stihl fs240,260,360,410,460 service manual
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STIH)
STIHL FS 240, 260, 360, 410, 460
2011-09
1 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
q
© ANDREAS STIHL AG & Co. KG, 2011
RA_752_00_01_04
1. Introduction and
safety precautions 3
1.1 Introduction 3
1.2 Safety precautions 4
2. Specifications 5
2.1 Engine 5
2.2 Fuel system 5
2.3 Ignition system 5
2.4 Gearbox 5
2.5 Tightening torques 6
3. Troubleshooting 8
3.1 Clutch 8
3.2 Gearbox 9
3.3 Drive tube assembly 10
3.4 Starter 11
3.5 Ignition system 13
3.6 Carburetor 14
3.7 Engine 18
4. Clutch 19
4.1 Clutch drum 19
4.1.1 Ball bearing 22
4.2 Clutch 23
5. Engine 25
5.1 Muffler 25
5.2 Leak testing 26
5.2.1 Preparations 26
5.2.2 Vacuum test 27
5.2.3 Pressure test 27
5.3 Oil seals 28
5.4 Shroud 29
5.5 Cylinder 30
5.6 Crankshaft 32
5.6.1 Ball bearing /
crankcase 35
5.7 Piston 36
5.8 Piston rings 38
6. Ignition system 39
6.1 Ignition timing 39
6.2 Ignition module 39
6.2.1 Control unit
(ignition module)
M-Tronic 41
6.3 Testing the
ignition module 42
6.4 Spark plug boot /
ignition lead 43
6.5 Flywheel 45
6.6 Short circuit wire 45
6.6.1 Testing 45
6.6.2 Short circuit wire
on engine,
removal and
installation 46
6.6.3 Short circuit wire
with M-Tronic on
engine, removal
and installation 48
6.6.4 Short circuit wire on
control handle for
loop handle,
removal and
installation 51
6.6.5 Short circuit wire
on control handle
for bike handle,
removal and
installation 52
6.6.6 Ground wire 54
6.6.7 Contact spring
versions with control
handle for bike handle 54
6.7 Troubleshooting,
Ignition System 55
7. M-Tronic 58
7.1 Calibrating
the control unit 58
7.2 Resetting the control
unit to factory defaults 58
7.3 Testing 58
7.3.1 Test preparations 58
7.3.2 Connect the test lead 58
7.3.3 Check screwed and
plug connections as
well as switch 59
7.3.4 Checking the solenoid
valve 59
7.3.5 Checking the start
detection function 60
7.3.6 Checking the wiring
harness 60
7.4 Removal and
installation 62
7.5 Troubleshooting,
M-Tronic 65
7.5.1 Engine does not start 65
7.5.2 Engine does not start
in position } 66
7.5.3 Engine speed drops
under load
– low power 67
7.5.4 Ignition – no ignition
spark 68
7.5.5 Engine stops
suddenly 69
7.5.6 Cut-off speed
not reached 70
8. Rewind starter 71
8.1 General 71
8.2 Starter 71
8.3 Pawls 71
8.4 ErgoStart/rope rotor 72
8.5 Starter rope /
starter grip 73
8.6 Tensioning
the rewind spring 75
8.7 Replacing
the rewind spring 75
Contents
2 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
Contents
9. Antivibration
elements 77
9.1 Rubber insert
1-point antivibration
system 77
9.2 Rubber buffers/
springs 4-point
antivibration system 78
10. Actuating levers 82
10.1 Control handle for
loop handle 82
10.1.1 Throttle trigger /
throttle trigger
interlock 82
10.1.2 Slide control 84
10.2 Control handle
for bike handle 85
10.2.1 Removal and
installation 85
10.2.2 Throttle trigger /
throttle trigger
interlock 86
10.2.3 Lever for stop function 89
10.2.4 Adjusting
the throttle cable 89
10.2.5 Throttle rod 90
11. Fuel system 91
11.1 Air filter 91
11.2 Filter housing 91
11.3 Carburetor 93
11.3.1 Leakage test 95
11.4 Repairing
the carburetor 96
11.4.1 Metering diaphragm 96
11.4.2 Inlet needle 97
11.4.3 Pump diaphragm 98
11.4.4 Throttle shaft lever 99
11.4.5 Choke lever/choke
knob 100
11.4.6 Adjusting screws,
carburetor
without M-Tronic 102
11.5 Carburetor
adjustment
with M-Tronic 103
11.6 Carburetor
adjustment
without M-Tronic 103
11.6.1 Basic setting 103
11.6.2 User adjustment 104
11.7 Spacer flange 105
11.8 Tank vent 107
11.8.1 Testing 107
11.8.2 Removal
and installation 108
11.9 Fuel intake 108
11.9.1 Pickup body 108
11.9.2 Fuel hose 109
11.9.3 Fuel tank 110
12. Drive tube assembly 112
12.1 Drive tube assembly
with loop handle 112
12.2 Drive tube assembly
with control handle
for bike handle 113
12.2.1 Disassembling
the drive tube
assembly with a
diameter of 25.4 mm 114
12.2.2 Disassembling
the drive tube
assembly with a
diameter of 28 mm 116
12.2.3 Loop handle
with barrier bar 117
12.3 Deflector 118
12.3.1 Deflector for
gearbox with 25.4 mm
drive tube assembly
diameter 118
12.3.2 Deflector for gearbox
with 28 mm drive tube
assembly diameter 119
12.3.3 One-piece
carrying ring 120
12.3.4 Support 120
12.4 Gearbox for drive tube
assembly 25.4 mm
with square profile 120
12.4.1 Removal and
installation 120
12.4.2 Disassembly 121
12.5 Gearbox for drive tube
assembly 28 mm
with serration 124
12.5.1 Removal and
installation 124
12.5.2 Disassembly 124
13. Special tools 129
14. Service accessories 131
3 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
1. Introduction and safety precautions
1.1 Introduction
This Service Manual contains
detailed descriptions of all the
typical repair and servicing
procedures for this machine.
Refer to the illustrated spare parts
lists during all repair work. These
lists show the installation position
and order in which the individual
parts and modules should be
assembled.
Refer to the latest edition of the
relevant spare parts list to check the
part numbers of any spare parts
required.
A fault on the machine may be due
to several causes. To help locate
the fault, consult the chapter on
"Troubleshooting" and the
"STIHL Service Training System"
for all functional groups.
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 spare parts list and
Service Manual until an updated
edition is issued.
The special tools mentioned in the
descriptions are listed in the chapter
"Special Servicing Tools" of this
manual. The tools can be identified
according to part number in the
"STIHL Special Tools" manual. The
manual lists all tools supplied by
STIHL.
Symbols are included in the text and
pictures for greater clarity.
The meanings are as follows:
In the text:
N 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
In the illustrations:
A Item pointer (short)
a Direction of
movement (long arrow)
@ 4.2 Reference to another
chapter, in this case to
Chapter 4.2
Service Manuals and technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed on to third parties.
Always use original STIHL
replacement parts.
They can be identified by the STIHL
part number
the logo {
and the
STIHL parts symbol K
The symbol may appear alone on
small parts.
Storage or disposal of oil and fuel
Collect fuel or lubricating oil in a
clean container and dispose of it in
accordance with environmental
regulations.
4 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
1.2 Safety precautions
Specific national safety regulations
and the safety instructions in the
instruction manual must be
observed if the machine has to be
started up during maintenance or
repair work.
Gasoline is highly inflammable and
can also be explosive under certain
conditions.
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.
Test for leakage after all work on the
fuel system and engine.
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.
Suitable protective gloves must be
worn without fail if parts are heated
for assembly/disassembly
purposes. Risk of burns from hot
grease. Lubricants in the parts
become hot due to heating.
Improper handling may result in
burns and other serious injuries.
Always replace damaged parts.
Check dismantled parts for wear
and damage before installation,
replace if necessary.
Only use the machine with the
shroud mounted – otherwise the
rotating fan wheel poses a risk of
injury and there is a risk of engine
damage due to overheating.
The chapter "Tightening Torques"
lists all components of this machine
that must be tightened with the
specified tightening torques or
coated with thread-locking
adhesive. These specifications
must be observed throughout the
Service Manual when tightening
screws and nuts as well as other
fasteners.
Fuel system – barbed
connectors
Pull or push the fuel hoses, by hand
whenever possible, in the direction
of the connector in order to ensure
leakproofness of the fuel system.
Avoid damaging the barbed
connectors
– sharp-edged pliers, screwdrivers,
etc., may not be used.
Also, do not cut open fuel hoses
with a knife or similar aids.
Do not reuse fuel hoses after
disassembly, but instead always
replace them with new hoses
– fuel hoses can be overstretched
when being detached.
Mount new fuel hoses dry or using
STIHL press fluid, b 14.
Other press fluids are not permitted
and may lead to fuel hose damage.
When using STIHL press fluid,
apply press fluid to the ends of the
hose and the connectors and press
the new hoses onto the barbed
connectors, b 14.
5 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
2. Specifications
2.1 Engine
FS 240 C, FS 360 C FS 260 C, FS 410 C FS 460 C
Displacement: 37.7 cm
3
41.6 cm
3
45.6 cm
3
Bore: 40.0 mm 42.0 mm 44.0 mm
Stroke: 30.0 mm 30.0 mm 30.0 mm
Engine power to ISO 8893: 1.7 kW (2.3 HP)
at 8500 rpm
2.0 kW (2.7 HP)
at 9000 rpm
2.2 kW (3.0 HP)
at 9500 rpm
Cut-off speed
(Nominal value): 12500 rpm, FS 240 RC
10500 rpm
12500 rpm, FS 260 RC
10500 rpm
12300 rpm
Idling speed
(Nominal value): 2800 rpm 2800 rpm 2700 rpm
Clutch: Centrifugal clutch
without linings
Centrifugal clutch
without linings
Centrifugal clutch
without linings
Clutch engages at: 3600 rpm 3600 rpm 3600 rpm
Crankcase leakage test
at gauge pressure: p
ü
= 0.5 bar p
ü
= 0.5 bar p
ü
= 0.5 bar
under vacuum: p
u
= 0.5 bar p
u
= 0.5 bar p
u
= 0.5 bar
2.2 Fuel system
Carburetor leakage test at
gauge pressure: p
ü
= 0.8 bar p
ü
= 0.8 bar p
ü
= 0.8 bar
Operation of tank vent at
gauge pressure: p
ü
= 0.5 bar p
ü
= 0.5 bar p
ü
= 0.5 bar
Fuel: as specified in instruction
manual
as specified in instruction
manual
as specified in instruction
manual
2.3 Ignition system
Air gap between ignition
module and fanwheel: 0.30 (+ 0.15/- 0.20) mm 0.30 (+ 0.15/- 0.20) mm 0.30 (+ 0.05/- 0.10) mm
Spark plug (suppressed): NGK CMR 6 H NGK CMR 6 H NGK CMR 6 H
Electrode gap: 0.5 mm 0.5 mm 0.5 mm
2.4 Gearbox
Quantity of gear
lubricant:
Drive tube assembly
diameter
25.4 mm/28.0 mm
9.5 g,
STIHL gear lubricant for
brushcutters
6 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
2.5 Tightening torques
DG and P screws are fitted in plastic and light alloy metal parts. These screws form a permanent thread when
they are installed for the first time. The material is permanently deformed. Screws can be removed and installed
as often as necessary without impairing the strength of the screwed assembly, provided that the specified
tightening torque is observed.
For this reason it is essential to use a torque wrench.
Fastener Thread size For component Tightening
torque
Nm
Comment
Screw M 5x17 Cover/ shroud 6.0
Screw D 5x24 Cover/ clutch housing 6.0 1), 5)
Screw P 4x14 Cover/ starter cover 2.0
Screw P 6x14 Line limiting blade/ deflector 2.5
Screw D 5x24 Starter 6.0 1)
Screw P 5x32 Plugs for antivibration springs/ antivibration
housing
3.0 6)
Screw M 5x48x22 Control handle/ handlebar/ locknut 2.5
Screw P 4x16 Control handle moldings outside/ inside 1.3
Screw M 5x12 Control handle clamp/ drive tube assembly 5.0
Screw P 4x10 Diagnostic jack/ bushing 1.5 7)
Screw M 5x21 Filter cover 6.0
Collar nut M 5 Filter housing 3.5
Screw M 6x35 Gearbox/ drive tube assembly 10.0 1)
Screw D 5x24 Gear housing/ drive tube assembly (1st stage) 4.0 1)
Screw D 5x24 Gear housing/ drive tube assembly (2nd stage) 9.0 1)
Screw M 5x10 Gear housing/ guard ring 8.0 2)
Screw M 5x48x22 Left handle/ handlebar/ locknut 2.5
Screw D 5x24 Shroud 6.0 1)
Screw P 4x14 Shroud/ slide 2.0
Screw P 4x10 Cable holder/ short circuit wire/ ignition
module
1.5
Screw M 6x30 Clamp/ drive tube assembly/ supports 8.0 1)
Screw M 5x16 Clamps handlebars 2.0 1)
Screw D 6x35 Clamping device clutch housing 8.0 1), 6)
Screw D 5x24 Fuel tank/ crankcase 6.0 1)
Screw M 6x25 Clutch/ flywheel 10.0
Screw D 5x24 Clutch housing/ crankcase 8.0 1)
Screw M 5x16 Crankcase fan side/ insert 6.0 2)
Screw D 5x24 Crankcase fan side/ starter side 8.0 1)
Screw P 3x6 Return spring/ fan housing 0.6
Screw M 5x16 Muffler / crankcase 9.0 2)
Screw M 5x16 Muffler/ cylinder/ first screw
(1st stage)
2.0 2)
Screw M 5x16 Muffler/ cylinder/ second screw
(2nd stage)
10.0 2)
Screw M 5x16 Muffler/ cylinder/ first screw
(3rd stage)
10.0 2)
Screw P 4x10 Switchgear/ bushing 1.5 7)
7 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
Fastener Thread size For component Tightening
torque
Nm
Comment
Screw M 5x20 Clamp/ control handle for loop handle/ nut 4.5 1)
Screw M 5x20 Cutting attachment deflector/ gear housing 4.3 1)
Screw M 5x23 Cutting attachment deflector/ gear housing 10.0
Screw IS 5x14 Deflector/ antivibration housing 4.0 6)
Screw D 5x32 Protective hip plate/ crankcase 8.0 1)
Nut M 8x1 Flywheel/ crankshaft 28.0
Screw M 6x14 Clamp/ drive tube assembly harness anchor 4.5 1)
Screw D 6x32 Clamp/ drive tube assembly with washer 12.0 1)
Screw M 5x18 Clamp/ supports/ drive tube assembly 4.0 1), 6)
Nut M 8x1 Starter cup / crankshaft 17.0
Screw P 6x19 Supports/ plugs antivibration springs 6.0 6)
Screw M 14x1.25x7 Supports/ muffler with spark arresting screen 8.0
Screw P 4x14 Bushing choke/ filter housing 2.0
Screw P 4x10 Shim/ deflector 1.0
Screw M 11x10 Screw plug/ gearbox 9.5
M 10x1 Spark plug/ cylinder 12.0
Screw D 4x18 Ignition module/ cylinder 4.0 1)
Screw M 5x20 Spacer flange/ cylinder 8.0 2)
Screw D 5x32 Cylinder / crankcase 9.0 1)
Remarks:
1) Easy-slide coating with locking serration
2) Microencapsulated with locking serration
3) Microencapsulated with washer
4) Connection between crankshaft and flywheel must be degreased and oil-free
5) 1-point antivibration system
6) 4-point antivibration system
7) M-Tronic
When inserting DG and P screws into an existing screw thread:
Insert the DG or P screw in the hole and turn counterclockwise until it gently drops into the hole in axial direction.
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.
As a rule, microencapsulated screws must be replaced after removal.
Screwdriver speed when used in plastic material: max. 500 rpm for DG and P-type screws.
Do not use an impact wrench to release or tighten screw connections.
Screws with and without locking serration must not be confused.
8 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
3. Troubleshooting
3.1 Clutch
Problem Cause Remedy
Cutting attachment stops under
load at full throttle
Clutch shoes badly worn Install new clutch
Clutch drum badly worn Install new clutch drum
Cutting attachment rotates at idle
speed
Idle speed too high Versions without M-Tronic:
Readjust idle speed screw LA
Versions with M-Tronic:
Carry out diagnosis
Tension springs of the clutch shoes
are stretched
Replace tension springs, replace
clutch if necessary
Tension springs of the clutch shoes
are broken
Replace tension springs
Loud noises Tension springs stretched Replace all tension springs
Ball bearing of the clutch drum is
damaged
Replace ball bearing
Screws of the clutch are loose Tighten screws, replace clutch if
necessary and check threaded
holes on the flywheel, replace
flywheel if necessary
Clutch shoes worn Install new clutch
9 FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
3.2 Gearbox
Problem Cause Remedy
Loud noises Ball bearings damaged or worn Replace ball bearings on the drive
side and non-drive side
Pinion damaged or worn Replace set of pinions on the drive
side and non-drive side
Too little or no gear lubricant in
gearbox
Gearbox drive tube assembly
25.4 mm:
Add gear lubricant
Gearbox drive tube assembly
28 mm:
Remove drive pinion and add gear
lubricant
Gearbox becomes too hot Excessive friction due to damaged
or worn ball bearings
Replace ball bearings on the drive
side and non-drive side
Too little or no gear lubricant in
gearbox
Gearbox drive tube assembly
25.4 mm:
Add gear lubricant
Gearbox drive tube assembly
28 mm:
Remove drive pinion and add gear
lubricant
Gearbox runs rough and stops
running under load
Drive shaft does not fully engage
drive pinion
Push gearbox onto drive tube
assembly until the drive shaft fully
engages the drive pinion
Square profile or serration in the
drive train is damaged or worn
Check drive pinion, drive shaft and
clutch drum, replace if necessary
Clutch worn Check clutch and clutch drum,
replace if necessary
Gearbox frozen Locking pin for changing tools not
removed
Remove locking pin
Damaged or worn ball bearings
jammed
Replace ball bearings on the drive
and non-drive sides, also check
bearing seats in the gear housing,
replace gear housing if necessary
Serration damaged or broken –
fragments jammed
Replace set of pinions on the drive
side and non-drive side
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If you're in need of a comprehensive service manual for the Stihl FS240, FS260, FS360, FS410, or FS460, you've come to the right place. These manuals are invaluable resources for both professional mechanics and DIY enthusiasts alike. Whether you're looking to perform routine maintenance or tackle more complex repairs, these manuals provide detailed guidance to help you get the job done right.
With clear and concise instructions, these manuals cover a wide range of topics including engine maintenance, fuel system troubleshooting, electrical system diagnostics, and much more. Whether you're working on a single unit or managing a fleet of equipment, having access to these manuals can save you time and money by ensuring that repairs are done correctly the first time.
These manuals are available in .PDF format, providing easy access and compatibility across a variety of devices. With their user-friendly layout and comprehensive content, these manuals are an essential addition to any workshop or toolbox.
