Stihl BR 500, BR 550, BR 600 Service Repair Manual INSTANT

STIH) STIHL Series 4140 Components BG, SH 2005-01

1 Series 4140 Components BG, SH q © ANDREAS STIHL AG & Co. KG, 2005 Contents 1. Introduction 2 2. Safety Precautions 3 3. Specifications 4 3.1 Fuel System 4 3.2 Tightening Torques 5 4. Troubleshooting 7 4.1 Rewind Starter 7 4.2 Fuel System 8 4.3 Engine 10 5. Housing 11 5.1 Handle Molding 11 5.2 Handle and Feet (BG 85, SH 85) 11 6. Engine 12 6.1 Removing and Installing 12 6.2 Muffler/Spark Arresting Screen 13 6.2.1 Without Cat 13 6.2.2 Muffler with Catalytic Converter 13 7. Rewind Starter 14 7.1 General 14 7.2 Removing and Installing 14 7.3 Starter Cup 15 7.4 Rope Rotor 15 7.5 Replacing the Rewind Spring 16 7.5.1 Tensioning the Rewind Spring 17 7.6 Starter Rope 17 7.7 Pawl 18 8. Throttle Control 18 8.1 Throttle Trigger 18 8.2 Setting Lever (BG 85, SH 85 only) 19 8.3 Stop Switch 19 8.3.1 Version up to 2001 19 8.3.2 Version from 2001 20 8.4 Short Circuit Wire/ Ground Wire 20 8.5 Throttle Cable 21 8.6 Throttle Rod 21 9. Fuel System 21 9.1 Air Filter 21 9.1.1 Removing and Installing 22 9.1.2 Choke Shutter 22 9.2 Carburetor 23 9.2.1 Leakage Test 23 9.2.2 Removing and Installing 24 9.2.3 Spacer Flange 24 9.3 Servicing the Carburetor 25 9.3.1 Manual Fuel Pump with Oval End Cover 25 9.3.2 Manual Fuel Pump with Square End Cover 26 9.3.3 Metering Diaphragm 26 9.3.4 Inlet Needle 27 9.3.5 Fixed Jet 28 9.3.6 Pump Diaphragm and Fuel Strainer 28 9.4 Adjusting the Carburetor 29 9.4.1 Carburetor with LD Screw 29 9.4.2 User Adjustment of Carburetor with H, L and LA Screws 29 9.4.3 Basic Setting on Carburetor with H, L and LA Srews 31 9.5 Tank Vent 32 9.5.1 General 32 9.5.2 Replacing 33 9.6 Fuel Tank 33 9.6.1 General 33 9.6.2 Pickup Body 34 9.6.3 Fuel Hoses 34 10. Blower and Vacuum Attachment 35 10.1 Fanwheel 35 10.2 Protective Screen (all except BG 45) 35 10.3 Protective Screen (BG 45 only) 35 10.4 Blower Tube (BG only) 36 10.5 Suction Tube (SH only) 36 10.6 Elbow (SH only) 36 11. Special Servicing Tools 37 12. Servicing Aids 38

2 Series 4140 Components BG, SH This service manual contains detailed descriptions of all typical repair and servicing procedures for models BG 45, 46, 55, 65, 85, SH 55, 85, which are based on the series 4140 powerhead. You will find detailed descriptions of procedures for servicing and repairing engine components in the service manual for the “Series 4140 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 list to check the part numbers of any replacement parts. A fault on the machine may have several causes. To help locate the fault, consult the chapter on "Troubleshooting" in this manual and the "STIHL Service Training System" for all assemblies. 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 servicing tools mentioned in the descriptions are listed in the chapter "Special Servicing Tools" of this manual. Use the part numbers to identify the tools in the "STIHL Special Tools” manual. The manual lists all special servicing tools currently available from STIHL. Symbols are included in the text and pictures for greater clarity. The meanings are as follows: In the descriptions: : = Action to be taken as shown in the illustration (above the text) – = Action to be taken that is not shown in the illustration (above the text) b 4.2 Reference to another chapter, i.e. chapter 4.2 in this example. In the illustrations: A Pointer aDirection of movement Service manuals and technical information bulletins are intended exclusively for the use of properly equipped repair shops. They must not be passed to third parties. Always use original STIHL replacement parts. They can be identified by the STIHL part number, the STIH) logo and the STIHL parts symbol ( This symbol may appear alone on small parts. 1. Introduction

3 Series 4140 Components BG, SH If the engine 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. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. Improper handling may result in burns or other serious injuries. Warning! Do not bring any fire, flame, spark or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. 2. Safety Precautions

4 Series 4140 Components BG, SH 3. Specifications 3.1 Fuel System Carburetor: Diaphragm carburetor Carburetor leakage test at gauge pressure: 0.8 bar (8 kPa) Operation of tank vent at gauge pressure: 0.3 bar (3 kPa) under vacuum: 0.05 bar (0.5 kPa) Fuel: see instruction manual Octane number: min. 90 RON Fuel mixture: Regular brand-name gasoline and STIHL 50:1 two-stroke engine oil or brand-name two-stroke engine oil Mix ratio: 50:1 with STIHL 50:1 two-stroke engine oil Fuel mix for units with catalytic converter: Use only STIHL 50:1 two- stroke engine oil with unleaded gasoline.

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Stihl BR 500, BR 550, BR 600 Service Repair Manual INSTANT

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