STIHL FS 91, 91 R Instruction Manual

English

Contents

Guide to Using this Manual 2 Maintenance and Repairs 42 Dear Customer,

Safety Precautions and Working Disposal 42 Thank you for choosing a quality
Techniques 2 EC Declaration of Conformity 43 engineered STIHL product.
Approved Combinations of Cutting
Original Instruction Manual

It has been built using modern

Attachment, Deflector, Handle and production techniques and
Harness 12 comprehensive quality assurance.
Approved Power Tool Attachments 13 Every effort has been made to ensure
Mounting the Bike Handle 14 your satisfaction and trouble-free use of
the product.
Mounting the Loop Handle 16
Adjusting the Throttle Cable 17 Please contact your dealer or our sales
company if you have any queries
Fitting the Carrying Ring 17
Printing inks contain vegetable oils, paper can be recycled.

concerning this product.

Mounting the deflector 18
Your
Mounting the Cutting Attachment 19
Fuel 22
Fueling 23
Fitting the Harness 23
Balancing the Machine 24
Printed on chlorine-free paper

Starting / Stopping the Engine 25 Dr. Nikolas Stihl

Transporting the Unit 28
Operating Instructions 30
Replacing the Air Filter 30
Adjusting the Carburetor 31
Spark Plug 31
Engine Running Behavior 32
Lubricating the Gearbox 32
Storing the Machine 33
© ANDREAS STIHL AG & Co. KG, 2020

Sharpening Metal Cutting Blades 33

Maintaining the Mowing Head 34
Maintenance and Care 36
0458-426-0121-A. VA6.A20.

Minimize Wear and Avoid Damage 38

0000007293_011_GB

Main Parts 39
Specifications 41

This instruction manual is protected by copyright. All rights reserved, especially the rights to reproduce, translate and process
with electronic systems.

FS 91, FS 91 R 1
English

Symbols in text
Guide to Using this Manual Safety Precautions and
Working Techniques
WARNING Some special safety pre-
Pictograms
Warning where there is a risk of an cautions must be
accident or personal injury or serious observed to reduce the
The meanings of the pictograms damage to property. risk of personal injury
attached to the machine are explained in when operating this
this manual. power tool because of the
NOTICE very high speed of its cut-
Depending on the model concerned, the
ting attachment.
following pictograms may be attached to Caution where there is a risk of
your machine. damaging the machine or its individual It is important that you
components. read the instruction man-
Fuel tank; fuel mixture of
ual before first use and
gasoline and engine oil
Engineering improvements keep it in a safe place for
future reference. Non-
Operate decompression observance of the
STIHL's philosophy is to continually
valve instruction manual may
improve all of its products. For this
result in serious or even
reason we may modify the design,
fatal injury.
engineering and appearance of our
products periodically. Observe all applicable local safety
Manual fuel pump regulations, standards and ordinances.
Therefore, some changes, modifications
and improvements may not be covered If you have not used this type of power
in this manual. tool before: Have your dealer or other
Operate manual fuel experienced user show you how it is
pump operated or attend a special course in its
operation.
Minors should never be allowed to use a
Tube of grease power tool.
Keep bystanders, especially children,
Intake air: Summer and animals away from the work area.
operation
When the power tool is not in use, shut it
off so that it does not endanger others.
Intake air: Winter Secure it against unauthorized use.
operation The user is responsible for avoiding
injury to third parties or damage to their
property.
Handle heating

2 FS 91, FS 91 R
 English

Do not lend or rent your power tool servicing dealer. Use only high quality Avoid clothing that could
without the instruction manual. Be sure tools and accessories in order to avoid get caught on branches
that anyone using it understands the the risk of accidents and damage to the or brush or moving parts
information contained in this manual. machine. of the machine. Do not
The use of noise emitting power tools STIHL recommends the use of genuine wear a scarf, necktie or
may be restricted to certain times by STIHL tools and accessories. They are jewelry. Tie up long hair
national or local regulations. specifically designed to match the so that it is above shoul-
product and meet your performance der level.
To operate the power tool you must be
requirements. Wear steel-toed safety
rested, in good physical condition and
mental health. Never attempt to modify your machine in boots with non-slip soles.
any way since this may increase the risk
If you have any condition that might be
of personal injury. STIHL excludes all
aggravated by strenuous work, check
liability for personal injury and damage
with your doctor before operating a
to property caused while using Sturdy shoes with non-slip soles may be
power tool.
unauthorized attachments. worn as an alternative only when using
Persons with pacemakers only: The mowing heads.
Do not use a pressure washer to clean
ignition system of your power tool
your power tool. The solid jet of water
produces an electromagnetic field of a
may damage parts of the power tool. WARNING
very low intensity. This field may
interfere with some pacemakers. STIHL The deflector on this power tool cannot To reduce the risk of eye
recommends that persons with protect the operator from all objects injuries, wear close-fit-
pacemakers consult their physician and thrown by the cutting attachment ting safety glasses in
the pacemaker manufacturer to reduce (stones, glass, wire, etc.). Such objects accordance with Euro-
any health risk. may ricochet and then hit the operator. pean Standard EN 166.
Do not operate the power tool if you are Make sure the safety
under the influence of any substance Clothing and Equipment glasses are a comforta-
(drugs, alcohol) which might impair ble and snug fit.
vision, dexterity or judgment. Wear proper protective clothing and Wear a face shield and make sure it is a
Depending on the cutting attachment equipment. good fit. A face shield alone does not
fitted, use your power tool only for provide adequate eye protection.
Clothing must be sturdy
cutting grass, wild growth, shrubs, but allow complete free- Wear hearing protection, e.g. earplugs
scrub, bushes, small diameter trees and dom of movement. Wear or ear muffs.
similar materials. snug-fitting clothing, an Wear a safety hard hat for thinning
Do not use your power tool for any other overall and jacket combi- operations, when working in high scrub
purpose because of the increased risk of nation, do not wear a and where there is a danger of head
accidents. work coat. injuries from falling objects.
Only use cutting attachments and Wear heavy-duty work
accessories that are explicitly approved gloves made of durable
for this power tool model by STIHL or material (e.g. leather).
are technically identical. If you have any
questions in this respect, consult a

FS 91, FS 91 R 3
English

STIHL offers a comprehensive range of Transporting by vehicle: Properly secure Before Starting
personal protective clothing and your power tool to prevent turnover, fuel
equipment. spillage and damage.
Check that your power tool is properly
assembled and in good condition – refer
Transporting the Power Tool Fueling
to appropriate chapters in the instruction
manual.
Gasoline is an extremely – Check the fuel system for leaks,
flammable fuel. Keep paying special attention to visible
clear of naked flames. Do parts such as the tank cap, hose
not spill any fuel – do not connections and the manual fuel
smoke. pump (on machines so equipped). If
Always shut off the engine before there are any leaks or damage, do
refueling. not start the engine – risk of fire.
Have your machine repaired by a
Do not fuel a hot engine – fuel may spill servicing dealer before using it
and cause a fire. again.
Open the fuel cap carefully to allow any – Use only an approved combination
pressure build-up in the tank to release of cutting attachment, deflector,
slowly and avoid fuel spillage. handle and harness. All parts must
Fuel your power tool only in well- be assembled properly and
002BA079 KN

ventilated areas. If you spill fuel, wipe securely.

the machine immediately – if fuel gets on – The stop switch must move freely.
your clothing, change immediately.
– Check smooth action of choke
After fueling, tighten knob, throttle trigger lockout and
Always shut off the engine.
down the fuel tank cap as throttle trigger – the throttle trigger
Carry the unit hanging from the shoulder securely as possible. must return automatically to the idle
strap or properly balanced by the drive position. The choke knob must
tube. spring back from the g and <
To reduce the risk of cut injuries, fit This reduces the risk of unit vibrations positions to the run position F when
transport guard on the cutting causing the fuel cap to loosen or come the throttle trigger lockout and
attachment, even when carrying the tool off and spill quantities of fuel. throttle trigger are squeezed.
for short distances – see also – Check that the spark plug boot is
To reduce the risk of serious or fatal
"Transporting the Unit". secure – a loose boot may cause
burn injuries, check for fuel leakage. If
To reduce the risk of seri- fuel leak is found, do not start the arcing that could ignite combustible
ous burn injuries, avoid engine. fumes and cause a fire.
touching hot parts of the – Check cutting tool or attachment for
machine, including the correct and secure assembly and
gearbox. good condition.

4 FS 91, FS 91 R
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– Check protective devices (e.g. Your power tool is a one-person unit. To Models with bike handle
deflector for cutting attachment, reduce the risk of injury from thrown
rider plate) for damage or wear. objects, do not allow other persons
Always replace damaged parts. Do within a radius of 15 meters of your own
not operate your machine with a position – even when starting.
damaged deflector or worn rider
To reduce the risk of
plate (lettering and arrows no longer
injury, avoid contact with

002BA055 KN
legible).
the cutting attachment.
– Never attempt to modify the controls
or safety devices in any way.
– Keep the handles dry and clean – Do not drop start the Right handle on control handle, left hand
free from oil and dirt – for safe power tool – start the on left handle.
control of the power tool. engine as described in
the instruction manual. Models with loop handle
– Adjust the harness and handle(s) to
suit your height and reach. See Note that the cutting
chapters on “Fitting the Harness” attachment continues to
and “Balancing the Machine". run for a short period
after you let go of the
To reduce the risk of accidents, do not throttle trigger – flywheel
operate your power tool if it is damaged effect.

002BA080 KN
or not properly assembled.
Check idle speed setting: The cutting
If you use a shoulder strap or full attachment must not rotate when the
harness: Practice removing and putting engine is idling with the throttle trigger
down the machine as you would in an released.
emergency. To avoid damage, do not On models with a loop handle and
throw the machine to the ground when To reduce the risk of fire, keep hot barrier bar, left hand on loop handle,
practicing. exhaust gases and hot muffler away right hand on control handle, even if you
from easily combustible materials (e.g. are left-handed.
Starting the Engine wood chips, bark, dry grass, fuel).
During Operation
Holding and Controlling the Power Tool
Start the engine at least 3 meters from
Make sure you always have good
the fueling spot, outdoors only.
Always hold the power tool firmly with balance and secure footing.
Place the unit on firm ground in an open both hands on the handles.
area. Make sure you have good balance In the event of imminent danger or in an
Make sure you always have good emergency, switch off the engine
and secure footing. Hold the unit
balance and secure footing. immediately – operate the stop switch.
securely. The cutting attachment must
be clear of the ground and all other
obstructions because it may begin to run
when the engine starts.

FS 91, FS 91 R 5
English

To reduce the risk of accidents, take a To reduce the risk of fire, do not smoke
15m (50ft) break in good time to avoid tiredness or while operating or standing near your
exhaustion. power tool. Note that combustible fuel
vapor may escape from the fuel system.
Work calmly and carefully – in daylight
conditions and only when visibility is The dusts, vapor and smoke produced
good. Stay alert so as not to endanger during operation may be dangerous to
others. health. If the work area is very dusty or
The cutting attachment may catch and
smoky, wear a respirator.
fling objects a great distance and cause Your power tool produces
injury - therefore, do not allow any other toxic exhaust fumes as If your power tool is subjected to
persons within a radius of 15 meters of soon as the engine is unusually high loads for which it was not
your own position. To reduce the risk of running. These fumes designed (e.g. heavy impact or a fall),
damage to property, also maintain this may be colorless and always check that it is in good condition
distance from other objects (vehicles, odorless and contain before continuing work – see also
windows). Even maintaining a distance unburned hydrocarbons "Before Starting".
of 15 meters or more cannot exclude the and benzol. Never run Check the fuel system in particular for
potential danger. the engine indoors or in leaks and make sure the safety devices
The correct engine idle speed is poorly ventilated loca- are working properly. Do not continue
important to ensure that the cutting tions, even if your model operating your power tool if it is
attachment stops rotating when you let is equipped with a cata- damaged. In case of doubt, consult your
go of the throttle trigger. lytic converter. servicing dealer.
Check and correct the idle speed setting To reduce the risk of serious or fatal Do not operate your power tool in the
regularly. If the cutting attachment injury from breathing toxic fumes, starting throttle position – engine speed
continues to rotate when the engine is ensure proper ventilation when working cannot be controlled in this position.
idling, have the machine checked by in trenches, hollows or other confined
your servicing dealer. STIHL locations. To reduce the risk
recommends an authorized STIHL of injury from
To reduce the risk of accidents, stop
servicing dealer. thrown objects,
work immediately in the event of
never operate the
Take special care in slippery conditions nausea, headache, visual disturbances
unit without the
(ice, wet ground, snow), on slopes or (e.g. reduced field of vision), problems
proper deflector for
uneven ground. with hearing, dizziness, deterioration in
the type of cutting
ability to concentrate. Apart from other
Watch out for obstacles: Roots and tree attachment being
possibilities, these symptoms may be
stumps which could cause you to trip or used.
caused by an excessively high
stumble. concentration of exhaust gases in the
Always stand on the ground while work area.
working, never on a ladder, work Operate your power tool so that it
platform or any other insecure support. produces a minimum of noise and
Be particularly alert and cautious when emissions – do not run the engine
wearing hearing protection because unnecessarily, accelerate the engine
your ability to hear warnings (shouts, only when working.
alarms, etc.) is restricted.

6 FS 91, FS 91 R
 English

Inspect the work area: The gearbox gets hot Metal cutting attachments must be
Stones, pieces of metal during operation. To sharpened regularly as specified.
or other solid objects may reduce the risk of burn Unevenly sharpened metal cutting
be thrown more than 15 injury, do not touch the attachments cause out-of-balance
meters and cause per- gearbox housing. which can impose extremely high loads
sonal injury or damage on the machine and increase the risk of
the cutting attachment When using mowing heads breakage.
and property (e.g. parked
vehicles, windows). Dull or improperly sharpened cutting
Equip the deflector with the additional edges can put a higher load on the
Special care must be taken when components specified in the instruction cutting attachment and increase the risk
working in difficult, over-grown terrain. manual. of injury from cracked or broken parts.
When cutting high scrub, under bushes Use only the deflector with properly Inspect metal cutting attachments for
and hedges: Keep cutting attachment at mounted line limiting blade to ensure the cracks or warping after every contact
a minimum height of 15 cm to avoid mowing lines are automatically trimmed with hard objects (e.g. stones, rocks,
harming small animals. to the approved length. pieces of metal). To reduce the risk of
injury, remove burrs and other visible
Always shut off the engine before To reduce the risk of injury, always turn
build-ups of material (use a file) because
leaving the machine unattended. off the engine before adjusting the nylon
they may become detached and be
line of manually adjustable mowing
Check the cutting attachment at regular thrown at high speed during operation.
heads.
short intervals during operation or If a rotating metal cutting attachment
immediately if there is a noticeable Using the unit with over-long nylon
makes contact with a rock or other solid
change in cutting behavior: cutting lines reduces the engine's
object there is a risk of sparking which
operating speed. The clutch then slips
– Turn off the engine. Hold the unit may cause easily combustible material
continuously and this causes
firmly and wait for the cutting to catch fire under certain
overheating and damage to important
attachment to come to a standstill. circumstances. Dry plants and scrub are
components (e.g. clutch, polymer
also easily combustible, especially in hot
– Check condition and tightness, look housing components) – and this can
and dry weather conditions. If there is a
for cracks. increase the risk of injury from the
risk of fire, do not use metal cutting
cutting attachment rotating while the
– Check sharpness. attachments near combustible
engine is idling.
materials, dry plants or scrub. Always
– Replace damaged or dull cutting
contact your local forest authority for
attachments immediately, even if Using metal cutting attachments
information on a possible fire risk.
they have only superficial cracks.
Do not continue using or attempt to
Clean grass and plant residue off the STIHL recommends the use of original repair damaged or cracked cutting
cutting attachment mounting at regular STIHL metal cutting attachments. They attachments by welding, straightening or
intervals – remove any build up of are specifically designed to match your modifying the shape (out of balance).
material from the cutting attachment and model and meet your performance
deflector. requirements. This may cause parts of the cutting
attachment to come off and hit the
To reduce the risk of injury, shut off the Metal cutting attachments rotate at very operator or bystanders at high speed
engine before replacing the cutting high speed. The forces that occur act on and result in serious or fatal injuries.
attachment. the machine, the attachment and the
material being cut.

FS 91, FS 91 R 7
English

To reduce the above-mentioned risks Continual and regular users should Do not turn the engine over on the
when using a metal cutting attachment, monitor closely the condition of their starter with the spark plug boot or spark
never use a metal cutting attachment hands and fingers. If any of the above plug removed since there is otherwise a
with a diameter larger than specified. It symptoms appear (e.g. tingling risk of fire from uncontained sparking.
must not be too heavy. It must be sensation in fingers), seek medical
To reduce the risk of fire, do not service
manufactured from materials of advice.
or store your machine near open flames.
adequate quality and its geometry must
be correct (shape, thickness). Maintenance and Repairs Check the fuel filler cap for leaks at
regular intervals.
To reduce the risk of injury, a metal
cutting attachment not manufactured by Service the machine regularly. Do not Use only a spark plug of the type
STIHL must not be heavier, thicker, attempt any maintenance or repair work approved by STIHL and make sure it is
have a different shape or a diameter not described in the instruction manual. in good condition – see "Specifications".
larger than the largest metal cutting Have all other work performed by a Inspect the ignition lead (insulation in
attachment approved by STIHL for this servicing dealer. good condition, secure connection).
power tool model.
STIHL recommends that you have Check the condition of the muffler.
Vibrations servicing and repair work carried out
exclusively by an authorized STIHL To reduce the risk of fire and damage to
servicing dealer. STIHL dealers are hearing, do not operate your machine if
Prolonged use of the power tool may regularly given the opportunity to attend the muffler is damaged or missing. –
result in vibration-induced circulation training courses and are supplied with Do not touch a hot muffler since burn
problems in the hands (whitefinger the necessary technical information. injury will result.
disease).
Only use high-quality replacement parts Vibration behavior is influenced by the
No general recommendation can be in order to avoid the risk of accidents condition of the AV elements – check the
given for the length of usage because it and damage to the machine. If you have AV elements at regular intervals.
depends on several factors. any questions in this respect, consult a
servicing dealer. Symbols on Deflectors
The period of usage is prolonged by:
STIHL recommends the use of original
– Hand protection (wearing warm
STIHL replacement parts. They are An arrow on the deflector shows the
gloves)
specifically designed to match your correct direction of rotation of the cutting
– Work breaks model and meet your performance attachments.
The period of usage is shortened by: requirements.
Some of the following symbols are
– Any personal tendency to suffer To reduce the risk of injury from applied to the outside of the deflector to
from poor circulation (symptoms: unintentional engine startup, always indicate the approved combination of
frequently cold fingers, tingling shut off the engine and disconnect the cutting attachment and deflector.
sensations). spark plug boot before performing any
repairs, maintenance or cleaning work. – Deflector may be used
– Low outside temperatures. Exception: Carburetor and idle speed with mowing heads.
– The force with which the handles adjustments.
are held (a tight grip restricts
circulation).

8 FS 91, FS 91 R
 English

Deflector must not be Shoulder Strap/Harness Mowing Head with Nylon Line
used with mowing heads.
The shoulder strap/harness is included
with the machine or available as a
special accessory.
Deflector may be used
with grass cutting blades.

0000-GXX-0498-A0
Deflector must not be
used with grass cutting
blades.

N Use the shoulder strap/harness.

Deflector may be used N With the engine running, attach the

machine to the shoulder

000BA015 KN
with brush knives.
strap/harness.
Grass cutting blades and brush knives
must always be used in combination
with a shoulder strap. Nylon line achieves a soft cut for edging
Deflector must not be and trimming around trees, fence posts,
used with brush knives. Circular saw blades must always be etc. – less risk of damaging tree bark.
used in combination with a full harness
with a quick-release system. The mowing head comes with an
instruction leaflet. Refill the mowing
head with nylon line as described in the
Deflector must not be instruction leaflet.
used with shredder
blades. WARNING
To reduce the risk of serious injury,
never use wire or metal-reinforced line in
Deflector must not be place of the nylon line.
used with circular saw
blades. STIHL Polycut Mowing Head with
Polymer Blades

For mowing unobstructed edges of

meadows (without posts, fences, trees
or similar obstacles).

FS 91, FS 91 R 9
English

Check the wear limit marks! Risk of Kickout (Blade Thrust) with Metal Grass Cutting Blade
Cutting Attachments

WARNING
When using metal cut-

002BA049 KN
ting attachments there is
a risk of kickout when the
rotating blade comes into
contact with a solid object
If one of the wear limit marks on the such as a tree trunk,
PolyCut mowing head is worn through branch, tree stump, rock
(arrow): Do not continue using the or similar. The machine is
mowing head. Install a new one. There thrown to the right or to
is otherwise a risk of injury from thrown the rear – opposite to the
parts of the head. attachment's direction of
It is important to follow the maintenance rotation.

000BA020 KN
instructions for the PolyCut mowing
head.
The PolyCut can also be equipped with
mowing line in place of the polymer Use for grass and weeds only – sweep
blades. the brushcutter in an arc like a scythe.

002BA135 KN
The mowing head comes with
instruction leaflets. Equip the mowing WARNING
head with polymers blades or nylon line
Improper use may damage the grass
as described in the instruction leaflets.
The risk of kickout is greatest when the cutting blade – risk of injury from thrown
black area of the rotating cutting parts.
WARNING attachment comes into contact with a Resharpen the grass cutting blade
Never use wire in place of the nylon solid object. according to instructions when it has
mowing line – risk of injury. dulled noticeably.

Brush Knife

For cutting matted grass, wild growth

and scrub and thinning young stands
with a stem diameter of no more than
2 cm – do not cut thicker stems – risk of
accidents.

10 FS 91, FS 91 R
 English

To reduce the risk of injury it is essential When felling, maintain a distance of at

to take the following precautions: least two tree lengths from the next
felling site.
– Avoid contact with stones, rocks,
pieces of metal and other solid Risk of kickout
foreign objects.

002BA355 KN
– Never cut wood or shrubs with a
stem diameter of more than 2 cm –
use a circular saw blade for such
work.
Use the brushcutter like a scythe (sweep
it to the right and left) at ground level – Inspect the brush knife at regular

002BA068 KN
when cutting grass and thinning young short intervals for signs of damage.
stands. Do not continue working with a
damaged brush knife.
– Resharpen the brush knife regularly The risk of kickout is highest in the black
and whenever it has dulled area of the blade: Do not use this area of
noticeably, and have it balanced if the circular saw blade for cutting.
necessary (STIHL recommends a
There is also a risk of kickout when
STIHL servicing dealer).
using the lighter shaded areas of the
002BA509 KN

blade: These areas of the blade should

Circular Saw Blade only be used by experienced operators
with specialized training.
To cut wild growth and scrub, lower the Suitable for cutting shrubs and trees with STIHL recommends that you use the
brush knife down onto the growth to a maximum stem diameter of 4 cm. non-shaded area of the circular saw
achieve a shredding effect – always blade. Always start the cut with this area
Before starting the cut, accelerate the
keep the cutting attachment below hip of the blade.
engine up to full throttle. Perform cut
level during this process.
with uniform pressure.
Exercise extreme caution when using
Use circular saw blades only with a
this method of cutting. The higher the
matching limit stop of the correct
cutting attachment is off the ground, the
diameter.
greater the risk of injury from cuttings
being thrown sideways.
WARNING
Warning! Improper use of a brush knife
may cause it to crack, chip or shatter – To reduce the risk of blade damage,
risk of injury from thrown parts. avoid contact with stones and the
ground. Resharpen the blade properly in
good time – dull teeth may result in the
blade cracking and shattering and
causing serious injury.

FS 91, FS 91 R 11
English

Approved Combinations of Cutting Attachment, Deflector, Handle and Harness

Cutting Attachment Deflector, Limit Stop Handle Harness

1 2 18
13 22 24

19 20
3 4
15
14 21 23 24
5 6

7 8

19 20
9 10 23 24
16

21
11

17
12 21 25

0000-GXX-1287-A2
12 FS 91, FS 91 R
 English

Approved Combinations 12 Chisel tooth circular saw blade 200-

22 (4112), chisel tooth circular saw Approved Power Tool
blade 200-22 HP (4001) Attachments
Select correct combination from the
table according to the cutting The following STIHL attachments may
attachment you intend to use. WARNING be used with the basic power tool:
Non-metal grass cutting blades, brush Attachment Application
WARNING knives and circular saw blades are not
approved. BF Cultivator
For safety reasons only the cutting FCS 2) 3) Edger
attachments, deflectors, handles and
Deflectors, Limit Stop FH 145° Power scythe,
harnesses shown in each row of the
adjustable
table may be used together. No other
combinations are permitted because of HL 0°1) Long reach hedge
13 Deflector for mowing heads
the risk of accidents. trimmer
14 Deflector with
HL 145° 2) Hedge trimmer,
15 skirt and blade, for mowing heads adjustable
Cutting Attachments
16 Deflector without skirt and blade, for
HT 1) Pole pruner
metal cutting attachments 7 to 11
RG 5) Weeder
Mowing heads 17 Limit stop for circular saw blades
SP 1) 4) Special harvester
1 STIHL SuperCut 20-2 Handles SP 10 1) Special harvester
2 STIHL AutoCut C 26-2 1) Not approved for models with bike
3 STIHL AutoCut 25-2
18 Loop handle handle
4 STIHL AutoCut 36-2 2)
19 Loop handle with Limited suitability for models with
5 STIHL DuroCut 20-2
20 Barrier bar bike handle
6 STIHL PolyCut 20-3 3)
21 Bike handle It is not necessary to use the
Metal cutting attachments shoulder strap
Harnesses 4)
Use handle hose supplied with the
7 Grass cutting blade 230-2
(230 mm dia.) machine
22 Shoulder strap may be used 5)
Use barrier bar supplied with the
8 Grass cutting blade 260-2
23 Shoulder strap must be used loop handle
(260 mm dia.)
24 Full harness may be used
9 Grass cutting blade 230-4 25 Full harness must be used
(230 mm dia.)
10 Grass cutting blade 230-8
(230 mm dia.)
11 Brush knife 250-3
(250 mm dia.)

FS 91, FS 91 R 13
English

N Pull out the wing screw – the

Mounting the Bike Handle washer (6) remains on the wing
screw.
N Separate the clamp moldings – the
Mounting Bike Handle with Swiveling
springs (4 and 5) remain in the
Handle Support
lower clamp.

The machine is supplied with the Securing the Handlebar

swiveling handle support already
mounted on the shaft. To mount the
8
handlebar it is necessary to remove the A
clamp moldings.
7
Removing the Clamp Moldings

0000-GXX-0510-A0
250BA046 KN
1
N Place the handlebar (7) in the lower
clamp (1) so that distance A is no N Place the secured assembly on the
more than 15 cm (6 in). handle support (8) with the wing
N Place the upper clamp in position screw at the side nearest the
and hold both clamp moldings engine.
together. N Push the wing screw into the handle
N Push the wing screw through the support as far as stop and then
two clamps as far as stop – hold all screw it down – but do not finally
parts together and secure them. tighten yet.
N Line up the handlebar at a right
angle to the drive tube – check
distance A again.
N Tighten down the wing screw firmly.

N Hold the lower clamp (1) and upper

clamp (2) firmly together.
N Release the wing screw (3) – the
clamps are loose once the wing
screw has been released. They are
pushed apart by the two
springs (4 and 5).

14 FS 91, FS 91 R
 English

Mounting the Control Handle Swiveling the Handlebar

Transport position

12 15 14
90°
3
14
11 15
9 13
10 15

0000-GXX-0512-A1
7
7
0000-GXX-0511-A0

0000-GXX-0513-A1
13
N Position the clamp (15) and handle
support (14) against the drive tube.
N Take out the screw (9) – the nut (10)
remains in the control handle (11). N Close the throttle cable N Loosen the wing screw (3) and
retainer (15). The retainer (15) unscrew it until the handlebar (7)
N Push the control handle onto the
snaps into place. can be rotated.
handlebar (7) until the holes (13)
line up – the throttle trigger (12) Adjusting the Throttle Cable N Rotate the handlebar 90°
must point towards the gearbox. counterclockwise and then swing
N Check adjustment of throttle cable –
N Insert the screw (9) and tighten it the handles down.
see chapter on "Adjusting the
down firmly. Throttle Cable". N Tighten down the wing screw (3)
firmly.
Fitting the Throttle Cable
Working position
NOTICE N Reverse the sequence described
above to swing the handles up and
Do not kink the throttle cable or lay it in turn the handlebar clockwise.
tight radii – make sure the throttle trigger
moves freely.

FS 91, FS 91 R 15
English

Mounting the Loop Handle without

Mounting the Loop Handle Barrier Bar
2
4
Mounting Loop Handle with Barrier Bar
7
7 8
8
4
3

5
2
6
3

002BA099 KN
7
5
1 6

002BA614 KN
N Place the clamp (3) in the loop
handle (4) and position them both
1
1 1
against the drive tube (5).
002BA098 KN

N Position the clamp (6) against the N Place the clamp (3) in the loop
drive tube. handle (4) and position them both
N Place the barrier bar (2) in position against the drive tube (5).
N Fit the square nuts (1) in the barrier as shown.
bar (2); the holes must line up. N Position the clamp (6) against the
N Line up the holes. drive tube.

N Insert the screws (7) in the holes N Line up the holes.

and screw them into the barrier N Fit washers (8) on the screws (7)
bar (2) as far as stop. and insert the screws in the holes.
N Go to "Securing the Loop Handle". Fit the square nuts (1) and screw
them down as far as stop.
N Go to "Securing the Loop Handle".

16 FS 91, FS 91 R
 English

Securing the Loop Handle

Adjusting the Throttle Cable Fitting the Carrying Ring

It may be necessary to correct the

Polymer Version
adjustment of the throttle cable after
assembling the machine or after a
prolonged period of operation.
Adjust the throttle cable only when the
A unit is completely and properly 1
assembled.

4
9

002BA655 KN
002BA615 KN

N Set the throttle trigger to the full

The loop handle can be adjusted to suit throttle position.

002BA529 KN
the height and reach of the operator and N Carefully rotate the screw in the
the application by changing throttle trigger in the direction of the
distance (A). arrow until you feel initial resistance.
Then rotate it another half turn in the For position of carrying ring see "Main
Recommendation: distance (A):
same direction. Parts".
about 20 cm (8 in)
N Push the carrying ring (1) over the
N Slide the handle to the required
drive tube.
position.
N Insert the M5 nut in the hex recess
N Line up the loop handle (4).
in the carrying ring.
N Tighten down the screws until the
N Fit the M5x14 screw.
loop handle can no longer be
rotated on the drive tube. If no N Line up the carrying ring.
barrier bar is fitted – lock the nuts if
N Tighten down the screw firmly.
necessary.
The sleeve (9) (not fitted on all models)
must be between the loop handle and
the control handle.

FS 91, FS 91 R 17
English

Fitting the Skirt and Blade Mounting the Blade

Mounting the deflector

WARNING
Mounting the Deflector
Risk of injury from thrown objects and
contact with the cutting attachment.
These parts must be fitted to the
1 deflector (1) when you use a mowing

002BA638 KN
head.

Fitting the Skirt

3 N Slide the line limiting blade into the
guide on the skirt.
N Insert the screw and tighten it down
2 firmly.

Mounting the Limit Stop

002BA637 KN
3 7
002BA636 KN

N Slide the lower guide slot of the skirt 6

onto the deflector – it must snap into
position.

002BA639 KN
1 Deflector for mowing attachments
2 Deflector for mowing heads Removing the Skirt
Deflectors (1 and 2) are both mounted to
the gearbox in the same way.
WARNING
N Place the deflector on the gearbox
flange. Risk of injury from thrown objects and
contact with the cutting attachment.
N Insert the screws (3) and tighten
Always fit the limit stop (6) when you use
them down firmly.
2. a circular saw blade.
002BA646 KN

1.
N Position the limit stop (6) on the
gearbox flange.

N Insert the stop pin into the hole in N Insert the screws (7) and tighten
the skirt and use it to push the skirt them down firmly.
to the left.
N Pull the skirt off the deflector.

18 FS 91, FS 91 R
 English

Blocking the Shaft

Mounting the Cutting
Attachment
3
Placing power tool on the ground 2

002BA330 KN
2
6 6

002BA104 KN
The output shaft (2) must be blocked
with the stop pin (6) or screwdriver (6) to
1 mount or remove cutting attachments.

0000-GXX0500-A0
These parts come standard with the
N Shut off the engine. machine or are available as special
accessories.
N Lay your power tool on its back so
that the cutting attachment N Insert the stop pin (6) or
mounting face is pointing up. Depending on the cutting attachment, it screwdriver (6) in the hole (7) in the
may be necessary to use the nut (3) and gearbox as far as stop – and apply
Mounting Hardware for Cutting rider plate (2). The thrust plate (1) must slight pressure.
Attachments be used with all cutting attachments.
N Rotate shaft, nut or cutting
These parts are included in a kit attachment until the stop pin slips
The mounting hardware supplied supplied with the machine and are also into position and blocks the shaft.
depends on the cutting attachment that available as special accessories.
comes as original equipment with the
Machine supplied without mounting
new machine.
hardware
Machine supplied with mounting
hardware
Mowing heads and metal cutting
attachments may be mounted.

2
002BA266 KN

Only mowing heads may be used which

mount directly to the shaft (2).

FS 91, FS 91 R 19
English

Removing the Mounting Hardware Fitting Mowing Head with Screw Remove the mowing head.
Mounting
N Block the shaft (4) with the stop pin
Keep the instruction leaflet for the (2).
mowing head in a safe place.
N Unscrew and remove the mowing
2 head (3) clockwise.

Mounting Metal Cutting Attachments

3
Keep the leaflet and packaging of the
4 metal cutting attachment in a safe place.
3
5 WARNING
4 Wear protective gloves to reduce the
6
risk of direct contact with the sharp
0000-GXX-1323-A0

1 cutting edges.
Mount only one metal cutting
1 attachment.

0000-GXX-1324-A0
N Block the shaft (5) with the stop pin
(1). 2
N Use the combination wrench (2) to
loosen and remove the nut (3) N Fit the thrust plate (1).
clockwise (left-hand thread).
N Screw the mowing head (3)
N Take the rider plate (4) off the counterclockwise on to the shaft (4)
shaft (5). Do not remove the thrust as far as stop.
plate (6).
N Block the shaft (4) with the stop pin
(2).
Mounting the Cutting Attachment
N Tighten down the mowing head (3)
firmly.
WARNING
NOTICE
Risk of injury from thrown objects and
contact with the cutting attachment. Use Remove the tool used to block the shaft.
a deflector that matches the cutting
attachment – see "Mounting the
Deflector".

20 FS 91, FS 91 R
 English

Check direction of rotation of cutting

attachment NOTICE
14 Remove the tool used to block the shaft.

Removing the Metal Cutting Attachment

13
1 3 WARNING
10
Wear protective gloves to reduce the
2 8 risk of direct contact with the sharp
11 cutting edges.
N Block the shaft (11) with the stop pin
4 6 9
(12).

0000-GXX-0502-A0
N Unscrew the mounting nut (13)
clockwise.
5 12 Remove cutting attachment and its
681BA303 KN

N
mounting hardware from the
7 8 N Fit the thrust plate (9). gearbox – but do not remove the
N Place the cutting attachment (8) on thrust plate (9).
Cutting attachments 2, 4, 5 and 6 may the thrust plate (9).
be mounted either way round – they
Collar (see arrow) must engage the
must be turned over regularly to help
cutting attachment's mounting hole.
avoid one-sided wear.
Securing the cutting attachment
The cutting edges of cutting
attachments 1, 3, 7 and 8 must point N Fit the rider plate (10).
clockwise.
N Block the shaft (11) with the stop pin
Direction of rotation is indicated by an (12).
arrow on the inside of the deflector.
N Use the combination wrench (14) to
screw the mounting nut (13) on to
the output shaft counterclockwise
and tighten it down firmly.

WARNING
There is a risk of injury if the cutting
attachment works loose. If the mounting
nut has become too loose, fit a new one.

FS 91, FS 91 R 21
English

Gasoline with an ethanol content of Storing Fuel

Fuel more than 10% can cause running
problems in engines with a manually
adjustable carburetor and should not be Store fuel only in approved safety-type
Your engine requires a mixture of fuel canisters in a dry, cool and safe
gasoline and engine oil. used in such engines.
location protected from light and the sun.
Engines equipped with M-Tronic deliver
full power when run on gasoline with an Fuel mix ages – only mix sufficient fuel
WARNING for a few weeks work. Do not store fuel
ethanol content of up to 25% (E25).
For health reasons, avoid direct skin mix for longer than 30 days. Exposure to
contact with gasoline and avoid inhaling Engine Oil light, the sun, low or high temperatures
gasoline vapor. can quickly make the fuel mix unusable.
If you mix the fuel yourself, use only
STIHL two-stroke engine oil or another STIHL MotoMix may be stored for up to
STIHL MotoMix 2 years without any problems.
high-performance engine oil in
accordance with JASO FB, JASO FC, N Thoroughly shake the mixture in the
STIHL recommends the use of STIHL JASO FD, ISO-L-EGB, ISO-L-EGC or canister before fueling your
MotoMix. This ready-to-use fuel mix ISO-L-EGD. machine.
contains no benzol or lead, has a high STIHL specifies STIHL HP Ultra two-
octane rating and ensures that you stroke engine oil or an equivalent high- WARNING
always use the right mix ratio. performance engine oil in order to
Pressure may build up in the canister –
STIHL MotoMix uses STIHL HP Ultra maintain emission limits over the
open it carefully.
two-stroke engine oil for an extra long machine’s service life.
engine life. N Clean the fuel tank and canister
Mix Ratio from time to time.
MotoMix is not available in all markets.
STIHL 50:1 two-stroke engine oil: 50 Dispose of remaining fuel and cleaning
Mixing Fuel parts gasoline to 1 part oil fluid properly in accordance with local
regulations and environmental
Examples requirements.

NOTICE Gasoline STIHL engine oil 50:1

Liters Liters (ml)
Unsuitable fuels or lubricants or mix
ratios other than those specified may 1 0.02 (20)
result in serious damage to the engine. 5 0.10 (100)
Poor quality gasoline or engine oil may 10 0.20 (200)
damage the engine, sealing rings, hoses 15 0.30 (300)
and the fuel tank.
20 0.40 (400)
Gasoline 25 0.50 (500)
Use only high-quality brand-name N Use a canister approved for storing
gasoline with a minimum octane rating fuel. Pour oil into canister first, then
of 90 – leaded or unleaded. add gasoline and mix thoroughly.

22 FS 91, FS 91 R
 English

Filling Up with Fuel

Fueling Fitting the Harness
Take care not to spill fuel while fueling
and do not overfill the tank. The type and style of the
harness/shoulder strap depend on the
STIHL recommends you use the STIHL market.
filler nozzle for fuel (special accessory).
The use of the shoulder strap is
Preparations N Fill up with fuel. described in the chapter on "Approved
Combinations of Cutting Attachment,
Closing the Tank Cap Deflector, Handle and Harness".

Shoulder Strap

0000-GXX-0476-A0

002BA448 KN
N Before fueling, clean the filler cap
and the area around it to ensure that
no dirt falls into the tank. N Place the cap in the opening.

N Position the machine so that the N Turn the cap clockwise as far as
tank cap faces up. stop and tighten it down as firmly as
possible by hand.
Opening the Tank Cap
2

0000-GXX-0503-A0
N Put on the shoulder strap (1).
002BA447 KN

N Adjust the length of the strap so that

the carabiner (2) is about a hand’s
width below your right hip.
N Turn the cap counterclockwise until N Balance the machine – see
it can be removed from the tank "Balancing the Machine".
opening.
N Remove the tank cap.

FS 91, FS 91 R 23
English

Full Harness
Balancing the Machine

Attaching Machine to Harness

1

3 2

2
1

002BA662 KN
2 2
1
0000-GXX-0504-A0

1
N Loosen the screw (1).
N Slide the carrying ring (2) along the
Put on the harness (1) and close the 2 drive tube.

002BA660 KN
N
locking plate (3). N Tighten the screw (1) moderately.
N Adjust the length of the strap – with N Allow the unit to hang freely.
the machine attached, the
The type and style of the shoulder strap N Check the position obtained:
carabiner (2) must be about a
and carabiner depend on the market.
hand's width below your right hip. Balanced positions
N Attach the carabiner (1) to the
N Balance the machine – see
carrying ring (2) on the drive tube.
"Balancing the Machine".
Balancing the Machine

The unit is balanced differently

002BA034 KN
depending on the cutting attachment A
used.
Proceed as follows until the conditions
specified under "Floating positions" Mowing tools (A) such as mowing
have been met: heads, grass cutting blades and brush
knives
N should just touch the ground.

24 FS 91, FS 91 R
 English

Version with Loop Handle

Starting / Stopping the
Engine
3
Controls
1

002BA035 KN

0000-GXX-0477-A0
B Version with Bike Handle
2
Circular saw blades (B)
N should "hover" about 20 cm (8 in) 1 Throttle trigger lockout
above the ground. 2 Throttle trigger
When the correct balanced position has 3 3 Stop switch with Run and Stop
been reached: positions. Depress the stop switch
(…) to switch off the ignition – see
N Tighten down the screw (1) on the
"Function of stop switch and ignition
carrying ring firmly.
system".
Disconnecting Machine from Harness 2 Function of stop switch and ignition
system
1 The ignition is switched off and the
engine stopped when the stop switch is

0000-GXX-0494-A0
pressed. The stop switch returns
automatically to the Run position when it
is released: The ignition is switched on
1 again after the engine stops – the engine
1 Throttle trigger lockout is then ready to start.
2 2 Throttle trigger
3 Stop switch with Run and Stop
positions. Depress the stop switch
1 (…) to switch off the ignition – see
"Function of stop switch and ignition
system".
1

2 2
002BA661 KN

N Press down the bar on the

carabiner (1) and pull the carrying
ring (2) out of the carabiner.

FS 91, FS 91 R 25
English

Starting the Engine Cranking

0000-GXX-0481-A0
0000-GXX-0479-A0
N Hold the starter grip with your right
hand.
N Pull the starter grip slowly until you
feel it engage and then give it a brisk
strong pull.

0000-GXX-0480-A0
NOTICE
0000-GXX-0478-A0

Do not pull out the starter rope all the

way – it might otherwise break.
N Place the unit on the ground: It must N Do not let the starter grip snap back.
rest securely on the engine support Guide it slowly back into the housing
N Press the manual fuel pump
and the deflector. so that the starter rope can rewind
bulb (9) at least five times – even if
properly.
the bulb is already filled with fuel. N If fitted: Remove the transport guard
from the cutting attachment. N Continue cranking until the engine
N Press in the choke knob (8) and turn
runs.
it to the position that suits the engine To reduce the risk of accidents, check
temperature: that the cutting attachment is not
touching the ground of any other
g if the engine is cold obstacles.
< for warm start – also use this posi-
N Make sure you have a firm footing,
tion if the engine has been running
either standing, stooping or
but is still cold.
kneeling.
The choke knob must engage in
N Hold the unit firmly on the ground
position.
with your left hand and press down
– do not touch the throttle trigger or
lockout lever – your thumb should
be under the fan housing.

NOTICE
Do not stand or kneel on the drive tube.

26 FS 91, FS 91 R
 English

As soon as the engine runs Stopping the Engine Fuel tank run until completely dry
N After refueling, press the manual
N Depress the momentary contact fuel pump bulb at least five times –
stop switch – the engine stops – even if the bulb is already filled with
release the stop switch – it springs fuel.
back to the run position. N Set the choke lever to suit the
engine temperature.
Other Hints on Starting
N Now start the engine.

Engine stalls in cold start position g or

under acceleration.
N Move the choke knob to < and
continue cranking until the engine
runs.
Engine does not start in warm start
position <
002BA664 KN

N Move the choke knob to g and

continue cranking until the engine
N Press down the throttle trigger runs.
lockout and open the throttle – the If the engine does not start
choke knob moves to the run
position F. After a cold start, warm N Check that all settings are correct.
up the engine by opening the N Check that there is fuel in the tank
throttle several times. and refuel if necessary.
N Check that the spark plug boot is
WARNING properly connected.
There is a risk of injury if the cutting N Repeat the starting procedure.
attachment runs when the engine is
idling. Adjust the carburetor so that the Engine is flooded
cutting attachment does not run when N Move the choke knob to F and
the engine is idling – see “Adjusting the continue cranking until the engine
Carburetor”. runs.
Your machine is now ready for
operation.

FS 91, FS 91 R 27
English

Transporting the Unit

Using Transport Guard

681BA269 KN
681BA270 KN
The type of transport guard depends on
the metal cutting attachment supplied
with the machine. Transport guards are
available as special accessories.

230 mm Grass Cutting Blades

681BA271 KN
681BA272 KN
681BA268 KN

250 mm Brush Knives

681BA272 KN
681BA268 KN
681BA269 KN

28 FS 91, FS 91 R
 English

Grass Cutting Blades up to 260 mm Circular Saw Blades

681BA301 KN

681BA302 KN
2. 2.

681BA305 KN
681BA275 KN

681BA275 KN
N Fit the transport guard on the cutting
1. attachment from below. 1.

N Disconnect wire rod from the N Disconnect wire rod from the
transport guard. transport guard.
N Swing wire rod outwards.

681BA311 KN
2.
N Swing wire rod into position.
N Hook wire rod to the transport
guard.

FS 91, FS 91 R 29
English

Operating Instructions Replacing the Air Filter

Filters have an average life of more than

During break-in period
a year. Do not remove the filter cover or
replace the air filter as long as there is no
A factory-new machine should not be noticeable loss of power.
run at high revs (full throttle off load) for
the first three tank fillings. This avoids If there is a noticeable loss of engine
unnecessary high loads during the power
break-in period. As all moving parts
have to bed in during the break-in
period, the frictional resistances in the
engine are greater during this period. 3 2
4
The engine develops its maximum
power after about 5 to 15 tank fillings. 1
681BA276 KN

0000-GXX-0482-A0
During Operation

N Swing wire rod outwards. 1

After a long period of full throttle
N Fit transport guard on saw blade operation, allow the engine to run for a
from below, making sure the limit N Turn the choke knob to g.
short while at idle speed so that engine
stop is properly seated in the heat can be dissipated by the flow of N Loosen the screws (1).
recess. cooling air. This protects engine- N Remove the filter cover (2).
mounted components (ignition,
carburetor) from thermal overload. N Clean away loose dirt from around
the filter.
After Finishing Work N Remove the filter element (3).
N Replace dirty or damaged filter
Storing for a short period: Wait for the element (3).
681BA277 KN

2. engine to cool down. Empty the fuel tank

N Replace any damaged parts.
and keep the machine in a dry place,
well away from sources of ignition, until
you need it again. For longer out-of- Installing the Filter Element
N Swing wire rod into position.
service periods – see "Storing the
N Hook wire rod to the transport Machine".
guard. N Install the filter element (3) in the
filter housing and fit the cover.
N Insert the screws (1) and tighten
them down firmly.

30 FS 91, FS 91 R
 English

Checking the Spark Plug

Adjusting the Carburetor Spark Plug

The carburetor has been set at the N If the engine is down on power,
factory to provide an optimum fuel-air difficult to start or runs poorly at idle
mixture under most operating speed, first check the spark plug.
conditions.
N Fit a new spark plug after about 100

000BA039 KN
operating hours – or sooner if the
Adjusting Idle Speed electrodes are badly eroded. Install
only suppressed spark plugs of the A
type approved by STIHL – see
"Specifications". N Clean dirty spark plug.
N Check electrode gap (A) and
Removing the Spark Plug
readjust if necessary – see
"Specifications".
0000-GXX-0495-A0

1 N Rectify the problems which have

caused fouling of the spark plug.
Possible causes are:
Engine stops while idling 2 – Too much oil in fuel mix.

0000-GXX 0537-A0
N Warm up the engine for about 3 – Dirty air filter.
3 minutes.
– Unfavorable running conditions.
N Turn the idle speed screw (LA)
slowly clockwise until the engine N Remove the cover (1).
runs smoothly – the cutting
attachment must not run. N Pull off the spark plug boot (2).
1
Cutting attachment runs when engine is N Unscrew the spark plug (3).
idling

000BA045 KN
N Turn the idle speed screw (LA)
slowly counterclockwise until the
cutting attachment stops running
and then turn the screw about
another 1/2 to 3/4 turn in the same WARNING
direction.
Arcing may occur if the adapter nut (1) is
loose or missing. Working in an easily
WARNING combustible or explosive atmosphere
If the cutting attachment continues to run may cause a fire or an explosion. This
when the engine is idling, have your can result result in serious injuries or
machine checked and repaired by your damage to property.
servicing dealer.

FS 91, FS 91 R 31
English

N Use resistor type spark plugs with a

properly tightened adapter nut. Engine Running Behavior Lubricating the Gearbox

Installing the Spark Plug If engine running behavior is

unsatisfactory even though the air filter
N Screw the spark plug (3) into the is clean and the carburetor is properly
cylinder. adjusted, the cause may be the muffler.
Have the muffler checked for 1

0000-GXX-0536-A0
N Tighten down the spark plug (3) with
the combination wrench. contamination (carbonization) by your
servicing dealer.
N Press the boot (2) firmly onto the
spark plug. STIHL recommends that you have
servicing and repair work carried out
Fit the cover (1) and screw it down Check grease level after every 25 hours
N exclusively by an authorized STIHL
firmly. of operation and re-lubricate if
servicing dealer.
necessary.
N Remove the screw plug (1).
N If no grease can be seen on the
inside of the screw plug (1): Screw
the tube (2) of STIHL gear lubricant
(special accessory) into the filler
hole.
N Squeeze no more than 5 g (1/5 oz)
grease into the gearbox.

NOTICE
Do not completely fill the gearbox with
grease.
N Unscrew the tube (2).
N Insert the screw plug (1) and tighten
it down firmly.

32 FS 91, FS 91 R
 English

Balancing
Storing the Machine Sharpening Metal Cutting
Blades
N After resharpening about 5 times,
For periods of 3 months or longer N Use a sharpening file (special check the cutting attachment for
accessory) to sharpen dull cutting out-of-balance on a STIHL balancer
N Drain and clean the fuel tank in a
attachments. In case of more (special accessory) or have it
well ventilated area.
serious wear or nicks: Resharpen checked by a dealer and re-
N Dispose of fuel properly in with a grinder or have the work done balanced as necessary – STIHL
accordance with local by a dealer – STIHL recommends a recommends a STIHL servicing
environmental requirements. STIHL servicing dealer. dealer.
N Run the engine until the carburetor N Sharpen frequently, take away as
is dry – this helps prevent the little metal as possible – two or three
carburetor diaphragms sticking strokes of the file are usually
together. enough.
N Remove, clean and inspect the
cutting attachment. Coat metal 1 1
cutting attachments with corrosion
inhibitor.
1
N Thoroughly clean the machine.
N Clean the air filter.
2 2
N Store the machine in a dry and 2
secure location – out of the reach of
children and other unauthorized
persons. 1 1

002BA665 KN
2 2

N Resharpen the teeth (1) uniformly –

do not alter the contour of the parent
blade (2) in any way.
See cutting attachment packaging for
additional sharpening instructions. Keep
the packaging for future reference.

FS 91, FS 91 R 33
English

Adjusting Nylon Line Repeat the above procedure as

Maintaining the Mowing necessary until both lines reach the
Head limiter blade on the deflector.
STIHL SuperCut
Rotating the spool from one stop to the
Placing power tool on the ground Fresh line is advanced automatically if next advances about 4 cm (1 1/2 in) of
the remaining line is at least 6 cm fresh line.
(2 1/2 in) long. The blade on the
deflector trims overlong lines to the
Replacing Nylon Line
correct length.
STIHL AutoCut
STIHL PolyCut
N With the engine running, hold the
Precut lengths of nylon line can be fitted

002BA104 KN
rotating mowing head above the
grass surface. to the PolyCut in place of the cutting
blades.
N Tap it on the ground once – fresh
line is advanced and the blade on STIHL DuroCut, STIHL PolyCut
N Shut off the engine. the deflector trims it to the right
N Lay your power tool on its back so length. WARNING
that the cutting attachment Fresh line is advanced every time the To reduce the risk of injury, always shut
mounting face is pointing up. mowing head is tapped on the ground. off the engine before refilling the mowing
For this reason observe the mowing head.
Replacing Nylon Line head's cutting performance during
N Fit precut lengths of nylon line in the
operation. If the mowing head is tapped
mowing head as described in the
Always check the mowing head for signs on the ground too often, the line limiting
instructions supplied.
of wear before replacing the nylon line. blade will unnecessarily cut off unused
lengths of nylon line.
Replacing Cutting Blades
WARNING Line feed operates only if both lines are
still at least 2.5 cm (1 in) long.
If there are signs of serious wear, STIHL PolyCut
replace the complete mowing head. STIHL TrimCut
Always check the mowing head for signs
The nylon mowing line is referred to as of wear before installing new cutting
"nylon line" or "line" in the following. WARNING
blades.
The mowing head is supplied with To reduce the risk of injury, always shut
illustrated instructions for replacing the off the engine before adjusting the nylon
line by hand. WARNING
nylon line. Keep the instructions for the
mowing head in a safe place. N Pull the spool up – rotate it about 1/6 If there are signs of serious wear,
turn counterclockwise until it replace the complete mowing head.
N If necessary, remove the mowing
head. engages – and allow it to spring The thermoplastic cutting blades are
back. referred to as "blades" in the following.
N Pull ends of the lines outward.

34 FS 91, FS 91 R
 English

The mowing head is supplied with

illustrated instructions for replacing the
blades. Keep the instructions for the
mowing head in a safe place.

WARNING
To reduce the risk of injury, always shut
off the engine before installing the
blades.
N Remove the mowing head.
N Replace blades as shown in the
illustrated instructions.
N Mount the mowing head on the
machine.

FS 91, FS 91 R 35
English

Maintenance and Care

The following intervals apply to normal operating conditions only. If your daily work-

after finishing work or daily

ing time is longer or operating conditions are difficult (very dusty work area, etc.),

after each refueling stop

shorten the specified intervals accordingly.

before starting work

every 12 months

as required
if damaged
if problem
monthly
weekly
Visual inspection (condition, leaks) X X

Complete machine Clean X

Replace any damaged parts X X

Control handle Check operation X X

Visual inspection X X
Air filter
Replace2) X

Check X
Manual fuel pump (if fitted)
Have repaired by servicing dealer1) X

Have checked by servicing dealer1) X

Pickup body (filter) in fuel tank
Have replaced by servicing dealer1) X X X

Fuel tank Clean X X

Check idle adjustment – the cutting

X X
Carburetor attachment must not rotate

Adjust idle speed X

Adjust electrode gap X

Spark plug
Replace after every 100 operating hours

Visual inspection X
Cooling inlets
Clean X
Cylinder fins Have cleaned by servicing dealer1) X

If power is low or cranking effort very

high, have valve clearance checked
Valve clearance X X
and, if necessary, adjusted by servicing
dealer1)

Combustion chamber Have cleaned after every 150 hours of

X
operation by servicing dealer1)

36 FS 91, FS 91 R
 English

The following intervals apply to normal operating conditions only. If your daily work-

after finishing work or daily

ing time is longer or operating conditions are difficult (very dusty work area, etc.),

after each refueling stop

shorten the specified intervals accordingly.

before starting work

every 12 months

as required
if damaged
if problem
monthly
weekly
All accessible screws and nuts (not adjust-
Retighten X
ing screws)

Check X X X
Antivibration elements
Have replaced by servicing dealer1) X

Visual inspection X X

Cutting attachments Replace X

Check tightness X X

Metal cutting attachments Sharpen X X

Check X
Gearbox lubrication
Replenish X

Safety labels Replace X

1) STIHL recommends an authorized STIHL servicing dealer.
2)
Only if there is a noticeable loss of engine power

FS 91, FS 91 R 37
English

servicing dealer. STIHL dealers are – Spark plug

Minimize Wear and Avoid regularly given the opportunity to attend
Damage – Antivibration elements
training courses and are supplied with
the necessary technical information.
Observing the instructions in this manual
helps reduce the risk of unnecessary If these maintenance operations are not
wear and damage to the power tool. carried out as specified, the user
assumes responsibility for any damage
The power tool must be operated,
that may occur. Among other parts, this
maintained and stored with the due care
includes:
and attention described in this owner's
manual. – Damage to the engine due to
neglect or deficient maintenance
The user is responsible for all damage
(e.g. air and fuel filters), incorrect
caused by non-observance of the safety
carburetor adjustment or
precautions, operating and maintenance
inadequate cleaning of cooling air
instructions in this manual. This includes
inlets (intake ports, cylinder fins).
in particular:
– Corrosion and other consequential
– Alterations or modifications to the
damage resulting from improper
product not approved by STIHL.
storage.
– Using tools or accessories which
– Damage to the machine resulting
are neither approved or suitable for
from the use of poor quality
the product or are of a poor quality.
replacement parts.
– Using the product for purposes for
which it was not designed. Parts Subject to Wear and Tear
– Using the product for sports or
competitive events. Some parts of the power tool are subject
– Consequential damage caused by to normal wear and tear even during
continuing to use the product with regular operation in accordance with
defective components. instructions and, depending on the type
and duration of use, have to be replaced
Maintenance Work in good time. Among other parts, this
includes:

All the operations described in the – Cutting attachments (all types)

"Maintenance Chart" must be performed – Mounting hardware for cutting
on a regular basis. If these maintenance attachments (rider plate, nut, etc.)
operations cannot be performed by the
– Deflectors for cutting attachments
owner, they should be performed by a
servicing dealer. – Clutch
STIHL recommends that you have – Filters (air, fuel)
servicing and repair work carried out
– Rewind starter
exclusively by an authorized STIHL

38 FS 91, FS 91 R
 English

Main Parts

1 Tank cap
4 5 2 Carburetor adjusting screw
9 3 Starter grip
8 2 3 4 Manual fuel pump
10 6
5 Cover
1 6 Muffler
# 7 Machine support
8 Throttle trigger
11 9 Stop switch
13 7
16 10 Throttle trigger lockout
15 17 11 Bike handle (handlebar)
21 14 14 12 Handle support
13 Wing screw
18 14 Throttle cable retainer
12
15 Carrying ring
16 Choke knob
17 Air filter cover
19 18 Fuel tank
19 Loop handle
20 15 9 10 20 Barrier bar (country specific)
21
21 Drive tube

0000-GXX-0514-A0
# Serial Number
8

FS 91, FS 91 R 39
English

1 Drive tube
1 2 Mowing head
3 Deflector for mowing heads only
4 Line limiting blade
5 Deflector for all mowing
attachments
3 6 Skirt for mowing heads
7 Metal mowing attachment
4 8 Circular saw blade
2 9 Limit stop for circular saw blades
1 only

6
2 4
1

7 5

9
8
002BA644 KN

40 FS 91, FS 91 R
 English

Weight with metal mowing

Specifications
attachment
Dry, without cutting attachment and FS 91 with bike handle: 105 dB(A)
Engine deflector FS 91 R with barrier bar: 105 dB(A)
FS 91: 5.8 kg Vibration level ahv,eq to ISO 22867
Single cylinder four-stroke engine with FS 91 R: 5.5 kg
Handle, Handle,
mixture lubrication with mowing head left right
Overall length
Displacement: 28.4 cc FS 91 with bike
Bore: 38 mm handle: 3.4 m/s2 3.0 m/s2
Stroke: 25 mm
without cutting FS 91 R: 5.3 m/s2 5.3 m/s2
attachment 1800 mm
Engine power to 0.95 kW with metal mow- Handle, Handle,
ISO 8893: (1.3 bhp) at Features ing attachment left right
7,000 rpm FS 91 with bike
Idle speed: 2,800 rpm handle: 3.2 m/s2 2.5 m/s2
Cut-off speed (rated): 9,500 rpm R Loop handle FS 91 R with bar-
Max. output shaft rier bar: 3.8 m/s2 4.3 m/s2
speed (cutting Noise and Vibration Data
attachment): 7,150 rpm Interchangeable Attachments
Valve clearance Cutting Attachment The noise and vibration data of the
Inlet valve: 0.10 mm approved attachments are listed in the
For details on compliance with Vibration instructions supplied with each
Exhaust valve: 0.10 mm Directive 2002/44/EC visit attachment.
www.stihl.com/vib.
Ignition System The K-factor in accordance with
Sound pressure level Lp to ISO 22868 Directive 2006/42/EC is 2.0 dB(A) for
the sound pressure level and sound
Electronic magneto ignition with mowing head power level; the K-factor in accordance
FS 91 with bike handle: 95 dB(A) with Directive 2006/42/EC is 2.0 m/s2
Spark plug (resistor
FS 91 R: 95 dB(A) for the vibration level.
type): Bosch USR 7 AC
Electrode gap: 0.5 mm with metal mowing
attachment REACH
Fuel System FS 91 with bike handle: 93 dB(A)
FS 91 R with barrier bar: 93 dB(A) REACH is an EC regulation and stands
for the Registration, Evaluation,
All position diaphragm carburetor with Sound power level Lw to ISO 22868
Authorisation and Restriction of
integral fuel pump Chemical substances.
with mowing head
Fuel tank capacity: 710 cc (0.71 l) FS 91 with bike handle: 106 dB(A) For information on compliance with the
FS 91 R: 106 dB(A) REACH regulation (EC) No. 1907/2006
see www.stihl.com/reach.

FS 91, FS 91 R 41
English

Exhaust Emissions
Maintenance and Repairs Disposal
The CO2value measured in the EU type
approval procedure is specified at Users of this machine may only carry out Observe all country-specific waste
www.stihl.com/co2. the maintenance and service work disposal rules and regulations.
described in this user manual. All other
The measured CO2value was repairs must be carried out by a
determined on a representative engine servicing dealer.
in accordance with a standardized test
procedure under laboratory conditions STIHL recommends that you have
and does not represent either an explicit servicing and repair work carried out
or implied guarantee of the performance exclusively by an authorized STIHL

000BA073 KN
of a specific engine. servicing dealer. STIHL dealers are
regularly given the opportunity to attend
The applicable exhaust emission training courses and are supplied with
requirements are fulfilled by the the necessary technical information.
intended usage and maintenance STIHL products must not be thrown in
described in this instruction manual. The When repairing the machine, only use the garbage can. Take the product,
type approval expires if the engine is replacement parts which have been accessories and packaging to an
modified in any way. approved by STIHL for this power tool or approved disposal site for environment-
are technically identical. Only use high- friendly recycling.
quality replacement parts in order to
Contact your STIHL servicing dealer for
avoid the risk of accidents and damage
the latest information on waste disposal.
to the machine.
STIHL recommends the use of original
STIHL replacement parts.
Original STIHL parts can be identified by
the STIHL part number, the {
logo and the STIHL parts symbol K
(the symbol may appear alone on small
parts).

42 FS 91, FS 91 R
 English

Done at Waiblingen, 28.11.2018

EC Declaration of Conformity
ANDREAS STIHL AG & Co. KG

ANDREAS STIHL AG & Co. KG

Badstr. 115
D-71336 Waiblingen
Germany
declare in exclusive responsibility that
Thomas Elsner
Category: Trimmer
Director Product Management and
Make: STIHL
Services
Model: FS 91
FS 91 R
Serial identification: 4180
Displacement: 28.4 cc
conforms to the relevant provisions of
Directives 2011/65/EU, 2006/42/EC,
2014/30/EU and 2000/14/EC and has
been developed and manufactured in
compliance with the following standards
in the versions valid on the date of
production:
EN ISO 11806-1, EN 55012,
EN 61000-6-1
The measured and guaranteed sound
power levels were determined according
to Directive 2000/14/EC, Annex V, using
the ISO 10884 standard.
Measured sound power level

106 dB(A)
Guaranteed sound power level

108 dB(A)
Technical documents deposited at:
ANDREAS STIHL AG & Co. KG
Produktzulassung (Product Licensing)
The year of manufacture and serial
number are applied to the product.

FS 91, FS 91 R 43
English

44 FS 91, FS 91 R
0458-426-0121-A
englisch
G

www.stihl.com

*04584260121A*
0458-426-0121-A