Stihl MS 441 Manual
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Stihl MS 441 Manual

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STIH)
STIHL MS 441
2006-06

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Summary of Contents for Stihl MS 441

  • Page 1 STIH) STIHL MS 441 2006-06...

  • Page 2: Table Of Contents

    Bar mounting studs 10.3 Pawls 10.4 Rope rotor 10.5 Starter rope / grip 10.6 Tensioning the rewind spring 10.7 Rewind spring 10.8 Starter rope guide bushing © ANDREAS STIHL AG & Co. KG, 2006 MS 441, MS 441 C...
  • Page 3 14.6.4 Impulse hose Special tools 14.7 Tank vent 14.7.1 Check 14.7.2 Removal and Servicing installation accessories 14.8 Fuel intake 14.8.1 Pick-up body 14.8.2 Fuel hoses 14.8.3 Fuel filler cap 14.8.4 Tank housing, removal and installation MS 441, MS 441 C...

  • Page 4: Introduction

    "Special Tools" of this manual. Use procedures for this power tool. the part numbers to identify the tools in the "STIHL Tools" manual You should make use of the which lists all the tools currently illustrated parts lists while carrying available from STIHL.

  • Page 5: Safety

    They can be identified by the STIHL part number, Test for leakages after all work on the STIH) logo and the fuel system and engine. the STIHL parts symbol ( This symbol may appear alone on small parts. MS 441, MS 441 C...

  • Page 6: Specifications

    0.5 mm Chain lubrication Speed-controlled oil pump with reciprocating piston – manual oil flow control Oil delivery rate: 6.0...17 cm /min at 10,000 rpm Oil pump with elevated 6.0...24 cm /min oil flow: at 10,000 rpm MS 441, MS 441 C...

  • Page 7: Tightening Torques

    Screw M 5x16 Intake elbow/cylinder Screw M 5x8.8 Crankcase Screw M 5x25 Crankcase 10.0 Screw M 4x12 Crankcase/brake band Screw M 5x20 Fan housing/crankcase M 12x1 L Crankshaft carrier 50.0 Muffler/flange bolt (with washer) 10.0 MS 441, MS 441 C...
  • Page 8 Screwdriver speed when fitted in plastic material: max. 500 rpm for DG and P-type screws. An impact wrench must not be used to unscrew or tighten the screw connections! Screws with and without locking serration must not be confused! MS 441, MS 441 C...

  • Page 9: Troubleshooting

    Replace the clutch springs Loud noises Clutch springs stretched Replace all clutch springs or fatigued Needle cage damaged Fit new needle cage Clutch shoe retainer broken Fit new retainer Clutch shoes and carrier worn Install new clutch MS 441, MS 441 C...

  • Page 10: Chain Drive, Chain Brake

    Saw chain does not stop Brake spring stretched or broken Fit new brake spring immediately when brake is activated Brake band stretched, worn or Fit new brake band broken Clutch drum worn Fit new clutch drum MS 441, MS 441 C...
  • Page 11 Chain brake is not released although trigger interlock is pressed Brake cable unhooked or broken Reattach or replace brake cable QuickStop Super Brake cable overstretched Adjust brake cable Chain brake does not brake properly – trigger interlock not pressed MS 441, MS 441 C...

  • Page 12: Chain Lubrication

    Install new oil pump Oil intake hose connection Fit new oil intake hose damaged Oil pump delivers insufficient oil Oil pump worn Install new oil pump Delivery rate of oil pump set too low Adjust oil pump MS 441, MS 441 C...

  • Page 13: Rewind Starter

    (spring (not containing any chlorinated or windings stick together) halogenated hydrocarbons), then pull rope carefully several times until normal action is restored Decompression valve is not open Open decompression valve and check, replace if necessary MS 441, MS 441 C...

  • Page 14: Ignition System

    Faulty insulation or break in ignition lead or short circuit wire. Check ignition lead / ignition module and replace if necessary. Check operation of spark plug, clean spark plug and replace if necessary. Crankcase damaged (cracks) Replace crankcase MS 441, MS 441 C...
  • Page 15 Faulty insulation or short-circuit in Check short circuit wire for short- short circuit wire circuiting to earth Break in ignition lead or insulation Check ignition lead, replace damaged if necessary Ignition module faulty Install new ignition module MS 441, MS 441 C...

  • Page 16: Carburetor

    Remove, clean and refit inlet needle Leak in diaphragm seal Fit a new diaphragm seal Metering diaphragm damaged or Fit a new metering diaphragm shrunk Impulse hose damaged or kinked Fit a new impulse hose MS 441, MS 441 C...
  • Page 17 Idle jet bores or ports blocked Clean the carburetor Idle jet too rich or too lean Set low speed screw L correctly Setting of the idle speed screw Set idle speed screw LA correctly incorrect – throttle shutter completely closed MS 441, MS 441 C...
  • Page 18 Air flap does not open fully at full Check carburetor; install a new final speed too low throttle carburetor if necessary Erratic idling, too lean Air flap does not close completely Check carburetor; install a new carburetor if necessary MS 441, MS 441 C...

  • Page 19: Engine

    Check carburetor; install a new carburetor if necessary Engine overheating Insufficient cylinder cooling. Air Thoroughly clean all cooling air inlets in fan housing blocked or openings and cooling fins cooling fins on cylinder very dirty MS 441, MS 441 C...

  • Page 20: Saw Chain / Chain Guide

    14.1. The clutch has a left-hand thread. : Pull boot (1) off spark plug. : Unscrew spark plug (1). Disassembling the clutch : Use hook (2) 5910 890 2800 to remove the clutch springs (1). MS 441, MS 441 C...
  • Page 21 Attach the springs to the side with – Washer (1) must be fitted. shoes. the raised hexagon (arrow). It has been fitted correctly when : Attach one end of each spring (1) "TOP" (arrow) faces outwards. to the clutch shoes. MS 441, MS 441 C...

  • Page 22: Clutch Drum

    – Tightening torques, b 3.5. : Press and hold the trigger interlock (1). – Pull locking strip out of the cylinder. – Remove clutch drum. – Reassemble all other parts in the reverse sequence. : Remove rim sprocket (1). MS 441, MS 441 C...
  • Page 23 – Fit clutch drum. 100% – Examine clutch drum (1) for signs The notch (arrow) in the clutch drum of wear. must engage the carrier (1) of the wormwheel. The mark (2) can be used for guidance. MS 441, MS 441 C...

  • Page 24: Checking Operation

    If the chain brake does not operate : Insert circlip (1) in the groove of properly, refer to the : Take out screws (arrows). the crankshaft stub. troubleshooting chart, b 4.2. – Reassemble all other parts in the reverse sequence. MS 441, MS 441 C...
  • Page 25 : Turn brake band (1) slightly aside Machines with QuickStop Super and disconnect it from the brake lever (arrow). : Attach brake band (1) to brake lever (arrow) sideways and turn it towards its mount. MS 441, MS 441 C...

  • Page 26: Brake Lever

    : Then guide brake band (1) over studs (arrows) and press it into the mount. : Press brake band (1) into guide : Take out screw (arrow). (arrow) and at the same time guide it over the studs (2). MS 441, MS 441 C...
  • Page 27 : Pull brake lever (2) out of hand : Slide hand guard with brake lever guard (1). across the machine until it rests against the pivot pin. – Examine brake lever and hand guard; fit new parts if necessary. MS 441, MS 441 C...

  • Page 28: Quickstop Super Brake Lever

    : Ease brake spring (1) off anchor The pin for the brake spring must be pin (arrow). replaced if it shows signs of wear at the groove, b 7.5. : Unhook brake spring (1) from brake lever. MS 441, MS 441 C...
  • Page 29 : Attach brake cable (1) to hole lever (2) off the pivot pins necessary, b 7.5. (arrow) in brake lever. simultaneously. – Examine cam lever and replace if – Take out hand guard and brake necessary, b 7.4. lever. MS 441, MS 441 C...
  • Page 30 = 20 mm – Tightening torques, b 3.5. The pin for the brake spring must be – Grease brake lever, b 17. replaced if it shows signs of wear at the groove, b 7.5. MS 441, MS 441 C...

  • Page 31: Adjusting Brake Cable

    : Press trigger interlock (2) down completely and hold it. : Take out screws (arrows). : The brake band (1) must rest : Undo clamping screw (arrow). against the crankcase (arrows) – Remove cover (1). without play. MS 441, MS 441 C...

  • Page 32: Brake Cable, Removal 10. And Installation

    : Pull brake cable (1) out slightly – Examine throttle cable (1), and disconnect it. brake cable (2) and throttle cable retainer (3) and replace any damaged parts. MS 441, MS 441 C...
  • Page 33 (2) down as far housing (arrow). (arrow) as far as possible. as possible. – Install throttle trigger and handle moulding, b 12.3. MS 441, MS 441 C...

  • Page 34: Cam Lever

    : Slide cam lever onto pivot pin (2). b 14.6.2. – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5. : Take out circlip (arrow). : Fit circlip (1). – Remove cam lever (1) from pivot pin. MS 441, MS 441 C...

  • Page 35: Pins

    : Pull out pins (arrows) with the aid : Drive home pins (3+4+6). of suitable tools. – Wet the knurled area of the new : Drive in pins (1+2+5) as specified pin (1) with Loctite before fitting below. the pin, b 17. MS 441, MS 441 C...

  • Page 36: Chain Tensioner

    – Remove side plate (1). : Turn spur gear (2) clockwise until : Pull out tensioner slide (1) with the tensioner slide (1) rests a suitable tool. against the right-hand side and the screw (arrow) is visible. MS 441, MS 441 C...
  • Page 37 (arrow). : Fit spur gear (2). : Push complete tensioner slide : Slide spur gear (1) fully over the with thrust piece (1) into the guide bearing journal (arrow) as far as (arrow). the stop. MS 441, MS 441 C...

  • Page 38: Bar Mounting Studs

    – Tightening torques, b 3.5. counterclockwise to remove the collar studs (arrows). – Reassemble all other parts in the reverse sequence. : Prise out plugs (arrows). : Unscrew nuts (arrows). MS 441, MS 441 C...
  • Page 39 – Move the machine into a vertical when installing the insulating position. mat (1): a = 11 mm : Examine and clean the sealing b = 9 mm faces (arrows), and remove any gasket residues. MS 441, MS 441 C...

  • Page 40: Leakage Testing

    : Screw on the nuts (arrows) and tighten them securely. – Press home plugs. – Tightening torques, b 3.5. – Carefully slide muffler (1) into position. : Slide the holes (arrows) into the stud bolts to secure the muffler in place. MS 441, MS 441 C...

  • Page 41: Preparations

    : Ensure that the sleeves (1) and – Push 35 mm long sleeves (1) washer (2) are present. onto the upper stud bolts. : Unscrew nuts (arrows). : Screw on nuts (arrows) and tighten them securely. MS 441, MS 441 C...

  • Page 42: Vacuum Test

    : Connect suction hose (1) of pump 0000 850 1300 to the nipple (arrow). : Slide ring (1) to the left. : Actuate lever (2) until the pressure gauge (arrow) indicates a vacuum of 0.5 bar. MS 441, MS 441 C...

  • Page 43: Oil Seals

    – Tightening torques, b 3.5. – Clean the sealing area with a little commercially available solvent- based degreasant not containing any chlorinated or halogenated hydrocarbons. – Grease the sealing lips of the new oil seal, b 17. MS 441, MS 441 C...
  • Page 44 – Slide oil seal over assembly reverse sequence. sleeve with the open side facing the crankcase. – Remove assembly sleeve (1). – Drive oil seal out of its seat with a light tap with a suitable tube or punch. MS 441, MS 441 C...

  • Page 45: Shroud, Removal And Installation

    (2) in the housing. : Pull boot off spark plug (1). : Examine slotted nut (1), insulating element (2) and rubber – Use STIHL Press Fluid for easier grommet (3), replace if insertion, b 17. necessary. : Unscrew slotted nut (arrow).

  • Page 46: Cylinder

    – Remove front handle, b 11.5 – Screw slotted nut on as far as Machines with handle heating, possible. b 11.5.1. – Reassemble all other parts in the reverse sequence. : Take out socket head screws (arrows). MS 441, MS 441 C...
  • Page 47 : Examine and clean the sealing – Wet piston, piston rings and face (arrow). face (arrow) and remove any inside of cylinder with oil, b 17. gasket residues. – Examine sealing faces on cylinder inlet and exhaust. MS 441, MS 441 C...
  • Page 48 – Push cylinder home as far as possible. : Fit screws (arrows) and secure cylinder with gasket. MS 441, MS 441 C...

  • Page 49: Crankshaft

    : Remove circlip (arrow). – Unscrew spindle (1) until it no – Unscrew spindle of assembly longer rests on the crankshaft tool (1) 5910 007 2220 until the stub. flange rests against the housing half – left-hand thread. MS 441, MS 441 C...

  • Page 50: Installation

    – Heat inner race of ball bearing to approx. 150 °C (300 °F). : Press crankshaft fully home on the crankshaft stub. The crankshaft must be fitted quickly, as the heat is transferred to the stub and the inner race contracts again. MS 441, MS 441 C...
  • Page 51 : Fit two screws (arrows) M5x72 on tapered stub (arrow) faces the the ignition side in the holes with ball bearing on the ignition side guide sleeves – for guidance and and push it home. to prevent twisting. MS 441, MS 441 C...
  • Page 52 (left-hand thread). : Ensure that the sleeves (arrows) : Turn spindle counterclockwise enter the holes and that the until the crankcase half rests housing gasket is not jammed or against the guide sleeves. buckled. MS 441, MS 441 C...

  • Page 53: Ball Bearing / Crankcase

    – Refer also to the troubleshooting chart, b 4.7. – Remove crankshaft, b 8.6.1. – Wear protective gloves to prevent injury due to burns. : Fit screws (arrows) and tighten them down working cross-wise. – Tightening torques, b 3.5. MS 441, MS 441 C...
  • Page 54 150 °C (300 °F). The bearing (1) drops out of its own The bearing (1) drops out of its own accord when the required accord when the required temperature is reached. temperature is reached. MS 441, MS 441 C...

  • Page 55: Piston

    – Reassemble all other parts in the : Apply assembly drift (1) reverse sequence. 1111 893 4700. : Remove piston (1) from con-rod. – Tightening torques, b 3.5. – Examine piston rings, replace if necessary, b 8.8. MS 441, MS 441 C...

  • Page 56: Installation

    : Remove sleeve and fit it over the magnet (2) and align it so that the opposite shaft end of the gap in the ring is on the flat side assembly tool, with the internal (arrow). pin pointing towards the flat surface. MS 441, MS 441 C...

  • Page 57: Piston Rings

    : Fit the new piston rings so that that the gap in the ring (arrow) the ground radii (arrows) at the points upwards or downwards in ring gap face upwards. axial direction of the piston. MS 441, MS 441 C...

  • Page 58: Decompression Valve

    – Fit decompression valve and screw in by hand. – Tighten down decompression valve. – Tightening torques, b 3.5. – Reassemble all other parts in the reverse sequence. MS 441, MS 441 C...

  • Page 59: Ignition Module

    : Take out screws (arrows). Since there is no mechanical wear cover (1). in these systems, the ignition timing cannot become maladjusted during operation. : Pull boot off spark plug (1). : Remove ignition module (1). MS 441, MS 441 C...
  • Page 60 : Before installing the ignition : Slide setting gauge (1) module in machines with handle 1111 890 6400 between arms of heating, ensure that the ignition module and flywheel generator lead (arrows) has been magnet. fitted correctly, b 15.7. MS 441, MS 441 C...

  • Page 61: Ignition Timing

    (1). Push the tester's output terminal (3) onto the spark plug. Beware of electric shocks due to the high voltage. : Crank engine quickly with rewind starter and check the spark in the tester's window (2). MS 441, MS 441 C...

  • Page 62: Spark Plug Boot / Ignition Lead

    (2). : Attach ground terminal (1) to the spark plug. : Use adjusting knob (4) to set the spark gap to approx. 2 mm, see window (3). : Peel cover off spark plug boot. MS 441, MS 441 C...
  • Page 63 : Pinch the hook of the leg spring : Make sure that the leg spring is into the centre of the lead (arrow). properly located in the spark plug boot (arrow). – Slide cover back over spark plug boot. MS 441, MS 441 C...

  • Page 64: Flywheel

    1135 890 4500 from the flywheel. Degrease crankshaft stub and bore in flywheel hub with a little commercially available solvent- based degreasant not containing any chlorinated or halogenated hydrocarbons. : Unscrew collar nut (arrow). – Reassemble in the reverse sequence. MS 441, MS 441 C...

  • Page 65: Short Circuit Wire

    (arrows). short circuit wire, b 9.6.2. Test ignition system in accordance with flow chart if no fault is found, b 9.8. – Reassemble in the reverse sequence. : Ease out the grommet (1). MS 441, MS 441 C...
  • Page 66 15.8. – Take short circuit wire out of the – Fit the short circuit wire in the guides (arrows). guides, starting at the ignition module. : Press short circuit wire (1) in guides (arrows). MS 441, MS 441 C...

  • Page 67: Ground Wire

    – Reassemble in the reverse sequence. – Tightening torques, b 3.5. : Take out screw (arrow). : Disconnect ground wire (1) from contact spring (2) and terminal – Remove and examine ground socket (3). wire (1), replace if necessary. MS 441, MS 441 C...

  • Page 68: Pre-Separator

    – Tightening torques, b 3.5. – Support eyelet at supporting : Pull out duct base (1). rib (1). – Examine pre-separator (2) and : Insert screw (2) and tighten it duct base (1) and replace if down. necessary. MS 441, MS 441 C...
  • Page 69 : Hook pre-separator (1) into the carburetor housing (arrows) and fit it in position. – Insert screws and tighten them down. – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5. MS 441, MS 441 C...

  • Page 70: Troubleshooting Chart, Ignition System

    – Spark plug boot damaged? – Replace spark plug boot and/or leg spring if necessary, b 9.4 Test ignition system: with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap, see TI 32.94), b 9.3 MS 441, MS 441 C...
  • Page 71 – Resistance of spark plug boot to ground: required 1,5...12 kohm – Measure resistance of ignition lead, required value < 10 ohm, – Replace spark plug boot and/or ignition lead with ignition module if necessary, b 9.4 MS 441, MS 441 C...
  • Page 72 9.1.1 Engine runs Engine runs faultlessly, – Look for fault in fuel system procedure is complete or carburetor – Check engine for leaks – Check position of flywheel on crankshaft, b 8.2, b 9.1 MS 441, MS 441 C...

  • Page 73: Rewind Starter

    Carefully pull out the starter rope several times and let it rewind until its normal smooth action is restored. Before installing, lubricate the rewind spring and post with STIHL special lubricant. If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed and disassembled.

  • Page 74: Pawls

    – Remove spring and pawls, b 10.3. – Press new pawls into holes – Take out washer (1). (arrows) and grease the pegs (1), b 17. The rewind spring must be relieved. MS 441, MS 441 C...

  • Page 75: Starter Rope / Grip

    – Install starter rope, b 10.5. – Tension rewind spring, b 10.6. – Grease pawl pegs, b 17. : Prise off the nipple (1) with : Press nipple (1) firmly into starter a suitable tool. grip until it engages. MS 441, MS 441 C...

  • Page 76: Tensioning The Rewind Spring

    – Hold rope rotor (2) securely. – Install fan housing, : Pull out the rope (1) with the b 10.2. starter grip and straighten it out. – Tightening torques, b 3.5. MS 441, MS 441 C...

  • Page 77: Rewind Spring

    – Remove frame. – Lubricate rewind spring with a few drops of STIHL special The rewind spring may pop out. lubricant before installing it, b 17. – Arrange spring (1) in its original position as illustrated.

  • Page 78: Starter Rope Guide Bushing

    (3) steady until the bushing is tight. The assembly tool flares the lower end of the rope bushing. – Remove assembly tool. – Reassemble all other parts in the reverse sequence. MS 441, MS 441 C...

  • Page 79: Anti-Vibration System, Repair

    : Insert annular buffer (1) between tank housing and crankcase. : Push annular buffer (1) off peg on – Use STIHL Press Fluid for easier tank housing. insertion, b 17. : Push peg (arrow) of tank housing as far as possible into annular buffer (1).

  • Page 80: Anti-Vibration Spring

    – Fit screws. – Ensure that bearing points are correctly seated during installation. – Tighten screws. – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5. : Prise off anti-vibration spring (1). MS 441, MS 441 C...

  • Page 81: Anti-Vibration Spring, Oil Tank

    (arrows). : Position anti-vibration spring (1) – Position stop buffer (1) with so that the form of the bearing the tapered side facing the plug (2) engages the mount in the crankcase. crankcase (arrow). MS 441, MS 441 C...

  • Page 82: Front Handle

    11.5 Front handle – Use STIHL Press Fluid for easier – Remove chain sprocket cover, insertion, b 17. bar and chain, b 5. : Press stop buffer (1) home until – Remove shroud, b 8.4. the groove (arrow) completely encloses the ridge (2) and the –...
  • Page 83 Tightening torques, b 3.5. : First lift stop (1) out of bottom : First push stop (1) into the upper mount (arrow) and then pull it up ridge (arrow), then press it into and off. the lower mount. MS 441, MS 441 C...

  • Page 84: Front Handle With Handle Heating

    – Slide insulating tubes (1) towards – Securely reconnect plugs and the front handle. terminal sockets (arrows). : Disconnect plug connections : Slide insulating tubes (1) back (arrows). over the plug connections. MS 441, MS 441 C...

  • Page 85: Actuating Levers

    : Examine switch shaft (1) and reverse sequence. replace if necessary. – Tightening torques, b 3.5. – Install short circuit wire (arrow), b 9.6.2. : Align switch shaft: the stop (1) must point towards the carburetor. MS 441, MS 441 C...

  • Page 86: Throttle Trigger / Throttle Trigger Interlock

    – Check correct operation. – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5. : Remove throttle trigger : Disconnect throttle cable (1). interlock (1). – Remove throttle trigger and lever. MS 441, MS 441 C...
  • Page 87 Machines with handle heating : When installing the trigger trigger (2), noting the installed interlock, ensure that the stop (1) position (arrow). Ensure that the wiring is located in engages the guide (arrow). the guides (arrows). MS 441, MS 441 C...

  • Page 88: Throttle Trigger / Throttle Trigger Interlock / Quickstop Super

    The drag lever is located in the : Pull out the lever (1). throttle trigger and must therefore also be removed. – Unhook leg spring (2) from throttle trigger. : Drive pins (arrows) out with a punch. MS 441, MS 441 C...
  • Page 89 – Drive in the pin until it is equidistant on both sides. – Check correct operation. – Grease roller (arrow) before installing it, b 17. : Push lever (1) into place. – Turn throttle trigger with lever over. MS 441, MS 441 C...

  • Page 90: Switch Lever

    – Tightening torques, b 3.5. : Disconnect brake cable (2). : Take out switch lever (1). – Examine switch lever (1), replace if necessary. : Hook brake cable (1) into hole (arrow) in switch lever. – Align switch lever. MS 441, MS 441 C...

  • Page 91: Throttle Trigger Interlock

    : Remove trigger interlock (1). : Align leg spring (1) and insert in trigger interlock. : Slide bushing (2) into hole (arrow) to secure leg spring in place. : Drive out bushing (1). – Remove leg spring. MS 441, MS 441 C...

  • Page 92: Chain Lubrication

    : Pull pick-up body (1) out of oil : Slide oil suction hose (1) through tank with assembly hook (2) opening in housing (arrow) with 5910 893 8800. the pick-up body first. Take care not to overstretch the suction hose. MS 441, MS 441 C...

  • Page 93: Oil Pump

    : Remove washer (1). : Pull worm (1) with spring (arrow) out of oil pump. : Push out detent between : Examine spring (1) and worm (2), crankcase and tank housing replace if necessary. (arrow). MS 441, MS 441 C...

  • Page 94: Repair

    – Check setting of oil pump, adjust – Check setting of oil pump, adjust if necessary, b 13.3.2. if necessary, b 13.3.2. : Slide connector of oil pump (1) into hole (arrow). – Fit and tighten screws. MS 441, MS 441 C...

  • Page 95: Adjustment

    : Drive new valve into hole delivery rate can be identified via tank. a = approx. 2 – 3 mm. the groove (1) or all-round groove (arrow) in the pump piston. – Reassemble all other parts in the reverse sequence. MS 441, MS 441 C...

  • Page 96: Oil Tank Cap

    O-ring, replace if necessary. : Remove carburetor box : Press nipple into mount (arrow) cover (1). inside tank. – Close oil tank cap. – Perform leakage test. : Unscrew twist lock (1). – Remove air filter. MS 441, MS 441 C...

  • Page 97: Baffle

    – Reassemble in the reverse – Examine baffle, replace if sequence. necessary. – Reassemble in the reverse sequence. – Tightening torques, b 3.5. – Test air filter, b 14.1. : Take out nuts (arrows). – Remove filter base (1). MS 441, MS 441 C...
  • Page 98 – Examine buffer (2) and filter – Coat bushing (2) with STIHL Machines with handle heating base (1), replace if necessary. Press Fluid before installing the filter base, b 17. : Attach lead (1) to mount (2) and press it into the cable guides : Push filter base (1) fully home in (arrows).

  • Page 99: Spacer Flange

    (arrow) until it encloses the hole : Take out screws (arrows). completely. – Turn switch shaft to position "#"1 – Use STIHL Press Fluid for easier and remove spacer flange (1). insertion, b 17. – Examine spacer flange, replace if : Press tab (arrow) downwards.

  • Page 100: Carburetor Removal

    – Tightening torques, b 3.5. – Check correct operation. Machines with handle heating – Refit carburetor. : Unplug connector (arrow) from : Lever (1) must engage lever (2) terminal socket. in the carburetor. MS 441, MS 441 C...

  • Page 101: Leakage Testing

    – Reassemble all other parts in the reverse sequence. : Push fuel line with nipple onto : In idle position, the air flap fuel connection (arrow). (arrow) must make contact with the housing all round and seal the air duct. MS 441, MS 441 C...

  • Page 102: Metering Diaphragm

    : Remove switch (1). position. – Reassemble in the reverse sequence. : Remove cover (1). If gasket and diaphragm stick to carburetor parts, they must be detached with great care. MS 441, MS 441 C...

  • Page 103: Inlet Needle

    : Position cover (1) so that the : Pull out inlet needle (1). connector (arrow) faces towards the choke shutter and is secured – Remove and examine spring (2), by the pegs. replace if necessary. MS 441, MS 441 C...

  • Page 104: Fixed Jet

    : Fit helical spring (2) in bore. : First position inlet control lever (3) with spindle (2) on the seat (arrow) of the spring, then push the clevis of the inlet control lever into the groove in the inlet needle (1). MS 441, MS 441 C...

  • Page 105: Pump Diaphragm

    : Fit end cover so that the lug pump diaphragm from the end out of the carburetor housing and (arrow) points towards the cover. clean it, replace if necessary. adjusting screws. – Reassemble in the reverse sequence. MS 441, MS 441 C...

  • Page 106: Choke Shaft / Choke Shutter

    : Fit and tighten screw. – Turn choke shaft until choke : Push choke shaft (1) towards shutter is closed. connector. : Take out screw (arrow) in choke – Remove lock washer (arrow). shutter. MS 441, MS 441 C...
  • Page 107 : Attach leg spring (1) to hole – Turn choke shaft until flat side (arrow). appears. : Slide choke shaft (2) through the : Fit choke shutter (1). leg spring into the carburetor. MS 441, MS 441 C...

  • Page 108: Throttle Shaft

    – Turn throttle shaft slightly. : Pull throttle shaft (1) out towards adjusting screws, detaching and : Pull out throttle shutter (1). relaxing the leg spring (arrow) at the same time. – Clean throttle shaft and guides. MS 441, MS 441 C...
  • Page 109 : Slide throttle shutter (1) into the slit in the throttle shaft with the recess (arrow) at the front and the hole (2) on the left. : Slide throttle cable retainer (1) onto the throttle shaft with the shoulder (arrow) first. MS 441, MS 441 C...

  • Page 110: Accelerator Pump

    – Press a new sealing plug in until flush with the hollow facing outwards. – Reassemble all other parts in the reverse sequence. Low speed screw : Screw puller (1) 5910 890 4500 onto limiter cap – left-hand thread. MS 441, MS 441 C...
  • Page 111 : Turn limiter cap until lug (2) is damage or wear, replace low lined up with groove (1). speed screw L if necessary. The dot on the limiter cap must be lined up with the mark (arrow). MS 441, MS 441 C...

  • Page 112: Carburetor Adjustment

    5910 890 2304 to assist in making 4. Set engine speed to 2,800 rpm the setting. with the low speed screw L. 5. Set maximum engine speed of 13,500 rpm with high speed screw H. MS 441, MS 441 C...

  • Page 113: Standard Setting

    – Switch off engine. – Carefully turn high speed screw H counterclockwise up to the stop, max. 3/4 turn. – Carefully turn low speed screw L clockwise up to the stop, then back off 1/4 turn. MS 441, MS 441 C...

  • Page 114: Throttle Cable

    (2) and guide wire through slot (arrow). : Pull throttle cable (1) out of : Push throttle cable grommet (1) carburetor housing. into guide (arrow) of throttle cable retainer (2). – Examine throttle cable and replace if necessary. MS 441, MS 441 C...

  • Page 115: Carburetor Support

    – Tightening torques, b 3.5. : Press rubber lips (arrows) of : Pull off preheating plate (1). intake elbow out through the openings in the carburetor – Remove contact spring b 9.6.2. support (1) towards the cylinder. MS 441, MS 441 C...
  • Page 116 – Examine fuel hose, replace if necessary, b 14.8.2. – Examine throttle cable, replace if necessary, b 14.6. – Examine intake elbow, replace if necessary, b 14.6.3. : Fit air guide inlet (1) until it engages the heel (arrow). MS 441, MS 441 C...

  • Page 117: Carburetor Housing

    9.6.2. – Remove carburetor support, b 14.6.1. – Remove intake elbow, b 14.6.3. – Use STIHL Press Fluid for easier – Guide throttle cable between fuel insertion, b 17. hose and impulse hose. – Remove anti-vibration spring on front handle, b 11.2.
  • Page 118 – Remove grommet / ignition cable retainer, b 8.4. : Take out screws (arrows). – Ease out grommet (1) and examine it, replace if necessary. – Disconnect ground wire. – Use STIHL Press Fluid for easier insertion, b 17. MS 441, MS 441 C...
  • Page 119 : Push fuel hose (2) onto elbow connector (arrow). connector (3). – Install ground wire, b 9.6.3. : Push throttle cable (4) through grommet (arrow). – Install wiring harness in machines with handle heating, b 15.8.2. MS 441, MS 441 C...

  • Page 120: Intake Elbow, Removal And Installation

    (arrow) until rubber lip encloses opening completely. – Remove carburetor housing, b 14.6.2. – Wet with STIHL Press Fluid, b 17. – Install carburetor housing, b 14.6.2. : Take out screws (arrows). : Pull impulse hose (1) off connector (arrow).

  • Page 121: Tank Vent

    A vacuum must not build up in the tank. – Clean area around the tank vent. – Replace tank or tank vent if necessary, b 14.7 or b 14.8.4. : Pull out elbow connector (1). MS 441, MS 441 C...

  • Page 122: Removal And 17. Installation

    – Press new tank vent as far as possible into opening. – Reassemble all other parts in the reverse sequence. : Pull pick-up body (1) out of the fuel tank with assembly hook 5910 893 8800. Do not over-extend the fuel hose. MS 441, MS 441 C...

  • Page 123: Fuel Hoses

    – Install pick-up body, b 14.8.1. : Ease out fuel hose (1). : Fit flange (1) and press it into the fixture (arrow) on the housing – Pull fuel hose out from inside until it rests against the housing. tank. MS 441, MS 441 C...

  • Page 124: Fuel Filler Cap

    – Open filler cap. opening (arrow). – Guide fuel hose (1) under brake : Prise out nipple inside tank – Use STIHL Press Fluid for easier cable (2) and push it onto the (arrow). insertion, b 17. elbow connector (arrow).

  • Page 125: Tank Housing, Removal And Installation

    (arrow). – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5. : First move front part of tank housing (1) down and out of the crankcase. MS 441, MS 441 C...
  • Page 126 If the reading obtained is outside this tolerance, each component must be tested separately. – Push insulating tube towards the heating element and unplug the connectors. : Remove heating element (1). MS 441, MS 441 C...
  • Page 127 (arrows). Thermostatic switch Ensure that wires are not crossed. – Install filter base, b 14.1.2. : Slide heating element (1) onto : Pull connector (arrow) off the carburetor. terminal socket. – Remove carburetor, b 14.3. MS 441, MS 441 C...
  • Page 128 – Wiring must rest in the retaining lug (strain relief). – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5. – Check correct operation. – Fit new thermostatic switch (1). : Fit and tighten screws (arrows). MS 441, MS 441 C...

  • Page 129: Troubleshooting Chart, Carburetor Heating Element

    Resistance Replace heating approx. 8 ohm? element, b 15.1 Replace thermostatic switch, b 15.1 Carburetor heating element OK Circuit diagram G = Generator 1 = Front handle 2 = Rear handle 3 = Heating switch MS 441, MS 441 C...

  • Page 130: Handle Heating Systems

    (1) from the heating element. towards wiring harness. – Install handle moulding, b 12.2. : Disconnect plug connection. Machines with carburetor heating : Disconnect lead from heating element (arrow). MS 441, MS 441 C...

  • Page 131: Heating Switch, Removal And Installation

    – Reassemble all other parts in the : Unscrew nut (arrow) of heating : Position heating switch so that reverse sequence. switch. the groove (arrow) is lined up with the mark (1) on the carburetor – Tightening torques, b 3.5. housing. MS 441, MS 441 C...

  • Page 132: Heating Element In Handle, Removal And Installation

    – Test generator and heating – Test generator and heating switch, b 15.3. switch, b 15.3. : Take out screws (arrows). – Reassemble in the reverse – Reassemble in the reverse – Remove generator (1). sequence. sequence. MS 441, MS 441 C...
  • Page 133 : Fit generator (1) with connecting : Lead wiring harness (1) through lead (arrow) facing the housing. under plug connection (arrow). – Fit and tighten screws. – Reassemble all other parts in the reverse sequence. MS 441, MS 441 C...

  • Page 134: Troubleshooting Chart, Handle Heating Systems And Generator

    Does it make complete contact? Replace rear handle heating element, b 15.5 Resistance of rear handle heating element about 1.6 ohm? Check generator: resistance between engine ground Replace and generator connection generator, about 0.5 – 1 ohm? b 15.7 MS 441, MS 441 C...
  • Page 135 (contact sleeve against switch housing): heating switch, about 0 ohm when closed? b 15.4 Circuit interrupted when open, b 15.4 (Reconnect plug connection to heating element on machines with carburetor heating), b 15.1 System OK MS 441, MS 441 C...

  • Page 136: Summary Of Test Connections And Test Values

    – Break in wire, heating Replace front element damaged handle Short circuit due to Repair insulation damaged insulation Pull wire out for this purpose MS 441, MS 441 C...
  • Page 137 Short circuit due to Repair insulation damaged insulation Circuit diagram G = Generator 1 = Front handle 2 = Rear handle 3 = Heating switch 4 = Heating element (carburetor) 5 = Thermostatic switch MS 441, MS 441 C...

  • Page 138: Wiring Harness

    : Prise out grommet (1) and pull it generator lead and disconnect carburetor heating element and off the wiring harness. plug connection. disconnect plug connection. – Examine grommet, replace if – Pull wiring harness out through necessary. opening at the side (arrow). MS 441, MS 441 C...

  • Page 139: Installation

    12.2 or b 12.3. – Remove throttle cable retainer, b 7.3.2. : Press wiring harness (1) and wiring (2) into the guides (arrows). – Install throttle trigger and trigger interlock, b 12.2. MS 441, MS 441 C...
  • Page 140 : Route wiring harness (1) through : Guide wiring harness (1) through harness until it rests against the the opening (arrow) and under the plug connection shrink hosing, then press it into grommet (2). (arrow). the opening (arrow). MS 441, MS 441 C...
  • Page 141 – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5. – Push connector and socket terminal (arrow) together as far as possible. : Slide insulating tube (1) over the plug connection. MS 441, MS 441 C...

  • Page 142: Special Tools

    Puller 1135 890 4500 Removal of flywheel Assembly tool set AS 5910 007 2205 Removal and installation of crankshaft (clutch side) Assembly tool set ZS 5910 007 2220 Removal and installation of crankshaft (starter side) MS 441, MS 441 C...
  • Page 143 5910 893 2420 Pulling in crankshaft Socket, 13 mm, long 5910 893 2804 Removal and installation of decompression valve Assembly hook 5910 893 8800 Pulling out pick-up body Remark: 1) Only to be used for releasing. MS 441, MS 441 C...

  • Page 144: Servicing Accessories

    (Loctite 270) Thread-locking adhesive, high 0786 111 2117 strength (Loctite 648) Commercially available solvent- Cleaning sealing surfaces and carburetor, based degreasant not containing cleaning crankshaft stub and cone in flywheel any chlorinated or halogenated hydrocarbons MS 441, MS 441 C...
  • Page 145 MS 441, MS 441 C...
  • Page 146 englisch / english 0455 219 0123. M7. G6. Fi. Printed in Germany...

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