FS 25-4, 65-4

Contents

1. Safety Precautions 1 9. Throttle Control 26 1. Safety

Precautions
2. Introduction 2 9.1 Throttle Trigger/Interlock
Lever (Bike Handle) 26 If the brushcutter is started up
3. Specifications 3 9.2 Contact Springs/Detent in the course of repairs or mainten-
Spring in Control Handle ance work, observe all local and
3.1 Engine 3 (Bike Handle) 27 country-specific safety regulations
3.2 Fuel System 3 9.3 Throttle Trigger/Interlock as well as the safety precautions
3.3 Ignition System 4 Lever (Loop Handle) 27 and warnings in the owner’s
3.4 Gearhead 4 9.4 Slide Control manual.
3.5 Special Accessories 4 (Loop Handle) 28
3.5.1 For User 4 9.5 Throttle Cable 29 Gasoline is an extremely flamma-
3.6 Dimensions and 9.5.1 Replacing 29 ble fuel and can be explosive in
Wear Limits 5 9.5.2 Adjusting 30 certain conditions.
3.7 Tightening Torques 6
10. AV System 30 Improper handling may result in
4. Troubleshooting 7 burns or other serious injuries.
11. Fuel System 32
5. Clutch 10 Warning! Do not smoke or bring
11.1 Air Filter 32 any fire or flame near the fuel. All
5.1 Removing and 11.2 Carburetor 32 work with fuel must be performed
Disassembling 10 11.2.1 Leakage Test 32 outdoors only. Spilled fuel must be
5.2 Assembling and 11.2.2 Removing/Installing 33 wiped up immediately.
Installing 10 11.2.3 Adjusting Idle Speed 34
11.3 Tank Vent 35 Wash hands thoroughly after
6. Engine 11 11.4 Pickup Body 35 every contact with waste oil.
11.5 Fuel Hoses 36
6.1 Checking/Adjusting 11.6 Fuel Tank 37 Do not pour waste oil down the
Valve Clearance 11 drain or allow it to soak into the
6.2 Checking Oil Level/ 12. Shaft 38 ground.
Changing Oil 13
6.3 Exhaust Muffler 14 12.1 Bike Handle 38 Collect waste oil and take it to an
6.4 Rocker Arms/Pushrods 14 12.2 Loop Handle 38 official disposal site for environ-
6.5 Cam Followers 15 12.3 Drive Shaft/ ment-friendly disposal.
6.6 Cam Gear 15 Flexible Liner 39
6.7 Diaphragm 15 12.4 Drive Tube 40
6.8 Crankcase,
Lower Half 16 13. Cutting Tool Drive 41
6.9 Crankshaft 17
6.10 Valves/Valve Springs 18 13.1 Gearhead 41
6.11 Crankcase/Cylinder 18 13.2 Clutch Drum 41

7. Ignition System 19 14. Special Servicing

Tools and Aids 43
7.1 Ignition Module 19
7.1.1 Ignition Timing 20 14.1 Special Servicing Tools 43
7.1.2 Removing/Installing 20 14.2 Servicing Aids 44
7.2 Flywheel 21
15. Maintenance chart 45
8. Rewind Starter 22

8.1 General 22
8.2 Rope Rotor 22
8.3 Starter Rope 23
8.4 Starter Grip 23
8.5 Rewind Spring 24
8.5.1 Replacing 24
8.5.2 Tensioning 24
8.6 Starter Cup/Fanwheel 25
© 1998, Andreas Stihl AG & Co, Waiblingen

FS 25-4, 65-4 1
2. Introduction
This service manual contains detai-
led descriptions of all the repair
and servicing procedures specific
to this power tool series.
There are separate handbooks for
servicing procedures for stand-
ardized parts and assemblies that
are installed in several STIHL po-
wer tool models. Reference is
made to these handbooks in the
appropriate chapters in this
manual.
Servicing the carburetor is descri-
bed in the separate "Carburetors"
manual.
As the design concept of models
FS 25-4 and FS 65-4 is almost
identical, the descriptions and
servicing procedures in this
manual generally apply to both
machines. Differences are
described in detail.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual
components and assemblies.
Refer to the latest edition of the
relevant parts list to check the part
numbers of any replacement parts
needed.
Parts lists on microfiche and CD-
ROM are always more up to date
than printed lists.
A fault on the power tool may have
several causes. Apart from the
chapter "Troubleshooting" in this
manual, also consult the troubles-
hooting charts for all assemblies in
the "Standard Repairs, Troubles-
hooting" 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 the
parts list until a revised edition is
issued.
2 FS 25-4, 65-4
The special servicing tools men- Secure the clamp to the assembly
tioned in the descriptions are stand with two washers and two
listed in the last chapter of this ma- M8 nuts.
nual.
Use the part numbers to identify The complete machine can then
the tools in the "STIHL Special be swivelled to the best position
Tools" manual. for the ongoing repair and this lea-
The manual lists all special ves both hands free.
servicing tools currently available
from STIHL. Always use original STIHL
replacement parts.
Symbols are included in the text They can be identified by the
and pictures for greater clarity. STIHL part number,
The meanings are as follows: the STIHL logo
and the
In the descriptions: STIHL parts symbol (
The symbol may appear alone on
• = Action to be taken as small parts.
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 technical
information bulletins describing
engineering changes are intended
exclusively for the use of STIHL
servicing dealers. They must not
be passed to third parties.
Servicing and repairs are made
considerably easier if the machine
is mounted on assembly stand (2)
5910 890 3100 with the aid of
clamp (1) 5910 890 8800.
3. Specifications

3.1 Engine

Single cylinder four-stroke overhead valve engine

FS 25-4 FS 65-4

Type: GX 22 GX 31
Displacement: 22 cm3 31 cm3
Bore: 33 mm 39 mm
Stroke: 26 mm 26 mm
Power output to ISO 8893: 0.6 kW (0.8 bhp) 0.85 kW (1.2 bhp)
at 7,000 rpm at 7,000 rpm
Max. engine speed: Maximum rpm is determined by main jet and is not adjustable
Idle speed: 3,100 ± 200 rpm
Compression pressure: 29 - 59 kPa (2.9 - 5.9 bar)
at 1,200 rpm
Piston pin diameter: 8 mm
Rewind starter: Pawl engagement
Pawls: Single pawl system
Reserve pull on rope rotor: min. 1/2 turn
Starter rope diameter: 3 mm
Clutch: Centrifugal clutch with press-fitted linings
Clutch engages at: 4,200 ± 200 rpm
Valve clearance
Inlet: 0.12 ± 0.02 mm
Exhaust: 0.15 ± 0.02 mm
Oil capacity: 0.1 l (100 cm3)
Oil grade: SAE 15W-40

3.2 Fuel System

Carburetor: Diaphragm carburetor

Carburetor leakage test
at gauge pressure: 8 kPa (0.8 bar)
Function of tank vent
at gauge pressure: ≤ 3 kPa (0.3 bar)
under vacuum: ≤ 0.5 kPa (0.05 bar)
Fuel tank capacity: 0.45 l (450 cm3) 0.65 l (650 cm3)
Fuel: Regular brand name gasoline
Octane rating: min. 90 RON
Air filter: Oil impregnated foam filter

FS 25-4, 65-4 3
3.3 Ignition System Type: Electronic magneto
ignition (breakerless)
with integral trigger unit
Ignition timing: 27 degrees B.T.D.C.
Air gap: 0.35 - 0.5 mm
Spark plug (suppressed): NGK CR5HSB,
Denso U16FSR-UB
Electrode gap: 0.6 - 0.7 mm

3.4 Gearhead Type: Spiral-toothed

bevel gear drive

Gear ratio: 1:1.4

Bearings: Deep groove ball bearings

Lubrication: STIHL gear lubricant

0781 120 1117, 1118
(capacity 7 g)

3.5 Special Accessories

3.5.1 For User Full harness

Safety glasses
Transport guard for
Metal cutting tools 4119 717 3005
STIHL gear lubricant (80 g tube) 0781 120 1109
STIHL gear lubricant (80 g tube) 0781 120 1117

4 FS 25-4, 65-4
3.6 Dimensions and Wear Limits

Description Standard Wear limit

Cylinder inside diameter 33.00 mm * 33.10 mm *

39.00 mm ** 39.10 mm **

Piston outside diameter 32.99 mm * 32.90 mm *

38.99 mm ** 38.90 mm **

Piston pin outside diameter 8.00 mm 7.95 mm

Cam lift 22.79 mm 22.49 mm

(inlet and exhaust)

Free length of valve springs 23.40 mm 22.50 mm

Valve stem outside diameter

Inlet: 3.985 mm 3.900 mm
Exhaust: 3.950 mm 3.880 mm

Valve guide inside diameter 4.000 mm 4.060 mm

Clearance between valve stem and guide

Inlet: 0.015 - 0.048 mm 0.098 mm
Exhaust: 0.050 - 0.083 mm 0.120 mm

Valve head diameter

Inlet: 12.5 mm *
13.5 mm **
Exhaust: 12.0 mm

Clutch lining: 2.0 mm 1.0 mm

* FS 25-4
** FS 65-4

FS 25-4, 65-4 5
3.7 Tightening Torques

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

Fastener Thread For component Torque Remarks

size Nm

Pan head screw M5x12 Valve cover 4.0

Pan head screw M5x22 Valve cover 4.0
Nut M5 Valve adjusting screw 5.0
Collar nut M8 Flywheel 15.0
M8 Starter cup 8.0
Nut M5 Carburetor 5.0
Pan head screw M6x28 Clutch shoes 10.0 1)
Pan head screw M8x28 Clutch shoes 15.0 2)
Pan head screw M4x16 Cam gear cover 3.0
Pan head screw M5x18 Crankcase 5.0
Pan head screw M5x55 Crankcase cover
1st stage 3.0
2nd stage 7.0
Spline screw IS-DG5x24 Gear housing/drive tube 8.5
Spline screw IS-M5x12 Clamp, control handle/
drive tube (loop handle) 2.0
Spline screw IS-M5x16 AV sleeve/drive tube (clamp screw) 5.5
Spline screw IS-M5x12 Clamp, control handle/drive tube 2.0
Spline screw IS-M5x16 Clamp/drive tube (harness) 4.5
Spline screw IS-M5x30 Control handle (bike handle) 2.0
Spline screw IS-M6x25 Clamp/loop handle 4.5
Screw plug M11x10 Gearhead 8.5
Plastoform screw IS-P4x16 Control handle/handle moldings 1.0
Collar screw IS-P3.5x10.6 Detent spring/slide control
(bike handle) 1.1
Nut M12x1.5 L Cutting tool 25.0
Spline screw IS-M5x16 Deflector/gearhead 4.3
All other screws M3 1.0
and nuts M5 5.0
M6 9.0

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,
which would weaken the assembly.

1) FS 25-4
2) FS 65-4

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

6 FS 25-4, 65-4
4. Troubleshooting

1. Engine difficult to start

Check fuel level in tank. No fuel Fill up with fuel and try starting
again.

Adequate fuel in
tank

Operate manual fuel pump Fuel does not flow – Check fuel line and fuel
and check that fuel is flowing to to carburetor
filter for blockages.
carburetor.
– Faulty carburetor diaphragm
or float needle valve,
Fuel flows to replace carburetor
carburetor

Remove spark plug and Dry Replace carburetor

check for damp or oily
electrodes.

Damp

No spark or only a – Change spark plug and

Check spark plug weak spark
repeat the spark test.
for spark.
– Check ignition lead for
damaged insulation and
Powerful spark leakage current.
– Check ignition coil.

Compression in order Check combustion chamber

Check compression.
for excessive build-up of
combustion deposits.

Compression too low – Check, adjust valve

Adequate compression clearance.
– Valves must be in good
condition.
– Check piston, rings and
Install spark plug and start cylinder for wear.
engine according to
instructions.

FS 25-4, 65-4 7
2. Erratic running behavior at low rpm

Inspect air filter element. Dirty Clean, replace air filter

element.

Not dirty

Remove spark plug and Abnormal – Clean spark plug and

check electrodes for coking, adjust electrode gap.
check electrode gap. – Replace spark plug.

Normal

– If fuel line is kinked

Check to see if fuel line is kin- Abnormal or pinched, fit a
ked, pinched or cracked. Check new one.
carburetor for looseness or air – Tighten loose carburetor
entering through spacer flange. nuts. Examine spacer
flange for damage and
install properly.
Normal

Check fuel filter.

Dirty Clean, replace filter.

Not dirty

Check correct function of

carburetor. Abnormal Replace carburetor.

Normal

Check compression. Abnormal – Check, adjust valve

clearance.
– Check combustion chamber
for excessive build-up of
Normal
combustion deposits.

– Check valves for faults.

Start engine according to – Check piston, rings and
instructions. cylinder for wear.

8 FS 25-4, 65-4
3. Erratic running behavior at high rpm

Inspect air filter element. Dirty Clean, replace air filter

element.

Not dirty

Remove spark plug and Abnormal – Clean spark plug and

check electrodes for coking, adjust electrode gap.
check electrode gap. – Replace spark plug.

Normal

Check to see if fuel line is kin- Abnormal – If fuel line is kinked

ked, pinched or cracked. Check or pinched, fit a
carburetor for looseness or air new one.
entering through spacer flange. – Tighten loose carburetor
nuts. Examine spacer
flange for damage and
Normal install properly.

Check correct function of

carburetor. Abnormal Replace carburetor.

Normal

Start engine according

to instructions.

FS 25-4, 65-4 9
5. Clutch
5.1 Removing and Disassembling
Troubleshooting chart - see
"Standard Repairs, Trouble-
shooting" handbook.
- Remove the shroud - see 6.1.
- Remove control handle from bike
handle - see 12.1.
- On loop handle machine, dis-
connect throttle cable from
carburetor - see 9.5.1.
• Take out the screws.
- Pull off clutch housing with drive
tube.
• Inspect clutch drum. There
should be no scores or signs
of excessive wear.
10
5.2 Assembling and Installing
Important: If there are signs of
serious wear on the inside
diameter, fit a new clutch drum -
see 13.2.
• Attach spring to clutch shoes.
- Block piston with locking screw -
see 7.2.
• Take out the collar screws (1). • Fit the washers.
• Remove the clutch shoes (2).
• Twist the clutch shoes and • Fit clutch shoes so that the
detach the spring. marks face outwards.
" " = FS 25-4
Important: Clutch shoes must " R " = FS 65-4
always be replaced in pairs.
FS 25-4, 65-4
 6. Engine 6.2 Checking /Adjusting
6.1 Valve Clearance

Note: Check and adjust valve clea-

rance only when engine is cold.

- Remove the rewind starter.

- Remove the air filter - see 11.1.

• Insert collar screws.

• Tighten down collar screws to 10 - Pull off the spark plug boot.
Nm (FS 25-4) or 15 Nm (FS 65-
4). • Take ignition lead out of the
retainer.
- Remove locking screw from cylin-
der.

- Install clutch housing with drive

tube.

- On loop handle machine, attach

throttle cable to carburetor.

- On bike handle machine, install

the control handle.

- Fit the shroud.

• Slacken off nut (1).

• Pull throttle cable (2) with short

circuit wire (3) and washer (4)
out of retainer.

FS 25-4, 65-4 11

• Remove shroud from bosses at
rewind starter side.
• Take out screws (1) at clutch
side.
• Remove the shroud (2).
Checking
• Pull vent hose (1) off the
valve cover.
• Pull ignition lead (2) and short
circuit wire (3) out of the
retainers.
12
Note: If the exhaust valve opens
while you are turning the flywheel
to T.D.C., rotate flywheel counter-
clockwise until the recess and
projection line up again.
• Take out the screws (1).
• Remove the valve cover (2).
• Remove the gasket. • Insert feeler gauge (1) between
rocker arm and valve stem.
- Remove clutch housing with dri-
ve tube - see 12.4. Inlet valve (2): 0.12 ± 0.02 mm
Exhaust valve (3): 0.15 ± 0.02 mm
• Rotate flywheel until blade
recess (1) lines up with the
projection (2) on the cam gear
cover (piston at T.D.C.).
FS 25-4, 65-4
 6.2 Checking Oil Level/
Changing Oil

Checking - Put engine down on a level

surface.
- Put engine down on a level
surface. - Fill up with engine oil to edge of
filler neck.
- Unscrew the dipstick and wipe it
with a clean cloth. - Screw dipstick home and tighten
down firmly.
- Push the dipstick into filler neck
as far as stop but do not screw it
home.

Adjusting

• Slacken off nut (1). Use 2.5 mm

Allen key to rotate adjusting
screw (2).

To increase valve clearance:

Turn screw counterclockwise.
To reduce valve clearance:
Turn screw clockwise.

- Hold adjusting screw steady and

tighten down nut to 5 Nm.

- Check valve clearance again.

Assemble in the reverse sequence.

- Use new gasket for valve cover.

- Tighten down valve cover

screws • Remove the dipstick and check
to 4 Nm. the oil level.

• If oil level is low, top up with

fresh engine oil to edge of filler
neck.

- Screw dipstick home and tighten

down firmly.

Changing

- Unscrew the dipstick.

- Tip the engine to one side to

drain oil into a suitable container.

Note: Observe safety precautions -

see 1.

FS 25-4, 65-4 13
6.3 Exhaust Muffler
- Remove the shroud - see 6.1.
• Take out the screws.
- Remove the guard.
• Take out the screws.
- Remove the muffler.
• Remove cover plate.
Assemble in the reverse
sequence.
Note different lengths of screws.
14
6.4 Rocker Arms/Pushrods
- Remove the valve cover - • Remove the pushrods.
see 6.1.
Assemble in the reverse
- Set piston to T.D.C. (both rocker sequence.
arms relieved).
- Pushrods must locate properly
• Pull out pin (1). in the adjusting screws.
• Remove rocker arms (2). - Adjust valves - see 6.1.
• To replace, slacken off nut (1)
and take out the adjusting
screw (2).
FS 25-4, 65-4
6.5 Cam Followers
- Remove the pushrods - see 6.4.
- Remove the flywheel
- see 7.2.
• Take out the screws.
- Remove the cover.
• Pull out pin (1).
• Remove the cam followers (2).
Install in the reverse sequence.
- Thoroughly clean the sealing
face on the cylinder and cover.
- Apply thin coating of sealant to
cylinder - see 14.2.
Important: Follow manufacturer’s
instructions.
- Tighten down screws on cover
to 3 Nm.
- Install the flywheel - see 7.2.
- Install the pushrods
- see 6.4.
FS 25-4, 65-4
6.6 Cam Gear 6.7 Diaphragm
- Remove the cam followers - Drain engine oil - see 6.2.
- see 6.5.
- Remove the fuel tank
• Pull out pin (1). - see 11.6.
• Remove the cam gear (2). • Take out the screws.
- Remove the cover.
- Set piston to T.D.C.: • Take out screw (1).
Slot (1) in crankshaft points up.
• Remove the support plate (2).
• Install cam gear so that marks
(2) line up and the marked
tooth (3) is in alignment with
the slot in the crankshaft.
Important: The marks must not
move out of position while cam
gear is being fitted.
• Install the cam followers
- see 6.5.
• Remove the diaphragm.
15

• The angled corner on the
diaphragm and support plate
must line up with the angle in
the crankcase (see arrows).
- Thoroughly clean the sealing fa-
ces on the crankcase and cover.
- Apply thin coating of sealant to
sealing face on crankcase -
see 14.2.
Important: Follow manufacturer’s
instructions.
- Fit the cover.
- Coat screw threads and flanges
with engine oil and insert screws.
• Initially tighten screws in
sequence shown (1 to 4) to
3 Nm, then finally tighten to
7 Nm in same sequence.
16
6.8 Crankcase,
Lower Half
- Remove cover over diaphragm - • Check to see if oil return bores
see 6.7. are blocked. Blow clear with
compressed air if necessary.
• Take out the screws.
- Thoroughly clean sealing faces
- Take away the lower half of the on both halves of crankcase.
crankcase.
- Apply thin coating of sealant to
lower half of crankcase -
see 14.2.
Important: Follow manufacturer’s
instructions.
- Tighten down screws to 5 Nm.
- Install cover over the diaphragm -
see 6.7.
• Unscrew dipstick if necessary.
• Remove grommets if necessary.
FS 25-4, 65-4
6.9 Crankshaft
- Remove cam gear cover -
see 6.5.
- Remove the fanwheel - see 8.6.
- Remove lower half of crankcase
- see 6.8.
• Lift crankshaft and pull piston out
of cylinder at the same time.
- Inspect cylinder running face,
replace cylinder if necessary -
see 6.11.
• Remove the oil seals (1).
• Inspect the piston (2), ball
bearing (3) and oil splash
plate (4).
FS 25-4, 65-4
- If one of these parts is damaged,
the complete crankshaft must be
replaced.
• Rotate cam gear so that the
marks (1) are in alignment.
- Carefully push the piston into the
cylinder.
Note: The piston rings and the oil
scraper ring are compressed as
they are eased into the tapered
cylinder.
• Turn the crankshaft so that the
slot (2) points towards the cam
gear.
• Continue pushing piston into
cylinder and make sure that the
marked tooth (3) lines up with
the slot.
- Fit new oil seals with the open
• Before installing the crankshaft, side facing the crankshaft and
check oilway for blockages push crankshaft fully home.
and blow clear with compressed
air if necessary.
- Coat piston, piston rings and oil
scraper ring with oil.
- Fit piston ring so that their gaps
are offset 120 degrees.
Important: Ring gaps must not be
in line with piston pin bore.
Note: Annular rib (1) must engage
groove (2).
Assemble all other parts in
the reverse sequence.
17
6.10 Valves/Valve Springs 6.11 Crankcase with
Cylinder

- Remove rocker arm/pushrods - Remove the valves - see 6.10.

- see 6.4.
- Remove the cam gear
- Remove the crankshaft - see 6.9. - see 6.6.

- Remove the muffler - see 6.3.

- Remove the carburetor -

see 11.2.2.

• Inspect seats on exhaust valve

(1), inlet valve (2) and cylinder
and replace parts as necessary.

• Check free length of valve

springs (3), replace springs if ne-
cessary.

Assemble in the reverse

sequence.

Important: Do not mix up inlet

and exhaust valves.

- Valve spring retainer must

engage properly in groove on
valve stem.

• Press valve spring retainer (1) • Take out the screws (1).
down and move it sideways so
that the valve stem is in the large • Remove the heat shield (2) and
hole. spacer flange (3).

• Let go of valve spring retainer

and remove it together with the
valve spring (2).

- Take valves out of cylinder.

• Take screws out of spacer flange.

18 FS 25-4, 65-4

• Remove the gasket.
Assemble in the reverse
sequence.
- Use a new gasket.
• Install spacer flange so that
recess (1) points down.
• Secure connector tag (2) for
short circuit wire with the upper
screw.
FS 25-4, 65-4
7. Ignition System
Warning! Exercise extreme
caution when carrying out
maintenance and repair work on
the ignition system. The high
voltages which occur can cause
serious or even fatal accidents!
Troubleshooting on the ignition sy-
stem should always begin at
the spark plug. See "Standard Re-
pairs, Troubleshooting" handbook.
Note: The electronic (breakerless)
ignition system basically consists
of an ignition module (1) and
flywheel (2).
7.1 Ignition Module
The ignition module accommoda-
tes all the components required to
control ignition timing.
There are two electrical connec-
tions on the coil body:
1. the high voltage output with
ignition lead (1)
2. the connector tag (2) for the
short circuit wire
Accurate testing of the ignition
module is only possible with
sophisticated test equipment. For
this reason it is only necessary to
carry out a spark test in the work-
shop. A new ignition module must
be installed if no ignition spark is
obtained (after checking that
wiring and stop switch are in good
condition).
19
7.1.1 Ignition Timing 7.1.2 Removing and Installing

Ignition timing is not adjustable.

Since there is no mechanical wear

in these systems, ignition timing
cannot get out of adjustment. How-
ever, an internal fault in the circuit
can alter the switching point in
such a way that a spark test will
still show the system to be in order
although timing is outside the
permissible tolerance. This will
impair engine starting and running
behavior. - Remove the shroud - see 6.1. • Take out the screws.

- Remove the clutch housing with - Remove the ignition module.

drive tube - see 12.4.

• Disconnect short circuit wire

from ignition module.

• Slip feeler gauge (0.4 mm)

between the arms of the ignition
module and the flywheel magnet
poles.

- Press the ignition module

against the feeler gauge and
tighten down the mounting
screws.

Reassemble all other parts in the

reverse sequence.

• Remove ignition lead from the

retainers.

20 FS 25-4, 65-4
7.2 Flywheel

• Use strap wrench to hold

flywheel steady and pull it off.
1

235RA138 VA
Removing the flywheel: • Check correct position of key.

- Remove the clutch - see 5.1.

• Screw locking screw (1) 4170

893 1200 into cylinder as far as
stop.

Inspect the flywheel (1) and • Fit flywheel in position, screw

• Unscrew the flywheel nut.
magnet poles (2) for cracks or ot- on the nut and tighten it down
her damage. If you find any to 15 Nm.
damage, install a new flywheel.
- Remove locking screw from cylin-
der.

Installing the flywheel: - Fit and tighten down the spark

plug.
Important: Clean the stub of the
crankshaft and the flywheel hub - Install the clutch - see 5.2.
bore with a standard commercial,
solvent-based degreasant which
contains no chlorinated or
halogenated hydrocarbons
- see 14.2.

• Attach puller (1) 4119 890 4501

to flywheel with M6x25 or
M8x25 screws (2).

FS 25-4, 65-4 21
8. Rewind Starter
8.1 General
If the action of the starter rope
becomes very stiff and the rope
rewinds very slowly or not com-
pletely, it can be assumed that
the starter mechanism is in order
but plugged with dirt. At very low
outside temperatures the lubri-
cating oil on the rewind spring may
thicken and cause the spring
windings to stick together. This
has a detrimental effect on the
function of the starter mechanism.
In such a case it is sufficient to
apply a few drops of paraffin
(kerosine) to the rewind spring.
Then carefully pull out the starter
rope several times and allow it to
rewind until its normal smooth
action is restored.
If clogged with dirt or pitch, the
entire starter mechanism, inclu-
ding the rewind spring, must be re-
moved and disassembled. Take
special care when removing the
spring.
Wash all parts in paraffin or white
spirit.
Lubricate the rewind spring and
starter post with STIHL special
lubricant, see 14.2, before
installing.
22
8.2 Rope Rotor
Troubleshooting chart - see
"Standard Repairs, Trouble-
shooting" handbook.
- Remove rewind starter and take
off the machine support.
Relieve tension of rewind spring:
Note: The rewind spring will not
be under tension if the starter rope
is broken.
- Pull out the starter rope about
20 cm and hold the rope rotor
steady.
- Locate starter rope in the notch
in the rope rotor.
• Use starter rope to turn rotor
clockwise until spring is no lon-
ger under tension.
• Take out screw (1).
• Remove carrier (2) with
spring (3).
• Carefully pull the rope rotor (4)
off the starter post.
Caution: The rewind spring is hou-
sed in the rope rotor. It may pop
out if the rope rotor is pulled out
too quickly.
- Remove the rewind spring -
see 8.5.1.
- Remove starter rope - see 8.3.
- Lubricate bore in rope rotor with
STIHL special lubricant -
see 14.2.
• Fit rope rotor on the starter post
so that the inner spring loop (1)
engages the groove (2) in the
starter post.
- Fit the carrier with spring so that
the spring engages the slot in
the rope rotor.
Important: Do not turn the rope
rotor clockwise.
- Insert screw and tighten it down
firmly.
- Tension the rewind spring -
see 8.5.2.
FS 25-4, 65-4
8.3 Starter Rope 8.4 Starter Grip

- Remove the rewind starter.

- Pull starter rope out a little and

hold the rope rotor steady.

362RA095 VA
- Remove the rope rotor - see 8.2. ElastoStart:

- Remove the starter grip - see 8.4. • Pry cap out of starter grip.

- Take remaining rope out of the - Pull rope out of starter grip.
rope rotor.

• Thread new starter rope through

the hole in the side of the rope
rotor and secure with one of the
special knots shown.

• Pull the rope back so that the

knot locates in the recess in the
rope rotor.

- Install the rope rotor - see 8.2.

Standard grip:
- Pull rope out of starter grip, untie
the knot and slip the grip off the
rope.
- Thread starter rope through the
new grip.
362RA096 VA
• Thread end of new starter rope
through the underside of the star-
ter grip.
- Secure end of rope with a simple
overhand knot.

• Secure end of rope with one of

the special knots shown.

- Pull starter rope back so that

the knot is snugly seated in the
starter grip.
362RA097 VA

• Pull the rope back to locate the

knot in the starter grip.

- Push cap into starter grip.

FS 25-4, 65-4 23
8.5 Rewind Spring
8.5.1 Replacing
- Remove the rope rotor - see 8.2.
- Take remaining pieces of rewind
spring out of rope rotor and star-
ter cover.
• Engage the outer spring loop in
the recess and fit the rewind
spring counterclockwise in the
rope rotor, starting outside and
working inwards.
- Lubricated spring with a few
drops of STIHL special lubricant -
see 14.2.
- Install the rope rotor - see 8.2.
- Tension the rewind spring -
see 8.5.2.
24
8.5.2 Tensioning
• Locate starter rope in notch in
the rope rotor and make a loop.
• Grip the rope close to the rotor
and use it to turn the rope rotor
five full turns counterclockwise.
• 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 rope
so that it can rewind properly.
Note: The rewind spring is correct-
ly tensioned when the starter grip
sits 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.
Do not overtension the rewind
spring as this will cause it to break.
- Fit the support plate - see 11.6.
- Install the rewind starter.
FS 25-4, 65-4
8.6 Starter Cup/Fanwheel

• Slip a screwdriver between the

punches and unscrew the starter
cup.

- Remove the rewind starter. • Tighten down starter cup to

8 Nm via flywheel nut.
- Remove the clutch - see 5.1.

• Fit clutch mounting screws

in tapped holes in flywheel.

• Use screwdriver to block

flywheel as shown.

• Remove fanwheel from stub of

crankshaft.

Assemble in the reverse

sequence.

• Insert punch in bores in starter • Block starter cup with punches

cup and hold steady. and screwdriver.

FS 25-4, 65-4 25
9. Throttle Control
9.1 Throttle Trigger/Interlock Lever (Bike Handle)
• Take out screw and washer.
- Pull off the control handle.
Warning: To avoid risk of electric
shock, do not start the unit while
the control handle is open.
• Remove screws with screwdriver
(1) 5910 890 2301.
- Separate two halves of handle.
• Lift the interlock lever (1) slightly
and turn it to one side until the
torsion spring (2) is relaxed.
• Pull the interlock lever off the
peg.
26
• Remove the torsion spring.
• Take the throttle trigger (1) with
torsion spring (2) and throttle
cable (3) off the peg.
• Disconnect throttle cable from
trigger.
Assemble in the reverse
sequence.
• Attach the throttle cable, then
position torsion spring as shown
and push its long arm into the
slot.
• 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).
FS 25-4, 65-4
9.2 Contact Springs/Detent Spring in Control Handle
(Bike Handle)
- Remove the throttle trigger
- see 9.1.
• Lift contact spring (1) a little and
remove the throttle cable (2).
• Remove spring from seats (1)
and peg (2).
• Remove contact spring from
peg (1) and collar screw (2).
FS 25-4, 65-4
• Take out slide control’s collar
screw (1).
• Remove detent spring (2).
• Pull slide control out of handle
molding.
Assemble in the reverse
sequence.
- Engage contact spring correctly
in groove of collar screw.
9.3 Throttle Trigger/Interlock
Lever (Loop Handle)
• Use screwdriver (1)
5910 890 2301 to remove screw.
• Push guard (2) forward.
Warning: To avoid risk of electric
shock, do not start the unit while
the control handle is open.
• Remove screws with screwdriver
(1) 5910 890 2301.
- Remove handle molding.
• Remove torsion spring.
27
 9.4 Slide Control
(Loop Handle)

• Pull throttle trigger (1) with • Pull interlock lever with contact - Remove the interlock lever
throttle cable (2) off the peg. spring off the peg. - see 9.3.

• Pull slide control off the handle

molding.

• Disconnect throttle cable from • Remove contact spring from

trigger. interlock lever. • Remove screws from clamps.

Assemble in the reverse - Take handle molding off the dri-

sequence. ve tube.

• Lift contact spring (1) a little and • Check positions of throttle cable • Remove torsion spring from peg.
remove the throttle cable (2). (1), contact spring (2), protective
tube (3) and insulator (4).

- Tighten screws to 1.0 Nm.

28 FS 25-4, 65-4
 9.5 Throttle Cable
9.5.1 Replacing

- Remove the air filter - see 11.1.

- Take throttle cable off the con-

tact spring - see 9.2.

Assemble in the reverse • Slacken off nut (1).

sequence.
• Pull throttle cable (2) out of hol-
- Tighten clamp screws to 2.0 Nm der.

• The groove (1) in the slide • Remove short circuit wire (3)
control must engage over the ou- from the throttle cable.
ter edge (2) of the handle mol-
ding.

• The torsion spring (3) must

engage the recess (4) in the sli-
de control.

• Pull short circuit wire off the • On bike handle, take throttle
connector tag. cable out of retainers.

Assemble in the reverse

sequence.

- Adjust throttle cable - see 9.5.2.

• Disconnect throttle cable nipple

(1) from slotted pin (2) on throttle
lever.

FS 25-4, 65-4 29
9.5.2 Adjusting 10. AV System

Rotate sleeve clockwise to The anti-vibration (AV) connection

move lever closer to housing. between the engine and drive tube
Rotate sleeve counterclockwise to consists of a rubber element
move lever away from housing. installed in the clutch housing.

- Lock adjusting sleeve with nut - Remove the drive tube

(1) after completing adjustment. - see 12.4.

- Install the air filter - see 11.1. - Remove the shroud - see 6.1.

Throttle lever (1) must butt against

housing (2) when throttle trigger is
squeezed (full throttle) and against
the idle speed screw when the
trigger is in the idle position.

Adjustment is effected by moving

the throttle cable in the holder.

- Remove the air filter - see 11.1.

• Take out the screws.

- Remove the clutch housing.

• Slacken off nut (1). • Use pliers (1) 0811 641 8380 to
remove retaining ring from clutch
• Rotate adjusting sleeve (2) as housing.
required.
- Remove retaining ring over
the AV sleeve.

30 FS 25-4, 65-4
• Push installing tool (1) • Release clamp screw (1) and - Coat rubber element with a
4126 893 4900 into AV sleeve fixing screw (2) if necessary. lubricant (e.g. washing-up liquid).
as far as stop.
• Pull the AV sleeve (3) off the • Push the rubber element into
• Tighten down clamp screw (2). installing tool. clutch housing as far as stop
so that slot (1) is opposite the
• Tighten the fixing screw (3) straight side (2) of the clutch hou-
moderately if necessary. sing.

- Apply a little lubricant (e.g. Assemble all other parts in the

washing-up liquid) between reverse sequence.
the clutch housing and rubber
element. - Retaining ring must locate
properly in the groove in the
clutch housing.

• Pull the rubber element off the

AV sleeve.

- Clamp installing tool in vice. • Push the rubber element, larger

diameter (1) first, onto the AV
• Pull clutch housing off the sleeve until the inner groove (2)
rubber element. engages the annular rib (3).

FS 25-4, 65-4 31
11. Fuel System
11.1 Air Filter
Dirty and clogged air filters reduce
engine power, increase fuel
consumption and make starting
more difficult.
The air filter must be cleaned
when there is a noticeable loss
of engine power.
- Close the choke shutter.
- Clean away any loose dirt from
around the filter and filter cover.
• Press down the tab.
• Swing the filter cover downwards
and lift it away.
• Remove the foam filter.
32
Wash the foam filter in a clean,
non-flammable solution (e.g. warm
soapy water) and dry.
Note: Replace a damaged foam
filter immediately.
- Soak foam filter in fresh engine
oil and then squeeze out surplus
oil.
- Install foam filter.
• Engage lugs on filter cover in
filter housing.
- Swing filter cover up so that it
snaps into position.
11.2 Carburetor
11.2.1 Leakage Test
Troubleshooting chart - see
"Standard Repairs, Trouble-
shooting" handbook.
Important: In the event of trouble
with the carburetor or the fuel
supply system, always check and
clean the tank vent - see 11.3.
The carburetor can be tested for
leaks with the carburetor and
crankcase tester 1106 850 2905.
- Remove the air filter - see 11.1.
• Pull fuel hose off carburetor’s
elbow connector.
2 1
143RA172 VA
• Fit fuel hose (1) 1110 141 8600
on nipple (2) 0000 855 9200.
FS 25-4, 65-4

• Push the fuel hose with nipple
onto the carburetor elbow
connector.
• Push the nipple into the tester’s
pressure hose.
• 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. 8 kPa (0.8 bar).
FS 25-4, 65-4
11.2.2 Removing and Installing
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. The metering diaphragm is
damaged. - Remove the air filter - see 11.1.
- After completing test, open the • Pull both fuel hoses off the elbow
vent screw and pull the fuel hose connectors.
off the elbow connector.
- Push the fuel hose onto the
elbow connector.
- Install the air filter - see 11.1.
• Disconnect throttle cable nipple
(1) from slotted pin (2) on throttle
lever.
• Pull vent hose off the filter
housing.
33

• Unscrew nuts (1).
• Remove the support plate (2).
• Pull the filter housing (3) away.
• Take the sealing ring off the
carburetor.
• Pull carburetor off the studs.
34
• Remove the gasket.
- Inspect spacer flange and
replace if necessary - see 6.11.
Assemble in the reverse sequence.
- Install new gasket and sealing
ring.
- Tighten down nuts to 5.0 Nm.
11.2.3 Adjusting Idle
Speed
- Check the air filter, replace if
necessary.
- Start the engine and allow it to
warm up.
• Adjust engine idle speed with the
idle speed screw.
Turn clockwise to increase rpm.
Turn counterclockwise to
reduce rpm.
Note: If you use a tachometer,
note that there is an ignition spark
on each crankshaft revolution.
FS 25-4, 65-4
11.3 Tank Vent
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.
Important: If problems occur on
the carburetor or the fuel supply
system, always check and clean
the tank vent.
Check function by performing
pressure and vacuum tests on
the tank via the fuel hose.
Equalization of pressure from the
outside inwards takes place via
the thread in the filler cap, the val-
ve and holes in the cap.
Equalization of pressure from the
inside outwards takes place via
the holes in the cap, the slots in
the valve body and thread in the fil-
ler cap.
FS 25-4, 65-4
Cleaning
- Unscrew the filler cap.
• Ease the cap (1) off the valve
body (2).
• Take the cap (3) out of the valve
body.
• Remove sealing ring (4) from the
valve body.
- If the sealing ring is damaged, fit
a new fuel filler cap (5).
• Wash valve body and valve (6)
in fresh gasoline.
- If the valve is damaged, fit a new
fuel filler cap.
• Insert cap (3) in the valve body.
• Slip sealing ring (4) over the val-
ve body.
• Fit cap (1) on valve body and
push it home until it snaps into
position.
- Screw on the fuel filler cap.
11.4 Pickup Body
The diaphragm pump draws fuel
out of the tank and into the
carburetor via the fuel hose. Any
impurities mixed with the fuel are
retained by the pickup body (filter).
The fine pores of the filter event-
ually become clogged with minute
particles of dirt. This restricts the
passage of fuel and results in fuel
starvation.
Important: 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.
Cleaning the fuel tank
- Unscrew the filler cap and drain
the tank.
- Pour a small amount of clean
gasoline into the tank.
- Close the tank and shake the
unit vigorously.
- Open the tank again and drain it.
Note: Dispose of fuel properly.
Pickup body
- Unscrew the filler cap and
remove it together with the
retainer.
35

• Use hook (1) 5910 893 8800 to
pull the pickup body out of the
fuel tank.
• Squeeze ends of hose clip (1)
together and push it down the
hose.
• Pull the pickup body (2) off the
fuel hose.
- Fit new pickup body.
Install in the reverse sequence.
36
11.5 Fuel Hoses
- Pull fuel hoses off the
carburetor - see 11.2.2.
• Take fuel hoses out of
the retainer.
• Ease the grommet out of the
fuel tank.
• Pull out fuel hoses with pickup
body.
• Squeeze ends of hose clip (1)
together and push it down the
hose.
• Pull the pickup body (2) off the
fuel hose.
• Pull the fuel hoses out of the
grommet.
Install in the reverse sequence.
• Pull fuel hoses into the
grommet so that the distance
"a" is 113 - 121 mm, and
"b" is 125 - 135 mm.
FS 25-4, 65-4
11.6 Fuel Tank

- Drain the fuel tank.

- Pull fuel hoses off the carburetor,

see 11.2.2, and out of retainer.

- Remove the rewind starter.

- Remove the tank guard.

• Ease the grommet (1) out of the • Position fuel tank so that the lugs
fuel tank. (1) engage the grommets (2).

- Pull out fuel hoses with pickup

body.

• Unscrew filler cap (2) with

remove together with cap
retainer.

Assemble in the reverse

sequence.

• Remove the support plate. • Inspect grommet in support plate

and fit new grommet if necessary
with the wider flange facing the
fuel tank.

• Remove the fuel tank. • Inspect grommets in crankcase

and fit new ones if necessary.

FS 25-4, 65-4 37
12. Shaft
12.1 Bike Handle
• Take out the screw.
- Pull off the control handle.
• Unscrew the nuts (1).
• Remove lower clamp (2),
support block (3), bike handle (4)
and upper clamp (5) with screws
(6).
• Use jaws (1) 5910 893 2700 to
clamp bike handle tube in vice.
38
12.2 Loop Handle
- To replace left grip, carefully cut
it open and pull it off.
- Coat inside of new grip with a
little lubricant (e.g. washing-up
liquid).
Note: If too much lubricant is
used, the grip will twist on the
tube. Always leave it to dry for a
while after fitting.
Loop handle without barrier bar
• Unscrew the nuts (1).
• Remove lower clamp (2).
• Push the grip into position so • Remove screws (1).
that the longer ends (see arrows)
point toward the gearhead at an • Remove the loop handle (2) and
angle of 7 - 15 degrees to the upper clamp (3).
shaft.
Reassemble in the reverse
Assemble all parts in the reverse sequence.
sequence.
• Align the loop handle at
distance "A" = 20 cm from the
control handle and tighten down
firmly.
FS 25-4, 65-4
 12.3 Drive Shaft/
Flexible Liner

The drive shaft is supported in a

flexible liner inside the drive tube.
The ends of the drive tube are sea- A
led with plugs.

- Remove the gearhead - see 13.1.

398RA179 VA
Loop handle with barrier bar • Push the drive shaft into the dri-
ve tube until dimension "A" is 23
• Take out the screws (1). mm. If necessary, apply slight
pressure to the shaft and rotate it
• Remove lower clamp (2). slowly until it can be pushed in to
the specified dimension.

Drive shaft - Fit the gearhead - see 13.1.

• Remove the barrier bar (1), loop • Pull the drive shaft out of the
handle (2) and upper clamp (3). drive tube.

• Take the square nuts (4) out of Note: If the shaft has turned blue,
the barrier bar. fit a new one.

Reassemble in the reverse - Coat the drive shaft with STIHL

sequence. gear lubricant 0781 120 1109, Flexible liner
see 14.2, before installation.

Important: Apply the grease

uniformly and thinly to the whole
drive shaft. Do not pump grease
directly into the drive tube.

- Push the drive shaft into the dri-

ve tube.

• Align the loop handle at - Remove the drive tube

distance "A" = 20 cm from the - see 12.4.
control handle and tighten down
firmly. • Pry the plug out of the drive tube.

FS 25-4, 65-4 39

• Pull out the flexible liner.
• The hole (1) must be between
the spokes (2).
- Insert plug, install the drive tube
- see 12.4.
40
12.4 Drive Tube
- Remove the drive shaft
- see 12.3.
- Remove the bike or loop handle
- see 12.1 or 12.2.
• On machines with bike handle,
take throttle cable out of
retainers.
• On machines with loop handle,
release screws on control handle
clamps.
• Take the fixing screw (1) out of
the AV sleeve.
• Release the clamp screw (2).
- Pull out the drive tube.
• On machines with loop handle,
pull the drive tube (1) out of the
control handle (2) at the same
time.
• Slip the throttle cable retainer, if
fitted, off the drive tube.
FS 25-4, 65-4
 13. Cutting Tool Drive
13.1 Gearhead 13.2 Clutch Drum

- Take rubber element (AV

system) out of clutch housing
- see 10.

• Remove screw from hose clamp - Remove deflector or stop, if fitted.

for harness.
• Release clamp screws.

- Pull gearhead off the drive tube.

- For further disassembly and

assembly procedures see
"Standard Repairs and Trouble-
shooting" handbook.

- Degrease clamp mounting area.

- Slide the gearhead onto the dri-

ve tube - turn the output shaft
back and forth at the same time
so that the square end of the dri-
ve shaft engages the square sok-
ket in the drive pinion.

- Push the gearhead as far as

• Pull the hose clamp apart and stop and line it up. • Use pliers (1) 0816 610 1495 to
take it off the drive tube. remove retaining ring from the
- Tighten down clamp screws clutch drum stub.
Reassemble in the reverse to 8.5 Nm.
sequence.
- Refit the deflector or stop.
- Degrease the clamp mounting
area.

• Push the drive tube home so that • Use drift (1) 1114 893 4700 to
the holes line up. press clutch drum out of ball bea-
ring.
- Tighten down fixing screw to
2.5 Nm and clamp screw to
5.5 Nm.

FS 25-4, 65-4 41
• Use pliers (1) 0811 641 8380 to • Use drift (1) 1114 893 4700 to
take retaining ring out of clutch press home clutch drum as far
housing. as stop.

• Use press arbor (1) 1118 893

7200 to remove ball bearing from
clutch housing.

Install in the reverse sequence.

• Use press arbor (1) 1118 893

7200 to press home ball bearing
as far as stop.

42 FS 25-4, 65-4
14. Special Servicing Tools and Aids
14.1 Special Servicing Tools

No. Part Name Part No. Application Rem.

1 Puller 4119 890 4501 Removing flywheel

2 Crimping tool 5910 890 8210 Attaching connectors to
electrical wires
3 Carburetor and 1106 850 2905 Testing carburetor
crankcase tester for leaks
4 - Nipple 0000 855 9200
5 - Fuel hose 1110 141 8600
6 Torque wrench 5910 890 0301 0.5 to 18 Nm 1)
5910 890 0302 2)
7 Torque wrench 5910 890 0311 6 to 80 Nm 1)
5910 890 0312 2)
8 Spline screw socket T27x125 0812 542 2104 IS screws
9 Hook 5910 893 8800 Removing pickup body
10 Installing tool 4126 893 4900 Removing rubber element
from AV sleeve
11 Pliers 0816 610 1495 External retaining ring
on clutch drum
12 Pliers C19 0811 641 8380 Internal retaining ring
in clutch housing
13 T-handle screwdriver QI-T27x150 5910 890 2400 For all IS screws 3)
14 Screwdriver T20x100 5910 890 2301 Separating handle moldings
15 Assembly drift 1114 893 4700 Removing and installing
clutch drum
16 Vice jaws 5910 893 2700 Holding drive tube and bike
handle
17 Press arbor 1118 893 7200 Removing and installing ball
bearing in clutch housing
18 Assembly stand 5910 890 3100 Holding FS units
19 - Clamp 5910 890 8800 Holds drive tube of FS units
for repairs
(in conjunction with assembly stand)
20 Locking screw 4170 893 1200 Blocking crankshaft

Remarks:
1) Always use torque wrench to tighten DG/P screws.
2) Wrench has optical/acoustic signal.
3) On DG/P screws, use for releasing only.

FS 25-4, 65-4 43
14.2 Servicing Aids

No. Part Name Part No. Application

1 Lubricating grease 0781 120 1111 Oil seals

(370 g tube)

2 Standard commercial, Cleaning crankshaft stub

solvent-based degreasant
containing no chlorinated or
halogenated hydrocarbons

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

4 Engine oil SAE 15W-40 Engine lubrication

5 Dirko sealant 0783 830 2120 Crankcase sealing faces

(100 g tube)

6 STIHL gear lubricant Drive shaft in drive tube

- 80 g tube: 0781 120 1109
- 225 g tube: 0781 120 1118

7 STIHL gear lubricant Gearhead lubrication

- 80 g tube: 0781 120 1117
- 225 g tube: 0781 120 1118

44 FS 25-4, 65-4
15. Maintenance chart

before starting work

Please note that the following maintenance intervals apply for normal

every 12 months or
after finishing work

if faulty, if required
every 3 months or

every 6 months or
operating conditions

every 100 hours

in first month or
refueling stop

every 25 hours

every 50 hours
after 10 hours
and after each
only. If your daily working time is longer than normal or operating condi-

if damaged
tions are difficult

or daily
(very dusty work area etc.) shorten the specified intervals accordingly.

Check oil level x

Engine oil
Change x x
Visual inspection (condition, leaks) x x
Complete machine
Clean
Control handle Check operation x x
Check x x
Air filter Clean x x
Replace x x
Check x x
Filter in fuel tank
Replace x x
Fuel tank Clean x
Check idle setting -
Carburetor cutting tool must not rotate x x
Readjust idle x
Spark plug Readjust electrode gap x
Cylinder fins Clean x
All accessible screws and nuts
(not adjusting screws) Retighten x
Visual inspection x x
Metal cutting tools
Sharpen x x
Check x
Gearbox lubrication
Top up
Check
Drive shaft
Relubricate x
Valve clearance Check and adjust if necessary x
Fuel lines Check and replace if necessary every 2 years

FS 25-4, 65-4 45