Stihl FS 45 Manual
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Stihl FS 45 Manual

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FS 45
CONTENTS
1.
2.
3.
3.1
Engine
3.2
3.3
3.4
3.4.1
3.4.2
3.5
4.
4.1
5.
5.1
5.2
5.3
5.3.1
5.3.2
5.3.3
Vacuum Test
5.4
5.5
5.5.1
Removal
5.5.2
Installation
5.6
5.7
6.
6.1
6.1.1
6.1.2
Removing and
Installing
6.2
6.3
Stop Switch/
Short Circuit Wire/
Ground Wire
FS 45
1
7.
7.1
2
7.2
7.2.1
7.2.2
3
7.3
3
7.4
3
4
4
8.
4
4
8.1
5
8.2
8.2.1
6
8.2.2
Cable
6
9.
8
9.1
9.2
8
9.2.1
9.2.2
9
10
9.2.3
10
9.3
11
9.4
12
9.5
12
14
14
15
10.
Shaft
16
10.1
16
10.2
10.3
18
11.
18
18
11.1
19
Tools
19
11.2
20
21
1.
SAFETY
1. SAFETY
21
22
If the brushcutter is started up
22
in thecourse of repairs or
23
maintenance work, observe all
local and country-specific safety
24
regulations as well as the safety
25
precautions and warnings in the
owner's manual.
25
Gasoline is an extremely flamm-
able fuel and can be explosive in
certain conditions.
25
26
Improper handling may result in
26
burns or other serious injuries.
27
Warning! Do not smoke or bring
any fire or flame near the fuel. All
work with fuel must be performed
27
outdoors only. Spilled fuel must be
wiped away immediately.
27
28
28
29
29
30
31
31
32
32
32
33
34
34
36
© 1998 Andreas Stihl AG & Co., Waiblingen
1

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  • Page 1: Table Of Contents

    Ignition System Special Servicing Ignition Module Tools and Aids 6.1.1 Ignition Timing 6.1.2 Removing and 11.1 Special Servicing Installing Tools Flywheel 11.2 Servicing Aids Stop Switch/ Short Circuit Wire/ Ground Wire © 1998 Andreas Stihl AG & Co., Waiblingen FS 45...

  • Page 2: Introduction

    Use the part numbers to identify There are separate handbooks The complete unit can then be the tools in the "STIHL Special for servicing procedures for stand- Tools" manual. swivelled to the best position for...

  • Page 3: Specifications

    SPECIFICATIONS Engine STIHL single-cylinder two-stroke engine with special impregnated cylinder bore Displacement: 27.2 cm (1.66 cu.in) Bore: 34 mm (1.34 in) Stroke: 30 mm (1.18 in) Engine power to ISO 7293: 0.75 kW (1 bhp) at 7000 rpm Max. permissible engine speed without cutting tool 9,500 ±...

  • Page 4: Ignition System

    Special Accessories 3.4.1 For User Shoulder strap Safety glasses STIHL ElastoStart (starter rope with grip) 0000 190 3400 STIHL gear lubricant for brushcutters - 80g/3oz tube 0781 120 1117 - 225g/8oz tube 0781 120 1118 3.4.2 For Service Carburetor parts kit...

  • Page 5: Tightening Torques

    Note: Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm, DG screws max. 500 rpm Important: Do not confuse screws with and without underhead locking teeth. 1) With locking teeth 2) Without locking teeth 3) Install with sealant FS 45...

  • Page 6: Clutch

    Take out screws at rear end of Remove throttle cable (1) nipple - Pull off the spark plug boot. shroud. from slotted pin (2) on throttle lever. - Unscrew the spark plug. • Fit locking strip (1) 4221 893 5900 in spark plug hole. FS 45...
  • Page 7 (2). • Detach the clutch springs (3). Important: Clutch springs must always be replaced in pairs. • Push pins of wrench (1) 4130 890 3600 into semicircular recesses in the clutch. • Unscrew the clutch. FS 45...

  • Page 8: Engine

    Use socket (1) 0812 540 1112 to Pull off the spark plug boot (1). Remove the gasket. tighten down clutch drum screw • to 4.0 Nm (3.0 lbf.ft). Take out the screws (2). • Remove the ignition module (3). FS 45...

  • Page 9: Exhaust Muffler

    - Clean the thread on the stub and coat with sealant - see 11.2. Important: Follow manufacturer’s instructions. - Fit the stub and tighten down to 15 Nm (11 lbf.ft). • Unscrew the starter cup from the crankshaft. Assemble in the reverse sequence. FS 45...

  • Page 10: Leakage Test

    - Use a new gasket. - Tighten screws to 9.0 Nm (6.6 lbf.ft). • Fit the test flange (1) 1128 850 4200 on the carburetor mounting studs. • Fit nuts (2) and tighten down to 3.5 Nm (2.6 lbf.ft). FS 45...

  • Page 11: Pressure Test

    0.5 bar 9.0 Nm (6.6 lbf.ft). (7.25 psi). If this pressure remains constant for at least - Install the carburetor - see 9.2.2. 20 seconds, the crankcase is airtight. - Fit the shroud. FS 45...

  • Page 12: Oil Seals

    11.2. - Lubricate sealing lips of oil seal with grease - see 11.2. • 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 45...
  • Page 13 Use the press sleeve (2) 1114 893 4601 to press it fully home. - Fit the engine housing. - Install the starter cup. • Slide the oil seal (1), open side facing the crankcase, over the installing sleeve. FS 45...

  • Page 14: Cylinder And Piston

    To ensure that the crankcase At the starter cup side, take the and engine pan do not come snap ring (B8x0.7) out of the apart when the cylinder is groove. removed, hold both parts together with the puller. FS 45...
  • Page 15 Rest piston (1) on 1114 893 4700 to push it up to wooden assembly block (2) stop against the hookless snap 1108 893 4800. ring (the pin slides home easily if the piston is hot). FS 45...

  • Page 16: Piston Ring

    (1) face screws to 9.0 Nm (6.6 lbf.ft). the fixing pin (2). - Inspect ball bearings and oil seals and replace if necessary. Assemble all other parts in the - Install the piston - see 5.5.2. reverse sequence. FS 45...
  • Page 17 Assemble all other parts in the reverse sequence. • Pull off the oil seals (1) and ball - Thoroughly clean the sealing bearings (2). faces on the crankcase and engine pan to remove all traces - Remove the washers. of sealant. FS 45...

  • Page 18: Ignition System

    A new ignition module must be installed if no ignition spark is obtained (after checking Note: The electronic (breakerless) that wiring and stop switch are in ignition system basically consists good condition). of an ignition module (1) and flywheel (2). FS 45...
  • Page 19 Assemble all other parts in the reverse sequence. • Take out the screws. Inspect the condition of the flywheel (1) and magnet poles (2). - Remove the ignition module. If you find any damage (cracks etc.), fit a new flywheel. FS 45...
  • Page 20 - Fit the boot on the spark plug. • Unhook the wires (1) from the retainer (2). • Ease the stop switch (3) out of the base. FS 45...

  • Page 21: Rewind Starter

    Take special care when removing the spring. Wash all parts in paraffin or white spirit. Lubricate the rewind spring and starter post with STIHL special lubricant, see 11.2, before installing. Install in the reverse sequence. •...

  • Page 22: Rewind Spring

    • Then use pointed nose pliers - It should be lubricated with a few to grip the rewind spring about drops of STIHL special lubricant 10 mm (0.4") from the end of before installation - see 11.2. the outer loop and place it in the starter cover.

  • Page 23: Tensioning

    Do not overtension the rewind spring as this will cause it to break. • Hold the rope rotor steady. • Pull out the rope with the starter grip and straighten it out. FS 45...

  • Page 24: Starter Rope/Starter Grip (Elastostart)

    • • Thread end of new starter rope Thread the starter rope through the underside of the 0000 195 8200 through the starter grip. guide bush from outside. - Secure end of rope with a simple overhand knot. FS 45...

  • Page 25: Starter Cup

    Fit starter cup and torque down Check the torsion spring and fit a Disconnect throttle cable from to 17.0 Nm (12.5 lbf.ft). new one if necessary. trigger. Install all other parts in the reverse Install in the reverse sequence. sequence. FS 45...

  • Page 26: Throttle Cable

    • • Take the throttle cable out of the Locate throttle cable’s protective rear part of the engine housing. sleeve in the retainers. - Check that rest of throttle cable is properly routed and seated. FS 45...

  • Page 27: Adjusting Throttle

    • • Turn the adjusting screw Take out the felt filter element. clock-wise until the throttle lever butts against the stop on the carburetor cover. FS 45...

  • Page 28: Carburetor

    Fit fuel hose (1) 1110 141 8600 Close the vent screw (1) on the on nipple (2) 0000 855 9200. rubber bulb (2) and pump air into the carburetor until the pressure gauge (3) shows a reading of approx. 0.8 bar (11.5 psi). FS 45...

  • Page 29: Removing And Installing

    - Mount approved cutting tool. - Check the air filter, replace if necessary. - Check spark arresting screen, clean or replace as necessary. - Start the engine and allow it to warm up. • Pull the fuel hoses off the elbow connectors. FS 45...

  • Page 30: Tank Vent

    - Refit the fuel filler cap. Equalization of pressure from the inside outwards takes place via the holes in the cap, the sintered filter, the slots in the valve body and the thread in the fuel filler cap. FS 45...

  • Page 31: Fuel Tank

    Take out screw (1). Tighten down screw on retainer Ease the grommet out of the to 4.0 Nm (3 lbf.ft). tank housing. • Remove the retainer (2). Note: Tighten down the screw only after fitting the starter cover. FS 45...

  • Page 32: Loop Handle

    • Pull out the filter (2) and fit a new housing and tighten down firmly. the deflector. one. • Pull the deflector off the end of Assemble in the reverse sequence. the drive tube. FS 45...

  • Page 33: Flexible Shaft

    Note: If the shaft has turned blue, fit a new one. Note: Illustration shows drive tube next to engine housing. - Coat the flexible shaft with STIHL gear lubricant - Turn the bearing housing back 0781 120 1117, 11.2, before and forth while pushing the drive installation.

  • Page 34: Special Servicing Tools And Aids

    (0.4 - 13.5 lbf.ft) 5910 890 0302 Torque wrench 5910 890 0311 6 - 80 Nm (4.4 - 60 lbf.ft) 5910 890 0312 Spline screw socket T27x125 0812 542 2104 IS screws Screwdriver 5910 890 2400 All IS screws Q-T27x150 FS 45...
  • Page 35 2) Equivalent to puller 0000 890 4400, but with longer sprindle 5910 890 8400. 3) Setting gauge 1111 890 6400 may be used as an alternative. 4) Always use torque wrench to tighten DG/P screws. 5) Wrench has optical/acoustic signal. 6) On DG/P screws, use for releasing only. FS 45...

  • Page 36: Servicing Aids

    Oil seals (370g/13oz tube) Standard commercial, Cleaning crankshaft stub solvent-based degreasant containing no chlorinated or halogenated hydrocarbons STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in rope rotor Electrical repair kit 5910 007 1050 Electrical system...

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