Stihl FS 120 Manual
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Stihl FS 120 Manual

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5/20/2018
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  • Page 1 Call 606-678-9623 or 606-561-4983 5/20/2018 STIHL FS 350 Service manual.pdf - slidepdf.com STIH) STIH)  F S 1 2 0 , 2 0 0 , 3 0 0 , 3 5 0 , 4 0 0 , 4 5 0 , STIHL  ...

  • Page 2: Table Of Contents

    Removing and Installing (FS 120/200) (FS 400/450, FR 450) 27 Repair Flywheel (FS 300...450) Short Circuit Wire Repair (FR 350/450)  © 2000, Andreas Stihl AG & Co., Waiblingen FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 2/63...

  • Page 3: Introduction

    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. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 3/63...

  • Page 4: Specifications

    Regular brand name gasoline and two-stroke engine oil Mix ratio:   50:1 with STIHL two-stroke engine oil 25:1 with other brand name two-stroke, air-cooled engine oils Air filter: Paper filter FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 4/63...

  • Page 5: Ignition System

    FS 120, 200, 300, 350, FR 350 4134 007 1050 Set of gaskets for FS 400, 450, FR 450 4128 007 1050 FS 400/450 only ** FS 120, 200, 350 and 450 FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 5/63...

  • Page 6: Tightening Torques

    IS-M5x16 AV sleeve/drive tube (clamp screw) Spline screw IS-M5x12 Clamp/control handle/drive tube 2) 5) Spline screw IS-M5x16 Clamp/drive tube (for harness) Spline screw IS-M5x30 Control handle (bike handle) FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 6/63...
  • Page 7 3) FS 120/200 4) FS 300/350 5) FR 350 6) with washer Note: Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm DG screws max. 500 rpm FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 7/63...

  • Page 8: Clutch

    Take out screws (1). Twist the clutch shoes and • • detach the springs. Remove cover (2). • Important: Clutch shoes and springs must always be replaced in pairs. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 8/63...

  • Page 9: Clutch Carrier

    24 Nm (17.7 lbf.ft). - Install the clutch - see 3.1.       A       V       3       3       2       A       R       0       5       2 Insert screws and tighten down • to 12 Nm (8.8 lbf.ft). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 9/63...

  • Page 10: Engine

    Take out the screw (1). • Press down the decompression • Pull spark arresting screen (2) valve (2). • out of the muffler. • Remove the shroud (3). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 10/63...

  • Page 11: Leakage Test

       4    1    0    A    R    0    5    2 Push the test flange (1) • 1128 850 4200 into position. Fit and tighten down the nuts (2) • firmly. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 11/63...

  • Page 12: Pressure Test

       R    0    5    2 Close vent screw (1) on • pump cylinder. Operate lever (2) until the gauge • (3) indicates a vacuum of 0.5 bar (7.25 psi). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 12/63...

  • Page 13: Oil Seals

    - 13.2. - Lubricate sealing lips of oil seal with grease - see 13.2. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 13/63...

  • Page 14: Exposing The Cylinder

    (2) and • and pull it out of the guide. throttle cable (3) in the retainer (4). - Tighten down screws to 6 Nm (4.4 lbf.ft). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 14/63...

  • Page 15: Cylinder And Piston

    All models: Ease the hookless snap rings • Illustrations show the out of the grooves in the piston FS 200 engine. bosses. Pull out the sealing ring. • FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 15/63...

  • Page 16: Installation

    5910 890 2210 as shown in dra- ting rod. wing. a = 30 degrees Installed position of piston: b = Ø 10 mm • 1 = Marking 2 = Flywheel FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 16/63...

  • Page 17: Piston Rings

    8.5 Nm (6.3 lbf.ft). and check that the piston rings are correctly positioned. Assemble all other parts in the reverse sequence. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 17/63...

  • Page 18: Removing Crankshaft

    Take short circuit wire (3) out of • - Install the piston - see 4.5.2. base of guide and remove it from - Remove the carrier - see 3.2. the retainers (4). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 18/63...
  • Page 19 ZS installing tool (1) 5910 notches "16" and "17" can be 890 2220 a little. modified as shown in the The illustration shows the under- illustration. side of the drilled plate. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 19/63...
  • Page 20 (2) and needle bearing form holes marked "16", fit washers at an inseparable unit. It must other side and screw on nuts. always be replaced as a com- plete unit. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 20/63...

  • Page 21: Installing Crankshaft

    7200 to remove ball bearing. stop. - Inspect both halves of the crank- case for cracks and replace if ne- cessary. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 21/63...
  • Page 22 (1) clockwise press arbor (1) 4119 893 7200 to onto the stub (2) as far as stop. press in the ball bearing as far as stop. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 22/63...
  • Page 23 Hold the spindle steady and Fit installing sleeve (1) 4112 893 • • rotate sleeve counterclockwise 2400 over the clutch end of the until it butts against the ball crankshaft. bearing. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 23/63...

  • Page 24: Decompression Valve

    - Fit spark plug boot over the ignition lead. - Use pliers to grip the end of the ignition lead inside the spark plug boot and pull it out. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 24/63...

  • Page 25: Ignition Lead (Fs 400/450, Fr 450)

    Unscrew the ignition lead from • securely. the contact pin and pull it out of the high voltage output. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 25/63...

  • Page 26: Ignition Module

    - Fit cable retainer and spark plug 1. the high voltage output (1) boot. 2. the connector tag (2) for the - Fit the ignition module - short circuit wire 5.3.3. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 26/63...

  • Page 27: Ignition Timing

       2       2 Pull short circuit wire connector Place the pad on the ignition • • (1) off tag on ignition module. module and apply firm and uniform pressure. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 27/63...

  • Page 28: Removing And Installing (Fs 400/450, Fr 450)

       A    V    2    0    1    A    R    0    5    2 Take ignition lead out of guide. • FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 28/63...

  • Page 29: Flywheel

    - Fit flywheel nut. Tighten nut on FS 120 to 24 Nm (17.7 lbf.ft). - Pull off the flywheel. Tighten nut on all other models to 32 Nm (23.6 lbf.ft). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 29/63...

  • Page 30: Short Circuit Wire

    Push out the grommet (1). • • retainers. Pull short circuit wire (2) out of • housing bore, remove it from the retainers and pull off the grommet. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 30/63...

  • Page 31: General

       A    V    8    1    1    A    R    0    5    2 Take out the screw and remove • any remaining pieces of spring from the fan housing. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 31/63...

  • Page 32: Tensioning

    - Fit fan housing, insert screws and tighten down to 6.0 Nm Hold the rope rotor steady. • (4.4 lbf.ft). Pull out the rope with the starter • grip and straighten it out. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 32/63...

  • Page 33: Starter Rope/Starter

    0000 195 8200 through the gui- ter grip. de bush from outside the fan housing. - Secure end of rope with a simple overhand knot. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 33/63...

  • Page 34: Throttle Control

    (1), contact spring torsion spring (2) is relaxed. (2), protective tube (3) and Assemble in the reverse insulator (4). Pull the interlock lever off the sequence. • peg. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 34/63...

  • Page 35: (Bike Handle)

    - Engage contact spring correctly in groove of collar screw. - Remove handle molding. Remove contact spring from peg Remove torsion spring. • • (1) and collar screw (2). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 35/63...

  • Page 36: Slide Control

    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 (0.75 lbf.ft). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 36/63...

  • Page 37: Throttle Cable

    - Remove the air filter housing - • housing must be 20 mm (0.8"). extended throttle cable (2). see 8.2.2. Remove screw (1) from • extended throttle cable (2). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 37/63...

  • Page 38: Adjusting

    Important: Note adjustment range of idle speed screw. Take throttle cable (1) out of • base of cable guide (2) and pull it out of opening (3) in carburetor housing. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 38/63...

  • Page 39: Fuel System

    - On FS 400/450, FR 450: Tighten screw to 3.0 Nm (2.2 lbf.ft).    A    V    2    5    1    A    R    0    5    2 FS 400/450, FR 450 Take out screw (1). • FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 39/63...

  • Page 40: Carburetor

    Remove the filter housing and Pull carburetor off the studs. • • • filter housing. pull stub out of grommet at the same time. - If necessary, pull fuel hose off carburetor. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 40/63...
  • Page 41       8       6    5       1    6       A    1    A       R       0    R       5    0       2    5    2 Disconnect fuel hose from Pull carburetor off the studs. • • connector. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 41/63...

  • Page 42: Leakage Test

    (3) shows a reading of Fit fuel hose (1) 1110 141 8600 approx. 0.8 bar (11.5 psi). • on nipple (2) 0000 855 9200. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 42/63...

  • Page 43: Adjusting

    – and then turn it about another one full turn in the clockwise for leaner mixture at same direction. high altutude, or counterclockwise for richer mixture at sea level. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 43/63...

  • Page 44: Adjusting

    7.5.    A    V    2    2    2    A    R    0    5    2 Adjust idle speed correctly with the idle speed screw (LD): the cutting tool must not rotate. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 44/63...

  • Page 45: Tank Vent

    Equalization of pressure from the inside outwards takes place via the holes in the cap, the holes in the valve body, the sintered filter and the hole in the fuel filler cap. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 45/63...

  • Page 46: Fuel Tank/Hoses

    FS 400/450 only Take out the screws. • Take out the screws. • - Remove the fuel tank. - Remove the guard plate. - Replace sleeves and grommets if necessary. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 46/63...
  • Page 47    8 together with retainer.    1    A    R    0    5    2 Pull out the fuel hose (1). • Pull out the return hose (2) • together with grommet (3). FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 47/63...
  • Page 48    2 Pull fuel pump out of its seat in Take the clutch shroud off the • • the filter/ carburetor housing. clutch housing. Install in the reverse sequence. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 48/63...
  • Page 49    R    R    2    0    9    5    3    2 Pull the rubber element off the Carefully ease the cable • • AV sleeve. retainers out of the AV housing. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 49/63...
  • Page 50 Pull the support (1) and AV • • at both sides between the AV housing (2) off the drive tube. Pull the rubber buffers off the housing and support. • clutch housing. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 50/63...
  • Page 51       A       V       2       4       2       A       R       0       5       2 Hold screws steady and unscrew • the nuts (1). Remove the springs (2) from the • support plate. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 51/63...
  • Page 52 Reassemble in the reverse sequence. - Lubricate thread of clamp screw with STIHL multipurpose grease - Use jaws (1) 5910 893 2700 to • see 13.2 clamp bike handle tube in vice. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 52/63...
  • Page 53 "A" = 20 cm (8") from distance "A" = 20 cm (8") from the control handle and tighten the control handle and tighten down firmly. down firmly. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 53/63...
  • Page 54    5    2 - Remove the drive tube - Press down lever on housing. • 10.6. - Pull out the shaft. Pry the plug out of the drive tube. • FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 54/63...
  • Page 55 • • • one if necessary. release screws on control handle fitted, off the drive tube. clamps. - Install flexible shaft and fit throttle cable in the retainers. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 55/63...
  • Page 56 - Tighten down clamp screw to 8.5 Nm (6.3 lbf.ft) (FS 300/350) Pull off the sleeve, if fitted. • or 12 Nm (8.8 lbf.ft) (FS 400/  450). Reassemble in the reverse sequence. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 56/63...
  • Page 57    A    V    9    0    2    A    R    0    5    2 FS 300...450 Remove retainer (1) - if fitted - • and thrust washer (2) from the output shaft. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 57/63...
  • Page 58 7200 to remove ball bearing from clutch drum stub. clutch housing. Take out the screws. • Install in the reverse sequence. - Pull off the clutch housing. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 58/63...
  • Page 59 6.0 Nm (4.4 lbf.ft).    A    V    3    5    2    A    R    0    5    2 Take out the screws. • - Remove bearing housing from support frame. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 59/63...
  • Page 60 1123 851 8300 1) 2) - Extension 4116 894 1000 1) 2) - Spline screw 9022 341 1190 1) 2) Puller 4119 890 4600 Removing crankshaft (clutch side) FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 60/63...
  • Page 61 4) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400. 5) Always use torque wrench to tighten DG/P screws. 6) Wrench has optical/acoustic signal. 7) On DG/P screws, use for releasing only. FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 61/63...
  • Page 62 - 225 g/8 oz tube: 0781 120 1110 STIHL gear lubricant Gearhead lubrication - 80 g/3 oz tube: 0781 120 1117 - 225 g/8 oz tube: 0781 120 1118 FS 120, 200, 300, 350, 400, 450, FR 350, 450 http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 62/63...
  • Page 63 5/20/2018 STIHL FS 350 Service manual.pdf - slidepdf.com engli /English 0455  0   . Printed in Germany http://slidepdf.com/reader/full/stihl-fs-350-service-manualpdf 63/63...

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