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Related Manuals for Stihl 4144 Series
Summary of Contents for Stihl 4144 Series
- Page 1 STIH) STIHL Series 4144 Components FC, FS, KM 2008-02 FS 40, FS 50, FS 56 FC 56 KM 56...
- Page 2 8.8.1 Testing 6.3.1 Carrier 8.8.2 Removing and Rope Rotor Installing Starter Rope / Grip Fuel Intake Tensioning the 8.9.1 Pickup Body Rewind Spring 8.9.2 Fuel Hoses © ANDREAS STIHL AG & Co. KG, 2008 Series 4144 Components FC, FS, KM...
- Page 3 "Special Servicing Tools" in this They can be identified by the STIHL this power tool. manual. Use the part numbers to part number, the {...
- Page 4 Safety Precautions If the engine is started up in the course of repairs or maintenance work, observe all local and country- specific 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.
- Page 5 Specifications Engine FS 40 FS 50, 56, FC 56, KM 56 Displacement: 27.2 cm 27.2 cm Bore: 34 mm 34 mm Stroke: 30 mm 30 mm Engine power to ISO 8893: 0.7 kW (1.0 bhp) 0.8 kW (1.1 bhp) at 8,500 rpm at 8,500 rpm Max.
- Page 6 Tightening Torquese 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.
- Page 7 Remarks: 1) Loctite 242 or 243, medium strength 2) Loctite 270, high strength 3) Loctite 649, high strength 4) Loctite 272, high strength up to 250°C 5) Degrease crankshaft/flywheel and mount oil-free 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.
- Page 8 Troubleshooting Clutch Condition Cause Remedy Cutting attachment stops under Clutch shoes badly worn Install new clutch load at full throttle Clutch drum badly worn Install new clutch drum Cutting attachment runs at idle Engine idle speed too high Readjust idle speed screw LA speed Clutch springs stretched or fatigued Replace the clutch springs or install new clutch...
- Page 9 Rewind Starter Condition Cause Remedy Starter rope broken Rope pulled out too vigorously as Fit new starter rope far as stop or over edge, i.e. not vertically Normal wear Fit new starter rope Starter rope does not rewind Very dirty or corroded Clean rewind spring or replace rope rotor Insufficient spring tension...
- Page 10 Ignition System Exercise extreme caution while carrying out maintenance and repair work on the ignition system. The high voltages which occur can cause serious or fatal accidents. Condition Cause Remedy Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug temporary loss of power and fit new spring if necessary Spark plug sooted, smeared with oil Clean the spark plug or replace if...
- Page 11 Condition Cause Remedy No spark Spark plug faulty Install new spark plug Faulty insulation or short in short Check short circuit wire for short circuit wire circuit to ground Break in ignition lead or insulation Check ignition lead, replace ignition damaged module if necessary Ignition module faulty...
- Page 12 Carburetor Condition Cause Remedy Carburetor floods; engine stalls Inlet needle not sealing Remove and clean the inlet needle, – foreign matter in valve seat or clean the carburetor cone Inlet control lever sticking on Check inlet control lever, replace if spindle necessary Helical spring not located on nipple...
- Page 13 Condition Cause Remedy Engine will not idle, idle speed too Throttle shutter opened too wide by Reset idle speed screw LA high idle speed screw LA correctly Oil seals/crankcase leaking Seal or replace oil seals/crankcase Engine stalls at idle speed Idle jet bores Clean the carburetor or ports blocked...
- Page 14 Condition Cause Remedy Engine speed drops quickly under Air filter dirty Clean air filter or replace if load – low power necessary Throttle shutter not opened fully Check throttle cable and cable adjustment and readjust if necessary Tank vent faulty Replace tank vent Fuel pickup body dirty Install new pickup body...
- Page 15 Engine Always check and, if necessary, repair the following parts before looking for faults on the engine: - Air filter - Fuel system - Carburetor - Ignition system Condition Cause Remedy Engine does not start easily, stalls Oil seals in crankcase damaged Replace the oil seals at idle speed, but operates normally at full throttle...
- Page 16 Engine Removing and Installing – Remove the drive tube, b 9.1 – Remove the rewind starter, b 6.2 : Pull the protective cap (1) off the : Disconnect the short circuit wire spark plug boot (2). (1) and ground wire (2). –...
- Page 17 Installing : Remove the air baffle (1). – Press down the throttle lever until the nipple (arrow) projects. : Position the engine so that the – Inspect the muffler and replace if clutch (1) faces the drive tube : Turn the pin (2) until the slot is in necessary, b 5.8 mounting (arrow) in the engine line with the throttle cable (1).
- Page 18 : Line up the air baffle (1). – Coat stubs (arrows) and ends of – Fit throttle cable (1) in the pin's hoses with STIHL press fluid, (2) slot. b 11 The air baffle's slot must engage the : Turn the pin until the nipple is...
- Page 19 : Insert the screws (1) – do not tighten them down yet. – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.4 : Push short circuit wire (1) and : Place the shroud (1) in position ground wire (2) firmly onto the behind the air baffle (arrows).
- Page 20 Muffler / Spark Arresting Screen Always check and, if necessary, Spark arresting screen repair the fuel system, carburetor, (if fitted) air filter and ignition system before looking for faults on the engine. – Troubleshooting, b 4.5 – Remove the drive tube, b 9.1 –...
- Page 21 Short Circuit Wire To locate the fault, test the wires for continuity and check insulation for 5.9.1 Testing damage. If the wires are in order, check operation of stop switch, b 5.10 If no fault can be found, check the ignition system with the aid of the troubleshooting chart, b 5.10.
- Page 22 – Push the flag terminals firmly on to the connector tags of the stop switch. : Push the flag terminal of the short circuit wire (1) onto the rear connector tag (see illustration). : Push the ground wire (2) onto the connector tag.
- Page 23 : Fit the wires, ground wire (1) first, : Push the support fully home and : Push short circuit wire (1) and in the guide – position the wires position the wires, short circuit ground wire (2) firmly onto the next to one another without wire first, in the guide (arrow).
- Page 24 5.9.3 Removing and Installing (Bike Handle Version) The short circuit wire (black), ground wire (blue) and throttle cable are in a protective tube. : Disconnect the short circuit wire : Pull the ground and short circuit (1) and ground wire (2). wires with throttle cable out of the guides (arrows).
- Page 25 : Disconnect the wires from the – Remove the handle molding and – Tie a thin piece of string to the levers, b 7.4 stop switch. straight terminal on the short circuit wire (1). : Pull short circuit wire (1) out of the protective tube (2) in direction of throttle cable retainer (3) and undo the string.
- Page 26 Installing : Push the protective tube (1) and – Fit the handle molding (1) in throttle cable (2) into their seats position. – Thread the short circuit and (arrows) in the handle molding. ground wires through the hole : Insert screws (arrows) and (arrow) in the handle molding.
- Page 27 5.9.4 Ground Wire A faulty ground wire may impair or prevent operation of the short circuit wire. The ground wire is fitted together with the short circuit in the protective tube and must be replaced if damaged. – Check for contact and continuity : Fit the short circuit wire (1) in the –...
- Page 28 5.10 Ignition System Troubleshooting Troubleshooting can be performed with the engine installed. Refer to service manuals of "Series 4144 Powerhead" or "Series 4144 Components – FS, FC, KM" for descriptions of procedures. Engine does not run Knob on carburetor: – in position "F"? Check the spark plug: –...
- Page 29 Powerful spark? Air gap: – Check ignition module/flywheel, – adjust if necessary, see "Series 4144 Check the flywheel: – Have pole shoes turned blue? – install new flywheel if necessary, see "Series 4144 Powerhead" Check short circuit wire: – Wire damaged? –...
- Page 30 Check stop switch: – Short circuit wire chafed? – Operation of stop switch: – Idle position = no connection – Position " " = connection – Install new short circuit wire if necessary, b 5.9 Powerful spark? Install new ignition module, see "Series 4144 Powerhead"...
- Page 31 Before installing, lubricate the rewind spring and starter post with STIHL special lubricant. If clogged with dirt or pitch, the entire starter mechanism, including – Position the rewind starter (1) so the rewind spring, must be removed that the cover (arrow) fits behind and disassembled.
- Page 32 : Fit the torsion spring (1) so that : Leg (arrow) of torsion spring must – Pull the boot off the spark plug. its leg (arrow) is against the pawl. be preloaded and locate against the carrier. – Unscrew the spark plug. The torsion spring must be pushed fully onto the locking peg (2).
- Page 33 All models – Check the rope rotor and replace if necessary. – Coat bore in rope rotor with STIHL special lubricant, A new rope rotor comes with the b 11 rewind spring preassembled. Models with ErgoStart The rope rotor accommodates the ErgoStart spring and rewind spring.
- Page 34 Starter Rope / Grip Models with ErgoStart – Remove the rewind starter, b 6.2 – Relieve tension of rewind spring, b 6.6 The system will not be under tension if the starter rope is broken. – Remove the rope rotor, b 6.4 : Fit the E-clip (arrow).
- Page 35 – Pull any remaining rope out of the sleeve. Inspect the individual parts and replace if necessary. Do not shorten the starter rope. : Thread the starter rope (1) – Thread the rope through the top of the starter grip. through the guide bushing (arrow).
- Page 36 Models with ErgoStart Tensioning the Rewind Spring – Hold the rope rotor (2) steady. : Thread the rope (1) through the : Pull out the twisted rope (1) with hole in the rotor (arrow). the starter grip and straighten it –...
- Page 37 A replacement spring is supplied ready to install with a new rope rotor. If the rewind spring has popped out, refit it in the rope rotor as follows: Wear a face shield and work gloves. – Remove the rope rotor, b 6.4 The rewind spring is correctly –...
- Page 38 Control Levers – Position < = warm start Switch Shaft / Control Lever – warm engine is started in this position. Switch Positions – Position g = cold start – cold engine is started in this On these machines the operating position modes are set on the handle and the carburetor:...
- Page 39 : Fit the torsion spring (1) in the : Press the interlock lever (1) into : Disconnect the throttle cable (1). interlock lever so that its leg the mounts until it snaps into (arrow) engages the recess as place. shown (arrow). –...
- Page 40 : Press the throttle trigger (1) into – Check the grub screw (1) and – Fit the lever on the same side as throttle trigger (2) and replace if the grub screw. the mounts until it snaps into necessary place. : Push the lever (1) onto the pivot Make sure the grub screw (1) is in pin so that the lug is below the...
- Page 41 : Take out the screws (arrows). : Carefully remove the interlock – Check operation. lever (1) – tension of torsion spring (2) is suddenly relieved. The throttle trigger must be locked – Remove the handle molding (1). in position when the interlock lever is not depressed.
- Page 42 : Push the interlock lever (1) into – Check that the stub (1) is in – Push the throttle trigger (1) onto place, fit a new grub screw if position and engage the torsion the pivot pin. necessary. spring (arrow). : Turn the interlock lever (2) A new throttle trigger comes with slightly and continue pushing the...
- Page 43 : Release the throttle trigger (2) – it must return to the stop : Fit the torsion spring (1) on the : Push the throttle cable (1) and throttle trigger and attach its loop protective tube (2) into the seats to the boss (arrow).
- Page 44 Handlebar (Bike Handle) – Remove the control handle, b 5.9.3 – Line up the handle so that its long – Position the preassembled side (arrow) faces the cutting handlebar on the drive tube. tool. – Fit the clamp (1), with tapped The handle must be fitted in the dry holes, against the underside of condition.
- Page 45 Fuel System Air Filter 8.1.1 Baffle 8.1.2 Filter housing Remove the air filter, b 8.1 Remove the air filter, b 8.1 Dirty air filters reduce engine power, increase fuel consumption and make starting more difficult. The air filter should be checked when there is a noticeable loss of engine power.
- Page 46 : Inspect the sealing faces : Connect tank vent hose (1) to – Press down the throttle lever until (arrows), and clean if necessary filter housing (arrow) the nipple (arrow) projects. b 11 – push it fully onto the stub. : Turn the pin (2) until the slot is in Always replace components with –...
- Page 47 – To simplify assembly, coat the b 8.6.2 stubs and ends of the new fuel hoses with a little STIHL press – Reassemble all other parts in the fluid, b 11 reverse sequence. : Push the new fuel return hose (1) –...
- Page 48 Leakage Test Servicing the Carburetor 8.4.1 Metering Diaphragm / In the case of problems with the Manual Fuel Pump carburetor or fuel supply system, also check and clean or replace the tank vent, b 8.8 The carburetor can be tested for leaks with the pump 0000 850 1300.
- Page 49 : Carefully separate the metering : Check the cap (1) and replace if – Place the flange in position diaphragm (2) and gasket (1). necessary – stub (1) must be on same side as throttle shutter. The diaphragm material is : Insert two screws (arrows) to hold subjected to continuous alternating stresses and eventually shows...
- Page 50 8.4.2 Inlet Needle – Remove the spring (2). Inspect Make sure the spring locates on the and replace if necessary. control lever’s nipple. – Press the inlet control lever down and secure it with the screw. – Check that inlet control lever moves freely.
- Page 51 : Carefully remove the gasket with : Use a needle to remove the fuel – Position the end cover (1) so that pump diaphragm from the end strainer (1) from the carburetor the idle speed screw (arrow) is at cover. body.
- Page 52 8.4.4 Throttle Lever / Rotary Knob – Remove the carburetor, b 8.2 : Position the throttle lever (1) so : Take out the screw (arrow). that the pin (arrow) faces up. – Pull off the rotary knob (1). : Take out the screw (arrow). –...
- Page 53 8.4.5 Adjusting Screws Low speed screw – Fit the spring (1) on the choke shaft. : Use special tool 5910 890 4501 There are three adjusting screws on to pry the limiter cap (1) off the – Position the rotary knob (2) so the carburetor: low speed screw.
- Page 54 Pre-installing limiter caps : Inspect the tip (arrow) for : Take out the high speed damage or wear and replace the screw (1). screw (L) if necessary. Low speed screw (L) Always use a new limiter cap and – Screw down the low speed position it so that the long part of the screw (L) as far as stop.
- Page 55 : Push screwdriver (1) High speed screw (H) High speed and low speed screws can now be adjusted through the 5910 890 2305 into the adjusting Always use a new limiter cap and pre-installed limiter caps. screws (arrow). position it so that the long part of the cap butts against the top of the stop Starting with the low speed and high Adjust idle speed with a tachometer.
- Page 56 8.5.2 Standard Setting Standard Setting – Shut down the engine. – Turn the high speed screw (H) slowly counterclockwise as far as stop, but not more than a 3/4 turn. – Turn the low speed screw (L) slowly clockwise as far as stop, but not more than a The limiter caps must be in their pre- 3/4 turn.
- Page 57 Erratic idling behavior, engine Adjustment for operation at high Removing and Installing speed drops when swinging the altitude Throttle Cable (Loop machine Handle) A minor correction may be Idle setting is too rich necessary if engine power is not satisfactory when operating at high –...
- Page 58 : Pull the throttle cable (1) out of – Position the throttle cable under – Turn the pin (1) until the slot is in the guides (arrows). the tank vent hose (1). line with the throttle cable. : Fit the throttle cable retainer (2) in : Press down the throttle lever (2).
- Page 59 8.6.1 Removing and Installing Checking adjustment of Throttle Cable (Bike throttle cable Handle) The throttle cable is installed in a protective tube together with the short circuit and ground wires and must therefore be removed as an assembly. – Remove the throttle cable at the carburetor end, b 5.9.3 : Push the throttle cable sleeve (1) into the guide as far as stop.
- Page 60 Adjusting the throttle cable – Reassemble in the reverse Always install a new gasket. sequence. Removing and Installing the Spacer Flange Remove the carburetor, b 8.2 : Squeeze the throttle trigger and turn the grub screw (arrow) until – Inspect the spacer flange and the throttle shutter is wide open.
- Page 61 8.8.1 Testing If problems occur on the carburetor or the fuel supply system, also check and clean the tank vent and replace it if necessary. Check function by performing pressure and vacuum tests on the tank via the fuel hose. –...
- Page 62 8.8.2 Removing and Installing Fuel Intake 8.9.1 Pickup Body 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.
- Page 63 To aid assembly, use STIHL press fluid at the points recommended. Do not use any other oil, fuel, grease or press fluids since they may damage the fuel hoses. – Open the tank cap. – Always install new fuel hoses.
- Page 64 – To simplify assembly, coat the stubs (arrows) and ends of the – Push the fuel suction hose home new fuel hoses with a little STIHL press fluid, b 11 until the rubber lip is properly seated in the hole and the flange lies flat against the tank housing.
- Page 65 8.10 Removing and Installing the Engine Housing – Drain the fuel tank, b 1 – Remove the drive tube, b 9.1 – Remove the engine, b 5.1 – Check the engine housing and replace if necessary. If a new engine housing is used, the short circuit wire, ground wire and throttle cable must be transferred from the old housing.
- Page 66 Drive Tube Removing and Installing – Push home the drive tube (1) as far as stop, turn the drive shaft to and fro until the square end of the The drive tube can be removed from drive shaft engages the square the machine without dismantling recess in the clutch drum.
- Page 67 Machines with bike handle : Pull the drive shaft (1) out of the : Grip the collar (arrow) and pull drive tube. the complete driver (1) out of the : Tighten down the screws drive tube. (arrows) firmly. If the drive shaft has turned blue, install a new one.
- Page 68 – Push the wire clips home as far as stop – they must be firmly seated. – Coat needle bearing in bushing and shank of driver with STIHL lubricating grease, b 11 : Push the bushing (3) into position. : Push the plug (1) into the drive tube as far as stop.
- Page 69 If the drive shaft has turned blue, the driver end of the drive tube as install a new one. – Before installing the drive shaft, far as stop. coat it with STIHL gear lubricant for hedge trimmers, : Tighten down the screw (arrow) b 11 firmly.
- Page 70 (3) as far as stop. – Before installing the drive shaft, : Pull the drive shaft (1) out of the coat it with STIHL gear lubricant drive tube. : Tighten down the screw (arrow) for hedge trimmers, b 11 firmly.
- Page 71 – Before installing the drive shaft, : Push the flexible liner (1) into the remove the hex nut at the other coat it with STIHL gear lubricant end of the drive tube with the side. for hedge trimmers, b 11 cross holes (arrows).
- Page 72 – Before installing the drive shaft, – Inspect the bearing housing and coat it with STIHL gear lubricant replace if necessary, b 9.1.5 – Pull off the deflector (1). for brushcutters, b 11 –...
- Page 73 Do not apply too much pressure to 9.1.6 Loop Handle the drive tube with the clamp since the tube will otherwise be permanently deformed and the bearing housing will no longer fit properly. : Pull out the bearing housing (2). –...
- Page 74 9.1.7 Loop Handle with Barrier Bar The engine end of the drive tube – Take out the screw (arrow) and has cross holes, this end is installed washer. in the machine. : Remove the barrier bar (1). – Remove the drive tube, b 9.1 –...
- Page 75 – Install the drive tube, b 9.1 : Take out the screw (1). : Push the line limiting blade (1) into its seat (arrow). : Position the loop handle (1) at a : Pull off the clamp (2). distance of about 5 cm (a) in –...
- Page 76 9.2.4 Retainer : Take out the screw (arrow). – Locate deflector (1) against the gearbox. – Remove the line limiting blade – Remove the drive tube, b 9.1 : Insert screw (arrow) and tighten it (1), check and sharpen or replace as necessary.
- Page 77 Special Servicing Tools New Special Servicing Tools Part Name Part No. Application Rem. Clamp 5910 890 1100 Removing and installing bearing housing Part Name Part No. Application Rem. Locking strip 0000 893 5904 Blocking the crankshaft Pump 0000 850 1300 Testing engine and carburetor for leaks Nipple 0000 855 9200...
- Page 78 Part No. Application Lubricating grease (225 g tube) 0781 120 1111 Oil seals, sliding and bearing points STIHL gear lubricant for hedge 0781 120 1110 Lubricating drive shafts in straight drive tubes trimmers (225 g tube) STIHL gear lubricant for...
- Page 79 Series 4144 Components FC, FS, KM...
- Page 80 Series 4144 Components FC, FS, KM...
- Page 81 Series 4144 Components FC, FS, KM...
- Page 82 englisch / english 0455 545 0123. M7. E8. FST. Printed in Germany...