Stihl 4180 Series Bedienungsanleitung
STIH)
STIHL Basismotor 4180 2007-11
HL 100
HT 100
HT 101
HT 130
HT 131
KM 90
KM 100
KM 110
KM 130
FC 90
FC 95
FC 100
FC 110
FS 90
FS 100
FS 110
FS 130
1Series 4180 Powerhead
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© ANDREAS STIHL AG & Co. KG, 2007
Contents
1. Introduction 2
2. Safety Precautions 3
3. Specifications 4
3.1 Engine 4
3.2 Spark plug 4
3.3 Fuel System 4
3.4 Tightening Torques 5
4. Troubleshooting 7
4.1 Clutch 7
4.2 Rewind Starter 8
4.3 Ignition System 9
4.4 Carburetor 10
4.5 Engine 12
5. Rewind Starter/
Shroud 14
5.1 General 14
5.2 Removing and
Installing 14
5.3 Rope Rotor 14
5.4 Starter Rope 16
5.4.1 Tensioning 17
5.5 Pawl 18
5.6 Replacing the
Rewind Spring 18
5.7 Removing the Shroud 18
6. Fuel System 19
6.1 Air Filter 19
6.2 Carburetor 20
6.2.1 Leakage test 20
6.2.2 Removing
and Installing 21
6.2.3 Manual Fuel Pump 21
6.2.4 Metering Diaphragm 22
6.2.5 Inlet Needle 23
6.2.6 Fixed Jet 23
6.2.7 Pump Diaphragm 23
6.3 Accelerator Pump 25
6.4 Adjusting Idle Speed 25
6.4.1 Basic Setting 26
6.5 Tank Vent 27
6.5.1 Checking Operation 27
6.5.2 Replacing Tank Vent 28
6.6 Fuel Supply 29
6.6.1 Cleaning the
Fuel Tank 29
6.6.2 Fuel Hoses and
Pickup Body 29
6.6.3 Fuel Tank 31
7. Engine 31
7.1 Compression
Pressure 32
7.2 Checking / Adjusting
Valve Clearance 32
7.3 Rocker Arms/
Pushrods 34
7.4 Cam Followers,
Cam Gear 35
7.4.1 Decompression
System 36
7.5 Muffler / Spark
Arresting Screen 36
7.6 Clutch 37
7.6.1 Removing and
Disassembling 37
7.6.2 Assembling and
Installing 38
7.6.3 Clutch Drum and
Bearing 39
7.7 Flywheel 40
7.8 Crankshaft 41
7.8.1 Replacing
the Oil Seals 41
7.8.2 Crankcase,
Lower Half 43
7.8.3 Crankshaft 44
7.8.4 Piston 45
7.8.5 Piston Rings 47
7.9 Valves/Valve Springs 48
7.10 Upper Half of
Crankcase with
Cylinder 49
7.11 Leakage Test 49
8. Ignition System 51
8.1 Spark Plug Boot 51
8.2 Ignition Module 52
8.2.1 Ignition Timing 52
8.2.2 Removing and
Installing 52
8.3 Testing the Ignition
System 54
8.4 Ignition System
Troubleshooting 55
9. Throttle Control 58
9.1 Throttle Trigger,
Lockout Lever 58
9.2 Tensioner 59
9.3 Adjusting Throttle
Cable 59
9.3.1 Control Handle
with Slide 59
9.3.2 Control Handle
without Slide 60
9.3.3 Checking Adjustment 61
9.4 Slide Control 61
10. AV System 62
11. Special Servicing
Tools 63
12. Special Accessories 64
2Series 4180 Powerhead
This service manual contains
detaileddescriptionsofallthe repair
andservicingproceduresspecificto
this powerhead.
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.
Refer to the latest edition of the
relevant parts lists to check the part
numbers of any replacement parts.
Refer to the “Technical Information”
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list until a
revised edition is issued.
The special tools mentioned in the
descriptions are listed in the last
chapter of this manual. Use the part
numbers to identify the tools in the
"STIHL Special Tools" manual.
Symbolsareincludedinthetextand
pictures for greater clarity.
The meanings are as follows:
In the descriptions:
:= Action to be taken that is
shown in the illustration
(above the text)
– = Action to be taken that is
not shown in the illustration
(above the text)
b4.2 = Reference to another
chapter, i.e. chapter 4.2 in this
example
+= Situation applies from
serial No.
*= Situation applies up to
serial No.
In the illustrations:
APointer (short arrow)
aDirection of movement
Service manuals and all technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed to third parties.
Servicing and repairs are made
considerably easier if the
powerheadismountedonassembly
stand (2) 5910 890 3100 with the
aid of clamp (1) 5910 890 8800.
The powerhead can then be
swivelled to the best position for the
ongoing repair. This leaves both
VA
249RA!63
2
1
hands free.
Always use original STIHL
replacement parts.
They can be identified by the
STIHL part number,
the {logo and the
STIHL parts symbol (
This symbol may appear alone on
small parts.
1. Introduction
3Series 4180 Powerhead
If the power tool 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 instruction manual.
Gasolineisanextremely flammable
fuel and can be explosive in certain
conditions.
Improper handling may result in
burns or other serious injuries.
Always wear suitable protective
gloves for operations in which
components are heated for
assembly or disassembly.
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.
Always perform leakage test after
working on the fuel system and the
engine.
2. Safety Precautions
4Series 4180 Powerhead
3. Specifications
Remarks: 1) install at inlet side only 2) may be installed at inlet and
exhaust sides
FS 90
FC 90, 95
KM 90
FS 100, 110
FC 100, 110
HT 100, 101
HL 100
KM 100, 110
FS 130
HT 130
HT 131
KM 130
3.1 Engine STIHL single cylinder four-stroke engine with mixture lubrication
Displacement: 28.4 cm331.4 cm336.3 cm3
Bore: 38 mm 40 mm 43 mm
Stroke: 25 mm 25 mm 25 mm
Engine power to ISO 8893 0.95 kW
at 7,000 rpm 1.05 kW
at 7,000 rpm 1.4 kW
at 8,500 rpm
Max. permissible engine speed with cut-off
by ignition module: 10,500 ± 500 rpm 10,500 ± 500 rpm 10,500 ± 500 rpm
Idle speed 2,800 rpm 2,800 rpm 2,800 rpm
Clutch: Centrifugal clutch, two clutch shoes without linings
Clutch engages at: 3,700 rpm 3,700 rpm 3,700 rpm
Valve clearance
Inlet valve: 0.10 mm 0.10 mm 0.10 mm
Exhaust valve: 0.10 mm 0.10 mm 0.10 mm
Valve diameter: 13.5 mm 13.5 mm 15.5 mm
Marking: A 1) A 1) B or :1)
E 2) E 2) I 2)
3.2 Spark plug
Type: BOSCH USR 7AC BOSCH USR 7AC NGK CMR 6H
Electrode gap: 0.5 mm 0.5 mm 0.7 mm
Air gap between ignition module
and flywheel: 0.15 ... 0.30 mm 0.15 ... 0.30 mm 0.15 ... 0.30 mm
3.3 Fuel System
Crankcase leakage test
at gauge pressure: 0.5 bar 0.5 bar 0.5 bar
under vacuum: 0.5 bar 0.5 bar 0.5 bar
Carburetor leakage test
at gauge pressure: 0.8 bar 0.8 bar 0.8 bar
Operation of tank vent
at gauge pressure: 0.3 bar 0.3 bar 0.3 bar
Fuel: as specified in instruction manual
5Series 4180 Powerhead
3.4 Tightening Torques
DG and P (Plastoform) screws are used in polymer and light metal 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.
For this reason it is essential to use a torque wrench.
Fastener Thread size For component Torque
Nm
Socket head screw IS-M6x25 Cover washer/clutch shoe/flywheel 12.0
Socket head screw IS-DG4x18 Cover/engine pan 4.5
Socket head screw IS-M5x30 Control handle/locknut with washer 2.0 1)
Socket head screw IS-P4x16 Control handle, inner/outer moldings 1.3 1)
Socket head screw IS-P4x16 Control handle, inner/outer moldings 1.3 2)
Socket head screw IS-M5x12 Clamp/control handle 5.0 2)
Socket head screw IS-DG4x18 Cover/cylinder 4.5
Socket head screw IS-M5x21 Filter cover/filter housing 3.5
Collar nut M5 Filter housing/carburetor 3.5
Socket head screw IS-D5x24 Gear housing/drive tube 8.0
Socket head screw IS-M4x9.5 Screen/muffler 2.0
Socket head screw IS-M5x24 Shroud/cylinder 6.0
Collar screw M5x16 Rocker lever collar screw/cylinder 9.0
Socket head screw IS-M6x30 Clamp/drive tube/handle support 8.0 1)
Socket head screw M6x30 Coupling sleeve wingscrew 6.0 3)
Socket head screw IS-M6x25 Coupling sleeve/nut, clamp 9.0 3)
Socket head screw IS-DG5x24 Engine pan/cylinder 9.0
Socket head screw IS-M6x25 Clamp/loop handle/nut 4.5 2)
Socket head screw IS-DG5x24 Fan housing/shroud/engine pan 6.0
Socket head screw IS-DG5x24 Fan housing/engine pan 6.0
Socket head screw P3.5x9 Detent spring/slide control 1.1 1)
Socket head screw IS-M5x23 Loop handle/clamp/drive tube 6.0 4)
Socket head screw IS-DG5x24 Muffler/crankshaft 9.0
Socket head screw IS-DG5x24 Muffler/cylinder 9.0
Socket head screw IS-M5x16 Cutting attachment deflector/gear housing 4.5
Nut M8x1 Flywheel/crankshaft 17.0 5)
Socket head screw IS-M6x14 Clamp/carrying ring 4.5
Socket head screw IS-M5x12 Clamp/drive tube, fan housing 6.0
Socket head screw IS-DG5x24 Starter cover/cover/engine pan 6.0
6Series 4180 Powerhead
Fastener Thread size For component Torque
Socket head screw IS-DG5x24 Starter cover/tank/engine pan 6.0
Nut M8x1 Starter cup/crankshaft 17.0
Socket head screw IS-M5x30 Valve cover/cylinder 3.5
Screw plug M11x10 Screw plug/gearbox 10.0
Spark plug IS-M10x1 Spark plug 9.0
Socket head screw IS-DG4x18 Ignition module/cylinder 4.5
Socket head screw IS-DG5x32 Spacer flange/cylinder 9.0
Socket head screw IS-P5x14 Fan housing/clutch drum bearing 4.0 6)
Remarks:
1) Version with bike handle
2) Version with loop handle
3) KombiEngine
4) FS 100 RX
5) Degrease crankshaft/flywheel and mount oil-free
6) FS 90, 100; KM 90, 100; FC 90, 95, 100
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.
Power screwdriver setting for polymer: DG and P screws max. 500 rpm
Do not use an impact wrench for releasing or tightening screws.
Do not mix up screws with and without binding heads.
Coat micro-encapsulated screws with medium strength Loctite 243 before reinstalling.
7Series 4180 Powerhead
4. Troubleshooting
4.1 Clutch
Condition Cause Remedy
Attachment stops under load at full
throttle Clutch badly worn Install new clutch
Clutch drum badly worn Install new clutch drum
Attachment runs when engine is
idling Engine idle speed too high Readjust with idle speed screw
(counterclockwise)
Clutch springs stretched or fatigued Install new clutch
Spring hooks broken Install new clutch
8Series 4180 Powerhead
4.2 Rewind Starter
Condition Cause Remedy
Starter rope broken Rope pulled out too vigorously as
far as stop or over edge, i.e. not
vertically
Fit new starter rope
Normal wear Fit new starter rope
Rewind spring broken (starter rope
does not rewind) Spring overtensioned – no reserve
when rope is fully extended Fit new rewind spring
Very dirty or corroded Clean or replace rewind spring
Starter rope can be pulled out
almost without resistance
(crankshaft does not turn)
Guide peg on pawl or pawl itself is
worn Fit new pawl
Spring clip on pawl fatigued Fit new spring clip
Starter rope is difficult to pull or
rewinds very slowly Starter mechanism is very dirty
(dusty conditions) Thoroughly clean complete starter
mechanism
Lubricating oil on rewind spring
becomes viscous at very low
outside temperatures (spring
windings stick together)
Clean rewind spring with standard
cleaner, then pull rope carefully
several times until normal smooth
action is restored. Then coat with
resin-free oil.
9Series 4180 Powerhead
4.3 Ignition System
Warning:
Exercise extreme caution while
carryingoutmaintenanceandrepair
work on the ignition system. The
ignition system. The high voltages
which occur can cause serious or
fatal accidents.
Condition Cause Remedy
Engine does not run No spark Check operation of slide control
and ignition module; replace
damaged parts
Spark plug dirty or faulty Clean or replace spark plug
Faulty insulation or break in ignition
coil, ignition lead or short circuit
wire
Use ohmmeter to check ignition coil
and lead for break. If break is
detected or resistance is high, fit a
new ignition coil and ignition lead;
check short circuit wire for ground
contact in run position
Engine runs roughly, misfires,
temporary loss of power Spark plug boot is loose Press boot firmly onto spark plug
and fit new spring if necessary
Spark plug sooted, smeared
with oil Install new spark plug
Weak spark or no spark Faulty insulation on ignition lead or
short circuit wire. Use ohmmeter to
check ignition lead for break. If
break is detected or resistance is
high, fit a new ignition lead.
Wrong air gap between ignition coil
and flywheel Reset air gap
Flywheel cracked or damaged Install new flywheel
Spark plug dirty or faulty. Check
slide control, ignition coil/lead for
damaged insulation and leakage
current.
Clean or replace spark plug.
Replace damaged parts of ignition
system
Andere Handbücher für 4180 Series
1
Dieses Handbuch passt für folgende Modelle
16
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