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STIHL FS 36, 40, 44
Service Manual
FS 36, FS 40 and FS 44
Brushcutters
You should make use of the illustrated
parts lists while carrying out repair
work. They show the installed positions
of the individual components and
assemblies. Microfilmed parts list are
always more up to date than printed
lists.
A fault on the machine may have
several
causes.
Consult
"troubleshooting charts" when tracing
faults.
Refer to the "Technical Information
Bulletins"
for
engineering
which have been introduced since
publication of this service manual.
Service
manuals
information
engineering
exclusively for the use of STIHL
servicing dealers and staff and must
not be passed on to third parties.
the
changes
and
technical
bulletins
describing
changes
are
intended
The STIHL Special Tools manual lists
all special servicing tools currently
available from STIHL.
Always use original STIHL
replacement parts.
Original STIHL parts can be identified
by the STIHL part number, the
STIHl logo and the STIHL parts
symbol (W The symbol may appear
alone on small parts.
STIHl
1
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Related Manuals for Stihl FS 36
Summary of Contents for Stihl FS 36
- Page 1 STIHL FS 36, 40, 44 Service Manual FS 36, FS 40 and FS 44 Brushcutters Service manuals technical The STIHL Special Tools manual lists You should make use of the illustrated information bulletins describing all special servicing tools currently parts lists while carrying out repair...
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Page 2: Table Of Contents
STIHL FS 36, 40, 44 CONTENTS Specifications Ignition System Contact Springs in Control Handle (FS 44 with Two-Handed Engine Repairing Component Handlebar) Fuel System Parts Ignition System 5.1.1 Spark Plug Handle Support Gearhead 5.1.2 Ignition Module Throttle Cable Weights 5.1.2.1 Ignition Timing... -
Page 3: Specifications
STIHL FS 36, 40, 44 SPECIFICATIONS Engine STIHL single-cylinder two-stroke engine with special impregnated cylinder bore. Displacement: (1.84 cu. in) 30.2 cm Bore: 34.8 mm (1.36 in) Stroke: 31.8 mm (1.25 in) Power output: 0.7 kW (0.95 bhp) Max. permissible engine... -
Page 4: Fuel System
STIHL FS 36, 40, 44 1.2 Fuel System Carburetor: All-position diaphragm carburetor with integral fuel pump Basic setting High speed adjusting screw H: Back off approx. 1 turn (only for service shop) Low speed adjusting screw L: Back off approx. 1 turn... -
Page 5: Special Accessories
STIHL FS 36, 40, 44 Gearhead FS 36 FS 40 FS 44 Type: Spiral-toothed bevel gears Gear ratio: 1.33 Bearings: Deep groove ball bearings Lubrication: STIHL gear lubricant 0781 120 1117 Weights without cutting tool 6.1 kg 4.9 kg 5.3 kg and deflector 10.8 lb... -
Page 6: Tightening Torques
STIHL FS 36, 40, 44 Tightening Torques The new "DG" screws are used in the light-alloy and However, it is essential to always use a torque wrench to fiberglass reinforced polymer components of models FS tighten the screw to the specified torques. If pneumatic or 36, 40 and 44. - Page 7 STIHL FS 36, 40, 44 Torque For component Fastener Thread size Remarks (Ibf.ft) (4.8) Muffler to cylinder Spline screw IS-DG5x60 Ignition module to Spline screw IS-M4x20 (2.6) cylinder Clamp on clutch Spline screw IS-M5x18 (4.8) housing Clamp on bearing Spline screw IS-M5x18 (4.8)
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Page 8: Troubleshooting Charts
STIHL FS 36, 40, 44 TROUBLESHOOTING CHARTS Clutch Cause Remedy Condition Clutch springs stretched or Fit new springs Insufficient frictional fatigued, spring hooks broken contact - clutch slips Engine idle speed too high Correct at idle speed Cutting tool rotates while... -
Page 9: Ignition System
STIHL FS 36, 40, 44 Ignition System Warning: Exercise extreme caution while carrying out maintenance and repair work on the ignition system, The high voltages which occur can cause serious or fatal accidents! Spark plug terminal firmly seated on spark plug? Remove spark plug. -
Page 10: Rewind Starter
STIHL FS 36, 40, 44 Rewind Starter Condition Cause Remedy Fit new starter rope Starter rope broken Rope pulled out too vigorously as far as stop or over edge Fit new rewind spring Rewind spring broken Spring overtensioned - no reserve when rope is... -
Page 11: Fuel System
STIHL FS 36, 40, 44 Fuel System Condition Cause Remedy Carburetor floods; Inlet needle not sealing. Remove and clean or replace engine stalls Foreign matter in valve seat inlet needle, clean fuel tank, or cone damaged. pickup body and fuel line if... - Page 12 STIHL FS 36, 40, 44 Condition Cause Remedy Engine will not idle, Throttle valve opened too Reset idle speed adjusting idle speed too high far by idle speed adjusting screw correctly screw Engine stalls at idle speed Idle jet bores or ports...
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Page 13: Clutch
STIHL FS 36, 40, 44 CLUTCH Disassembly Top: Top: Clutch housing mounting screws Top: Removing clutch drum mounting screw Locking screw 4112 893 1200 Bottom: Bottom: Removing starter grip from clutch Bottom: Clutch drum friction surface housing Locking screw fitted in cylinder Troubleshooting chart - see 2.1. - Page 14 STIHL FS 36, 40, 44 Top: Unscrewing the clutch Top: Wrench 4130 890 3600 Bottom: 1 = Clutch shoes 1 =Spacer sleeve Bottom: 2 = Springs 2 = Washer Wrench fitted on clutch 3 = Carrier - Push the carrier out of the clutch shoes.
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Page 15: Assembly
STIHL FS 36, 40, 44 Assembly Top: Top: Fitting the clutch Top: Correctly positioned clutch springs Fitting the spacer sleeve Bottom: Bottom: Rotating clutch until knocking Bottom: Pressing carrier into clutch shoes sound is heard Fitting the washer - Slide the spacer sleeve (if removed) - Page 16 STIHL FS 36, 40, 44 Top: Correct position of starter rope guide Top: Top: bush Tightening the clutch Clutch housing against fan housing Bottom: Bottom: Bottom: Clutch housing mounting screws Fitting the clutch drum Retainer for short circuit wire - Screw the locking screw back into...
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Page 17: Engine
STIHL FS 36, 40, 44 ENGINE Removing and Refitting Exhaust Muffler Top: Removing gasket Top: Bottom: Shroud mounting screws 1 = Fastening screws 2 = Screen frame Bottom: 1 = Angle molding 3 = Spark arrestor screen Muffler mounting screws... -
Page 18: Exposing The Cylinder
STIHL FS 36, 40, 44 Exposing the Cylinder Top: 1 = Spark plug terminal Top: 2 = Spark plug Muffler mounting screws Bottom: Bottom: Ignition module mounting screws Removing gasket Withdrawing throttle cable Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine. -
Page 19: Cylinder And Piston
STIHL FS 36, 40, 44 Cylinder and Piston 4.3.1 Removal Top: Removing connecting rod from Top: Top: crankshaft Cylinder base screws Diaphragm carrier mounting screws Bottom: Bottom: Bottom: Removing cylinder gasket Piston ring Removing gasket For preparations see 4.2. - Pull the connecting rod off the... -
Page 20: Installation
STIHL FS 36, 40, 44 4.3.2 Installation Top: Top: Correct position of piston Fitting cylinder gasket Bottom: Bottom: Tabs on diaphragm carrier Piston ring correctly positioned Pushing aligned cylinder on to piston - Insert screws in diaphragm carrier - Thoroughly clean the seating face - Lubricate the cylinder with oil, line it and tighten to a torque of 5.5 Nm... -
Page 21: Piston Ring
STIHL FS 36, 40, 44 Piston Ring Crankcase 4.5.1 Removing and Installing the Crankshaft Top: Top: Top: Removing the flywheel Spline screwdriver bit 0812 542 2104 Piston ring groove Bottom: Bottom: Bottom: Woodruff key Tightening cylinder base screws Fitting piston ring - Fit cylinder base screws and tighten - Remove the cylinder - see 4.3.1. -
Page 22: Ball Bearings And Oil Seal
STIHL FS 36, 40, 44 4.5.2 Ball Bearings and Oil Seal Top: Top: Top: Removing washer Circlip pliers 0811 641 8380 Spiral housing mounting screws Bottom: Bottom: Bottom: Pressing in crankshaft Removing circlip Pressing out crankshaft Removal: - Remove the spiral housing - Remove the washer from the - Remove the crankshaft - see 4.5.1. - Page 23 STIHL FS 36, 40, 44 Top: Removing circlip Top: Top: Installing circlip Positioning oil seal Bottom: Removing oil seal with press sleeve Bottom: Bottom: 4112 893 2401 Press sleeve 4112 893 2401 Fitting circlip - Remove the circlip at the diaphragm...
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Page 24: Leakage Testing The Crankcase
STIHL FS 36, 40, 44 Leakage Testing the Crankcase Top: Top: Carburetor and crankcase tester Pressing in ball bearing 1106 850 2905 Bottom: Bottom: Positioning ball bearing Vacuum pump 0000 850 3500 A defective oil seal, a faulty diaphragm - Press in the open ball bearing at the... - Page 25 STIHL FS 36, 40, 44 4.6.1 Preparations Top: Top: Top: Sealing plate fitted in position Test flange fitted in position Muffler mounting screws Bottom: Bottom: Bottom: 1 = Sleeves 0000 963 1008 Modified flange 1119 850 4200 Sealing plate 0000 855 8105 2 = Flange 1119 850 4201 a = 10 mm (13/32")
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Page 26: Pressure Test
STIHL FS 36, 40, 44 4.6.2 Pressure Test Top: Tester's pressure hose fitted on test flange nipple Bottom: Pressure-testing the crankcase Closing the vent screw However, if the indicated pressure - Remove the test flange. - Connect tester's pressure hose to nipple on test flange. -
Page 27: Vacuum Test (For Diaphragm)
STIHL FS 36, 40, 44 4.6.3 Vacuum Test (for Diaphragm) Diaphragm leakage test with Tester's suction hose fitted on vacuum pump test flange nipple On these machines the fuel-air mixture is drawn into the crankcase via a diaphragm which closes to prevent any backflow. -
Page 28: Vacuum Test (For Oil Seal)
STIHL FS 36, 40, 44 4.6.4 Vacuum Test (for Oil Seal) Top: 1 = Support plate 2 = Fastening screw Bottom: Diaphragm carrier mounting screws Removing the diaphragm Fitting the diaphragm carrier The oil seal tends to fail when sub- Test procedure: jected to a vacuum , i.e. -
Page 29: Ignition System
- Use brass wire brush to clean the spark plug and then blow it clear with compressed air. STIHL FS 36, FS 40 and FS 44 brushcutters saws are equipped Note: Never use a steel wire brush for with a transistor-controlled (breaker- this job. - Page 30 STIHL FS 36, 40, 44 Warning: Do not touch any live parts - To install the spark plug: Checking the spark plug: contact with high voltage can cause serious or fatal accidents! - Clean the spark plug seat and inspect...
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Page 31: 5.1.2.2 Removing And 5 Installing
STIHL FS 36, 40, 44 5.1.2 Ignition Module 5.1.2.1 Ignition Timing 5.1.2.2 Removing and Installing Top: Spark plug terminal Bottom: 1 = High voltage output Ignition module mounting screws 2 = Contact spring (not FS 44) Ignition timing is fixed at 1.6 mm (0.063") B.T.D.C. -
Page 32: Contact Spring
STIHL FS 36, 40, 44 5.1.3 Contact Spring 5.1.4 Flywheel (FS 36 and FS 40) Top: Top: Top: Setting gauge 1111 890 6400 Contact spring Removing the flywheel Bottom: Bottom: Setting gauge fitted between flywheel Correct contact spring gap Bottom: and ignition module "a"... -
Page 33: Spark Plug Terminal
STIHL FS 36, 40, 44 5.1.5 Spark Plug Terminal Top: Top: Pulling leg spring out of spark plug 1 = Flywheel terminal 2 = Magnet poles Bottom: Bottom: Correct position of leg spring in spark Attaching leg spring Woodruff key for flywheel... -
Page 34: 5.1.6 Short Circuit Wire
STIHL FS 36, 40, 44 5.1.6 Short Circuit Wire (FS 44) Top: Outer shroud mounting screws Top: Top: Fan housing mounting screws Protective hose Bottom: 1 = Retainer Bottom: Bottom: 2 = Protective hose Short circuit wire connectors Correct position of short circuit wire - Remove the clutch - see 3.1. -
Page 35: Rewind Starter
STIHL FS 36, 40, 44 Replacing the REWIND STARTER Starter Rope (with Fan Housing Fitted) Routine Maintenance Top: Clutch housing mounting screws (fourth screw hidden in this view) Top: Fitting starter rope Bottom: 1 = Clutch housing Bottom: 2 = Throttle cable... -
Page 36: Tensioning The 13 Rewind Spring
STIHL FS 36, 40, 44 Tensioning the Rewind Spring (with Fan Housing Fitted) Top: 1 = Rope guide bush 2 = Starter grip 3 = Special knot Bottom: Winding rope onto rotor Starter grip against fan housing Special knots used... -
Page 37: Rope Rotor
STIHL FS 36, 40, 44 Rope Rotor 6.4.1 Removal Top: Removing circlip Top: Top: Outer shroud mounting screws Removing starter rope from rotor Bottom: 1 = Rope rotor Bottom: Bottom: 2 = Washer Pliers 0811 611 8380 Removing fan housing To relieve tension of rewind spring: Troubleshooting chart - see 2.4. -
Page 38: Installation
- Thread starter rope through the - Use a suitable pair of pliers to grip the - Coat bore in rope rotor with STIHL smaller bore, pull it out the other side knot in the starter rope and pull it low temperature lubricant, see 11.2,... -
Page 39: Tensioning The Rewind
- Hold the rope rotor steady. together by a strap. It should be lubricated with a few drops of STIHL - Now wind two full turns of the rope on low temperature lubricant, see 11.2, to the rotor in the clockwise direction. -
Page 40: Starter Pawls
STIHL FS 36, 40, 44 Starter Pawls Top: 1 = Pawl Top: Prying out pin 2 = Pin Bottom: Bottom: Rewind spring fitted in position Bent end of torsion spring Correct position of torsion spring - Fit the spring into the fan housing. -
Page 41: Throttle Control
STIHL FS 36, 40, 44 Throttle Control Throttle Trigger (FS 36, FS 40) Top: Top: Top: Trigger housing fastening screws Disconnecting the throttle cable Correct position of torsion spring Bottom: Bottom: Bottom: Removing left half of housing Groove in handle support... -
Page 42: Throttle Trigger, Throttle Trigger Interlock
STIHL FS 36, 40, 44 Throttle Trigger, Throttle Trigger Interlock, Stop Switch (FS 44) 7.2.1 Disassembly Top: Top: Withdrawing stop switch Trigger housing fastening screws Top: Removing left half of housing Bottom: Bottom: 1 = Stop switch Removing throttle trigger interlock lever... - Page 43 STIHL FS 36, 40, 44 7.2.2 Assembly Top: Top: Groove in handle support 1 = Lever Top: 2 = Helical spring Bottom: Correct position of stop switch Correct positions of Bottom: 1 = Short circuit wires Bottom: 1 = Slot in interlock lever...
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Page 44: Handlebar)
STIHL FS 36, 40, 44 Throttle Trigger, Throttle Trigger Interlock (FS 44 with Two-Handed Handlebar) Top: Removing throttle trigger Top: Top: Torsion spring Handle mounting screw Bottom: Disconnecting throttle cable from Bottom: Bottom: trigger Prying out rivet Handle molding fastening screws... - Page 45 STIHL FS 36, 40, 44 Contact Springs in Control Handle (FS 44 with Two-Handed Handlebar) Top: Top: Correct position of trigger's torsion spring Top: Wire connections on contact springs Removing trigger interlock lever Bottom: Correct positions of throttle cable and...
- Page 46 Pull out the rivet - Pull the short circuit wires out of the and remove the contact spring. - On FS 36: Remove handle support – groove and throttle cable out of the see 10.4. handle support.
- Page 47 Note: Take care not to kink the front end of the throttle cable during in- stallation. Caution: FS 36 throttle cable is shorter. - Take out the handle support - Pull the throttle cable out of the fastening screw and remove the handle support - see 7.5.
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Page 48: Fuel System
STIHL FS 36, 40, 44 FUEL SYSTEM Leakage Testing the Carburetor Air Filter Top: Top: Removing foam filter element Shroud mounting screws Bottom: Bottom: Fitting filter cover Fuel hose on elbow connector Filter cover mounting screw The air filter's function is to remove... - Page 49 STIHL FS 36, 40, 44 Top: Tester's pressure hose connected to Top: nipple Fuel line 1110 141 8600 fitted on nipple 0000 855 9200 Bottom: Pressure testing carburetor with car- Bottom: buretor/crankcase tester 1106 850 2905 Fuel line fitted on elbow connector...
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Page 50: Removing The Carburetor
STIHL FS 36, 40, 44 Removing the Servicing the Carburetor Carburetor Top: Top: Top: Fuel hose on elbow connector Disconnecting throttle cable Removing choke lever Bottom: Bottom: Bottom: Fuel hose on nipple Removing gasket Pump end cover fastening screw - Pull the fuel hose off the carburetor... - Page 51 STIHL FS 36, 40, 44 Top: Top: Top: Fuel strainer in carburetor body Metering diaphragm and gasket on Pump diaphragm on carburetor body carburetor body Bottom: Fastening screws on metering Bottom: Bottom: diaphragm end cover Separating gasket and diaphragm Fuel pump end cover with gasket...
- Page 52 STIHL FS 36, 40, 44 Top: Round head screw holds control lever spindle Bottom: Top: 1 = Round head screw Top: Carburetor adjusting screws 2 = Inlet control lever Damaged inlet needle 3 = Spindle Bottom: 4 = Helical spring...
- Page 53 STIHL FS 36, 40, 44 Top: Valve jet fitted - lower edge of jet flush Top: with venturi wall Non-return valve Bottom: Bottom: Pressing in non-return valve Correct position of inlet control lever Control valve - Fit the inlet needle and the helical spring in their respective bores.
- Page 54 STIHL FS 36, 40, 44 Top: Top: 1 = Bore 1 = Gasket 2 = Copper washer Top: 2 = Pump diaphragm 3 = Control valve Locating pegs on carburetor body Bottom: Bottom: Bottom: Locating pegs on pump end cover...
- Page 55 STIHL FS 36, 40, 44 Top: Top: Top: E-clip Withdrawing throttle shaft Fitting the throttle shutter Bottom: Bottom: Bottom: Fuel pump end cover Correctly positioned torsion spring Choke shutter fastening screw - Take the throttle shutter out of the - Fit the throttle shutter so that the - Carefully pull the throttle shaft out of carburetor.
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Page 56: Carburetor Adjustment
STIHL FS 36, 40, 44 Carburetor Adjustment Top: Withdrawing choke shaft Bottom: 1 = Ball 2 = Spring 3 = Groove in choke shaft Correct position of choke shutter When the engine is tested at the factory the carburetor is set to obtain... -
Page 57: Basic Setting
STIHL FS 36, 40, 44 Screwdriver guide fitted in position 1 = Bore for high speed adjusting screw 2 = Bore for low speed adjusting screw 3 = Bore for idle speed adjusting screw Screwdriver guide 4130 855 7700 Corrections to the high speed adjusting... - Page 58 STIHL FS 36, 40, 44 Diaphragm Carrier, Diaphragm Top: Removing diaphragm Top: Top: Bottom: Diaphragm carrier mounting screws Withdrawing the fuel pump 1 = Short hose 2 = Bore Bottom: Bottom: 3 = Throttle cable Removing gasket Support plate fastening screw...
- Page 59 STIHL FS 36, 40, 44 Pickup Body and Fuel Hose Top: Top: Disconnecting the pickup body Assembly hook 5910 893 8800 Bottom: Bottom: Fuel hose on elbow connector Withdrawing pickup body Fuel filler cap The diaphragm pump draws fuel out of the tank and into the carburetor via the fuel hose.
- Page 60 STIHL FS 36, 40, 44 Fuel Tank Tank Vent Top: Removing fuel tank Bottom: Vent hose Fuel hose cut at angle Removing vent valve - Withdraw the fuel hose from the tank Correct operation of the carburetor is housing. only possible if atmospheric pressure...
- Page 61 STIHL FS 36, 40, 44 8.10 Fuel Pump Top: 1 = Short hose 2 = Fuel pump Top: Top: 3 = Long hose Fuel hose on nipple Vent hose Bottom: Bottom: Bottom: Fitting the fuel pump Withdrawing fuel pump Vent connector - Remove the shroud - see 8.2.
- Page 62 STIHL FS 36, 40, 44 AV SYSTEM (FS 40 and FS 44) Repair Top: Top: Withdrawing the clip 1 = Flat on drive tube Top: 2 = Pads on rubber element Bottom: Mounting screws on cap 1 = Rubber element...
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Page 63: Cutting Tool Drive
STIHL FS 36, 40, 44 CUTTING TOOL DRIVE 10.1 Bearing Housing (FS 36, FS 40) Top: Top: 1 = Clamp Setscrew 2 = Deflector shield Top: Removing washer Bottom: Bottom: Removing circlip with pliers 1 = Bearing housing Bottom: 0811 611 8200... - Page 64 Pressing in needle bearing - Slide the bearing housing onto the - FS 40: Remove washer from the - FS 36: Use press arbor to press in drive tube so that the holes are in the two flanged plain bearings until output shaft.
- Page 65 STIHL FS 36, 40, 44 10.2 Gearhead (FS 44) 10.2.1 Disassembly Top: Top: 1 = Screws Removing circlip (output end) 2 = Back plate Top: 3 = Deflector shield Circlip pliers 0811 641 8380 Bottom: 1 = Ball bearing Bottom:...
- Page 66 STIHL FS 36, 40, 44 10.2.2 Assembly Top: 1 = Drive pinion Top: 2 = Open ball bearing Top: Pressing drive pinion out of ball 3 = Ball bearing, closed at one side Circlip pliers 0811 611 8200 bearings Bottom:...
- Page 67 STIHL FS 36, 40, 44 Top: Top: Top: Pushing bevel gear onto output shaft Fitting circlip (input end) Fitting the output shaft Bottom: Bottom: Bottom: Fitting the ball bearing in the gearhead Fitting circlip (output end) Fitting the drive pinion...
- Page 68 Note: Use STIHL gear lubricant, see - Refit the deflector shield. 11.2, for lubrication of the bevel gears. - Remove bearing housing on FS 36 and FS 40 or gearhead on FS 44 - Important: Fill the gearhead with see 10.1 or 10.2.
- Page 69 - see 9.1. from the drive tube. - Remove the input shaft - see 10.3. - Release clamp screw on FS 36 clutch housing and bend clamp open a little. - Pull the clutch housing and clamp off the drive tube.
- Page 70 - FS 36 and FS 40: Release the clamp Assembly is a reversal of the disas- screw and pull the loop handle off the - Turn the crosspiece of the loop sembly sequence.
- Page 71 STIHL FS 36, 40, 44 Special Servicing Tools and Aids 11.1 Special Servicing Tools Part Name Part No. Application Locking screw 4112 893 1200 Blocking crankshaft Press sleeve 4112 893 2401 Installing ball bearing and oil seal Crimping tool 5910 890 8210...
- Page 72 STIHL FS 36, 40, 44 11.2 Servicing Aids Part Name Part No. Application Medium-strength 0786 111 1101 Throttle and choke shutter threadlocking adhesive fastening screws, thread of (Loctite 242) control valve Standard commercial, Cleaning crankshaft stub solvent-based degreasant containing no CFCs...
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