Stihl BT 45 Manual
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Stihl BT 45 Manual

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STIH)
STIHL Components 4140
BT 45
2009-07

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Summary of Contents for Stihl BT 45

  • Page 1 STIH) STIHL Components 4140 BT 45 2009-07...

  • Page 2: Table Of Contents

    Replacing the Tools Rewind Spring 6.4.1 Tensioning the Rewind Spring Service Accessories 41 Starter Rope Starter Rope Guide Bush Pawl Throttle Control Throttle Trigger Replacing the Throttle Cable Stop Switch © ANDREAS STIHL AG & Co. KG, 2009 BT 45...

  • Page 3: Introduction

    "Special Servicing Tools" of this They can be identified by the procedures for the BT 45 which is manual. Use the part numbers to STIHL part number, the STIH) logo based on the series 4140 identify the tools in the "STIHL...

  • Page 4: Safety Precautions

    Warning! Do not smoke or bring any fire, flame or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. BT 45...

  • Page 5: Specifications

    Octane rating: min. 90 RON Fuel mixture: Regular brand-name gasoline and STIHL 50:1 two-stroke engine oil or brand-name two-stroke engine oil Mix ratio: 50:1 with STIHL two-stroke engine oil Fuel mix for units with catalytic converter: Use only STIHL 50:1 two-...

  • Page 6: Tightening Torques

    IS-DG5x24 Gear housing/crankcase Screw IS-DG5x24 Gear housing/engine pan Screw IS-DG5x24 Handle housing, left/right Screw IS-DG5x16 Shroud/gearbox Manifold/carburetor/flange/screw M8x1.25L Carrier/crankshaft 12.5 17.0 M12x1.25 Friction clutch 10.5 14.0 M14x1.25 Spark plug 20.0 Remarks: 1) Install screw with medium-strength Loctite 243 BT 45...
  • Page 7 This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly. Power screwdriver settings for polymer: Plastoform screws max. 600 rpm DG screws max. 500 rpm Important: Do not mix up screws with and without binding head BT 45...

  • Page 8: Troubleshooting

    Spring hooks broken Fit new clutch springs Loud noises Clutch springs stretched or fatigued Replace all clutch springs Clutch shoe retainer (carrier) Fit new retainer (carrier) or clutch broken Clutch shoes and carrier worn Install a new clutch BT 45...
  • Page 9 Lubricating oil on rewind spring Coat rewind spring with a standard becomes viscous at very low solvent-based degreasant outside temperatures (spring (containing no chlorinated or windings stick together) halogenated hydrocarbons). Then pull rope carefully several times until normal action is restored BT 45...
  • Page 10 Main jet bores or ports blocked Clean the bores and ports Fuel pickup body dirty Install new pickup body Engine will not idle, Throttle shutter opened too wide by Reset idle speed screw correctly idle speed too high idle speed screw BT 45...
  • Page 11 Remove inlet control lever and refit of inlet control lever correctly Perforated disc on diaphragm is Fit new metering diaphragm deformed and presses constantly against inlet control lever Inlet control lever too low Fit new inlet control lever (relative to correct installed position) BT 45...

  • Page 12: Engine

    Fit new lines or position cracked without kinks Engine overheating Insufficient cylinder cooling. Thoroughly clean all cooling air Air inlets in fan housing passages and cooling fins blocked or cooling fins on cylinder very dirty see "Series 4140 Powerhead" service manual BT 45...

  • Page 13: Shroud/Housing Parts

    (arrow). Do not kink the throttle cable during this operation. – Remove the left-hand handle housing. Install in the reverse sequence. : Take out the screws (arrows). BT 45...

  • Page 14: Clutch

    80% of the original thickness, fit a Note that clutch carrier has a left- new clutch drum. hand thread. : Take the clutch shoes off the carrier and clean the individual parts - b 11 – Replace any damaged parts. BT 45...

  • Page 15: Engine

    Install in the reverse sequence. Installing Install in the reverse sequence while observing the specified tightening torques - b 3.3. : Remove the exhaust gasket (1). BT 45...

  • Page 16: Rewind Starter

    - b 11. the stub (1). Lubricate the rewind spring and – Clean the spark arresting screen starter post with STIHL special lubricant, see b 11, before or install a new stub if necessary. installing. – Clean the thread of the stub and...

  • Page 17: Starter Cup

    – Replace the broken or worn starter rope - b 6.5 Installing – Coat bore in rope rotor with STIHL special lubricant - b 11 : Fit the rotor on the starter post so that the driver (1) on the rope rotor slips behind the inner spring loop (2).

  • Page 18: Replacing The Rewind Spring

    - b 6.7 and 11 – Before installing, lubricate the new spring with a few drops of STIHL special lubricant - b 11 : Then grip the rewind spring with pointed nose pliers about 10 mm from the end of the outer loop and place it in the starter.

  • Page 19: Tensioning The Rewind Spring

    – Let go of the rope rotor and slowly release the starter grip so – Thread the other end of the rope that the rope winds itself onto the through the starter grip. Tie a rotor. simple overhand knot in the end of the rope. BT 45...

  • Page 20: Starter Rope Guide Bush

    – Use a suitable tool to pry the damaged bush out of the fan – Remove the installing tool. cover. Installing the rope bush – Place the new bush in its seat in the fan housing/starter cover. BT 45...

  • Page 21: Pawl

    (arrow) from the throttle properly if the spring clip is trigger (1). deformed. : Remove throttle trigger from the – Install the rewind starter - pivot pin on the handle housing. b 6.1 Install in the reverse sequence. BT 45...

  • Page 22: Replacing The Throttle

    (arrows) in the left-hand handle housing. Assemble all other parts in the reverse sequence. Install in the reverse sequence. : When installing, check that the throttle cable is properly seated in the retainers and guides (arrows) in the left-hand handle housing. BT 45...

  • Page 23: Fuel System

    Replace a damaged air filter immediately. Install in the reverse sequence. : Slide the choke shutter to the left until the guides (arrows) are on the necked parts of the choke shaft. : Take out the choke shutter. BT 45...

  • Page 24: Carburetor

    : Close the vent screw (1) on the 1110 141 8600 onto the rubber bulb (2) and pump air into nipple (2) 0000 855 9200. the carburetor until the pressure gauge (3) shows a reading of approx. 0.8 bar. BT 45...

  • Page 25: Removing And Installing The

    – Use a new gasket if necessary. Always use new gaskets when installing the gaskets. – Position the fuel hoses so that they are not kinked. – Observe tightening torques - b 3.3 : Disconnect fuel hoses from elbow connectors on carburetor. BT 45...

  • Page 26: Spacer Flange

    Install in the reverse sequence. Use new gaskets and observe tightening torques - b 3.3. : Take out the screws (1) and pull : Remove the flange. the spacer flange with hex head screws (2) out of the air baffle. BT 45...

  • Page 27: Metering Diaphragm

    Assemble in the reverse sequence. : Place the gasket (1) on the carburetor body. Line up the hole in the gasket (2) with the compensating bore in the carburetor. BT 45...

  • Page 28: Inlet Needle

    The spring (2) may pop out during disassembly. : If there is an annular indentation (arrow) on the sealing cone of the inlet needle, it will be necessary to replace the inlet needle because it will no longer seal properly. BT 45...

  • Page 29: Pump Diaphragm And Fuel Strainer

    : Remove the pump The pump diaphragm (1), diaphragm (1). gasket (2) are held in position by pegs (arrows) on the end cover (3). If the gasket and diaphragm are stuck to the carburetor, remove and separate them very carefully. BT 45...
  • Page 30 Then turn running behavior. the screw about another half to one full turn in the same direction. – Carry out the standard setting. – Start the engine and allow it to warm up. – Open the throttle wide. BT 45...

  • Page 31: Basic Setting

    Always install a new limiter cap. – Carry out standard setting - b 8.4.6 – Screw down both adjusting screw (H and L) clockwise until their are against their seats. Now make the following adjustments: BT 45...

  • Page 32: Replacing

    – Examine O-ring for damage and necessary. replace if necessary. – Close the tank and shake the machine vigorously. Install in the reverse sequence. Install in the reverse sequence. – Open the tank again and drain it. Dispose of fuel properly. BT 45...

  • Page 33: Hoses

    (1) (l/h front and back. of about 60° as shown. thread) from the chuck while : Loosen the screw (2) and pull off holding the shaft steady with a 13 mm open-end wrench (2). the rotary knob (3). BT 45...

  • Page 34: Diassembling And Assembling

    Install in the reverse sequence housing (1) with shafts (2+3) and : As the recesses (1) are different, components, ball bearings, the rotary knob (2) can only be gears, clutch drum (4), for signs fitted one way in the driver. of damage. BT 45...
  • Page 35 : To install the ball bearings (1) on – Inspect the clutch drum (1). It must not be scored or There the clutch drum, heat the ball should be no scores or signs of bearings and push them on as far excessive wear. as stop. BT 45...
  • Page 36 (1) (friction clutch) - b 3.3 : Use puller to remove the ball When removing the gearwheel, take bearing (1). care not to damage the web (arrow) in the gearbox housing. Support with a suitable tool if necessary. BT 45...
  • Page 37 : Place the shaft (1) in the right- the shaft is properly seated. hand gearbox housing. : Remove the screw. The ball bearings (3) on the clutch drum (2) are bonded in the right- hand gearbox housing with Loctite 648 - b 11. BT 45...
  • Page 38 : Pull the output gears (1) and (2) Disassembling and assembling the shaft (1) and washers (3) off the shaft. If the shaft (1) is stripped down, always install new ball bearings (2). BT 45...
  • Page 39 (3) and O-ring (4) out of the gearbox housing. Install in the reverse sequence : When fitting the driver, make sure : Check that output gear (1) is that its peg (arrow) points located in the shift fork (2). upwards. BT 45...
  • Page 40 – Apply a thin bead of sealant, b 11, to the mating faces of both halves of the gearbox. : Marry the two halves of the gearbox housing. : Insert the screws (1). Tighten down to the prescribed torque - b 3.3. BT 45...

  • Page 41: Special Servicing Tools

    Remarks: Always use torque wrench to tighten DG or P screws. Alternative: Torque wrench 5910 890 0302 with optical/acoustic signal. Alternative: Torque wrench 5910 890 0312 with optical/acoustic signal. Only use for releasing/removing DG or P screws. BT 45...

  • Page 42: Service Accessories

    Muffler screws, sealing faces of spur gear housing STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring STIHL gear lubricant for brushcutters - 80 g tube 0781 120 1117 Lubrication of spur gear drive - 225 g tube...
  • Page 43 englisch / english 0455 421 0123. M0. G09. xxx.

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