STIHL 009/010/011 Chainsaw Service & Repair Manual

STIHL 009, 010, 011 1 SERVICE MANUAL STIHL 009, 010, 011 FOREWORD This Service Manual covers model 010 chain saws up to machine number 7 900 000 as well as later machines unless technical information bulletins have been issued in the meantime with updated repair procedures. Models 009 and 011 have substantially the same constructional features as model 010 chain saws. This Service Manual can therefore be used for the 009 and 011 chain saws as well. In the event of faults it is quite possible that a single fault may have several causes. It is therefore advisable to consult the "Troubleshooting Chart" in each chapter when tracing faults. We also recommend that you make use of the exploded views in the illustrated parts lists when carrying out repair work. This service manual and all technical information bulletins are intended exclusively for the use of STIHL servicing dealers and staff and must not be passed on to third parties. SPECIAL TOOL MANUAL Repair work is made considerably Our special tool manual illustrates easier if the chain saw is mounted on and lists the part numbers of ail assembly stand 5910 850 3100. The available machine-related tools as saw is easily secured to the stand by well as general purpose tools for all means of the bar mounting stud and machines. collar nut. The special tool manual is available While on the assembly stand the chain in several languages and can be saw can be swivelled into any required ordered by quoting the appropriate position within a certain range to suit part number listed hereunder. the repair in question. This not only has the advantage of keeping the German 0455 901 0023 component in the most convenient English 0455 901 0123 position for the repair but also leaves French 0455 901 0223 both hands free for the work and thus Spanish 0455 901 0323 effects a considerable time saving. Yugoslav 0455 901 0423 Swedish 0455 901 0523 Italian 0455 901 0723 Portuguese 0455 901 1223 STIHl Andreas Stihl Postfach 1760 D-7050 Waiblingen

STIHL 009, 010, 011 2 CONTENTS 1. Specifications 4 3.7 Installation of 4.5.2 Adjusting Breaker- Crankshaft Controlled Ignition 34 1.1 Engine 4 - Assembly of 4.6 Magneto Edge Gap 1.2 Fuel System 4 Crankcase 16 on Breaker- 1.3 Ignition System 5 3.8 Leakage Testing the Controlled Ignition 34 1.4 Tightening Torques 5 Crankcase 18 1.5 Cutting Attachment 6 3.8.1 Pressure Test 19 1.6 Weights 6 3.8.2 Vacuum Test 20 1.7 Special Accessories 6 3.8.3 Replacing the Oil 5. Rewind Starter 35 Seals 20 5.1 Construction and Operation 35 2. Clutch, Chain Drive 5.2 Troubleshooting Chart 35 and Chain Brake 7 5.3 Disassembly 36 4. Ignition System 21 5.4 Replacing the 2.1 Construction and Operation 7 Starter Rope 36 2.1.1 Clutch and Chain 4.1 Construction 21 5.5 Replacing the Sprocket 7 4.2 Description of Rewind Spring 37 2.1.2 Chain Brake 8 Operation 21 5.6 Tensioning the 2.2 Troubleshooting Chart 8 4.2.1 Breaker-Controlled Rewind Spring 37 2.3 Repair 9 Magneto Ignition 22 5.7 General Maintenance 37 2.3.1 Disassembly 4.3 Troubleshooting and Assembly of Clutch 9 Chart 23 2.3.2 Disassembly of 4.4 Function and Repair Chain Brake 10 of Components 24 6. AV Handle System 38 2.3.2.1 Assembly of Chain Brake 10 4.4.1 Spark Plug 24 4.4.2 Ignition Lead 25 6.1 Construction and 4.4.3 Ground Lead Contakt 26 Operation 38 4.4.4 Flywheel 27 6.2 Repair 38 3. Engine 11 4.4.5 Ignition Armature 28 4.4.5.1 Resistance Test on 3.1 Construction 11 Primary Winding 29 7. Chain Lubrication 39 3.2 Troubleshooting Chart 11 4.4.5.2 Resistance Test on 3.3 Exposing the Cylinder 12 Secondary Winding 29 7.1 Construction and 3.4 Disassembly of 4.4.5.3 Disassembly and Operation of Cylinder and Piston 12 Assembly 29 Oil Pump 39 3.5 Assembly of Piston 4.4.6 Condenser 30 7.2 Troubleshooting Chart 40 and Cylinder 14 4.4.7 Contact Set 31 7.3 Oil Tank/Tank Vent 41 3.6 Disassembly of Crank- 4.5 Ignition Timing 32 7.4 Notes on Repair 41 case - Removal of 4.5.1 Checking Breaker- 7.5 Disassembly and Repair Crankshaft 15 Controlled Ignition 33 of Pump Housing 42

STIHL 009, 010, 011 3 8. Fuel System 43 8.1 Construction and Operation of Carburetor 43 8.1.1 Operation of Fuel Pump 43 8.1.2 Operation of Carburetor 43 8.2 Troubleshooting Chart 45 8.3 Leakage Test (Pressure Test) on Carburetor 47 8.4 Disassembly of Carburetor 47 8.5 Repair of Carburetor 48 8.6 Carburetor Adjustment 50 8.6.1 Notes for Fine Adjust- ment of Carburetor 50 8.7 Fuel Line 51 8.8 Tank Vent 51 8.9 Air Filter and Choke Valve 52

STIHL 009, 010, 011 4 1. SPECIFICATIONS 1.1 Engine Single cylinder two-stroke engine with specially processed cylinder bore Displacement 009, 010: 37 cm³ (2.26 cu. in) Bore 009, 010: 36 mm (1.42 in) Displacement 011: 41 cm³ (2.50 cu. in) Bore 011: 38 mm (1.50 in) Stroke: 36 mm (1.42 in) Compression ratio: 9.8:1 Max. torque: 1.8 Nm (1.3 Ibf. ft) at 4500 r.p.m. Rated speed, off load with bar and chain: 9500 - 9800 r.p.m. Mean idle speed: 2200 - 2400 r.p.m. Crankshaft: Drop forged Crankshaft bearings: 2 needle sleeves Crankpin: 13 mm (0.51 in) dia. Big-end bearing: Cylindrical rollers without cage Piston pin: 9 mm (0.35 in) dia. Small-end bearing: Needle sleeve Rewind starter: Pawl engagement with automatic starter rope rewind mechanism Starter rope: 3.5 mm (0.14 in) dia., 960 mm (38 in) long Clutch: Centrifugal clutch without linings, 64 mm (2.5 in) dia. Clutch engages at: 3200 - 3300 r.p.m. Crankcase leakage test with overpressure: 0.5 bar (7.1 Ibf/in²) with vacuum: 0.5 bar (7.1 Ibf/in²) 1.2 Fuel System Carburetor: All-position diaphragm carburetor with integral fuel pump Adjustment: High-speed adjustment screw H: Open 1 turn Low-speed adjustment screw L: Open 1 turn (basic setting starting with screws lightly against their seats) Carburetor leakage test with overpressure: 0.4 bar (5.7 Ibf/in²) Fuel capacity: 0.26 L (0.55 US pt)

STIHL 009, 010, 011 5 Fuel mixture: Regular grade gasoline and branded two-cycle engine oil Mix ratio 1:40 with STIHL two-cycle engine oil: 1:25 with other branded two-cycle engine oils Air filter: Large area felt mat 1.3 Ignition System Type: Breaker-controlled magneto ignition Magneto edge gap: 5 mm (0.2 in) Ari gap: 0.2 mm (0.008 in) Ignition timing: 1.8-2.1 mm before T D.C. Ignition advance angle: 23°-24° Breaker point gap: 0.3-0.4 mm (0.012-0.016 in) Condenser: Capacitance 0.17 μF Ignition armature: Coil winding resistance Primary Secondary 0.8-1.3 Ω 7.2-8.8 kΩ Spark plug (suppressed): Bosch WSR 6 F or Champion RCJ 6 Y Heat range 200 Electrode gap 0.5 mm (0.02 in) Spark plug thread: M 14x1.25; 9.5 mm (0.37 in) long 1.4 Tightening Torques Crankshaft nut (ignition side) M 8x1: 30 Nm (22.1 Ibf. ft) Clutch (sprocket side): 30 Nm (22.1 Ibf. ft) M 6 socket head screws: 10 Nm (74 Ibf. ft) M 5 pan head screws: 5 Nm (3.7 Ibf. ft) M 4 pan head screws: 2.5 Nm (1.8 Ibf. ft) M 5 nuts: 5 Nm (3.7 lbf. ft) Spark plug: 25 Nm (18.4 Ibf. ft)

STIHL 009, 010, 011 6 1.5 Cutting Attachment Guide bars: STIHL Standard guide bars without stellite-tipped nose STIHL Duromatic guide bars with stellite-tipped nose STIHL Rollomatic guide bars with sprocket nose All types with corrosion-resistant finish and induction hardened rails Bar lengths: Duromatic 30 and 35 cm (12 and 14 in) Rollomatic 30, 35 and 40 cm (12, 14 and 16 in) Chain: 9.32 mm (3/8")-Oilomatic-Picco Chain sprocket: 6-tooth for 3/8" Picco pitch Chain speed: 13 m/s (42.6 ft/sec) at 7000 r.p.m. Chain lubrication: Speed-controlled oil pump with Diaphragm Oil delivery rate: 6-12 cm 3 /min (0.37-0.74 cu. in/min) at 7000 r.p.m. Oil tank capacity: 0.28 L (0.59 US pt) 1.6 Weights Model: 009 010 AV 011 AV Dry powerhead with 30 cm bar and chain: 4.3 kg 4.6 kg 4.7 kg (9.51 b) (10.1lb) (10.4Ib) 1.7 Special Accessories STIHL repair kit 009, 010, 011 1120 900 5000 Set of gaskets 009, 010, 011 1120 007 1050

STIHL 009, 010, 011 7 The construction of the clutch is identical on both models of the saw (with and without chain brake). While the engine is running at idle speed there is no change in the shape of the clutch, i.e. its outside diameter remains constant because the rigidity of the laminate block's smallest cross section is greater than the centrifugal force applied. As engine speed increases the outer diameter of the clutch becomes larger when the centrifugal force overcomes the rigidity of the laminate block. This causes the clutch to be pressed against the clutch drum and thus transmit engine torque positively via the clutch drum and the chain sprocket to the saw chain. The rigidity of the clutch is designed so that the clutch begins to make contact with the clutch drum at an engine speed of approx. 3200 r.p.m. The clutch engages fully above this speed. It is therefore very important to set the carburetor to the correct idle speed in order to insure that the clutch engagement speed (3200 r.p.m.) is not reached when the engine is idling. The transmission of power from the engine to the saw chain is effected via a centrifugal clutch which has no linings. The clutch consists of a laminate block made up of seven separate metal sheets which are riveted together. The laminate block is screwed to the crankshaft. A cranked U-plate is fitted between the laminate block and the clutch drum and acts as a guard which prevents parts of the clutch coming adrift in the event of breakage. Clutch with cranked U-plate in position Component parts of clutch 2. CLUTCH, CHAIN DRIVE AND CHAIN BRAKE 2.1 Construction and Operation 2.1.1 Clutch and Chain Sprocket

STIHL 009, 010, 011 8 2.1.2 Chain Brake The chain brake is a spring-loaded The chain brake is disengaged by The chain brake is engaged by band brake without any friction linings. pulling the hand guard back toward moving the hand guard toward the Its main components are the brake the handlebar. This movement is bar nose. This movement unlatches band, tension spring, hand guard and transmitted via a lever system which the locked brake lever and causes the lever system. preloads the tension spring and re- the brake band to be clamped leases the brake band. around the clutch drum by the force The chain brake is actuated via the of the preloaded tension spring. The hand guard which can be used to The actuating lever, which is attached cluch drum and saw chain are disengage or engage the brake. to the hand guard, remains locked in brought to a standstill in a split the idle position after the operator second. releases the hand guard. 2.2 Troubleshooting Chart Condition Cause Remedy Saw chain turns at idle speed Engine idle speed too high Readjust at idle speed adjusting screw Clutch broken Fit new clutch Excessive chain sprocket wear Incorrect chain tension Tension chain correctly Saw chain does not stop Tension spring broken Fit new tension spring immediately when chain brake is actuated

STIHL 009, 010, 011 9 2.3 Repair 2.3.1 Disassembly and Assembly of Clutch First remove the chain sprocket cover Caution: The clutch has a lefthand and the cutting attachment. On Quick- thread - unscrew it clockwise! stop models it is necessary to disengage the chain brake so that the After unscrewing the clutch, remove the brake band releases the clutch drum. chain sprocket, needle cage and thrust washer from the crankshaft. Examine Take out the spark plug and fit the clutch for signs of cracks or breaks. locking screw in its place. Use the If hairline cracks are found in the special wrench to turn the clutch and sprung part of the clutch, fit a new the crankshaft clockwise until the clutch. The cranked U-plate should piston head butts against the locking also be inspected for hairline cracks. screw. Now use wrench to unscrew If any are found, fit a new Cranked the clutch. U-plate. Wash needle cage, thrust washer and stub of crankshaft with clean gasoline. Replace needle cage if it is faulty. Lubricate needle cage, thrust washer and stub of crankshaft with antifriction bearing grease before assembly. When refitting the clutch make sure that the side on which the thread is counterbored to a depth of about 2 mm (0.08 in) faces the crankcase. Tighten down clutch with the wrench to a torque load of 30 Nm (3.0 kpm). Top: Top: Locking screw 1107 191 1200 Wrench 1113 890 3600 Bottom: Bottom: Locking screw in position Unscrewing the clutch Counterbored side of clutch

STIHL 009, 010, 011 10 2.3.2 Disassembly of Chain Brake 2.3.2.1 Disassembly of Chain Brake Top: Detaching tension spring Top: Brake band, brake lever and tension spring in Center: position Removing retaining washer Bottom: Bottom: Fitting tension spring with installing tool Removing plastic cover Removing brake band 1117 890 0900 The chain brake components are inte- grated in the chain sprocket cover. It is therefore necessary to remove the sprocket cover to gain access to the brake components. After removing the sprocket cover, engage the chain brake, unscrew the plastic cover and detach the tension spring from the pin in the housing. Remove retaining washer from brake lever pivot pin and then prise brake lever together with the brake band and the tension spring out of their seats in the cover. The relay lever and actuating lever cannot be disassembled. If either one of these levers is faulty the complete chain sprocket cover (1120 640 1740) must be replaced. Check levers and brake band for signs of wear. Renew damaged parts and apply a little grease to the pivot points before reassembly. First engage brake band in the brake lever. Then attach the tension spring to the brake lever and install the pre- assembled parts in the chain sprocket cover. Fit the retaining washer and use installing tool to attach tension spring to the retaining pin. Finish off by securing the plastic cover.

STIHL 009/010/011 Chainsaw Service & Repair Manual

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