Stihl 4141 Series Manual
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Stihl 4141 Series Manual

Stihl 4141 Series Manual

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Summary of Contents for Stihl 4141 Series

  • Page 2: Table Of Contents

    5.8.2 Replacing the Main Bearings 5.8.3 Installing the Servicing Aids Crankshaft Special Accessories 41 Ignition System Spark Plug Boot Ignition Module 6.2.1 Ignition Timing 6.2.2 Removing and Installing Flywheel © 2000 Andreas Stihl AG & Co., Waiblingen Series 4141 Powerhead...

  • Page 3: Introduction

    Always use original STIHL ROM are always more up to date In the illustrations: replacement parts. than printed lists. They can be identified by the STIHL Pointer part number, the logo A fault on the machine may have and the STIHL parts symbol several causes.

  • 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 owner’s manual. Gasoline is an extremely flammable fuel and can be explosive in certain conditions.

  • Page 5: Specifications

    Specifications Engine STIHL single cylinder two-stroke engine Displacement: 25.4 cm (1.55 cu.in) Bore: 34 mm (1.34 in) Stroke: 28 mm (1.10 in) Engine power to ISO 8893: at 9,250 rpm 0.9 kW (1.2 bhp) Max. permissible engine speed without cutting tool - without cut-off 12,900 ±...

  • Page 6: Tightening Torques

    Tightening Torques DG and P (Plastoform) screws 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 impairing the strength of the screwed assembly, providing the specified tightening torque is observed.
  • Page 7 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. – 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 and weaken the assembly.

  • Page 8: Cutch

    Cutch Removing Troubleshooting chart - see Note: "Standard Repairs, Trouble- Do not disconnect clutch spring. shooting" handbook. – Remove shroud - see 5.1. – Remove throttle and plug connectors from the control 100% handle - see 8.2. Important: If there are signs of serious wear on the inside diameter, check the remaining wall thickness.

  • Page 9: Installing

    Installing Replacing the Clutch Drum  Insert screws in crankcase and – Fit spacer washers. – Remove clutch drum with tighten down to 6 Nm (4.4 lbf.ft). housing - see 4.1. Note:  Release and remove screws. Note installed position of clutch. –...

  • Page 10: Replacing Bearings

    4.3.1 Replacing Bearings  Use press sleeve (1)  Use circlip pliers to remove circlip  Use press arbor (1) 1127 851 8300 to remove clutch from clutch housing. 4116 893 7205 to install the new drum. bearing. – Secure bearing in position with circlip.

  • Page 11: Clutch Spring

    Clutch Spring Engine Removing Shroud Important: Check installed position of spring. The arrows on the clutch shoes face upwards. Install the clutch shoes and clutch housing - see 4.2.  Remove screws (1 and 2) from – Remove shroud - see 5.1. rewind starter.

  • Page 12: Exhaust Muffler/Spark

    Exhaust Muffler/ Spark Arresting Screen – Remove wiring from the guide in Troubleshooting chart - see the shroud. "Standard Repairs, Trouble- shooting" handbook. Install in the reverse sequence. Warning! To reduce the risk of burn injury, do not touch hot parts of exhaust system.

  • Page 13: Leakage Test

    Leakage Test 5.3.1 Pressure Test Defective oil seals and gaskets or cracks in castings are the usual causes of leaks. Such faults allow supplementary air to enter the engine and thus upset the fuel-air mixture. This makes adjustment of the prescribed engine idle speed difficult, if not impossible.

  • Page 14: Vacuum Test

    5.3.2 Vacuum Test Oil seals tend to fail when subjected Note: If a leak is still indicated, check for to a vacuum, i.e. the sealing lip lifts If the vacuum reading remains damage in the area of the cylinder/ away from the crankshaft during the constant, or rises to no more than oil seals.

  • Page 15: Replacing The Oil Seals

    Replacing the Oil Seals  Use clutch screws to secure Note: Installing oil seal at flywheel side It is not necessary to disassemble puller (1) 4112 890 4502 to the complete engine to replace the flywheel. – Inspect crankshaft running face oil seals.
  • Page 16 – Fit the shroud - see 5.1. Starter side – Remove shroud - see 5.1. – Remove the rewind starter - see 7.2.  Apply puller (1) 5910 890 4400 Important: with jaws 6 (2) and tension the Note installed position: Closed side puller arms.

  • Page 17: Replacing/Sealing Components Of Mixture

    Replacing/Sealing Components of Mixture Supply System Always check and repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine. Troubleshooting chart - see "Standard Repairs, Trouble- shooting" handbook. – Remove shroud - see 5.1. –...

  • Page 18: Supply System

    Cylinder and Piston 5.6.1 Removing  If a new cylinder has to be Installing Components Always check and repair the fuel of Mixture Supply System system, carburetor, air filter and installed, always fit the matching ignition system before looking for piston.

  • Page 19: Installing

    5.6.2 Installing – Inspect piston rings and ring grooves - see 5.7.  Use the assembly drift (2) – Clean the gasket seating surface 1108 893 4700 to push the piston on the crankcase so that it looks pin (1) out of the piston. bright.
  • Page 20  Use the assembly drift (2) 1108 893 4700 to center the small end and piston. Then push the piston pin (1) into position by hand (the pin slides home easily if the piston is hot). – Fit the snap rings on the right and left so that the ring gaps face either up or down on the piston’s vertical axis.

  • Page 21: Piston Rings

    Piston Rings Crankcase 5.8.1 Removing the Crankshaft – Remove the piston - see 5.6.1. – Remove the shroud - see 5.1. Note: – Remove the air filter - see 9.1. To avoid carbon residue falling into the crankcase, always remove the –...

  • Page 22: Crankshaft

    5.8.2 Replacing the Main Bearings  Use clutch screws to secure  The crankshaft (1), connecting Replacing main bearing at puller (1) 4112 890 4502 to rod (2) and needle bearing are an flywheel side flywheel. Tighten down center inseparable assembly. It must  Carefully pry the oil seal (1) out of screw to remove the flywheel.
  • Page 23 Note: This operation must be carried out very quickly because the bearing absorbs heat and begins to expand. If it is not possible to heat the crankcase, use press arbor (1) 4116 893 7205 to install the bearing. – Fit the oil seal after installing the crankshaft - see 5.4.

  • Page 24: Installing The

    5.8.3 Installing the Crankshaft Each half of the crankcase may be – Fit the fuel tank - see 9.8.1. replaced separately in the case of damage. – Install the piston - see 5.6.2. Ball bearings are factory-installed in Note: replacement crankcases. Cylinder is installed later.

  • Page 25: Ignition System

    Ignition System Spark Plug Boot – Set air gap between flywheel and Exercise extreme caution when ignition module - see 6.2.2. carrying out maintenance and repair work on the ignition system. – Connect the fuel hoses. The high voltages which occur can cause serious or even fatal –...

  • Page 26: Ignition Module

    Ignition Module 6.2.1 Ignition Timing Ignition timing is not adjustable. Since there is no mechanical wear in these systems, ignition timing cannot get out of adjustment. However, 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.

  • Page 27: Removing And Installing

    6.2.2 Removing and Installing Flywheel Removing the ignition module Note: Flywheel magnets must face – Remove the shroud - see 5.1. away from the ignition module. – Remove the shroud - see 5.1. – Remove complete clutch - see  Place the module (2) with spacer 4.1.

  • Page 28: Rewind Starter

    Wash all parts in paraffin/kerosine or white spirit. Lubricate the rewind spring and starter post with STIHL special lubricant - see 11, before installing. Note: The flywheel (1) and magnet poles (2) must not be cracked or damaged in any way.

  • Page 29: Removing And Installing The Rewind Starter

    Removing and Installing Starter Cup Rewind Spring the Rewind Starter 7.4.1 Replacing Troubleshooting chart - see "Standard Repairs, Trouble- shooting" handbook. – Remove the shroud - see 5.1. – Remove the rewind starter - see 7.2. Note: The rewind spring will not be under tension if the starter rope is broken.
  • Page 30 (1) in ready for installation and is held slot (2) at the same time. together by a wire retainer. It should be lubricated with a few drops of STIHL special lubricant before installation - see 11. Series 4141 Powerhead...

  • Page 31: Tensioning

    7.4.2 Tensioning Starter Rope – Hold the starter grip firmly to keep the rope tensioned. – Let go of the rope rotor and slowly release the starter grip so the starter rope can rewind properly. Note: The rewind spring is correctly tensioned when the starter grip sits firmly in the rope guide bush without  Make a loop in the starter rope.

  • Page 32: Throttle Control

    Throttle Control Throttle Trigger/Interlock Lever  Thread other end of rope through  Take out the screw.  Take the throttle trigger (1) with the "ElastoStart" grip (1) and torsion spring (2) and throttle spring (2). Secure with a simple cable (3) off the peg.

  • Page 33: Replacing The Throttle Cable

    Replacing the Adjusting the Throttle Cable Throttle Cable  The interlock lever must be – Remove the filter cover - see 9.1. Note: behind the throttle trigger. Throttle lever (1) must butt against  Disconnect wires (1 and 2) on the stop (3) when throttle trigger is –...

  • Page 34: Fuel System

    Fuel System Air Filter Dirty and clogged air filters reduce – Wash the filter mat and prefilter in engine power, increase fuel a fresh, non-flammable cleaning consumption and make starting solution (e.g. warm soapy water) more difficult. and dry them. Note: Note: The air filter must be cleaned when...

  • Page 35: Carburetor

    Carburetor 9.2.1 Leakage Test Troubleshooting chart - see – Repeat the leakage test with the "Standard Repairs, Trouble- hose attached to the carburetor’s shooting" handbook. rear elbow connector. Important: If there is any loss of pressure, In the event of trouble with the service the carburetor.

  • Page 36: Removing And

    Removing and Installing Servicing the Carburetor the Carburetor 5 Spacer flange with inlet needle valve 6 Pump diaphragm 7 Gasket – Remove the filter cover and filter – Remove the carburetor - see 9.3. elements - see 9.1. Servicing the carburetor includes  Pull fuel hoses off carburetor the replacement of all gaskets and elbow connectors.
  • Page 37 – Remove inlet control level with spindle. – Pull out the inlet needle. Note: If there is an annular indentation on the sealing cone of the inlet needle, it will be necessary to replace the inlet needle because it will no longer seal properly.

  • Page 38: Adjusting The Carburetor

    Adjusting the Carburetor Note: The carburetor is designed to Do not drive home the jet body with provide an optimum fuel-air mixture a hammer because the support ring in all engine operating conditions. might break. Installing the jet with a punch damages the jet body.

  • Page 39: Tank Vent

    Tank Vent Pickup Body Correct operation of the carburetor The diaphragm pump draws fuel out is only possible if atmospheric of the tank and into the carburetor pressure and internal fuel tank via the fuel hose. Any impurities pressure are equal at all times. This mixed with the fuel are retained by is ensured by the tank vent.

  • Page 40: Fuel Tank/Fuel Hoses

    Fuel Tank/Fuel Hoses 9.8.2 Fuel Hoses 9.8.1 Fuel Tank Pickup body – Drain the fuel tank. – Unscrew the filler cap and remove together with retainer.  Use the assembly hook (1) – Remove the filter cover and filter  Pull fuel hoses with rubber 5910 893 2800 to pull the pickup elements - see 9.1.

  • Page 41: Special Servicing Tools

    Special Servicing Tools Part Name Part No. Application Clamp 5910 890 8800 Holder for item 2 Assembly stand 5910 890 3100 Holding powerhead Locking screw 4170 893 1200 Blocking crankshaft Sleeve 1127 851 8300 Removing clutch drum, installing main jet body Press arbor 4119 893 7200 Removing clutch drum bearing...

  • Page 42: Servicing Aids

    5910 007 1050 Electrical system Special Accessories Part Name Part No. Safety glasses STIHL gear lubricant for brushcutters - 80 g/2.8 oz tube 0781 120 1117 - 225 g/8 oz tube 0781 120 1118 Stihl-Getriebefett für Heckenscheren - 80 g/2.8 oz tube...
  • Page 43 Series 4141 Powerhead...

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