA129 VA

270
392RA318 VA

Correct operation of the carburetor is only possible if atmospheric pressure and internal fuel tank pressure are equal at all times. This is ensured by the tank vent. In the event of trouble with the carburetor or the fuel supply system, always check the tank vent and replace it if necessary. Testing the tank vent Open the tank cap slowly and drain the tank. Refit the tank cap, making sure it is tight. Disconnect the fuel hoses from the carburetor, b 9.2.2 Seal one of the fuel hoses with a suitable plug. Connect vacuum pump 0000 850 3501 to the other fuel hose and produce a vacuum in the fuel tank by operating the pump quickly. If the vacuum remains unchanged, install a new tank vent, b 9.5.2 If the vacuum slowly disappears, the tank vent is in order.

: On carburetors with a short limiter cap: Line up the new cap for the high speed screw (H) against the rich stop and press it on only as far as the second noticeable detent position. The stop limits the adjustment range of the high speed screw (H) to a 3/4 turn. Do not press the cap against the carburetor body as it will otherwise be damage. Carry out standard setting, b 9.4.2

: On carburetors with a long limiter cap: Line up the new cap for the high speed screw (H) against the rich stop so that the high speed screw (H) can only be rotated a 3/4 turn clockwise. : Push on the limiter cap until it butts against the carburetor body. Carry out standard setting, b 9.4.2

32

Series 4140 Components BG, SH

9.5.2

Replacing

9.6 9.6.1 Always use a new sealing ring. Install in the reverse sequence.

Fuel Tank General

If no equalization of pressures takes place, replace the tank vent. Remove the filter housing, b 9.1.1 Note installed position of tank vent.

Fuel tank The fuel tank is part of the inner fan housing and cannot be replaced separately. If the fuel tank is damaged, replace the complete inner fan housing. The diaphragm pump draws fuel out of the tank and into the carburetor via the fuel hose. Any impurities mixed with the fuel are retained by the pickup body (filter). The fine pores of the filter eventually become clogged with minute particles of dirt. This restricts the passage of fuel and results in fuel starvation. Always observe all safety precautions when working on the fuel system, b 2. In the event of trouble with the fuel supply system, always check the fuel tank and the pickup body first. Clean the fuel tank if necessary.

1
932RA096 VA

Cleaning the fuel tank Unscrew the fuel filler cap and drain the tank. Pour a small amount of clean gasoline into the tank. Close the tank and shake the machine vigorously. Open the tank again and drain it. Dispose of fuel properly.

2
Machines up to 2002 : Pull out the tank vent (1). : Pull out the grommet (2). Install in the reverse sequence.

1
932RA321 VA

2
Machines from 2002

: Carefully pry out the tank vent (1) with sealing ring (2).

Series 4140 Components BG, SH

33

9.6.2

Pickup Body

9.6.3

Fuel Hoses

Unscrew the fuel filler cap and drain the tank. Remove the fan housing with rewind starter, b 7.2 Remove the carburetor, b 9.2.2 Remove the pickup body. Unscrew the fuel filler cap and drain the tank. : Use hook (1) 5910 893 8800 to pull the pickup body out of the fuel tank. Pull off the tank vent, b 9.5.2

Unscrew the spark plug. Use locking strip 4221 893 5900 to block the piston. Remove the blower tube and elbow, b 10.4 and b 10.6

: Pull the pickup body (1) off the fuel hose and check it for contamination, replace if necessary. Install in the reverse sequence.

: Pull out the fuel hoses (arrow). Note installed position. Install in the reverse sequence.

BG 55, 65, 85 only : Take out the screws and lift away the outer fan housing.

: On BG 45, take out the screws and lift away the outer fan housing.

34

Series 4140 Components BG, SH

932RA162 VA

932RA164 VA

10. 10.1

Blower and Vacuum Attachment Fanwheel

10.2

Protective Screen (all except BG 45)

10.3

Protective Screen (BG 45 only)

2
932RA163 VA 932RA161 VA 932RA166 VA

SH 55, 85 only : Unscrew the star nut (1), take out the screws and lift away the outer fan housing.

SH units only Remove suction tube, b 10.5 : Press down the retaining tab (1) on the protective screen and swing the screen open.

: Take out the screws (1). : Lift the right-hand side of the protective screen so that it comes out of the guide (2)

3 4

2
932RA165 VA 932RA167 VA

: Unscrew the nut (1) clockwise (left-hand thread). : On SH 55, 85, remove the shredder blade (2). : Remove the washer (3), fanwheel (4) and the washer behind it. Inspect all blades and replace fanwheel if necessary. Install in the reverse sequence.

: Use a screwdriver or similar tool to press down the retaining tabs (1) on the outer fan housing and lift away the protective screen (2).

Remove the protective screen. : Before reinstalling, check the seal (1) for damage and make sure it is properly seated. Install in the reverse sequence. Make sure the protective screen engages in the guide.

: Remove the torsion spring (arrow). Install in the reverse sequence.

Series 4140 Components BG, SH

35

10.4

Blower Tube (BG only)

10.5

Suction Tube (SH only)

10.6

Elbow (SH only)

: Insert a screwdriver or similar tool in the recess (arrow) on the blower stub and push the retaining tab up. At the same time, turn the blower tube counterclockwise as far as stop (1/4 turn). Pull the blower tube off the stub. Fit by inserting blower tube with lug in the stub. Rotate the blower tube clockwise until the bayonet coupling engages.

932RA094 VA

: Turn the suction tube counterclockwise as far as stop (1/4 turn). Pull the suction tube off the stub. To fit, open the protective screen.

: Loosen the star nut (1). : Insert a screwdriver or similar tool in the recess (arrow) on the blower stub and push the retaining tab up. At the same time, turn the elbow counterclockwise as far as stop (1/4 turn). Pull the elbow off the stub. Fit by inserting blower tube with lug in the stub.

: Insert suction tube so that its guide slots (arrow) engage the lugs (arrow) on the stub. Rotate the suction tube clockwise until the bayonet coupling engages. 36

: Check that rubber sealing ring (arrow) is properly seated. Rotate elbow clockwise until the bayonet coupling engages.

Series 4140 Components BG, SH

932RA169 VA

932RA168 VA

11.

Special Servicing Tools

No. 1 2

Part Name Locking strip Socket

Part No. 4221 893 5900 0812 540 1112

Application Blocking crankshaft Installing and removing spline socket head screws with electric or pneumatic screwdrivers Testing crankcase and carburetor for leaks, testing tank vent Testing crankcase and carburetor for leaks Testing carburetor for leaks Testing carburetor for leaks Carburetor nuts

Rem.

3 4 5 6 7 8 9 10 11

Vacuum pump Carburetor and crankcase tester Nipple Hose for leakage test Screwdriver Q-SW 8 x 200 Crimping tool Torque wrench Torque wrench Socket, T 27 x 125

0000 850 3501 1106 850 2905 0000 855 9200 1110 141 8600 5910 890 2420 5910 890 8210 5910 890 0301 5910 890 0311 0812 524 2104

12 13

T-handle screwdriver Q - T 27 x 150 Hook

5910 890 2400 5910 893 8800

Attaching connectors to electrical wires 0.5 to 18 Nm 1) 2) 6 to 80 Nm 1) 3) Installing and removing spline socket head screws with electric or pneumatic screwdrivers, tightening with torque wrench IS screws 4) Removing pickup body

Remarks: 1) 2) 3) 4) Always use torque wrench for tightening DG or P screws. Alternative: Torque wrench 5910 890 0302 with optical/acoustic signal. Alternative: Torque wrench 5910 890 0312 with optical/acoustic signal. Only use for releasing/removing DG or P screws.

Series 4140 Components BG, SH

37

12.

Servicing Aids

No. 1 2 3

Part Name Dirko gray sealant (100 g tube) STIHL special lubricating oil Standard commercial, solventbased degreasant containing no chlorinated or halogenated hydrocarbons

Part No. 0783 830 2120 0781 417 1315

Application Guard on muffler Bearing bore in rope rotor, rewind spring Cleaning sealing faces

38

Series 4140 Components BG, SH

Series 4140 Components BG, SH

39

40

Series 4140 Components BG, SH

englisch / English
0455 295 0123. M7. A5. S. Printed in Germany