STIHL 4-Stroke Engine Check ©2010 STIHL Incorporated 4. Check condition of cutting attachment or blower tube and nozzle. 2. Check throttle for proper operation, opens completely, returns to idle. 3. Empty fuel tank: check for debris, contamination, and verify if ol is mixed. Warning! Gasoline is extremely flammable. Keep away from spark or other ignition source. Properly dispose of fuel per local regulations. 4. Inspect spark plug connector and high tension lead, 5. Check for spark with a ZAT 4 tester with plug installed, if no spark retest with new plug. Verify stop switch function. 6. Verify that spark plug is correct heat range and set electrode gap to .020" (0.5 mm). FS 90, FS 100, FS 110, KM 110, HL 100, FC 100, FC 110, HT 100,HT.101______| STIHL 0000 400 7009 Bosch USR7AC NGK _CMR5H 7. Remove shroud, loosen muffler and inspect fire screen, inspect air filter, remove carburetor. 8. Check for sheared flywheel key by verifying flywheel is in time with crankshaft (note flywheel ‘markings in relation to ignition armature when piston is positioned at top dead center). 9. Verify proper air gap between ignition module and flywheel. Use tool 4116 890 6401. MASTERWRENCH SERVICE 10. Set valve clearance to 0.1 mm (0.004") when cold. 0.1 to.0.3 mm (0.004" to 0.012") is acceptable. Perform cylinder leak down test. Maximum of 10% leakage is acceptable. 12. Install valve cover and new gasket. Install spark plug; perform crankcase pressure and vacuum test, Pressure specification: Pressurize to 0.5 bar (7 psi). Leakage to 0.3 bar (4 psi) in 20 seconds is acceplable. Vacuum specification Apply vacuum of -0.5 bar (-7 psi). Leakage to -0.3 bar (-4 psi) in 20 seconds is acceptable. 13, Verify impulse signal Connect a second gauge to impulse hose while performing pressure and vacuum tests. Gauge needle should move while performing tests.14, Perform carburetor check-shafted products: Step 1: Attach tester to fuel supply fitting Pressurize carburetor 0.0.7 bar (10 psi). If pressure holds, the fuel pump components and inlet needle are sealing. Go to step 2 Step 3: Attach tester to primer return hose. Push primer bulb; gauge should indicate pressure and hold. If not, purge primer is faulty. Step 2: With pressure present from step 1, pump primer bulb and the gauge needle should go down. Put tester in vacuum mode and pump bulb 3 times and the needle should show a vacuum for a minimum of 1 second. If not, carburetor has an internal leak. Step 3: Attach tester to return fine fitting in pressure mode. Pump primer bulb and gauge should indicate pressure and hold. If not, purge primer flange is faulty Repl 14, Perform carburetor check-backpack blowers: 16, Pressure test tank to 0.3 bar (5 psi). There should be no leakage 16. Vacuum test tank, it should slowly leak back to atmospheric pressure. If not, tank vent is. faulty 17. Inspect or replace fuel fiter. Important: use only STIHL filter part no. 0000 350 3502. 18, Pressure test fuel lines to 0.3 bar (5 psi). There should be no leakage 19. Perform necessary repairs and re-assemble. 20. Set the carb H and L screws with limiter cap removed to initial start-up setting of H = 3 Step 1: Attach tester to fuel line fitting. Pressurize turns out from lightly seated, L = 2 turns out carburetor to 0.7 bar (10 psi). If pressure holds, the from lightly seated (refer to repair fuel pump components and inlet needle are specification charts for detailed settings). sealing. Go to step 2. Final adjustment may vary significantly. 21. Verify throttle cable adjustment, 22, Start engine, warm up and perform final carburetor adjustments. Verify idle speed and maximum RPM (refer to repair specification charts). Seat limiter caps in place. ‘Step 2: With pressure present from step 1, pump 28. Test run machine under load primer bulb and the gauge needle should go down. Put tester in vacuum mode and pump bulb 3 times, 24. Verify stop switch function and the needle should show a vacuum for a minimum of 1 second. If not, carburetor has an Checklist complete. internal leak.