CONTENTS

1 Introduction 2 7 Rewind Starter 27

7.1 General 27
2 Safety Precautions 3 7.2 Removing and
Installing the Rewind
Starter 28
3 Specifications 4 7.3 Starter Cup 28
7.4 Rewind Spring 28
3.1 Engine 4 7.4.1 Replacing 28
3.2 Ignition System 4 7.4.2 Tensioning 30
3.3 Fuel System 4 7.5 Starter Rope 30
3.4 Tightening Torques 5

8 Throttle Control 31

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4 Cutch 7

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8.1 Throttle Trigger/
4.1 Removing 7 Interlock Lever 31
4.2 Installing 8 8.2 Replacing the

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4.3 Replacing the Throttle Cable 32
Clutch Drum 8 8.3 Adjusting the
4.3.1 Replacing Bearings 9 Throttle Cable 32

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4.4 Clutch Spring 10

9 Fuel System 33
5 Engine 10
9.1 Air Filter
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5.1 Removing Shroud 10 9.2 Carburetor 34
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5.2 Exhaust Muffler/ 9.2.1 Leakage Test 34
Spark Arresting 9.3 Removing and
Screen 11 Installing the
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5.3 Leakage Test 12 Carburetor 35

5.3.1 Pressure Test 12 9.4 Servicing the
5.3.2 Vacuum Test 13 Carburetor 35
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5.4 Replacing the Oil 9.5 Adjusting the

Seals 14 Carburetor 37
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5.5 Replacing/Sealing 9.6 Tank Vent 38

Components of Mixture 9.7 Pickup Body 38
Supply System 16 9.8 Fuel Tank/Fuel Hoses 39
5.6 Cylinder and Piston 17 9.8.1 Fuel Tank 39
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5.6.1 Removing 17 9.8.2 Fuel Hoses 39

5.6.2 Installing 18
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5.7 Piston Rings 20

5.8 Crankcase 20 10 Special Servicing
5.8.1 Removing the Tools 40
Crankshaft 20
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5.8.2 Replacing the Main

Bearings 21 11 Servicing Aids 41
5.8.3 Installing the
On

Crankshaft 23
12 Special Accessories 41

6 Ignition System 24

6.1 Spark Plug Boot 24

6.2 Ignition Module 25
6.2.1 Ignition Timing 25
6.2.2 Removing and
Installing 26
6.3 Flywheel 26
© 2000 Andreas Stihl AG & Co., Waiblingen

Series 4141 Powerhead 1

1 Introduction
This service manual contains
detailed descriptions of all repair
and servicing procedures specific to
this powerhead.
There are separate handbooks for
servicing procedures on
standardized parts and assemblies
that are installed in several STIHL
power tool models. Reference is
made to these handbooks in the
appropriate chapters of this
manuals.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual
components and assemblies.
Refer to the latest edition of the
relevant parts list to check the part
numbers or any replacement parts.
Parts lists on microfiche and CD-
ROM are always more up to date
than printed lists.
A fault on the machine may have
several causes. To help locate the
fault, consult the troubleshooting
charts for all assemblies in the
"Standard Repairs, Trouble-
shooting" handbook.
Refer to the "Technical Information"
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list until a
revised edition is issued.
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On
2 Series 4141 Powerhead
The special servicing tools
mentioned in the descriptions are
listed in the last chapter of this
manual.
Use the part numbers to identify the
tools in the "STIHL Special Tools"
manual. 1
The manual lists all special
232RA001 VA
servicing tools currently available 2
from STIHL.
Symbols are included in the text and
pictures for greater clarity. Servicing and repairs are made
The meanings are as follows: considerably easier if the machine
t
is mounted on assembly stand (2)
in
In the descriptions: 5910 890 3100 with the aid of clamp
(1) 5910 890 8800. Remove the
pr
 = Action to be taken as shown in shroud and muffler first.
the illustration (above the text) The powerhead can then be
swivelled to the best position for the
re
– = Action to be taken that is not ongoing repair. This leaves both
shown in the illustration (above hands free.
the text)
or
Always use original STIHL
In the illustrations: replacement parts.
They can be identified by the STIHL
f
Pointer part number, the logo
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and the STIHL parts symbol .
Direction of movement This symbol may appear alone on
small parts.
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Service manuals and all technical
Information bulletins are intended
exclusively for the use of STIHL
n
servicing dealers. They must not be
passed to third parties.
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2 Safety Precautions

If the engine is started up in the

course of repairs or maintenance
work, observe all local and country-
specific safety regulations as well
as the safety precautions and
warnings in the owner’s manual.

Gasoline is an extremely flammable

fuel and can be explosive in certain
conditions.

Improper handling may result in

burns or other serious injuries.

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Warning!

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Do not smoke or bring any fire,
flame or other source of heat near
the fuel. All work with fuel must be

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performed outdoors only. Spilled
fuel must be wiped away
immediately.

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Series 4141 Powerhead 3

3 Specifications

3.1 Engine STIHL single cylinder two-stroke engine

Displacement: 25.4 cm3 (1.55 cu.in)
Bore: 34 mm (1.34 in)
Stroke: 28 mm (1.10 in)
Engine power to ISO 8893:
at 9,250 rpm 0.9 kW (1.2 bhp)
Max. permissible engine speed
without cutting tool
- without cut-off 12,900 ± 800 rpm
- with cut-off in ignition module 10,500 ± 500 rpm
Idle speed: 3,000 rpm
Bearings: Crankshaft supported in heavy-duty
deep-groove ball bearings, needle

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cages on small and big ends

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Piston pin diameter: 8 mm (0.315 in)
Clutch: Centrifugal clutch with linings
Clutch engages at: 4,100 ± 200 rpm

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Crankcase leakage test
at gauge pressure: 0.5 bar (7.25 psi)
under vacuum: 0.5 bar (7.25 psi)

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3.2 Ignition System Type:
fo Transistorized magneto ignition
(breakerless) with integral
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trigger unit
Air gap: 0.25 mm (0.010 in)
Spark plug: NGK CMR 7A
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Electrode gap: 0.5 mm (0.020 in)

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3.3 Fuel System Carburetor: Rotary valve carburetor

Idle setting: Open about 6 turns

(standard setting)
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Carburetor leakage test:

at gauge pressure 0.8 bar (11.6 psi)
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Fuel tank capacity: 700 cm3 (23.7 fl.oz)

Octane number: min. 90 RON (USA/CAN: pump
octane min. 87 unleaded)
Fuel mixture: Regular brand-name gasoline
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and brand-name two-stroke engine

oil
Mix ratio: 50:1 with STIHL two-stroke engine
On

oil
Air filter Foam element and prefilter (wire
mesh)

4 Series 4141 Powerhead

3.4 Tightening Torques

DG and P (Plastoform) screws are used in polymer and lightmetal components. These screws form a
permanent thread when they are installed for the first time. They can be removed and installed as often as
necessary without impairing the strength of the screwed assembly, providing the specified tightening torque is
observed.
For this reason it is essential to use a torque wrench.

Fastener Thread size For component Torque Remarks

lbf.ft Nm
Spline screw IS-M5x10 Heat shield/cylinder 3 4
Spline screw IS-M5x16 Rewind starter/crankcase 3 4

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Spline screw IS-M5x30 Control handle (bike handle) 1.5 2 with washer
Plastoform screw IS-P4x16 Control handle/handle halves
(bike handle) 0.75 1

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Plastoform screw IS-P4x16 Control handle/handle halves
(loop handle) 0.75 1
Spline screw IS-M5x12 Control handle clamps/drive tube

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(loop handle) 2.6 3.5
Spline screw IS-M5x60 Filter housing/carburetor/spacer flange 2.6 3.5
Spline screw
Spline screw
IS-DG5x24
IS-M5x16
Gear housing/drive tubefo
Shroud/rewind starter/crankcase
6.6
3
9
4
Spline screw IS-M5x16 Shroud/clutch housing/crankcase 3 4
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Spline screw IS-M5x8 Sleeve (setscrew) 3 4
Spline screw IS-M5x30 Sleeve (tube clamp) 4.4 6
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Spline screw IS-M6x35 Clamp molding/clamp (bike handle) 3.3 4.5

Collar screw M6x22 Clutch/flywheel 7.5 10 with washer
Spline screw IS-M5x16 Clutch housing/crankcase 4.4 6
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Spline screw IS-M5x30 Crankcase 7.5 10

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Spline screw IS-M5x25 Clampi/loop handle (loop handle) 3.3 4.5

Spline screw IS-M4x8 Diaphragm carrier 2.6 3.5
Plastoform screw P3.5x10.6 Detent spring/slide control
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(control handle) 0.8 1.1

Spline screw IS-M5x50 Muffler/cylinder 5.9 8
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Spline screw IS-M5x10 Guard/crankcase 3 4

Nut M8x1 Flywheel/crankshaft 14 19
M8 Starter cup/crankshaft 14 19
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Spline screw IS-M3x8 Guard plate/diaphragm carrier 1.1 1.5 micro-

encapsulated
Spline screw IS-M5x16 Tank housing/crankcase 4.4 6
On

Spline screw IS-M5x20 Spacer flange/cylinder 4.4 6

Spline screw IS-M5x22 Cylinder/crankcase 6.6 9
M10x1 Spark plug 11 15
Spline screw IS-M4x16 Ignition module/cylinder 3.7 5

Series 4141 Powerhead 5

Use the following procedure when refitting a DG or P screw in an existing thread:

– Place the screw in the hole and rotate it counterclockwise until it drops down slightly.
– Tighten the screw clockwise to the specified torque.

This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.

Note:
Power screwdriver settings for polymer:

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– Plastoform screws max. 600 rpm

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– DG screws max. 500 rpm

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6 Series 4141 Powerhead

4 Cutch
4.1 Removing

Troubleshooting chart - see Note:

"Standard Repairs, Trouble- Do not disconnect clutch spring.
shooting" handbook.

– Remove shroud see 5.1.

– Remove throttle and plug

connectors from the control
100%

145RA006 VA
handle see 8.2.
80% !

Important:
If there are signs of serious wear on

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the inside diameter, check the

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remaining wall thickness. If it is less
than about 80% of the original
thickness, fit a new clutch drum see

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4.3.

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1
fo 2
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380RA004 VA

380RA006 VA

380RA007 VA
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 Remove screws from clutch  Remove the spark plug. Fit the  Check thickness of clutch linings
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housing. locking screw (1) 4170 893 1200 (2).

in the spark plug hole. Turn the Lining thickness must be at least
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– Pull off the clutch housing with crankshaft counterclockwise until 1.5 mm / 0.06 in (new 3.0 mm /
drive tube and put them to one the piston butts against the 0.12 in).
side. locking screw.
Note:
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Damaged or oily linings must be

replaced.
1
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2
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On
380RA005 VA

380RA007 VA

 Inspect the clutch drum. There  Take out the screws (1) and
should be no scores or signs of remove the clutch. Remove the
excessive wear. spacer washers from between
the clutch and flywheel.

Series 4141 Powerhead 7

4.2 Installing 4.3 Replacing the
Clutch Drum

380RA008 VA

380RA004 VA

380RA066 VA
– Fit spacer washers.  Insert screws in crankcase and – Remove clutch drum with
tighten down to 6 Nm (4.4 lbf.ft). housing see 4.1.

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Note:

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Note installed position of clutch. – Install the shroud (check that  Release and remove screws.
Arrows on clutch shoes point toward electrical wires are properly
clutch housing (see arrows in routed) and fit the spark plug

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illustration). boot.

– Turn crankshaft clockwise until – Fit throttle cable, connect

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the piston butts against the electrical wires in control handle.
locking screw 4170 893 1200.

 Fit the clutch and tighten the

screws (1) to 10 Nm (7.5 lbf.ft).
fo 1
ot
– Remove locking screw 2

380RA067 VA
4170 893 1200, fit spark plug and
torque down to 15 Nm (11 lbf.ft).
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 Pull out the lower sleeve (3).

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Then pull out the second sleeve

(with centering lug, (2)).
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 Take out the rubber grommet (1).

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in

2
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On
380RA009 VA

380RA068 VA

 Position engine against clutch  Use circlip pliers to remove the

housing, making sure the pegs circlip from the clutch housing.
(1) engage the holes (2) in the
crankcase.

8 Series 4141 Powerhead

 4.3.1 Replacing Bearings

1
1

380RA069 VA

380RA070 VA

380RA072 VA
 Use press sleeve (1)  Use circlip pliers to remove circlip  Use press arbor (1)
1127 851 8300 to remove clutch from clutch housing. 4116 893 7205 to install the new

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drum. bearing.

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– Secure bearing in position with
circlip.

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1

fo 1
2
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380RA071 VA

380RA073 VA
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 Use press arbor (1)  Press home the clutch

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4119 893 7200 to remove the drum (2) with assembly drift (1)
clutch drum ball bearing from the 1110 893 4700.
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outside inwards.
– Install the circlip.
rs

Note:
Take care not to damage guide Reassemble in the reverse
pegs on clutch housing during sequence.
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removal process.
e
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On

Series 4141 Powerhead 9

4.4 Clutch Spring 5 Engine
5.1 Removing Shroud

Important:
Check installed position of spring.
The arrows on the clutch shoes face
upwards.
1
2
Install the clutch shoes and clutch
housing see 4.2.

380RA001 VA
380RA074 VA

– Remove shroud see 5.1.  Remove screws (1 and 2) from

rewind starter.

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– Remove clutch housing and

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clutch see 4.1.

Removing the spring

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 Twist the clutch shoes in the
direction of the arrows. This

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relaxes the spring so that it can
be unhooked and removed.

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380RA002 VA
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 Pull off the spark plug boot.

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1
On

380RA003 VA
380RA075 VA

Fitting the spring  Take out screw (1) on clutch

housing.
 Engage spring in holes and slide
clutch shoes together in the  Lift away the shroud and slip the
direction of the arrows. spark plug boot through the
shroud at the same time.

10 Series 4141 Powerhead

 5.2 Exhaust Muffler/
Spark Arresting Screen

– Remove wiring from the guide in Troubleshooting chart - see

the shroud. "Standard Repairs, Trouble-
shooting" handbook. 1
Install in the reverse sequence.
Warning!
To reduce the risk of burn injury, do
not touch hot parts of exhaust 2
system.

380RA011 VA
Allow exhaust system to cool down
first.

Exhaust muffler

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– Remove shroud see 5.1.

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 Remove screws (arrows) from
mufler (1).

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 Remove exhaust gasket (2) and
fit a new one.

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Reassemble in the reverse
sequence.
fo – Tighten down muffler screws to
8 Nm (5.9 lbf.ft).
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380RA010 VA

– Fit the shroud.

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Spark arresting screen

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– Remove shroud see 5.1.

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 Use screwdriver to pry stub out of

muffler outlet. Remove the stub.
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– Clean the spark arresting screen

or fit a new stub (with screen) if
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necessary.
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On

Series 4141 Powerhead 11

5.3 Leakage Test 5.3.1 Pressure Test

Defective oil seals and gaskets or

1
cracks in castings are the usual
causes of leaks. Such faults allow 1
supplementary air to enter the
engine and thus upset the fuel-air
mixture.

This makes adjustment of the

380RA015 VA

prescribed engine idle speed
difficult, if not impossible.
Moreover, the transition from idle
speed to part or full throttle is not 
smooth.
380RA014 VA
2
2
Release muffler mounting screws  Connect pressure hose (2) of
(2) and back them off half-way. tester 1106 850 2905 to nipple on

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test flange (1).

in
The crankcase can be checked  Slide the sealing plate (1)
thoroughly for leaks with the carbu- 0000 855 8106 between the

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retor and crankcase tester and the gasket and cylinder and retighten

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vacuum pump. the mounting screws moderately.

– Remove shroud see 5.1. Note:

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The sealing plate must completely
– Make sure the spark plug is fill the space between the two
properly tightened down. screws.

– Remove the air filter and

fo 1

carburetor see 9.1 and 9.3.

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143RA046 VA
– Set the piston to top dead center
(T.D.C.). This can be checked
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through the intake port.

 Close the vent screw (1) on the

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rubber bulb.
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– Use rubber bulb to pump air into

the crankcase until the gauge
indicates a pressure of 0.5 bar
(7.25 psi). If this pressure
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remains constant for at least

20 seconds, the crankcase is
1
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airtight.

– If the pressure drops, the leak

must be located and the faulty
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2 part replaced. Repeat the

pressure test in such a case.
On
380RA012 VA

Note:
To find the leak, coat the suspect
area with oil and pressurize the
crankcase again. Bubbles will
 Mount test flange (1) appear if a leak exists.
4141 850 4200 to spacer flange
with M5 x 40 screws (2). – Open the vent screw and
disconnect the hose.

– The pressure test must always be

followed by a vacuum test.

12 Series 4141 Powerhead

5.3.2 Vacuum Test

Oil seals tend to fail when subjected
to a vacuum, i.e. the sealing lip lifts
away from the crankshaft during the
piston’s induction stroke because
there is no internal counter-
pressure.
A test with the vacuum pump
0000 850 3501 is carried out to
detect this kind of fault.
Note:
If the vacuum reading remains
constant, or rises to no more than
0.3 bar (4.25 psi) within 20 seconds,
it can be assumed that the oil seals
are in good condition.
If a leak is still indicated, check for
damage in the area of the cylinder/
oil seals.
If the leak no longer exists, look for
defect in the area of the diaphragm
carriers/impulse hoses.
– Check impulse hoses for damage
or porosity and replace if
necessary.

– Repeat the leakage tests after

finishing repairs.

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– Remove the test flange.

– Install impulse hoses, paying

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attention to the markings on the
hoses:
F = flywheel side
1 1 1 2

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S = starter side

– Install the carburetor and air filter.

fo – Loosen muffler mounting screws
and remove the sealing plate.
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Tighten the screws to 8 Nm
380RA103 VA
380RA014 VA

2 (5.9 lbf.ft).
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Reassemble in the reverse

sequence.
 Connect suction hose of the  However, if the pressure
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vacuum pump (2) 0000 850 3501 continues to rise (reduced

to the nipple on the test flange vacuum), replace the oil seals,
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(1). impulse hoses (1) and/or the

diaphragm carriers (2) on the
right and left of the cylinder.
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2
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3
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2
On
232RA037 VA

380RA013 VA

 Close vent screw (1) on pump  In order to exclude the influence

cylinder. of the impulse hoses on the
leakage test, use hose (2)
 Operate lever (2) until the gauge 4203 708 9506 to connect the
(3) indicates a vacuum of 0.5 bar two diaphragm carriers (1)
(7.25 psi). together. Repeat the test with this
setup.

Series 4141 Powerhead 13

5.4 Replacing the Oil Seals

1
1
1

380RA006 VA

380RA018 VA

380RA020 VA
3

Note:  Use clutch screws to secure Installing oil seal at flywheel side
It is not necessary to disassemble puller (1) 4112 890 4502 to

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the complete engine to replace the flywheel. – Inspect crankshaft running face

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oil seals. for scores.
– Tighten down center screw to
Flywheel side remove the flywheel. – Clean sealing face in the

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crankcase and lubricate lip of oil
– Remove shroud see 5.1. – Remove the Woodruff key from seal with grease see 11.
the crankshaft stub.
 Fit installing sleeve(2)

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– Remove the complete clutch see
4.1. Important: 1129 898 4600 over the
Take care not to damage crankshaft crankshaft.
 Remove the spark plug. Fit the
locking screw (1) 4170 893 1200
stub. fo  Slip the oil seal (3) over the
in the spark plug hole. Turn the crankshaft and against the
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crankshaft counterclockwise until crankcase.
the piston butts against the
locking screw. Important:
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Note installed position: Closed side

of oil seal faces the flywheel.

 Use the press sleeve (1)

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4112 893 2401 to press home the

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oil seal until it is flush with the

crankcase.

Important:
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Clean crankshaft stub and hole in

flywheel with a standard solvent-
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based degreasant containing no

1 chlorinated or halogenated
1 hydrocarbons see 11.
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2 – Fit Woodruff key in crankshaft,

2
mount the flywheel and tighten
down the nut to 19 Nm (14 lbf.ft).
On
380RA017 VA

380RA019 VA

– Remove the locking screw

 Release and unscrew nut (2)  Apply puller (1) 5910 890 4400
from flywheel (1). with jaws 6 (2) and tension the
puller arms.
 Pull out the oil seal.
4170 893 1200, install the spark
plug and tighten down to 15 Nm
(11 lbf.ft).
– Check air gap between magnets
on flywheel and ignition module
see 6.2.2.

– Install the clutch see 4.2.

14 Series 4141 Powerhead

– Fit the shroud see 5.1.

Starter side 1
1
– Remove shroud see 5.1.
2
2
– Remove the rewind starter see

380RA022 VA

380RA023 VA
7.2. 3
3

 Apply puller (1) 5910 890 4400 Important:

with jaws 6 (2) and tension the Note installed position: Closed side

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puller arms. of oil seal (3) faces the rewind

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starter.
 Pull out the oil seal (3).
 Use press sleeve (1)

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Important: 4119 893 2400 to press home the
Take care not to damage the oil seal (3) until it is flush with the
crankshaft stub. crankcase.

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1
– Inspect crankshaft running face  Remove the installing sleeve (2)
for scores. and press sleeve (1).
fo
– Clean sealing face in the – Fit starter cup on the crankshaft
crankcase and lubricate lip of oil and tighten to 19 Nm (14 lbf.ft).
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seal with grease see 11.
380RA006 VA

– Remove the locking screw

4170 893 1200, fit spark plug and
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tighten down to 15 Nm (11 lbf.ft).

 Remove the spark plug. Fit the – Install the rewind starter see 7.2.
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locking screw (1) 4170 893 1200

in the spark plug hole. Turn the – Fit the shroud see 5.1.
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crankshaft counterclockwise until

the piston butts against the
locking screw.
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2
2
On
380RA021 VA

380RA023 VA

 Use wrench (2) 4141 893 1300 to
remove starter cup (1) from the
crankshaft.
Installing oil seal at starter side
 Fit installing sleeve (2)
1129 898 4600 over the
crankshaft.
 Slip the oil seal (3) over the
crankshaft and against the
crankcase.

Series 4141 Powerhead 15

5.5 Replacing/Sealing Components
of Mixture Supply System

Always check and repair the fuel

1
system, carburetor, air filter and
ignition system before looking for
faults on the engine.

Troubleshooting chart - see 4 2 1

"Standard Repairs, Trouble-
shooting" handbook.

380RA024 VA

– Remove shroud see 5.1.
– Remove the air filter see 9.1.

– Remove throttle cable and plugs
380RA026 VA
3 2
Take the spacer flange off the  Take out the screws (1) and
cylinder, fit a new gasket (2). remove the diaphragm carrier

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from control handle see 8.2. (2). Fit a new gasket.

in
 Check impulse hoses (1), replace
– Remove the ignition module see porous or torn hoses.

pr
6.2.2.

– Remove the carburetor see 9.3.

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Replacing gaskets on intake
stubs

or
Note:
The cylinder has to be
1
disassembled to remove the
f
diaphragm carriers.
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2

380RA027 VA
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 Inspect diaphragm with support

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plate (1) for signs of damage.

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 To remove the diaphragm, take

out the screw (2) on the support
s

plate.
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Checking diaphragm function

1
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– Check function of diaphragm by

1 blowing through or applying
suction to the connecting stub.
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4 2 Suction: diaphragm closed

2 Blowing: diaphragm opens
If the diaphragm does not close
On

3
380RA024 VA

380RA025 VA

tight, install a new one.

3

Sealing the spacer flange  Take out the cylinder mounting

 Remove mounting screws (3)
from spacer flange (4) lösen.
 Disconnect impulse hoses (1)
from the diaphragm carriers on
the right and left of the cylinder.
screws (2).
 Raise the cylinder (1) slightly and
slide the wooden assembly block
(3) 1108 893 4800 under the
piston.
– Lift away the cylinder.

16 Series 4141 Powerhead

 5.6 Cylinder and Piston
5.6.1 Removing

Installing Components
of Mixture Supply System
Fit diaphragm carriers on the right
and leftof the cylinder, tighten
screws to 3.5 Nm (2.6 lbf.ft).
Note:
Install a new cylinder gasket; the
word "FAN" must face upwards and
towards the flywheel.
– Refit the cylinder see 5.6.2.
Always check and repair the fuel 
system, carburetor, air filter and
ignition system before looking for
faults on the engine.
Troubleshooting chart - see
"Standard Repairs, Trouble-
shooting" handbook.
– Before removing the piston,
– Remove shroud see 5.1.
– Remove the muffler see 5.2.
– Use combination wrench
If a new cylinder has to be
installed, always fit the matching
piston. New cylinders are only
available with piston. Transfer the
heat shield (1), the diaphragm
carriers (4) and ignition module to
the new cylinder.
decide whether or not the
crankshaft has to be removed as
well. To remove the clutch and
starter cup, block the piston with
the wooden assembly block.

t
– Install the impulse hoses, paying 4141 890 3400 to take out the Disassemble the crankcase see

rin
attention to the markings on the spark plug. Remove the ignition 5.8.
hoses: module see 6.2.2.
F = flywheel side

ep
S = starter side – Remove air filter, carburetor and
components of mixture supply
Install all other parts in the reverse system see 9.1, 9.2 and 5.5.

r
sequence.

or
Note:
Install new gaskets. f
ot
-n
n
sio
er

1
ev

2
lin

3
On

380RA030 VA

380RA031 VA

5 4

 Take out the cylinder mounting  Ease the hookless snap rings out
screws (3) and raise the cylinder of the grooves.
(2) slightly. Slide the wooden
assembly block (5)
1108 893 4800 under the piston.

 Lift away the cylinder (2).

Series 4141 Powerhead 17

 5.6.2 Installing

– Inspect piston rings and ring

1 2 2 3 4
grooves see 5.7.

380RA032 VA

380RA035 VA
 Use the assembly drift (2) – Clean the gasket seating surface
1108 893 4700 to push the piston on the crankcase so that it looks

t
pin (1) out of the piston. bright.

rin
Note:  Fit cylinder gasket (4) (the word
If the piston pin is stuck, tap the end "FAN" faces up, arrow points to

ep
of the drift lightly with a hammer. flywheel).
Hold the piston steady during this
process to ensure that no jolts are – Set connecting rod to top dead

rr
transmitted to the connecting rod. center.

 Lubricate the needle bearing (3)

fo with oil and fit it in the small end.

 Fit cover washers (1) on either

ot
side of small end, flat sides facing
outwards to piston.
-n

 Place the wooden assembly

block (2) 1108 893 4800 in
position.
n

– Heat the piston until it is hand hot.

io
rs
ve

1 2
1
e

2
in

3
l
On
380RA033 VA

380RA036 VA

 Pull the piston (1) off the  Slip the piston over the
connecting rod (3), collect the connecting rod, paying attention
cover washers (2). to cover washers on needle
bearing.
– Push needle bearing out of
connecting rod.  Note installed position of piston:
Arrow on piston crown points to
exhaust port

18 Series 4141 Powerhead

 Use the assembly drift (2)
1108 893 4700 to center the
small end and piston. Then push 1
the piston pin (1) into position by
hand (the pin slides home easily
if the piston is hot). 2

– Fit the snap rings on the right and

380RA028 VA

380RA029 VA
left so that the ring gaps face 1
either up or down on the piston’s
vertical axis.

 Position the piston rings (1) so  Slide the cylinder over the piston
that the radii at the ring gap meet - the clamping strap is pushed

t
at the fixing pin in the piston downward as the piston rings slip

rin
groove see 5.7. into the cylinder.
.
 Lubricate piston and piston rings – Remove the clamping strap and

ep
with oil and rest the piston on the wooden assembly block.
wooden assembly block (2)
1108 893 4800. – Line up the cylinder and gasket.
1

r
Note: – Insert cylinder mounting screws

or
Lubricate the inside of the cylinder and tighten down to 9 Nm
with oil and line it up so that it is (6.6 lbf.ft).
positioned as it will be in the
f
installed condition. It is important to Assemble all other parts in the
ot
observe this point as the piston reverse sequence.
380RA037 VA

rings might otherwise break.

2
Note:
-n

Install new gaskets.

 Install diaphragm carriers (2) on Set air gap between flywheel and
n

the right and left of the cylinder ignition module see 6.2.2.
and tighten down to 3.5 Nm
sio

(2.6 lbf.ft).

Note:
Install new gaskets.
er

 Fit heat shield (1) on cylinder and

ev

tighten mounting screws to 4 Nm

(3 lbf.ft).

Note installed position:

lin

Cutout for ignition lead (see arrow)

is at exhaust side.
On

380RA029 VA

 Use clamping strap (1)

0000 893 2600 to compress the
piston rings around the piston.

Series 4141 Powerhead 19

5.7 Piston Rings 5.8 Crankcase
5.8.1 Removing the Crankshaft

– Remove the piston see 5.6.1. – Remove the shroud see 5.1.

Note: – Remove the air filter see 9.1.

To avoid carbon residue falling into
the crankcase, always remove the – Remove the throttle cable and
piston to install the piston rings and connectors from the control 2
clean the ring grooves handle see 8.2.

380RA041 VA
Note:
Do not remove the muffler, ignition
module, components of mixture 1
supply system and the carburetor
from the cylinder.  Place wooden assembly block
1108 893 4800 (2) under the

t
piston and rest piston (1) on it.

rin
Note:
The wooden assembly block is used

ep
to block the crankshaft for removal
of the cutch, flywheel and starter
cup.

rr
– Remove rewind starter and
starter cup from the crankshaft
fo see 7.2 and 7.3.

– Remove complete clutch see 4.1.

ot
380RA034 VA

380RA039 VA
-n

 Take the piston rings (arrows) off  Disconnect the fuel hoses
n

the piston. (arrows) from the carburetor and

plug them. Clean area around
sio

– Use a piece of old piston ring to carburetor so that no dirt can fall
scrape the grooves clean. into crankcase.
er
ev

2 1
lin

1 2
On
380RA038 VA

380RA040 VA

380RA017 VA

 Install the new piston rings in the 
grooves so that the radii face
upward.
– Install the piston see 5.6.2.
Take out cylinder mounting  Release and unscrew nut (2)
screws (1) and lift away cylinder from flywheel (1).
(2) complete with attached
components.

20 Series 4141 Powerhead

 5.8.2 Replacing the Main
Bearings

1
1
2

380RA018 VA

380RA043 VA

380RA044 VA
 Use clutch screws to secure  The crankshaft (1), connecting Replacing main bearing at
puller (1) 4112 890 4502 to rod (2) and needle bearing are an flywheel side

t
flywheel. Tighten down center inseparable assembly. It must

rin
screw to remove the flywheel. always be replaced as complete  Carefully pry the oil seal (1) out of
unit. the crankcase.
– Take the Woodruff key out of the

ep
crankshaft. – When fitting a replacement
crankshaft, always install new
– Remove the fuel tank see 9.8.1. ball bearings and oil seals see

rr
5.4.
– Remove the piston see 5.6.1.

fo
ot

380RA045 VA
-n

 Use circlip pliers to remove circlip

n

from crankcase.
sio
er

1
ev
in

2
l
On
380RA042 VA

380RA046 VA

 Remove screws (arrows) from  Use press arbor (2)

crankcase and separate the two 4116 893 7205 to remove the ball
halves. Remove gasket from bearing (1).
between two parts of crankcase.
– Install circlip in groove.

Series 4141 Powerhead 21

 Note:
This operation must be carried out
very quickly because the bearing
1 absorbs heat and begins to expand.
1 If it is not possible to heat the
crankcase, use press arbor (1)
4116 893 7205 to install the bearing.

380RA047 VA

380RA050 VA
– Fit the oil seal after installing the
crankshaft see 5.4.
2

– Heat bearing seat on flywheel  Use press sleeve (1)

side of crankcase to about 120°C 4112 893 2401 (1) to press the

t
(250°F). ball bearing out of the crankcase.

rin
 Fit the ball bearing (2) by hand Note:
from inside the crankcase and Ball bearing is pressed out from the

ep
push it home as far as stop. starter side of the crankcase.

Note:

r
This operation must be carried out
very quickly because the bearing

or
absorbs heat and begins to expand.
If it is not possible to heat the
crankcase, use press arbor (1)
f
4116 893 7205 to install the bearing.
ot
 Fit the oil seal after installing the
crankshaft see 5.4.
-n
n
sio
er
ev

1
lin

1
On
380RA049 VA

380RA051 VA

Replacing main bearing at – Heat bearing seat on starter side

starter side of crankcase to about 120°C
(250°F).
 Carefully pry the oil seal (1) out of
the crankcase.  Fit the ball bearing (2) by hand
from inside the crankcase and
push it home as far as stop.

22 Series 4141 Powerhead

5.8.3 Installing the Crankshaft

Each half of the crankcase may be – Fit the fuel tank see 9.8.1.
replaced separately in the case of
damage. – Install the piston see 5.6.2.

Ball bearings are factory-installed in Note:

replacement crankcases. Cylinder is installed later.

If the original crankcase is used

380RA054 VA
again, remove the gasket residue
and clean the mating surfaces - they
must be cleaned very thoroughly to
ensure a perfect seal.
 Place gasket over pins on
crankcase.

t
rin
 Insert crankshaft in ball bearing
at starter side and push the two
halves of the crankcase together.

ep
Guide sleeves at starter side
must engage holes in flywheel
side of crankcase.

rr
2
1
fo 2
ot
380RA053 VA

380RA041 VA
-n

 Install crankshaft (1) in flywheel  Slide wooden assembly block (2)

n

side of crankcase. 1108 893 4800 under the piston

and rest piston (1) on it.
sio

Note:
The long crankshaft stub with the – Fit the Woodruff key.
slot for the Woodruff key (2) must be
installed at the flywheel side. Important:
er

Clean crankshaft stub and hole in

flywheel with a standard solvent-
ev

based degreasant containing no

chlorinated or halogenated
hydrocarbons see 11.
in

– Fit flywheel on crankshaft and

tighten down nut to 19 Nm
l

(14 lbf.ft).
On

380RA042 VA

– Install the clutch see 4.2.

– Fit starter cup on crankshaft and

 Insert screws from flywheel side tighten down to 19 Nm (14 lbf.ft).
of crankcase and tighten down to Install rewind starter and tighten
10 Nm (7.5 lbf.ft). down to 4 Nm (3 lbf.ft) see 7.2
and 7.3.
– Install oil seals see 5.4.
– Install cylinder with attached
components see 5.6.2.

Series 4141 Powerhead 23


– Set air gap between flywheel and
ignition module see 6.2.2.
– Connect the fuel hoses.
– Install the air filter see 9.1.
– Fit throttle cable und connectors
on control handle see 8.2.
– Fit the shroud see 5.1.
lin
On
24
6 Ignition System 6.1 Spark Plug Boot
Exercise extreme caution when
carrying out maintenance and repair
work on the ignition system.
The high voltages which occur can
cause serious or even fatal
accidents!
Troubleshooting on the ignition
380RA076 VA
system should always begin at the
spark plug. See "Standard Repairs,
Troubleshooting" handbook.
– Remove the shroud see 5.1.
t
 Use suitable pliers to grip the
rin
spring and pull it out of the spark
plug boot.
ep
– Unhook the leg spring from the
ignition lead.
rr
– Slip the spark plug boot off the
ignition lead.
fo – Push back insulating tube and
coat end of the ignition lead
1 (about 20 mm/3/4") with oil.
ot
2
380RA055 VA
– Fit spark plug boot over the
ignition lead.
-n
– Use suitable pliers to grip the end
Note: of the ignition lead inside the
n
The electronic (breakerless) ignition spark plug boot and pull it out.
system basically consists of the
sio
ignition module (1) and flywheel (2).
er
ev
380RA077 VA
 Pinch the hook of the spring into
the center of the lead, about
5 mm (3/16") from the end of the
lead.
Series 4141 Powerhead
 6.2 Ignition Module 6.2.1 Ignition Timing

Ignition timing is not adjustable.

3
1
Since there is no mechanical wear
in these systems, ignition timing
4 cannot get out of adjustment.
However, an internal fault in the
2 circuit can alter the switching point
in such a way that a spark test will

366RA104 VA

 Pull the lead back into the boot so
that the spring locates properly
380RA056 VA
The ignition module accommodates
all the components required to
still show the system to be in order
although timing is outside the
permissible tolerance. This will
impair engine starting and running
behavior.

t
inside it. control ignition timing.

rin
– Fit the shroud see 5.1. Ignition module components and
connections

ep
– Fit boot on spark plug.
1. Ignition lead with
insulating tube

rr
2. High voltage output

3. Connector tag for

short circuit wire
fo
ot
4. Ground wire

Note:
-n

The ignition lead is molded to the

module.
n

Accurate testing of the ignition

module is only possible with special
sio

test equipment. For this reason it is

only necessary to carry out a spark
test in the workshop. A new ignition
module must be installed if no
er

ignition spark is obtained (after

checking that wiring and stop switch
ev

are in good condition).

lin
On

Series 4141 Powerhead 25

6.2.2 Removing and Installing 6.3 Flywheel

2 1

3 2

380RA057 VA

380RA058 VA

380RA006 VA
1 3

Removing the ignition module Note: Flywheel magnets must face – Remove the shroud see 5.1.
away from the ignition module.

t
– Remove the shroud see 5.1. – Remove complete clutch see 4.1.

rin
 Place the module (2) with spacer
– Remove the clutch housing see washers in position, insert  Unscrew the spark plug and fit
4.1. screws (1) but do not tighten locking screw (1) 4170 893 1200

ep
them down yet. in its place. Turn crankshaft
 Disconnect short circuit wire (2) counterclockwise until piston
and ground wire (3). – Secure the ground wire to the left butts against the locking screw.

rr
mounting screw.
– Turn crankshaft so that flywheel
magnets face away from the  Slide the setting gauge (3)
ignition module. fo
1111 890 6400 under the arms of
the ignition module, rotate
 Take out the screws (1). flywheel so that magnets face the
ot
module.
Note:
Spacer washers are fitted between – Press the ignition module against
-n

the ignition module and cylinder. the setting gauge and tighten the
Collect them when removing the screws to 5 Nm (3.7 lbf.ft).
module.
n

– Remove the ignition module.

sio

Install in the reverse sequence.

er
ev

1
lin

2
On

380RA017 VA

 Release and remove nut (2) from

flywheel (1).

26 Series 4141 Powerhead

 7 Rewind Starter
7.1 General

Installing the flywheel If the action of the starter rope

Important:
Clean crankshaft stub and hole in
1 flywheel with a standard solvent-
based degreasant containing no
chlorinated or halogenated
hydrocarbons see 11.
becomes very stiff and the rope
rewinds very slowly or not com-
pletely, it can be assumed that the
starter mechanism is in order but
plugged with dirt. At very low
outside temperatures the lubri-
cating oil on the rewind spring may

380RA018 VA
 Use clutch screws to secure
puller (1) 4112 890 4502 to
– Install in the reverse sequence.
Tighten down flywheel nut to
19 Nm (14 lbf.ft).
– Adjust air gap between ignition
thicken and cause the spring
windings to stick together. This has
a detrimental effect on the function
of the starter mechanism. In such a
case it is sufficient to apply a few
drops of paraffin (kerosine) to the

t
flywheel. module and magnets see 6.2.2. rewind spring.

in
 Tighten down center screw to Then carefully pull out the starter

r
remove the flywheel. rope several times and allow it to

ep
rewind until its normal smooth
– Remove Woodruff key from action is restored.
crankshaft.

rr
If clogged with dirt or pitch, the
entire starter mechanism, including
the rewind spring, must be removed
fo and disassembled. Take special
care when removing the spring.
ot
Wash all parts in paraffin/kerosine
or white spirit.
-n

Lubricate the rewind spring and

starter post with STIHL special
lubricant see 11, before installing.
n
sio
er
ev
lin

1
On
380RA059 VA

Note:
The flywheel (1) and magnet poles
(2) must not be cracked or damaged
in any way.
Install a new flywheel if necessary.

Series 4141 Powerhead 27

7.2 Removing and Installing 7.3 Starter Cup 7.4 Rewind Spring
the Rewind Starter 7.4.1 Replacing

Troubleshooting chart - see

"Standard Repairs, Trouble-
1
shooting" handbook.

– Remove the shroud see 5.1.

– Remove the rewind starter see

7.2.

380RA060 VA

– Remove the shroud see 5.1.
380RA006 VA
Note:
The rewind spring will not be under
tension if the starter rope is broken.
– Remove the shroud see 5.1.

t
 Take screws (arrows) out of  Remove the spark plug and fit the

rin
rewind starter. locking screw 4170 893 1200 (1)
in its place. Turn crankshaft
– Lift away the rewind starter. counterclockwise until the piston

ep
butts against the locking screw.
Reassemble in the reverse
sequence.
2

r
f or
ot

380RA061 VA
-n

– To relieve tension, pull out the

n

starter rope a few centimeters.

Hold the rope rotor steady.
sio

 Use assembly hook (1)

5910 890 2800 (1) to make loop
starter rope. While still holding
er

rope rotor (2) steady, unwind two

turns of the rope.
1
ev

– Pull out rope with the starter grip,

let go of rotor and allow it to spin
back to relieve spring tension.
lin

2 Note:
It is not necessary to remove the
On

380RA021 VA

starter rope to replace the rewind

spring.

 Use wrench (2) 4141 893 1300 to

remove starter cup (1) from
crankshaft.

Install in the reverse sequence.

Tighten down starter cup to 19 Nm
(14 lbf.ft).

28 Series 4141 Powerhead

 4 1 1 1

2 2
3

380RA107 VA
380RA062 VA
3

380RA106 VA
2 3

 Take out the screw (1) and  Fit rewind spring (1) in the rope  Fit spring (3) with washer (2) and
remove the spring (3) with rotor so that the anchor loop (2) tighten down screw (1) to 1.1 Nm

t
washer (2). engages the recess (3). The wire (0.8 lbf.ft).

rin
retainer slips off during
 Carefully remove the rope installation. – Tension the rewind spring see
rotor (4). 7.4.2.

ep
Caution: – Install the rewind starter see 7.2.
Caution: The rewind spring may pop out and
The rewind spring is installed in the uncoil during installation.

rr
rope rotor. It may pop out and uncoil
if the rope rotor is not removed very If the rewind spring has popped out,
carefully. see "Standard Repairs, Trouble-

– Take the rewind spring out of the

shooting" handbook. fo
rope rotor.
ot
-n
n
sio
er
ev

2
lin
On
392RA073 VA

380RA063 VA

Note:  Fit rope rotor in starter cover and

The replacement spring comes engage inner spring loop (1) in
ready for installation and is held slot (2) at the same time.
together by a wire retainer. It should
be lubricated with a few drops of
STIHL special lubricant before
installation see 11.

Series 4141 Powerhead 29

7.4.2 Tensioning 7.5 Starter Rope

– Hold the starter grip firmly to keep

the rope tensioned.

– Let go of the rope rotor and

slowly release the starter grip so
the starter rope can rewind
properly.
1

380RA108 VA

 Make a loop in the starter rope.
380RA064 VA
Note:
The rewind spring is correctly
tensioned when the starter grip sits
firmly in the rope guide bush without
drooping to one side. If this is not It is not necessary to remove the
the case, tension the spring by one rope rotor to replace the starter

t
– Push starter rope into notch in additional turn. rope.

rin
rope rotor.
When the starter rope is fully – Remove the rewind starter see
extended, it must still be possible to 7.2.

ep
rotate the rope rotor at least another
half turn before maximum spring – Pull rope out all the way with the
tension is reached. If this is not the starter grip.

rr
case, pull the rope out, hold the
rope rotor steady and take off one  Hold the rope rotor steady.
turn of the rope.

Do not overtension the rewind

fo  Undo knot at end of rope (1) and
pull out the rope.
spring as this will cause it to
ot
break. – Gradually release rope rotor until
380RA109 VA

spring tension is relieved.

– Install the rewind starter see 7.2.
-n

– Remove the rope rotor for

cleaning see 7.4.
 Grip the rope close to the rotor
n

and use it to turn the rope rotor Note:

about six full turns counter- The rewind spring will not be under
sio

clockwise. tension if the starter rope is broken.

 Thread new starter rope from

inside to outside of rope rotor and
er

starter cover.
ev

 Tie a simple overhand knot (1) in

the end of the rope and pull the
rope back to locate the knot in the
rotor.
lin
On
380RA110 VA

 Hold the rope rotor steady.

 Pull out the rope with the starter

grip and straighten it out.

30 Series 4141 Powerhead

 8 Throttle Control
8.1 Throttle Trigger/Interlock Lever

3 3

392RA083 VA
380RA065 VA

392RA087 VA
1 2 1 2

 Thread other end of rope through  Take out the screw.  Take the throttle trigger (1) with
the "ElastoStart" grip (1) and torsion spring (2) and throttle

t
spring (2). Secure with a simple cable (3) off the peg.

in
overhand knot.

 Pull rope with spring back into the

pr
"ElastoStart" grip. Fit cap (3).

re
– Tension the rewind spring see
7.4.2. 1

or
– Install the rewind starter see 7.2.
f
ot
392RA084 VA

392RA088 VA
-n

 Use screwdriver (1)  Disconnect throttle cable from

n

5910 890 2301 (1) to remove trigger.

screws.
io

Reassemble in the reverse

– Separate the two halves of the sequence.
s

handle. Pay attention to the following points

during installation.
er
ev

1
lin
On

392RA085 VA

392RA089 VA

 Lift the interlock lever (1) slightly 
and turn it to one side until the
torsion spring (2) is relaxed.
 Pull the interlock lever and
torsion spring off the peg.
Attach the throttle cable, then
position torsion spring as shown
and push its long arm into the
slot.

Series 4141 Powerhead 31

 8.2 Replacing the 8.3 Adjusting the
Throttle Cable Throttle Cable

4 3 1 2

392RA090 VA

380RA078 VA

380RA080 VA
1

 The interlock lever must be – Remove the filter cover see 9.1. Note:
behind the throttle trigger. Throttle lever (1) must butt against

t
 Disconnect wires (1 and 2) on the stop (3) when throttle trigger is

rin
– Tighten handle screws to 2.5 Nm throttle cable. squeezed (full throttle). Throttle
(1.8 lbf.ft). lever must butt against the low
speed screw (2) (stop screw) when

ep
the trigger is in the idle position.

The throttle cable is adjusted by

1 2 5 34

rr
moving the tensioning sleeve (4).

– Adjust idle speed correctly see

fo 9.5.
Throttle lever must butt against
the low speed screw. Now shut
ot
off the engine.
380RA079 VA

– Remove the filter cover see 9.1.

-n

– To adjust the throttle cable, open

 Loosen hex nut (2) and unscrew throttle wide on control handle.
n

tensioning sleeve (1) from the

retainer.
sio

– Take out the throttle cable

through the slot.
er

 Detach throttle cable nipple (3)

from slotted pin (4) on lever (5).
1 3
ev

2
Remove the throttle trigger see 8.1.

Reassemble in the reverse

lin

sequence.

Adjust the throttle cable see 8.3.

On

380RA104 VA

 Use tensioning sleeve (1) to

adjust the throttle cable until
lever (3) butts against stop (2).

32 Series 4141 Powerhead

 9 Fuel System
9.1 Air Filter

Dirty and clogged air filters reduce – Wash the filter mat and prefilter in
1 2 3
engine power, increase fuel a fresh, non-flammable cleaning
consumption and make starting solution (e.g. warm soapy water)
more difficult. and dry them.

Note: Note:
The air filter must be cleaned when Replace damaged parts
there is a noticeable loss of engine immediately.

380RA105 VA
power.
Reassemble in the reverse
– Close the choke shutter. sequence.

 Release the throttle trigger (idle – Clean away any loose dirt from – Note installed position of prefilter.
position). The throttle lever (2) around the air filter and filter Tapped hole for the filter cover

t
must now butt against the low cover. and the choke shaft must be

in
speed screw (3) (arrow). accessible.

 If idle and full-load stops are

pr
reached, tighten down the hex
nut (1).

re
– Fit the filter cover.

f or
ot
380RA081 VA

1
-n

 Release the screw (1) and lift

n

away the filter cover.

sio
er
ev
lin

1
2
On

380RA082 VA

 Take out the filter mat (foam

element) (1) and prefilter (wire
mesh) (2).

Series 4141 Powerhead 33

9.2 Carburetor
9.2.1 Leakage Test

Troubleshooting chart - see – Repeat the leakage test with the

"Standard Repairs, Trouble- hose attached to the carburetor’s
shooting" handbook. rear elbow connector.

Important: If there is any loss of pressure,

In the event of trouble with the service the carburetor.
carburetor or the fuel supply
system, always check and clean the After completing the repairs, repeat

380RA083 VA
tank vent see 9.6. the leakage test.

The carburetor can be tested for

leaks with the carburetor and
crankcase tester 1106 850 2905.  Push the hose (with nipple and
tester) onto the carburetor’s front

t
elbow connector.

rin
r ep
f or
1
ot
143RA046 VA
380RA039 VA

-n

– Remove the air filter cover see  Close vent screw (1) on rubber
n

9.1. bulb.
sio

 Pull fuel hoses off carburetor  Use rubber bulb to pump air into
elbow connectors. the carburetor until gauge
indicates a pressure of 0.8 bar
(11.5 psi).
er

If this pressure remains constant,

ev

2 1 the carburetor is airtight. However, if

the pressure drops, there are two
possible causes:
lin

1. The inlet needle is not sealing

(foreign matter in valve seat or
sealing cone of inlet needle is
On
143RA172 VA

damaged or inlet control lever

sticking).

2. Metering diaphragm damaged.

 Attach hose (1) 1110 141 8600 to
one end of nipple (2) In either case the carburetor must
0000 855 9200 and tester’s be serviced.
pressure hose to other end.
– After completing test, open the
vent screw and pull the pressure
hose off the elbow connector.

34 Series 4141 Powerhead

9.3 Removing and Installing 9.4 Servicing the Carburetor
the Carburetor

5 Spacer flange with inlet

needle valve
6 Pump diaphragm
7 Gasket

380RA039 VA

380RA085 VA
– Remove the filter cover and filter – Remove the carburetor see 9.3.
elements see 9.1.

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Servicing the carburetor includes

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 Pull fuel hoses off carburetor the replacement of all gaskets and
elbow connectors. diaphragms. The gasket kit contains
all the parts required.

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– Clean exterior of carburetor.

 Release and remove screws on

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the underside of the carburetor.

f or
ot
380RA084 VA

915RA065 VA
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– Remove the throttle cable see Manual fuel pump

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8.2.
 Push cap (pump bulb) out of end
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 Remove screws and take cover and fit a new one.

carburetor with air filter housing
off the spacer flange.
er

– When installing, tighten the

screws to 3.5 Nm (2.6 lbf.ft).
2 3 4 5 6 7
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1
– Install a new gasket between the
carburetor and spacer flange.
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Reassemble in the reverse

sequence.
On

380RA086 VA

380RA087 VA

– Adjust throttle cable see 8.3.

 Disassemble parts of manual fuel  Pull the valve out of the flange.
pump:
1 End cover with cap (bulb) – Inspect valve and replace if
2 Flange with valve necessary.
3 Metering diaphragm
4 Gasket

Series 4141 Powerhead 35

 – Remove inlet control level with
spindle.

– Pull out the inlet needle.

1
1
2 Note:
If there is an annular indentation on
the sealing cone of the inlet needle,

380RA088 VA

380RA092 VA
it will be necessary to replace the
inlet needle because it will no longer
seal properly.

Metering diaphragm Removing rotary valve

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– Take the metering diaphragm off  Loosen screws (arrows) and pull

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the flange. rotary valve out of carburetor.

Note: Note:

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The diaphragm is exposed to Installed position: Stop for rotary
continuous alternating stresses and valve lever at air filter side.
the material eventually shows signs

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of fatigue. The diaphragm distorts – Tighten the screws securely.
and swells and has to be replaced.

 Fit metering diaphragm (1) with

the perforated plate facing the 1
fo 2

inlet control (2). The diaphragm is

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located by the pegs on the flange.
380RA090 VA
-n

 Fit the inlet needle.

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 Fit helical spring (1) in the hole.

sio

 Insert spindle (2) in the inlet

control lever (3).
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– Engage clevis of inlet control

lever in annular groove on the
1
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head of the inlet needle.

– Press down the inlet control lever

and secure it with the screw.
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Note:
Make sure that the helical spring
On
380RA089 VA

locates on the control lever's nipple

– Check that inlet control lever

moves freely.
Inlet needle
Important:
– Remove the metering Upper edge of inlet control lever
diaphragm. must be flush with bottom of
metering chamber.
 Take out the screw (1).

36 Series 4141 Powerhead

 9.5 Adjusting the Carburetor

Note: The carburetor is designed to

1 Do not drive home the jet body with provide an optimum fuel-air mixture
a hammer because the support ring in all engine operating conditions.
might break. Installing the jet with a
punch damages the jet body.

Standard setting

380RA091 VA
– Mount the cutting attachment.

On nylon line heads:

Check that length of cutting line is
Main jet correct. Each cutting line must
reach as far as line limiting blade on

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 Ease the main jet (1) out of the the deflector.

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carburetor body.

 Remove the sealing ring.

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1
1
fo
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380RA101 VA

380RA093 VA
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 Use punch (1) to drive out the jet – Check the air filter and clean if
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body from the outside inwards. necessary.

sio

– Inspect spark arresting screen

and clean or replace as
necessary.
er

 Adjust idle speed with the low

speed screw (1).
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1
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On
380RA102 VA

 Use sleeve (1) 1127 851 8300 to

install new jet body from inside.

Series 4141 Powerhead 37


380RA111 VA
 Back off the low speed screw
(stop screw) until the end of the
screw (arrow) is no longer visible,
then turn it six full turns
clockwise.
Adjusting idle speed
– Carry out standard setting.
– Start engine and warm it up to
normal operating temperature.
– If the engine stops while idling:
Turn low speed screw slowly
clockwise until the engine runs
smoothly. The cutting attachment
must not rotate.
– If the cutting attachment rotates
while engine is idling: Turn low
speed screw counterclockwise
until cutting attachment stops
rotating. Then turn screw another
two turns in the same direction.
ev
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On
38
9.6 Tank Vent
Correct operation of the carburetor
is only possible if atmospheric
pressure and internal fuel tank
pressure are equal at all times. This
is ensured by the tank vent.
Important:
In the event of trouble with the
carburetor or the fuel supply
system, always check and clean the
tank vent. Check functions by
performing pressure and vacuum
tests on the fuel tank via the fuel
hoses.
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fo
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380RA094 VA
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1
– Disconnect both fuel hoses from
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the carburetor.
sio
– Seal one fuel hose with a suitable
plug. Perform pressure or
vacuum test on tank via the other
fuel hose.
er
 Equalization of pressure from the
outside inwards takes place via
the valve (1). There must be no
build up of pressure or vacuum in
the tank. In case of malfunction,
install a new valve.
9.7 Pickup Body
The diaphragm pump draws fuel out
of the tank and into the carburetor
via the fuel hose. Any impurities
mixed with the fuel are retained by
the pickup body (filter). The fine
pores of the filter eventually become
clogged with minute particles of dirt.
This restricts the passage of fuel
and results in fuel starvation.
t
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1
380RA095 VA
Important:
In the event of trouble with the fuel
supply system, always check the
fuel tank and the pickup body first.
Clean the fuel tank if necessary.
Cleaning the fuel tank
 Unscrew the filler cap (1) and
drain the tank.
– Pour a small amount of clean
gasoline into the tank.Close the
tank and shake the powerhead
vigorously.
– Open the tank again and drain it.
Note:
Dispose of old fuel at approved
disposal site.
Series 4141 Powerhead
 9.8 Fuel Tank/Fuel Hoses 9.8.2 Fuel Hoses
9.8.1 Fuel Tank

380RA096 VA

380RA039 VA

380RA099 VA
Pickup body – Drain the fuel tank. – Unscrew the filler cap and
remove together with retainer.

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 Use the assembly hook (1) – Remove the filter cover and filter

in
5910 893 2800 to pull the pickup elements see 9.1.  Pull fuel hoses with rubber
body out of the fuel tank. grommet (1) out of tank.

pr
 Pull fuel hoses off the carburetor
elbow connectors. – Install new fuel hoses and pickup
body.

re
2
f or
ot
380RA097 VA

-n

Note:
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Do not stretch the fuel hose while

removing it.
sio

 Use pliers to remove clip (2).

 Pull pickup body (1) off the fuel

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hose and fit a new one.

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Reassemble in the reverse

sequence.
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On

380RA098 VA

 Take out screws on fuel tank and

lift away the tank.

Remove the fuel hoses if necessary.

Reassemble in the reverse

sequence.

Series 4141 Powerhead 39

10 Special Servicing Tools

No. Part Name Part No. Application

1 Clamp 5910 890 8800 Holder for item 2
2 Assembly stand 5910 890 3100 Holding powerhead
3 Locking screw 4170 893 1200 Blocking crankshaft
4 Sleeve 1127 851 8300 Removing clutch drum,
installing main jet body
5 Press arbor 4119 893 7200 Removing clutch drum bearing
6 Press arbor 4116 893 7205 Installing clutch drum bearing
7 Assembly drift 1110 893 4700 Installing clutch drum
8 Test flange 4141 850 4200 Crankcase leakage test

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9 Sealing plate 0000 855 8106 Sealing exhaust port for leakage test
10 Carburetor and crankcase tester 1106 850 2905 Testing crankcase and carburetor for leaks
11 Vacuum pump 0000 850 3501 Crankcase leakage test

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12 Hose 4203 708 9506 Connecting diaphragm valves for leakage test
13 Puller 4112 890 4502 Removing flywheel

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14 Puller 5910 890 4400 Universal puller
- Jaws (No. 6) Removing oil seals
15 Installing sleeve 1129 898 4600 Installing oil seal
16 Press sleeve 4112 893 2401
fo
Installing oil seals and ball bearings
17 Wrench 4141 893 1300 Removing starter cup
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18 Press sleeve 4119 893 2400 Installing oil seal
19 Wooden assembly block 1108 893 4800 Fitting piston
-n

20 Clamping strap 0000893 2600 Compressing piston rings

21 Combination wrench 4141 890 3400 Spark plug
22 Assembly drift 1108 893 4700 Removing piston pin
n

23 Setting gauge 1111 890 6400 Setting air gap between ignition module and
flywheel
sio

24 Assembly hook 5910 890 2800 Starter rope, pickup body

25 Screwdriver 5910 890 2301 Screws
26 Fuel line 1110 141 8600 Carburetor leakage test
er

27 Nipple 0000 855 9200 Carburetor leakage test

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On

40 Series 4141 Powerhead

11 Servicing Aids

No. Part Name Part No. Application

1 Lubricating grease 0781 120 1111 Oil seals
(370 g/13 oz tube)
2 Standard commercial, solvent- Cleaning crankshaft stub
based degreasant containing no
chlorinated or halogenated
hydrocarbons
3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor,
rewind spring
4 Electrical repair kit 5910 007 1050 Electrical system

t
rin
12 Special Accessories

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Part Name Part No.

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Safety glasses
STIHL gear lubricant for brushcutters
- 80 g/2.8 oz tube
- 225 g/8 oz tube
0781 120 1117
0781 120 1118
fo
Stihl-Getriebefett für Heckenscheren
ot
- 80 g/2.8 oz tube 0781 120 1109
- 225 g/8 oz tube 0781 120 1110
-n
n
sio
er
ev
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On

Series 4141 Powerhead 41