Stihl SR200 backpack sprayer service manual

STIH) STIHL SR 200 2013-05

1 SR 200 q © ANDREAS STIHL AG & Co. KG, 2013 RA_457_00_01_01 1. Introduction and Safety Precautions 2 1.1 Introduction 2 1.2 Safety Precautions 3 2. Specifications 4 2.1 Engine 4 2.2 Fuel System 4 2.3 Ignition System 4 2.4 Tightening Torquese 5 3. Troubleshooting 7 3.1 Rewind Starter 7 3.2 Blower 8 3.3 Ignition System 9 3.4 Carburetor 11 3.5 Engine 14 4. Engine 15 4.1 Muffler / Spark Arresting Screen 15 4.2 Leakage Test 16 4.2.1 Preparations 16 4.2.2 Vacuum Test 17 4.2.3 Pressure Test 17 4.3 Oil Seals 18 4.4 Engine 18 4.5 Cylinder 20 4.6 Crankshaft 23 4.7 Bearings / Crankshaft 25 4.8 Piston 26 4.8.1 Piston Rings 29 5. Ignition System 30 5.1 Install new ignition module 30 5.1.1 Removing and Installing 30 5.2 Ignition Timing 32 5.3 Testing the Ignition Module 32 5.4 Spark Plug Boot 33 5.5 Flywheel 34 5.6 Short Circuit and Ground Wires 35 5.6.1 Checking the Wires 35 5.6.2 Removing and Installing 36 5.7 Ignition System Troubleshooting 39 6. Rewind Starter 42 6.1 General 42 6.2 Fan Housing 42 6.3 Pawls 43 6.4 Rope Rotor 43 6.5 Starter Rope / Grip 44 6.6 Tensioning the Rewind Spring 45 6.7 Replacing the Rewind Spring 46 6.8 Rope Guide Bushing 48 7. Servicing the AV System 49 7.1 AV Springs 49 7.2 Stop Buffers on Fan Housing 50 8. Control Levers 51 8.1 Switch Positions 51 8.2 Setting Lever 51 8.3 Throttle Trigger / Lockout Lever 52 8.4 Valve Lever 55 9. Fuel System 57 9.1 Air filter 57 9.2 Baffle / Filter Housing 58 9.3 Carburetor Removing and Installing 59 9.3.1 Leakage Test 60 9.4 Servicing the Carburetor 60 9.4.1 Metering Diaphragm / Fuel Pump 60 9.4.2 Inlet Needle 62 9.4.3 Pump Diaphragm 62 9.4.4 Throttle Lever 64 9.4.5 Choke Knob 64 9.4.6 Adjusting Screws 65 9.5 Adjusting the Carburetor 66 9.5.1 Basic Setting 66 9.5.2 Standard Setting 67 9.5.3 Adjusting Idle Speed 68 9.6 Throttle Cable 68 9.6.1 Adjusting the Throttle Cable 68 9.7 Spacer Flange Removing and Installing 69 9.8 Tank Vent 70 9.8.1 Testing 70 9.8.2 Removing and Installing 71 9.9 Fuel Intake 72 9.9.1 Pickup Body 72 9.9.2 Fuel Hoses 72 9.9.3 Connector 73 9.10 Fuel Tank 74 9.10.1 Fuel Tank Cap 75 10. Blower and Vacuum Attachment 76 10.1 Removing Inner Blower Housing 76 10.1.1 Vent Hose 76 10.2 Installing Inner Blower Housing 76 10.3 Stop Buffer 76 10.4 Blower Wheel 76 10.5 Container 77 10.6 Pressure Pump 79 10.6.1 Disassembling and Re- assembling 80 10.7 Nozzle / Valve 81 10.7.1 Nozzle 81 10.7.2 Valve 82 10.8 Elbow 83 10.9 Hoses 84 10.9.1 Hose clamps 84 10.9.2 Hose on Control Handle 84 11. Backplate 85 11.1 Removing and Installing the Backplate 85 11.2 Harness 85 11.3 Back Padding 86 12. Special Servicing Tools 87 13. Servicing Aids 88 Contents

2 SR 200 1. Introduction and Safety Precautions 1.1 Introduction This service manual contains detailed descriptions of all the repair and servicing procedures specific to this power tool. 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" 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 tools mentioned in the descriptions are listed in the chapter on "Special Servicing Tools" in 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 that is 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 Pointer (short arrow) aDirection of movement b 4.2 = Reference to another chapter, i.e. chapter 4.2 in this example. 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. Preparations for servicing Always use original STIHL replacement parts. They can be identified by the STIHL part number, the STIHL) logo and the STIHL parts symbol ( This symbol may appear alone on small parts. Storing and disposing of oils and fuels Collect fuel or lubricating oil in a clean container and dispose of it properly in accordance with local environmental regulations.

3 SR 200 1.2 Safety Precautions 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. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. Always wear suitable protective gloves for operations in which components are heated for assembly or disassembly. Improper handling may result in burns or other serious injuries. 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. Always replace damaged parts. Check disassembled parts for wear or damage before re-installing – replace as necessary. Run the machine only with the shroud mounted in position – there is otherwise a risk of injury from the flywheel and a risk of engine damage due to overheating. The chapter on tightening torques lists all machine components that have to be tightened to a specific torque. The specifications must be maintained when tightening down screws, nuts and other fasteners in all the procedures described in this service manual. Fuel system – hose barb connectors Pull off or push on fuel hoses in line with the connector, preferably by hand, to ensure the tightness of the fuel system. Avoid damaging the hose barb – do not use sharp-edged pliers, screwdrivers, etc. Do not cut open fuel hoses with a knife or similar tool. Do not re-use fuel hoses after removal. Always install new hoses – fuel hoses can be overstretched during removal. Install new fuel hoses either dry or with the aid of STIHL press fluid, b 13. Other press fluids are not approved and may result in damage to the fuel hoses. Coat the ends of the hoses and the connectors with STIHL press fluid and then push the new hoses on to the hose barbs, b 13.

4 SR 200 2. Specifications 2.1 Engine Displacement: 27.2 cc Bore: 34 mm Stroke: 30 mm Engine power to ISO 7293: 0.8 kW (1.1 bhp) Max. permissible speed (with nozzle): 7,500 rpm Idle speed: 2,500 rpm Engine leakage test under vacuum: 0.5 bar at gauge pressure: 0.5 bar 2.2 Fuel System Carburetor leakage test at gauge pressure: 0.8 bar Operation of tank vent at gauge pressure: 0.5 bar Fuel: as specified in instruction manual 2.3 Ignition System Air gap between ignition module and fanwheel: 0.15 ... 0.30 mm Spark plug (resistor type): NGK CMR 6 H Electrode gap: 0.5 mm

5 SR 200 2.4 Tightening Torquese 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 Remarks Nm Pressure pump P 5x25 Pressure pump/blower housing 3.0 Nut M 5 Filter housing/carburetor/spacer flange 3.5 Screw P 6x19 Blower housing, outer/inner 6.0 Screw D 5x24 Blower housing, inner/crankcase 8.0 2) Screw D 5x24 Blower housing, inner/engine pan 8.0 2) Nut M 8x1 LH-06 Blower wheel/crankshaft 21.0 Screw P 4x19 Handle molding, outer/inner 1.5 Screw P 6x26.5 Handle molding/blower tube 4.0 Screw P 6x19 Retainer, inside blower housing 4.0 Screw P 6x25 Fuel tank/backplate 6.0 Screw D 5x60 Engine pan/crankcase/cylinder 9.0 2) Screw D 5x20 Fan housing / spiral housing 6.0 3) Screw P 5x18 Backplate/plug 4.0 Screw P 5x14 Back padding/backplate 3.0 Screw D 5x20 Muffler / cylinder 9.0 2) Nut M 8x1 Flywheel / crankshaft 17.0 1) Screw D 5x20 Spiral housing / crankcase 6.0 2) Screw D 5x20 Spiral housing/engine pan 6.0 2) Screw P 6x25 Bracket/backplate 6.0 M 10x1 Spark plug 12.0 Screw D 4x18 Ignition module / cylinder 3.5 2) Screw D 5x20 Spacer flange/cylinder, stage 1 2.0 2), 4) Screw D 5x20 Spacer flange/cylinder, stage 2 6.0 2), 4)

6 SR 200 Remarks: 1) Degrease crankshaft/flywheel and mount oil-free 2) anti-friction coating with binding head 3) anti-friction coating 4) Tightening sequence: bottom left, top center, bottom right 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.

7 SR 200 3. Troubleshooting 3.1 Rewind Starter Condition Cause Remedy Starter rope broken Starter rope pulled out too vigorously as far as stop or over edge, i.e. not vertically Install new starter rope Normal wear Install new starter rope Starter rope does not rewind Rewind spring very dirty or corroded Clean or replace rewind spring Insufficient spring tension Check rewind spring and increase tension Rewind spring worn Install new rewind spring Starter rope cannot be pulled out far enough Spring overtensioned Check rewind spring and reduce tension Starter rope can be pulled out almost without resistance (crankshaft does not turn) Guide pegs on pawls or pawls themselves are worn Replace pawls Pawl spring fatigued Install new pawl spring Starter rope is difficult to pull or rewinds very slowly Starter mechanism is very dirty Thoroughly clean complete starter mechanism Lubricating oil on rewind spring becomes viscous at very low outside temperatures (spring windings stick together) Coat rewind spring with a small amount of standard solvent-based degreasant (containing no chlorinated or halogenated hydrocarbons), then pull rope carefully several times until normal action is restored

8 SR 200 3.2 Blower Always switch off the engine before working on the blower. Condition Cause Remedy Blower does not blow Blower wheel loose Tighten down nut on blower wheel firmly Blower wheel blocked Clean blower housing Blower wheel worn or blades broken Install new blower wheel

9 SR 200 3.3 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, 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 Clean the spark plug or replace if necessary. Fuel/oil mixture – too much oil Use correct mixture of fuel and oil Incorrect air gap between ignition module and flywheel Set air gap correctly Flywheel shows signs of damage (e.g. scores) or pole shoes have turned blue Install new flywheel Ignition timing out of adjustment, flywheel warped, key in flywheel sheared Install new flywheel Flywheel magnetization weak – pole shoes have turned blue Install new flywheel Irregular spark Check operation of stop switch and ignition module Check ignition lead/module, replace ignition module if necessary Check ignition lead and short circuit wire for damaged insulation or break and replace if necessary. Check operation of spark plug. Clean the spark plug or replace if necessary. The carburetor or engine may also be the cause of poor engine running behavior

Stihl SR200 backpack sprayer service manual

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