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. STIH) STIHL Series 4149 Powerhead 2014-10 FS 94 KM 94 SP 92, SP 92 T. Stop switch lever Ignition Timing (momentary contact switch): Install new ignition module Adjusting Wheel Testing the Adjusting the Ignition Module Throttle Cable 6.3.1 Testing Ignition Module with STIHL MDG 1 © ANDREAS STIHL AG & Co. KG, 2014 Series 4149 Powerhead.

Always use original STIHL descriptions are listed in the chapter replacement parts. On 'Special Servicing Tools' in this They can be identified by the STIHL This service manual contains manual. Use the part numbers to part number, detailed descriptions of all the repair. Install new fuel hoses either dry or Always wear suitable protective with the aid of STIHL press fluid, gloves for operations in which b 12. Components are heated for assembly or disassembly. Hot Other press fluids are not approved grease can cause burn injuries. Specifications Engine SP 92, SP 92 T FS 94, KM 94 Displacement: 21.4 cm 24.1 cm Bore: 33.0 mm 35.0 mm Stroke: 25.0 mm 25.0 mm Engine power to ISO 8893: 0.75 kW (1.0 bhp) 0.9 kW (1.2 bhp) at 8,500 rpm at 8,500 rpm Max.

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. Fastener Thread size For component Torque Remarks Screw D 5x12 Carburetor / throttle cable M 10x1 Spark plug / cylinder 12.0 Screw D 4x20 Ignition module / cylinder 1), 2) Screw D 5x28 Spacer flange / cylinder 1), 2) Remarks: 1) Screws with binding head 2) Waxed screws 3) Micro-encapsulated screws. Troubleshooting Clutch Condition Cause Remedy Working tool stops under full load Clutch shoes badly worn Install new clutch Clutch drum badly worn Install new clutch drum Working tool runs when engine Engine idle speed too high Readjust with idle speed screw LA is idling Clutch spring stretched Replace the clutch spring or install. Rewind Starter Condition Cause Remedy Starter rope broken Rope pulled out too vigorously as Install new starter rope far as stop or constantly over the edge Normal wear Install new starter rope Starter rope does not rewind Rewind spring very dirty or Clean or replace rewind spring corroded Insufficient spring tension.

Condition Cause Remedy Starter rope is difficult to pull or Starter mechanism is very dirty Thoroughly clean complete starter rewinds very slowly mechanism ErgoStart spring in rope rotor Replace ErgoStart spring, check fatigued carrier and rope rotor, replace if necessary At very low outside temperatures: Coat rewind spring with a small Lubricating oil on rewind spring. Ignition System 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. Condition Cause Remedy Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug temporary loss of power and fit new spring if necessary Spark plug sooted, smeared with oil Clean the spark plug or replace if. Carburetor Condition Cause Remedy Carburetor floods; engine stalls Inlet needle not sealing Remove and clean the inlet needle, – foreign matter in valve seat or clean the carburetor cone Inlet needle worn Fit new inlet needle Inlet control lever sticking on Check the inlet control lever and spindle replace if necessary. Condition Cause Remedy Engine loses power during Jet on the Clean the carburetor acceleration low speed screw L dirty – insufficient volume of fuel, engine running too lean Fuel strainer dirty Clean fuel strainer and carburetor Engine will not idle, idle speed too Control valve opened too wide by Reset idle speed screw (LA) high.

Condition Cause Remedy Working tool runs when engine is Engine idle speed too high Readjust idle speed screw idling LA (counterclockwise) Clutch spring stretched or fatigued Replace the clutch spring or install new clutch Clutch spring hooks broken Replace the clutch spring Engine speed drops quickly under Air filter dirty Clean or replace fleece filter. Condition Cause Remedy Engine running extremely rich, has Cold start device of control valve Check and clean the control valve no power and a very low maximum sticking or does not return to or replace if necessary speed original position Engine does not start No spark Replace spark plug, check ignition. Engine Always check and, if necessary, repair the following parts before looking for faults on the engine: - Air filter - Fuel system - Carburetor - Ignition system Condition Cause Remedy Engine does not start easily, stalls Oil seals in engine damaged Install new oil seals at idle speed, but operates normally at full throttle. Clutch Clutch Drum Installing – Troubleshooting, b 3.1 – Remove the rewind starter, b 7.2 – Remove the shroud, b 5.4 – Remove the drive tube, b 9.1: Place the fan housing (1) on ring (2) 5910 893 7008 – this ensures the fan housing (1) is –.

– Install the drive tube, b 9.1 Clutch – Fit the shroud, b 5.4 – Remove the fan housing, b 4.1: Install circlip (1) at the other side. – Remove the sleeve and rubber element, b 8.1: Fit screws (1), then tighten down: Pull boot (1) off the spark plug. Assembling: The locking strip (1): Fit upper cover washer (1) so that 0000 893 5904 must butt against the recesses (arrows) face up the cylinder wall (arrow): Fold the clutch shoes (1) and and the holes are in alignment. Engine Muffler / Spark Arresting Installing Screen Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine.

– Troubleshooting, b 3 – Remove the shroud, b 5.4: Remove the muffler gasket (1) Before removing the muffler, set the and pull out the heat shield (2) piston to top dead center to ensure. Leakage 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 upset the fuel-air mixture. This makes adjustment of the prescribed idle speed difficult, if not impossible. 5.2.1 Preparations – Remove the shroud, b 5.4 Make sure the gasket (1) is in place. – Pull off the boot and unscrew the spark plug. – Set the piston to top dead center.

This can be checked through the spark plug hole. 5.2.3 Pressure Test – Install the gasket, heat shield and muffler, b 5.1 Carry out the same preparations as – Reassemble all other parts in the for the vacuum test, b 5.2.2 reverse sequence. Oil Seals: Connect hose (1) of pump 0000 850 1300 to the nipple (arrow). Ignition Side – Reassemble all other parts in the reverse sequence.

– Remove the clutch, b 4.2 – Remove the flywheel, b 6.5 Starter Side – Remove the rewind starter, b 7.2 – Block the piston, b 4.2: Fit the installing sleeve (1) 4149 893 4600. Installing Installing – Clean the sealing face. – Lubricate sealing lips of new oil seal with grease, b 12: Use hexagon (arrow) to screw carrier (1) into place clockwise, then tighten it down firmly.: Fit the shroud (1) so that the tabs (arrows) engage between the crankcase (2) and fan –. 5.4.1 Air guide shroud: Line up the manual fuel pump (1) so that the lug (2) points towards the carburetor. – Remove the drive tube, b 9.1: Push the manual fuel pump (1) – Remove the shroud, b 5.4 into the retainer (3) on the air guide shroud until the locking –. Cylinder – Remove the ignition module and Versions with 0.75 kW engine air guide shroud, b 6.2 Before removing the cylinder, – Remove the muffler, b 5.1 decide whether or not the crankshaft has to be removed as well.

– Remove the fuel tank, b 10.9 Cylinder installed To remove the clutch, flywheel or carrier, block the.crankshaft. Versions with 0.9 kW engine Versions with replaceable needle If the piston or the oil seals are cage damaged, also inspect the inside of – Remove the piston, b 5.7 the cylinder for signs of damage and install a new cylinder if necessary.

Installing Versions with 0.75 kW engine: Pull out the needle cage (1). Versions with 0.9 kW engine – Lubricate the piston, piston rings While sliding the cylinder over the and cylinder wall with oil, b 12 piston, hold the clamping strap: Fit the new cylinder gasket (1) tightly around the piston so that the over the piston, attach it to the rings do not project –.

Crankshaft Modifying an existing drilled plate – Remove the flywheel, b 6.5 – Remove the carrier, b 7.3 – Remove the cylinder, b 5.5 – Remove the piston, b 5.7 – Always install new bearings and: Inspect and clean the needle 18,2 oil seals after removing the cage (1), replace crankshaft if. Ignition side of crankcase Versions with replaceable needle cage The crankshaft, connecting rod and needle bearing form an inseparable unit.

Always replace as a complete unit. Versions with fixed needle cage The crankshaft, connecting rod with needle cage and needle bearing: Unscrew the spindle (1) form an inseparable unit. All models Installing Starter side of crankcase Ignition side of crankcase Take care not to damage the crankshaft stub. Take care not to damage the crankshaft stub.

– Lubricate the crankshaft stub with oil.: Remove any gasket residue and clean the sealing faces (arrows) thoroughly (including the peripheral groove in the starter. pattern until the two halves of the – Check and install the cylinder, crankcase are together.

B 5.5: Tighten down the screws (1) – Reassemble all other parts in the firmly. Reverse sequence. Versions with replaceable needle 5.6.1 Bearings / Crankcase cage Inspect both halves of the crankcase for cracks and all sealing. Ignition side of crankcase: Push the ball bearing (1) home as far as stop.

– Check that the bearing is properly seated. If necessary, use press arbor 4224 893 7200 to press the bearing fully home. Starter side of crankcase –. Piston – Replace the cylinder gasket, – Lubricate the cleaned needle inspect and clean the sealing cage with oil, b 12 faces, b 5.5 – Remove the cylinder, b 5.5 All models The piston has only one snap ring. It Installing is fitted at the ignition side.: Slide the assembly drift (1): Installing tool: Install the new piston rings in the 1130 893 4700, small diameter 5910 890 2208 with the sleeve’s grooves so that the radii face first, through the side of the taper against the piston boss, upward (arrows).

Ignition System Exercise extreme caution when Testing in the workshop is limited to troubleshooting and carrying out a spark test. A new ignition module maintenance or repair work on the must be installed if no ignition spark ignition system. The high voltages is obtained (after checking that which occur can cause serious or wiring and stop switch are in good.: Push the ignition module back: Press the ignition module (1): Starting at the flag terminal, push and slide the setting gauge (1) against the setting gauge (2) and the short circuit wire (1) snugly 0000 890 6400 between the tighten down the screws (3) into the guide (arrow). If a spark is visible, the ignition system is in order. – To run diagnosis, select 'Other STIHL Products'. Then start the – If no spark is visible in the diagnostic function and follow the window, check the ignition steps in the diagnostic software.

– Reassemble all other parts in the reverse sequence. – Coat the inside of the spark plug boot with STIHL press fluid, b 12: Apply the puller (1) 4119 890 4501, insert screws (2): Hold the ignition lead and leg. Short Circuit Wire The resistance measured must be infinitely high.

If not, install a new throttle cable, b 6.6. The short circuit and ground wires are combined with the throttle cable Perform the contact and continuity to form a unit. If either is damaged, test on the ground wire too. 6.6.2 Short Circuit Wire: Check the cable holder (2), on Engine replace throttle cable if – Removing and necessary. Installing – Remove the short circuit wire from the control handle, b 6.6.3 – If necessary, remove the drive tube, b 9.1 Installing –.: Connect short circuit wire's flag terminal (2) to the tag (3) so that its crimped side faces the carburetor. – Reassemble all other parts in the reverse sequence. 6.6.3 Short Circuit Wire and Contact Springs on Control Handle: Press the short circuit wire (1): Pull the contact spring (1) with –.

(arrows) until the contact – the terminal must be pushed spring (1) is behind the lug (4). Fully home.: Apply thin coating of STIHL lubricating grease to radius of contact spring (1) – the contact face must remain free from grease, b 12: Press the ground wire (1) fully into the guides (arrows). Check operation: Depress stop switch lever (1), the contact springs (arrows) must touch each other – the contact springs must be free from grease.

– Install the throttle trigger / lockout lever, b 9.3 – The travel of the throttle trigger in the direction of full throttle is limited by rotating the throttle set wheel. Ignition System Troubleshooting Engine does not run Stop switch lever: – Stop switch lever not depressed?

Check the spark plug: – Smeared with oil, black? – Electrode gap correct? – Contacts shorted? – Clean, readjust or replace the spark plug, b 6.3 Check the spark plug boot: –.

Ignition spark? Air gap: – Check ignition module/flywheel, reset if necessary, b 6.2 Check the flywheel: – Have pole shoes turned blue? – Install new flywheel if necessary, b 6.5 Check short circuit wire: – Wire damaged? – Connectors firmly seated?.

Check operation of stop switch lever: – Short circuit wire chafed? – Function between contact springs on stop switch lever: – Stop switch lever not depressed = no contact – Stop switch lever depressed = contact – If necessary, install new short circuit wire or contact springs, b 6.6.2 Ignition spark?

Install new ignition module. General Rewind Starter Installing – Lubricate pegs on pawls with If the action of the starter rope STIHL multipurpose grease, becomes very stiff and the rope b 12 rewinds very slowly or not completely, it can be assumed that the starter mechanism is in order but plugged with dirt. Pawl / Carrier Installing – Remove the rewind starter, b 7.2 – Block the piston, b 4.2: Push the pawls (1) into the bores until they snap into place and: Push the torsion springs (1) onto locate the ends of the springs the pawls (2) so that the hooks (arrow) against the side of the (arrow) locate against the. ErgoStart / Rope Rotor Relieving tension of rewind spring The system will not be under tension if either the starter rope or rewind spring is broken. – Remove the rewind starter, b 7.2: Carefully release the rope Rewind spring must be relaxed. Rotor (1), while holding the starter rope (2) in the notch (arrow), until: Carefully remove the rope.

Installing – Lubricate full length of starter post with STIHL special lubricant, b 12 – Fit the starter rope on the rotor, b 7.5: Fit the carrier (1) in position so: Push the end of the starter that the recess (arrow) engages rope (1) out a little and undo the the spring's loop (2).: Thread the rope (1) through the: Use hook (2) 5910 893 8800 to – Hold the starter grip firmly to keep guide bushing and the rotor (2). Pull out the starter rope (1) the rope tensioned. Between the notch (arrow) and rope guide bushing. – Lubricate the rewind spring in the rotate it slightly until the spring is out and unwound. Frame with a few drops of STIHL properly seated.

Special lubricant before installing, – Wear a face shield and work. Installing unwound rewind spring If the rewind spring has popped out, refit it in the frame as follows:: Fit the anchor loop in its seat (arrow) in the frame.: Fit the rewind spring (1) in the frame in the clockwise direction. The procedure is otherwise the same as that for installing a new rewind spring. (2) as far as stop.: Tighten down the screw (3) firmly: Stand fan housing (1) upright,: Loosen the screw (1) and pull the then apply STIHL press fluid to sleeve (2) off the installing profile (arrows) of rubber tool (3). Installing: Coat outside of rubber: Insert the screw (1) – do not element (4) with STIHL press tighten down yet.

– Clamp square shank of installing fluid – do not use oil or any other tool in the vise. Control Levers Control Handle on Drive Tube Removing and Installing: Take out the screw (1) The clamps in the control handle on – serves to fix the drive tube in the drive tube must be loose.

Position.: Push the control handle (1) onto the end of the drive tube (2) with To avoid strain on the throttle cable, This control handle (1) with.: Tighten down the screws (4) – Check the control levers and firmly. Replace if necessary, – The control handle is now Throttle trigger and lockout lever, clamped securely to the drive b 9.3, tube. Stop switch lever (momentary contact switch), b 9.4, Adjusting wheel, b 9.5 –. Version for bike handle – Remove control handle from bike handle, b 9.2: Fit new locknut (1) in the recess: Disconnect the throttle cable (1) and push the screw (2) through from the trigger (2). The control handle and handlebar from the other side.: Remove the torsion spring (1).: Turn the upper leg (1) of the: Push the lockout lever (1) onto torsion spring counterclockwise the pivot pin and turn it and push it behind the web counterclockwise until it engages –.

Version with control handle on drive tube: Fit the lever (1) in the throttle: Lift the lockout lever (1) slightly trigger (2) so that the hooked and push the throttle trigger (2) leg (3) projects from the opening into position until the lug (arrow) (arrow) and the stop (4) is next to engages the lockout lever (1). Check operation: Lift the stop switch lever (1) The contact spring (1) must be slightly, pull the contact spring (2) located properly in the stop switch The throttle trigger (2) must be out of the guide (arrow) and push lever (2). Adjusting Wheel Version with control handle on drive tube – Remove control handle from drive tube, b 9.1 Remove control handle from bike handle, b 9.2 – Remove the throttle trigger and lockout lever, b 9.3 – Remove stop switch lever, b 9.4: Reach through the opening (arrow) and push the adjusting wheel (1) off the pivot pin.: Lubricate spiral groove (arrows) molding and position it against in adjusting wheel (3) and slot the rabbet as shown (arrow).

(arrow) in lever (2) with STIHL lubricant, b 12: Insert the screw (2) – do not tighten down yet. (1) is behind the lug (4). Free from grease.: Turn adjusting wheel (1) in direction of '+' up to stop.: Apply thin coating of STIHL – Install the throttle trigger / lockout lubricating grease to radius of lever, b 9.3. The throttle cable must not be under Engine does not return to idle tension when the throttle trigger is speed – working tool runs in this released since the control valve's position rotary piston may not close properly – the engine idle speed will then be –. Fuel System 10.1 Air filter Fleece filter 10.2 Filter Housing – See also Troubleshooting, – Remove the air filter, b 10.1 b 3.4, b 3.6 Paper filter: Take out the screw (1) and remove the filter cover (2).: Unscrew the nuts (1) and remove the filter housing (2).

– Collect the fuel in a clean container, b 1 Disconnect the fuel hose only when – Use STIHL press fluid to ease the tank cap is open. Installation, b 12: Pry the fuel return hose (1) out of.: Squeeze locking tabs (arrows): Remove the gasket (1) – always – Use STIHL press fluid to make under the retainer (1) together install a new gasket. Installation easier, b 12 and push out the manual fuel pump (2). Check operation – Check throttle cable and trigger adjustments and re-adjust if necessary, b 9.6 – Install the air filter, b 10.1 – Reassemble all other parts in the reverse sequence.: Line up the manual fuel pump (1) – Push the pressure hose of pump so that the lug (2) points towards 0000 850 1300 onto the elbow 10.3.1 Leakage Test. Leakage test without manual – After completing the test, push fuel pump the ring to the left to vent the system and then pull the pressure hose off the elbow connector.

– Install the carburetor, b 10.3 – Reassemble all other parts in the reverse sequence.: Carefully separate the metering: Note installed positions of – Check that metering and pump diaphragm (1) and gasket (2). Gasket (1) and metering diaphragms with gaskets are diaphragm (2). Properly seated, re-position if necessary. The diaphragm material is subjected to continuous alternating: Fit the gasket (1) and metering stresses and eventually shows.

Installing 10.4.3 Pump Diaphragm – Troubleshooting, b 3.4 – Remove carburetor with fuel hoses still attached and the manual fuel pump, b 10.3 – Remove the end cover, b 10.4.1: Take the inlet control lever (1) with spindle (2) out of the inlet: Fit the inlet needle (1). – Inspect the flange and replace if necessary – if a new flange is installed, the attached fuel hoses must also be replaced. – Reassemble in the reverse sequence.

Installing: Carefully separate the pump: Position the complete flange (1) diaphragm (1) and gasket (2) with fuel hoses attached against the underside of the carburetor. Check operation If the carburetor cannot be adjusted properly, the problem may be the adjusting screws. The high speed screw H and low speed screw L have a special hex head and can only be adjusted with screwdriver 5910 890 2311 –.: Insert screwdriver (2) 10.5 Adjusting the Carburetor 5910 890 2311 through the sleeve (1) and locate it on the hex The new carburetors are tuned at head of the low speed screw L. The factory so that the engine receives an optimum fuel-air: Hold the sleeve (1) steady and mixture in all environments and. Fine Tuning Preparations for adjusting idle speed The carburetor and air filter must be installed. – Mount the deflector and working tool (mowing head) – see instruction manual – the working tool must run freely, clean if necessary. – Check the air filter (fleece element) and clean or replace if necessary –.

10.5.2 Adjustments by User Engine stops while idling – Adjust engine idle speed with a – Turn the idle speed screw LA tachometer or the STIHL MDG 1. Clockwise until the working tool Adjust specified engine speeds starts running, then turn it back within a tolerance of ±. 10.6 Spacer Flange Installing – Troubleshooting, b 3.6 – Remove carburetor with fuel hoses still attached and put it to one side, b 10.3: Remove the gasket (1) – always install a new gasket.: Fit the new gasket (1) over the peg (2) and lug (3) and against –. 10.7 Tank Vent 10.7.1 Testing If problems occur on the carburetor or the fuel supply system, also check and clean the tank vent and replace it if necessary.

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Check function by performing pressure and vacuum tests on the tank via the fuel hose. – Always install a new fuel hose. Installing – If necessary, install a new tank – Use STIHL press fluid to make vent or tank, b 10.7 or b 10.9 installation easier, b 12: Push the tank vent hose (1) onto. Close the tank and shake the machine vigorously. – Use STIHL press fluid to make installation easier, b 12 – Open the tank again and drain it.: Push nipple of new tank vent (1) fully into the tank vent hose (2).: Position the fuel suction hose (1): Pry out the elbow connector (1) under the tank vent hose (2). With fuel suction hose (2).

– Use STIHL press fluid to make installation easier, b 12 – Remove the tank housing, b 10.9. – the elbow connector (1) must be pushed fully into the fuel suction hose (2). – Use STIHL press fluid to make: Pry the fuel return hose (1) out of installation easier, b 12 the bore (arrow) in the tank housing.: Pull off the fuel hose (1) and fuel: Line up the manual fuel pump (1) – Use STIHL press fluid to simplify return hose (2).

So that the lug (2) points towards assembly, b 12 the carburetor.: Check the manual fuel pump (3). 10.9 Fuel Tank 10.9.1 Fuel Tank Removing and Installing – Remove the drive tube, b 9.1 – Drain the fuel tank, b 1 – Remove the rewind starter, b 7.2 – Remove the shroud, b 5.4: Pull the tank vent hose (1) off the –. Installing – Use STIHL press fluid to make – Use STIHL press fluid to simplify installation easier, b 12 assembly, b 12 – Use STIHL press fluid to simplify assembly, b 12: Fit the elbow connector (1) with: Push the fuel return hose (1) fully fuel suction hose (3) under the into the bore (arrow).: Pull the fuel tank (1) out of the connector (arrow) on the rubber mounts (2) and lift it away.

– Use STIHL press fluid to simplify assembly, b 12 FS 94, KM 94: Push the rubber mounts (1) fully –.: Hold the fuel tank steady, lift the so that the lug (2) points towards tank guard (1) at the starter side – Use STIHL press fluid to make the carburetor. (arrow) and pull it off the lugs (2) installation easier, b 12 at the same time. Special Servicing Tools New Special Tools Part Name Part No. Application Rem. Press sleeve 4149 893 2400 Installing oil seal (ignition side / starter side) Installing sleeve 4149 893 4600 Protecting oil seal at ignition side Screwdriver 5910 890 2311 Adjusting the carburetor –.

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Part Name Part No. Application Rem. Thrust piece 4116 894 1000 Extension for spindle of screw sleeve, from service tool set ZS Puller 4119 890 4501 Removing flywheel Press arbor 4224 893 7200 Installing ball bearings hot and pressing fully home if necessary (ignition side of crankcase) Installing tool 4126 893 4900. 0781 120 1110 STIHL lubricating grease Oil seals, sliding and bearing points - 225 g tube 0781 120 1111 STIHL press fluid OH 723 0781 957 9000 Rubber elements, antivibration elements, fuel hoses Dirko HT red sealant 0783 830 2000. englisch / english 0455 593 0123.