STIH)

STIHL MS 441 2006-06

Contents

1. Introduction 3 8. Engine 37 11. Anti-vibration system,

repair 78
8.1 Muffler / spark
2. Safety 4 arresting screen 37 11.1 Annular buffers 78
8.2 Leakage testing 39 11.2 Anti-vibration spring,
8.2.1 Preparations 40 front handle 79
3. Specifications 5 8.2.2 Vacuum test 41 11.3 Anti-vibration spring,
8.2.3 Pressure test 41 fuel tank 79
3.1 Engine 5 8.3 Oil seals 42 11.3.1 Anti-vibration spring,
3.2 Fuel system 5 8.4 Shroud, removal oil tank 80
3.3 Ignition system 5 and installation 44 11.4 Stop buffers 80
3.4 Chain lubrication 5 8.5 Cylinder 45 11.5 Front handle 81
3.5 Tightening torques 6 8.6 Crankshaft 48 11.5.1 Front handle with
8.6.1 Removal 48 handle heating 83
8.6.2 Installation 49
4. Troubleshooting 8 8.6.3 Ball bearing /
crankcase 52 12. Actuating levers 84
4.1 Clutch 8 8.7 Piston 54
4.2 Chain drive, chain brake, 8.7.1 Removal 54 12.1 Switch shaft 84
chain tensioner 9 8.7.2 Installation 55 12.1.1 Removal and
4.3 Chain lubrication 11 8.8 Piston rings 56 installation 84
4.4 Rewind starter 12 8.9 Decompression valve 57 12.2 Throttle trigger / throttle
4.5 Ignition system 13 trigger interlock 85
4.6 Carburetor 15 12.3 Throttle trigger /
4.7 Engine 18 9. Ignition system 57 throttle trigger interlock /
QuickStop Super 87
9.1 Ignition module 58 12.3.1 Switch lever 89
5. Saw chain / 9.1.1 Removal and 12.3.2 Throttle trigger
chain guide 19 installation 58 interlock 90
9.2 Ignition timing 60
9.3 Testing the ignition
6. Clutch 19 module 60 13. Chain lubrication 91
9.4 Spark plug boot /
6.1 Clutch drum 21 ignition lead 61 13.1 Pick-up body 91
9.5 Flywheel 63 13.2 Oil suction hose 91
9.6 Short circuit wire 64 13.3 Oil pump 92
7. Checking operation 9.6.1 Testing 64 13.3.1 Repair 93
of chain brake 23 9.6.2 Removal and 13.3.2 Adjustment 94
installation 64 13.4 Valve 94
7.1 Brake band, removal 9.6.3 Ground wire 66 13.5 Oil tank cap 95
and installation 23 9.7 Pre-separator 67
7.2 Brake lever 25 9.8 Troubleshooting chart,
7.3 QuickStop Super ignition system 69
brake lever 27
7.3.1 Adjusting brake cable 30
7.3.2 Brake cable, removal 10. Rewind starter 72
and installation 31
7.4 Cam lever 33 10.1 General 72
7.5 Pins 34 10.2 Removal and
7.6 Chain tensioner 35 installation 72
7.7 Bar mounting studs 37 10.3 Pawls 73
10.4 Rope rotor 73
10.5 Starter rope / grip 74
10.6 Tensioning the rewind
spring 75
10.7 Rewind spring 76
10.8 Starter rope guide
bushing 77
q
© ANDREAS STIHL AG & Co. KG, 2006

MS 441, MS 441 C 1
Contents

14. Fuel system 95 15. Heating 124

14.1 Air filter 95 15.1 Carburetor heating 124

14.1.1 Baffle 96 15.2 Troubleshooting chart,
14.1.2 Filter base 96 carburetor heating
14.2 Spacer flange 98 element 128
14.3 Carburetor removal 15.3 Handle heating
and installation 99 systems 129
14.3.1 Leakage testing 100 15.3.1 Troubleshooting 129
14.4 Carburetor repair 100 15.4 Heating switch, removal
14.4.1 Air flap 100 and installation 130
14.4.2 Metering diaphragm 101 15.5 Heating element in
14.4.3 Inlet needle 102 handle, removal and
14.4.4 Fixed jet 103 installation 131
14.4.5 Pump diaphragm 104 15.6 Heating element in
14.4.6 Choke shaft / front handle, removal
choke shutter 105 and installation 131
14.4.7 Throttle shaft / 15.7 Generator, removal
throttle shutter 107 and installation 131
14.4.8 Accelerator pump 109 15.7.1 Troubleshooting chart,
14.4.9 Adjusting screws 109 handle heating systems
14.5 Carburetor and generator 133
adjustment 111 15.7.2 Summary of test
14.5.1 Basic setting 111 connections and test
14.5.2 Standard setting 112 values 135
14.6 Throttle cable 113 15.8 Wiring harness 137
14.6.1 Carburetor support 114 15.8.1 Removal 137
14.6.2 Carburetor housing 116 15.8.2 Installation 138
14.6.3 Intake elbow, removal
and installation 119
14.6.4 Impulse hose 119 16. Special tools 141
14.7 Tank vent 120
14.7.1 Check 120
14.7.2 Removal and 17. Servicing
installation 121 accessories 143
14.8 Fuel intake 121
14.8.1 Pick-up body 121
14.8.2 Fuel hoses 122
14.8.3 Fuel filler cap 123
14.8.4 Tank housing, removal
and installation 124

2 MS 441, MS 441 C
1. Introduction
This service manual contains
detailed descriptions of all the
typical repair and servicing
procedures for this power tool.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions and sequence of
steps for the individual components
and assemblies.
Always refer to the latest edition of
the relevant parts list to check the
part numbers of any replacement
parts.
A fault on the machine may have
several causes. To help locate the
fault, consult the chapter on
"Troubleshooting" and the "STIHL
Service Training System" for all
functional groups.
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 and
service manual until an updated
edition is issued.
MS 441, MS 441 C
The special tools mentioned in the
descriptions are listed in the chapter 1
"Special Tools" of this manual. Use 3
the part numbers to identify the
tools in the "STIHL Tools" manual
which lists all the tools currently 2
available from STIHL.
219RA000 TG
Symbols are included in the text and
pictures for greater clarity. The
meanings are as follows:
In the descriptions: Servicing and repairs are made
considerably easier by mounting the
: = Action to be taken as shown machine on assembly stand (3)
in the illustration 5910 890 3100. For this purpose,
(above the text) secure the clamping rail (2)
5910 850 1650 to the assembly
– = Action to be taken that is stand with two screws (1) and
not shown in the illustration washers.
(above the text)
The screws must not protrude,
In the illustrations: as they may damage the housings
when clamping the machine,
A Pointer (short) depending on the model.
aDirection of movement (long)
b 4.2 = Reference to another
chapter, i.e. chapter 4.2
in this example.
Service manuals and technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed to third parties.
3

219RA001 TG
The flange bolts on the chainsaw
are guided through the outer holes
in the clamping rail and secured
with the nuts (arrows).
The sprocket wheel cover, bar and
chain must be removed first. Pull
the hand guard back against the
front handle for this purpose.
Always use original STIHL
replacement parts.
They can be identified by the
STIHL part number,
the STIH) logo and
the STIHL parts symbol (
This symbol may appear alone on
small parts.
4 MS 441, MS 441 C
2. Safety
All local and specific national safety
regulations as well as the safety
precautions and warnings in the
instruction manual must be
observed if the machine is started
up in the course of repairs or
maintenance work.
Gasoline is an extremely flammable
fuel and can be explosive in certain
conditions.
Suitable gloves must be worn
without fail if parts are heated for
assembly/disassembly purposes.
Improper handling may result in
burns or other serious injuries.
Do not bring any fire, flame, spark or
other source of heat near the fuel.
All work with fuel must be performed
outdoors only. Spilled fuel must be
wiped away immediately.
Test for leakages after all work on
the fuel system and engine.
3. Specifications

3.1 Engine

MS 441

Displacement: 70.7 cm3

Bore: 50 mm
Stroke: 36 mm
Engine power to ISO 7293: 4.1 kW (5.8 HP)
at 9,500 rpm
Max. permissible engine speed
(with bar and chain): 13,500 rpm
Idle speed: 2,800 rpm
Clutch: Centrifugal clutch without linings
Clutch engages at: 3,700 rpm
Crankcase leakage test
at gauge pressure: pü = 0.5 bar
under vacuum: pu = 0.5 bar

3.2 Fuel system

Carburetor leakage test

at gauge pressure: pü = 0.8 bar
Operation of tank vent
at gauge pressure: pü = 0.5 bar
Fuel: as specified in instruction
manual

3.3 Ignition system

Air gap between ignition

module and fan wheel: 0.15...0.35 mm
Spark plug (suppressed): NGK BPMR 7 A
Electrode gap: 0.5 mm

3.4 Chain lubrication

Speed-controlled oil pump with reciprocating piston –

manual oil flow control

Oil delivery rate: 6.0...17 cm3/min

at 10,000 rpm

Oil pump with elevated 6.0...24 cm3/min

oil flow: at 10,000 rpm

MS 441, MS 441 C 5
3.5 Tightening torques

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

Fastener Thread size For component Torque Remarks

Nm

Screw M 4x8 Chain tensioner cover plate/crankcase 3.0

Screw M 7x12.5 Fan housing shaft 12.0
Screw P 5x20 AV spring, crankcase/bearing plug 4.0
Screw M 5x20 AV spring, bearing plug/front handle 6.0
Screw M 5x16 AV spring, bearing plug/cylinder 10.0 2)
Screw P 5x20 AV spring, tank housing/bearing plug 4.0
Screw P 4x10 Brake cable/throttle cable retainer 1.0 Q
Collar screw M 8x21.5 Bar mounting stud 23.0 1)
Collar screw M 6x20 Collar screw/crankcase 12.0 1)
Screw M 4x12 Cover, chain brake/crankcase 3.0
Screw UNC 2.84x9 Switch/carburetor cover 0.7 VW
M 10x1 Decompression valve 14.0
Collar nut M5 Filter base/baffle/carburetor/collar 3.5
screw
Collar nut M5 Filter base/carburetor/collar screw 3.5
Screw B 4.2x9.5 Spark arresting screen/muffler 2.0
Screw P 4x10 Throttle cable retainer/handle housing 0.8
Screw M 5x16 Housing/crankcase 7.5
Mutter M 12x0.75 Housing/switch 2.0 W, VW
Screw M 4x12 Generator/crankcase 3.0 1), W, VW
Screw P 6x30 Front handle/tank housing 7.0
Screw M 5x35 Hand guard, left/crankcase 6.0
Screw M 5x20 Chain catcher/spiked bumper/ 8.0
crankcase
Screw M 5x12 Spiked bumper/top of crankcase/ 8.0
lock nut

Screw M 5x16 Intake elbow/cylinder 6.0

Screw M 5x8.8 Crankcase 6.0
Screw M 5x25 Crankcase 10.0
Screw M 4x12 Crankcase/brake band 3.0 1)
Screw M 5x20 Fan housing/crankcase 6.0
M 12x1 L Crankshaft carrier 50.0
Nut M5 Muffler/flange bolt (with washer) 10.0

6 MS 441, MS 441 C
Fastener Thread size For component Torque Remarks
Nm

Screw M 4x12 Oil pump/crankcase 3.5

Screw M 5x16 Muffler/cylinder 10.0 1)
Screw P 4x10 Slide/housing 1.0
Nut M5 Slotted nut, shroud/stud, cylinder 3.0
Screw P 4x10 Guard/handle housing 1.5
Nut M 8x1 Flywheel/crankshaft 28.0 3)
Screw M 4x8 Side plate/crankcase 3.0
Screw M 5x8.5 Stud/cylinder 1.4
Nut M5 Hexagon cap nut/baffle/flange bolt 1.5
Screw M 4x12 Pre-separator/crankcase 3.0 1)
Screw M 5x16 Elbow connector/front handle 10.0 R
Screw P 6x30 Elbow connector/front handle/ 7.0 R
handle housing
M 14x1.25 Spark plug 25.0
Screw M 5x20 Ignition module/crankcase 8.0
(with washer)
Screw M 5x12 Spacer flange/housing 5.0
Screw M 6x25 Cylinder/crankcase 15.0

Remarks:

1) Loctite 243 medium strength

2) Loctite 270 high strength
3) Connection between crankshaft and flywheel must be degreased and installed oil-free
Q = QuickStop Super chain brake
R = Wrap-around handle
V = Carburetor heating
W = Handle heating

When inserting the DG and P-type screws in an existing thread:

Insert the DG or P-type screw in the hole and turn it counterclockwise until it gently drops into the hole in axial
direction.
Turn the screw in clockwise and tighten with the specified torque.

This ensures that the screw engages the existing thread and does not cut a new thread, thus preserving the
strength of the screw connection.

Micro-encapsulated screws must be wetted with Loctite 243, medium strength, before being refitted.

Screwdriver speed when fitted in plastic material: max. 500 rpm for DG and P-type screws.
An impact wrench must not be used to unscrew or tighten the screw connections!

Screws with and without locking serration must not be confused!

MS 441, MS 441 C 7
4. Troubleshooting
4.1 Clutch

Condition Cause Remedy

Saw chain stops under load at full Clutch shoes badly worn Install new clutch
throttle

Clutch drum badly worn Install new clutch drum

Saw chain rotates at idle speed Engine idle speed too high Readjust with idle speed screw LA
(counterclockwise)

Clutch springs stretched Replace the clutch springs or install

or fatigued new clutch

Clutch spring hooks broken Replace the clutch springs

Loud noises Clutch springs stretched Replace all clutch springs

or fatigued

Needle cage damaged Fit new needle cage

Clutch shoe retainer broken Fit new retainer

Clutch shoes and carrier worn Install new clutch

8 MS 441, MS 441 C
4.2 Chain drive, chain brake, chain tensioner

Condition Cause Remedy

Chain sprocket wears rapidly Chain not properly tensioned Tension chain as specified

Wrong chain pitch Fit chain of correct pitch

Insufficient chain lubrication Check chain lubrication

Chain sprocket worn Fit new chain sprocket

Saw chain stops under load at full Clutch shoes badly worn Install new clutch
throttle

Clutch drum badly worn Install new clutch drum

Brake band blocked Check freedom of movement and

function of brake band. Check
brake cable on machines with
QuickStop Super.

Saw chain rotates at idle speed Engine idle speed too high Readjust with idle speed screw LA
(counterclockwise)

Clutch springs stretched or fatigued Replace the clutch springs or install

new clutch

Clutch spring hooks broken Replace the clutch springs

Saw chain does not stop Brake spring stretched or broken Fit new brake spring
immediately when brake
is activated

Brake band stretched, worn or Fit new brake band

broken

Clutch drum worn Fit new clutch drum

MS 441, MS 441 C 9
Condition Cause Remedy

QuickStop Super Brake cable stretched Adjust brake cable

Chain brake is not released
although trigger interlock is pressed

Brake cable unhooked or broken Reattach or replace brake cable

QuickStop Super Brake cable overstretched Adjust brake cable

Chain brake does not brake
properly – trigger interlock not
pressed

10 MS 441, MS 441 C
4.3 Chain lubrication

In the event of trouble with the chain

lubrication system, check and .
rectify other sources of faults before
disassembling the oil pump.

Condition Cause Remedy

Chain receives no oil Oil tank empty Fill up with oil, check oil pump
setting if necessary

Oil inlet hole in guide bar Clean oil inlet hole

is blocked

Intake hose or pick-up body Fit new intake hose and pick-up
clogged or intake hose ruptured body

Valve in oil tank blocked Clean or replace valve

Tooth flanks of worm worn Replace worm

Oil pump damaged or worn Install new oil pump

Machine loses chain oil Oil pump housing defective Install new oil pump

Oil pump damaged or worn Install new oil pump

Oil intake hose connection Fit new oil intake hose

damaged

Oil pump delivers insufficient oil Oil pump worn Install new oil pump

Delivery rate of oil pump set too low Adjust oil pump

MS 441, MS 441 C 11
4.4 Rewind starter
Condition Cause
Starter rope broken Rope pulled out too vigorously
as far as stop or over edge, i.e. not
vertically
Normal wear
Starter rope does not rewind Very dirty or corroded
Spring not properly tensioned
Rewind spring broken
Starter rope cannot be pulled out Rewind spring overtensioned
far enough
Starter rope can be pulled out Guide peg on pawl or pawl itself is
almost without resistance worn
(crankshaft does not turn)
Fit new pawl
Starter rope is difficult to pull or Starter mechanism is very dirty
rewinds very slowly
Lubricating oil on rewind spring
becomes viscous at very low
outside temperatures (spring
windings stick together)
Decompression valve is not open
12
Remedy
Fit new starter rope
Fit new starter rope
Clean or replace rewind spring
Check rewind spring and increase
tension
Fit new rewind spring
Check rewind spring and reduce
tension
Spring clip fatigued
Fit new spring clip
Thoroughly clean complete starter
mechanism
Coat rewind spring with a little
standard solvent-based degreasant
(not containing any chlorinated or
halogenated hydrocarbons), then
pull rope carefully several times
until normal action is restored
Open decompression valve and
check, replace if necessary
MS 441, MS 441 C
4.5 Ignition system

Extreme caution must be exercised

when looking for faults and when
carrying out maintenance and repair
work on the ignition system.
The high voltages occurring can
cause serious or fatal accidents!

Condition Cause Remedy

Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug
temporary loss of power and fit new spring if necessary

Spark plug sooted, smeared Clean the spark plug or replace

with oil if necessary

Ignition lead is loose in ignition Secure ignition lead

module

Fuel/oil mixing ratio – contains too Use fuel mixture with correct mixing
much oil ratio

Incorrect air gap between ignition Set correct air gap

module and flywheel

Flywheel cracked or has other Install new flywheel

damage or pole shoes have turned
blue

Ignition timing wrong, flywheel out Install new flywheel

of adjustment, key in flywheel has
sheared off

Weak magnetization in flywheel – Install new flywheel

pole shoes have turned blue

Irregular spark Check operation of switches /

contact springs and ignition
module.
Faulty insulation or break in ignition
lead or short circuit wire.
Check ignition lead / ignition module
and replace if necessary.
Check operation of spark plug,
clean spark plug and replace if
necessary.

Crankcase damaged (cracks) Replace crankcase

MS 441, MS 441 C 13
Condition Cause Remedy

No spark Spark plug faulty Install new spark plug

Faulty insulation or short-circuit in Check short circuit wire for short-

short circuit wire circuiting to earth

Break in ignition lead or insulation Check ignition lead, replace

damaged if necessary

Ignition module faulty Install new ignition module

14 MS 441, MS 441 C
4.6 Carburetor

Condition Cause Remedy

Carburetor floods; engine stalls Inlet needle not sealing – Remove and clean inlet needle or
Impurities in valve seat or cone clean carburetor

Inlet control lever sticking on Restore easy movement of inlet

spindle control lever

Helical spring not located on nipple Remove inlet control lever and refit
of inlet control lever it correctly

Perforated disc on diaphragm is Fit a new metering diaphragm

deformed and presses constantly
against the inlet control lever

Poor acceleration Setting of low speed screw Check basic carburetor setting,
"too lean" correct if necessary

Setting of high speed screw Check basic carburetor setting,

"too lean" correct if necessary

Inlet needle sticking in valve seat Remove, clean and refit inlet
needle

Leak in diaphragm seal Fit a new diaphragm seal

Metering diaphragm damaged or Fit a new metering diaphragm

shrunk

Impulse hose damaged or kinked Fit a new impulse hose

MS 441, MS 441 C 15
Condition Cause Remedy

Engine will not idle, idle speed too Throttle shutter opened too wide by Correct setting of idle speed
high idle speed screw LA screw LA

Oil seals / crankcase leaking Seal or replace oil seals /

crankcase

Air flap dirty – air flap does not Clean air flap, install new
close carburetor if necessary

Air flap stiff Check carburetor, replace if

necessary

Throttle cable stiff – throttle shutter Fit new throttle cable

does not close

Engine stalls at idle speed Idle jet bores or ports blocked Clean the carburetor

Idle jet too rich or too lean Set low speed screw L correctly

Setting of the idle speed screw Set idle speed screw LA correctly
incorrect – throttle shutter
completely closed

16 MS 441, MS 441 C
Condition Cause Remedy

Engine speed drops quickly Air filter dirty Clean air filter, replace if necessary
under load – low power

Throttle shutter does not open fully Check throttle cable and rod

Tank vent faulty Fit new tank vent

Fuel pick-up body dirty Install a new pick-up body

Fuel strainer dirty Clean fuel strainer in carburetor,

replace if necessary

Leak in fuel line from tank to fuel Seal connections, replace line if
pump necessary

Setting of high speed screw H too Check basic carburetor setting,

rich adjust if necessary

Main jet bores or ports blocked Clean carburetor

Pump diaphragm damaged or Fit a new pump diaphragm

fatigued

Impulse hose damaged or kinked Fit a new impulse hose

Engine runs extremely richly, no Air flap does not open Check carburetor; install a new
power and very low final speed carburetor if necessary

Engine too rich, loss of power and Air flap does not open fully at full Check carburetor; install a new
final speed too low throttle carburetor if necessary

Erratic idling, too lean Air flap does not close completely Check carburetor; install a new
carburetor if necessary

MS 441, MS 441 C 17
4.7 Engine

Always check and, if necessary,

repair the following parts before
looking for faults on the engine:

– Air filter,
– Fuel supply,
– Carburetor,
– Ignition system

Condition Cause Remedy

Engine does not start easily, stalls Oil seals in crankcase damaged Replace the oil seals
at idle speed, but operates normally
at full throttle

Crankcase leaking or damaged Seal or replace the crankcase

(cracks)

Engine does not deliver full power Piston rings worn or broken Fit new piston rings
or runs erratically

Muffler / spark arresting screen Clean the muffler (inlet and

carbonized exhaust), replace spark arresting
screen, replace muffler if necessary

Air filter dirty Replace air filter

Fuel line / impulse line severely Fit new hoses or position them
kinked or damaged without kinks

Decompression valve not closed Close decompression valve,

check and replace if necessary

Air flap does not open Check carburetor; install a new

carburetor if necessary

Engine overheating Insufficient cylinder cooling. Air Thoroughly clean all cooling air
inlets in fan housing blocked or openings and cooling fins
cooling fins on cylinder very dirty

18 MS 441, MS 441 C
5. Saw chain / chain guide 6. Clutch

– Troubleshooting chart, b 4.1.

1
– Remove chain sprocket cover,
bar and chain, b 5.

– Remove clutch drum, b 6.1.

3

219RA017 TG
138RA002 VA
2 1

Wear work gloves to protect your : Push locking strip (1)

hands from injury. 0000 893 5903 into the spark
plug hole so that "OBEN-TOP"
: Unscrew hex nuts (1). faces up.

: Remove chain sprocket

cover (2).

: Remove bar (3) and chain.

1 1
– Reassemble in the reverse
sequence.

219RA015 TG

219RA018 TG
– Remove carburetor box cover, : Unscrew clutch (1).
b 14.1.
The clutch has a left-hand thread.
: Pull boot (1) off spark plug.

1 1 2
219RA016 TG

219RA019 TG

: Unscrew spark plug (1). Disassembling the clutch

: Use hook (2) 5910 890 2800 to

remove the clutch springs (1).

MS 441, MS 441 C 19
 : Use hook (2) 5910 890 2800
1 1 2 to attach the other end of the
spring and press it firmly into the
clutch shoe.

219RA020 TG

219RA023 TG
– Pull clutch shoes off the carrier. : Fit clutch shoes (2) over the
arms (1).
: Pull retainers (1) off the clutch
shoes.

219RA024 TG

219RA026 TG
219RA021 TG

– Clean all parts. : Clamp the clutch in a vice : Check the clutch: all springs
(arrow). (arrows) must be attached
– Replace any damaged parts. completely.

TOP
1
1 1
219RA022 TG

219RA025 TG

219RA027 TG

: Slip retainers (1) onto the clutch Attach the springs to the side with
shoes. the raised hexagon (arrow).
: Attach one end of each spring (1)
to the clutch shoes.
– Washer (1) must be fitted.
It has been fitted correctly when
"TOP" (arrow) faces outwards.

20 MS 441, MS 441 C
 6.1 Clutch drum

TOP

1
1

219RA028 TG

219RA033 TG
219RA030 TG
: Position clutch on crankshaft stub – Remove chain sprocket cover, : Remove clutch drum (1).
so that the raised hexagon bar and chain, b 5.
(arrow) faces outwards.
: Pull hand guard (1) towards the
front handle.

1 2

1 1
219RA031 TG
219RA029 TG

: Screw clutch (1) onto the
crankshaft stub with the hexagon
(arrow) and tighten it down – left-
hand thread.
219RA034 TG
: Remove circlip (1). Machines with QuickStop Super
: Remove washer (2). Disengage the brake before
removing the clutch drum.

– Tightening torques, b 3.5. : Press and hold the trigger

interlock (1).
– Pull locking strip out of the
cylinder. – Remove clutch drum.

– Reassemble all other parts in the

reverse sequence.

1
219RA032 TG

: Remove rim sprocket (1).

MS 441, MS 441 C 21
 If there are signs of serious wear on
the inside diameter of the clutch
drum (1), check the remaining wall
thickness. If it is less than about
80 % of the original thickness, fit
1 a new clutch drum. 1

– Reassemble in the reverse

219RA038 TG
sequence.
219RA035 TG

: Remove needle cage (1). : Fit clutch drum (1).

Clean the needle cage and

crankshaft stub with a little
commercially available solvent-
based degreasant not containing
any chlorinated or halogenated
hydrocarbons.

1
1
219RA036 TG

219RA034 TG
– Grease needle cage and Machines with QuickStop Super
crankshaft stub, b 17.
Disengage the brake before fitting
: Push needle cage (1) onto the the clutch drum.
crankshaft stub.
: Press and hold the trigger
interlock (1).

– Fit clutch drum.

1
TOP
1

2
100%
148RA101 VA

219RA037 TG

80% !

– Examine clutch drum (1) for signs The notch (arrow) in the clutch drum
of wear. must engage the carrier (1) of the
wormwheel.

The mark (2) can be used for

guidance.

22 MS 441, MS 441 C
 7. Checking operation of 7.1 Brake band, removal and
chain brake installation

The chain brake is one of the most

important safety devices on the
chainsaw. Its efficiency is measured
in terms of the chain braking time,
i.e. the time that elapses between
1

a
activating the brake and the saw
chain coming to a complete
standstill.

219RA039 TG
The clutch drum is correctly seated
in the carrier of the wormwheel
when the crankshaft stub protrudes
approx. 5 mm (= distance a) from
the clutch drum.
219RA042 TG
Contamination (particularly with
chain oil, chips, fine particles of
abrasion, etc.) and smoothing of the
friction surfaces of the brake band – Troubleshooting chart, b 4.2.
and clutch drum impair the
coefficient of friction. This in turn – Remove chain sprocket cover,
extends the braking time. A fatigued bar and chain, b 5.
or stretched brake spring has the
same negative effect. : Take out screw (arrow).

: Remove side plate (1).

– Start the engine
1 2
– With the chain brake activated
(locked), open the throttle
wide for a brief period (max.
3 seconds) – the chain must not
rotate.
219RA040 TG

– With the chain brake released,

open the throttle wide and
activate the brake manually – the
chain must come to an abrupt
– Fit rim sprocket (1). stop.

: Fit washer (2) with the flange The braking time is OK if

facing towards the chain sprocket deceleration of the saw chain is
cover. imperceptible to the naked eye.

Machines with QuickStop Super

1
– With the chain brake released,
open the throttle wide and
release the trigger interlock in the
rear handle – the chain must
come to an abrupt stop.
219RA041 TG

The chain must come to a complete

219RA043 TG

stop within less than one second.

If the chain brake does not operate

: Insert circlip (1) in the groove of properly, refer to the : Take out screws (arrows).
the crankshaft stub. troubleshooting chart, b 4.2.

– Reassemble all other parts in the

reverse sequence.

MS 441, MS 441 C 23
 219RA044 TG

219RA049 TG
219RA046 TG
1 1

: Remove cover (1). : Take out screw (1). Install a new brake band if there
are noticeable signs of wear (large
: Ease brake band out of guide areas on the inside diameter and/or
(arrow). parts of the outside diameter)
and its remaining thickness is less
than 0.6 mm.

1
219RA047 TG
219RA045 TG

219RA514 TG
1 1

: Release the chain brake by
pushing the hand guard (1)
towards the front handle.
: Additionally press and hold the
trigger interlock (2) on machines
with QuickStop Super.
: Guide brake band (1) past guides
(arrows) and take it out.
The brake band must not be
overstretched.
: Attach brake band (1) to brake
lever (arrow) sideways and turn it
towards its mount.

The brake band is now relaxed.

– Remove clutch drum, b 6.1.

– Remove clutch, b 6. 1
1
219RA048 TG

219RA050 TG

: Turn brake band (1) slightly aside
and disconnect it from the brake
lever (arrow).
Machines with QuickStop Super
: Attach brake band (1) to brake
lever (arrow) sideways and turn it
towards its mount.

24 MS 441, MS 441 C
 7.2 Brake lever

219RA051 TG

219RA052 TG
219RA611 TG
1

: First place brake band in guide : Fit and tighten down screw (1). – Troubleshooting chart, b 4.2.
(arrow).
– Tightening torques, b 3.5. – Remove shroud, b 8.4.

– Reassemble all other parts in the – Remove brake band, b 7.1.

reverse sequence.
– Push hand guard towards saw
– Check correct operation. chain.

The brake spring is now relaxed.

: Ease brake spring (1) off pivot pin

(arrow).

– Disconnect brake spring from

brake lever.
219RA047 TG

: Then guide brake band (1) over

studs (arrows) and press it into
the mount.

1
2
219RA053 TG

219RA054 TG

: Press brake band (1) into guide : Take out screw (arrow).
(arrow) and at the same time
guide it over the studs (2).

MS 441, MS 441 C 25
 1

219RA058 TG

219RA060 TG
219RA055 TG

: Take out circlip (arrow).
– Examine pins and replace : Slightly lift up bearing eye of the
if necessary, b 7.5. hand guard and brake lever and
guide the parts over the pivot pins
– Examine cam lever and replace (arrows).
if necessary, b 7.4.

Clean the dismantled parts with

a little commercially available
solvent-based degreasant not
2 containing any chlorinated or
1 halogenated hydrocarbons.

– Position brake lever so that

mount for brake spring (arrow) is
at the top. 1
: Slide brake lever (1) into recess

219RA061 TG
219RA056 TG

in hand guard until the holes are

lined up.

: Draw hand guard (1) and brake : Turn cam lever (1) aside until the
lever (2) off the pivot pins cam of the hand guard (arrow)
(arrows) simultaneously. slides past.

– Take out hand guard and brake – Press bearing eye of hand guard
lever. and brake lever onto the pivot
pins.

1
219RA057 TG

219RA059 TG

: Pull brake lever (2) out of hand
guard (1).
– Examine brake lever and hand
guard; fit new parts if necessary.
: Slide hand guard with brake lever
across the machine until it rests
against the pivot pin.

26 MS 441, MS 441 C
 7.3 QuickStop Super
brake lever

1 1

219RA066 TG
219RA064 TG
219RA062 TG
1

: Fit circlip (1). : Hook brake spring (1) into brake The cover (1) on machines with
lever (arrow). QuickStop Super is marked with the
letter "Q" (arrow).

1 1

219RA065 TG

219RA067 TG
219RA063 TG

: The turns of the brake spring
must be tightly spaced when not
installed; use a new brake spring
if necessary.
Check correct position of protective
tube: it must be centred on the
spring.
a = 20 mm
The pin for the brake spring must be
replaced if it shows signs of wear at
the groove, b 7.5.
: Use assembly tool (2)
1117 890 0900 to attach brake
spring (1) to anchor pin (arrow).
– Reassemble all other parts in the
reverse sequence.
– Tightening torques, b 3.5.
– Grease brake lever, b 17.
– Troubleshooting chart, b 4.2.
– Remove shroud, b 8.4.
– Remove brake band, b 7.1.
– Push hand guard towards chain.
– The brake spring is now relaxed.
: Ease brake spring (1) off anchor
pin (arrow).
: Unhook brake spring (1) from
brake lever.

MS 441, MS 441 C 27
 Clean the dismantled parts with
1 a little commercially available
solvent-based degreasant not
1 containing any chlorinated or
halogenated hydrocarbons.

– Position brake lever so that

219RA068 TG
mount for brake spring (arrow) is
at the top.

219RA070 TG
: Slide brake lever (2) into recess
in hand guard (1) until the holes
: Ease brake spring (1) of brake : Detach brake cable (1). are lined up.
lever off the anchor pin (arrow).

: Unhook brake spring (1) from

brake lever.

219RA073 TG
219RA071 TG
219RA054 TG

: Take out screw (arrow). : Pull brake lever (1) out of hand
guard (2).
– Examine brake lever and hand
guard; fit new parts if necessary.
: Slide hand guard with brake lever
across the machine until it rests
against the pivot pins (arrows).

1 2 1
2
219RA069 TG

219RA072 TG

219RA074 TG

: Draw hand guard (1) and brake
lever (2) off the pivot pins
simultaneously.
– Take out hand guard and brake
lever.
– Examine pins and replace if : Attach brake cable (1) to hole
necessary, b 7.5. (arrow) in brake lever.
– Examine cam lever and replace if
necessary, b 7.4.

28 MS 441, MS 441 C

219RA075 TG
: Slightly lift up bearing eye of hand
guard and brake lever and guide
the parts over the pivot pins
(arrows).
219RA076 TG
: Turn cam lever (1) aside until
cam of hand guard (arrow) slides
past.
– Press bearing eye of the hand
guard and brake lever onto the
pivot pins.
MS 441, MS 441 C
2 1
219RA077 TG
: Attach brake spring (1) to brake
lever (arrow) and anchor pin (2).
219RA078 TG
: The turns of the brake spring
must be tightly spaced when not
installed; use a new brake spring
if necessary.
Check correct position of protective
tube: it must be centred on the
spring.
a = 20 mm
The pin for the brake spring must be
replaced if it shows signs of wear at
the groove, b 7.5.
219RA165 TG
: Hook brake spring (1) into brake
lever (arrow).
219RA079 TG
: Use assembly tool (2)
1117 890 0900 to attach brake
spring (1) to anchor pin (arrow).
– Adjust brake cable, b 7.3.1.
– Reassemble all other parts in the
reverse sequence.
– Tightening torques, b 3.5.
– Grease brake lever, b 17.
29
7.3.1 Adjusting brake cable

If the chain brake does not operate

properly although the brake band, 1
brake lever and brake cable are B
intact, it may be necessary to adjust
the brake cable.

– Troubleshooting chart, b 4.2.

219RA080 TG
– Remove chain sprocket cover,

219RA082 TG
bar and chain, b 5.
1

The brake cable (1) must be loose, – Release trigger interlock (1).
i.e. without tension, when the trigger
interlock is not pressed. : Press trigger interlock (1) gently
to check the play.

– The play must not exceed the

mark (B).

The play is equal to the distance

2 travelled by the trigger interlock (1)
without causing the brake lever to
move at the same time.
1
The play must be adjusted if it is too
great.
219RA042 TG

– Remove carburetor housing,

219RA045 TG

b 14.6.2.
1

: Take out screw (arrow). : Pull hand guard (1) towards

handle.
– Remove side plate (1).
: Press trigger interlock (2) down
completely and hold it.

1
219RA166 TG

219RA081 TG

219RA083 TG

: Take out screws (arrows). : The brake band (1) must rest : Undo clamping screw (arrow).
against the crankcase (arrows)
– Remove cover (1). without play.

30 MS 441, MS 441 C
 7.3.2 Brake cable, removal and
installation

219RA066 TG
219RA084 TG

219RA086 TG
1

: Use a size 6 fork wrench to
adjust the play via the adjusting
screw (1).
Turn the fork wrench
counterclockwise to reduce the
play.
Turn the fork wrench clockwise to
increase the play.
: Tighten clamping screw (arrow).
– Reassemble all other parts in the
reverse sequence.
– Remove chain sprocket cover, : Pull throttle cable out of guide
bar and chain, b 5. (arrow).
– Remove cover (1), b 7.1.
The cover (1) for machines with
QuickStop Super is marked with the
letter "Q" (arrow).
– Remove carburetor housing,
b 14.6.2.
– Remove throttle trigger, b 12.3.
1
– Remove switch lever, b 12.3.1.

– Tightening torques, b 3.5. – Unhook brake spring from

219RA087 TG
brake lever, b 7.3.

: Take out screw (arrow).

– Remove throttle cable retainer (1)

with brake cable and pull brake
cable out of crankcase.

3
219RA085 TG

219RA088 TG

1 2

: Pull brake cable (1) out slightly – Examine throttle cable (1),
and disconnect it. brake cable (2) and throttle cable
retainer (3) and replace any
damaged parts.

MS 441, MS 441 C 31
The new brake cable is supplied
with preassembled throttle cable
retainer.
The throttle cable retainer must be
removed from the brake cable if
only the retainer is to be replaced.
1 1
219RA089 TG
2 1
: Undo clamping screw (arrow)
and take out adjusting screw (1).
– Pull out brake cable (2) and
replace throttle cable retainer.
1 2
219RA090 TG
: Slide long hook (1) of brake cable
through hole (arrow) and turn
adjusting screw (2) down as far
as possible.
32
1
219RA091 TG
– Tighten clamping screw.
: Slide short hook (1) of brake
cable through hole (arrow).
219RA174 TG
: Pull brake cable (1) through
opening in housing and attach it
to hole (arrow) in brake lever.
1
219RA092 TG
: Push grommet of brake cable (1)
as far as possible into opening in
housing (arrow).
1
2
219RA093 TG
: Slide lug of throttle cable
retainer (1) into mount (arrow)
and press it into the mount (2).
– Fit and tighten the screw.
219RA094 TG
: Insert brake cable (1) in guide
(arrow).
– Install switch lever, b 12.3.1.
219RA095 TG
: Push end of throttle cable (1) with
round nipple through guide
(arrow) as far as possible.
– Install throttle trigger and handle
moulding, b 12.3.
MS 441, MS 441 C
 7.4 Cam lever

– Check correct operation and
adjust brake cable if necessary,
b 7.3.1.
The cam lever defines the engaged
position of the hand guard. The
hand guard cannot be engaged in
the position "Release or apply
2
brake" if the spring or cam on the
cam lever or hand guard is
defective.

– Remove brake lever, b 7.2.

219RA173 TG
QuickStop Super, b 7.3.
1

– Examine cam lever (1) and

spring (2) and fit new parts if
necessary.

– Check condition of cam guide

(arrow) and replace hand guard if
necessary.

2 1

1
1

219RA099 TG
219RA096 TG

219RA097 TG

: Guide fuel hose (1) under brake : Unhook spring (1) from anchor – Position cam lever (1) so that
cable (2) and push it onto pin (arrow). cam (arrow) points towards
connector (arrow). throttle trigger.

– Install carburetor housing, : Slide cam lever onto pivot pin (2).
b 14.6.2.

– Reassemble all other parts in the

reverse sequence.
1 1
– Tightening torques, b 3.5.
219RA098 TG

219RA168 TG

: Take out circlip (arrow). : Fit circlip (1).

– Remove cam lever (1) from pivot

pin.

MS 441, MS 441 C 33
 7.5 Pins

The pins ensure that the springs are
2 securely mounted. They must
therefore be replaced when worn,
otherwise the springs may pop out.
1
For reasons of simplicity, the parts
connected to the pins have already
219RA167 TG
been removed in the following
illustrations.
: The pin (1) must be inserted in
the hole (arrow) so that the
knurling on the pin engages the
knurled profile.
Turn the pin back and forth slightly
until it fits.

: Attach spring (1) to to cam lever

so that opening of hook (arrow)
faces towards housing.

The pin for the brake spring must be

replaced if it shows signs of wear at
the groove, b 7.5.

– Attach spring (1) to pin (2).

4
The cam lever is not yet tensioned,
the spring may become detached
again.

– Reassemble all other parts in the

reverse sequence.

219RA171 TG
219RA169 TG

– Tightening torques, b 3.5.

3 6
– Grease cam lever, b 17.
: Pull out pins (arrows) with the aid : Drive home pins (3+4+6).
of suitable tools.

1 1 2
219RA170 TG

219RA610 TG

– Wet the knurled area of the new : Drive in pins (1+2+5) as specified
pin (1) with Loctite before fitting below.
the pin, b 17.

34 MS 441, MS 441 C
 7.6 Chain tensioner

– Remove chain sprocket cover,

2 a bar and chain, b 5.
1 – Troubleshooting chart, b 4.2.
5
c

219RA172 TG

219RA176 TG
b
: Carefully drive the pins in with : Take out screw (arrow).
gentle taps until the following
values have been reached:
Pin (1) a approx. 4.3...4.7 mm
Pin (2) b approx. 3.0...3.4 mm
Pin (5) c approx. 3.0...3.4 mm

Pin (6) is only found in the machines

with QuickStop Super. 1

The pins must be driven in square.

1
– Reassemble all other parts in the
reverse sequence.
219RA042 TG

– Tightening torques, b 3.5.

219RA177 TG
– Grease brake and cam levers,
b 17.
: Take out screw (arrow). : Pull out complete spur gear (1)
with a suitable tool.
– Remove side plate (1).

2 1
219RA178 TG
219RA175 TG

: Turn spur gear (2) clockwise until : Pull out tensioner slide (1) with
the tensioner slide (1) rests a suitable tool.
against the right-hand side and
the screw (arrow) is visible.

MS 441, MS 441 C 35
 1
1
3 4 2
7 6
2 219RA179 TG
3

219RA182 TG

219RA185 TG
5

: Examine thrust piece (1), spur
gear (2), tensioning screw (3),
tensioner slide (4), cover
plate (5), support (6) and
O-ring (7) and replace any
damaged parts.
: Pull spur gear (1) out of the hole : Fit O-ring in the groove (arrow) of
in the support (2). the spur gear.
– Remove cover plate (3). – Clean the dismantled parts with
a little commercially available
solvent-based degreasant not
containing any chlorinated or
halogenated hydrocarbons.

2 Tensioning screw and spur gear

must always be replaced together.
2
– Grease screw threads, gear
1 wheels and O-ring with STIHL
multi-purpose grease, b 17.
1
– Reassemble in the reverse
219RA180 TG

219RA183 TG

sequence.
3

: Pull out thrust piece (1) and – Lay cover plate (1) on support,
remove tensioning screw (2) from with the bulge in the recess
tensioner slide (3). (arrow).

: Fit spur gear (2).

1 1
219RA181 TG

219RA184 TG

: Push complete tensioner slide : Slide spur gear (1) fully over the
with thrust piece (1) into the guide bearing journal (arrow) as far as
(arrow). the stop.

36 MS 441, MS 441 C
7.7 Bar mounting studs 8. Engine
8.1 Muffler / spark arresting
screen
Before looking for faults on the
engine, always check and, if
necessary, repair the fuel supply,
carburetor, air filter and ignition
system.

– Troubleshooting chart, b 4.

219RA186 TG

219RA187 TG
1

– Remove chain sprocket cover, : Coat the screw thread (arrow)

bar and chain, b 5.
– Remove side plate, b 7.6.
: Push stud puller (1)
5910 893 0501 over collar studs
as far as it will go and turn it
counterclockwise to remove the
collar studs (arrows).
of the collar studs with Loctite
before fitting them, b 17.
– Fit collar studs and tighten them
down securely.
– Tightening torques, b 3.5.
– Reassemble all other parts in the
reverse sequence.

219RA188 TG
: Prise out plugs (arrows).

1 2
219RA189 TG

: Unscrew nuts (arrows).

MS 441, MS 441 C 37
 1
1

219RA193 TG
219RA190 TG

: Take out screws (arrows).
– Remove and examine muffler (1),
replace if necessary.
: Pull out spark arresting
screen (1).
– Clean spark arresting screen (1)
and fit a new screen if necessary.
219RA195 TG
– Examine stud bolts (arrows) and
replace if necessary.
: Take out stud bolts (arrows).

2 1
1
219RA191 TG

219RA194 TG

: Remove heat shield (1) and : Examine insulating mat (1)
gasket (2). if fitted and use a new mat if
necessary.
219RA196 TG
– Coat screw thread (arrow) of stud
bolts with screw locking adhesive
before fitting the stud bolts,
b 17.

Spark arresting screen

a
219RA192 TG

219RA194 TG

219RA197 TG

: Take out screw (arrow). – Note the following dimensions – Move the machine into a vertical
when installing the insulating position.
mat (1):
a = 11 mm : Examine and clean the sealing
b = 9 mm faces (arrows), and remove any
gasket residues.

38 MS 441, MS 441 C
 8.2 Leakage testing

Defective oil seals and gaskets or

cracks in castings cause leaks.
Such faults allow supplementary air
to enter the engine and thus impair
1 the fuel-air mixture.

This makes adjustment of the

specified idle speed difficult or even

219RA277 TG
219RA198 TG
impossible.

It also prevents a smooth transition

: Fit heat shield (1) and line it up
with the recesses (arrows)
engaging the sealing face of the
cylinder.
– Fit screws (arrows) and check
that gasket is correctly
positioned.
: Tighten down screws (arrows).
1 2
from idle speed to part or full
throttle.
Always test under vacuum first and
then continue at gauge pressure.
The power unit can be thoroughly
checked for leaks under vacuum
and at gauge pressure with the
pump 0000 850 1300.

1
219RA189 TG
219RA199 TG

: Fit gasket (1) between the bumps
(arrows) so that it is held in place.
– To ensure that the muffler is
correctly secured and tight,
tighten down screw (1) with 5 Nm
and screw (2) with 10 Nm, then
tighten screw (1) further to
10 Nm.

: Screw on the nuts (arrows) and

tighten them securely.

– Press home plugs.

– Tightening torques, b 3.5.

1
219RA276 TG

– Carefully slide muffler (1) into

position.

: Slide the holes (arrows) into the

stud bolts to secure the muffler in
place.

MS 441, MS 441 C 39
8.2.1 Preparations

2 1 1

219RA279 TG

219RA281 TG

– Remove shroud, b 8.4.
– Set piston to top dead centre
(TDC) (can be seen through the
spark plug hole).
– Remove decompression valve,
b 8.9.
: Screw in plug (1) 1122 025 2200
and tighten it securely.
: Screw in spark plug (2) and
tighten it securely.
219RA283 TG
: Undo screws (arrows). : Pin (1) must be present on test
flange 1138 890 1200 – seal
: Slide sealing plate (1) impulse hose.
0000 855 8107 between cylinder
exhaust port and heat shield and
lightly retighten the screws.
The sealing plate must fill the space
between the screws completely.
– Remove carburetor, b 14.3. 1
2

– Tightening torques, b 3.5.

219RA284 TG
– Slide test flange
1138 890 1200 (1) into place.

– The pin must be inserted in the

impulse hose (2) when sliding the
test flange into place.

1 1 1 1
1

2
1
219RA280 TG

219RA285 TG
219RA282 TG

: Prise out plugs (1).
: Unscrew nuts (arrows).
: Ensure that the sleeves (1) and – Push 35 mm long sleeves (1)
washer (2) are present. onto the upper stud bolts.
: Screw on nuts (arrows) and
tighten them securely.

40 MS 441, MS 441 C
8.2.2 Vacuum test 8.2.3 Pressure 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 counterpressure.
Faults of this kind can be detected
with the aid of the pump
0000 850 1300.
The oil seals are in good condition if
the indicated vacuum is maintained 1
or if the pressure rises to no more
than 0.3 bar within 20 seconds.
The oil seals must be replaced if the
pressure in the crankcase continues
to rise, b 8.3.
– When the test is complete, push

219RA286 TG
the pump ring to the right to vent
the system.

– Test at gauge pressure, b 8.2.3. The preparations are the same as

for the vacuum test, b 8.2.2.

– Test under vacuum, b 8.2.2

before testing at gauge pressure.

: Slide pressure hose (1) of the

pump 0000 850 1300 over the
nipple (arrow).
1
219RA286 TG

: Connect suction hose (1) of

pump 0000 850 1300 to the
nipple (arrow).

2
219RA287 TG

: Slide ring (1) to the left.

: Actuate lever (2) until the

pressure gauge (arrow) indicates
a vacuum of 0.5 bar.

MS 441, MS 441 C 41
 8.3 Oil seals

It is not necessary to disassemble

the complete engine if only the oil
seals have to be replaced.

2 2
Ignition side

– Remove fan housing, 1

b 10.2.

219RA292 TG
219RA287 TG

1 – Remove flywheel, b 9.5.

: Push the ring (1) to the right.
: Actuate lever (2) until the
pressure gauge (arrow) indicates
an excess pressure of 0.5 bar.
The crankcase is airtight if this
pressure remains constant for at
least 20 seconds.
– If the pressure drops, the leak
must be located and the faulty
part replaced.
To locate the leak, coat the suspect
area with soapy water and
pressurize the crankcase again.
Bubbles will appear at the coated
Machines with handle heating – Thinly coat the outer
circumference of the oil seal with
– Remove generator, b 15.7. sealant, b 17.
– Slide oil seal over crankshaft stub
with the open side facing the
crankcase.
: Press oil seal (1) fully home with
press sleeve (2) 1122 893 2405.
1
The press surface must be plane
and free from burr.
– Turn the crankshaft through
several times after approx. one
minute.
219RA291 TG

area if a leak exists.

– When the test is complete, push
the pump ring to the left to vent
the system. Pull off the hose.
– Remove test flange.
– Install carburetor, b 14.3.
– Loosen muffler screws and pull
out the sealing plate.
– The cone on the crankshaft must
be free from grease, therefore
– Drive oil seal out of its seat with clean it with a little commercially
a light tap with a suitable tube or available solvent-based
punch. degreasant not containing any
chlorinated or halogenated
: Fit puller (1) 5910 890 4400 hydrocarbons.
with jaws 0000 893 3706
(profile No. 3.1). – Reassemble all other parts in the
reverse sequence.
– Tension legs.

– Retighten muffler screws. – Pull out oil seal.

– Reassemble all other parts in the The crankshaft stub must not be
reverse sequence. damaged.

– Tightening torques, b 3.5. – Clean the sealing area with a little

commercially available solvent-
based degreasant not containing
any chlorinated or halogenated
hydrocarbons.

– Grease the sealing lips of the

new oil seal, b 17.

42 MS 441, MS 441 C
Clutch side : Fit puller (1) 5910 890 4400
with jaws 0000 893 3706
– Remove chain sprocket cover, (profile No. 3.1).
bar and chain, b 5.
– Tension legs.
– Remove clutch, b 6. 1
– Pull out oil seal.
– Remove oil pump, b 13.3.
2

219RA296 TG
The crankshaft stub must not be
damaged.

– Clean the sealing area with a little

commercially available solvent- : Press oil seal (2) fully home with
based degreasant not containing press sleeve (1) 1118 893 2401.
any chlorinated or halogenated
hydrocarbons.

– Grease the sealing lips of the

new oil seal, b 17.

1
1
219RA293 TG

219RA295 TG

219RA297 TG
: Take out circlip (arrow). : Fit assembly sleeve (1) : Fit circlip (arrow).
1122 893 4600.
– Turn the crankshaft through
– Thinly coat the outer several times after approx. one
circumference of the oil seal with minute.
sealant, b 17.
– Reassemble all other parts in the
– Slide oil seal over assembly reverse sequence.
sleeve with the open side facing
the crankcase.

– Remove assembly sleeve (1).

219RA294 TG

– Drive oil seal out of its seat with

a light tap with a suitable tube or
punch.

MS 441, MS 441 C 43
8.4 Shroud, removal and
installation

1 2 3
1

219RA288 TG

219RA290 TG
219RA015 TG

1 2

– Remove carburetor box cover, : Pull off rubber grommet (3) and
b 14.1. remove slotted nut (1).
: Pull boot off spark plug (1). : Examine slotted nut (1),
insulating element (2) and rubber
grommet (3), replace if
necessary.
: Press rubber grommet (1) in until
the groove (arrow) engages the
rebate (2) in the housing.
– Use STIHL Press Fluid for easier
insertion, b 17.

1 1 2

2
219RA299 TG

219RA290 TG

219RA360 TG
1

: Unscrew slotted nut (arrow).
: Lift shroud (1) off decompression
valve (2).
– Slide slotted nut (1) with – Remove filter base, b 14.1.2.
insulating element into hole.
: Push out rubber grommet (1) and
: Fit rubber grommet (2) until it examine it, replace if necessary.
engages the groove in the slotted
screw.

1
219RA278 TG

219RA361 TG
219RA298 TG

: Pull off stop buffer (1) and : Ease out rubber grommet (1) and : Pull grommet (1) in until the lug
examine it, fit a new stop buffer if examine it, fit a new grommet if (arrow) has been pulled in
necessary. necessary. completely.

– Use STIHL Press Fluid for easier

insertion, b 17.

44 MS 441, MS 441 C
 8.5 Cylinder

Before removing the cylinder,

decide whether or not the
crankshaft has to be removed.

With cylinder installed

1 The crankshaft must be prevented 1
from twisting by blocking the piston
in order to remove the flywheel and

219RA100 TG

219RA100 TG
clutch.

With cylinder removed

: Remove grommet (1) and
examine it, replace if necessary.
– Reassemble in the reverse
sequence.
To remove the flywheel and clutch,
the crankshaft must be blocked by : Pull off grommet (1).
resting the piston on the wooden
assembly block.
– Remove shroud, b 8.4.

– Remove fan housing,

b 10.2.

– Remove spacer flange, 1

b 14.2.

1 – Remove carburetor, b 14.3.

– Remove intake elbow,

b 14.6.3.
219RA362 TG

219RA101 TG
– Remove muffler, b 8.1.

– Remove decompression valve,

: Press lugs (arrows) on shroud (1) b 8.9. : Pull impulse hose (1) off
into rubber grommets. connector (arrow).
– Pull boot off spark plug and
Ensure that the stud bolt contacts remove spark plug, b 6.
the slotted screw.
– Remove front handle, b 11.5
– Screw slotted nut on as far as Machines with handle heating,
possible. b 11.5.1.

– Reassemble all other parts in the

reverse sequence.
219RA102 TG

: Take out socket head screws

(arrows).

MS 441, MS 441 C 45
 The sealing face must be in The sealing faces must be in
faultless condition and undamaged. faultless condition and undamaged.
Parts with damaged sealing face Use a new cylinder if the sealing
must be replaced, b 8.6.3. faces are damaged.
1
Always fit a new cylinder gasket
whenever the cylinder has been
removed.
219RA103 TG

: Carefully pull off the cylinder (1).

Do not use pointed or sharp-edged

tools for this job.

1 1

219RA108 TG
219RA622 KN
219RA621 KN

: Remove the cylinder gasket (1). – Position the cylinder gasket (1) : Slide wooden assembly block (1)
so that the tab (arrow) faces 1108 893 4800 between piston
towards the muffler. and crankcase.

: Fit cylinder gasket (1).

1
219RA107 TG

219RA105 TG

219RA109 TG

– Examine and clean the sealing : Examine and clean the sealing – Wet piston, piston rings and
face (arrow). face (arrow) and remove any inside of cylinder with oil, b 17.
gasket residues.

– Examine sealing faces on

cylinder inlet and exhaust.

46 MS 441, MS 441 C
: Fit clamping strap (1) – Tighten down screws cross-wise.
0000 893 2600 round piston and
piston rings. – Tightening torques, b 3.5.

– Ensure that piston rings are

correctly positioned, b 8.8.

The clamping strap (1) must be

fitted in such a way that the piston

219RA111 TG
rings do not protrude beyond the
piston sides.

: Slide cylinder over piston; the

clamping strap is removed at the
same time.

219RA112 TG
219RA110 TG

219RA114 TG
2 1

: Position cylinder so that the inlet : Remove clamping strap (1) and : Push impulse hose (1) onto
(arrow) faces the rear handle. wooden assembly block (2). connector (arrow).

When fitting the cylinder over the Ensure that the cylinder gasket is – Reassemble all other parts in the
piston, ensure that the clamping correctly positioned. reverse sequence.
strap securely encloses the piston
and that none of the piston rings
protrudes, otherwise it may break.
219RA113 TG

– Push cylinder home as far as

possible.

: Fit screws (arrows) and secure

cylinder with gasket.

MS 441, MS 441 C 47
8.6 Crankshaft
8.6.1 Removal

– Remove chain sprocket cover, : Slide removing tool

bar and chain, b 5. 5910 890 2205 over the collar
screws, screw on nuts and
– Remove oil pump, b 13.3. tighten them down.

– Remove brake band, b 7.1. : Turn spindle (1) in clockwise until

the crankshaft stub has been
– Remove brake lever, b 7.2 forced out of the ball bearing.

219RA116 TG
QuickStop Super, b 7.3.
The crankcase half on the clutch
– Remove cylinder, b 8.5. side is removed in this way and the
two halves of the crankcase
– Remove piston, b 8.7. : Take out screws (arrows). separated.

– Remove tank housing, – Remove chain tensioner, b 7.6. – Replace ball bearings and oil
b 14.8.4. seals, b 8.3 and b 8.6.3.

– Remove flywheel, b 9.5.

– Machines with handle heating,

remove generator, b 15.7.
1
– Drain fuel tank and oil tank.

Fuel and oil must be disposed of in

accordance with environmental 6,5 mm
regulations.
90 90
Always fit new ball bearings and oil

219RA119 TG
219RA117 TG

seals when the crankshaft is

removed.

: The existing removing tool : Remove gasket (1).

5910 890 2205 must be
reworked as illustrated.

Clutch side Ignition side

3 20 20
2

20

20
1
219RA293 TG

219RA120 TG
219RA118 TG

: Remove circlip (arrow). – Unscrew spindle (1) until it no – Unscrew spindle of assembly
longer rests on the crankshaft tool (1) 5910 007 2220 until the
stub. flange rests against the housing
half – left-hand thread.

48 MS 441, MS 441 C
 8.6.2 Installation

: Position flange (2) of assembly Before installing the crankshaft,

tool 5910 893 2101 against it must be cleaned with a little
crankcase half on ignition side so commercially available solvent-
that the number 20 (arrow) is at based degreasant not containing
20
the bottom. any chlorinated or halogenated
20

hydrocarbons.
: Insert three screws M5x72 (3) 20

through the holes marked "20" 20

1 Ignition side

219RA122 TG
and tighten them down against
the crankcase half. The crankshaft stub must not be
damaged.

: Turn spindle (1) Examine and clean the sealing

counterclockwise until the
crankshaft has been forced out of
the housing half on the ignition
side.
faces of the crankcase half on the
ignition side (including the cylinder
sealing face). There must not be
any sign of damage on the sealing
faces.

21.3 34
1
20
20
33.1

38
12

20
39.3
49.9
3.2
0
12

20 2 219RA123 TG
219RA121 TG

219RA124 TG
94

2.3
10.4
39.3

Assembly tools without "20" holes : Crankshaft (1), con-rod (2) and
can be reworked as illustrated. the needle bearing between them
form a complete unit which must
The drilled plate is shown as seen always be replaced as such.
from above.
– Examine the two halves of the
Values are stated in millimetres. crankcase and ball bearings and
replace if necessary, b 8.6.3.
– Line the crankshaft up so that the
tapered stub (arrow) faces the
ball bearing on the ignition side.
Wear protective gloves to prevent
injury due to burns.
– Heat inner race of ball bearing to
approx. 150 °C (300 °F).

: Press crankshaft fully home on

the crankshaft stub.

The crankshaft must be fitted

quickly, as the heat is transferred to
the stub and the inner race
contracts again.

MS 441, MS 441 C 49
 1
2
176RA128 VA
If it is not possible to heat the inner
race, the crankshaft is drawn in with
assembly tool 5910 893 2101.
: Screw threaded sleeve (1)
5910 893 2420 as far as possible
onto the completely screwed-in
spindle of the assembly tool kit
(2) 5910 893 2101.
Coat the tapered crankshaft stub
with oil.
. twisting. Screw spindle (1) in
219RA124 TG
: Line the crankshaft up so that the
tapered stub (arrow) faces the
ball bearing on the ignition side
and push it home.
50
1
219RA125 TG
219RA127 TG
2 1
: Fit threaded sleeve (1) over : Fit new gasket (1) and secure it
thread (2) of the tapered stub and with the guide sleeves (arrows).
screw it on.
Clutch side
The crankshaft stub must not be
damaged.
Examine and clean the sealing
faces of the crankcase half on the
clutch side (including the cylinder
sealing face). There must not be
20 20
any sign of damage on the sealing
faces.
20
20
1
219RA126 TG
– Turn spindle (1) until the drilled
plate rests against the crankcase
half on the ignition side.
: Fit assembly tool with three
screws (arrows) M5x72 in the
holes marked "20" on the drilled
plate and secure it to prevent it
clockwise.
– Pull crankcase half on ignition
side in until it is fully home.
The crankshaft rotates when it is
drawn in with the assembly tool,
219RA128 TG
therefore ensure that the small end
always faces upwards towards the
cylinder.
– Remove assembly tool. : Fit two screws (arrows) M5x72 on
the ignition side in the holes with
guide sleeves – for guidance and
to prevent twisting.
MS 441, MS 441 C
 If it is not possible to heat the inner
race, the crankcase half is drawn in
with assembly tool 5910 890 2205.

– Coat cylindrical crankshaft stub

with oil.

– Line crankcase half up with the

219RA129 TG

219RA131 TG
cylindrical stub and the two
screws (arrows).

– Coat cylindrical crankshaft stub – Fit threaded sleeve on crankshaft

with oil. stub and push assembly tool over
collar screws.
– Line crankcase half up with the
cylindrical stub and the two : Hold crankshaft steady and
screws (arrows). screw threaded sleeve onto
thread of crankshaft stub by
Wear protective gloves to prevent turning the spindle
injury due to burns. counterclockwise.

– Heat inner race of ball bearing to – Release crankshaft, but hold

approx. 150 °C (300 °F). assembly tool steady instead and
continue turning the spindle until
: Press crankcase half fully home. the assembly tool rests against
the crankcase half.
The crankcase half must be fitted
176RA137 VA

quickly, as the heat is transferred to – Fit nuts for chain sprocket cover
the stub and the inner race on the collar screws and tighten
contracts again. 1 them down by hand.

– Turn spindle of assembly tool

5910 890 2205 fully into the
assembly tool (left-hand thread).

: Screw threaded sleeve (1)

5910 893 2409 on assembly tool
5910 890 2205 fully home on the
spindle (left-hand thread).
219RA130 TG

219RA132 TG

: Ensure that the sleeves (arrows) : Turn spindle counterclockwise

enter the holes and that the until the crankcase half rests
housing gasket is not jammed or against the guide sleeves.
buckled.

MS 441, MS 441 C 51

219RA130 TG
Ensure that the sleeves (arrows)
enter the holes and that the housing
gasket is not jammed or buckled.
– Unscrew nuts.
– Turn spindle clockwise to remove
assembly tool.
– Take out screws M5x72 which
were fitted to prevent twisting.
219RA116 TG
: Fit screws (arrows) and tighten
them down working cross-wise.
– Tightening torques, b 3.5.
52
8.6.3 Ball bearing / crankcase
If the two halves of the crankcase
are damaged, they can be replaced
separately.
New crankcase halves are supplied
with the relevant parts already fitted
– see spare parts list. Those parts
1 which are not supplied with the new
219RA297 TG
crankcase halves must be removed
from the old halves and examined
or replaced if necessary.
: Install circlip (1) in groove The serial number must be punched
(arrow). 2.5 mm deep into the number strip
of the crankcase with figure stamps
– Examine and install piston, before installing a new crankcase.
b 8.7.2.
If the original crankcase is reused,
– Examine and install cylinder, install new oil seals and ball
b 8.5. bearings, remove the gasket
residues and thoroughly clean the
– Reassemble all other parts in the sealing faces. The sealing faces
reverse sequence. must be absolutely clean to ensure
a perfect seal.
Examine both crankcase halves for
cracks and all sealing faces for any
signs of damage.
– Refer also to the troubleshooting
chart, b 4.7.
– Remove crankshaft, b 8.6.1.
– Wear protective gloves to prevent
injury due to burns.
MS 441, MS 441 C
 219RA134 TG

219RA137 TG

Crankcase half on ignition side
: Carefully drive out oil seal with
a suitable punch.
219RA140 TG
– Heat area around bearing seat to Crankcase half on clutch side
approx. 150 °C (300 °F).
: Carefully drive out oil seal with
– Position ball bearing so that the a suitable punch.
open side (balls visible) faces the
outside of the crankcase.

: Press ball bearing fully home.

The ball bearing must be fitted

quickly as it absorbs heat and
expands.
219RA135 TG

219RA141 TG
: Examine and clean crankcase : Examine and clean crankcase
half, replace if necessary. half, replace if necessary.

Replace the ball bearing if the Replace the ball bearing if the
crankcase half is OK. crankcase half is OK.

219RA142 TG
219RA136 TG

1 1

– Heat area around bearing seat to – Heat area around bearing seat to
approx. 150 °C (300 °F). approx. 150 °C (300 °F).

The bearing (1) drops out of its own The bearing (1) drops out of its own
accord when the required accord when the required
temperature is reached. temperature is reached.

MS 441, MS 441 C 53
 8.7 Piston
8.7.1 Removal

Since the crankcase half on the Before removing the cylinder,

clutch side does not have a fixed decide whether the crankshaft is to 2 1
bearing seat, the oil pump must be be removed, b 8.6.
installed. It then serves as
reference. – Remove cylinder, b 8.5.

– Install oil pump, b 13.3.

219RA149 TG
: Push piston pin (1) out of the
piston with assembly drift (2)
1111 893 4700.

If the piston pin is stuck, it can be

loosened by lightly tapping the
assembly drift with a hammer. The
piston must be steadied during this
process to ensure that jolts are not
transmitted to the con-rod.
219RA147 TG
219RA143 TG

– Heat area around bearing seat to : Prise hookless snap rings on

approx. 150 °C (300 °F). both sides out at the recess
(arrow) with a suitable tool.
– Position ball bearing so that the
centring ring (arrow) points
towards the oil pump.

: Press ball bearing fully home (oil

pump).

The ball bearing must be fitted

quickly as it absorbs heat and 1
expands.

– Remove oil pump, b 13.3.

219RA148 TG

219RA150 TG

– Install crankshaft, b 8.6.

– Install oil seals, b 8.3.

1

– Reassemble all other parts in the : Apply assembly drift (1)

reverse sequence. 1111 893 4700. : Remove piston (1) from con-rod.

– Tightening torques, b 3.5. – Examine piston rings, replace

if necessary, b 8.8.

54 MS 441, MS 441 C
8.7.2 Installation

1 2 1

219RA154 TG

219RA156 TG
219RA151 TG
1 2

: Pull out and clean needle bearing
(1), replace if necessary.
– Coat needle bearing with oil and
slide it into the small end.
– Coat piston pin with oil.
: Fit piston pin (2) on the stub of
assembly drift (1) and slide it into
the piston.
: Slide slotted end of sleeve over
the magnet and snap ring.
The internal pin must point towards
the flat surface on the shaft.

1
219RA153 TG

219RA155 TG

219RA157 TG
2 1

– Line up the piston so that the
arrow in the piston base points
towards the cylinder exhaust
port.
– Place piston on small end.
: Remove sleeve (1) : Press assembly tool down in the
5910 893 1706 from assembly sleeve until the magnet reaches
tool (2) 5910 890 2212. the end of the guide slits.
Push down onto a suitable surface.

: Push assembly drift (1)

1111 893 4700 mit dem Zapfen
voraus durch Kthrough piston
and small end (needle cage) with
the small diameter first and
secure the piston.
219RA158 TG
442RA406 TG

2 1

: Place snap ring (1) against
magnet (2) and align it so that the
gap in the ring is on the flat side
(arrow).
: Remove sleeve and fit it over the
opposite shaft end of the
assembly tool, with the internal
pin pointing towards the flat
surface.

MS 441, MS 441 C 55
 8.8 Piston rings

– Remove piston, b 8.7.1.

– Remove piston rings from piston.

219RA159 TG

219RA161 TG
: Apply assembly tool – Examine piston rings, replace if
5910 890 2212 to the piston boss necessary, b 8.8.
with the tapered end of the
sleeve, hold the piston steady – Install cylinder, b 8.5.
and press the tool shaft in until
the snap ring engages in the – Reassemble all other parts in the
groove. reverse sequence.

The tool must be precisely lined up – Tightening torques, b 3.5.

in axial direction of the piston pin.

This procedure must be performed

for both sides, as the piston has
a snap ring on each side.

219RA162 TG
: Scrape the grooves clean with
a piece of old piston ring.

1
219RA163 TG
219RA160 TG

The snap ring (1) must be fitted so : Fit the new piston rings so that
that the gap in the ring (arrow) the ground radii (arrows) at the
points upwards or downwards in ring gap face upwards.
axial direction of the piston.

56 MS 441, MS 441 C
 8.9 Decompression valve 9. Ignition system

Great care must be taken when

looking for faults and when carrying
out maintenance and repair work on
the ignition system. The high
voltages encountered can cause
serious or even fatal accidents.

Troubleshooting on the ignition

219RA164 TG
system should always start with the

219RA363 TG
spark plug, b 4.5.
1
– Remove fan housing,
: Install the piston rings so that the – Remove shroud, b 8.4. b 10.2.
ground radii at the ring gap meet
at the fixing pin in the piston : Unscrew decompression
groove (arrows). valve (1).

: Ensure that the piston rings are

positioned correctly (arrows).

– Install piston, b 8.7.

– Reassemble all other parts in the

reverse sequence.

376RA337 TG

219RA364 TG
2 1

: Examine sealing cone (arrow) on The electronic breakerless ignition

decompression valve for signs of system essentially comprises the
damage. ignition module (1) and flywheel (2).

The decompression valve must be

replaced if the sealing cone on the
decompression valve does not
close completely or is damaged.

– Fit decompression valve and

screw in by hand.

– Tighten down decompression

valve.

– Tightening torques, b 3.5.

– Reassemble all other parts in the

reverse sequence.

MS 441, MS 441 C 57
9.1 Ignition module 9.1.1 Removal and installation

– Remove fan housing,

b 10.2. 2
1
– Remove pre-separator, b 9.7.
1

219RA365 TG

219RA369 TG
2

The ignition module accommodates : Remove ignition lead (1) from

all the components required to rubber buffer (2) and cable guide
control the ignition timing. Only two (arrow).
electrical connections emerge from
the ignition module.

– High-voltage output (1) with

permanently connected ignition
lead.

– Connector tag (2) for short circuit

wire.
1
Testing of the ignition module only
encompasses a spark test. The
ignition module must be replaced if 1
219RA367 TG

an ignition spark is not obtained

219RA370 TG
(although wiring and stop switch are
intact).

The ignition timing is fixed and – Release clamps (arrows). : Disconnect short circuit wire (1).
cannot be adjusted.
: Remove carburetor box : Take out screws (arrows).
Since there is no mechanical wear cover (1).
in these systems, the ignition timing
cannot become maladjusted during
operation.

1
219RA015 TG

219RA371 TG

: Pull boot off spark plug (1). : Remove ignition module (1).

58 MS 441, MS 441 C

1 2
3 – Tighten screws.
219RA372 TG
: Slide grommet (1) away from
ignition module.
: Unscrew ignition module from
ignition lead (2).
– Examine ignition module (3),
replace if necessary.
– Examine spark plug boot and
ignition lead, replace if
necessary, b 9.4.
– Reassemble in the reverse
sequence.
– Troubleshooting chart, b 4.5.
219RA373 TG
: Before installing the ignition
module in machines with handle
heating, ensure that the
generator lead (arrows) has been
fitted correctly, b 15.7.
MS 441, MS 441 C
– Press ignition module against
1 setting gauge.
– Tightening torques, b 3.5.
– Pull out setting gauge.
219RA374 TG
: Fit ignition module (1) and insert
screws (arrows), but do not
tighten them down yet.
N
S 1
219RA375 TG
219RA377 TG
: Turn flywheel until the magnets : Connect short circuit wire (1) and
(arrows) are beside the ignition press it into the guide (arrow).
module.
– Fit wiring harness with short
circuit wire in machines with
handle heating,
b 15.8.2 and b 9.6.2.
1
N
S
219RA376 TG
: Slide setting gauge (1)
1111 890 6400 between arms of
ignition module and flywheel
magnet.
59
 9.2 Ignition timing 9.3 Testing the ignition
module

The ignition timing is fixed and
2 cannot be adjusted.
Since there is no mechanical wear
1 in these systems, the ignition timing
cannot become maladjusted during
operation.
219RA369 TG
To test the ignition module, use
either the ZAT 4 ignition system
tester 5910 850 4503 or the ZAT 3
ignition system tester
5910 850 4520.
The ignition test refers only to
a spark test, not to ignition timing.

: Press ignition lead (1) into rubber

buffer and cable guides (arrow).

– Press boot onto spark plug.

– Reassemble all other parts in the

reverse sequence.

212RA209 VA
1 2 3

Using the ZAT 4 ignition system

tester 5910 850 4503

– Before starting the test, install

a new spark plug in the cylinder
and tighten it down firmly.

– Tightening torques, b 3.5.

: Connect spark plug boot to input

terminal (1). Push the tester's
output terminal (3) onto the spark
plug.

Beware of electric shocks due to the

high voltage.

: Crank engine quickly with rewind

starter and check the spark in the
tester's window (2).

60 MS 441, MS 441 C

The engine may start and
accelerate during the test.
If a spark is visible, the ignition
system is in order.
If no spark is visible in the
window (2), check the ignition
system with the aid of the
troubleshooting chart, b 9.8.
1 rewind starter and check the
2 3
Using the ZAT 3 ignition system
tester 5910 850 4520
– Before starting the test, install
a new spark plug and tighten it
down firmly.
– Tightening torques, b 3.5.
: Connect spark plug boot to
terminal (2).
: Attach ground terminal (1) to the
spark plug.
: Use adjusting knob (4) to set
the spark gap to approx. 2 mm,
see window (3).
MS 441, MS 441 C
9.4 Spark plug boot / ignition
lead
1 2
5
1
376RA135 TG
219RA382 TG
2 34
While using the ZAT 3, hold it only – Remove ignition module,
by the handle (4) or position it in a b 9.1.1.
safe place. Keep fingers and other
parts of the body at least 1 cm away : Pull grommet (1) off high-voltage
from the spark window (3), high connection (arrow).
voltage connection (2), ground
connection (5) and ground – Unscrew ignition lead (2) from
terminal (1). contact pin and pull it out of the
high-voltage connection.
Beware of electric shocks due to the
high voltage. – Pull grommet (1) off ignition lead.
– Crank the engine quickly with the
spark in the tester's window (3).
376RA134 TG
The engine may start and
accelerate during the test.
4
If a spark is visible, the ignition
system is in order.
If no spark is visible in the
window (3), check the ignition
system with the aid of the
troubleshooting chart, b 9.8.
176RA158 VA
: Peel cover off spark plug boot.
61

212RA236 VA
: Use suitable pliers to pull leg
spring out of spark plug boot.
– Unhook leg spring from ignition
lead.
– Pull boot off ignition lead.
– Cut new ignition lead to the
specified length.
– Use a pointed tool to pierce the
centre of the new ignition lead's
insulation about 15 mm from the
end of the lead.
376RA136 TG
: Pinch the hook of the leg spring
into the centre of the lead (arrow).
62
376RA136 TG
– Coat the inside of the spark plug
boot with STIHL Press Fluid,
b 17.
: Hold ignition lead together with
leg spring and push them into the
spark plug boot.
176RA161 VA
: Make sure that the leg spring is
properly located in the spark plug
boot (arrow).
– Slide cover back over spark plug
boot.
176RA162 VA
: Pierce the end of the ignition lead
to be screwed into the ignition
module with a pointed tool.
– Slide grommet into place.
Do not use either graphite grease or
silicone insulating paste.
– Install ignition module and adjust
clearance between ignition
module and flywheel, b 9.1.
– Reassemble all other parts in the
reverse sequence.
MS 441, MS 441 C
9.5 Flywheel

219RA017 TG

219RA384 TG

219RA385 TG
2

– Remove fan housing, : Turn screws of puller (1)
b 10.2. 1135 890 4500 into the holes
(arrows) of the flywheel until the
– Block piston with locking strip (1), puller makes contact. Ensure that
b 6. the screws are turned in
uniformly.
: Turn screw (2) clockwise until the
flywheel is released from the
crankshaft stub.
– Unscrew puller (1)
1 1135 890 4500 from the flywheel.
219RA383 TG
Flywheel and magnet poles
(arrows) must not show any signs of
damage or discoloration, otherwise
the flywheel must be replaced.
The magnet ring must also be
examined for signs of damage in
machines with handle heating,
b 15.7.
Flywheel and crankshaft stub must
be free from grease for installation.
Degrease crankshaft stub and bore
in flywheel hub with a little
commercially available solvent-
based degreasant not containing

any chlorinated or halogenated

hydrocarbons.

: Unscrew collar nut (arrow). – Reassemble in the reverse

sequence.

MS 441, MS 441 C 63
 9.6 Short circuit wire 9.6.2 Removal and installation
9.6.1 Testing

– Remove fan housing,

b 10.2.

– Remove ignition lead from guide,

b 9.1.1.

– Remove filter base, b 14.1.2.

219RA387 TG
– Remove switch shaft, b 12.1.
219RA386 TG

1 – Remove carburetor support,

b 14.6.1.
: Make sure that the machined key If spark plug, ignition lead and spark
(arrow) engages the slot in the plug boot are in order, test the short
crankshaft. circuit wire.

– Adjust clearance between – Remove fan housing, b 10.2.

ignition module and flywheel,
b 9.1.1. : Disconnect short circuit wire (1).

– Reassemble all other parts in the – Connect ohmmeter to ground

reverse sequence. (arrow) and short circuit wire (1).

– Tightening torques, b 3.5. – Set switch shaft to "$". 1

The measured resistance must be

approx. 0 Ω. If the value is
significantly higher, a break has
occurred and the wire must be

219RA388 TG
replaced, b 9.6.2.

– Set switch shaft to "#".

: Disconnect short circuit wire (1)
The measured resistance must be and remove it from the cable
infinitely high, otherwise replace the guide (arrows).
short circuit wire, b 9.6.2.

Test ignition system in accordance

with flow chart if no fault is found,
b 9.8.

– Reassemble in the reverse

sequence. 1
219RA389 TG

: Ease out the grommet (1).

64 MS 441, MS 441 C
 2 1

219RA390 TG

219RA393 TG

219RA395 TG
1
N

: Pull short circuit wire (1) out of
the grommet (arrow).
The wiring harness (2) is
additionally drawn through the
grommet in machines with handle
heating, b 15.8.
: Carefully push retaining lug
(arrow) aside and pull out contact
spring (1).
: Push contact spring (1) fully
home in the guide.
Ensure that the contact spring is
secured by the retaining lug (arrow).

3 2 2 1

1 219RA394 TG
219RA391 TG

219RA396 TG
1

: Pull short circuit wire (1) out : Examine short circuit wire (1), : Slide the short circuit wire
through the recess (arrow). contact spring (2) and through the opening (2) and
grommet (3), replace if grommet (1), then connect it to
– Pull short circuit wire out of the necessary. the ignition module (arrow).
guides below the carburetor
support. The wiring harness must
additionally be pulled off the
generator lead in order to replace
the grommet in machines with
handle heating, b 15.8. 2
1
219RA397 TG
219RA392 TG

– Take short circuit wire out of the – Fit the short circuit wire in the
guides (arrows). guides, starting at the ignition
module.

: Press short circuit wire (1) in

guides (arrows).

MS 441, MS 441 C 65
 9.6.3 Ground wire

– Press grommet (2) in until it Functioning of the short circuit wire,

completely encloses the opening. as well as of the heaters in
machines with handle heating, may
be impaired or made impossible by 1
a faulty ground wire.

The ground wire must be removed

and tested for contact and
continuity.

219RA529 TG
– Remove filter base, b 14.1.2.

– Pull out switch shaft, : Fit ground wire (1) and support
b 12.1. eyelet at supporting rib (2).

– Remove carburetor support, : Fit screw (3) and tighten it down.

b 14.6.1.
– Reassemble all other parts in the
reverse sequence.

1
219RA398 TG

219RA399 TG

: Lay the short circuit wire (1) flat in : Disconnect ground wire (1) from
the guides (arrows). contact spring (arrow).

Press the short circuit wire home in

the guides with a narrow, blunt tool.

– Ensure that the short circuit wire Machines with handle heating
is correctly located in the guides
during the further assembly work.
2 1 3
– Reassemble in the reverse
sequence. 1
– Tightening torques, b 3.5.
219RA400 TG

219RA401 TG

: Take out screw (arrow). : Disconnect ground wire (1) from

contact spring (2) and terminal
– Remove and examine ground socket (3).
wire (1), replace if necessary.

66 MS 441, MS 441 C
 9.7 Pre-separator

: Push connector (3) onto the

terminal socket so that it is out of
line in counterclockwise direction
– the loop (arrow) must face the 1
1 housing wall.

219RA368 TG
219RA402 TG
2

: Take out screw (arrow). – Remove fan housing,

b 10.2.
– Remove and examine ground
wire (1) and cable guide (2), : Take out screws (arrows).
replace if necessary.
– Slide pre-separator (1) up slightly
and take it out.

1
219RA527 TG

219RA403 TG

: Fit ground wire (1) and cable : Wiring harness and short circuit
guide (2) and insert screw. wire must lie flat in the guides
(arrows).

– Reassemble all other parts in the

reverse sequence.

– Tightening torques, b 3.5.

2
3

1
1
2
219RA379 TG
219RA620 TG

– Support eyelet at supporting : Pull out duct base (1).

rib (1).
– Examine pre-separator (2) and
: Insert screw (2) and tighten it duct base (1) and replace if
down. necessary.

MS 441, MS 441 C 67
 1

219RA380 TG

: Push duct base (1) fully home in

the recesses (arrows).

1
219RA381 TG

: Hook pre-separator (1) into the

carburetor housing (arrows) and
fit it in position.

– Insert screws and tighten them

down.

– Reassemble all other parts in the

reverse sequence.

– Tightening torques, b 3.5.

68 MS 441, MS 441 C
9.8 Troubleshooting chart, ignition system

Engine does not run

Stop switch:
– In position "#"?

Check spark plug:

– Smeared with oil, black?
– Sooted?
– Electrode gap OK?
– Contacts shorted (threads)?
– Clean, adjust or replace
spark plug,
b 9.3

Check spark plug boot:

– Firmly seated on spark plug (leg spring)?
– Leg spring hook in centre of ignition lead?
– Spark plug boot damaged?
– Replace spark plug boot and/or leg spring if
necessary,
b 9.4

Test ignition system:

with ZAT 3 or ZAT 4
(use ZAT 3 as main spark gap,
see TI 32.94),
b 9.3

MS 441, MS 441 C 69
 1

Powerful yes
spark?

no

Air gap:
– Check ignition module / flywheel,
– Adjust if necessary, b 9.1.1

Check flywheel:
– Have pole shoes turned blue?
– Replace flywheel if necessary,
b 9.5

Check short circuit wire:

– Insulation of plug connection
– Connector seated securely
– Replace short circuit wire if necessary,
b 9.6.1

Check ignition lead:

– Lead severely chafed?
–Spark plug boot: holes / cracks?
– Resistance of spark plug boot to ground:
required 1,5...12 kohm
– Measure resistance of ignition lead,
required value < 10 ohm,
– Replace spark plug boot and/or ignition lead
with ignition module if necessary,
b 9.4

2 3

70 MS 441, MS 441 C
 2 3

Check operation
of switch shaft:
– Short circuit wire chafed?
– Contact spring in contact with switch
shaft in position "#"?
– Replace short circuit wire if necessary,
b 9.6.2

Powerful yes
spark?

no

Replace ignition
module,
b 9.1.1

yes Engine no
runs

Engine runs faultlessly, – Look for fault in fuel system

procedure is complete or carburetor
– Check engine for leaks
– Check position of flywheel
on crankshaft,
b 8.2, b 9.1

MS 441, MS 441 C 71
10. Rewind starter 10.2 Removal and installation
10.1 General

If the action of the starter rope – Reassemble all other parts in the
becomes very stiff and the rope 1 reverse sequence.
rewinds very slowly or not
completely, it can be assumed that
2
the starter mechanism is in order
but plugged with dirt. At very low
outside temperatures, the
lubricating oil on the rewind spring

219RA366 TG
may thicken and cause the spring
windings to stick together. This has
a detrimental effect on the function
of the starter mechanism.
: Take out screws (arrows).
To clean the rewind spring, it is
sufficient to apply a few drops of – Lift hand guard (1) slightly and
commercially available solvent- remove fan housing (2).
based degreasant not containing
any chlorinated or halogenated
hydrocarbons to the spring.

Carefully pull out the starter rope

several times and let it rewind until
its normal smooth action is restored.
1
Before installing, lubricate the
rewind spring and post with STIHL
special lubricant.
1
219RA404 TG

If clogged with dirt or pitch, the

219RA406 TG
entire starter mechanism, including
the rewind spring, must be removed
and disassembled. Take particular
care when removing the spring. : Prise out segment (1) at the lugs – Fit screws (arrows). The hand
(arrows) and remove the fan guard is additionally secured with
– Clean all components. housing. the longer screw (1).

– Examine fan housing and – Tighten screws.

segment, replace if necessary.
– Tightening torques, b 3.5.

1
219RA405 TG

: First slide segment (1) into the

slits (arrows) in the fan housing,
then press it home on the lugs.

72 MS 441, MS 441 C
10.3 Pawls 10.4 Rope rotor

1 2
1

219RA414 TG
219RA407 TG

219RA410 TG
– Remove fan housing, : Position spring (1) so that its Relieve tension of rewind spring
b 10.2. anchor loops engage the pegs of
the pawls and the curved part of – Remove fan housing,
: Carefully ease spring (1) off the the spring (arrow) is located in b 10.2.
rope rotor post. the groove of the rope rotor post.
: Pull out the starter rope (1) about
: Then slide the straight part of the 5 cm, holding the rope rotor (2)
spring over the rope rotor post steady at the same time.
until it engages in the groove.
– Take three full turns off the
– Reassemble all other parts in the installed rope rotor.
reverse sequence.
1 – Pull out the rope with the starter
grip and carefully release the
1 rope rotor.
219RA408 TG

– Remove the starter rope and any

remaining rope, b 10.5.

The system will not be under

: Pull out pawls (1). tension if either the starter rope or
the rewind spring is broken.

– Remove spring and pawls,

b 10.3.

1 1
1
219RA409 TG

219RA412 TG

– Press new pawls into holes – Take out washer (1).

(arrows) and grease the pegs (1),
b 17. The rewind spring must be relieved.

MS 441, MS 441 C 73
 10.5 Starter rope / grip

: Carefully pull off rope rotor (1) – – Remove fan housing and
the rewind spring could pop out. segment, b 10.2.

– Examine the rope rotor, replace if – Relieve tension of rewind spring, 1

necessary. b 10.4.

– Lubricate the hole of the rope The spring is not under tension if the
rotor with STIHL special starter rope is broken.

219RA417 TG
lubricant, b 17.
– Remove any remaining rope from
the rope rotor and starter grip.

The starter rope must not be : Pull rope or remaining rope (1)
shortened. out of the starter grip.

Do not shorten the starter rope.

1 1

219RA418 TG
219RA413 TG

219RA415 TG

: Fit rotor on starter post so that
inner spring loop (arrow) slips
into recess (1).
The recess on the rope rotor hub
serves as carrier for the spring loop.
: Push starter rope (1) out a short : Push new starter rope (1) into the
distance and undo the knot. top of the grip.
– Pull starter rope out of rope rotor – Pull starter rope through starter
and fan housing. grip completely.

– Fit washer.

– Install pawls and spring, 1

b 10.3.

– Install starter rope, b 10.5. 1

– Tension rewind spring, b 10.6.

376RA318 TG

219RA419 TG

– Grease pawl pegs, b 17.

: Prise off the nipple (1) with : Press nipple (1) firmly into starter
a suitable tool. grip until it engages.

74 MS 441, MS 441 C
 10.6 Tensioning the rewind
spring

1 1

219RA425 TG
219RA420 TG

219RA423 TG
1

: Then pull starter rope (1) through – Remove fan housing and – Hold the starter grip firmly to keep
the opening (arrow). segment, b 10.2. the rope tensioned.

: Pull out part of the starter : Let go of the rope rotor and
rope (1). slowly let the starter rope rewind
on the rope rotor.
: Turn rope (1) with rope rotor (2)
six times clockwise.
1 The rope is twisted as the rope and
rope rotor are turned. The rewind
spring is now tensioned.

Hold the tensioned rope rotor

securely as it may damage the
rewind spring if it pops back
abruptly.
219RA422 TG

219RA426 TG
– Thread starter rope (1) into rope The rewind spring is correctly
rotor. tensioned when the starter grip sits
firmly in the rope guide bushing
: Tie a simple knot in the end of the (arrow) without drooping to one
starter rope (1). side. If this is not the case, tension
the spring by one additional turn.
– Pull rope into rotor until the knot
rests in the recess (arrow) of the When the starter rope is fully
rope rotor. extended, it must still be possible to
2 turn the rope rotor at least another
– Reassemble all other parts in the half-turn before maximum spring
reverse sequence. tension is reached. If this is not the
case, the spring tension must be
– Tightening torques, b 3.5. relieved otherwise the spring will
1 break.
219RA424 TG

To relieve the spring tension:

Pull the rope out, hold the rope rotor
steady and take off one turn of the
rope.
– Hold rope rotor (2) securely.
– Install fan housing,
: Pull out the rope (1) with the b 10.2.
starter grip and straighten it out.
– Tightening torques, b 3.5.

MS 441, MS 441 C 75
10.7 Rewind spring
– Troubleshooting, b 4.4.
The replacement spring comes
ready for installation and is secured
in a frame.
Wear a face shield and protective
gloves.
– Remove fan housing and
segment, b 10.2.
– Relieve tension of rewind spring
if necessary and remove rope
rotor, b 10.4.
– Remove any remaining scraps of
the old spring.
– Lubricate rewind spring with
a few drops of STIHL special
lubricant before installing it,
b 17.
219RA427 TG
: Position the replacement spring
with frame so that the anchor
loop (arrow) is over the fixture (1).
76
If the rewind spring pops out, fit it in
the fan housing as follows:
219RA416 TG
: Apply suitable tools (screwdriver,
punch, etc.) at the recesses
(arrows) and push the spring into
its seat in the housing. The spring
slips out of its frame.
– Remove frame.
The rewind spring may pop out.
219RA429 TG
– Arrange spring (1) in its original
position as illustrated.
: Position the anchor loop in the
fixture (arrow).
1
219RA428 TG
219RA430 TG
Make sure that the new rewind : Fit rewind spring (1), working in
spring (1) is fully inserted and the circular fashion in clockwise
anchor loop is located in the fixture direction.
(arrow).
: Hold the fitted spring turns to
prevent them popping out.
MS 441, MS 441 C
 10.8 Starter rope guide
bushing

Wear on the guide bushing is

accelerated by the starter rope
being pulled sideways. The wall of 1
the bushing eventually wears
through and the bushing becomes
loose.

– Remove fan housing,

219RA431 TG

219RA433 TG
b 10.2.

– Relieve the tension of the rewind

– Make sure the rewind spring
cannot pop out.
: Use suitable pliers to align the
inner spring loop (arrow) so that it
rests against the rope rotor post
at a slight angle.
spring and remove starter rope,
b 10.4. : Insert screw spindle (1) of
assembly tool 0000 890 2201
through the starter rope guide
bushing from the inside (arrow)
outwards.

– Install rope rotor, b 10.4.

– Reassemble all other parts in the 2

1
reverse sequence. 1

219RA434 TG
219RA432 TG

– Use a suitable tool to remove the : Fit thrust sleeve (1) and screw on
defective guide bushing. hex nut (2).

: Insert new guide bushing (1) in : Tighten down hex nut, holding
the hole of the fan housing. screw (3) steady until the bushing
is tight.

The assembly tool flares the lower

end of the rope bushing.

– Remove assembly tool.

– Reassemble all other parts in the

reverse sequence.

MS 441, MS 441 C 77
11. Anti-vibration system,
repair
The front handle / tank housing and
engine housing are connected by
vibration-damping rubber buffers
and springs.
Damaged rubber buffers (annular
buffers) and springs must always be
replaced as a matter of principle.
78
11.1 Annular buffers
Defective annular buffers must be
replaced.
– Remove chain sprocket cover,
bar and chain, b 5.
– Remove anti-vibration spring on
oil tank, b 11.3.1.
219RA302 TG
– Remove front handle, b 11.5
Machines with handle heating,
1
b 11.5.1.
– Hold annular buffer (1) so that the
tapered side (arrow) faces the
tank housing.
: Insert annular buffer (1) between
tank housing and crankcase.
1 1
219RA300 TG
219RA303 TG
: Push annular buffer (1) off peg on – Use STIHL Press Fluid for easier
tank housing. insertion, b 17.
: Push peg (arrow) of tank housing
as far as possible into annular
buffer (1).
– Reassemble in the reverse
sequence.
– Tightening torques, b 3.5.
1
2
219RA301 TG
: Push tank housing (1) aside and
prise off annular buffer (2).
MS 441, MS 441 C
11.2 Anti-vibration spring, 11.3 Anti-vibration spring,
front handle fuel tank

– Remove fan filter,

b 14.1. 1

– Remove spacer flange,

b 14.2.

For reasons of simplicity, the

carburetor housing is not shown in

219RA304 TG

219RA307 TG
the following illustrations.
1

– Remove shroud, b 8.4. – Examine anti-vibration spring,

replace if necessary.
: Take out screws (arrows).
: Ensure that spring (1) is fully
– Remove and examine anti- screwed into the bearing plugs
vibration spring (1), replace if (arrows).
necessary.

– Reassemble in the reverse

sequence.

– Tightening torques, b 3.5.

219RA305 TG

219RA308 TG
– Remove anti-vibration spring on : Install anti-vibration spring so that
front handle, b 11.2. it engages the mounts (arrows).

: Take out screws (arrows). – Fit screws.

– Ensure that bearing points are

correctly seated during
installation.

– Tighten screws.

– Reassemble all other parts in the

reverse sequence.
1
– Tightening torques, b 3.5.
219RA306 TG

: Prise off anti-vibration spring (1).

MS 441, MS 441 C 79
11.3.1 Anti-vibration spring, 11.4 Stop buffers
oil tank

The stop buffers are located

between tank housing and
crankcase and are installed on the
ignition and clutch sides.

1 1 Stop buffer on clutch side

– Remove chain sprocket cover,

219RA309 TG

219RA309 TG
bar and chain, b 5.

– Remove chain catcher, b 6. – Press anti-vibration spring (1)

into bearing seat in tank housing.
: Take out screws (arrows).
: Fit screws (arrows) and tighten
– Prise off anti-vibration spring (1). them down.

– Tightening torques, b 3.5.

– Reassemble all other parts in the

reverse sequence.
219RA310 TG

219RA312 TG
1 1

– Examine anti-vibration spring, : Prise out stop buffer (1).

replace if necessary.
– Examine stop buffer and replace
: Ensure that spring (1) is fully if necessary.
screwed into the bearing plugs
(arrows).

3
2
1
1
219RA314 TG
219RA311 TG

: Position anti-vibration spring (1) – Position stop buffer (1) with

so that the form of the bearing the tapered side facing the
plug (2) engages the mount in the crankcase.
crankcase (arrow).

80 MS 441, MS 441 C
 11.5 Front handle

– Use STIHL Press Fluid for easier – Remove chain sprocket cover,
insertion, b 17. bar and chain, b 5.

: Press stop buffer (1) home until – Remove shroud, b 8.4.

the groove (arrow) completely
encloses the ridge (2) and the – Remove anti-vibration spring on
peg (3) of the tank housing front handle, b 11.2.
engages the hole in the stop

219RA317 TG
buffer.

Stop buffer on ignition side

1 2

– Remove ignition module, – Position stop buffer (1) with the

b 9.1.1. tapered side facing the
crankcase.

: Press stop buffer (1) home until

the peg (2) of the tank housing
engages the hole in the stop
buffer.

– Install ignition module, b 9.1.1.

Machines with handle heating

– Ensure accurate routing of the

generator lead, b 15.7.
219RA315 TG

219RA318 TG
– Reassemble all other parts in the
reverse sequence.
1
– Tightening torques, b 3.5.
: Prise out stop buffer (1). : Take out screws (arrows)
underneath machine.
– Examine stop buffer and replace
if necessary.

219RA319 TG

: Take out screws (arrows).

MS 441, MS 441 C 81
 1
2
1
1

219RA323 TG

219RA326 TG
219RA320 TG

: Lift front handle (1) slightly at the
side and remove it from the guide
(arrow).
: Pull handle inlays (1) out of front
handle (2).
– Examine handle inlays, front
handle and stop, replace if
necessary.
: First position front handle (1)
against the bottom handle mount
(arrow), then turn it towards the
rear handle.

– Slide handle inlays (1) back into

front handle.

1
1
219RA321 TG

219RA327 TG
: Slide front handle (1) out of lower : Lift front handle (1) slightly at the
guide and turn it towards the side and ease it into the guide
spiked bumper. (arrow).

– Remove front handle. – Ensure that the stop is correctly

positioned.

– Fit and tighten screws.

– Reassemble all other parts in the

reverse sequence.

Tightening torques, b 3.5.

1
1
219RA324 TG
219RA322 TG

: First lift stop (1) out of bottom : First push stop (1) into the upper
mount (arrow) and then pull it up ridge (arrow), then press it into
and off. the lower mount.

82 MS 441, MS 441 C
11.5.1 Front handle with handle
heating

As the front handle is heated in

these machines, the wiring must
also be disconnected for
installation. 1 1

– Troubleshooting, b 15.3.1.

Except for the electrical

219RA330 TG

219RA332 TG
connections, removal and
installation of the front handle is the
same as for the front handle without
heating, b 11.5.
: Pull out leads (arrows) between – Test handle heating,
– Unscrew carburetor housing and stop (1) and housing. b 15.3.1.
lift it up, b 14.6.2.
– Remove front handle, b 11.5.1. – Install front handle, b 11.5.1.

: Fit leads (arrows) between

stop (1) and housing.

1
219RA331 TG
219RA328 TG

: Pull plug connections (arrows) : Pull handle inlays (1) out of front
out of guides. handle (2).

– Pull wiring out of cable guides. – Examine handle inlays, front

handle and stop, replace if
necessary.

1 1
219RA329 TG

219RA333 TG

1 1

– Slide insulating tubes (1) towards – Securely reconnect plugs and

the front handle. terminal sockets (arrows).

: Disconnect plug connections : Slide insulating tubes (1) back

(arrows). over the plug connections.

MS 441, MS 441 C 83
 12. Actuating levers 12.1.1 Removal and installation
12.1 Switch shaft

1
2

219RA336 TG
219RA334 TG

219RA337 TG
3
1 4 1

The insulating tubes must
completely enclose the plug
connections – risk of short-
circuiting.
: Press plug connections (1) into
the guides (arrows).
The following operating states are – Remove filter base, b 14.1.2.
set with the switch shaft:
: Pull out switch shaft (1).
– Position (1) = Engine off,
ignition is switched off
– Position (2) = Operation,
engine is running or may start

The throttle trigger interlock and 1

throttle trigger must be pressed
simultaneously to adjust the switch
lever from # to k or l.

– Position (3) = Hot start, engine is

already warm when it is started.
219RA335 TG

: Press wiring (arrows) into the
cable guides.
– Reassemble all other parts in the
reverse sequence.
219RA338 TG
The switch shaft returns to the
operating position when the throttle
trigger is squeezed.
– Disconnect short circuit wire from
– Position (4) = Cold start, switch shaft (arrow), b 9.6.2.
engine is cold when it is started.
: Examine switch shaft (1) and
replace if necessary.

– Tightening torques, b 3.5.

1
219RA339 TG

– Install short circuit wire (arrow),

b 9.6.2.

: Align switch shaft: the stop (1)

must point towards the
carburetor.

84 MS 441, MS 441 C
 12.2 Throttle trigger / throttle
trigger interlock

219RA342 TG
219RA340 TG

219RA345 TG
2

– Lift contact spring (1). – Remove spacer flange, The drag lever is located in the
b 14.2. throttle trigger and must therefore
: Push switch shaft (2) into the also be removed.
bearing guides (arrows) until it : Push pegs (arrows) apart and
engages. through the tank housing. : Drive pins (arrows) out with
a punch.

1 1 2

219RA343 TG

219RA346 TG
219RA341 TG

– Contact spring (1) must engage : Remove handle moulding (1). : Lift and turn throttle trigger (1)
the guide of the switch shaft (2). with lever (2).
The trigger interlock (arrow) may
: Contact must be made between pop out.
short circuit wire and contact
spring (arrow) in switch position
"$".

– Install filter base, b 14.1.2.

1 1
– Install wiring to heating element
in machines with handle heating,
b 15.1.

– Check correct operation.

219RA347 TG

– Reassemble all other parts in the

219RA344 TG

reverse sequence.

– Tightening torques, b 3.5.

: Remove throttle trigger : Disconnect throttle cable (1).
interlock (1).
– Remove throttle trigger and lever.

MS 441, MS 441 C 85
 2
1 1
1

219RA348 TG

219RA351 TG

219RA354 TG
2

: Pull out the lever (1). : Push lever (1) into place. : Centre the throttle trigger (1) with
punch (2).
: Unhook leg spring (2) from – Turn throttle trigger with lever
throttle trigger. over. – Drive in the pin until it is
equidistant on both sides.

3 4 2 2 1

1
219RA352 TG

219RA355 TG
219RA349 TG

1 2

– Examine throttle trigger (1), : Push throttle cable (1) into hole : Centre lever (1) with punch (2).
lever (2), trigger interlock (3) and until the wire engages the guide
leg spring (4), replace if (arrow) of the lever (2). – Drive in the pin until it is
necessary. equidistant on both sides.

1
1
219RA353 TG
219RA350 TG

219RA356 TG

: Hook leg spring (1) into throttle Machines with handle heating : When installing the trigger
trigger (2), noting the installed interlock, ensure that the stop (1)
position (arrow). Ensure that the wiring is located in engages the guide (arrow).
the guides (arrows).

86 MS 441, MS 441 C
 12.3 Throttle trigger / throttle
trigger interlock /
QuickStop Super

1 1 2

219RA437 TG
219RA342 TG
219RA357 TG
2

: Hook trigger interlock (1) into leg – Remove spacer flange, : Lift and turn throttle trigger (1)
spring (2) and insert it in the b 14.2. with lever (2).
bearing guides (arrows).
: Push pegs (arrows) apart and
The trigger interlock may pop out. through the tank housing.

1 1 1

219RA438 TG
219RA358 TG

219RA435 TG

– Attach handle moulding (1) : Remove handle moulding (1). : Disconnect throttle cable (1).
(arrow).
– Remove throttle trigger and lever.
: Fit handle moulding (1) over the
trigger interlock and press the
pegs into the mounts (2) until
they engage.

– Check correct operation.

2
– Reassemble all other parts in the
reverse sequence.
1
– Tightening torques, b 3.5.
219RA439 TG
219RA436 TG

The drag lever is located in the : Pull out the lever (1).
throttle trigger and must therefore
also be removed. – Unhook leg spring (2) from
throttle trigger.
: Drive pins (arrows) out with
a punch.

MS 441, MS 441 C 87
 2 2 1 1
3

219RA352 TG

219RA445 TG
219RA440 TG

– Examine throttle trigger (1),
lever (2) and leg spring (3),
replace if necessary.
: Push throttle cable (1) into hole
(arrow) until the wire (2) engages
the guide of the lever (3).
: Centre the throttle trigger (1) with
punch (2).
– Drive in the pin until it is
equidistant on both sides.

1 1 1
219RA444 TG

219RA446 TG
219RA441 TG

2 2 2

: Hook leg spring (1) into throttle : Fit throttle trigger (1) with lever : Centre lever (1) with punch (2).
trigger (2), noting the installed (2) so that the leg spring is
position (arrow). located in the guide (arrow). – Drive in the pin until it is
equidistant on both sides.

– Check correct operation.

– Grease roller (arrow) before

installing it, b 17.

1
219RA442 TG

: Push lever (1) into place.

– Turn throttle trigger with lever

over.

88 MS 441, MS 441 C
 12.3.1 Switch lever

1 1

219RA450 TG
219RA447 TG

219RA443 TG
2
2

– Attach handle moulding (1) – Remove handle moulding, : Centre switch lever (1) with
(arrow). b 12.3. punch (2).

: Fit handle moulding (1) over the
trigger interlock and press the
pegs into the mounts (2) until
they engage.
– Check correct operation again.
– Reassemble all other parts in the
reverse sequence.
– Tightening torques, b 3.5.
: Drive out pin (arrow) with – Drive in the pin until it is
a punch. equidistant on both sides.
– Reassemble in the reverse
sequence.
– Tightening torques, b 3.5.
– Check correct operation.
1
219RA448 TG

: Disconnect brake cable (2).

: Take out switch lever (1).

– Examine switch lever (1), replace

if necessary.

1
219RA449 TG

: Hook brake cable (1) into hole

(arrow) in switch lever.

– Align switch lever.

MS 441, MS 441 C 89
12.3.2 Throttle trigger interlock

1
1

219RA456 TG
219RA454 TG
219RA451 TG

2
3

– Remove handle moulding, – Examine trigger interlock (1), – The leg (arrow) of the leg spring
b 12.3. leg spring (2) and bushing (3), must rest against the tank
replace if necessary. housing.
: Drive out pin (arrow) with
a punch. : Centre trigger interlock (1) with
punch (2).

– Drive in the pin until it is

equidistant on both sides.

– Reassemble in the reverse

sequence.

1 – Tightening torques, b 3.5.

1
– Check correct operation.
219RA455 TG
219RA452 TG

: Remove trigger interlock (1). : Align leg spring (1) and insert in
trigger interlock.

: Slide bushing (2) into hole

(arrow) to secure leg spring in
place.

1
219RA453 TG

: Drive out bushing (1).

– Remove leg spring.

90 MS 441, MS 441 C
13. Chain lubrication 13.2 Oil suction hose
13.1 Pick-up body

Impurities gradually clog the fine – Remove chain sprocket cover,

pores of the filter with minute 2 bar and chain, b 5.
particles of dirt. This prevents the oil
pump from supplying sufficient oil to – Remove clutch, b 6.
the bar and chain. In the event of
problems with the oil supply system, – Remove oil pump, b 13.3.
first check the oil tank and the pick-
up body. Clean the oil tank if – Unscrew oil tank cap and drain oil
necessary. tank.

– Troubleshooting chart, b 4.3.
– Unscrew oil tank cap and drain
oil tank.
Collect chain oil in a clean container
and dispose of it in accordance with
environmental regulations.
219RA458 TG
1 Collect chain oil in a clean container
and dispose of it in accordance with
– Hold suction hose (2). environmental regulations.
: Pull pick-up body (1) off suction
hose.

219RA459 TG

219RA460 TG
1

– Rinse oil tank.
– Fit a new pick-up body.
: Push pick-up body (1) into
suction hose (2) and return it to
the oil tank.
: Prise out oil suction hose (1) and
pull it out.
– Examine oil suction hose and
pick-up body, replace if
necessary. Installation of pick-up
body, b 13.1.

– Reassemble all other parts in the

1 reverse sequence. 1

2
219RA457 TG

219RA461 TG

: Pull pick-up body (1) out of oil : Slide oil suction hose (1) through
tank with assembly hook (2) opening in housing (arrow) with
5910 893 8800. the pick-up body first.

Take care not to overstretch the

suction hose.

MS 441, MS 441 C 91
 13.3 Oil pump

– Troubleshooting chart, b 4.3.

– Remove clutch, b 6.

1 – Remove side plate, b 7.1. 1

219RA464 TG
219RA462 TG

: Align oil suction hose (1) – the tab : Take out cover (1).
(arrow) must engage in the guide.

– Press oil suction hose in until the

groove engages the bevel on the
crankcase.

– Check position of pick-up body

with the aid of assembly hook
5910 893 8800 if necessary.

– Install oil pump, b 13.3. TOP

1
– Reassemble all other parts in the
reverse sequence.
1
219RA463 TG

– Tightening torques, b 3.5.

219RA465 TG
: Remove washer (1). : Pull worm (1) with spring (arrow)
out of oil pump.

2
219RA616 TG

219RA470 TG

: Push out detent between : Examine spring (1) and worm (2),
crankcase and tank housing replace if necessary.
(arrow).

92 MS 441, MS 441 C
 13.3.1 Repair

1 5 1

219RA466 TG

178RA118 VA
219RA469 TG
4 76 7 3 2

: Take out screws (arrows). : Slide cover (1) into recess Check suction hose and pick-up
(arrow) until it engages. body before dismantling the oil
– Remove and examine oil pump.
pump (1), repair or replace if
necessary. – Remove oil pump, b 13.3.

– Drive roll pin (1) out with a drift

dia. 2 mm.

– Pull out control bolt (2).

1 TOP – Remove O-rings (3).

– Prise out plug (4).

1
– Pull out pump piston (5) with
219RA027 TG

compression spring (6) and

219RA467 TG

washers (7).

– Check whether parts can be

: Fit new O-ring (1) and check – Push worm into oil pump.
connection (arrow) of oil suction
hose. – Grease worm before installing it,
b 17.
Always fit a new O-ring.
: Slide washer (1) into place so
that the word "TOP" (arrow) is
visible.
– Reassemble all other parts in the
reverse sequence.
– Tightening torques, b 3.5.
1 – Check setting of oil pump, adjust
if necessary, b 13.3.2.
219RA468 TG
reused and clean them, b 17.
Always use new O-rings.
– Grease pump piston and worm
before installing them, b 17.
– Press plug (4) in against the
spring pressure when fitting the
control bolt (2).
– Reassemble in the reverse
sequence.
– Check setting of oil pump, adjust
if necessary, b 13.3.2.

: Slide connector of oil pump (1)

into hole (arrow).

– Fit and tighten screws.

MS 441, MS 441 C 93
13.3.2 Adjustment
a – Remove chain sprocket cover,
219RA471 TG
The relevant settings are described
in the instruction manual.
In the case of oil pumps with
increased delivery rate, note that
the oil tank is empty before the fuel
tank and the saw chain may
therefore run dry when range "a" is
reached.
For setting range "a", the fuel tank
should therefore only be half-filled
or the oil tank refilled when the fuel
tank is half-empty.
1
219RA472 TG
The oil pump with increased
delivery rate can be identified via
the groove (1) or all-round groove
(arrow) in the pump piston.
94
13.4 Valve
A valve is installed in the tank wall to
keep internal tank pressure equal to
atmospheric pressure. The valve
must be replaced if faulty.
bar and chain, b 5.
– Unscrew oil tank cap and drain
219RA477 TG
oil tank.
Collect chain oil in a clean container
and dispose of it in accordance with Ensure that valve is correctly
environmental regulations. positioned.
: Insert valve in hole (arrow) of
engine housing.
219RA475 TG
219RA478 TG
: Carefully drive valve out of the : Carefully drive valve into hole in
housing from the outside, into the engine housing from the outside
tank, with a drift dia. 6 mm. with a drift dia. 6 mm, noting the
insertion depth.
219RA479 TG
219RA476 TG
: Remove old valve (1) from oil : Drive new valve into hole
tank. a = approx. 2 – 3 mm.
– Reassemble all other parts in the
reverse sequence.
MS 441, MS 441 C
13.5 Oil tank cap 14. Fuel system
14.1 Air filter

Dirty air filters reduce engine power,

increase fuel consumption and 1
make starting more difficult.

The air filter should be checked if

engine power declines noticeably.

– See troubleshooting chart,

b 4.6.

219RA481 TG

219RA484 TG
2

– Open oil tank cap. HD filter (black) for use in dry, very
dusty conditions.
: Prise out nipple inside tank
(arrow). : Pull pre-filter (1) off air filter (2).

– Examine pre-filter and air filter,

clean or replace if necessary.

– Clean pre-filter (1).

– Tap HD filter (2) clean or blow

through compressed air from the
1 inside outwards.

219RA367 TG
219RA482 TG

– Examine oil tank cap, rope and – Release clamps (arrows).

O-ring, replace if necessary.
: Remove carburetor box
: Press nipple into mount (arrow) cover (1).
inside tank.

– Close oil tank cap.

– Perform leakage test.

1
219RA473 TG

: Unscrew twist lock (1).

– Remove air filter.

MS 441, MS 441 C 95
 14.1.1 Baffle 14.1.2 Filter base

1
1

219RA485 TG

219RA486 TG

219RA488 TG
Standard filter (green) with wire – Remove air filter, b 14.1. – Remove baffle, b 14.1.1.
mesh for normal operating
conditions and use in winter. : Take out nuts (arrows). – Remove spacer flange,
b 14.2.
– Examine air filter, replace if – Remove baffle (1).
necessary. : Disconnect lead (1) on machines
with handle heating (arrows).
– Tap filter clean or blow through
compressed air from the inside
outwards.

– To remove stubborn dirt, wash

the filter in STIHL all-purpose
detergent or a clean, non-
flammable cleaning liquid (e.g.
lukewarm soapy water) and then
dry it.
219RA487 TG

Do not oil the filter.

– Reassemble in the reverse – Examine baffle, replace if

sequence. necessary.

– Reassemble in the reverse

sequence.

– Tightening torques, b 3.5.

– Test air filter, b 14.1.

1
219RA490 TG

: Take out nuts (arrows).

– Remove filter base (1).

96 MS 441, MS 441 C
 1 2
1 2
1

219RA493 TG
219RA491 TG

219RA494 TG
2 2

– Examine buffer (2) and filter
base (1), replace if necessary.
– Coat bushing (2) with STIHL
Press Fluid before installing the
filter base, b 17.
: Push filter base (1) fully home in
bushing (2) and mounts (arrows).
Machines with handle heating
: Attach lead (1) to mount (2) and
press it into the cable guides
(arrows).
The lead must not touch either the
carburetor levers or the spacer
flange.

– Reassemble in the reverse

sequence.

– Tightening torques, b 3.5.

219RA492 TG

: Slide filter base (1) onto stud

bolts (arrows).

1
219RA617 TG

: The groove (arrow) on the buffer

must engage the ridge (1) of the
carburetor housing.

– Fit nuts and screw them tight.

MS 441, MS 441 C 97
14.2 Spacer flange

– Examine clamps, replace if

necessary.

– Install clamps in reverse

1 sequence, taking care to ensure
1 that the tab engages.

219RA498 TG
219RA495 TG

– Remove air filter, b 14.1. : Press rubber buffer (1) into hole
(arrow) until it encloses the hole
: Take out screws (arrows). completely.

– Turn switch shaft to position "#"1 – Use STIHL Press Fluid for easier
and remove spacer flange (1). insertion, b 17.

1
219RA499 TG
219RA496 TG

– Examine spacer flange, replace if
necessary.
The new spacer flange is supplied
complete with rubber buffers and
clamps.
: Press tab (arrow) downwards.
– Turn clamps downwards.
219RA489 TG
Ensure that the clamps are open.
: Slide spacer flange (1) into
position over the switch shaft
(arrow).
– The bearing guides must engage
the buffers in the filter base.

– Insert screws and tighten them

down.
1
– Reassemble all other parts in the
reverse sequence.

– Tightening torques, b 3.5.

219RA500 TG
219RA497 TG

: Drive out rubber buffers (arrows) : Slide clamps (1) up and out of the
and examine them, replace if mount.
necessary.

98 MS 441, MS 441 C
14.3 Carburetor removal
and installation

– Remove air filter, b 14.1.

2 1
– Remove filter base, b 14.1.2.

– Open filler cap and drain fuel

tank.

– Collect fuel in a clean container

219RA205 TG
and dispose of it in accordance

with environmental regulations.
The carburetor may only be
removed when the tank filler cap is
open.
219RA202 TG
1 2
: Push fuel hose (1) and impulse – Hoses must be located in the
hose (2) back slightly to release mounts (arrows).
them.
– When reconnecting the hoses,
– Remove carburetor. ensure that connectors (1+2) are
pushed into the hoses.

1 1

1
219RA203 TG

219RA206 TG
219RA200 TG

: Set throttle trigger (arrow) to full
throttle and disconnect throttle
cable (1).
– Examine carburetor, replace if
necessary.
: Remove and examine
bushing (1), replace if necessary.
: Hook throttle cable into the
throttle cable retainer (1) so that
the nipple is squarely seated in
the mount (arrow).
– Reassemble all other parts in the
reverse sequence.

– Tightening torques, b 3.5.

2
– Check correct operation.

1
219RA204 TG
219RA201 TG

Machines with handle heating – Refit carburetor.

: Unplug connector (arrow) from : Lever (1) must engage lever (2)
terminal socket. in the carburetor.

MS 441, MS 441 C 99
14.3.1 Leakage testing 14.4 Carburetor repair
14.4.1 Air flap

In the case of problems with the

carburetor or fuel supply system, 2 3
also check and clean the tank vent,
b 14.7.

The carburetor can be tested for

leaks with the pump 2
0000 850 1300. 1

219RA208 TG

219RA209 TG
– Remove carburetor, b 14.3.
1

– Connect pressure hose of pump
0000 850 1300 to nipple.
: Slide ring (1) to the right and
pump air into the carburetor until
the pressure gauge (2) shows
a reading of approx. 0.8 bar
(80 kPa).
2 1 If this pressure remains constant,
the carburetor is airtight. If it drops,
this may be due to three causes:
1. Inlet needle valve is not sealing
(impurities in valve seat or
sealing cone of inlet needle is
143RA172 VA
The air flap must not be removed,
nor may any changes be made in
the control system.
– Troubleshooting chart, b 4.6.
The screws (arrows + 1, 2) are
bonded into place and must not be
loosened or removed.
Screws (1+2) and adjusting
screw (3) must not be adjusted,
otherwise the manufacturer's
setting will no longer be correct and
operation may be impaired.

damaged or inlet control lever

sticking). Remove to clean,
b 14.4.3.

: Push fuel line (1) 1110 141 8600 2. Metering diaphragm or gasket is
onto nipple (2) 0000 855 9200. damaged, replace if necessary,
b 14.4.2.

3. Pump diaphragm or gasket is

damaged, replace if necessary,
b 14.4.5. Check air flap

– After completing the test, slide

ring (1) to the left and vent the
system, then disconnect fuel line
from elbow connector of
carburetor.

– Install carburetor, b 14.3.

219RA207 TG

– Tightening torques, b 3.5.

219RA613 TG

– Reassemble all other parts in the

reverse sequence.
: Push fuel line with nipple onto : In idle position, the air flap
fuel connection (arrow). (arrow) must make contact with
the housing all round and seal the
air duct.

100 MS 441, MS 441 C

 14.4.2 Metering diaphragm

: Examine a soiled air flap and the

surrounding area, clean with 1 2
a little commercially available
solvent-based degreasant not
containing any chlorinated or
halogenated hydrocarbons if
necessary, taking care not to
damage the air flap.

219RA210 TG

219RA213 TG
Setting of throttle shutter
(throttle trigger position) / air flap

The correct setting of the air flap
can be visually checked as follows.
– Throttle shutter in idle position –
air flap fully closed.
– Throttle shutter in idle position to
full throttle – air flap closed to fully
open1).
– Remove carburetor, b 14.3.
: Take out screws (arrows).
: Carefully detach metering
diaphragm (1) from gasket (2).
The diaphragm material is
subjected to continuous alternating
stresses and eventually shows
signs of fatigue, i.e. the diaphragm
distorts and swells and has to be
replaced.

– Throttle shutter in full throttle – Examine metering diaphragm for

position – air flap fully open1). signs of damage and wear,
1 replace gasket.
– Throttle shutter during cold
start l – air flap fully closed

– Throttle shutter during warm

219RA211 TG

start k – air flap open approx.

10°
1)
Air flap must move in both Machines with handle heating
directions (open and closed) and
must always return to its starting : Remove switch (1).
position.

– Reassemble in the reverse

sequence.

1
219RA212 TG

: Remove cover (1).

If gasket and diaphragm stick to

carburetor parts, they must be
detached with great care.

MS 441, MS 441 C 101

 14.4.3 Inlet needle

2
1 1
3

219RA216 TG
219RA214 TG

219RA218 TG
– Note installation sequence for Machines with handle heating – Remove metering diaphragm,
metering diaphragm (2) and b 14.4.2.
gasket (1). : Fit switch (1).
: Take out screw (arrow).
: Position gasket (1) and metering
diaphragm (2) in the pegs
(arrows), ensuring that the tab (3)
faces towards the adjusting
screws.
2
219RA210 TG

219RA219 TG
1

: Insert screws (arrows) and
tighten them down.
– Check that diaphragm and
gasket are correctly seated, then
tighten screws cross-wise.
: Pull inlet control lever (1) with
spindle (2) out of the groove in
the inlet needle.
The spring under the inlet control
lever may pop out.

– Reassemble all other parts in the

reverse sequence.

1 1
2
219RA212 TG

219RA220 TG

: Position cover (1) so that the : Pull out inlet needle (1).
connector (arrow) faces towards
the choke shutter and is secured – Remove and examine spring (2),
by the pegs. replace if necessary.

102 MS 441, MS 441 C

 14.4.4 Fixed jet

The helical spring must locate on

the control lever's nipple. 1

– Press inlet control lever down

and secure it with the screw.

– Check that inlet control lever

moves freely.

219RA223 TG
212RA281 VA
– Install metering diaphragm,
b 14.4.2.

: The inlet needle must be – Remove metering diaphragm,

replaced if a circular indentation b 14.4.2.
(arrow) is visible on the needle's
sealing cone. : Unscrew fixed jet (1) with
a suitable screwdriver.

Take care not to damage the jet.

– Examine the fixed jet and replace

if necessary.

– Reassemble in the reverse

1 sequence.
2
219RA221 TG

: Fit inlet needle (1).

: Fit helical spring (2) in bore.

1 2
219RA222 TG

: First position inlet control

lever (3) with spindle (2) on the
seat (arrow) of the spring, then
push the clevis of the inlet control
lever into the groove in the inlet
needle (1).

MS 441, MS 441 C 103

14.4.5 Pump diaphragm

2 1 3

2
219RA224 TG

219RA274 TG

– Remove carburetor, b 14.3.
: Take out screw (arrow).
219RA228 TG
: Carefully separate pump : Fit gasket (1) so that tab (2) is
diaphragm (1) and gasket (2). opposite lug (3) and the gasket is
secured by the pegs (arrows).
The diaphragm material is
subjected to continuous alternating
stresses and eventually shows
signs of fatigue, i.e. the diaphragm
distorts and swells and has to be
replaced.

– Examine pump diaphragm for 2

signs of damage and wear, 1
replace gasket.

1 – Examine fuel strainer for

contamination and damage,
219RA225 TG

219RA229 TG
clean or replace if necessary.
3

: Carefully remove end cover (1). : Place diaphragm (1) on the

gasket so that tab (2) is opposite
lug (3) and the diaphragm is
secured by the pegs (arrows).

1
219RA226 TG

219RA227 TG

219RA230 TG

: Carefully remove gasket with : Pull fuel strainer (1) with needle : Fit end cover so that the lug
pump diaphragm from the end out of the carburetor housing and (arrow) points towards the
cover. clean it, replace if necessary. adjusting screws.

– Reassemble in the reverse

sequence.

104 MS 441, MS 441 C

 14.4.6 Choke shaft /
choke shutter

– Fit end cover on carburetor

housing from below so that the 1
gasket and pump diaphragm
remain secured in position on the
end cover.

219RA234 TG
219RA232 TG
– Remove carburetor, b 14.3. : Turn choke shaft slightly and take
out choke shutter (1).
The screws (arrows) must not be
removed. They have been set and
sealed by the manufacturer. The
choke or throttle shaft must be
removed to replace the
corresponding leg spring.

If the choke shaft moves stiffly or if 1

the choke shutter does not open or
close properly:

Remove choke shaft and clean the

1 shaft and shaft guides with a little
commercially available solvent-

219RA235 TG
based degreasant not containing
219RA231 TG

any chlorinated or halogenated

hydrocarbons.

– Move the end cover (1) slightly : Take out screw (arrow).
until the pegs in the end cover
engage the holes in the – Remove lever (1).
carburetor housing.

– Check that diaphragm and

gasket are correctly seated.

: Fit and tighten screw.

1
-74
62

219RA234 TG
219RA233 TG

– Turn choke shaft until choke : Push choke shaft (1) towards
shutter is closed. connector.

: Take out screw (arrow) in choke – Remove lock washer (arrow).

shutter.

MS 441, MS 441 C 105

 1 2
219RA237 TG
– Pull choke shaft (1) out towards
adjusting screws.
– Examine choke shaft (1) and leg
spring (2), replace if necessary.
: Note installed position (arrow)
when fitting the leg spring.
– Clean choke shaft and guides.
– Reassemble in the reverse
sequence.
1 1
219RA238 TG
: Attach leg spring (1) to hole
(arrow).
: Slide choke shaft (2) through the
leg spring into the carburetor.
106
3 1
2
-7 4
62
219RA242 TG
219RA239 TG
– Push choke shaft towards lever. The choke shutter (3) must be
installed so that the hole (1) is
: Install lock washer (arrow) and above the choke shaft and the
release choke shaft. number (2) is below it.
– Coat screw with screw locking
adhesive, b 17.
: Fit new screw in shaft and tighten
it down lightly.
– Close choke shutter (3) and
1 centre it in the hole of the
carburetor housing so that
a small air gap remains – open
throttle shutter to check.
219RA240 TG
– Tighten screw securely.
– Turn leg spring roughly half a turn
: Fit lever (1) on choke shaft so clockwise and attach it to the
that the legend "TOP" is visible lever (arrow).
and engages properly (arrow).
– Check correct operation and
– Fit and tighten screw. easy movement.
– Reassemble all other parts in the
reverse sequence.
-74
62
219RA241 TG
– Turn choke shaft until flat side
appears.
: Fit choke shutter (1).
MS 441, MS 441 C
14.4.7 Throttle shaft /
throttle shutter

If the throttle shaft moves stiffly or

the throttle shutter does not open or 2 1 2
close properly:

– Remove carburetor, b 14.3.

– Carburetor troubleshooting chart,

b 4.6.

219RA248 TG
219RA245 TG
– Remove throttle shaft and clean
the shaft and shaft guides with 1
a little commercially available
solvent-based degreasant not : Take out screw (arrow). – Examine throttle shaft (1) and leg
containing any chlorinated or spring (2), replace if necessary.
halogenated hydrocarbons. – Disconnect lever (1) and throttle
cable retainer (2). – Note installed position (arrow) of
leg spring.

1
2
219RA243 TG

219RA249 TG
219RA246 TG

: Take out screw (arrow). : Remove lock washer (arrow). – Turn leg spring (1) roughly half
a turn clockwise to tension it.

– Drive ball of accelerator pump

into bore in carburetor with
a suitable tool, b 14.4.8.

: Slide throttle shaft (2) with

tensioned leg spring into
1 carburetor housing from the side
with the adjusting screws.

1
219RA244 TG

219RA247 TG

– Turn throttle shaft slightly. : Pull throttle shaft (1) out towards
adjusting screws, detaching and
: Pull out throttle shutter (1). relaxing the leg spring (arrow) at
the same time.

– Clean throttle shaft and guides.

MS 441, MS 441 C 107

 1

219RA275 TG
219RA250 TG

219RA253 TG
2

: Position tensioned leg spring on
shoulder (arrow) of carburetor
housing.
– Position lever (1) so that the word : Insert and tighten screw (arrow).
"TOP" is at the front.
– Turn throttle shaft to full throttle
: Lever (1) must be fitted behind position.
lever (2); then push it into the
groove (arrow) of the throttle
cable retainer and onto the
mating lug of the throttle shaft.

2 1

219RA254 TG
219RA251 TG

: Install circlip (1). : Slide throttle shutter (1) into the

slit in the throttle shaft with the
recess (arrow) at the front and
the hole (2) on the left.

1
219RA252 TG

: Slide throttle cable retainer (1)

onto the throttle shaft with the
shoulder (arrow) first.

108 MS 441, MS 441 C

 14.4.8 Accelerator pump 14.4.9 Adjusting screws

H 2
1
2 3

219RA255 TG

219RA256 TG

219RA259 TG
– Coat screw with screw locking : Prise out sealing plug (arrow). There are three adjusting screws on
adhesive, b 17. the carburetor
– Remove throttle shaft, H = High speed screw (1)
: Fit new screw (1) in flat side of b 14.4.7. L = Low speed screw (2)
shaft and tighten it lightly. LA = Idle speed screw (3)

– Close throttle shutter (2) and If the carburetor can no longer be

centre it in the hole of the adjusted, this may also be due to
carburetor housing so that the adjusting screws.
a small air gap remains. 1 2 3
The high speed screw H and low
The recess (arrow) in the throttle speed screw L have limiter caps
shutter must line up with the small which must be removed before
hole in the carburetor housing. removing the adjusting screws.

– Tighten screw securely. Always use new limiter caps.

219RA257 TG

– Check correct operation and – Remove carburetor, b 14.3.

easy movement.
– See also carburetor
– Reassemble all other parts in the – Put on protective goggles and troubleshooting chart, b 4.6.
reverse sequence. cover the hole in the accelerator
pump with your fingers to prevent
the parts popping out.

: Examine ball (1), pump piston (2)

and spring (3), replace pump
piston set if necessary.

– Press a new sealing plug in until 1

flush with the hollow facing
outwards.

– Reassemble all other parts in the

reverse sequence.
219RA260 TG

Low speed screw

: Screw puller (1) 5910 890 4500

onto limiter cap – left-hand
thread.

MS 441, MS 441 C 109


H L
2
219RA261 TG
1 1
: Turn limiter cap until lug (2) is
lined up with groove (1).
The dot on the limiter cap must be
lined up with the mark (arrow).
1 1
219RA262 TG
: Pull off limiter cap (1).
– Unscrew low speed screw L.
219RA263 TG
: Examine tip (arrow) for signs of
damage or wear, replace low
speed screw L if necessary.
110
– Turn in low speed screw L until it
is fully in its seat.
– Continue with high speed screw.
219RA267 TG
: Pull off limiter cap (1).
– Unscrew high speed screw H.
219RA265 TG
219RA268 TG
High speed screw : Examine tip (arrow) for signs of
damage or wear, replace high
: Screw puller (1) 5910 890 4500 speed screw H if necessary.
onto limiter cap – left-hand
thread. – Turn in high speed screw H until
it is fully in its seat.
– Continue with Fitting the limiter
caps.
H L
2
219RA266 TG
: Turn limiter cap until lug (2) is
lined up with groove (1).
The dot on the limiter cap must be
lined up with the mark (arrow).
MS 441, MS 441 C

1 The basic setting must always be
219RA269 TG
Fitting the limiter caps
: Press new limiter caps (1) onto
the hole in the adjusting screw
until they engage the first position
(arrow) – do not push them down
fully.
If screwdriver 5910 890 2304 is not
available, the basic setting must be
made without fitting the limiter caps.
– Reassemble in the reverse
sequence.
– Make basic setting, b 14.5.1.
MS 441, MS 441 C
14.5 Carburetor adjustment
14.5.1 Basic setting
Only required if it is necessary to
replace the high speed screw H or
low speed screw L and for cleaning
or making basic settings on the
carburetor.
made after removing the limiter
caps.
The carburetor and air filter are
installed, the adjusting screws
preset and the new limiter caps
have been fitted.
– Check chain tension, adjust if
necessary.
– Examine spark arresting screen
(if installed), clean or replace if
necessary, b 8.1.
– Examine air filter, clean or
replace if necessary, b 14.1.
– Check air flap, clean if necessary,
b 14.4.1.
– With the low speed and high
speed screws in their seats, turn
them one turn counterclockwise.
– Let engine warm up.
Setting washer 5910 893 6600 can
be fitted on screwdriver
5910 890 2304 to assist in making
the setting.
1
2
0
4
14
6
12
10
8
219RA270 TG
: Position screwdriver (1)
5910 890 2304 through the
grommet (arrow) and fitted limiter
caps on the adjusting screws.
Set idle speed with speed tester.
Set the specified speed with
a tolerance of ± 200 rpm.
1. Adjust engine speed with idle
speed screw LA to 3,300 rpm.
2. Turn low speed screw L
clockwise or counterclockwise to
obtain maximum engine speed.
If this speed is higher than
3,700 rpm, abort the procedure and
start again with step 1.
3. Use idle speed screw LA to set
engine speed to 3,300 rpm
again.
4. Set engine speed to 2,800 rpm
with the low speed screw L.
5. Set maximum engine speed of
13,500 rpm with high speed
screw H.
111
 14.5.2 Standard setting

Set idle speed

– Let engine warm up.

– Open low speed screw L 1/4 turn.

– Turn idle speed screw LA

clockwise up to the stop or until
219RA272 TG

219RA273 TG
chain starts to rotate, then back
off 1 1/2 turns.

Erratic idling behaviour, poor

: Insert a suitable punch through
the holes (arrow) and press the
limiter caps fully home.
The basic setting of the high speed
screw H and low speed screw L is
now secured.
The limiter caps must not be
removed when making the standard
setting.
The following steps must be taken
for all settings in order to avoid
complications:
– Troubleshooting, b 4.6.
– Check chain tension, adjust if
necessary.
– Examine spark arresting screen
(if installed), clean or replace if
necessary, b 8.1.
acceleration
(despite standard setting)
Idle setting too lean.
– Let engine warm up.
– Turn low speed screw L
counterclockwise until engine
runs and accelerates smoothly,
but no further than the stop.
It is usually necessary to change the
setting of the idle speed screw LA
whenever the setting of the low
speed screw L is corrected.

– Examine air filter, clean or

replace if necessary, b 14.1.

– Check air flap, clean if necessary,

b 14.4.1.

Standard setting

– Switch off engine.

– Carefully turn high speed screw

H counterclockwise up to the
stop, max. 3/4 turn.

– Carefully turn low speed screw L

clockwise up to the stop, then
back off 1/4 turn.

112 MS 441, MS 441 C

 14.6 Throttle cable

Correcting the carburetor setting

for operation at high altitude 2 2

A minor correction may be

necessary if engine performance is
not satisfactory.

– Check standard setting.

– Let engine warm up.
– Turn high speed screw H
clockwise (leaner), but no further
than the stop.
If the setting is made too lean, the
engine may be damaged due to
insufficient lubrication and
overheating.
219RA133 TG
219RA501 TG
1
1
– Remove carburetor, b 14.3. : Slide throttle cable (1) through
grommet (2) with the double-
– Remove anti-vibration spring on nipple (arrow) first.
fuel tank, b 11.3.
: Disconnect throttle cable (1) from
lever (2).

If these adjustments do not yield

any improvement, refer also to the 1
troubleshooting chart for ignition
system, carburetor and engine,
b 4.5, b 4.6 and b 4.7.

219RA378 TG
219RA502 TG

2 1

: Pull throttle cable (1) out of guide – Examine throttle cable retainer,
(arrow). replace if necessary, b 7.3.2.

: Connect throttle cable (1) to

lever (2) and guide wire through
slot (arrow).

1
2
219RA503 TG
219RA115 TG

: Pull throttle cable (1) out of : Push throttle cable grommet (1)
carburetor housing. into guide (arrow) of throttle cable
retainer (2).
– Examine throttle cable and
replace if necessary.

MS 441, MS 441 C 113

 14.6.1 Carburetor support

1 1

1 2
2
1
3

219RA399 TG
219RA217 TG

: Fit throttle cable (1) between
impulse hose (2) and fuel hose
(3), then hook it into carburetor
support (arrow).
219RA282 TG
– Remove carburetor, b 14.3. – Remove carburetor support.
– Remove switch shaft, b 12.1. : Disconnect ground wire (1) from
contact spring (arrow).
: Take out sleeves (1) and remove
washer (2).

1
1
2

3
219RA509 TG
219RA504 TG

219RA511 TG
2

Machines with handle heating : Pull out throttle cable (1), impulse : Remove air guide inlet (1) and
hose (2) and fuel hose (3). air guide outlet (2).
If the throttle cable retainer is
replaced, ensure that the wiring is
routed correctly (arrows).

– Reassemble all other parts in the

reverse sequence.

– Tightening torques, b 3.5. 1

1
219RA510 TG

219RA512 TG

: Press rubber lips (arrows) of : Pull off preheating plate (1).

intake elbow out through the
openings in the carburetor – Remove contact spring b 9.6.2.
support (1) towards the cylinder.

114 MS 441, MS 441 C

 1

219RA516 TG
219RA513 TG

219RA614 TG
1

: Remove washers (arrows) and
pull out felt (1).
– Examine carburetor support and
all attached parts, replace if
necessary.
: Fit air guide outlet (1) until it : Tie a piece of string round each
engages the heel (arrow). Peg (2) flange (arrows), forming a loop
must engage the notch. with a simple knot and gently
pulling it tight.

1
219RA507 TG

219RA517 TG
219RA515 TG

– Slide washers onto stud bolts.
: Slide preheating plate (1) onto
stud bolts so that it engages the
air duct (arrow).
– Install contact spring b 9.6.2.
: Slide felt (1) into mount.
– Examine impulse hose, replace
if necessary, b 14.6.4.
– Examine fuel hose, replace if
necessary, b 14.8.2.
: Guide the ends of the string
through the openings (arrows) in
the carburetor support (1).
– Fit carburetor support against
intake elbow and slip ground wire
connector onto contact spring.

1 – Examine throttle cable, replace

if necessary, b 14.6.

– Examine intake elbow, replace

if necessary, b 14.6.3.
219RA508 TG

: Fit air guide inlet (1) until it

engages the heel (arrow).

MS 441, MS 441 C 115

 14.6.2 Carburetor housing

– Remove pre-separator, b 9.7.

2 1
– Remove shroud, b 8.4.
3
– Remove short circuit wire,
b 9.6.2.

– Remove carburetor support,

4

219RA520 TG
219RA518 TG
b 14.6.1.

– Remove intake elbow,

b 14.6.3.
– Use STIHL Press Fluid for easier – Guide throttle cable between fuel
insertion, b 17. hose and impulse hose. – Remove anti-vibration spring on
front handle, b 11.2.
: Pull elbow flanges through the : Press throttle cable (1) into guide,
openings in the carburetor so that wire glides through Machines with handle heating
support with the aid of the string. felt (2).
– Remove wiring harness,
The rubber lips must enclose the : Press impulse hose (3) and fuel b 15.8.1.
openings completely. hose (4) into the mounts
(arrows). – Remove heating switch,
b 15.4.
– Reassemble all other parts in the
reverse sequence.

– Tightening torques, b 3.5.

1
2
1
219RA519 TG
219RA282 TG

: Press sleeves (1) into the : Pull off grommet (1) and examine
openings of the elbow and fit it, replace if necessary.
washer (2).
– Use STIHL Press Fluid for easier
insertion, b 17.

116 MS 441, MS 441 C

 1

1
1 2

219RA528 TG
219RA523 TG
219RA521 TG
3

: Press grommet (1) into holes – Lift carburetor housing (1) and : Take out screw (arrow).
(arrows) until rubber lips enclose turn it aside.
holes completely. – Pull out slide (1).
: Pull fuel hose (2) off elbow
connector (arrow).

: Pull out throttle cable (3).

– Pull out wiring harness on

1 machines with handle heating,
b 15.8.
1
– Remove and examine carburetor
housing, replace if necessary.

If a new housing is installed, all

219RA101 TG

219RA524 TG
attached parts must be transferred
to the new housing.

– Remove impulse hose,

: Pull impulse hose (1) off b 14.6.4. : Push slide (1) fully home in the
connector (arrow). guide (arrow).
– Remove fuel hose,
b 14.8.2. – Fit and tighten screw.

– Remove grommet / ignition cable

retainer, b 8.4.

1
219RA522 TG

219RA525 TG

: Take out screws (arrows). – Ease out grommet (1) and

examine it, replace if necessary.
– Disconnect ground wire.
– Use STIHL Press Fluid for easier
insertion, b 17.

MS 441, MS 441 C 117

: Press grommet in until rubber lip
completely encloses the oblong 2
hole.

– Install impulse hose, 1

b 14.6.4.

– Install fuel hose,

219RA522 TG
b 14.8.2.

219RA096 TG
– Install grommet / ignition cable
retainer, b 8.4.
Machines with QuickStop Super – Install intake elbow,
b 14.6.3.
– Guide fuel hose (1) under brake
cable (2) and push it onto the : Check that intake elbow is
elbow connector (arrow). correctly seated and tighten all
four screws (arrows) securely.

– Throttle cable must be routed

between impulse hose and fuel
1 1 hose.

– Reassemble all other parts in the

reverse sequence.

2 – Tightening torques, b 3.5.

3
219RA526 TG

219RA114 TG

– Fit carburetor housing (1) and – Fit carburetor housing.

turn it aside.
: Push impulse hose (1) onto
: Push fuel hose (2) onto elbow connector (arrow).
connector (3).
– Install ground wire, b 9.6.3.
: Push throttle cable (4) through
grommet (arrow).

– Install wiring harness in

machines with handle heating,
b 15.8.2.

118 MS 441, MS 441 C

14.6.3 Intake elbow, removal 14.6.4 Impulse hose
and installation

A damaged intake elbow can lead to

impaired engine operation. 1

– Troubleshooting chart, b 4.6 or

b 4.7.

– Remove carburetor support,

b 14.6.1.

219RA532 TG
A damaged impulse hose can lead
to impaired engine operation.
– Remove carburetor housing,
b 14.6.2.
219RA534 TG
: Push impulse hose (1) through
opening (arrow) until rubber lip
encloses opening completely.
– Wet with STIHL Press Fluid,
b 17.

– Install carburetor housing,

b 14.6.2.
1

1
219RA101 TG
219RA530 TG

: Take out screws (arrows). : Pull impulse hose (1) off

connector (arrow).
– Remove intake elbow (1) and
examine it, replace if necessary.

– Fit intake elbow on cylinder

intake port.

– Fit and tighten screws.

1
– Check that intake elbow is
correctly seated and tighten
screws securely. 1
– Ensure that short circuit wire is
correctly located in the guides
219RA533 TG

during the further installation

219RA114 TG

procedure.

– Reassemble all other parts in the

reverse sequence. : Push impulse hose (1) out of : Push impulse hose (1) onto
carburetor housing. connector (arrow).
– Tightening torques, b 3.5.
– Examine impulse hose, replace if – Reassemble all other parts in the
necessary. reverse sequence.

MS 441, MS 441 C 119

14.7 Tank vent
14.7.1 Check

Always check and clean the tank

vent in the event of trouble with the
carburetor or fuel supply system,
replace if necessary. Check function
by testing the fuel tank under 1 2
vacuum or at gauge pressure via
the fuel hose.

219RA538 TG
219RA536 TG
– Open fuel filler cap and drain fuel
tank.
1
Collect fuel in a clean container and
dispose of it in accordance with : Push nipple (1) Pressure test
environmental regulations. 0000 855 9200 into flange
(arrow) of intake hose. : Slide ring (1) to the right and
– Close fuel filler cap. connect pump (2) 0000 850 1300
to nipple (arrow). Build up
– Remove carburetor, b 14.3, pressure in fuel tank.
before checking function via fuel
hose. – Actuate pump until pressure
gauge shows a reading of
Work through the following steps 0.5 bar. If this pressure is
and repeat the test if a leak is found. maintained for at least
20 seconds, the tank and tank
– Remove carburetor housing, 2 vent are airtight. If the pressure
b 14.6.2. drops, the leak must be located
and the faulty part replaced.
219RA537 TG

– Reassemble in the reverse

sequence.
1

Vacuum test

: Slide ring (1) to the left and

connect pump (2) 0000 850 1300
to nipple (arrow).
Build up vacuum in fuel tank.

Equalization of pressure takes

place via the tank vent. A vacuum
must not build up in the tank.

– Clean area around the tank vent.

– Replace tank or tank vent if

1 necessary, b 14.7 or b 14.8.4.
219RA535 TG

: Pull out elbow connector (1).

120 MS 441, MS 441 C

14.7.2 Removal and installation 14.8 Fuel intake
14.8.1 Pick-up body

Any impurities mixed with the fuel

are retained by the pick-up body 1 2
(filter). The fine pores of the filter
eventually become clogged with
minute particles of dirt. This restricts
the passage of fuel and results in
1 fuel starvation.

217RA286 TG
In the event of trouble in the fuel

219RA539 TG
system, always check the fuel tank
and pick-up body first.

: Prise off and remove cover (1). – Troubleshooting, b 4.6 or : Pull pick-up body (1) off the fuel
b 4.7. hose (2).

– Examine pick-up body and clean

or replace if necessary.

– Reassemble in the reverse

sequence.
1 Clean fuel tank if necessary.

– Open fuel filler cap and drain fuel

tank.

– Fill tank with a little fresh

gasoline, close the tank and
219RA540 TG

shake it thoroughly.

– Reopen and empty the tank.

: Prise out tank vent (1). – Dispose of fuel in accordance

with environmental regulations.
Always fit a new tank vent.

– Wet O-ring of new tank vent with

STIHL Press Fluid, b 17.

– Press new tank vent as far as

possible into opening.

– Reassemble all other parts in the

reverse sequence.
219RA542 TG

: Pull pick-up body (1) out of the

fuel tank with assembly hook
5910 893 8800.

Do not over-extend the fuel hose.

MS 441, MS 441 C 121

14.8.2 Fuel hoses

219RA544 TG

219RA547 TG

219RA550 TG
1

– Remove carburetor housing, : Examine fuel hoses and replace : Push elbow connector (1) into
b 14.6.2. if necessary. fuel hose (arrow).

: Push fuel hose (1) out.

1 1

219RA551 TG
219RA545 TG

219RA548 TG

: Pull off elbow connector (1). : Push fuel hose (1) into opening : Pull fuel intake hose (1) out of
(arrow) in fuel tank. fuel tank with assembly hook
– Remove pick-up body, b 14.8.1. 5910 893 8800.

Do not over-extend the fuel hose.

– Install pick-up body, b 14.8.1.

1 1
219RA549 TG
219RA546 TG

: Ease out fuel hose (1). : Fit flange (1) and press it into the
fixture (arrow) on the housing
– Pull fuel hose out from inside until it rests against the housing.
tank.

122 MS 441, MS 441 C

 14.8.3 Fuel filler cap

1
1

219RA552 TG

219RA555 TG
219RA096 TG
: Push fuel hose (1) through the Machines with QuickStop Super – Open filler cap.
opening (arrow).
– Guide fuel hose (1) under brake : Prise out nipple inside tank
– Use STIHL Press Fluid for easier cable (2) and push it onto the (arrow).
insertion, b 17. elbow connector (arrow).

– Reassemble all other parts in the

reverse sequence.
219RA553 TG

219RA556 TG
1

– Press fuel hose (1) in until rubber – Examine filler cap, rope and
lip (arrow) encloses the opening O-ring, replace if necessary.
completely.
: Press nipple into mount (arrow)
inside tank.

– Close fuel filler cap.

– Perform leakage test.

MS 441, MS 441 C 123

14.8.4 Tank housing, removal 15. Heating
and installation 15.1 Carburetor heating

– Drain fuel tank. Current is supplied via wires to the

heating element installed between
Collect fuel in a clean container and filter base and carburetor.
dispose of in accordance with
environmental regulations. The heating element is controlled
via the temperature regulator on the
– Remove front handle, b 11.5 or carburetor.
b 11.5.1.
The heating element must also be

219RA558 TG
1
– Remove carburetor housing, checked if running problems occur
b 14.6.2. when the cold engine is idling or
running at part load, particularly at
– Remove stop buffer, b 11.4 : Then turn tank housing (1) to the sub-zero temperatures.
side and remove it.
– Remove actuating lever, Idling problems with a hot engine
b 12. – Examine tank housing, replace if may also indicate a fault in the
necessary. heating element.
– Remove anti-vibration springs,
b 11.

– Remove wiring harness,

b 15.8.1 in machines with
handle heating.
2
1
219RA554 TG

Only those parts of the old tank

housing should be reused which are
not included with the new tank
housing – see spare parts list.

: Fit right-hand peg (2) of tank

housing (1) into the hole of the
stop buffer on the clutch side first,
then turn it into the crankcase
past the moulded bump (arrow).

– Reassemble all other parts in the

reverse sequence.
1
– Tightening torques, b 3.5.
219RA557 TG

: First move front part of tank

housing (1) down and out of the
crankcase.

124 MS 441, MS 441 C

Complete system

The generator and heating element

are checked in the following test,
which should be performed at an
1
ambient temperature of at least
+ 20 °C (68 °F).

219RA559 TG
If the temperature is below + 13 °C

219RA488 TG
30 20 10
50 5
(55 °F), the thermostatic switch may 10
0

25
10 20
0

close and produce false readings. 1

Check the carburetor heating in
accordance with the
troubleshooting chart, carburetor
heating, b 15.2.
– Remove filter base, b 14.1.2.
– Set ohmmeter to measuring
range "Ω".
: Clip one of the two test leads onto Heating element
the carburetor and the other onto
a cylinder fin. – Remove air filter, b 14.1.
– If the system is in good condition, : Pull wiring (1) out of retainers
the ohmmeter will indicate (arrows).
about 8 ohm in the measuring
range "Ω". – Remove filter base, b 14.1.2.
To ensure good electrical contact,
press the heating plate and heating
element against the carburetor
during the measurement.

If the reading obtained is outside

this tolerance, each component
must be tested separately.

1
219RA560 TG

– Push insulating tube towards the

heating element and unplug the
connectors.

: Remove heating element (1).

MS 441, MS 441 C 125

 1 2
1

219RA561 TG

219RA562 TG

219RA494 TG
: Clip one of the two test lines onto – Push connector and terminal : Attach wiring (1) to mount (2) and
the heating element and the socket (arrow) together as far as press it into the cable guides
other onto the round connector. possible. (arrows).

If the heating element is in good : Slide insulating tube (1) over the The wiring must not touch either the
condition, the ohmmeter will plug connection. carburetor levers or the spacer
indicate about 8 ohm in the flange.
measuring range "Ω".

– Check correct operation,

b 15.2.

1
219RA565 TG

The insulating tube must cover the

plug connection completely – risk of
short circuiting.

: Press plug connection (1) into the

guides (arrows).
Thermostatic switch
Ensure that wires are not crossed.

1 – Install filter base, b 14.1.2.

219RA201 TG
219RA563 TG

: Slide heating element (1) onto : Pull connector (arrow) off

the carburetor. terminal socket.

– Remove carburetor, b 14.3.

126 MS 441, MS 441 C

 1

219RA567 TG
219RA564 TG
: Take out screws (arrows). – Install carburetor, b 14.3.

– Remove thermostatic switch (1). : Push connector (arrow) onto

terminal socket.

– Wiring must rest in the retaining

lug (strain relief).

– Reassemble all other parts in the

1 reverse sequence.

– Tightening torques, b 3.5.

– Check correct operation.

219RA566 TG

– Fit new thermostatic switch (1).

: Fit and tighten screws (arrows).

MS 441, MS 441 C 127

15.2 Troubleshooting chart, carburetor heating element

Measure resistance
of heating element
at temperature = +20 °C (68 °F)

Resistance no Replace heating

approx. 8 ohm? element, b 15.1

yes

Replace thermostatic
switch, b 15.1

Carburetor heating
element OK

Circuit diagram

G = Generator
1 = Front handle
2 = Rear handle
1 3 = Heating switch

G
3
219RA615 TG

128 MS 441, MS 441 C

15.3 Handle heating systems
15.3.1 Troubleshooting
The entire handle heating system is
maintenance-free and not subject to
electrical wear. Faults in the
generator, heating elements and
wiring are generally caused by
mechanical damage.
Failures in the heating system may
be due to two reasons:
1. A break in the circuit due to
a faulty wire or component.
2. A short circuit resulting from
damage to the insulation.
219RA618 TG
1 – Measure resistance in rear
– Remove handle moulding,
b 12.2.
: Detach plug connection from
guide and slide insulating tube (1)
towards wiring harness.
219RA619 TG
: Disconnect plug connection.
MS 441, MS 441 C
1 will show a reading of about 10 ohm
219RA568 TG
: Set heating switch (1) to
position "#".
– Set ohmmeter to "Ω" position.
219RA570 TG
– Set slide control to position "$".
: Clip test leads onto the lead from
the wiring harness and the lead
from the heating element.
219RA579 TG
Machines with carburetor heating
: Disconnect lead from heating
element (arrow).
All electrical components of the
handle heating system are
connected in series with the
ohmmeter.
If the system is OK, the ohmmeter
in the measuring range "Ω".
If the pointer does not move, there
is a break in the circuit.
If the ohmmeter shows a very low
value, there is a short circuit in one
of the components.
In both cases, each component
must be checked individually,
ensuring that the generator
connection remains separate from
the heating element connection.
– Test according to the
troubleshooting chart, handle
heating and generator,
b 15.7.1.
– Measure resistance in front
handle, b 15.6.
handle, b 15.5.
– After testing, reconnect the leads
and slide the protective tube back
over the plug connection.
– Install handle moulding, b 12.2.
129
15.4 Heating switch, removal
and installation

: Fit washer (2), screw on hex

2 1 nut (3) and tighten it securely.

2
219RA571 TG

219RA574 TG
– Remove carburetor, b 14.3. : Pull heating switch (1) with
socket terminal (2) off to the
– Remove grommet (1), b 14.6.2. inside and examine them,
replace if necessary.
: Pull off cable retainer (2).

1 3 1 2

1 3

2
219RA572 TG

219RA577 TG
219RA575 TG

: Pull contact sleeve (1) out of : Reconnect heating switch (1) and
heating switch. socket terminal (2) and push
them through the opening (arrow)
: Disconnect plug (arrow) from – the groove (3) must face
socket terminal. upwards.
– Push contact sleeve (1) into
switch.
– Fit cable retainer (2).
– Fit terminal socket ground
wire (3) so that the loop in the
lead faces towards the housing.

: Push wiring harness into guides

1 (arrows).

– Install carburetor and connect

plug of thermostatic switch in
machines with carburetor
heating, b 14.3.
219RA573 TG

219RA576 TG

– Check correct operation.

2 3
– Reassemble all other parts in the
: Unscrew nut (arrow) of heating : Position heating switch so that reverse sequence.
switch. the groove (arrow) is lined up with
the mark (1) on the carburetor – Tightening torques, b 3.5.
housing.

130 MS 441, MS 441 C

15.5 Heating element in 15.6 Heating element 15.7 Generator,
handle, removal and in front handle, removal removal and installation
installation and installation
The heating element in the front
1 handle cannot be replaced. The 1
complete front handle must be
replaced if the heating element is
faulty.

– Remove front handle, b 11.5.1.

219RA596 TG

219RA581 TG
1

– Remove handle moulding, – Remove ignition module,

b 12.2. b 9.1.1.

: Slide insulating tubes (1) towards – Remove flywheel, b 9.5.

wiring harness and disconnect
plug connections. : Detach plug connection (1) and
wiring from guides (arrows).

219RA580 TG
219RA578 TG

219RA582 TG
30 20 10 30 20 10
50 5 50 5
0 0
10 0 10
20 0 20
5 10

– Take heating element out of – Clear connecting leads, : Slide insulating tube (1) towards
handle moulding. b 11.5.1 wiring harness and disconnect
plug connection.
: Examine heating element, : Clip measuring instrument onto
replace if necessary. the two round connectors.

If the heating element is OK, the If the heating element is OK, the
ohmmeter will indicate a reading ohmmeter will indicate a reading of
of about 2 ohm in the measuring about 7 ohm in the measuring
range "Ω". range "Ω".

The heating element must be The heating element must be

replaced if the value is outside this replaced if the value is outside this
range. range. 1
If the heating element does not work If the heating element does not work
despite a resistance being despite a resistance being
219RA583 TG

measured: measured:

– Test generator and heating – Test generator and heating

switch, b 15.3. switch, b 15.3. : Take out screws (arrows).

– Reassemble in the reverse – Reassemble in the reverse – Remove generator (1).

sequence. sequence.

MS 441, MS 441 C 131

 – Apply screw locking adhesive,
b 17.

– Tightening torques, b 3.5.

219RA586 TG
212RA270 VA

: Check generator and poles : Lay generator lead in bottom of

(arrow) for cracks or other recess (arrow).
damage. Replace generator if
necessary.

1
219RA584 TG

219RA587 TG
219RA605 TG

: Check magnet ring (arrow) in
flywheel for cracks or other
damage. Replace flywheel if
necessary.
: Connect plug and socket terminal : Press wiring and plug connection
(arrow). into guides (arrows).
– Slide insulating tube (1) over plug
connection.

The insulating tube must enclose

the plug connection completely –
risk of short circuiting.
1
1
219RA600 TG
219RA585 TG

: Fit generator (1) with connecting : Lead wiring harness (1) through
lead (arrow) facing the housing. under plug connection (arrow).

– Fit and tighten screws. – Reassemble all other parts in the

reverse sequence.

132 MS 441, MS 441 C

15.7.1 Troubleshooting chart, handle heating systems and generator

Start

yes Do both handles warm up?

no
Turn on switch
no
Heating switch on "#"?

yes

Measure resistance of individual

heating elements with ohmmeter

(on machines with carburetor heating,

disconnect wire from carburetor
heating element),
b 15.1

Check rear handle heating element:

in good condition?
Does it make complete contact? no

Replace rear
yes handle heating
element,
Resistance of rear handle no b 15.5
heating element
about 1.6 ohm?
yes

Check generator:
resistance between engine ground no Replace
and generator connection generator,
about 0.5 – 1 ohm? b 15.7

yes

1 2 3

MS 441, MS 441 C 133

 1 2 3

Test ground wire

to carburetor housing Replace
no
ground wire,
resistance between socket terminal and b 9.6.3
engine housing about 0 ohm?

yes

Disconnect and clear plug connections

to front handle heating element,
b 11.5.1

Test front handle Replace

no
heating element front handle,
resistance about 6.4 ohm? b 11.5.1

yes

Test heating switch Replace

(contact sleeve against switch housing): no heating switch,
about 0 ohm when closed? b 15.4
Circuit interrupted when open,
b 15.4

yes

(Reconnect plug connection

to heating element on machines
with carburetor heating),
b 15.1

System OK

134 MS 441, MS 441 C

15.7.2 Summary of test connections and test values

– The wires in the rear handle

must be unplugged to test the
individual components
separately.

Component Ohmmeter connection Resistance in ohm If faulty

(either test lead can be
used)
Lead 1 Lead 2 Required Actual Cause Remedy
Switch Switch Switch < 0.5 – Switch faulty Replace switch
connection1) housing

Socket terminal Socket Ground 0 > 1.0 Poor ground Replace ground
terminal connection wire
Heating element Connector Connector 1.6 1.5 – 2.0 Heating element OK
in rear handle to lead to lead
from from
heating heating
element element
– Break in wire, heating Replace heating
element damaged element and repair
insulation
0 Short circuit due to
damaged insulation

Heating element in Connector Connector 6.4 6.0...8.0 Heating element OK

front handle to lead to lead
from front from front
handle handle
heating heating
element element
– Break in wire, heating Replace front
element damaged handle

0 Short circuit due to Repair insulation

damaged insulation

1)
Pull wire out for this purpose

MS 441, MS 441 C 135

Component Ohmmeter connection Resistance in ohm If faulty
(either test lead can be
used)
Lead 1 Lead 2 Required Actual Cause Remedy
Generator Connector Ground 0.6 0.5 – 1 Generator OK
to
generator
lead
– Break in wire, Replace generator
generator damaged
0 Short circuit due to Repair insulation
damaged insulation

Circuit diagram

G = Generator
1 = Front handle
1 4
2 = Rear handle
3 = Heating switch
4 = Heating element
2 5 (carburetor)
5 = Thermostatic switch
G
3
219RA505 TG

136 MS 441, MS 441 C

15.8 Wiring harness
15.8.1 Removal

– Remove shroud, b 8.4.

2 1
– Pull boot off spark plug, b 9.4.
1
– Remove ignition module,
b 9.1.1.

Remove flywheel, b 9.5, so that

219RA590 TG
generator lead can be routed

219RA593 TG
N
correctly.

– Remove carburetor support,

b 14.6.1. : Pull grommet (1) off wiring : Pull cable retainer (1) off.
harness (2).
– Remove short circuit wire,
b 9.6.2. – Examine grommet for signs of
damage, replace if necessary.

1
219RA588 TG

219RA594 TG
219RA591 TG

: Pull wiring harness (1) and plug
connection out of cable guides
(arrows).
: Pull plug connection (1) and : Pull contact sleeve (1) out of
wiring out of guides (arrows). heating switch.
: Pull wiring harness out of cable
guides (arrows).

1
1

1
219RA589 TG

219RA592 TG

219RA595 TG

: Slide insulating tube (1) towards
generator lead and disconnect
plug connection.
: Slide insulating tube (1) towards
carburetor heating element and
disconnect plug connection.
– Pull wiring harness out through
opening at the side (arrow).
: Prise out grommet (1) and pull it
off the wiring harness.
– Examine grommet, replace if
necessary.

MS 441, MS 441 C 137


– Remove carburetor housing and
turn it aside, b 14.6.2.
1 2
219RA569 TG
1 1
: Pull wiring harness (1) out of
carburetor housing.
– Disconnect front handle heating
element from wiring harness,
b 11.5.
– Remove throttle trigger and
trigger interlock, b 12.2 or
b 12.3.
– Remove throttle cable retainer,
b 7.3.2.
138
15.8.2 Installation
1 1
219RA606 TG
219RA596 TG
1
: Slide insulating tubes (1) towards For all the following assembly steps:
handle heating element and
disconnect plug connections. : Insulating tubes must enclose the
plug connections completely –
risk of short circuiting.
1
219RA597 TG
219RA598 TG
1
: Detach wiring harness (1) and – Push connector and socket
wiring (2) from guides and terminals (arrows) together as far
examine them, replace if as possible.
necessary.
: Slide insulating tubes (1) over the
plug connections.
2
219RA599 TG
: Press wiring harness (1) and
wiring (2) into the guides
(arrows).
– Install throttle trigger and trigger
interlock, b 12.2.
MS 441, MS 441 C
– Install throttle cable retainer and
throttle cable, b 7.3.2. 1
1
Reconnect front handle heating
element and wiring harness,
b 11.5.

219RA605 TG
219RA603 TG
: Push round connector (1) into : Push connector and socket
heating switch. terminal (arrow) together as far
as possible.

– Slide insulating tube (1) over the

plug connection.

1 1

219RA604 TG

219RA607 TG
219RA601 TG

: Pull wiring harness (1) through : Fit cable retainer (1). – Press wiring and plug connection
the opening (arrow). into the cable guides (arrows).
: Press wiring into cable guides
– Install carburetor housing, (arrows). The generator lead must be
b 14.6.2. accurately seated in the cable
guides.

2
1

1
1
219RA608 TG

219RA600 TG
219RA602 TG

: Push grommet (1) over wiring : Route wiring harness (1) through : Guide wiring harness (1) through
harness until it rests against the the opening (arrow) and under the plug connection
shrink hosing, then press it into grommet (2). (arrow).
the opening (arrow).

MS 441, MS 441 C 139


219RA609 TG
: Lay wiring harness and short
circuit wire in cable guides
(arrows) under the ignition lead.
1 reverse sequence.
219RA562 TG
– Push connector and socket
terminal (arrow) together as far
as possible.
: Slide insulating tube (1) over the
plug connection.
140
219RA565 TG
: Press plug connection (1) and
wiring into guides (arrows).
– Install short circuit wire and press
grommet into place, b 9.6.
Ensure that wires are not crossed.
– Install filter base, b 14.1.2.
1 2
219RA494 TG
Machines with handle heating
: Attach wiring (1) to retainer (2)
and press it into the guides
(arrows).
The wiring must not touch either the
carburetor levers or the spacer
flange.
– Reassemble all other parts in the
– Tightening torques, b 3.5.
MS 441, MS 441 C
16. Special tools

New special tools

No. Part name Part No. Use Remarks

1 Sealing plate 0000 855 8107 Sealing exhaust port

2 Test flange 1138 890 1200 Leakage testing
3 Clamping rail for assembly stand 5910 850 1650 Clamping machine on assembly stand
4 Screwdriver 5910 890 2304 Carburetor adjustment
5 Sleeve 5910 893 1706 Supplements assembly tool 12

Existing special tools

No. Part name Part No. Use Remarks

1 Carburetor and crankcase tester 0000 850 1300 Testing crankcase and carburetor for
leaks
- Hose for leakage testing 1110 141 8600 Testing carburetor for leaks
- Plug for leakage testing 1122 025 2200 Testing decompression valve for leaks
- Nipple 0000 855 9200 Testing carburetor for leaks
2 Assembly tool 0000 890 2201 Installation of starter rope guide
bushing
3 Clamping strap 0000 893 2600 Clamping piston rings
4 Locking strip 0000 893 5903 Blocking crankshaft
5 Bushing 0000 963 1008 Supplement for test flange
6 Pliers DIN 5254-A 19 0811 611 8380 Removal and installation of external
retaining rings
7 Screwdriver bit T 27 x 125 0812 542 2104 Removal and installation of spline
socket head screws with electric or
pneumatic screwdrivers; tightening
down screws with torque wrench
8 Wooden assembly block 1108 893 4800 Fitting the piston
9 Assembly drift 1114 893 4700 Removal and installation of piston pins
10 Assembly tube 1117 890 0900 Connecting helical spring
11 Setting gauge 1111 890 6400 Adjusting air gap between ignition
module and flywheel
12 Assembly sleeve 1118 893 2401 Pressing in oil seals (clutch side)
13 Press arbor 1118 893 7200 Pressing in and removing ball bearings
14 Assembly sleeve 1122 893 2405 Pressing in oil seals (starter side)
15 Assembly sleeve 1122 893 4600 Protecting oil seals (clutch side)
16 Combination wrench 1129 890 3401 Spark plug 1)
17 Puller 1135 890 4500 Removal of flywheel
18 Assembly tool set AS 5910 007 2205 Removal and installation of crankshaft
(clutch side)
19 Assembly tool set ZS 5910 007 2220 Removal and installation of crankshaft
(starter side)

MS 441, MS 441 C 141

No. Part name Part No. Use Remarks

20 Locking strip for assembly stand 5910 850 1650 Clamping machine on assembly stand
21 Ignition system tester ZAT 4 5910 850 4503 Testing ignition system
22 Ignition system tester ZAT 3 5910 850 4520 Testing ignition system
23 Torque wrench 5910 890 0302 Screw connections (0.5 to 18 Nm)
24 Torque wrench 5910 890 0312 Screw connections (6 to 80 Nm)
25 Assembly tool 12 5910 890 2212 Fitting hookless snap rings in piston
26 Screwdriver 5910 890 2304 Carburetor adjustment
- Setting washer 5910 893 6600 Supplement to screwdriver
(carburetor adjustment)
27 Screwdriver bit T 27 x 150 5910 890 2400 IS-P screws (4 mm)
28 Assembly hook 5910 890 2800 Disconnecting helical springs from
clutch shoes
29 Assembly stand 5910 890 3100 Mounting chainsaw for repairs
30 Puller 5910 890 4400 Pulling out oil seals
- Claws (with profile No. 3.1) 0000 893 3706 Pulling out oil seal(s)
31 Puller 5910 890 4500 Pulling off limiter caps
32 Crimping pliers 5910 890 8210 Cable ties, cable lugs, etc.
33 Stud puller M8 5910 893 0501 Unscrewing bar mounting studs
34 Screw sleeve 5910 893 2420 Pulling in crankshaft
35 Socket, 13 mm, long 5910 893 2804 Removal and installation
of decompression valve
36 Assembly hook 5910 893 8800 Pulling out pick-up body

Remark:
1) Only to be used for releasing.

142 MS 441, MS 441 C

17. Servicing accessories

No. Part name Part No. Use

1 Lubricating grease (225 g tube) 0781 120 1111 Oil seals, sliding surfaces and bearings

2 STIHL special lubricating oil 0781 417 1315 Bearing bore in rope rotor, rewind spring in fan
housing

3 Press Fluid OH 723 0781 957 9000 Rubber elements in anti-vibration system

4 STIHL multi-purpose grease 0781 120 1109 High-voltage output on ignition module

5 Sealant Dirko HT red 0783 830 2000 Engine pan, oil seals (outside)

5 Thread-locking adhesive, 0786 111 2101

medium strength (Loctite 242)

6 Thread-locking adhesive, normal 0786 111 2109

strength (Loctite 270)

7 Thread-locking adhesive, high 0786 111 2117

strength (Loctite 648)

8 Commercially available solvent- Cleaning sealing surfaces and carburetor,

based degreasant not containing cleaning crankshaft stub and cone in flywheel
any chlorinated or halogenated
hydrocarbons

MS 441, MS 441 C 143

144 MS 441, MS 441 C
englisch / english
0455 219 0123. M7. G6. Fi. Printed in Germany