Sthil Fs 120

STIH)
STIHL FS 120, 200, 300, 350, 400, 450

STIHL FR 350, 450 2003-04
CONTENTS
1. Introduction 2 6. Rewind Starter 30 10. Shaft 51
6.1 General 30 10.1 Bike Handle

2. Specifications 3 6.2 Rewind Spring 30 (FS 120/200) 51
6.2.1 Replacing 30 10.2 Bike Handle
2.1 Engine 3 6.2.2 Tensioning 31 (FS 300...450) 51
2.2 Fuel System 3 6.3 Starter Rope/Starter 10.3 Loop Handle 52
2.3 Ignition System 4 Grip (ElastoStart) 32 10.4 Drive Shaft/
2.4 Gearhead 4 Flexible Liner 52
2.5 Special Accessories 4 10.5 Flexible Shaft
2.5.1 For User 4 7. Throttle Control 33 (FR 350/450) 53
2.5.2 For Service 4 10.6 Drive Tube 54
2.6 Tightening Torques 5 7.1 Throttle Trigger/Interlock 10.7 Housing
Lever (Bike Handle) 33 (FR 350/450) 56
7.2 Contact Springs/Detent
3. Clutch 7 Spring in Control Handle
(Bike Handle) 34 11. Cutting Tool
3.1 Removing and Installing 7 7.3 Throttle Trigger/Interlock Drive 56
3.2 Clutch Carrier 8 Lever (Loop Handle) 34
7.4 Slide Control 11.1 Gearhead 56
(Loop Handle) 35 11.2 Clutch Drum 57
4. Engine 9 7.5 Throttle Cable 36
7.5.1 Replacing 36
4.1 Exhaust Muffler/ 7.5.2 Adjusting 37 12. Support Frame
Spark Arresting Screen 9 (FR 350/450) 58
4.2 Leakage Test 10
4.2.1 Preparations 10 8. Fuel System 38 12.1 Repair 58
4.2.2 Pressure Test 11
4.2.3 Vacuum Test 11 8.1 Air Filter 38
4.3 Oil Seals 12 8.2 Carburetor 39 13. Special Servicing
4.4 Exposing the Cylinder 13 8.2.1 Removing and Installing Tools and Aids 59
4.5 Cylinder and Piston 14 (FS 120...350, FR 350) 39
4.5.1 Removal 14 8.2.2 Removing and Installing 13.1 Special Servicing Tools 59
4.5.2 Installation 15 (FS 400/450, FR 450) 40 13.2 Servicing Aids 61
4.6 Piston Rings 17 8.2.3 Leakage Test 41
4.7 Crankcase 17 8.2.4 Adjusting
4.7.1 Removing Crankshaft 17 (three screws) 42
4.7.2 Installing Crankshaft 20 8.2.5 Adjusting
4.8 Decompression Valve 23 (one screw) 43
8.3 Tank Vent 44
8.4 Pickup Body 44
5. Ignition System 23 8.5 Fuel Tank/
Hoses 45
5.1 Spark Plug Boot 23 8.6 Manual
5.2 Ignition Lead Fuel Pump 47
(FS 400/450, FR 450) 24
5.3 Ignition Module 25
5.3.1 Ignition Timing 26 9. AV System 47
5.3.2 Removing and Installing
(FS 120...350, FR 350) 26 9.1 Repair
5.3.3 Removing and Installing (FS 120/200) 47
(FS 400/450, FR 450) 27 9.2 Repair
5.4 Flywheel 28 (FS 300...450) 48
5.5 Short Circuit Wire 29 9.3 Repair
(FR 350/450) 50
qS
© 2011, Andreas Stihl AG & Co., Waiblingen
FS 120, 200, 300, 350, 400, 450, FR 350, 450 1

1. INTRODUCTION
This service manual contains de- The special servicing tools mentio- Secure the clamp to the assembly
tailed descriptions of all the repair ned in the descriptions are stand with two washers and two
and servicing procedures specific listed in the last chapter of this M8 nuts.
to this power tool series. manual.
There are separate handbooks for Use the part numbers to identify
servicing procedures for stand- the tools in the "STIHL Special
ardized parts and assemblies that Tools" manual.
are installed in several STIHL The manual lists all special
power tool models. Reference is servicing tools currently available
made to these handbooks in the from STIHL.
appropriate chapters in this
manual. Symbols are included in the text
and pictures for greater clarity.
As the design concept of models The meanings are as follows:
FS 120, FS 200, FS 300, FS 350,
FS 400, FS 450 and FR 350, FR In the descriptions:
450 is almost identical, the descrip-
tions and servicing procedures in • = Action to be taken as 1
this manual generally apply to all shown in the illustration
models. Differences are described (above the text)
250RA227VA
in detail. 2
- = Action to be taken that
You should make use of the is not shown in the
illustrated parts lists while carrying illustration Servicing and repairs to the power-
out repair work. They show the (above the text) head are considerably easier if it is
installed positions of the individual mounted on assembly stand (2)
components and assemblies. In the illustrations: 5910 890 3100 with the aid of
clamping plate (1) 5910 890 2101.
Refer to the latest edition of the = Pointer
relevant parts list to check the part First remove the clutch housing
numbers of any replacement parts = Direction of movement and secure the powerhead to the
needed. stand with two M6x20 and two
Parts lists on microfiche and CD- Service manuals and all technical M10x25 hex. head screws.
ROM are always more up to date information bulletins describing
than printed lists. engineering changes are intended The machine or powerhead can
exclusively for the use of STIHL then be swivelled to the best posi-
A fault on the power tool may have servicing dealers. They must not tion for the ongoing repair and this
several causes. Consult the be passed to third parties. leaves both hands free.
troubleshooting charts for all as-
semblies in the "Standard Repairs, Always use original STIHL
Troubleshooting" handbook. replacement parts.
They can be identified by the
Refer to the "Technical Informa- STIHL part number,
tion" bulletins for engineering the STIHL
changes which have been intro- and the STIHL parts symbol (
duced since publication of this The symbol may appear alone on
service manual. Technical informa- small parts.
tion bulletins also supplement the
parts list until a revised edition is
issued. 2
250RA228 VA
Servicing and repairs are made

considerably easier if the machine
is mounted on assembly stand (2)
5910 890 3100 with the aid of
clamp (1) 5910 890 8800.
2 FS 120, 200, 300, 350, 400, 450, FR 350, 450

2. SPECIFICATIONS
2.1 Engine
STIHL single cylinder two-stroke engine with special impregnated cylinder bore
FS 120/300 FS 200/350 FS 400 FS 450

FR 350 FR 450
Displacement: 30.8 cm3 36.3 cm3 40.2 cm3 44.3 cm3

1.88 cu.in 2.21 cu.in 2.45 cu.in 2.70 cu.in
Bore: 35 mm 38 mm 40.0 mm 42.0 mm
1.38 in 1.49 in 1.57 in 1.65 in
Stroke: 32 mm 32 mm 32 mm 32 mm
1.26 in 1.26 in 1.26 in 1.26 in
Power output: 1.3 kW (1.8 bhp) 1.6 kW (2.2 bhp) 1.9 kW (2.6 bhp) 2.1 kW (2.8 bhp)
at 9,000 rpm
Max. permissible engine speed
without cutting tool
(cut-off speed): 12,500 ± 1000 rpm 12,500 ± 800 rpm
Idle speed: 2,800 rpm
Bearings: Crankshaft supported in heavy-duty ball bearings, needle cages on
small and big ends
Piston pin diameter: 10 mm (0.39 in)
Rewind starter: ElastoStart
Pawls: Single pawl system
Reserve pull on rope rotor: min. 1/2 turn
Starter rope: 3.0 mm (0.12 in) dia. x 800 mm (31.5 in)
Clutch: Centrifugal clutch without linings
Clutch engages at: 4,300 rpm
Crankcase leakage
test
at gauge pressure: 0.5 bar (7.25 psi)
under vacuum: 0.5 bar (7.25 psi)
2.2 Fuel System
Carburetor: Diaphragm carburetor

Standard setting on carburetors
with three adjusting screws
High speed screw H: Open approx. 1 turn
Low speed screw L: Open approx. 1 turn
Carburetor leakage test
at gauge pressure: 0.8 bar (11.6 psi)
Function of tank vent
at gauge pressure: ≤ 0.3 bar (4.35 psi)
under vacuum: ≤ 0.05 bar (0.725 psi)
Fuel tank capacity: 0.64 l (1.35 US pt) 0.68 l (1.44 US pt)
Octane rating: min. 90 RON (US/CAN; pump octane min. 87)
Fuel mixture: Regular brand name gasoline
and two-stroke engine oil
Mix ratio: 50:1 with STIHL two-stroke engine oil
25:1 with other brand name two-stroke, air-cooled engine oils
Air filter: Paper filter
FS 120, 200, 300, 350, 400, 450, FR 350, 450 3

2.3 Ignition System Type: Electronic magneto
ignition (breakerless)
with integral trigger unit
and electronic speed
governor
Air gap: 0.2 - 0.5 mm (0.008 - 0.020 in)
Length of ignition lead: 305 mm * (12 in)*
Spark plug (suppressed): Bosch WSR 6F,
NGK BPMR 7 A or
Champion RCJ 6Y
Electrode gap: 0.5 mm (0.020 in)
Splark plug thread: M14x1.25
Length of thread: 9.5 mm (0.37 in)
2.4 Gearhead Type: Spiral-toothed

bevel gear drive
Gear ratio: 1:1.4 **

1:1.235
Bearings: Deep groove ball bearings
Lubrication: STIHL gear lubricant 0781 120 1117

(7 g / 0.25 oz)
2.5 Special Accessories
2.5.1 For User Full harness

Safety glasses
Transport guard for
metal cutting tools
STIHL gear lubricant (80 g/3 oz tube) 0781 120 1109
STIHL gear lubricant (80 g/3 oz tube) 0781 120 1117
2.5.2 For Service Carburetor parts kit 4134 007 1060

Set of gaskets
for FS 120, 200, 300, 350, FR 350 4134 007 1050
Set of gaskets
for FS 400, 450, FR 450 4128 007 1050
* FS 400/450 only
** FS 120, 200, 350 and 450
4 FS 120, 200, 300, 350, 400, 450, FR 350, 450

2.6 Tightening Torques
DG and P screws (Plastoform) are used in polymer and lightmetal components. These screws form a perma-
nent thread when they are installed for the first time. They can be removed and installed as often as necessary
without detrimentally affecting 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 For component Torque Remarks

size Nm lbf.ft
Self-tapping screw IS-B3.5x6.5 Rewind spring/fan housing 1.5 1.1

Self-tapping screw IS-B4.2x9.5 Muffler/spark arresting screen 2.5 1.8 1) 2)
Spline screw IS-DG4x20 Ignition module/crankcase 4.5 3.3 3) 4) 5)
Spline screw IS-DG5x24 Ignition module/crankcase 6.0 4.4 1) 2)
Spline screw IS-DG5x12 AV sleeve/drive tube (fixing screw) 2.5 1.8 3)
Spline screw IS-DG5x12 Guard ring/gear housing 5.0 3.7 1) 4)
Spline screw IS-DG5x20 Fan housing/crankcase 6.0 4.4
Spline screw IS-DG5x20 Fan housing/shroud/crankcase 6.0 4.4
Spline screw IS-DG5x20 Carburetor housing/crankcase/
cylinder 6.0 4.4
Spline screw IS-DG5x20 Filter housing/ground wire/
crankcase 6.0 4.4
Spline screw IS-DG5x20 Ground wire/crankcase 6.0 4.4 1) 2)
Spline screw IS-DG5x26 Fuel tank/crankcase 6.0 4.4
Spline screw IS-DG5x24 Bracket/crankcase 6.0 4.4 1)
Spline screw IS-DG5x20 Shroud/clutch housing 6.0 4.4
Spline screw IS-DG5x26 Guard plate/fuel tank/
crankcase 6.0 4.4 1) 2)
Spline screw IS-DG5x28 Cylinder/crankcase 10.5 7.5
Spline screw IS-DG5x24 Muffler/crankcase 8.5 6.3
Spline screw IS-DG5x24 Muffler/cylinder 8.5 6.3
Spline screw IS-DG5x24 Crankcase 8.5 6.3
Spline screw IS-DG5x24 Clutch housing/crankcase 8.5 6.3 1) 2) 4) 5)
Spline screw IS-DG5x24 Clutch housing/crankcase 6.0 4.4 3)
Spline screw IS-DG6x28 Clutch housing/drive tube 12.0 8.8 1) 6)
Spline screw IS-DG5x24 Clutch housing/drive tube 8.5 6.3 4)
Spline screw IS-DG5x24 Gear housing/drive tube 8.5 6.3 2) 3) 5)
Spline screw IS-DG5x25 Gear housing/drive tube
Stage 1 1.5 1.1 1) 4)
Stage 2 7.5 5.5 1) 4)
Collar nut M5 Filter housing/carburetor housing 3.5 2.6
Collar screw M5/P6 Carburetor housing 4.0 3.0
Spline screw IS-M5x12 Clamp/control handle/
drive tube (loop handle) 2.0 1.5 3) 4)
Spline screw IS-M5x16 AV sleeve/drive tube (clamp screw) 5.5 4.0 3)
Spline screw IS-M5x12 Clamp/control handle/drive tube 2.0 1.5 2) 5)
Spline screw IS-M5x16 Clamp/drive tube (for harness) 4.5 3.3 3)
Spline screw IS-M5x30 Control handle (bike handle) 2.0 1.5 6)
FS 120, 200, 300, 350, 400, 450, FR 350, 450 5

Fastener Thread For component Torque Remarks
size Nm lbf.ft
Spline screw IS-M6x25 Clamp/loop handle 4.5 3.3 3)

Spline screw IS-M6x25 Support/drive tube 6.0 4.4 1) 4) 6)
Spline screw IS-M6x35 Clamp moldings/support block
(handle support/bike handle) 4.5 3.3 3)
M8 Carrier 24.0 17.7
Spline screw IS-M6x18 Clutch shoe/carrier 12.0 8.8
M8 Flywheel 32.0 23.6
M10 Decompression valve 14.0 10.3 1) 2) 4) 5)
M14x1.25 Spark plug 20.0 15.0
Screw plug M11x10 Gearhead 8.5 6.3
Spline screw IS-M5x14 Filter cover/filter housing 6.0 4.4 1) 2)
Plastoform screw IS-P4x16 Control handle/handle moldings 1.0 0.75
Collar screw IS-P3.5x10.6 Detent spring/slide control
(bike handle) 1.1 0.80 1) 3) 4)
Nut M12x1.5 L Cutting tool 25.0 18.5
Spline screw IS-M5x16 Cutting tool deflector/gearhead 4.3 3.2
Spline screw IS-M6x14 Spring/support plate 10.0 7.5 2) 5)
Spline screw IS-M6x25 Housing/shaft clamp screw 4.5 3.3 2) 5)
Spline screw IS-M6x14 Bearing housing/support frame 10.0 7.5 2) 5)
Spline screw IS-M10x20 Support plate/ball bearing/
support frame 20.0 15.0 2) 5)
Use the following procedure to fit a DG or P screw in an existing thread:

– Place the DG or P 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.
1) FS 400/450
2) FR 450
3) FS 120/200
4) FS 300/350
5) FR 350
6) with washer
Note: Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm
DG screws max. 500 rpm
6 FS 120, 200, 300, 350, 400, 450, FR 350, 450

3. CLUTCH
3.1 Removing and Installing
Removal
1
Troubleshooting chart - see
"Standard Repairs, Trouble-
shooting" handbook.
- Remove clutch housing -

see 9.1 or 11.2.
250RA001 VA
250RA230 VA
FS 120...350, FR 350 • Remove clutch shoes with
• Fit locking strip (1) bushings.
0000 893 5903.
250RA002 VA
250RA005 VA
250RA003 VA
FS 400/450, FR 450 • Take bushings out of the clutch

• Fit locking strip (1) shoes.
All models 4221 893 5900.
• Inspect clutch drum. There
should be no scores or signs of
excessive wear.
Important: If there are signs of

serious wear on the inside
diameter, fit a new clutch drum -
see 11.2.
- Remove the shroud - see 4.1.

1 1
- Pull off the spark plug boot.
- Unscrew the spark plug.

250RA229 VA
250RA004 VA
• Take out screws (1). • Twist the clutch shoes and

detach the springs.
• Remove cover (2).
Important: Clutch shoes and
springs must always be replaced
in pairs.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 7

3.2 Clutch Carrier
- Pull locking strip out of cylinder.
- Fit spark plug and tighten down

to 20 Nm (15 lbf.ft).
Important: If the spark plug

comes with a separate terminal
nut, always fit the nut on the
250RA234 VA
thread and tighten it down
250RA231 VA
securely.
- Fit the boot on the spark plug.

Installation - Remove clutch - see 3.1.
- Fit the shroud - see 4.1.
• Fit clutch shoes with springs and • Unscrew carrier from end of
bushings so that the arrows point - Fit clutch housing - crankshaft.
counterclockwise. see 9.1 or 11.2.
250RA232 VA
250RA235 VA
• Fit cover in position. • Fit the carrier and tighten it
down to 24 Nm (17.7 lbf.ft).
- Install the clutch - see 3.1.

250RA233 VA
• Insert screws and tighten down

to 12 Nm (8.8 lbf.ft).
8 FS 120, 200, 300, 350, 400, 450, FR 350, 450

4. ENGINE
4.1 Exhaust Muffler/Spark Arresting Screen
- Clean or replace spark arresting

screen if necessary.
- Tighten down screw to 2.5 Nm

(1.8 lbf.ft).
250RA006 VA
250RA011 VA
Troubleshooting chart - see • Take out the screws.
shooting" handbook. - Lift away the muffler.
Muffler
Spark arresting screen
FS 400/450, FR 450
FS 120...350, FR 350 - Remove air filter cover - see 8.1.
• Pull spark arresting screen out of
the muffler.
- Clean or replace spark arresting

screen if necessary.
250RA009 VA
250RA012 VA
All models • Remove the gasket.
• Remove screws from clutch
housing. Reassemble in the reverse
sequence.
- Use a new gasket.
- Tighten down screws to 8.5 Nm

(6.3 lbf.ft).
1 2 2 3
250RA007 VA
250RA010 VA
1 1
FS 400/450, FR 450 • Take out screws (1).

• Take out the screw (1).
• Press down the decompression
• Pull spark arresting screen (2) valve (2).
out of the muffler.
• Remove the shroud (3).
FS 120, 200, 300, 350, 400, 450, FR 350, 450 9

4.2 Leakage Test 4.2.1 Preparations
Defective oil seals, gaskets, - Remove the carburetor - see

cracks in castings or a faulty sea- 8.2.1 and 8.2.2.
ling ring between the carburetor 1
housing and cylinder are the usu- - Set the piston to top dead center
al causes of leaks. Such faults al- (T.D.C.). This can be checked
low air to enter the engine and through the inlet port.
thus upset the fuel-air mixture.
- Make sure the spark plug is
This makes adjustment of the properly tightened down.
250RA015 VA
prescribed idle speed difficult, if
not impossible.
Moreover, the transition from idle - Back off the muffler mounting
speed to part or full throttle is not screws half-way.
smooth.
• Slide the sealing plate (1)
The crankcase can be checked 0000 855 8106 between the
thoroughly for leaks with the carbu- gasket and cylinder exhaust
retor and crankcase tester and the port and retighten the mounting
vacuum pump. screws moderately.
Note: The sealing plate must

completely fill the space between
the two mounting screws.
250RA013 VA
• Slide a new gasket over the

carburetor studs.
1 2
250RA014 VA
• Push the test flange (1)

1128 850 4200 into position.
• Fit and tighten down the nuts (2)

firmly.
10 FS 120, 200, 300, 350, 400, 450, FR 350, 450

4.2.2 Pressure Test 4.2.3 Vacuum Test
Oil seals tend to fail when sub-

jected to a vacuum, i.e. the sealing
lip lifts away from the crankshaft
during the piston’s induction stroke
because there is no internal
counterpressure.
An additional test can be carried

out with the vacuum pump to
250RA016 VA
250RA017 VA
detect this kind of fault.
- Carry out preparations -

- Carry out preparations - • However, if the indicated pressu- see 4.2.1.
see 4.2.1. re drops, the leak must be
located and the faulty part
• Connect pressure hose of tester replaced.
1106 850 2905 to nipple on test
flange. Note: To find the leak, coat the
suspect area with oil and
pressurize the crankcase again.
Bubbles will appear if a leak exists.
- If the decompression valve is not

airtight, install a new one - see
1 4.8.
- Repeat the pressure test.
- Carry out the vacuum test - see

143RA046 VA
4.2.3.
250RA016 VA
- After finishing the test, open the
vent screw and disconnect the
• Close the vent screw (1) on hose. • Connect the suction hose of
the rubber bulb. vacuum pump 0000 850 3501
- Remove the test flange. to test flange nipple.
- Use rubber bulb to pump air into
the crankcase until the gauge - Slacken off the muffler mounting
indicates a pressure of 0.5 bar screws.
(7.25 psi). If this pressure re-
mains constant for at least 20 - Pull out the sealing plate and
seconds, the crankcase or de- tighten down the screws to
compression valve, if fitted, is 8.5 Nm (6.3 lbf.ft).
airtight. 3
- Install carburetor - see 8.2.1 or
8.2.2.
2
250RA018 VA
• Close vent screw (1) on

pump cylinder.
• Operate lever (2) until the gauge

(3) indicates a vacuum of 0.5 bar
(7.25 psi).
FS 120, 200, 300, 350, 400, 450, FR 350, 450 11

4.3 Oil Seals
Note: If the vacuum reading It is not necessary to disassemble

remains constant, or rises to no the complete engine to replace the
more than 0.3 bar (4.25 psi) within oil seals.
20 seconds, it can be assumed
that the oil seals are in good The FS 200 engine is shown in the 1
condition. illustrations.
However, if the pressure continues
to rise (reduced vacuum in the
crankcase), the oil seals must be
250RA020 VA
Starter side:
replaced.
- Remove the flywheel - see 5.4.
- After finishing the test, open the
vent screw and disconnect the - Tap the oil seal with a suitable • Use the press sleeve (1)
hose. piece of pipe or a punch to 4112 893 2401 to press it fully
release it from its seat. home.
- Remove the test flange.
- Install flywheel - see 5.4.
- Sacken off the muffler screws.
- Remove the sealing plate tighten

screws to 8.5 Nm (6.3 lbf.ft).
- Install carburetor - see 8.2.1 and

8.2.2.
1
250RA019 VA 1
250RA021 VA
• Apply the puller (1) Clutch side:
5910 890 4400 (with No. 3.1
jaws 0000 893 3706). - Remove carrier - see 3.2.
- Tension the arms. - Tap the oil seal with a suitable

piece of pipe or a punch to
- Pull out the oil seal. release it from its seat.
Important: Take care not to • Apply the puller (1)

damage crankshaft stub. 5910 890 4400 (with No. 3.1
jaws 0000 893 3706).
- Clean sealing surface with a
standard solvent-based degrea- - Tension the arms.
sant containing no chlorinated or
halogenated hydrocarbons - see - Pull out the oil seal.
13.2.
Important: Take care not to dama-
- Lubricate sealing lips of oil seal ge crankshaft stub.
with grease - see 13.2.
- Clean sealing surface with a
- Slide the oil seal, open side standard solvent-based degrea-
facing the crankcase, over the sant containing no chlorinated or
end of the crankshaft. halogenated hydrocarbons - see
13.2.
- Lubricate sealing lips of oil seal

12 FS 120, 200, 300, 350, 400, 450, FR 350, 450

4.4 Exposing the Cylinder
Always check and, if necessary,

1
repair the fuel system, carburetor,
2
air filter and ignition system before
looking for faults on the engine.
1
shooting" handbook.
1
250RA022 VA
250RA026 VA
- Remove the muffler - see 4.1.
- Remove the carburetor - see

• Slip installing sleeve (1) 4112 8.2.1 and 8.2.2. • Take out screws (1).
893 2400 over the end of the
crankshaft. • Pull away the carburetor hous-
ing (2), ease grommet out of
carburetor housing and pull the
extended throttle cable out of the
housing opening.
Assemble in the reverse

sequence.
2
250RA024 VA
250RA023 VA
1 1
- Push the oil seal, open side • Take out screws (1).
facing the crankcase, over the
installing sleeve and press it • Pull away the carburetor housing
home with the press sleeve. (2).
• Press home with press sleeve

(1) 1118 893 2401.
- Remove the installing sleeve.
- Install carrier - see 3.2. 2
1
250RA025 VA
250RA027 VA
3 4
FS 400/450, FR 450 • Fit stub (1) on carburetor hou-

• Disconnect hose from fuel pump sing in the sealing ring (2) and
and pull it out of the guide. throttle cable (3) in the retainer
(4).
- Tighten down screws to 6 Nm

(4.4 lbf.ft).
FS 120, 200, 300, 350, 400, 450, FR 350, 450 13
4.5 Cylinder and Piston
4.5.1 Removal
- Preparations - see 4.4.

4 3
see 9.1 and 11.2.
- Pull off the spark plug boot.
- On FS 120...350, FR 350: Take

ignition lead out of the retainers
250RA028 VA
250RA031 VA
on the throttle cable holder.
1 2
FS 400/450, FR 450 • Release and unscrew the
• Fit throttle cable (1) and grom- - Unscrew the decompression four cylinder base screws.
met (2) in opening in carburetor valve, if fitted.
housing. - Pull the cylinder off the piston.
• Insert stub (3) in the sealing - Inspect the cylinder and replace
ring (4). it if necessary.
- Secure lug of extended throttle - If a new cylinder has to be

cable between the raised marks installed, always fit the matching
and tighten down the screws piston. New cylinders are only
to 6 Nm (4.4 lbf.ft). available with piston.
- Before removing the piston,

decide whether or not the cranks-
haft has to be removed as well.
To remove the clutch and carrier,
block the crankshaft by sliding
250RA029 VA
the wooden assembly block

between the piston and crank-
case.
FS 400/450, FR 450
• Take cable retainer out of - Remove the cylinder gasket.
cylinder.
250RA030 VA
250RA032 VA
All models: • Ease the hookless snap rings

Illustrations show the out of the grooves in the piston
FS 200 engine. bosses.
• Pull out the sealing ring.
14 FS 120, 200, 300, 350, 400, 450, FR 350, 450

4.5.2 Installation
1 2 1 2
3
250RA035 VA
250RA033 VA
250RA038 VA
2
• Now use the assembly drift (2) • Thoroughly clean the gasket • Push the assembly drift, small
1110 893 4700 to push the pi- seating surface (1). diameter first, through the piston
ston pin (1) out of the piston. and small end (needle cage) and
• Check that adapter sleeves (2) line up the piston.
Note: If the piston pin is stuck, tap are in place. Fit them if necessa-
the end of the drift lightly with a ry.
hammer if necessary. Hold the
piston steady during this process • Lubricate the needle cage (3)
to ensure that no jolts are trans- with oil and fit it in the connecting
mitted to the connecting rod. rod.
1 2
- Remove piston and take the
needle cage out of the connec-
ting rod.
250RA039 VA
• Fit the piston pin (1) on the
assembly drift (2) and slide it
into the piston (the pin slides
home easily if the piston is hot).
1 2
a
b
250RA057 VA
250RA034 VA
250RA037 VA
• Inspect piston rings and replace • To simplify assembly, heat the pi- • Modify sleeve of installing tool
if necessary - see 4.6. ston and slip it over the connec- 5910 890 2210 as shown in dra-
ting rod. wing.
a = 30 degrees
• Installed position of piston: b = Ø 10 mm
1 = Marking
2 = Flywheel
FS 120, 200, 300, 350, 400, 450, FR 350, 450 15
1
1
250RA036 VA
250RA041 VA
2
250RA044 VA
• Use installing tool (1) • Lubricate piston and piston rings - Lubricate the inside of the
5910 890 2208 to fit the snap with oil. Rest piston (1) on cylinder with oil and line it up so
rings. wooden assembly block (2) that it is positioned as it will be in
1108 893 4800. the installed condition. It is im-
Note: For instructions on how to portant to observe this point as
use the installing tool see the piston rings might otherwise
"Standard Repairs, Trouble- break.
shooting" handbook.
• Slide the cylinder over the piston
- the clamping strap is pushed
downward as the piston rings
slip into the cylinder.
- Remove the clamping strap

and wooden assembly block.
- Line up the cylinder and gasket.

250RA042 VA
• Position the piston rings so that

the radii at the ring gap meet at
the fixing pin in the piston groove
when the rings are compressed.
1
250RA040 VA
250RA043 VA
250RA045 VA
• Fit new cylinder gasket on the • Use the clamping strap (1) • Use socket (1) 0812 542 2104
crankcase. 0000 893 2600 to compress the to tighten down cylinder base
piston rings around the piston screws to 8.5 Nm (6.3 lbf.ft).
and check that the piston rings
are correctly positioned. Assemble all other parts in the
reverse sequence.
16 FS 120, 200, 300, 350, 400, 450, FR 350, 450

4.6 Piston Rings 4.7 Crankcase
4.7.1 Removing Crankshaft
- Remove the piston - see 4.5.1. - Remove the ignition module -

see 5.3.2 and 5.3.3.
Note: The piston must be re-
moved to make sure that no - Remove the fuel tank - see 8.5.
residue can fall into the crankcase
when installing the piston rings - Remove the cylinder - see 4.5.1.
and cleaning their grooves.
Illustrations show piston
250RA050 VA
in model FS 200.
- Remove rings from piston.

FS 400/450, FR 450
• Remove short circuit wire from
the retainers.
250RA048 VA
250RA046 VA
250RA051 VA
• Use a piece of old piston ring to All models • Ease the grommets out of the
scrape the grooves clean. • Take out screw (1). housing and pull out the short
circuit wire.
• Remove top of cable guide (2).
FS 120...350, FR 350
1 1 2 1
3
250RA052 VA
250RA049 VA
250RA047 VA
4
2
• Install the new piston rings in the • Take throttle cable (1) out of All models
grooves so that the radii (1) face base of guide (2). • Pull the base of the guide
the fixing pin (2). off the housing.
• Take short circuit wire (3) out of
- Install the piston - see 4.5.2. base of guide and remove it from - Remove the carrier - see 3.2.
the retainers (4).
FS 120, 200, 300, 350, 400, 450, FR 350, 450 17

• Hold ZS installing tool against
clutch side of crankcase so that
the notch marked "16" is at the
bottom.
• Insert M6x20 screws (2) in holes

marked "17" and tighten them
down against the drilled plate.
250RA056 VA
- Remove the flywheel - see 5.4.
- Remove the piston - see 4.5.1.
• Take out the screws.
33.3 38.0
32.25 33.6
1
20.6 17.3
15.5
17
250RA062 VA
17
18
41.6
18
• Place extension (1) 4116 894
33.85
1000 on crankshaft stub at clutch
2.25
9.7
20.1
16
side of crankcase. 16
12.6
18
17.65
24.75
26.85
18
41.25
16
16
17 2
17
16
2.5
25.5 19.9
17 1
2 33.7 22.5
250RA219 VA
16 + 18 = 5,5
250RA063 VA
16
17 = 6,5
1
• Back off spindle (left-hand thre- Note: ZS installing tools without Holes "16" and "18" are needed at
ad) of ZS installing tool (1) 5910 holes "16", "17" and "18" and the starter side of the crankcase.
890 2220 a little. notches "16" and "17" can be
modified as shown in the The illustration shows the under-
illustration. side of the drilled plate.
18 FS 120, 200, 300, 350, 400, 450, FR 350, 450

FS 400/450, FR 450
1 - Hold ZS installing tool against
starter side of crankcase so that
2 2 the notch marked "17" is at the
bottom.
- Insert M5x60 screws in holes

marked "18", fit washers at other
side and screw on nuts.
250RA061 VA
250RA058 VA
1
• Rotate spindle (1) counterclock- • Place extension (1) 4116 894

wise until the crankshaft comes 1000 on crankshat stub and
out of the ball bearing. The two sleeve (2) 1123 851 8300 on
halves of the crankcase are bores at starter side of crank-
separated in this process. case.
All models
3
2
16
1
250RA065 VA
250RA059 VA
250RA064 VA
2 1 1
• Puller (1) 4119 890 4600 can be • Hold ZS installing tool (1) • Rotate spindle (1) counterclock-
used in place of the ZS installing 5910 890 2220 against starter wise until the crankshaft comes
tool. It is mounted to the clutch side of crankcase so that the out of the ball bearing.
side of the crankcase wit M6x20 notch marked "16" is at the
screws (2). bottom.
• Turn thrust bolt (3) clockwise

until the crankshaft is released
from the ball bearing.
FS 120...350, FR 350
- Back off spindle (left-hand thre- 1 1 1
ad) of ZS installing tool 16 16
5910 890 2220 a little. 16
1 16
1
250RA060 VA
250RA066 VA
• Insert screws (1) 9022 341 1190 • The crankshaft (1), connecting
(from ZS installing tool kit) in rod (2) and needle bearing form
holes marked "16", fit washers at an inseparable unit. It must
other side and screw on nuts. always be replaced as a com-
plete unit.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 19

4.7.2 Installing Crankshaft
Each half of the crankcase may Note: This operation must be

be replaced separately. carried out very quickly because
the bearing absorbs heat immedi-
New crankcases come with ately and begins to expand.
factory-installed ball bearings.
If the original crankcase is used

again, remove the gasket residue
and clean the mating surfaces -
250RA067 VA
they must be cleaned very
thoroughly to ensure a perfect
seal.
- When fitting a replacement
crankshaft always install new oil
seals and ball bearings.
• Carefully knock the oil seals out

of the crankcase.
250RA071 VA
250RA068 VA
250RA070 VA
• Use press arbor (1) 4119 893 • Check that bushings are in posi- • If it is not possible to heat the
7200 to remove ball bearing. tion. If necessary, drive bushings starter side of the crankcase,
into the crankcase. use press arbor (1) 4119 893
7200 to press in the ball bearing
- Heat area of bearing seat on as far as stop.
starter side of crankcase to
approx. 120°C (250°F). - Heat area of bearing seat on
clutch side of crankcase to
approx. 120°C (250°F).
1
250RA071 VA
250RA069 VA
• Use press arbor (1) 4119 893 • Fit ball bearing in crankcase by
7200 to remove ball bearing. hand and push it home as far as
stop.
- Inspect both halves of the crank-
case for cracks and replace if ne-
cessary.
20 FS 120, 200, 300, 350, 400, 450, FR 350, 450

250RA077 VA
250RA075 VA
250RA073 VA
• Fit ball bearing in crankcase by • Position the straight stub of the • Hold the spindle steady and
hand and push it home as far as crankshaft in the bearing at the rotate sleeve counterclockwise
stop. clutch side of the crankcase. until it butts against the ball
bearing.
Note: This operation must be
carried out very quickly because
the bearing absorbs heat immedi-
ately and begins to expand.
2 1
392RA044 VA
250RA078 VA
• Screw spindle (1) of installing • Hold the sleeve steady and
tool 5910 890 2202 fully into the rotate spindle clockwise until the
sleeve (2) (left-hand thread). crankshaft butts against the ball
bearing.
Important: During this process

the connecting rod (without
piston) must point towards the
cylinder flange.
- Hold the crankshaft steady and

unscrew spindle from the stub.
1
- Apply a thin coating of sealant to
crankcase mating face - see
13.2.
Important: Follow manufacturer’s

250RA074 VA
250RA076 VA
instructions.
1 2
• If it is not possible to heat the • Hold the crankshaft steady and

clutch side of the crankcase, use screw the spindle (1) clockwise
press arbor (1) 4119 893 7200 to onto the stub (2) as far as stop.
press in the ball bearing as far
as stop.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 21

1
250RA079 VA
250RA082 VA
250RA085 VA
• Fit starter side of crankcase over • Hold the sleeve steady and - Slide the oil seal, open side
the crankshaft stub. rotate spindle clockwise until the facing the crankcase, over the
two halves of the crankcase are installing sleeve.
together.
- Remove the installing tool. (1) 1118 893 2401.
1
250RA080 VA
250RA083 VA
250RA086 VA
1 2
• Hold crankshaft steady and • Insert screws and use socket (1) - Remove the installing sleeve.
screw the spindle (1) clockwise 0812 542 2104 to tighten them
onto the stub (2) as far as stop. down to 8.5 Nm (6.3 lbf.ft). - Slide the oil seal, open side
facing the crankcase, over the
- Lubricate sealing lips of oil seals starter end of the crankshaft.
(1) 4112 893 2401.
Assemble as other parts in the

reverse sequence.
- Adjust throttle cable - see 7.5.2.

1
250RA084 VA
250RA081 VA
• Hold the spindle steady and • Fit installing sleeve (1) 4112 893
rotate sleeve counterclockwise 2400 over the clutch end of the
until it butts against the ball crankshaft.
bearing.
22 FS 120, 200, 300, 350, 400, 450, FR 350, 450

4.8 Decompression Valve 5. IGNITION SYSTEM 5.1 Spark Plug Boot
Warning! Exercise extreme - Remove the shroud - see 4.1.

caution when carrying out
maintenance and repair work on - Pull off the spark plug boot.
the ignition system. The high
voltages which occur can cause - On FS 400/450, FR 450, take
serious or even fatal accidents! cable holder off the cylinder.
Troubleshooting on the ignition

system should always begin at the
250RA091 VA
spark plug. See "Standard Re-
pairs, Troubleshooting" handbook.
• Use standard commercial long-

reach 13 mm socket to unscrew
the decompression valve.
- Install new decompression valve

and tighten down to 14 Nm
(10.3 lbf.ft).
1
- Fit the shroud.
250RA088 VA
250RA087 VA
Note: The electronic (breakerless) • Use pliers to grip the leg spring
ignition system basically consists and pull it out of the spark plug
of an ignition module (1) and boot.
flywheel (2).
- Unhook the leg spring from the
The illustration shows the FS 200. ignition lead.
- Pull spark plug boot off the

ignition lead.
- Coat end of the ignition lead

(about 20 mm/3/4") with oil.
- Fit spark plug boot over the

ignition lead.
- Use pliers to grip the end of the

ignition lead inside the spark
plug boot and pull it out.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 23

5.2 Ignition Lead
(FS 400/450, FR 450)
- On FS 400/450, FR 450, attach

the cable retainer to the cylinder.
- Fit the boot on the spark plug.
250RA089 VA
250RA092 VA
2 1
• Pinch hook of leg spring into the - Remove the ignition module -
center of the lead, i.e. about see 5.3.3.
10 mm (3/8") from the end of
the lead. • Remove spark plug boot (1) -
see 5.1.
• Pull off the cable retainer (2).

250RA090 VA
250RA053 VA
• Pull the lead back into the • Remove the retainer.
boot so that the leg spring
locates properly inside it.
250RA008 VA
250RA094 VA
Important: If the spark plug • Pull rubber boot (1) off the high
comes with a separate terminal voltage output.
nut, always fit the nut on the
thread and tighten it down • Unscrew the ignition lead from
securely. the contact pin and pull it out of
the high voltage output.
24 FS 120, 200, 300, 350, 400, 450, FR 350, 450

5.3 Ignition Module
- Slip the rubber boot off the Accurate testing of the ignition
2
ignition lead. 1 module is only possible with
sophisticated test equipment. For
- Cut new ignition lead to length this reason it is only necessary to
(see parts list or cut to same carry out a spark test in the work-
length as old lead). shop. A new ignition module must
be installed if no ignition spark is
obtained (after checking that
wiring and stop switch are in good
250RA054 VA
condition).
3
The ignition module accommo-

dates all the components required
to control ignition timing.
FS 120...350, FR 350
There are two electrical connec-
tions on the coil body:
1. the high voltage output (1) with

ignition lead (2)
2. the connector tag (3) for the

short circuit wire
A vibration damping pad is bonded

to the side of the ignition module.
338RA142 VA
• Use a pointed tool (awl or gimlet)

to pierce the center of the
ignition lead that is to be scre-
wed into the module.
- Slip the rubber boot over the FS 400/450, FR 450

lead. There are two electrical connec-
tions on the coil body:
- Pack the high voltage output with
STIHL multipurpose grease - see
13.2.
Important: Do not use graphite

grease (Molykote) or silicone
insulating paste for this job. 1
- Screw home the ignition lead.

250RA095 VA
- Fit rubber boot on the high

voltage output. 2
- Fit cable retainer and spark plug 1. the high voltage output (1)
boot.
2. the connector tag (2) for the
- Fit the ignition module - see short circuit wire
5.3.3.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 25

5.3.1 Ignition Timing 5.3.2 Removing and Installing (FS 120...350, FR 350)
Ignition timing is not adjustable. - Remove the shroud - see 4.1.
Since there is no mechanical wear - Pull the boot off the spark plug.
in these systems, ignition timing
cannot get out of adjustment. How- - Remove the fan housing - see
ever, an internal fault in the circuit 6.2.
can alter the switching point in
such a way that a spark test will - Remove clutch housing -
still show the system to be in order see 9.1.
250RA097 VA
although timing is outside the
permissible tolerance. This will
impair engine starting and running
behavior. • Take out the screws.
- Remove the ignition module.
- Remove the spark plug boot -

see 5.1.
Note: The ignition lead is molded

to the ignition module.
Important: Before installing a new

ignition module, make sure area
for vibration damping pad is free
from grease, dirt and moisture.
- Peel the backing off the new

vibration damping pad.
250RA096 VA
• Remove ignition lead from the

retainers.
3
250RA099 VA
250RA098 VA
• Pull short circuit wire connector • Place the pad on the ignition
(1) off tag on ignition module. module and apply firm and
uniform pressure.
26 FS 120, 200, 300, 350, 400, 450, FR 350, 450

5.3.3 Removing and Installing (FS 400/450, FR 450)
250RA103 VA
250RA100 VA
250RA101 VA
1 2
- Place the module in position, - Remove the shroud - see 4.1. • Take out the screws.
insert the screws but do not
tighten them down yet. - Remove the fan housing - see
6.2.
- Check that ignition lead is
properly seated in grommet. • Pull boot (1) off the spark plug.
• Slide the setting gauge (1) • Pull cable retainer (2) out of
1127 890 6400 between the cylinder.
arms of the ignition module and
the flywheel magnet poles.
- Press the ignition module

against the flywheel and tighten
down the mounting screws to a
torque of 4.5 Nm (3.3 lbf.ft).
Reassemble all other parts in the
250RA104 VA
reverse sequence.
• Lift ignition module away slightly

and disconnect short circuit wire
from ignition module.
- Remove the ignition lead - see

5.2.
- Connect the short circuit wire,

place the module in position,
insert the screws but do not
tighten them down yet.
250RA102 VA
• Take ignition lead out of guide.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 27

5.4 Flywheel
1
1
250RA105 VA
250RA109 VA
250RA106 VA
2
• Secure cable retainer (1) with Removing the flywheel: Note: If the flywheel cannot be
outer screw. removed by hand, screw on the
- Remove the fan housing - see puller (1) 4133 893 0800 and tap
• Slide the setting gauge (2) 6.2. its end to release the flywheel.
1127 890 6400 between the Unscrew the puller.
arms of the ignition module and - Pull off the spark plug boot.
the flywheel magnet poles.
- Press the ignition module
against the flywheel and tighten
down the mounting screws to a FS 120...350, FR 350
torque of 6.0 Nm (4.4 lbf.ft). • Fit locking strip (1)
0000 893 5903.
Reassemble all other parts in the 1
reverse sequence.
FS 400/450, FR 450
- Fit locking strip
4221 893 5900.
250RA110 VA
2
Inspect the flywheel (1) and

magnet poles (2). If you find any
damage, install a new flywheel.
Installing the flywheel:
All models Important: Clean the stub of the

crankshaft and the flywheel hub
bore with a standard commercial,
solvent-based degreasant which
contains no chlorinated or
halogenated hydrocarbons - see
13.2.
- Fit the flywheel.
Note: Check position of slot.

250RA107 VA
Assemble all other parts in the

reverse sequence.
• Unscrew the flywheel nut.
- Fit flywheel nut. Tighten nut on
- Pull off the flywheel. FS 120 to 24 Nm (17.7 lbf.ft).
Tighten nut on all other models
to 32 Nm (23.6 lbf.ft).
28 FS 120, 200, 300, 350, 400, 450, FR 350, 450

5.5 Short Circuit Wire
- Remove the ignition module -

1 2
see 5.3.2 and 5.3.3.

see 9.1 and 11.2.
250RA113 VA
250RA115 VA
1
FS 400/450, FR 450 All models

- Remove the fuel tank - see 8.5. • Take out the screw (1).
- Remove the muffler - see 4.1. • Remove top of cable guide (2).
• Push out the outer grommet (1).
FS 120...350, FR 350 • Pull short circuit wire out of

housing bore and remove
grommet.
2 1
250RA116 VA
250RA111 VA
• Pull short circuit wire out of • Lift the throttle cable (1) a little.
grommet.
• Remove short circuit wire
connector (2) from base of cable
guide.

sequence.
- Check and adjust throttle

cable - see 7.5.2.
250RA112 VA
250RA114 VA
1
2
• Remove short circuit wire from • Push out the grommet (1).
retainers.
• Pull short circuit wire (2) out of
housing bore, remove it from
the retainers and pull off the
grommet.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 29

6. REWIND STARTER 6.2 Rewind Spring
6.1 General 6.2.1 Replacing
If the action of the starter rope Note: The replacement spring

becomes very stiff and the rope comes ready for installation and is
rewinds very slowly or not com- secured with a washer.
pletely, it can be assumed that
the starter mechanism is in order - It should be lubricated with a few
but plugged with dirt. At very low drops of STIHL special lubricant
outside temperatures the lubri- before installation - see 13.2.
cating oil on the rewind spring may
thicken and cause the spring
250RA117 VA
windings to stick together. This
has a detrimental effect on the
function of the starter mechanism.
In such a case it is sufficient to Troubleshooting chart - see
apply a few drops of paraffin "Standard Repairs, Trouble-
(kerosine) to the rewind spring. shooting" handbook.
Then carefully pull out the starter • Take out the screws.
rope several times and allow it to
rewind until its normal smooth • Remove fan housing with rewind
action is restored. starter.
If clogged with dirt or pitch, the - Remove the rope rotor - see
entire starter mechanism, inclu- "Standard Repairs, Trouble-
ding the rewind spring, must be re- shooting" handbook.
moved and disassembled. Take
special care when removing the
spring.
Wash all parts in paraffin or white

spirit.
250RA119 VA
Lubricate the rewind spring and
starter post with STIHL special
lubricant, see 13.2, before • The washer slips off the rewind
installing. spring as it is pushed into the fan
housing. Engage the outer
spring loop in the recess in the
fan housing at the same time.
Caution: The rewind spring may

pop out and uncoil during
installation.
- If the rewind spring has popped

out, refit it as follows:
250RA118 VA
• Take out the screw and remove

any remaining pieces of spring
from the fan housing.
30 FS 120, 200, 300, 350, 400, 450, FR 350, 450

6.2.2 Tensioning
- Hold the starter grip firmly to

keep the rope tensioned.
- Let go of the rope rotor and

slowly release the starter rope
so that it can rewind properly.
250RA120 VA
250RA122 VA
• Engage outer spring loop in the • Make a loop in the starter rope.
recess and refit rewind spring in
fan housing in the counterclock-
wise direction, starting outside
and working inwards.
250RA121 VA
250RA123 VA
250RA125 VA
A
• Check the position of the • Grip the rope close to the rotor Note: The rewind spring is cor-
inner spring loop. It should be and use it to turn the rope rotor rectly tensioned when the starter
2 mm (0.08") away from the hub. six full turns counterclockwise. grip sits firmly in the rope guide
bush without drooping to one side.
- Fit screw and tighten it down to If this is not the case, tension the
1.5 Nm (1.1 lbf.ft). spring by one additional turn.
- Install the rope rotor - see When the starter rope is fully
"Standard Repairs, Troubleshoo- extended, it must still be possible
ting" handbook. to rotate the rope rotor at least
another half turn before maximum
- Tension the rewind spring - see spring tension is reached. If this is
6.2.2. not the case, pull the rope out,
hold the rope rotor steady and
take off one turn of the rope.
Do not overtension the rewind

250RA124 VA
spring as this will cause it to

break.
- Fit fan housing, insert screws

• Hold the rope rotor steady. and tighten down to 6.0 Nm
(4.4 lbf.ft).
• Pull out the rope with the starter
grip and straighten it out.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 31

6.3 Starter Rope/Starter Grip (ElastoStart)
- Remove fan housing with rewind

starter - see 6.2.
Starter rope
- Remove rope rotor - see

shooting" handbook.
362RA097 VA
250RA127 VA
- Remove the starter rope from
the rotor.
• Pull the rope back to locate the • Thread rope through the hole in
knot in the starter grip. the side of the rotor.
- Push cap into starter grip. - Secure the starter rope with a
simple overhand knot.
- Secure starter rope to rope rotor.
- Install the rope rotor.
Starter grip
The starter grip is supplied with
starter rope.
- Remove the rope rotor - see

shooting" handbook.
- Pull the knot out of the recess in
the rope rotor.
250RA128 VA
362RA095 VA
- Undo the knot and pull the rope

out of the rotor and fan housing.
• Pry cap out of starter grip. - On FR 350/450, slip tube • Pull the rope back into thr rotor
(75 mm/2.95") over the starter so that the knot locates in the
- Pull rope out of starter grip. rope. recess.
- On FR 350/450, slip tube - Install the rope rotor - see

(75 mm/2.95") over the starter "Standard Repairs, Trouble-
rope. shooting" handbook.
- Tension the rewind spring - see

6.2.2.
- Fit fan housing with rewind

starter - see 6.2.2.
362RA096 VA
250RA126 VA
• Thread end of new starter rope • Thread the starter rope

through the underside of the star- 0000 195 8200 through the gui-
ter grip. de bush from outside the
fan housing.
- Secure end of rope with a simple
overhand knot.
32 FS 120, 200, 300, 350, 400, 450, FR 350, 450

7. THROTTLE CONTROL
7.1 Throttle Trigger/Interlock Lever (Bike Handle)
• Take out screw and washer. • Remove the torsion spring. • Attach the throttle cable, then
position torsion spring as shown
- Pull off the control handle. and push its long arm into the
slot.
Warning: To avoid risk of electric • Take the throttle trigger (1) with • The interlock lever must be
shock, do not start the unit while torsion spring (2) and throttle behind the throttle trigger.
the control handle is open. cable (3) off the peg.
• Use screwdriver (1) 5910 890

2301 to take out the screws.
- Separate the two halves of the

handle.
• Lift the interlock lever (1) slightly • Disconnect throttle cable from • Check correct positions of
and turn it to one side until the trigger. throttle cable (1), contact spring
torsion spring (2) is relaxed. (2), protective tube (3) and
Assemble in the reverse insulator (4).
• Pull the interlock lever off the sequence.
peg.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 33

7.2 Contact Springs/Detent Spring in Control Handle 7.3 Throttle Trigger/Interlock
(Bike Handle) Lever (Loop Handle)
- Remove the throttle trigger - see • Take out slide control’s collar FR 350/450
7.1. screw (1). • Use screwdriver (1) 5910 890
2301 to remove screw.
• Lift contact spring (1) a little and • Remove detent spring (2).
remove the throttle cable (2). • Push guard (2) forward.
All models
• Remove spring from seats (1) • Pull slide control out of handle Warning: To avoid risk of electric
and peg (2). molding. shock, do not start the unit while
the control handle is open.
sequence. • Use screwdriver (1) 5910 890
2301 to take out the screws.
- Engage contact spring correctly
in groove of collar screw. - Remove handle molding.
• Remove contact spring from peg • Remove torsion spring.

(1) and collar screw (2).
34 FS 120, 200, 300, 350, 400, 450, FR 350, 450

7.4 Slide Control
(Loop Handle)
• Pull throttle trigger (1) with • Pull interlock lever with contact - Remove the interlock lever - see
throttle cable (2) off the peg. spring off the peg. 7.3.
• Pull slide control off the handle

molding.
• Disconnect throttle cable from • Remove contact spring from • Remove screws from clamps.
trigger. interlock lever.
- Take handle molding off the dri-
Assemble in the reverse ve tube.
sequence.
• Lift contact spring (1) a little and • Check positions of throttle cable • Remove torsion spring from peg.
remove the throttle cable (2). (1), contact spring (2), protective
tube (3) and insulator (4).
- Tighten screws to 1.0 Nm

(0.75 lbf.ft).
FS 120, 200, 300, 350, 400, 450, FR 350, 450 35

7.5 Throttle Cable
7.5.1 Replacing
All models

see 9.1 and 11.2.
- Remove the air filter - see 8.1.
- Take throttle cable off the con-
250RA143 VA
tact spring - see 7.2 and 7.3.
2 1
Note: On FS 120...350, FR 350,
Assemble in the reverse sequence. remove spark plug boot and take • Disconnect throttle cable nipple
ignition lead out of retainers on top (1) from slotted pin (2) on throttle
- Tighten clamp screws to 2 Nm and base of cable guide. lever.
(1.5 lbf.ft).
• The groove (1) in the slide

control must engage over the
outer edge (2) of the handle
molding.
1 2 1 2 3
• The torsion spring (3) must
engage the recess (4) in the
slide control.
250RA144 VA
250RA141 VA
• Take out the screw (1). • Take throttle cable (1) out of
base of cable guide (2) and
• Remove top of cable guide (2). retainer (3) on carburetor
housing.
a
250RA142 VA
250RA145 VA
250RA237 VA
1 2 1 2
• On FR 350/450, the distance "a" FS 120...350, FR 350 FS 400/450, FR 450

between the control handle and • Remove screw (1) from - Remove the air filter housing -
housing must be 20 mm (0.8"). extended throttle cable (2). see 8.2.2.
• Remove screw (1) from

extended throttle cable (2).
36 FS 120, 200, 300, 350, 400, 450, FR 350, 450

7.5.2 Adjusting
1 1
250RA146 VA
250RA239 VA
250RA148 VA
2 2
• Disconnect throttle cable nipple Reassemble in the reverse • Throttle lever (1) must butt
(1) from slotted pin (2) on throttle sequence. against the stop on the carbure-
lever. tor cover (2) when throttle trigger
is squeezed (full throttle).
FS 400/450, FR 450
• Make sure grommet is properly
located in the carburetor housing.
- Secure lug between the raised

marks.
FS 120...350, FR 350
- Place lug and extended throttle
cable in the corner of the filter
housing.
- Tighten screw of extended

250RA238 VA
250RA149 VA
throttle cable to 6.0 Nm
(4.4 lbf.ft).
• Pull grommet out of carburetor - Adjust throttle cable - see 7.5.2. • On carburetors with an idle
housing. speed screw: Throttle lever must
butt against the idle speed screw
when the trigger is in the idle
position.
Note: The filter housing is not

shown in the illustration.
Adjustment is effected by moving

2 1 3 the throttle cable in the holder.
- On FS 300...450, remove cover

from AV housing - see 9.2.
- Check correct setting of idle

250RA147 VA
speed screw (if fitted).
Important: Note adjustment range

• Take throttle cable (1) out of of idle speed screw.
base of cable guide (2) and pull
it out of opening (3) in carburetor
housing.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 37

8. FUEL SYSTEM
8.1 Air Filter
Dirty and clogged air filters reduce • Swing the filter cover (2)
engine power, increase fuel forwards and take it off the lower
consumption and make starting lugs on the filter housing.
more difficult.
The air filter must be cleaned

when there is a noticeable loss
of engine power.
250RA150 VA
- Close the choke shutter.
1 2
- Clean away any loose dirt from
• Release screw (1) and pull around the filter and filter cover.
throttle cable (2) out a little.
Note: The throttle lever moves

towards the carburetor cover.
- Squeeze throttle trigger all the

way (full throttle position), hold FS 120...350, FR 350
it steady and tighten screw to
6.0 Nm (4.4 lbf.ft).
- Release throttle trigger (idle

position). The throttle lever must
butt against the idle speed
screw, if fitted.
- On FS 300...450, fit cover on AV

housing.
250RA151 VA
250RA153 VA
- Fit the shroud.
• Press down the tab. All models

• Remove the filter.
• Push the filter cover downwards
and take it off the lower lugs on - If the filter is heavily loaded with
the filter housing. dirt or damaged, fit a new one.
- Fit filter in the housing.
- Position filter cover so that it

locates properly in the lower lugs.
2 - On FS 400/450, FR 450:
1 Tighten screw to 3.0 Nm
(2.2 lbf.ft).
250RA152 VA
FS 400/450, FR 450
• Take out screw (1).
38 FS 120, 200, 300, 350, 400, 450, FR 350, 450

8.2 Carburetor
FS 120...350, FR 350
2 1
shooting" handbook.
Important: In the event of trouble

with the carburetor or the fuel
supply system, always check and
250RA156 VA
250RA159 VA
clean the tank vent - see 8.3.

• Disconnect fuel hoses from • Check heat shield (1). If necessa-
- Remove the air filter - see 8.1. manual fuel pump. ry, push out the grommet (2) and
remove the heat shield.
2
2
1
250RA157 VA
250RA160 VA
250RA154 VA
• Take out screw (1) of extended • Unscrew the nuts. • Disconnect throttle cable nipple
throttle cable. (1) from slotted pin (2) on throttle
lever.
• Pry choke knob (2) out of filter
housing and pull it off the choke • Pull the fuel hose (3) off the
shaft. elbow connector on the carbure-
tor.
250RA155 VA
250RA158 VA
250RA161 VA
• Take fuel hose out of retainer in • Remove the filter housing and • Pull carburetor off the studs.
filter housing. pull stub out of grommet at the
same time. - If necessary, pull fuel hose off
carburetor.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 39

2 2
250RA013 VA
250RA166 VA
250RA163 VA
1
• Remove the gasket. FS 400/450, FR 450 • Pry choke knob out of carburetor
housing and pull it off the choke
Reassemble in the reverse - Remove the shroud - see 4.1. shaft.
sequence.
• Take out screw (1).
- Use a new gasket.
• Unscrew the nuts (2).
- Tighten down nuts on filter
housing to 3.5 Nm (2.6 lbf.ft).
1
- Tighten down screw on extended
throttle cable to 6.0 Nm
(4.4 lbf.ft). 2
3
250RA164 VA
250RA167 VA
• Remove the filter housing and • Disconnect throttle cable nipple
pull stub out of grommet at the (1) from slotted pin (2) on throttle
same time. lever.
• Disconnect fuel hose (3)

from carburetor.
250RA168 VA
250RA165 VA
• Disconnect fuel hose from • Pull carburetor off the studs.

connector.
40 FS 120, 200, 300, 350, 400, 450, FR 350, 450

8.2.3 Leakage Test
The carburetor can be tested for

leaks with the carburetor and
crankcase tester 1106 850 2905.
250RA169 VA
250RA171 VA
• Remove the gasket. • Push the fuel hose with nipple
onto the carburetor elbow
Reassemble in the reverse connector.
sequence.
- Use a new gasket.
- Tighten down nuts on filter

housing to 3.5 Nm (2.6 lbf.ft).
- Tighten down screw on filter hou-

sing to 6.0 Nm (4.4 lbf.ft).
250RA172 VA
250RA170 VA
FS 400/450, FR 450 • Push the nipple into the tester’s

- Remove the shroud - see 4.1. pressure hose.
• Pull fuel hose off carburetor’s

elbow connector.
2 1
3
2
143RA172 VA
250RA173 VA
FS 120...350, FR 350 • Close the vent screw (1) on the

- Remove the carburetor - see rubber bulb (2) and pump air into
8.2.1. the carburetor until the pressure
gauge (3) shows a reading of
• Fit fuel hose (1) 1110 141 8600 approx. 0.8 bar (11.5 psi).
on nipple (2) 0000 855 9200.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 41

8.2.4 Adjusting
(three screws)
If this pressure remains constant, Turn screw slowly and carefully –

1 2
the carburetor is airtight. However, slight changes have a noticeable
if it drops, there are two possible effect on engine running behavior.
causes:
H L Adjusting idle speed
1. The inlet needle is not sealing
(foreign matter in valve seat or Engine stops while idling:
sealing cone of inlet needle is LA
damaged or inlet control lever - Carry out standard setting.
250RA220 VA
sticking).
3 Turn the idle speed screw (LA)
2. The metering diaphragm is clockwise until cutting tool begins
damaged. Standard setting to rotate, and then turn screw back
one half turn.
In either case the carburetor must If the carburetor has to be
be removed and serviced - see adjusted from scratch, first carry
"Carburetor" handbook. out the standard setting.
- After completing test, open the - Carefully screw in both adjusting

vent screw and pull the fuel hose screws clockwise until they are
off the elbow connector. hard against their seats.
- Install the carburetor - see 8.2.1. Now make the following adjust-
ments:
FS 400/450, FR 450 H = Open high speed screw (1)

- Push the fuel hose onto the one full turn L
H
elbow connector. L = Open low speed screw (2) 1 LD
one full turn

250RA221 VA
A slight correction to this setting
may be necessary at high altitudes
(mountains) or near sea level. Use
the following procedure: Turn the idle speed screw (LD)
clockwise until engine runs
- Mount approved cutting tool. smoothly – cutting tool must not
rotate.
- Check the air filter, replace if
necessary.
Cutting tool rotates while
- Check spark arresting screen, engine is idling:
clean or replace as necessary.
- Carry out standard setting.
- Start the engine and allow it to
warm up. Turn the idle speed screw (LA)
counterclockwise until cutting tool
Turn high speed screw (H) stops rotating – and then turn it
clockwise for leaner mixture at about another one full turn in the
high altutude, same direction.
or counterclockwise for richer
mixture at sea level.
42 FS 120, 200, 300, 350, 400, 450, FR 350, 450

8.2.5 Adjusting
(one screw)
Turn the idle speed screw (LD) The carburetor has no adjusting Adjusting idle speed
counterclockwise until cutting tool screws for maximum engine
stops rotating –and then turn it speed (H screw) or idle mixture
about another one full turn in the (L screw). Engine stops while idling:
same direction.
The carburetor is tuned so that the Turn the idle speed adjusting
engine receives an optimum fuel- screw (LD) clockwise until engine
air mixture in all operation condi- runs smoothly –cutting tool must
Note: tions. not rotate.
If the engine does not reach
6,000 rpm in starting throttle A slight correction of the idle
position, readjust the throttle speed may be necessary. Use the Cutting tool rotates while
cable, see 7.5. following procedure: engine is idling:
- Mount approved cutting tool. Turn the idle speed screw (LD)
counterclockwise until cutting tool
- Check the air filter, replace if stops rotating –and then turn
necessary. screw about another one full in the
same direction.
- Check spark arresting screen,
clean or replace as necessary.
- Start the engine and allow it to Note:

warm up. If the engine does not reach
6,000 rpm in starting throttle
position, readjust the throttle
cable, see 7.5.
1
+
LD
-
250RA222 VA
Adjust idle speed correctly with the

idle speed screw (LD): the cutting
tool must not rotate.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 43

8.3 Tank Vent 8.4 Pickup Body
Correct operation of the carburetor The diaphragm pump draws fuel

is only possible if atmospheric out of the tank and into the
pressure and internal fuel tank 1 carburetor via the fuel hose. Any
pressure are equal at all times. 3 6 impurities mixed with the fuel are
This is ensured by the tank vent. retained by the pickup body (filter).
7 5 The fine pores of the filter even-
Important: If problems occur on 4 tually become clogged with minute
the carburetor or the fuel supply 2 particles of dirt. This restricts the
system, always check and clean passage of fuel and results in fuel
250RA225 VA
the tank vent. starvation.
Check function by performing Important: In the event of trouble

pressure and vacuum tests on Cleaning with the fuel supply system,
the tank via the fuel hose. always check the fuel tank and
- Unscrew the fuel filler cap. the pickup body first. Clean the
fuel tank if necessary.
• Ease the cap (1) off the valve
body (2).
Cleaning the fuel tank
• Take sintered filter (3) out of cap.
- Unscrew the filler cap and drain
• Pry valve body out of fuel filler the tank.
cap (4).
- Pour a small amount of clean
• Pry sintered filter (5) out of fuel gasoline into the tank.
filler cap.
- Close the tank and shake the
- Wash valve body in clean unit vigorously.
gasoline.
- Open the tank again and drain it.
250RA223 VA
• If diaphragm in the valve (6) is

damaged, pull it out of valve Note: Dispose of fuel properly.
body and fit new one.
Equalization of pressure from the
outside inwards takes place via • Push new sintered filter (5) into Pickup body
the hole in the fuel filler cap, the filler cap.
sintered filter, the valve and holes - Unscrew the filler cap and re-
in the cap. • Fit sealing ring (7) over valve move it together with the retainer.
body.
- Fit valve body in filler cap and

press it home until it snaps into
position.
- Fit new sintered filter in the cap.
- Fit cap on valve body and press

it down until it snaps into position.
- Refit the fuel filler cap.

250RA224 VA
Equalization of pressure from the

inside outwards takes place via
the holes in the cap, the holes in
the valve body, the sintered filter
and the hole in the fuel filler cap.
44 FS 120, 200, 300, 350, 400, 450, FR 350, 450

8.5 Fuel Tank/
Hoses
All models - Remove fuel hoses if necessary.

- Drain the fuel tank.
1 Reassemble in the reverse
- Remove the shroud - see 4.1. sequence.
- Remove the fan housing - see - Tighten down screws to 6.0 Nm

6.2.1. (4.4 lbf.ft).
250RA174 VA
FS 120...350, FR 350 FS 400/450, FR 450
- On FR 350, remove powerhead - On FR 450, remove powerhead
from support frame - see 9.3. from support frame - see 9.3.
• Use hook (1) 5910 893 8800 to
pull the pickup body out of the - Remove the carburetor - see
fuel tank. 8.2.2.
Note: Do not stretch the fuel hose.
250RA178 VA
250RA175 VA
250RA176 VA
• Pull the pickup body off the fuel - Remove the filter housing - see • Disconnect fuel hose from lower
hose. 8.2.1. connector on manual fuel pump
and pull it out of the guide.
- Fit new pickup body. • Pull fuel hose off carburetor
elbow connector.
Install in the reverse
sequence.
250RA179 VA
250RA177 VA
• Take out the screws. FS 400/450 only

- Remove the fuel tank.
- Remove the guard plate.
- Replace sleeves and grommets
if necessary.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 45

2
1 1
250RA181 VA
250RA184 VA
250RA180 VA
• Take out the screws. • Use hook (1) 5910 893 8800 to Install in the reverse sequence.
pull pickup body out of tank.
- Remove the fuel tank. • On FS 400/450, FR 450, fit fuel
hose (1) next to filler neck (2).
1
A
2
250RA226 VA
250RA185 VA
250RA182 VA
• Take sleeves (1) out of • Pull pickup body off the fuel hose. • Length "A" of return hose must
grommets. be 190 mm (7.5") on FS
120...350 and 200 mm (7.9") on
• Ease grommets (2) out of fuel FS 400/450.
tank.
- Remove fuel hoses if necessary.
Reassemble in the reverse

sequence.
2
- Tighten down screws to 6.0 Nm
(4.4 lbf.ft).
1
Fuel hoses
- Unscrew filler cap and remove

250RA183 VA
together with retainer.

3
• Pull out the fuel hose (1).
• Pull out the return hose (2)

together with grommet (3).
46 FS 120, 200, 300, 350, 400, 450, FR 350, 450

8.6 Manual Fuel Pump 9. AV SYSTEM
9.1 Repair (FS 120/200)
The anti-vibration (AV) connection

between the engine and drive tube
consists of a rubber element
installed in the clutch housing.
- Remove the drive tube - see

10.6.
250RA186 VA
250RA192 VA
- Remove the shroud - see 4.1. • Lever the retaining ring out of the
clutch housing.
- On FS 120...350, FR 350,
remove the air filter - see 8.1. - Remove retaining ring over
the AV sleeve.
• Disconnect hoses from
connectors.
2
3
250RA193 VA
250RA190 VA
250RA187 VA
• Carefully push back the retaining • Take out the screws. • Push installing tool (1)
tabs. 4126 893 4900 into AV sleeve
- Remove the clutch housing and as far as stop.
clutch shroud.
• Tighten down clamp screw (2).
• Tighten fixing screw (3) modera-

tely if necessary.
- Apply a little lubricant (e.g. was-

hing-up liquid) between the
clutch housing and rubber ele-
ment.
250RA189 VA
250RA191 VA
• Pull fuel pump out of its seat in • Take the clutch shroud off the
the filter/ carburetor housing. clutch housing.
Install in the reverse

sequence.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 47

9.2 Repair
(FS 300...450)
The anti-vibration (AV) connection

1
between the engine and drive tube
consists of four rubber buffers in
the AV housing.
- Remove the control handle - see

10.1.
392RA136 VA
250RA194 VA
2
- Clamp installing tool in vice. • Push the rubber element,

tapered end (1) first, onto the AV
• Pull clutch housing off sleeve until the flange (2) is
the rubber element. behind the rubber element.
1 1
3
392RA134 VA
250RA195 VA
250RA196 VA
2 2 2 1
• Release clamp screw (1) and - Coat rubber element with a lubri- Rubber buffers
fixing screw (2) if necessary. cant (e.g. washing-up liquid).
• Press snap hook (1) down and
• Pull the AV sleeve (3) off the • Push the rubber element into remove the cover (2).
installing tool. clutch housing as far as stop so
that slot (1) is opposite the lug
(2).
Assemble all parts in the reverse

sequence.
- Retaining ring must locate

properly in the groove in the
clutch housing.
- Tighten down clutch housing

mounting screws to 6.0 Nm
(4.4 lbf.ft).
392RA135 VA
250RA197 VA
• Pull the rubber element off the • Carefully ease the cable
AV sleeve. retainers out of the AV housing.
48 FS 120, 200, 300, 350, 400, 450, FR 350, 450

- Slip the rubber buffers over the • Push support in direction of AV
pegs on the clutch housing and housing until the four steel bars
support. are tight.
- Coat rubber buffers with a little - Tighten down screw to 6.0 Nm

lubricant (e.g. washing-up liquid). (4.4 lbf.ft).
- Push AV housing onto the rub- - Take out the steel bars.
ber buffers.
250RA198 VA
Assemble all parts in the
- Push support onto AV housing reverse sequence.
and engage the rubber buffers
• Release clamp screw on support. as the same time. - Place cover in the lower slot and
push it home until it snaps into
position.
AV housing
- Remove bike handle -

see 10.2.
- Remove the gearhead - see 11.1.
- Remove throttle cable from AV

housing.
- Release clamp screw on support.

250RA201 VA
250RA199 VA
• Push the support forwards and • To set the gap (7 mm/0.27")

pull off the rubber buffers. between the clutch housing and
AV housing, fit steel bar (e.g.
120x30x7 mm) at both sides
(see ill.).
250RA200 VA
250RA203 VA
250RA202 VA
2 1
- Push the AV housing forwards. • Fit a steel bar (e.g. 90x30x7 mm) • Pull the support (1) and AV
at both sides between the AV housing (2) off the drive tube.
• Pull the rubber buffers off the housing and support.
clutch housing.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 49

9.3 Repair
(FR 350/450)
- Inspect rubber buffers, replace if The anti-vibration connection Reassemble in the reverse
necessary. between the engine and support sequence.
frame consists of three springs.
- Adjust gap after fitting the AV - Use new locknuts and tighten
housing and support. - Remove flexible shaft from them down to 10 Nm (7.5 lbf.ft).
clutch housing - see 10.5.
Assemble all parts in the - Tighten down spline screws and
reverse sequence. hexagon head screw to 10 Nm
(7.5 lbf.ft).
1
250RA162 VA
• Take spline screws (1) and hex.

head screw (2) out of clutch hou-
sing.
- Take powerhead off the support

plate.
2 1 1
2
250RA242 VA
• Hold screws steady and unscrew

the nuts (1).
• Remove the springs (2) from the

support plate.
50 FS 120, 200, 300, 350, 400, 450, FR 350, 450

10. SHAFT 10.2 Bike Handle
10.1 Bike Handle (FS 120/200) (FS 300...450)
- To replace left grip, carefully cut

it open and pull it off. 1
- Coat inside of new grip with a
little lubricant (e.g. washing-up
liquid).
Note: If too much lubricant is

used, the grip will twist on the
tube. Always leave it to dry for a 2
while after fitting.
• Take out the screw.
- Pull off the control handle.
250RA205 VA
• Unscrew the nuts (1). • Push the grip into position so - Remove the control handle - see
that the longer ends (see arrows) 10.1.
• Remove lower clamp (2), point toward the gearhead at an
support block (3), bike handle (4) angle of 7 - 15 degrees to the • Take out the clamp screw (1).
and upper clamp (5) with screws shaft.
(6). • Swing open the upper clamp (2)
Assemble all parts in the reverse and lift it away.
sequence.
• Remove bike handle (3) and
lower clamp (4).
• If necessary, take springs (5) of

out lower clamp.
- Replace left grip if necessary -

see 10.1.

sequence.
- Lubricate thread of clamp screw

• Use jaws (1) 5910 893 2700 to with STIHL multipurpose grease -
clamp bike handle tube in vice. see 13.2
FS 120, 200, 300, 350, 400, 450, FR 350, 450 51

10.3 Loop Handle 10.4 Drive Shaft/
Flexible Liner
The drive shaft is supported in a

flexible liner inside the drive tube.
The ends of the drive tube are
sealed with plugs.
- Remove the gearhead - see 11.1.
Loop handle without barrier bar Loop handle with barrier bar
• Unscrew the nuts (1). • Take out screws (1).
• Remove lower clamp (2). • Remove lower clamp (2).
Drive shaft
• Remove screws (1). • Remove the barrier bar (1), loop • Pull the drive shaft out of the
handle (2) and upper clamp (3). drive tube.
• Remove the loop handle (2) and
upper clamp (3). • Take the square nuts (4) out of Note: If the shaft has turned blue,
the barrier bar. fit a new one.
sequence. Reassemble in the reverse - Coat the drive shaft with STIHL
sequence. gear lubricant 0781 120 1109,
see 13.2, before installation.
Important: Apply the grease

uniformly and thinly to the whole
drive shaft. Do not pump grease
directly into the drive tube.
- Push the drive shaft into the

drive tube.
• Align the loop handle at • Align the loop handle at

distance "A" = 20 cm (8") from distance "A" = 20 cm (8") from
the control handle and tighten the control handle and tighten
down firmly. down firmly.
52 FS 120, 200, 300, 350, 400, 450, FR 350, 450

10.5 Flexible Shaft
(FR 350/450)
250RA241 VA
362RA177 VA
• Push the drive shaft into the • Pull out the flexible liner. • Take throttle cable out of the two
drive tube until dimension "A" is retainers.
20 mm/0.8" (FS 120/200) or 30
mm/1.2" (FS 300...450).
If necessary, apply slight pres-
sure to the shaft and rotate it
slowly until it can be pushed in to
the specified dimension.
- Fit the gearhead - see 11.1.
250RA240 VA
• On FS 120/200, the hole (1) • Press down lever on clutch
must be between the spokes (2). housing.
- Insert plug, install the drive tube - - Pull out the shaft.
see 10.6.
Flexible liner
250RA243 VA
- Remove the drive tube - see • Press down lever on housing.

10.6.
- Pull out the shaft.
• Pry the plug out of the drive tube.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 53

10.6 Drive Tube
FS 120/200
- Remove the drive shaft - see 1
10.4.
- Remove the bike or loop handle -

see 10.1 and 10.3.
392RA129 VA
362RA174 VA
2
• Pull flexible shaft out of the • Take the fixing screw (1) out of
drive tube. the AV sleeve.
Note: If flexible shaft has turned • Release the clamp screw (2).
blue, fit a new one.
- Coat the flexible shaft with

STIHL gear lubricant 0781 120
1109, see 13.2, before installa-
tion.
Important: Apply the grease

uniformly and thinly to the whole
shaft. Do not pump grease directly
into the drive tube.
392RA156 VA
2 1
• On machines with bike handle, - Pull out the drive tube.

take throttle cable out of
retainers. • On machines with loop handle,
pull the drive tube (1) out of the
control handle (2) at the same
time.
250RA206 VA
362RA175 VA
• Inspect the 0-ring and fit a new • On machines with loop handle, • Slip the throttle cable retainer, if
one if necessary. release screws on control handle fitted, off the drive tube.
clamps.
- Install flexible shaft and fit
throttle cable in the retainers.
54 FS 120, 200, 300, 350, 400, 450, FR 350, 450

250RA249 VA
392RA139 VA
1 2 1 3
• Remove screw from hose clamp • Degrease the clamp mounting FR 350/450
for harness. area and push the drive tube - Remove the drive shaft - see
home so that the holes line up. 10.4.
- Tighten down fixing screw to - Remove the housing - see 10.7.

2.5 Nm (1.8 lbf.ft) and clamp
screw to 5.5 Nm (4.0 lbf.ft). • Release screws (1) on clamps of
control handle (2).
• Pull off the control handle.
• Pull off the sleeve (3).

sequence.
- Line up control handle relative to

housing - see 7.4.
250RA208 VA
- Tighten screws on clamps to

2.0 Nm (1.5 lbf.ft).
• Pull the hose clamp apart and FS 300...450
take it off the drive tube. - Remove the AV housing - see
9.2.
- Remove the drive shaft - see

10.4.
• Release the clamp screw.
- Pull the drive tube out of the

clutch housing.

sequence.
- Degrease the clamp mounting

area and push the drive tube
home into clutch housing as far
250RA207 VA
as stop.
- Tighten down clamp screw to

• Pull off the sleeve, if fitted. 8.5 Nm (6.3 lbf.ft) (FS 300/350)
or 12 Nm (8.8 lbf.ft) (FS 400/
Reassemble in the reverse 450).
sequence.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 55

10.7 Housing (FR 350/450) 11. CUTTING TOOL DRIVE
11.1 Gearhead
250RA243 VA
250RA210 VA
2 1
• Press down the lever. Illustration shows FS 120/200 • Take out screws (1).
gearhead.
• Pull out the flexible shaft. • Remove the guard ring (2).
- Remove deflector or stop, if fitted.
- For other disassembly and
• Release clamp screws. assembly procedures see
"Standard Repairs and Trouble-
- Pull gearhead off the drive tube. shooting" handbook.
- On FS 300...450, tighten down

screws on guard ring to 5.0 Nm
(3.7 lbf.ft).
- Install a new retainer.
- Degrease clamp mounting area.
- Slide the gearhead onto the

250RA244 VA
drive tube - turn the output shaft

2 1 back and forth at the same time
so that the square end of the
• Release the clamp screw (1). drive shaft engages the square
socket in the drive pinion.
• Pull off the housing (2).
- Push the gearhead as far as
- Service the housing - see stop and line it up.
shooting" handbook. - On FS 120/200 and FR 350/450,
tighten down clamp screws to
Reassemble in the reverse 8.5 Nm (6.3 lbf.ft).
sequence.
- On FS 300...450, first tighten
- Degrease clamp mounting area. clamp screws to 1.5 Nm (1.1
lbf.ft) and then finally tighten
- Tighten down clamp screw to them down to 7.5 Nm (5.5 lbf.ft).
4.5 Nm (3.3 lbf.ft).
- Refit the deflector or stop.
250RA209 VA
2 1
FS 300...450
• Remove retainer (1) - if fitted -
and thrust washer (2) from the
output shaft.
56 FS 120, 200, 300, 350, 400, 450, FR 350, 450

11.2 Clutch Drum
FS 120/200
1
- Take rubber element (AV
system) out of clutch housing -
see 9.1. 2 2 1
FS 300...450
- Remove the control handle - 3
see 10.1.
250RA250 VA
250RA214 VA
- Remove the throttle cable from
the AV housing - see 9.2. 2
FR 350/450 • Use drift (1) 1108 893 4700 or

1110 893 4700 to press clutch
- Remove the powerhead from the drum out of ball bearing.
support frame - see 9.3.
• Remove screws (1) from the

shroud.
• Remove screws (2) from the

clutch housing (3).
1
- Take off the clutch housing.
250RA215 VA
250RA211 VA
• Release the clamp screw. • Use pliers (1) 0811 641 8380 to
take retaining ring out of clutch
- Pull the drive tube out of the housing.
clutch housing.
Illustrations show the FS 120/200

clutch housing.
1
1
250RA216 VA
250RA212 VA
250RA213 VA
- Inspect rubber buffers, replace if • Use pliers (1) 0816 610 1495 to • Use press arbor (1) 1120 893
necessary. remove retaining ring from the 7200 to remove ball bearing from
clutch drum stub. clutch housing.
Install in the reverse sequence.
- Pull off the clutch housing.
FS 120, 200, 300, 350, 400, 450, FR 350, 450 57

12. SUPPORT FRAME (FR 350/450)
12.1 Repair
1
1
250RA251 VA
250RA254 VA
250RA217 VA
• Use press arbor (1) 1118 893 - Remove the powerhead from the • Use press arbor (1) 1118 893
7200 to press home ball bearing support frame - see 9.3. 7200 to remove ball bearing from
as far as stop. bearing housing.
• Remove screw from support
frame. Reassemble in the reverse
sequence.
1
250RA252 VA
1
250RA218 VA
250RA255 VA
• Use drift (1) 1108 893 4700 or • Lever the support frame out of • Use press arbor (1) 1118 893
1110 893 4700 to press home the ball bearing. 7200 to press home ball bearing
clutch drum as far as stop. as far as stop.
- On FS 300...450, adjust gap - - Tighten down bearing housing

see 9.2. mounting screws to 10.0 Nm
(7.5 lbf.ft).
- Tighten down clutch housing
mounting screws to 8.5 Nm (6.3 - Tighten down support frame
lbf.ft). mounting screw to 20.0 Nm (15
lbf.ft).
- On FS 120/200, tight down
clutch housing mounting screws
to 6.0 Nm (4.4 lbf.ft).
250RA253 VA
- Remove bearing housing from

support frame.
58 FS 120, 200, 300, 350, 400, 450, FR 350, 450

13. Special Servicing Tools and Aids
13.1 Special Servicing Tools
No. Part Name Part No. Application Rem.
1 Locking strip for piston 0000 893 5903 Blocking crankshaft 1) 2)

2 Locking strip for piston 4221 893 5900 Blocking crankshaft 2) 3)
3 Press sleeve 4112 893 2401 Fitting oil seal
(starter side)
4 Press sleeve 1118 893 2401 Fitting oil seal
(clutch side)
5 Installing sleeve 4112 893 2400 Protecting oil seal
(clutch side)
6 Puller 5910 890 4400 Removing oil seals 4)
7 - Jaws (No. 3.1 + 4) 0000 893 3706
8 Puller 4133 893 0800 Removing flywheel
9 Crimping tool 5910 890 8210 Attaching connectors to
electrical wires
10 Assembly drift 1110 893 4700 Removing and fitting piston pin
Removing and installing
clutch drum 2) 3)
11 Clamping strap 0000 893 2600 Compressing piston rings
12 Wooden assembly block 1108 893 4800 Fitting piston
13 Carburetor and 1106 850 2905 Testing carburetor
crankcase tester for leaks
14 Vacuum pump 0000 850 3501 Testing crankcase for leaks
15 - Nipple 0000 855 9200
16 - Fuel hose 1110 141 8600
17 Sealing plate 0000 855 8106 Sealing exhaust port for
leakage test
18 Test flange 1128 850 4200 For leakage test
19 Setting gauge 1127 890 6400 Setting air gap between ignition
module and flywheel
20 Socket, 13 mm 5910 893 5608 Clutch and flywheel nut,
decompression valve
21 Torque wrench 5910 890 0301 0.5 - 18 Nm 5)
(0.4 - 13.5 lbf.ft)
5910 890 0302 6)
22 Torque wrench 5910 890 0311 6 - 80 Nm 5)
(4.4 - 60 lbf.ft)
5910 890 0312 6)
23 Spline screw socket T27x125 0812 542 2104 IS screws
24 Hook 5910 893 8800 Removing pickup bodies
25 Installing tool 5910 890 2210 Installing hookless snap rings
in piston
26 Press arbor 4119 893 7200 Removing and installing ball bearings
27 Service tool ZS 5910 890 2220 Removing crankshaft
28 - Sleeve (4x) 1123 851 8300 1) 2)
29 - Extension 4116 894 1000 1) 2)
30 - Spline screw 9022 341 1190 1) 2)
31 Puller 4119 890 4600 Removing crankshaft
(clutch side)
FS 120, 200, 300, 350, 400, 450, FR 350, 450 59

No. Part Name Part No. Application Rem.
32 Installing tool 5910 890 2202 Installing crankshaft

33 Installing tool 4126 893 4900 Removing rubber element
from AV sleeve
34 Circlip pliers 0816 610 1495 External circlip on
clutch drum
35 Pliers C19 0811 641 8380 Internal circlip in
clutch housing
36 T-handle screwdriver QI-T27x150 5910 890 2400 For all IS screws 7)
37 Screwdriver T20x100 5910 890 2301 Separating handle moldings
38 Assembly drift 1108 893 4700 Removing and installing
clutch drum 1) 2)
39 Vice jaws 5910 893 2700 Holding drive tube and bike
handle
40 Press arbor 1120 893 7200 Removing ball bearing in
clutch housing
41 Press arbor 1118 893 7200 Installing ball bearing in
clutch housing,
removing and installing
ball bearing in bearing
housing (support frame) 2)
42 Assembly stand 5910 890 3100 Holding FS and FR units
43 - Clamp 5910 890 8800 Holds drive tube of FS units
for repairs
(in conjunction with assembly stand)
44 - Clamping plate 5910 890 2101 Holds powerhead of FS and
FR units for repairs
(in conjunction with assembly stand)
Remarks:
1) FS 120...350
2) FR 350/450
3) FS 400/450
4) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400.
5) Always use torque wrench to tighten DG/P screws.
6) Wrench has optical/acoustic signal.
7) On DG/P screws, use for releasing only.
60 FS 120, 200, 300, 350, 400, 450, FR 350, 450

13.2 Servicing Aids
No. Part Name Part No. Application
1 Lubricating grease 0781 120 1111 Oil seals

(225 g/0.79 oz tube)
2 Standard commercial, Cleaning crankshaft stub

solvent-based degreasant
containing no chlorinated or
halogenated hydrocarbons
3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor,
rewind spring in rope rotor
4 Ignition lead HTR (10 m/33’) 0000 930 2251
5 Dirko sealant 0783 830 2120 Crankcase sealing faces

(100 g/3 1/2 oz tube)
6 STIHL gear lubricant Drive shaft and clamp screw on

- 80 g/3 oz tube: 0781 120 1109 bike handle
- 225 g/8 oz tube: 0781 120 1110
7 STIHL gear lubricant Gearhead lubrication

- 80 g/3 oz tube: 0781 120 1117
- 225 g/8 oz tube: 0781 120 1118
FS 120, 200, 300, 350, 400, 450, FR 350, 450 61

62
63
64
englisch / English
0455 250 0123. M0,15. L11. FST. Printed in Germany

Sthil Fs 120

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STIHL FS 120, 200, 300, 350, 400, 450

1. Introduction 2 6. Rewind Starter 30 10. Shaft 51

6.1 General 30 10.1 Bike Handle

FS 120, 200, 300, 350, 400, 450, FR 350, 450 1

Servicing and repairs are made

2 FS 120, 200, 300, 350, 400, 450, FR 350, 450

FS 120/300 FS 200/350 FS 400 FS 450

Displacement: 30.8 cm3 36.3 cm3 40.2 cm3 44.3 cm3

2.2 Fuel System

Carburetor: Diaphragm carburetor

FS 120, 200, 300, 350, 400, 450, FR 350, 450 3

2.4 Gearhead Type: Spiral-toothed

Gear ratio: 1:1.4 **

Bearings: Deep groove ball bearings

Lubrication: STIHL gear lubricant 0781 120 1117

2.5 Special Accessories

2.5.1 For User Full harness

2.5.2 For Service Carburetor parts kit 4134 007 1060

4 FS 120, 200, 300, 350, 400, 450, FR 350, 450

Fastener Thread For component Torque Remarks

Self-tapping screw IS-B3.5x6.5 Rewind spring/fan housing 1.5 1.1

FS 120, 200, 300, 350, 400, 450, FR 350, 450 5

Spline screw IS-M6x25 Clamp/loop handle 4.5 3.3 3)

Use the following procedure to fit a DG or P screw in an existing thread:

6 FS 120, 200, 300, 350, 400, 450, FR 350, 450

- Remove clutch housing -

FS 400/450, FR 450 • Take bushings out of the clutch

Important: If there are signs of

- Remove the shroud - see 4.1.

- Unscrew the spark plug.

• Take out screws (1). • Twist the clutch shoes and

FS 120, 200, 300, 350, 400, 450, FR 350, 450 7

- Pull locking strip out of cylinder.

- Fit spark plug and tighten down

Important: If the spark plug

- Fit the boot on the spark plug.

- Install the clutch - see 3.1.

• Insert screws and tighten down

8 FS 120, 200, 300, 350, 400, 450, FR 350, 450

- Clean or replace spark arresting

- Tighten down screw to 2.5 Nm

- Clean or replace spark arresting

- Use a new gasket.

- Tighten down screws to 8.5 Nm

FS 400/450, FR 450 • Take out screws (1).

FS 120, 200, 300, 350, 400, 450, FR 350, 450 9

Defective oil seals, gaskets, - Remove the carburetor - see

Note: The sealing plate must

• Slide a new gasket over the

• Push the test flange (1)

• Fit and tighten down the nuts (2)

10 FS 120, 200, 300, 350, 400, 450, FR 350, 450

Oil seals tend to fail when sub-

An additional test can be carried

- Carry out preparations -

- If the decompression valve is not

- Repeat the pressure test.

- Carry out the vacuum test - see

• Close vent screw (1) on