Stihl 4144 Series Manual
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Stihl 4144 Series Manual

Powerhead
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STIH)
STIHL Series 4144 Powerhead
2008-01
FS 40, FS 50, FS 56
FC 56
KM 56

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Summary of Contents for Stihl 4144 Series

  • Page 1 STIH) STIHL Series 4144 Powerhead 2008-01 FS 40, FS 50, FS 56 FC 56 KM 56...

  • Page 2: Table Of Contents

    Vacuum Test 6.1.3 Pressure Test Oil seals Removing and Installing the Engine Removing and Installing the Cylinder Crankshaft 6.5.1 Removing and Installing Bearings / Crankshaft Piston 6.7.1 Piston Ring © ANDREAS STIHL AG & Co. KG, 2008 Series 4144 Powerhead...

  • Page 3: Introduction

    "Special Servicing Tools" in this They can be identified by the STIHL this power tool. manual. Use the part numbers to part number, identify the tools in the...

  • Page 4: Safety Precautions

    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

    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

    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: Troubleshooting

    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 8: Ignition System

    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 9 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 10: Engine

    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 11: Clutch

    Clutch Clutch Drum – Inspect the clutch drum (1) for signs of wear. – Troubleshooting, b 4.1 If there are signs of serious wear on the inside diameter of the clutch – Remove the engine – see service drum (1), check the remaining wall manual for "Series 4144 thickness.

  • Page 12: Clutch

    Clutch – Block the piston, b 5.1 – Remove the clutch drum, b 5.1 – Remove the clutch, b 5.2 : Remove the cup spring (1) and washer (2). : Push clutch drum (1) onto crankshaft stub (arrow) at ignition –...
  • Page 13 Installing : Unhook the springs (1) from the : Position the wrench (1) clutch shoes. 4130 890 3600 on the crankshaft : Push the washer (2) and cup stub so that its pins engage the spring (1) onto the crankshaft recesses (arrows).

  • Page 14: Engine

    Engine Removal and installation of the 6.1.1 Preparations engine is described in the service manual for "Series 4144 Components – FS, FC, KM". Leakage Test Defective oil seals and gaskets or cracks in castings are the usual causes of leaks. Such faults allow supplementary air to enter the : Fit the sealing plate (1) engine and upset the fuel-air...

  • Page 15: Vacuum Test

    The new flange 5910 850 4200 : Fit the nuts (arrows) and tighten : Push ring (1) to the left. replaces the previous flange 1128 them down firmly. 850 4200. The new flange has an : Operate the lever (2) until the additional recess (arrow) in its pressure gauge (arrow) indicates sealing face.

  • Page 16: Pressure Test

    6.1.3 Pressure Test To find the leak, coat the suspect Oil seals area with oil and pressurize the engine. Bubbles will appear if a leak It is not necessary to disassemble exists. the engine to replace the oil seals. – After finishing the test, push the Ignition side ring to the left to vent the pump –...
  • Page 17 Carrier side Take care not to damage the crankshaft stub. – Remove the engine – see service manual for "Series 4144 – Clean the sealing face, b 9 Components – FS, FC, KM" – Lubricate sealing lips of new oil seal with grease, b 9 –...

  • Page 18: Removing And Installing The Engine

    Removing and Installing the Cylinder Before removing the piston, decide whether or not the crankshaft, clutch or carrier have to be removed as well. Cylinder installed To remove the clutch or carrier, block the.crankshaft by inserting the locking strip in the spark plug hole. : Use press sleeve (1) : Take out the screws (arrows).
  • Page 19 Always use a new cylinder gasket when re-installing the cylinder. : Apply the puller (1) 5910 890 : Carefully lift the cylinder (1) 4400 with the jaws under the away. crankcase ribs (arrows) and line up the spindle (2) so that the Do not use pointed or sharp-edged bushing (3) is centered on the –...
  • Page 20 The sealing faces must be in perfect – Check correct installed position condition. If the sealing faces are of ring, b 6.7.1 damaged, install a new cylinder or spacer flange. Apply the clamping strap (1) so that the piston ring does not project –...
  • Page 21 : Remove the clamping strap (1) : Fit the new gasket (1) over the Use a new exhaust gasket. and wooden assembly block (2). guides (arrows) on the spacer flange. – Insert the screws. Make sure the cylinder gasket is properly seated.

  • Page 22: Crankshaft

    Crankshaft 6.5.1 Removing and Installing – Remove the engine – see service manual for "Series 4144 Components – FS, FC, KM" The puller is not necessary for removal of the crankshaft. : Loosen the engine pan (1) at the – Inspect the crankcase and lug (arrow).
  • Page 23 : Fit the installing sleeve (1) : Apply thin coating of sealant to – Inspect and clean the sealing 4119 893 4600. outside diameter (arrows) of the faces on the engine pan and oil seals, b 9 remove any gasket residue, b 9 : Push the new oil seals, open side facing the ball bearings, on to the The sealing faces must be in perfect...

  • Page 24: Bearings / Crankshaft

    – Install the cylinder, b 6.4 – Tightening torques, b 3.3 – Remove the puller. – Clean the crankshaft stubs, b 9 – Install the engine – see service manual for "Series 4144 Components – FS, FC, KM" – Line up the engine pan so that –...

  • Page 25: Piston

    – Tightening torques, b 3.3 – Reassemble all other parts in the reverse sequence. Piston – Remove the engine – see service manual for "Series 4144 Components – FS, FC, KM" : Pull the ball bearing (1) off the Use a firm base (2) to protect the straight crankshaft stub.
  • Page 26 : Use the assembly drift (2) : Check the needle cage (1) and : Push the assembly drift (1) 1130 893 4700 to push the piston clean it if necessary 1130 893 4700, small diameter pin (1) out of the piston. first, through the piston and small end (needle cage).
  • Page 27 : Attach the snap ring (1) to the : Press the installing tool – Position the snap ring against the magnet (2) so that the snap ring downwards into the sleeve until carrier side of the piston. gap is on the flat side of the tool's the magnet butts against the end shank (arrow).

  • Page 28: Piston Ring

    Ignition System Exercise extreme caution when troubleshooting and carrying out maintenance or repair work on the ignition system. The high voltages which occur can cause serious or fatal accidents. Troubleshooting on the ignition system should always begin at the spark plug, b 4.2 –...

  • Page 29: Ignition Module

    Ignition Module 7.1.1 Removing and Installing – Remove the engine – see service manual for "Series 4144 Components – FS, FC, KM" The air gap between the ignition module and flywheel can be adjusted only when the engine is removed. : Remove the ignition module (1).

  • Page 30: Ignition Timing

    – Check operation – rotate the flywheel and make sure it does not touch the ignition module. – Position the insulator (1) so that – Push the ignition module (1) back the connecting bar (2) points towards the carburetor. : Slide the setting gauge (2) 1127 890 6400 between the : Attach the lugs (arrows) of the arms of the ignition module and...

  • Page 31: The Ignition Module

    Testing the Ignition : Crank the engine quickly with the Module rewind starter and check spark in the tester’s window (2). To test the ignition module, use The engine may start and either the ZAT 4 ignition system accelerate during the test. tester 5910 850 4503 or the ZAT 3 ignition system tester If a spark is visible, the ignition...

  • Page 32: Spark Plug Boot

    Spark Plug Boot – Pull the boot off the ignition lead. The ignition module (1) and ignition lead (2) form a unit. A new ignition module must be installed if the ignition lead is damaged. The engine does not need to be removed.

  • Page 33: Flywheel

    : Make sure the leg spring (arrow) – Remove the clutch, b 5.1 The flywheel and magnet poles locates properly inside the spark (arrows) must not be damaged or plug boot. have turned blue. Replace flywheel If the flywheel is stuck, use a puller. if necessary.

  • Page 34: Ignition System Troubleshooting

    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 35 Powerful spark? Air gap: – Check ignition module/flywheel, – reset if necessary, b 7.1.1 Check the flywheel: – Have pole shoes turned blue? – Install new flywheel if necessary, b 7.5 Check short circuit wire: – Wire damaged? – Connectors firmly seated? –...
  • Page 36 Check stop switch on control handle: – Short circuit wire chafed? – Operation of stop switch: – Idle position = no connection – Position " " = connection – Replace short circuit wire if necessary – see service manual for "Series 4144 Components –...

  • Page 37: Special Servicing Tools

    Special Servicing Tools New Special Tools Part Name Part No. Application Rem. Test flange 5910 850 4200 Crankcase leakage test Sleeve (with 20° chamfer) 5910 893 1708 for intstalling tool 8 Puller 5910 893 0800 Removing flywheel Existing Special Tools Part Name Part No.
  • Page 38 Part Name Part No. Application Rem. Torque wrench 5910 890 0302 0.5 to 18 Nm Part Name Part No. Application Rem. Torque wrench 5910 890 0312 6 to 80 Nm Screwdriver bit, T 27 x 125 0812 542 2104 Removing and installing spline socket screws with electric or pneumatic screwdrivers;...

  • Page 39: Servicing Aids

    Part Name Part No. Application Lubricating grease (225 g tube) 0781 120 1111 Oil seals, sliding and bearing points STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in starter Press fluid OH 723 0781 957 9000...
  • Page 40 Series 4144 Powerhead...
  • Page 41 Series 4144 Powerhead...
  • Page 42 englisch / english 0455 938 0123. M7. D8. Rei. Printed in Germany...

This manual is also suitable for:

Fs 40Fs 50Fs 56Fc 56Km 56

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