Stihl 034 Series, 036 Series, 036 QS Series User Manual

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Page 1

1034, 036, 036 QS

Contents

1 Introduction 2

2 Safety Precautions 3

3 Specifications 4

3.1 Engine 4

3.2 Fuel System 4

3.3 Ignition System 5

3.4 Cutting Attachment 5

3.5 Tightening Torques 6

3.6 Special Accessories 7

3.6.1 For User 7

3.6.2 For Service 7

4 Clutch, Chain Drive,

Chain Brake and Chain Tensioner 8

4.1 Clutch Drum and Chain Sprocket 8

4.2 Replacing the Chain Catcher 9

4.3 Clutch 9

4.4 Chain Brake (034, 036)10

4.4.1 Removing 10

4.4.2 Installing 11

4.5 Chain Brake (036 QS) 12

4.5.1 Removing 12

4.5.2 Installing 14

4.5.3 Checking Play 15

4.5.4 Adjusting Play 16

4.5.5 Checking Operation of Chain Brake 17

4.6 Chain Tensioner 17

4.7 Bar Mounting Studs 18

5Engine 19

5.1 Removing and Installing Muffler 19

5.2 Exposing the Cylinder 20

5.3 Cylinder and Piston 20

5.3.1 Removing 20

5.3.2 Installing 21

5.4 Piston Rings 24

5.5 Crankcase 24

5.5.1 Removing the Crankshaft 24

5.5.2 Installing the Crankshaft 26

5.6 Crankcase Leakage Test 31

5.6.1 Preparations 31

5.6.2 Pressure Test 32

5.6.3 Vacuum Test 33

5.7 Replacing the Oil Seals 33

6 Ignition System 34

6.1 Ignition Lead/ Spark Plug Boot 34

6.2 Short Circuit Wire/ Ground Wire 35

6.3 STOP Contact 37

6.4 Flywheel 38

6.4.1 Removing 38

6.4.2 Installing 38

6.5 Ignition Module 39

6.5.1 Removing and Installing 39

6.5.2 Ignition Timing 40

7 Rewind Starter 40

7.1 Routine Maintenance 40

7.2 Rope Rotor, Pawls, Starter Rope, Rope Guide Bush 40

7.3 Rewind Spring 41

7.3.1 Replacing the Rewind Spring (034) 41

7.3.2 Replacing the Rewind Spring (036, 036 QS) 41

7.4 Tensioning the Rewind Spring 42

8 AV Handle System 42

8.1 Repair 42

9Master Control 43

9.1 Construction and Function 43

9.2 Throttle Trigger/Interlock Lever (034, 036) 44

9.3 Throttle Trigger/Interlock Lever/Switch Lever (036 QS) 45

9.4 Switch Shaft 46

10 Electric Handle Heating

System (034, 036) 47

10.1 Troubleshooting 47

10.1.1 Troubleshooting Chart 49

10.1.2 Test Connections and Test Values 50

10.2 Heater Switch 51

10.3 Heating Element in Rear Handle 51

10.4 Heating Element in Front Handle 53

10.5 Generator 54

10.5.1 Removing 54

10.5.2 Installing 55

11 Chain Lubrication 55

11.1 Pickup Body 55

11.2 Suction Hose 56

11.3 Vent Valve 56

11.4 Removing and Installing the Oil Pump 57

11.5 Servicing the Oil Pump 58

12 Fuel System 59

12.1 Air Filter 59

12.2 Leakage Testing the Carburetor 60

12.3 Removing and Installing the Carburetor 61

12.4 Servicing the Carburetor 62

12.5 Adjusting the Carburetor 66

12.6 Tank Vent 67

12.7 Fuel Filter and Fuel Hose 68

12.8 Tank Hous ing 69

12.8.1 Removing and Installing 69

13 Special Servicing

Tools and Aids 71

13.1 Special Servicing Tools 71

13.2 Servicing Aids 72

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2 034, 036, 036 QS

This service manual contains detailed descriptions of all the repair and servicing procedures specific to this series of chain saws.

There are separate handbooks for servicing procedures on standardized parts and assemblies that are installed in several STIHL power tool models. Reference is made to these handbooks in the appropriate chapters of this manual

You should make use of the illustrated parts lists while carrying out repair work. They show the installed positions of the individual components and assemblies.

Refer to the latest edition of the relevant parts list to check the part numbers or any replacement parts. Parts lists on microfiche and CDROM are always more up to date than printed lists.

A fault on the machine may have several causes. To help locat e the fault, consult the troubleshooting charts for all assemblies in the "Standard Repairs, Troubleshooting" handbook.

Refer to the "Technical Info rmation" bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list until a revised edition is issued.

The special servicing tools mentioned in the descriptions are listed in the last chapter of this manual. Use the part numbers to identify the tools in the "STIHL Special Tools" manual. The manual lists all special servicing tools currently available from STIHL.

Symbols are included in the text and pictures for greater clarity. The meanings are as follows:

In the descriptions:  = Action to be taken as

shown in the illustration (above the text)

– = Action to be taken that is

not shown in the illustration (above the text)

= Situation applies from

serial number

= Situation applies up to

serial number

In the illustrations:

Pointer Direction of movement

Service manuals and all technical Information bulletins are intended exclusively for the use of STIHL servicing dealers. They must not be passed to third parties.

Servicing and repairs are made considerably easier if the powerhead is mounted on assembly stand (1) 5910 890 3100. Remove the chain sprocket cover, bar and chain first. The powerhead can then be swivelled to the best position for the

138RA001

ongoing repair. This leaves both hands free.

Always use original STIHL replacement parts.

They can be identified by the STIHL part number, the

67,+logo and the

STIHL parts symbol This symbol may appear alone on small parts.

1 Introduction

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3034, 036, 036 QS

If the engine is started up in the course of repairs or maintenance work, observe all local and countryspecific safety regulations as well as the safety precautions and warnings in the owner’s manual.

Gasoline is an extremely flammable fuel and can be explosive in certain conditions.

Improper handling may result in burns or other serious injuries.

Warning!

Do not smoke or bring any fire, flame or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately.

2 Safety Precautions

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4 034, 036, 036 QS

3 Specifications

3.1 Engine

STIHL single cylinder two-stroke engine with special impregnated cylinder bore

034 036, 036 QS

Displacement: Bore: Stroke: Compression ratio: Engine power to ISO 8893:

Max. torque: Max. permissible engine speed with

bar and chain: Mean idle speed: Crankshaft: Main bearings: Crankshaft journal diameter: Big end bearing: Piston pin diameter: Small end bearing: Connecting rod length: Rewind starter:

Starter rope: Clutch: Diameter: Clutch engages at: Crankcase leakage test at gauge pressure: under vacuum:

56.5 cm

46 mm 34 mm

9.5:1

3.0 kW (4.1 bhp) at 9,500 rpm

3.5 Nm at 6,500 rpm

13,000 rpm 2,700 rpm Two-part, drop forged Two deep-groove ball bearings

14.4 mm Needle cage 10 mm Needle cage 58 mm Pawl engagement with automatic starter rope rewind mechanism

3.5 mm dia., 960 mm Centrifugal clutch without linings 76 mm approx. 3,500 rpm

0.5 bar

61.5 cm

48 mm 34 mm

9.5:1

3.4 kW (4.6 bhp) at 9,500 rpm

3.7 Nm at 6,500 rpm

13,000 rpm 2,700 rpm Two-part, drop forged Two deep-groove ball bearings

14.4 mm Needle cage 10 mm Needle cage 58 mm Pawl engagement with automatic starter rope rewind mechanism

3.5 mm dia., 960 mm Centrifugal clutch without linings 76 mm approx. 3,500 rpm

0.5 bar

3.2 Fuel System 034, 036, 036 QS

Carburetor: Standard setting

High speed screw H: Low speed screw L: Idle setting:

Carburetor leakage test at gauge pressure: Fuel tank capacity: Fuel mixture:

Mix ratio:

Air filter:

All positon diaphragm carburetor with integral fuel pump

approx. 1 turn open approx. 1 turn open (starting with screws firmly against their seats)

0.4 bar 625 cm

Regular brand-name gasoline and brand-name two-stroke engine oil 50:1 with STIHL two-stroke engine oil 25:1 with other brand-name twostroke, air-cooled engine oils Large area, bisectional box filter with wire mesh

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5034, 036, 036 QS

3.3 Ignition System

Type: Air gap:

Spark plug (suppressed): Electrode gap: Spark plug thread: Thread length: Heat range:

034, 036, 036 QS

Transistorized magneto ignition (breakerless)

0.2 - 0.3 mm Bosch WSR 6 F

0.5 mm M14x1.25

9.5 mm 200

3.4 Cutting Attachment

Guide bars:

Cutting lengths: Oilomatic chain:

Chain sprockets: Chain speed:

Chain lubrication:

Oil delivery rate: Oil tank capacity:

STlHL Rollomatic S bars with nose sprocket. STlHL Duromatic bars with stellitetipped nose. Both types with corrosion-resistant finish and induction hardened rails. Rollomatic 37, 40, 45 and 50 cm Duromatic 37, 40, 45 and 50 cm

9.32 mm (3/8") Rapid-Micro, Rapid-Super (Options: 8.25 mm (0.325") Rapid-Micro, Rapid-Super, Topic-Micro and Topic-Super) 7-tooth, 3/8" rim sprocket

20.7 m/s at 9,500 rpm (with 7-toot h, 3/8" sprocket) Fully automatic, speed-controlled reciprocating oil pump; no oil feed at idle speed. Additional manual oil flow control Adjustable 5.5 - 15.5 cm

/min at 10,000 rpm 320 cm

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6 034, 036, 036 QS

3.5 Tightening Torques

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

Fastener Thread size For component Torque

Remarks

Pan head screw M4x8 Chain tensioner cover plate 3.0

M7x12.5 Starter post to fan housing 12.0 1)

Screw M8x22 Brake band/crankcase

(036 QS II) 10.0 2) Self-tapping screw B3.9x13 Brake cable retainer/tank housing (036 QS II) 1.5 Collar screw M8x21.5 Guide bar 23.0 2) Spline screw IS-M4x12 Cover, chain brake/crankcase 3.0

M10x1 Decompression valve (036, 036 QS) 14.0 Spline screw M3.5x12 Generator (W version) 2.0 3) Spline screw IS-P6x21.5 Front handle/tank housing, top right

(W version) 7.0 3)

Spline screw IS-P6x19 Front ha nd le /ta nk housing, bottom

(W version) 7.0 3) Spline screw IS-P6x32,5 Front handle/tank housing, top right, polymer 5.0 3) Spline screw IS-P6x21,5 Front handle/tank housing, bottom, polymer 5.0 3) Spline screw IS-P4x19 Handle mo ldin g 1.6 Screw assembly M5x30 Hand guard, left 7.0 2) Spline screw IS-P6x19 Chain catcher 2.8 Spline screw IS-M5x12 Spiked bumber 7.5 Spline screw IS-M5x20 Crankcase 9.0 Spline screw IS-M5x20 Fan housing/crankcase 7.0

M12x1 L Carrier 50.0 Screw HL6x18.5 Annular buffer to rear left/right of tank housing 5.0 Spline screw IS-P6x19 Annular buffer to front right of tank housing 5.0 Spline screw IS-M5x6 Muffler, upper/lower casing 6.5 2) Spline screw IS-M5x25 Muffler/crankcase 10.0 2) Spline screw IS-M5x16 Muffler/cylinder (036, 036 QS) 10.0 2) Spline screw IS-M5x25 Muffler/crankcase (034) 10.0 4) Spline screw IS-M5x20 Muffler/cylinder (034) 10.0 4) Spline screw IS-M5x22 Muffler/cylinder (034/Z version) 10.0 4) Slotted nut M5 Shroud 3.3 Slotted nut M5 Air filter 2.0

M8x1 Flywheel 33.0 6) Setscrew M5x8.5 Setscrew, l/h side of cylinder 1.4 5) Setscrew M5x8.5 Setscrew, r/h side of cylinder 1.4

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7034, 036, 036 QS

Hexagon nut M5 Carburetor (initial) 2.0 Hexagon nut M5 Carburetor (final) 3.5 Spline screw IS-M5x20 Cylinder/crankcase (036, 036 QS) 11.5 Spline screw IS-M5x20 Cylinder/crankcase (034) 10.5

M14x1.25 Spark plug 25.0 Spline screw IS-M5x20 Ignition module (with washer) 8.0 2) Spline screw IS-M4x12 Oil pump/crankcase 3.5

1) Micro-encapsulated

2) Threadlocking method: medium strength adhesive (e.g . LOCTITE 243)

3) Threadlocking method: high strength adhesive (e.g. LOCTITE 649)

4) Threadlocking method: high strength adhesive up to 250 °C (e.g. LOCTITE 272)

5) Threadlocking method: high strength adhesive (e.g. LOCTITE 270)

6) Degrease taper with cleaning agent (e.g. Somentor 33)

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

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

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

Note:

Power screwdriver settings for polymer:

– Plastoform screws max. 600 rpm – DG screws max. 500 rpm

3.6 Special Accessories

3.6.1 For User

3.6.2 For Service

Intake air preheating kit Intake air preheating kit .325", 8-tooth rim sprocket kit .325", 7-tooth rim sprocket kit 3/8", 7-tooth rim sprocket kit 3/8", 7-tooth spur sprocket .325", 7-tooth spur sprocket

Gasket set Carburetor parts kit Gasket panel

034, 036, 036 QS

1125 007 1035 (036) 1125 007 1004 (034/034S) 1125 007 1000 1125 007 1001 1125 007 1002 1125 640 2000 1125 640 2005

1125 007 1050 1128 007 1065 0457 281 0604

Fastener Thread size For component Torque

Remarks

Page 8

8 034, 036, 036 QS

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

 Unscrew nuts (1) from chain

sprocket cover (2). Remove the sprocket cover , bar and chain (3).

138RA002

 Disengage the chain brake by

pulling the hand guard toward the front handle.

143RA004

 Remove the E-clip (1) and

washer (2). If a rim sprocket (3) is fitted, pull it off.

148RA061

036 QS

 Disengage the additional brake

by pressing down the throttle trigger and interlock lever. Remove the clutch drum (1) and needle cage (2).

148RA062

034, 036

 Pull off the chain sprocket (1) or

clutch drum (2).

– Take out the needle cage.

138RA003

 Inspect the clutch drum (1).

There should be no scores or signs of excessive wear.

Important:

If there are signs of serious wear on the inside diameter of the clutch drum (1), check the remaining wall

148RA101

80%

100%

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

Note:

Clean stub of crankshaft. Wash needle cage, examine it for damage and replace if necessary. Lubricate needle cage with STIHL multipurpose grease - see 13.2.

Reassemble in the reverse sequence - start by fitting the ne edle cage on the crankshaft stub.

4 Clutch, Chain Drive,

Chain Brake and Chain Tensioner

4.1 Clutch Drum and Chain Sprocket

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9034, 036, 036 QS

– Remove chain sprocket cover -

see 4.1.

 Take out screw (1 ) an d re m ove

the inner side plate (2).

 Take out screw (3 ) an d re m ove

the chain catcher (4).

148RA063

2 1

Reassemble in the reverse sequence.

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

– Remove clutch drum/chain

sprocket - see 4.1.

 Release twist lock (1) on

carburetor box cover (2) and lift cover off vertically.

148RA064

Note:

 When reassembling, check

correct position of groove and guide.

148RA065

 Unscrew the slotted nut (1). – Pull boot off the spark plug.  Remove the shroud (2).

148RA066

 On powerheads with a

decompression valve (1), remove the cover and unscrew the decompression valve.

 Unscrew the spark plug (2).

148RA067

 Push the locking strip (1)

0000 893 5903 into the cylinder so that the words "OBEN - TOP" face upward.

148RA069

4.2 Replacing the

Chain Catcher

4.3 Clutch

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10 034, 036, 036 QS

 Unscrew the clutch clockwise

from the crankshaft (left-hand thread).

On 036, 036 QS:

Remove cover washer from the crankshaft stub.

148RA068

– Disassemble and reassemble the

clutch - see "Standard Repairs, Troubleshooting" handbook.

– Reassemble in the reverse

sequence.

Note:

Observe tightening torque for clutch (see "Tightening Torques").

Troubleshooting chart - see "Standard Repairs, Tro ubleshooting" handbook.

– Remove the chain sprocket cover

and cutting attachment - see 4.1.

– Remove the clutch drum/chain

sprocket - see 4.1

 Remove mounting screw (1 ) from

inner side plate (2) and lift side plate away.

– Engage the chain brake by

pushing the hand guard away from the front handle.

138RA004

 Remove mounting screws (1)

from cover (2) and lift the cover away.

138RA005

 Carefully pry the brake spring (1)

off the anchor pin and disconnect it from the lever (2).

138RA006

 Ease the brake band (1) out of

its seat in the crankcase and disconnect it from the lever (2).

138RA007

 Remove screw with captive

washer from the hand guard.

Note:

When installing, tighten down the screw with captive washer firmly (see "Tightening Torques").

138RA008

4.4 Chain Brake (034, 036)

4.4.1 Removing

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11034, 036, 036 QS

 Remove the E-clip from the pivot

pin.

– Pull the hand guard and lever

from the pivot pins.

138RA009

– Pull the lever out of the hand

guard.

 Remove the E-clip (3) from pivot

pin of lever (2) and detach the spring (1).

 Remove the cam lever and

138RA010

2 3

spring.

– Clean all disassembled parts in

white spirit. Replace any worn or damaged parts.

 Fit the cam lever (2) and

spring (1).

– Fit the E-clip.

138RA011

 Insert lever in th e side of the hand

guard so that short arm of lever points up.

Note:

Check correct installed position of lever.

138RA012

 Position the hand guard (1)

against the pivot pin and fit the other side of the hand guard over the fan housing.

138RA013

 Press the cam lever slightly

downward and push the hand guard and lever onto the pivot pins.

– Secure lever with E-clip. – Insert hand guard mounting

138RA014

screw with captive washer at fan side and tighten down firmly (see "Tightening Torques")

Important:

Coat all sliding and bearing points with STIHL multipurpose grease,

see 13.2, or (better) with

molybdenum grease (e.g. Molykote), see 13.2. Do not lubricate the brake band.

 First att ach the brake band (1) to

the lever (2) and then push it into the crankcase recess (arrow).

138RA007

4.4.2 Installing

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12 034, 036, 036 QS

 Check that protective tube is

correctly positioned: a = 20 mm b = 33 mm

138RA016

 Hook the brake sp ring to the

lever.

138RA017

 Use the assembly tool

1117 890 090 0 to at tach the brake spring (1) to the anchor pin.

– Fit cover over the chain brake.

138RA015

– Fit the inner side plate - see 4.1. – Install the clutch drum/chain

sprocket - see 4.1.

– Fit the cutting attachment and

chain sprocket cover - see 4.1.

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

– Remove the chain sprocket cover

and cutting attachment - see 4.1.

– Remove clutch drum/chain

sprocket - see 4.1.

 Remove mounting screw (1) from

inner side plate (2) and lift side plate away.

 Remove mounting screws (3)

from cover (4) and lift the cover away.

148RA070

– Engage the chain brake by

pushing the hand guard away from the front handle.

4.5 Chain Brake (036 QS)

4.5.1 Removing

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13034, 036, 036 QS

 Carefully pry the brake spring (1)

off the anchor pin and disconnect it from the lever (2).

148RA071

 Remove the screw (1).  Ease the brake band ( 2) out of

its seat in the crankcase and disconnect it from the lever (3).

148RA072

 Remove screw with captive

washer from the hand guard.

Note:

When installing, tighten down the screw with captive washer firmly (see "Tightening Torques").

138RA008

 Carefully pry spring (1) off the

pivot pin.

148RA073

 Pull the hand guard (2) and brake

lever (1) off the pivot pins.

148RA074

 Disconnect brake cable ( 1) from

the brake lever (2).

– Take the brake lever out of the

hand guard.

148RA075

 Disconnect spring (1) from

lever (2).

 Pry the E-clip (3) off the pivot pin

and remove the lever with spring.

Clean all disassembled parts in

148RA076

2 3

white spirit. Replace any worn or damaged parts.

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14 034, 036, 036 QS

 Fit the lever (2) and spring (1).  Fit the E-clip (3).

148RA076

2 3

 Insert lever in the side of the hand

guard as shown.

148RA077

 Attach brake cable (1) to hole

(arrow) in brake lever (2).

148RA075

 Position the hand guard (1)

against the pivot pin and fit the other side of the hand guard over the fan housing.

 Press the lever (1) slightly

downward and push the hand guard and brake lever (2) onto

148RA078

the pivot pins.

– Insert screw with captive washer

for hand guard and tighten down firmly (see "Tightening Torques").

Important:

Coat all sliding and bearing points with STIHL multipurpose grease,

see 13.2, or (better) with

molybdenum grease (e.g. Molykote), see 13.2. Do not lubricate the brake band.

 Attach spring (1) to the pivot pin.

148RA073

 First att ach the brake band (2) to

the brake lever (3) and then pu sh it into the slot in the crankcase.

 Install screw (1) with LOCTITE

243 and tighten down firmly (see "Tightening Torques")

148RA072

 Hook the brake spring (1) to the

brake lever (2).

148RA071

4.5.2 Installing

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15034, 036, 036 QS

 Use the assembly tool

1117 890 090 0 to at tach the brake spring (1) to the anchor pin.

– Fit cover over the chain brake -

see 4.5.1.

– Fit inner side plate - see 4.5.1.

148RA098

– Install the clutch drum/chain

sprocket - see 4.1.

– Fit the cutting attachment and

chain sprocket cover - see 4.1.

– Pull hand guard toward front

handle.

– Unscrew nut from chain sprocket

cover and remove the cover - see

4.1.

– Remove the cutting att a chment -

see 4.1.

 Take out screw (1) and remove

the side plate (2).

 Take out screws (3) an d re m ove

the cover (4).

148RA070

 The brake cable (1) must hang

loosely in the crankcase when the brake is disengaged.

148RA079

 Press down interlock lever (1) all

the way and hold it in that position.

148RA080

 The brake band (1) must locate

without any play against the points (A) in the crankcase.

148RA081

 Let go of the interlock lever (1).  Check free travel by slowly

squeezing the interlock lever (1). Play must be within the mark (B) at the front end of the interlock lever.

148RA082

4.5.3 Checking Play

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16 034, 036, 036 QS

The brake lever must not move. If it does, adjust play - see 4.5.4

Reassemble in the reverse sequence.

 Open twist lock (1) and lift away

the carburetor box cover (2) vertically.

148RA064

 Release and unscrew slotted

nuts (1).

 Remove the air filter (2).

148RA084

 Loosen the self-tapping

screw (1).

 Use a 6mm open-end wrench to

adjust play with nut (2).

148RA085

Turn wrench to right to reduce play.

Turn wrench to left to increase play.

 Lock the setting with se lf-tapping

screw (1).

Reassemble in the reverse sequence.

4.5.4 Adjusting Play

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17034, 036, 036 QS

Check operation of the chain brake with the bar and chain mounted.

Note:

When starting the machine observe local safety regulations and the safety precautions in the owner’s manual.

– With the engine running, open

the throttle wide. – Release the rear handle. The chain must come to a standstill

in less than one second.

If the brake does not operate properly, service the sliding and bearing points shown in the illustrations as follows:

If lightly contaminated:

– Clean all parts with a brush and

white spirit.

If heavily contaminated or clogged with resin:

– Remove the parts concerned and

clean in white spirit or a resin

solvent.

– Replace worn or damaged parts. – Before re-installing parts, the

machine recesses and seats.

 Lubricate bearing points with

Mobilplex grease (see 13.2).

148RA047

 Lubricate these points (1) with

Mobilplex grease (see 13.2).

 Coat outside diam eter of clutch

drum (2) with chain oil.

Note:

If a biological chain oil is preferred,

148RA048

STIHL recommends the use of rapidly biodegradable STIHL Bioplus. To guarantee t roublefree oper ation, use only original STIHL replacement parts as per the latest parts list.

– Remove chain sprocket cover

and cutting attachment - see 4.1.

 Remove mounting scre w (1) from

inner side plate (2) and lift side plate away.

138RA004

 Use a screwdriver to turn the spur

gear clockwise until tensioner slide butts against the thrust pad.

Note:

Older machines are equipped wi th a front chain tensioner - see 5.5.2.

148RA086

4.5.5 Checking Operation of Chain Brake 4.6 Chain Tensioner

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18 034, 036, 036 QS

 Take out the cover plate

mounting screw (1).

 Remove the cover plate (2) with

retainer (3) from the spur gear.

148RA087

1 2

 Pull out the spur gear (1).  Take out the tensio ne r slid e (3 )

with adjusting screw (4) and thrust pad (2).

– Inspect the teeth on the spur gear

and adjusting screw, remove

4 3

148RA088

thrust pad if necessary.

– Take the adjusting screw out of

the tensioner slide and replace the parts.

Install in the reverse sequence.

 Check that O-ring is fit ted in spur

gear.

– Lubricate O-ring with a little oil

before fitting the spur gear.

Note:

Coat teeth of adjusting screw and

138RA018

spur gear with grease, see 13.2, before refitting.

The adjusting screw and spur gear must be replaced as a matching pair.

– Remove chain sprocket cover

and cutting attachment - see 4.1.

 Push stud puller 5910 893 0501

over the collar stud as far as it will go. Use a 15 mm wrench to unscrew the collar stud counterclockwise.

138RA019

– Before installing, coat thread of

collar stud with LOCTITE - see

13.2.

– Install and tighten down t he collar

studs (see "Tightening Torques").

4.7 Bar Mounting Studs

Page 19

19034, 036, 036 QS

Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine.

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

(034)

 Take out the screws and remove

the upper casing.

138 RA 219

(036, 036 QS)

 Take out screws and remove the

upper casing.

138 RA 220

 Take out the screws and remove

the lower casing.

138 RA 020

(034)

 Remove exhaust gasket (1) and

flange.

138RA021

(036, 036 QS)

 Remove heat shield (1) and

gasket (2) from the upper casing (3).

138RA022

 Install new gasket (1) so that its

bead points toward the muffler.

Note:

If the bores of the lower casing are not reinforced, fit washers under the heads of the mounting screws.

138RA021

– Coat threads of mounting screws

with LOCTITE - see 13.2.

– Insert and tighten down the

mounting screws firmly (see "Tightening Torques").

5Engine

5.1 Removing and Installing Muffler

Page 20

20 034, 036, 036 QS

Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine.

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

– Drain the fuel and oil tanks. – Remove the air filter - see 12.1 – Remove the carburetor - see 12.3

 Pull the washer (1) off the studs

and remove the sleeve (2) from the manifold.

– Remove the shroud, spark plug

and, if fitted, the decompression valve - see 4.3.

138RA023

– Remove the muffler - see 5.1 Reassemble in the reverse

sequence.

– Preparations - see 5.2  Take out the four cylinder base

screws.

148RA089

 Pull the cylinder off the piston

and, at the same time, push the manifold through the tank housing opening.

Caution:

Do not use pointed or sharp-edged tools for this job.

138RA024

 Remove the cylinder gasket.

138RA025

 Release the hose clamp (1) on

the manifold (2). Pull the manifold off the intake port.

– Inspect the cylinder and replace it

if necessary.

Note:

138RA026

If a new cylinder has to be installed, always fit the matching piston. New cylinders are only supplied complete with piston for this reason.

5.2 Exposing the Cylinder 5.3 Cylinder and Piston

5.3.1 Removing

Page 21

21034, 036, 036 QS

Important:

Before removing the piston, decide whether or not the crankshaft has to be removed as well.

 To remove the flywheel and

clutch, block the crankshaft by

sliding the wooden assembly

138RA027

block (1) 1 108 893 4800 between

the piston and crankcase.  Use a scriber or similar tool to

ease the hookless snap rings out

of the grooves in the piston.

 Use the assembly drift (2)

1 1 10 893 4700 to push the pist on

pin (1) out of the piston.

Note:

– If the piston pin is stuck, tap the

end of the drift lightly with a

hammer if necessary.

138RA028

Important: Hold the piston

steady during this process to ensure that no jolts are transmitted to the connecting rod.

– Remove piston and take the

needle cage out of the connecting rod.

 Inspect piston r ings and replace if

necessary - see 5.4.

138RA029

– Thoroughly clean the gasket

seating surface on the cylinder.

 Lubricate the need le cage with oil

and fit it in the small end.

138RA030

 Install a snap ring in the front

piston boss (2), i.e. the piston boss facing you when the arrow (1) on the piston head is pointing to the right.

Note:

Use installing tool 5510 890 2210 to

138RA031

fit the snap ring - see "S tandard Repairs, Troubleshooting" handbook.

– Heat the piston on an electric

heating plate to about 60°C.

5.3.2 Installing

Page 22

22 034, 036, 036 QS

 Slip the piston over the

connecting rod so that arrow on piston crown points to exhaust port.

138RA032

– Push the assembly drift

1110 893 4700, sma ll dia m et er first from the clutch side, through the piston and small end (needle cage) and line up the piston.

 Fit piston pin on the end of the

assembly drift and push it into the

138RA033

piston.

– Use installing tool 5910 890 2210

to fit the snap ring - see "S tandard Repairs, Troubleshooting" handbook.

– Fit new cylinder gasket on the

crankcase.

– Lubricate piston and piston rings

with oil.

 Slide the wooden assembly

block between the piston and crankcase.

 Rest the piston on the wooden

assembly block.

138RA034

 Position the piston rings so that

the radii at the ring gap meet at the fixing pin in the piston groove when the rings are compressed.

138RA035

 Push the manifold on to the

intake port so that its tab lines up with the rib on the cylinder.

138RA036

 Slide the hose clamp on to the

manifold. The screw head must point to the right.

 The screw on the hose clamp

must be below the manifold and at a right angle to the cylinder axis.

138RA037

 Tighten the screw until the gap

"a" between the two ends of the hose clamp is 3.5 to 4.5 mm.

Note:

If a new cylinder is installed in an older machine, it is necessary to shorten the seventh cylinder fin. Use the edge of the eighth fin as a guide for the modification (see arrow in illustration).

138RA038

10mm

Page 23

23034, 036, 036 QS

– Coat thread of setscrew in

cylinder with LOCTITE - see

13.2.

– Insert setscrew and t ighten down

firmly (see "Tightening Torques").

– Lubricate the inside of the

cylinder with oil and line it up so

that it is positioned as it will be in

the installed condition.  Use the clamping strap

0000 89 32600 to compress the

rings around the piston. Check

138 RA 039

correct installed position of rings

once again.

Note:

T o make cylinder inst allation easier , apply clamping strap so that it is just below the piston crown.

 Slide the cylinder over the piston. – Remove the wooden assembly

block and clamping strap.

138 RA 040

 Wind a piece of string (about

15 cm long) around the back of the manifold flange, press the manifold down and pass the ends of the string through the intake opening.

138RA041

 Pull the ends of the string

outward. The manifold flange is pulled through the tank housing intake opening without damaging the manifold.

138RA042

– Carefully line up the cylinder and

gasket.

– Fit cylinder base screws and

torque down firmly in a diagonal pattern (see "Tightening Torques").

Important:

It is essential to observe the specified tightening torque as the screws might otherwise work loose.

Assemble all other parts in the reverse sequence. Always install new gaskets.

Page 24

24 034, 036, 036 QS

– Remove the piston - see 5.3.1. – Remove rings from piston.

 Use a piece of old piston ring to

scrape the grooves clean.

Warning:

138RA043

Do not install 1.2 mm rings in pistons with 1.5 mm grooves.

 Install the new piston rings in the

grooves so that the radii at the ends of the rings face upward.

– Install the piston - see 5.3.2.

138RA044

– Remove the chain brake - see 4.4

and 4.5.

– Remove the oil pump - see 11.4 – Remove the flywheel - see 6.4.1 – Remove the ignition module - see

138RA045

6.5.1

– On machines with handle and/or

carburetor heating, remove the generator - see 10.5.1.

– Remove the cylinder and piston -

see 5.3.1.

– Remove the tank housing - see

12.8.1.

– Remove the spiked bumper.  Use a 5 mm drift or other suitable

tool to drive out the two dowel pins from the clutch side.

 Unscrew the five mounting

screws which join the two halves of the crankcase.

138RA046

 Use a screwdriver to rotate the

spur gear clockwise until the tensioner slide butts against the thrust pad.

Note:

Use service tools AS 5910 007 2205 and

148RA086

ZS 5910 007 2200 to remove and install the crankshaft. Follow the instructions supplied with the tools.

– Back off spindle on service tool

AS all the way.

 Slip service tool

AS 5910 007 2205 over the two collar studs, fit the hexagon nuts (for sprocket cover) and tighten them down by hand.

138RA047

5.4 Piston Rings 5.5 Crankcase

5.5.1 Removing the Crankshaft

Page 25

25034, 036, 036 QS

 Turn the spindle of the service

tool clockwise until the crankshaft is pressed out of the ball bearing. The two halves of the crankcase separate during this process.

138RA048

 Fit thrust sleeve 1107 894 1000

from clutch puller 1107 890 4500 to protect the crankshaft thread during the following operation.

138RA049

 Fit service tool

ZS 5910 007 2200 aga inst the outside of the crankcase.

138RA050

Note:

The tool’s drilled plate must locate flat against the crankcase.

 With the crankcase horizontal

(cylinder flange upright), rotate service tool until the number 7 on the plate is at the bottom.

 Secure the service tool to the

crankcase with M5x72 mounting screws 9022 341 1190. Insert the screws in the holes marked "7" and tighten them down against the drilled plate.

– Turn spindle counterclockwise

138RA051

(left-hand thread) until it locates against the crankshaft.

– Use a 19 mm wrench to continue

turning the spindle and push the crankshaft out of its bear ing seat.

 The crankshaft (1), connecting

rod (2) and needle bearing form an inseparable unit. This means that the crankshaft must always be replaced as a complete unit in the event of damage to any one of these parts.

138RA052

– When fitting a replacement

crankshaft, always install new oil seals and ball bearings.

– Remove the gasket from the

crankcase sealing face.

 Use a screwdriver to pry the oil

seal out of the ball bearing at t he clutch side.

138RA053

Page 26

26 034, 036, 036 QS

 Use press arbor 1118 893 7200

to press the ball bearing out of its seat.

138RA054

 Use a screwdriver or similar tool

to knock the oil seal out of its seat at the ignition side.

138RA055

 From outs ide the crankcase, use

arbor 1 120 893 7200 to pre ss the ball bearing inwards and out of its seat.

138RA056

– Pull the oil suction hose out of

crankcase.

– Inspect both halves of the

crankcase for cracks and replace if necessary.

Note:

Always install new gaskets and ball bearings when replacing the crankcase. The crankcase must be replaced as a complete unit even if only one half is damaged.

All other parts which are still serviceable can be transferred to the new crankcase after the new bearings have been fitted (crankcase has to be heated).

Use the stud puller 5910 893 0501 to remove and install the bar mounting studs - see 4.7.

– If the original crankcase is used

again, remove all the gasket residue and clean the mating surfaces.

Note:

Clean the mating surfaces thoroughly to ensure a perfect seal.

Note:

A new front chain tensioner is supplied with replacement crankcases.

1 Tensioner slide 2 Adjusting screw 3 Thrust pad

138RA058

1 5

2 3 4

4 Cover plate 5 Pan head screw

– Stamp the machine’s serial

number on the crankcase with

2.5 mm figure stamps.

– Check that dowel pin is in

position. If necessary, drive dowel pin into new crankcase.

5.5.2 Installing th e Crankshaft

Page 27

27034, 036, 036 QS

See illustrated parts list for correct installed sequence and positions of crankcase components.

 Pull the plastic plug out of the oil

pump.

138RA059

 Position the oil pump ag ainst the

crankcase. Insert and tighten down the mounting screws.

– Before heating the crankcase,

remove all rubber and polymer

138RA060

components, such as oil suction and delivery hoses, grommets, annular buffers and levers - see

8.1 and 11.4.

– Inspect condition of all parts and

replace as necessary.

– Heat area of bearing seat on

clutch side of crankcase to approx. 120°C.

 Place ball bearing in posit ion and

press it in until it locates against the oil pump.

Note:

The ball bearing can be fitted by hand if the crankcase is heated as specified. This operation must be

138RA061

carried out very quickly because the bearing absorbs heat immediately and begins to expand.

– Remove the oil pump and refit the

plastic plug.

 Push the two annular buffers,

tapered end first, into position so that the groove (1) engages over the housing rib.

138RA062

 Push the oil suction hose into the

crankcase bore.

138RA063

 Use a blunt tool to push the oil

suction hose into the bore so that its tab locates in the bottom right recess.

138RA064

Page 28

28 034, 036, 036 QS

 Fit the lever (1) over the pivot pin,

secure it with the E-clip and attach the spring (2).

 Install the chain tensioner (3) -

see 4.6

138RA065

– Heat area of bearing seat on

ignition side of crankcase to approx. 120°C.

 Use press arbor 1118 893 7200

to install the ball bearing (open side up).

138RA066

Important:

the ball bearing is closed at one side. The open side must be on the inside of the crankcase to guarantee proper lubrication.

Note:

The ball bearing can be fitted by hand if the crankcase is heated as specified. This operation must be carried out very quickly because the bearing absorbs heat immediately and begins to expand.

 Push annular buffer into

crankcase bore, from outside, until its groove (1) engages the inner rib.

138RA067

 Extend the spindle of service tool

ZS (2) 5910 007 2200 fully and then screw the threaded sleeve (1) 5910 893 2420 onto the spindle as far as it will go.

148RA093

 Lubricate short crankshaft stub

with oil and position it in the bearing from inside the ignition side of the crankcase.

148RA090

Important:

The original crankshaft must not be installed in model 034S.

 Apply threaded sleeve (1) to

thread (2) on crankshaft stub.

148RA091

1 2

 Hold the service tool and

crankshaft steady and continue turning the spindle clockwise until the service tool butts against the crankcase.

148RA092

Page 29

29034, 036, 036 QS

 T urn the spindle clockwise to pull

in the crankshaft until it locates against the ball bearing.

Important:

The connecting rod must point toward the cylinder flange while the crankshaft is being installed.

138RA069

– Remove service tool ZS: First

release the spindle counterclockwise and then unscrew the service tool ZS, also counterclockwise.

– Screw the spindle fully into

service tool AS 5910 007 2205 in the clockwise direction.

 Screw threaded sleeve (2)

5910 893 2409 onto the spindle of service tool AS (1) as far as it will go (left-hand thread)

– Lubricate crankshaft stub at

clutch side with oil.

138RA070

– Fit crankcase gasket. – Push the clutch side of the

crankcase over the crankshaft stub as far as it will go.

 To prevent the crankcase

and gasket twisting, fit M5x72 screws (1) (from service tool ZS 5910 007 2200) in two crankcase holes).

138RA071

– Push threaded sleeve over the

crankshaft stub.

– Hold the crankshaft steady

and rotate the spindle counterclockwise to screw the threaded sleeve onto the crankshaft.

 Release the crankshaf t. Hold the

service tool (2) steady and continue turning the spindle until the tool locates against the guide bar mounting face.

 Fit the two hexagon nuts (3) on

the bar mounting studs and screw them down finger-tight.

 Turn the spindle counterclock-

wise until the crankshaft locates against the ball bearing.

138RA072

Page 30

30 034, 036, 036 QS

– Unscrew the hexagon nuts.

Unscrew the spindle clockwise and take away the service tool.

– Take out the two M5x72 screws.

 Drive home the two dowel pins.

138RA073

 Fit the five crankcase mounting

screws and tighten them down alternately in a diagonal pattern (see "Tightening Torques").

138RA046

 Trim away any excess gasket

material in the area of the cylinder mounting face.

138RA074

 If the crankshaft does not turn

freely, it is sufficient to tap the end of the stub with a plastic mallet to relieve axial stresses.

138RA075

 Before installing oil seal, coat

cavity between dust and sealing lips with grease - see 13.2.

138RA076

 Fit the installing sleeve (1)

1118 893 4602 over the clutch end of the crankshaft.

 Slip the oil seal (2), open side

facing the crankcase, over the installing sleeve.

138RA077

 Press home the oil seal with

press sleeve (1) 1118 893 2401.

– Remove the installing sleeve.

138RA078

Page 31

31034, 036, 036 QS

– Slide the oil seal, open side

facing the crankcase, over the ignition end of the crankshaft.

 Use press sleeve 1121 893 2400

to press home oil seal until sleeve butts against the crankcase.

138RA079

Important:

It is essential to observe the correct installed depth of the oil seal to achieve a proper seal. Always use the press sleeve for this operation.

– Reassemble all other part s in the

reverse sequence.

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

This makes adjustment of the prescribed idle speed difficult, if not impossible.

Moreover, the transition from idle speed to part or full throttle is not smooth.

The crankcase can be checked thoroughly for leaks with the carburetor and crankcase tester 1106 850 2905 and the vacuum pump 0000 850 3501.

– Remove the shroud from the

cylinder - see 4.3.

– T ake out the muf fler upper casing

mounting screws and remove the upper casing - see 5.1.

 Loosen the muffler lower casing

mounting screws about half way.

138 RA 020

 Fit sealing plate 0000 855 8106,

from above and narrow end first, between the muffler lower casing and cylinder exhaust port.

Note:

The sealing plate must completely fill the space between the two

138RA080

5.6 Crankcase Leakage Test 5.6.1 Preparatio n s

Page 32

32 034, 036, 036 QS

mounting screws. Push the narrow end of the sealing plate home so that it is just below the lower casing.

– Retighten the mounting screws

moderately.

– Remove the carburetor - see 12.3 – Set the piston to top dead center

(T.D.C.). This can be checked through the inlet port.

– Remove screw 1128 855 9000

from test flange 1128 850 4200.

 Fit the test flange (1), numbe r "1"

facing up and flat side first, on the carburetor studs.

 While fitting th e test flange, make

148RA051

2 1

sure the impulse opening on the manifold flange is properly sealed (see arrow).

 Fit the two hexagon nuts (2) and

tighten them down moderately.

– Preparations - see 5.6.1. – Check tightness of spark plug

before starting leakage test.

– If decompression valve is fitted,

make sure it is tight and closed.

 Connect pressure hose (1) of

tester 1 106 850 2905 to nipple on test flange (2).

148RA052

 Close the vent screw (1) on the

rubber bulb.

143RA046

– Pump air into the crankcase with

rubber bulb until the gauge indicates a pressure of 0.5 bar . If this pressure remains constant for at least 20 seconds, the crankcase is airtight.

– However, if the pressure drops,

the leak must be located and th e faulty part replaced. Then repeat the pressure test.

Note:

To find the leak, coat the suspe ct area with oil and pressurize the crankcase. Bubbles will appear if a leak exists.

– Open the vent screw and

disconnect the hose.

– A pressure must always be

followed by a vacuum test - see

5.6.3.

– After finishing the tests,

reassemble all parts in the reverse sequence.

Note:

Coat the mounting screws for the upper and lower muffler casings with LOCTITE. Insert and tighten down the screws (see "Tightening Torques").

5.6.2 Pressure Test

Page 33

33034, 036, 036 QS

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.

An additional test can be carried out with vacuum pump 0000 850 3501 to detect this kind of fault.

 Connect suction hose of vacuum

pump 0000 850 3501 (1) to nipple of test flange (2).

148RA052

 Close the vent screw (1) on the

pump.

 Operate lever (2) until pressure

gauge (3) indicates a vacuum of

0.5 bar.

232RA037

Note:

If the vacuum reading remains constant, or rises to no more than

0.3 bar within 20 seconds, it can be assumed that the oil seals are in good condition. However, if the pressure continues to rise (reduced vacuum in the crankcase), the oil seals must be replaced, even if no leaks were detected in the pressure test.

– After finishing the test,

reassemble all parts in the reverse sequence.

Note:

Coat the mounting screws for the upper and lower muffler casings with LOCTITE. Insert and tighten down the screws (see "Tightening Torques").

It is not necessary to disassemble the complete crankcase to replace the oil seals.

– Remove the flywheel - see 6.4.1. – Remove the Woodruff key from

the crankshaft stub.

 On machines with handle or

carburetor heating system, take out the generator mounting screws, lift the generator away and put it to one side.

– Remove the clutch - see 4.3.

138RA084

– Remove the brake band - see

4.4.1 and 4.5.1.

– Remove the oil pump - see 11.4. – Fit No. 3.1 jaws 000 893 3706 in

the universal oil seal puller 5910 890 4400.

5.6.3 Vacuum Test 5.7 Replacing the Oil Seals

Page 34

34 034, 036, 036 QS

 Apply the puller at the clut ch side

and rotate the spindle clockwise to pull the oil seal out of the crankcase.

138RA083

 Apply the puller at the ignition

side and rotate the spindle clockwise to pull the oil seal out of the crankcase.

Important:

When using the puller, make sure it does not damage the crankcase

138RA085

surface or the ball bearing cages. Install the oil seals as described

under 5.5.2.

– Install the generato r - see 10 .5.2 . – Reassemble all other parts in the

reverse sequence.

Exercise extreme caution when carrying out maintenance and repair work on the ignition system. The high voltages which occur can cause serious or even fatal accidents.

Troubleshooting on the ignition system should always begin at the spark plug - see "S tandard Rep airs, Troubleshooting" handbook.

Note:

The electronic (breakerless) ignition system basically consists of an ignition module (1) and flywheel (2) which requires no outside power source (battery or dynamo). A special flywheel (with ring magnet for the generator) is installed in

138RA086

2 1

models with handle or carburetor heating system.

– Remove the air filter - see 12.1 – Pull boot off the spark plug. – Remove the shroud - see 4.3 – Remove the ignition module - see

6.5.1

– Pull the ignition lead out of seat in

crankcase.

 Unscrew the ignition lead (1) f rom

high voltage output on ignition module (2).

– Pull the insulating tube off the

ignition lead.

138RA087

 Use a suitable pair of pliers to grip

the leg spring and pull it out of the spark plug boot.

138RA088

6 Ignition System 6.1 Ignition Lead/

Spark Plug Boot

Page 35

35034, 036, 036 QS

– Unhook the leg spring from the

ignition lead and slip the spark plug boot off the lead.

– Coat the end of the ignition lead

and insulating tube (about 20 mm) with oil.

– Fit spark plug boot over the lead. – Use a suitable pair of pliers to grip

the end of the ignition lead inside the spark plug boot and pull it out.

 Pinch the hook of the leg spring

into the center of the lead, i.e. about 15 mm from the end of the lead.

138RA089

 Pull the lead back into the boot so

that the leg spring locates properly inside it.

366RA104

– Use a pointed tool to pierce the

center of the other end of the ignition lead.

– Slip the insulating tube over the

ignition lead.

– Screw the ignition lead into the

ignition module.

– Push the insulating tube right up

the ignition module’s high volt age output.

– Install the ignition module - see

6.5.1.

– Push ignition lead into seat in

crankcase.

– Fit the shroud - see 4.3. – Fit boot on the spark plug. – Fit the air filter - see 12.1.

Note:

If the insulation of the short circuit wire (2) is damaged it can cause a short circuit to ground and upset or completely interrupt ignition.

To remove the short circuit wire (2) and ground wire (1), perform the

138RA208

following operations: – Remove the fan housing - see

6.4.

– Remove the shroud - see 4.3. – Remove the air filter - see 12.1. – Remove the tank vent - see 12.6.

 Use a small screwdriver to ease

the connector sleeve of the short circuit wire (1) out of its seat in the switch shaft.

138RA090

6.2 Short Circuit Wire/ Ground Wire

Page 36

36 034, 036, 036 QS

 Pull ground wire connector

sleeve out of contact spring.

138RA092

– On machines with handle or

carburetor heating, disconnect the pin and socket connectors of

the heating systems - see 10.3.  Pull grommet out of t ank housing. – Slip grommet off the wires.

138RA211

– Pull the boot off the spark plug

and remove the ignition lead from

its seat in the crankcase. – Pull the insulating tube through

the cable gland in the crankcase.

Removing the short circuit wire:

 Disconnect short circuit wire f rom

ignition module.

– Pull short circuit wire out of

retainer on ignition module.

138RA104

– Pull the short circuit wire through

the insulating tube.

– Install in the reverse sequence.

Note:

A ground wire is installed because the contact spring in the polymer tank housing is not connected to ground on the ignition module.

Removing the ground wire:

 Take out the screw (1) and

remove the ground wire (2).

138RA093

– Pull the ground wire out through

the insulating tube.

– Install the new ground wire in the

reverse sequence. Check that the insulating tube is properly located in the crankcase cable gland.

Important:

Use an ohmmeter to check correct operation of the ground and short circuit wires as well as the STOP contact.

– Set the ohmmeter to measuring

range "Ω x 1".

 Clip one of the two test leads to

the contact spring (1).

138RA094

 Clip the other test lead to the

ground wire terminal.

138RA095

Page 37

37034, 036, 036 QS

– The ohmmeter must now show a

reading of 0 Ω. If no reading is obtained, check the connection between the contact spring and connector sleeve.

Checking short circuit wire and STOP contact :

– Leave one test lead clipped to the

contact spring.

– On machines with carburetor

heating, pull the thermostatic switch’s flag connector off the contact spring.

– Move the Master Control lever

upwards to "STOP".

– Clip other lead to short circuit

wire’s terminal.

– The ohmmeter must again show

a reading of 0 Ω. If no reading is obtained, check the connection between the connector sleeve in the switch shaft’s cam and the contact spring.

– On machines with carburetor

heating, push the thermostatic switch’s flag connector onto the contact spring.

– Remove the air filter - see 12.1 – Remove the tank vent - see 12.6.

 The short circuit system is in

order if the short circuit wire makes contact with the connector sleeve when the Master Control

138RA096

lever is in the "STOP" position.

Replacing a bent or broken contact spring:

– T o avoid damaging the fuel hose,

pull it off the carburetor’s elbow connector.

– On machines with carburetor

heating, pull the thermostatic switch’s flag connector off the contact spring.

 Pull the ground wire connector

sleeve out of the contact spring.

– Move Master Control lever to

"STOP" position.

138RA092

 Squeeze the contact spring so

that is disengages from the Master Control lever and, at the same time, use a screwdriver to pry it out of its seat in the crankcase.

– Install the new contact spring.

138RA097

– Reconnect the ground wire

connector sleeve.

Important:

– Check operation of the short

circuit wire - see 6.2.

– On machines with carburetor

heating, push the thermostatic switch’s flag connector onto the contact spring.

– Fit the tank vent - see 12.6. – Fit the air filter - see 12.1.

6.3 STOP Contact

Page 38

38 034, 036, 036 QS

 Take out mounting screws and

remove the fan housing. – Rotate the flywheel so that the

magnet poles are opposite the

ignition module.

138RA098

– Use locking strip 0000 893 5903

to block the piston - see 4.3.  Unscrew the flywheel mounting

nut from the crankshaft.

138RA099

 Screw puller 1110 890 4500 into

flywheel hub as far as stop.  Hold puller steady with a 24 mm

wrench and use a 17 mm wrench

to screw home the thrust bolt until

the flywheel comes away from its

seat on the crankshaft.

138RA100

– Take off the flywheel. – Inspect the flywheel. If you find

any damage (e.g. cracks, , broken fan blades), fit a new flywheel.

Important:

If a new flywheel 1125 400 1208 is installed in a machine with heated handles

X 31 813 247, the original front handle must always be replaced by front handle 1125 790 1702 to take account of the higher power output. In addition, the new heating element 1 128 434 5000 must be fit ted in the rear handle since the heating elements may otherwise burn out. The old front handle 1 125 790 1707 and the old heating elements 1125 434 5000 may only be installed in machines with flywheel 1125 400 1207.

Front handles and heating elements can be identified with the aid of the following resistances:

Rear handle heating element: Old version (1) 0.225...0.275 Ω New version (2) 0.922...1.1 Ω

Front handle heating element: Old version 1.44 ...1.76 Ω New version 6.3 ...7.7 Ω

148RA217

1 2

 Check correct position of

Woodruff key.

138RA101

Important:

– Clean the stub of the crankshaft

and the flywheel hub bore with a standard commercial, solventbased degreasant containing no chlorinated or halogenated hydrocarbons - see 13.2.

138RA102

– Fit the flywheel in position.  Fit and tighten down the flywheel

nut (see "Tightening Torques").

Reassemble all other parts in the reverse sequence. Observe tightening torques when refitting the fan housing (see "Tightening Torques").

6.4 Flywheel

6.4.1 Removing

6.4.2 Installing

Page 39

39034, 036, 036 QS

The ignition module accommodates all the components required to control ignition timing.

Ignition module components a nd connections

1 Ignition lead with insulating tube

138RA103

2 High voltage output 3 Ground wire 4 Connector tag for

short circuit wire

Accurate testing of the ignition module is only possible with special test equipment. For this reason it is only necessary to carry out a spark test in the workshop. A new ignition module must be installed if no ignition spark is obtained (after checking that wiring and stop switch are in good condition).

– Remove the fan housing - see

6.4.1

 Use a screwdriver to disconnect

the short circuit wire from the ignition module.

138RA104

 Take out the two mounting

screws and lift away the ignition module.

Note:

If the ignition module is faulty, unscrew the ignition lead counterclockwise and transfer it

138RA105

along with the spark plug boot and cable retainer to the new ignition module.

– To install the ignition module,

connect short circuit wire to tag on ignition module and then push the short circuit wire into the retainer.

– Place the ignition module in the

crankcase.

– Coat threads of ignition module

mounting screws with LOCTITE -

see 13.2.

– Use lower mounting screw to

connect the ground wire to the ignition module.

 Fit the two screws and tighten

them down moderately.

– Rotate the flywheel until the

magnets are between the two arms of the ignition module.

 Slide the setting gauge

1111 890 6400 or 0.2 mm metal gauge between the arms of the ignition module and the flywheel magnets.

– Press the ignition module against

the flywheel and tighten down the

138RA107

mounting screws (see "Tightening Torques").

Important:

Tighten the upper screw first. – Remove the setting gauge and

use a feeler gauge to check the air gap. It should be 0.2 to

0.3 mm.

– Fit the fan housing - observe

tightening torques (see "Tightening Torques").

6.5 Ignition Module 6.5.1 Removing and Installing

Page 40

40 034, 036, 036 QS

Ignition timing on electronic (breakerless) magneto ignition systems is fixed at 2.5 mm B.T.D.C. at 8,000 rpm and is not adjustable.

However , in view of the permissible tolerances in the electronic circuitry , it may vary between 1.8 and 2.6 mm B.T.D.C. at 8,000 rpm.

Since there is no mechanical wear in these systems, ignition timing cannot get out of adjustment. However, an internal fault in the circuit can alter the switching point in such a way that a spark test will still show the system to be in order although timing is outside the permissible tolerance. This will impair engine starting and running behavior.

Troubleshooting chart - see "Standard Repairs, Tro ubleshooting" handbook.

If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not completely, it can be assumed that the starter mechanism is in order but plugged with dirt. At very low outside temperatures the lubricating oil on the rewind spring may thicken and cause the spring windings to stick together . Th is has a detrimental effect on th e function of the starter mechanism. In such a case it is sufficient to apply a few drops of paraffin (kerosine) to the rewind spring.

Then carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored.

If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed and disassembled. Take special care when removing the spring.

Wash all parts in paraffin/kerosine or white spirit.

Lubricate the rewind spring and starter post with STIHL special lubricant, see 13.2, before inst alling.

– Remove the fan housing - see

6.4.1

Note:

For descriptions on removing and installing the rope rotor, replacing the starter rope, p awls or rope guide bush - see "Standard Repairs, Troubleshooting" handbook. Observe tightening torques when refitting the fan housing (see "Tightening Torques").

6.5.2 Ignition Timing 7 Rewind Starter

7.1 Routine

Maintenance

7.2 Rope Rotor, Pawls, Starter Rope, Rope Guide Bush

Page 41

41034, 036, 036 QS

– Remove the rope rotor - see 7.2.

 Use suitable pliers to grip the

anchor loop of the rewind spring and lift it up.

– Take the sp ring housing and

rewind spring out of the fan

138RA108

housing.

– Remove any remaining bits of

spring from the fan housing.

– Lubricate die rewind spring with

STIHL special lubricant and fit it with the spring housing (bottom plate facing up) in the fan housing.

– Engage the spring loop over the

lug in the fan housing.

Warning:

The rewind spring may pop out and uncoil during installation. If the rewind spring has popped out, refit it in the spring housing as follows:

 Position anchor loop about

25 mm from the edge of the spring housing.

138RA109

 Refit the rewind spring in the

spring housing in the counterclockwise direction, starting outside and working inwards.

– Fit the spring housing in the fan

housing.

138RA110

– Engage the spring loop over the

lug in the fan housing.

– Install the rope rotor - see 7.2. – Tension the rewind spring - see

7.4.

– Remove the rope rotor - see 7.2. – Use suitable pliers to grip the

anchor loop of the rewind spring and pull it out carefully.

Warning:

The rewind spring jumps out of its seat in the fan housing in this process.

– Remove any remaining bits of

spring from the fan housing.

– Lubricate the rewind spring with

STIHL special lubricant.

 Engage the anchor loop over the

lug in the fan housing and fit the rewind spring in the fan housing in the clockwise direction, starting outside and working inwards.

– Install the rope rotor - see 7.2.

148RA053

– Tension the rewind spring - see

7.4.

7.3 Rewind Spring

7.3.1 Replacing the Rewind Spring (034)

7.3.2 Replacing the Rewind Spring (036, 036 QS)

Page 42

42 034, 036, 036 QS

 Grip the rope between the guide

bush and rotor, pull it out and make a loop.

 Hold the rope close to the rotor

and use it to turn the rotor about five full turns clockwise.

138RA112

– Hold the rope rotor steady.

 Pull out the rope with the starter

grip and straighten it out.

– Hold the starter grip firmly to keep

the rope tensioned.

– Let go of the rope rotor and

slowly guide the starter grip back

138RA113

so the starter rope can rewind properly.

Note:

The rewind spring is correctly tensioned when the starter grip sits firmly in the rope guide bush without drooping to one side. If this is not the case, tension the spring by one additional turn.

When the starter rope is fully extended, it must still be possible to rotate the rope rotor a t least another half turn before maximum spring tension is reached. If this is not the case, pull the rope out, hold the rope rotor steady and take off one turn of the rope.

Do not overtension the rewind spring as this will cause it to break.

– Fit the fan housing - see 6.4.

The crankcase and tank housing are connected by vibration damping rubber buffers. Damaged rubber buffers (annular buffers) must always be replaced in sets.

Note:

When replacing annular buffers, make sure you always install the latest type.

Annular buffers must be replaced in sets of the same hardness. Harder buffers are installed for more accurate control but reduced vibration damping, while softer butters provide better vibration damping.

T o remove the annular buf fers at the clutch side:

– Remove the chain sprocket cover

and cutting attachment - see 4.1.

– Remove the chain catcher - see

4.2.

 Use a screwdriver to remove the

two plugs from the annular buffers.

138RA115

7.4 Tensioning the Rewind Spring 8 AV Handle System

8.1 Repair

Page 43

43034, 036, 036 QS

– Take out the annular buffer

mounting screws.

– Use a screwdriver to pry the

annular buffers out of their seats.

To remove the annular buffer at the ignition side:

– Remove the carburetor box cover

and shroud - see 4.3.

– Remove the fan housing - see

6.4.

 Use a screwdriver to ease the

plug (1) out of the annular buffer.

– Take out the annular buffer

mounting screw.

138RA209

– Use a screwdriver to pry the

buffer out of its seat.

Note:

The tank housing has to be removed, see 12.8.1 , to replace the stop buffer.

– Take out the stop buffer and fit a

new one.

– Install the tank housing - see

12.8.1.

Installing new annular buffers:  Push the annular buffer, washer

first, into the crankcase seat un til groove (1) engages over the inner housing rib.

– Insert the mounting screw and

138RA114

tighten it down firmly (see "Tightening Torques").

– Lubricate the bead of the plug

with oil and then push it into the annular buffer.

Reassemble all other parts in the reverse sequence.

The main part of the Master Contro l is the switch shaft with an integrally molded multi-function operating lever, a molded cam and a second lever. The switch shaft located forward of the rear handle in the tank housing and is supported at two points.

The Master Control lever moves the switch shaft to select the required function. The following positions can be selected with the Master Control lever:

STOP (1) (closes short circuit

contact and interrupts ignition)

RUN (2) (normal operating

position)

138RA116

The cam on the left holds the connector sleeve of the short circuit wire and is also the stop for locking the Master Control lever in the "RUN" position.

START (3) (warm start -

starting throttle/ choke shutter open)

CHOKE (4) (cold start -

starting throttle/ choke shutter closed)

9Master Control

9.1 Construction and Function

Page 44

44 034, 036, 036 QS

In the "STOP" position the connector sleeve moves against the contact spring (arrow).

138RA096

The molded lever on the center of the switch shaft operates the throttl e trigger when the "START" and "CHOKE" positions are selected:

138RA117

The choke shutter actuating lever is molded to the right-hand end of t he switch shaft. It closes the choke shutter when the Master Control lever is set to "CHOKE".

138RA118

– Remove the air filter - see 12.1  Take out the handle molding

fastening screw. Lift away the handle molding.

138RA120

– Move Master Control lever to

"RUN" position.

 Pull the throttle interlock lever out

of its seat.

138RA121

 Detach throttle rod from the

trigger.

138RA122

 Use a 5 mm drift to drive out the

cylindrical pin (3). Take the throttle trigger (2) and torsion spring (1) out of the handle.

Install in the reverse sequence.

138RA123

Note:

The torsion spring must be under the interlock lever and locate in the notch (arrow).

138RA128

 Press the interlock lever (1)

down, pull the throttle trigger (2) up and move the Master Control lever (3) to "CHOKE".

138RA124

3 2

9.2 Throttle Trigger/Interlock Lever (034, 036)

Page 45

45034, 036, 036 QS

 Fit the handle molding so that the

lug at its front end engages properly under the seat on the tank housing.

– Fit handle molding fastening

screw (see "Tightening Torques").

138RA125

– Remove the air filter - see 12.1.  Unscrew fastening screw (1)

from handle molding (2). Lift away the handle molding.

148RA001

 Use a 3 mm drift to drive the

needle roller (2) out of the interlock lever (1). Remove the lever.

148RA099

 Use a 4.5 mm drift to drive the

bushing (1) out of the interlock lever (2) and then remove the torsion spring (3).

Install in the reverse sequence.

148RA100

 To remove the switch lever (1),

swing it back (arrow).

148RA054

 Disconnect brake cable (1) from

switch lever (2).

– Use a 3 mm drift to drive the

needle roller out of the switch.

– Take out the switch lever.

148RA055

Install in the reverse sequence.

9.3 Throttle Trigger/Interlock Lever/Switch Lever (036 QS)

Page 46

46 034, 036, 036 QS

– To remove the throttle trigger,

first remove the switch shaft -

see 9.4

 Use a 5 mm drift to drive out the

cylindrical pin (3) and then remove the throttle trigger (2) with torsion spring (1).

148RA058

– Take the torsion spring off the

throttle trigger.

Install in the reverse sequence.

Note:

When installing, make sure that short arm of torsion sp ring locates in the throttle trigger. The long arm points toward the carburetor.

– Remove the air filter - see 6.4.  Take out the handle molding

fastening screw. Lift away the handle molding.

138RA130

(034, 036)

– Remove the interlock lever -

see 9.2

 Take short circuit wire (1) out of

cam on switch shaft.

138RA090

– Move the Master Control lever up

to "STOP".

 Pry the switch shaft out of its

mounting at the ignition side.

138RA126

 Take the switch shaft out of its

mounting.

Install in the reverse sequence.

138RA127

Note:

When installing, make sure that the throttle rod is above the switch shaft and the lug at the front end of the handle molding engages properly under the seat on the tank housing

Note: (034, 036)

138RA128

When fitting the handle molding make sure that the torsion spring, throttle rod and interlock lever are correctly positioned. The torsion spring must pass under the interlock lever’s pivot mount and engage the notch in the interlock lever (arrow).

9.4 Switch Shaft

Page 47

47034, 036, 036 QS

The entire handle heating system is maintenance-free and subject to practically no wear. Faults in the generator, heating elements and wiring are generally caused by mechanical damage.

Important:

The heating element in the rear handle (arrow) may overheat and fail if it is not bonded firmly in position, i.e. completely flat without creases.

138RA129

There are two reasons for failures in the heating system:

a) A break in the circuit due to a faulty wire or component.

b) A short circuit resulting from damage to the insulation.

To trace the cause of a fault: – Remove the air filter - see 12.1.

 Take out handle molding

fastening screw and lift away handle molding.

– Remove the interlock lever.

138RA130

1 = Wire from generator 2 = Wire to front handle

heating element

3 & 4 = Wires of rear handle

heating element

– On machines with carburetor

heating, pull pin of wire from

138RA132

1 3

heating element out of round plug.

 Slide back the insulating tube

from pin and socket connector of wire (1) between generator and rear handle heating element.

 Separate pin and socket

connector of wire (1), from generator, and wire (3) of rear handle heating element.

 Clip ohmmeter test leads to wires

1 and 3.

138RA133

 Set the heater switch to "I".

Note:

All electrical components of the heating system are connected in series with the ohmmeter.

138RA134

10 Electric Handle Heating System (034, 036)

10.1 Troubleshooting

Page 48

48 034, 036, 036 QS

If the system is in order, the ohmmeter should indicate, in measuring range "Ω x 1", a value of about 2.5 Ω on previous heating elements or between 7.2 Ω and

9.4 Ω on new heating elements (see also 6.4.). If no reading is obtained, there is a break in the circuit. If the ohmmeter shows a value of less than 2.5 Ω or 7.2 Ω, there is a short circuit in one of the components. In either case it is necessary to check each component separately. The generator wire remains disconneted from the heating element during this check.

Type of heating element

(see 6.4.1)

Reading in Ω

Condition Remedy

Previous version approx. 2.5 OK

No reading Break in

circuit

Check individual components - see

10.1.2

less than 2.5 Short circuit in a

component

Check individual components - see

10.1.2

New version 7.2 - 9.4 in Ordnung

No reading Break in

circuit

Check individual components - see

10.1.2

less than 7.2 Short circuit in a

component

Check individual components - see

10.1.2

Page 49

49034, 036, 036 QS

10.1.1 Troubleshooting Chart

Check generator

Resistance between generator

connection (1) and engine ground

approx. 0.6 Ω?

Start

Check ground wire between tank housing

and crankcase

Resistance between switch housing

and crankcase approx. 0 Ω?

Do both handles warm up?

System in order.

Measure resistance of

individual heating elements

with ohmmeter

(On machines with carburetor heating, pull connector

pin of wire from heating element out of the

round plug)

yes

Turn on

switch

yes

Resistance

Previous heating element approx. 0.25 Ω ?

New heating element approx. 1 Ω ?

(see 10.1 and 10.3)

Check rear handle heating element

In good condition?

Bonding OK?

Disconnect plug connection at

heater switch

Switch has to be partly removed

for this purpose.

Check front handle heating element

Previous heating approx. 1.6 Ω?

New heating element approx. 7 Ω?

Check heater switch

Closed: approx. 0 Ω?

Open: high reading?

(On machines with carburetor heating, refit connector

pin of wire from heating element in the

round plug)

Heater switch on "I"

Replace

rear handle

heating element

Replace

generator

Fit new ground

wire between

heater switch

and

crankcase

Replace

front handle

Fit new

switch

yes

Page 50

50 034, 036, 036 QS

10.1.2 Test Connections and Test Values

– The pin and socket connections

of wires 1 to 4 must be disconnected to test the individual components. (see 10.1, fig.138 RA 132 VA)

Component Ohmmeter connection

(use either test lead)

Resistance If faulty

Leadl 1 Lead 2 Spec. Actual Cause Remedy

Switch Switch

terminal

Ground 0 - Switch faulty Replace switch

Heating element, rear handle (previous)

Connector on wire 3

Connector on wire 4

0.25 approx.

0.25

Heating element OK

- Break in wire, heating element damaged

Replace heating element

0 Short circuit -

damaged insulation

Repair insulation

Heating element, rear handle (new version)

Connector on wire 3

Connector on wire 4

1 approx. 1Heating element OK

- Break in wire, Heating element damaged

Replace heating element

0 Short circuit -

damaged insulation

Repair insulation

Heating element, front handle (previous)

Connector on wire 2

Ground 1.6 approx.

1.6

Heating element OK

- Break in wire, heating element damaged

Replace front handle

0 Short circuit durch

damaged insulation

Repair insulation

Heating element in front handle (new version)

Stecker an Leitung 2

Ground 7 approx. 7Heating element OK

- Break in wire, Heating element damaged

Replace front handle

0 Short circuit -

damaged insulation

Repair insulation

Generator Connector

on wire 1

Ground 0.6 approx.

0.6

Generator OK

- Break in wire, generator damaged

Replace generator

0 Short circuit -

damaged insulation

Repair insulation

Page 51

51034, 036, 036 QS

– The front handle has to be

removed for access to the heater switch - see 12.8.1.

 Take the ground wire ring

terminal off the switch.

138RA135

 Pull the switch out of its seat.

138RA136

 Push back the r ubber grommet a

little and pull the connector sleeve out of the switch.

138RA137

Reassemble in the reverse sequence.

Note:

Check correct installed position of switch in its seat (switch seat in not symmetrical).

138RA138

– Remove the handle molding -

see 10.1

 Slide the insulating tubes off the

two pin and socket connectors. Separate the connectors.

138RA131

 Take the pressure pad out of the

handle recess.

– Release and remove the heating

element.

138RA143

Important:

 Make sure you install the heating

element that matches the

flywheel - see 6.4 1 = Previous heating element 2 = New heating element

148RA217

1 2

10.2 Heater Switch 10.3 Heating Element in Rear Handle

Page 52

52 034, 036, 036 QS

– Before fitting the new heating

element, clean the surface inside the handle so that it is free from grease, dirt and moisture.

Note:

The previous rear handle heat ing elements (rectangular) can still be used together with the previous front handles in the modified tank housing if they are bonded in position at an angle.

 Bond the rectangular heating

element in the rear handle at an angle.

138RA140

 Cut the previous version of the

expanded rubber pressure pad as shown so that the lug (arrow) in the handle does not get in its way.

138RA141

– Remove the backing paper from

the new heating element.

 Press the heating element firmly

and uniformly into position, taking special care at the corners and along the edges.

138RA142

Important:

Avoid creases. If the heating element is not fitted perfectly flat, heat transfer will be interrupted, causing the element to overheat and fail. The ambient temperature during installation should not be less than +15°C.

 Fit a new expanded rubber

pressure pad on top of the heating element. The heating element must be completely covered.

138RA143

– Reconnect the wires and slide

the insulating tubes back over the pin and socket connectors.

Reassemble all other parts in the reverse sequence.

– Check operation of heating

element. Run the saw at maximum revs for no more than 30 seconds with the heating switched on.

Note:

The heat generated during this process also helps the element's adhesive set faster.

Page 53

53034, 036, 036 QS

The heating element in the front handle is not replaceable. A new handle must be fitted if the heating element is faulty.

– To disassemble the front handle,

remove the carburetor box cover

- see 4.3.

– Remove the air filter - see 12.1. – Remove the handle molding and

interlock lever - see 9.2.

– Remove the carburetor - see

12.3.

 Separa te pin and socket

connector of wire (2) of front handle heating element and wire (4) of rear handle heating element.

– Pull of the insulating tube.

138RA139

– Remove wires from switch -

see 10.2.

– Take out the mounting screws at

the side and bottom of the front handle.

Important:

The special screws used for polymer joints are secured with LOCTITE. Always heat the screwed joint before loosening, e.g. with a hair dryer. T ake care not to overheat the polymer.

– Remove the front handle.  Pull the connecting wire out of

the carburetor box through the grommet (arrow).

138RA145

Install the new front handle in the reverse sequence.

Note:

Mounting front handle without stiffener to original-type tank housing up to and including index "e": Fit a washer under each screw

1125 791 1000

138RA144

head. – Coat front handle mounting

screws with LOCTITE, insert and tighten down firmly (see "Tightening Torques")

 Check that the wire of the front

handle heating element and the generator wire are properly positioned in the rear handle.

138RA146

10.4 Heating Element in Front Handle

Page 54

54 034, 036, 036 QS

– Remove the air filter - see 12.1. – Remove the tank vent - see 12 .6. – Remove the shroud - see 4.3

– Remove the handle molding and

interlock lever, disconnect the throttle rod - see 9.2.

– Take out ignition module

mounting screws, see 6.5.1, and leave ignition module to one side.

– Remove the flywheel - see 6.4

 Disconnect generator wire (see

10.1, fig.138 RA 132 VA, wire 1)

in rear handle.

138RA148

 Pull connector sleeves of short

circuit wire (2) and ground wire (1) out of switch shaft and conta ct spring.

138RA208

 Use pliers to pull the grommet out

of the tank housing.

138RA149

 Remove the generator mounting

screws.

Note:

The screws are secured with LOCTITE and may be difficult to remove.

138RA150

– Remove the generator.  Use pliers to pull the cable

retainer out of the crankcase.

138RA151

– Pull the generator wire out of the

rear grommet, through the insulating tube and the retainer.

Note:

Inspect generator and poles for cracks or other damage. If damage is found, replace the generator.

Inspect magnet ring in flywheel for cracks or other damage. If damage is found, replace the flywheel.

10.5 Generator

10.5.1 Removing

Page 55

55034, 036, 036 QS

 Thread the generator wire (1)

through the retainer (4), the insulating tube (2) and rubber grommet (3).

2 3

138RA152

– Position the generator against

the flange face.

 The generator wire must locate in

the crankcase recess (arrow).

138RA153

– Coat threads of screws with

LOCTITE, see 13.2, fit them in the generator and tighten down moderately.

138RA154

 Fit centering tool 1118 893 3500

on the crankshaft so that its groove engages the Woodruff key.

 Finally tighten the three

generator mounting screws (see "Tightening Torques").

 Remove the centering tool. If

necessary, use the puller 1107 890 4500 to remove the centering tool from the crankshaft.

– Install the ignition module - see

6.5.1

138RA155

Reassemble all other parts in the reverse sequence.

Impurities gradually clog the fine pores of the filter with tiny particles of dirt. This prevents the oil pump from supplying sufficient oil to the bar and chain. In the event of problems with the oil supply, first check the oil tank and the pickup body. Clean the oil tank if necessary.

 Remove the oil filler cap and the

cap retainer.

– Drain the oil tank.

138RA156

 Use hook 5910 893 8800 to pull

the pickup body out of the oil tank.

Note:

Do not stretch the oil hose too much during this operation.

138RA157

10.5.2 Installing 11 Chain Lubrication

11.1 Pickup Body

Page 56

56 034, 036, 036 QS

 Hold the oil hose steady and pull

out the pickup body.

138RA158

 Use side cutters or similar too l to

remove the strainer from the connector.

Important:

Always replace any damaged parts.

138RA159

– Flush out the oil tank.  Wash the strainer (2) and

connector (1) in white spirit and blow out with compressed air.

Reassemble in the reverse sequence.

138RA160

– Remove the pickup body - see

11.1.

– Remove the oil pump - see 11.4.  Grip the tab of the suction hose

and pull it out of the crankcase.

138RA161

 Use a blunt tool to push the

suction hose into the crankcase so that the tab locates it its seat at the bottom right.

– Fit the pickup body - see 11.1. – Install the oil pump - see 11.4.

138RA162

A valve (1) is installed in the tank wall to keep internal tank pressure equal to atmospheric pressure.

– Remove the inner side plate -

see 4.2

– Drain the oil tank.

148RA049

 Use a 7 mm drift to carefully drive

the vent valve (1) into the crankcase and take it out of the oil tank.

 Carefully press in the new valve

until it is about 1 mm below the face of the crankcase.

– Fit the inner side plate - see 4.2.

1 mm

138RA164

11.2 Suction Hose 11.3 Vent Valve

Page 57

57034, 036, 036 QS

– Remove the brake band - see

4.4.1 and 4.5.1.

– Remove the clutch - see 4.3.

 Rotate th e worm and drive spring

clockwise and pull them off the crankshaft stub.

138RA165

 Take out the oil pump mounting

screws.

138RA166

 Carefully pry the oil pump off its

seat and lift it away.

138RA167

 Pull the ring (1) of f the crankshaft

stub and remove the washer (2).

Note:

To remove the oil delivery hose it is necessary to pry the sleeve out of the bar mounting flange. The hose is damaged in this process and

138RA168

1 2

must be replaced.

A new oil pump version is installed from machine serial number

X 20 239 583. This new oil pump can also be installed in older machines.

 The adjustment range of the oil

quantity control bolt (1) between

138RA169

minimum and maximum oil flow has been reduced from 720 degrees (2 turns) to 90 degrees (1/4 turn).

 Setting the oil pump to the

E matic position "E " is the most economic position under normal operating conditions using a STIHL E matic guide bar.

138RA170

11.4 Removing and Installing the Oil Pump

Page 58

58 034, 036, 036 QS

Install in the reverse sequence.

Note:

Pay special attention to the following points:

 Cut new oil delivery hose to a

length of 74 mm and coat the ends with oil. Use modified flat nose pliers (a = 5,5 mm) to fit the oil delivery hose on the oil pump nipple.

– Push the oil delivery hose

138RA171

through the bore in the bar mounting flange (from the inside outwards) and allow it to project about 10 - 20 mm. If the hose cannot be pushed through on older machines, drill out the bore to a diameter of 6.2 mm and deburr carefully.

 Hold the projecting end with the

modified flat nosed pliers. Now push home the sleeve with the modified carburetor screwdriver (R = 1.5 mm).

– Place oil pump in installed

position. Use modified carburetor

138RA172

R=1,5mm

screwdriver to push hose into bar mounting flange so that it is recessed about 1-2 mm.

– Insert oil pump mounting screws

and tighten them down firmly (see "Tightening Torques").

Always check the suction hose and pickup body before disassembling the oil pump.

– Remove the oil pump - see 11.4.  Use a 2 mm drift to drive out the

spring pin (6). Pull the control bolt

138RA173

1 2 3 4 3

7 8

(8) out of the housing (5) and remove the O-rings (7).

Note:

The previous pump has an adjusting screw which must be unscrewed clockwise.

 Pry the plug (1) out of housing (5)

and remove the pump piston (2) with spring (4) and washers (3).

 Wash all part in white spirit.

Inspect parts for damage and replace as necessary.

Reassemble in the reverse sequence.

Note:

Always install new O-rings. Coat pump piston and worm with grease,

see 13.2, before installing.

11.5 Servicing the Oil Pump

Page 59

59034, 036, 036 QS

The air filter’s function is to remove dust and dirt sucked in with the combustion air and thus help reduce wear on engine components to a minimum.

Note:

Older machines have a prefilter in the carburetor box cover which is not fitted in newer machines with compensator (on carburetor ). Apart from the carburetor box cover, the air filter was also modified on machines with compensator. The components of the new air filter system (air filter, end cover with compensator stub and carburetor box cover) can only be installed in model 036 from serial number

X 32 185 626 and only as a

complete assembly. – Before removing the air filter,

close the choke shutter to prevent dirt falling into the carburetor.

Removing the prefilter (034, 0 36) :

– Remove the carburetor box

cover.

– Remove grommet from

carburetor box.

138RA177

 Insert a screwdriver between the

prefilter and carburetor box cover and lever the prefilter out of the retainer.

– Pull the prefilter out of the guides

in the carburetor box cover.

Removing the main filter:

– Remove the carburetor box

cover.

– Clean away any loose dirt from

around the filter.

138RA178

 Unscrew the two slotted nuts so

that the filter can be pulled off the collar studs.

Cleaning the prefilter and main filter:

Coarse dirt is retained by the wire mesh prefilter in the carburetor box cover.

Note:

The air filter consists of two parts.

 Insert a screwdriver (combination

wrench) in the slot at the side of the filter. Twist the screwdriver to separate the two halves.

– For daily cleaning it is sufficient to

clean the two halves of the main filter and the prefilter with a soft

138RA179

brush.

– If heavily plugged with dirt, wash

the prefilter and main filter in fresh white spirit and blow out with compressed air - if available.

Note:

Do not clean flocked air filters with compressed air, brushes or rags.

If the wire mesh (or flocked coating) is damaged, immediately replace the part of the filter concerned.

12 Fuel System

12.1 Air Filter

Page 60

60 034, 036, 036 QS

Installing the pref ilter (034, 036):

– Slide the prefilter in the guides in

the carburetor box cover and make sure its snaps into position.

Installing the main filter:

– Assemble the two halves of the

main filter.

– Fit the filter over the two collar

studs and tighten down the slotted nuts firmly (see "Tightening Torques")

– Fit the carburetor box cover, see

also 4.3, and secure by turning the twist lock one quarter turn to the right.

Troubleshooting chart - see "Standard Repairs, Tro ubleshooting" handbook.

Important:

In the case of problems with the carburetor or fuel supply system, also check and clean the tank vent

- see 12.6. The carburetor can be tested for

leaks with the carburetor and crankcase tester 1106 850 2905.

– Remove the air filter - see 12.1.  Pull fuel hose off the carburetor’s

elbow connector.

148RA050

 Push fuel hose 1 1 10 141 8600 (1)

onto one end of the nipple 0000 855 9200 (2). Connect nipple to tester’s pressure hose.

143RA172

2 1

 Push fuel hose (1) with nipple (2)

and tester (3) onto carburetor’s elbow connector.

– Close the vent screw on the

rubber bulb.

– Squeeze rubber bulb to pump air

138RA218

1 2 3

into the carburetor until the pressure gauge shows a reading of approx. 0.4 bar.

If this pressure remains constant, the carburetor is airtight. However, if it drops, there are two possible causes:

1. The inlet needle is not sealing (foreign matter in valve seat or sealing cone of inlet needle is damaged (see 12.4) or inlet control lever sticking).

2. The metering diaphragm is damaged.

In either of these cases the carburetor must be serviced.

– After completing the test, open

the vent screw and pull the fuel hose off the carburetor.

Reassemble in the reverse sequence.

Repeat the leakage test after finishing repairs.

12.2 Leakage Testing the Carburetor

Page 61

61034, 036, 036 QS

The all-position diaphragm carburetor consists of a fuel pump and the actual carburetor. Although the fuel pump shares a common housing with the carburetor, it operates as a completely separate and independent unit.

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

– Remove the air filter - see 12.1

 Lever the grommet off the

carburetor adjusting screws.

– Detach the throttle rod and choke

lever.

138RA180

– Pull the fuel hose off the

carburetor’s elbow connector .

 Unscrew the carburetor mounting

nuts.

138RA176

 On machines with a carburetor

heating system, first pull the thermostatic switch’s flag connector (1) off the contact spring and then remove heater plate (3) and heating element (2) from the collar studs and leave them to one side.

138RA222

– Pull the carburetor off the collar

studs.

Install in the reverse sequence.

Note:

The gasket is not fitted on machines from

X 18 8 92 140 which are equipped with a Zama carburetor. The gasket must still be installed on Tillotson carburetors.

138RA181

Note:

 Check that sleeve (2) (in

manifold) and washer (1) are in place before fitting the carbur etor (new version).

– Tighten down the mounting nuts

(see "Tightening Torques").

138RA023

12.3 Removing and Installing the Carburetor

Page 62

62 034, 036, 036 QS

– Remove the carburetor - see 12.3 It is advisable to check the

serviceability of the fuel pump whenever the carburetor is removed for repair.

– Inspect pump diaphragm - see

"Carburetors" handbook, chapter

7.3, Pump Diaphragm

Note:

If the fuel strainer (arrow) in the pump side of the carburetor body is dirty, use a scriber to pry it out and then clean it.

Important:

If the fuel strainer is damaged, fit a

138RA182

new one. – If the strainer is dirty, also check

the fuel pickup body and replace it if necessary - see 12.7.

 To disassemble the carburetor,

take out the screws (1) of the metering chamber end cover (2) and lift away the cover.

Note:

There is no compensator stub (3) on the end cover (2) of older

138RA183

3 1

carburetors installed in model

034

1 45 945 205 and model

036

X 32 622 640.

 Remove the mete ring diaphragm

and gasket from the carburetor body or the end cover.

Note:

If the gasket and diaphragm are stuck, remove them very carefully.

138RA184

 Carefully separate t he diaphragm

and gasket.

Note:

The diaphragms are the most delicate parts of the carburetor. They are subjected to continuous alternating stresses and the

915RA042

material eventually shows signs of fatigue, i.e. the diaphragms distort and swell. Check and replace if necessary.

 The inlet needle valve is located

in a recess in the metering diaphragm chamber. Remove the round head screw (1).

138RA226

12.4 Servicing the Carburetor

Page 63

63034, 036, 036 QS

 Remove the inlet control lever (1)

with spindle (2), spring (3) and inlet needle (4).

138RA186

1 4

 If there is an annular indentation

on the sealing cone of the inlet needle, it will be necessary to replace the inlet needle because it will no longer seal properly.

138RA175

 Use a suitable drift to press the

valve jet out of its seat, from outside in the direction of the venturi, and wash it in white spirit.

138RA227

 A part-load f ixed jet (2) is

installed in addition to the valve jet (1) in machines from

X 35 047 484. It helps prevent the mixture becoming over-lean in the part-load range.

 As the part-load fixed jet (2)

148RA040

cannot be removed, blow it out with compressed air.

Note:

Owing to differences in calibration, the old versions of valve jets, high speed and low speed adjusting screws must not be installed in carburetors with a part-load fixed jet (see also parts list).

 Remove the carburetor adjusting

screws.

138RA187

 Use a drift to press the center of

the sealing plate down until it buckles and can be removed.

Caution:

The sealing plug is destroyed during removal. Remove it only if a replacement is available.

138RA188

– Wash the carburetor body and all

serviceable parts in fresh white spirit and blow clear with compressed air, paying special attention to the bores and ports.

– Fit the new sealing plate,

curvature facing up, in the bore and use a large diameter drift to carefully press it flat.

– When inserting the valve jet,

make sure it is exactly vertical in the bore.

– Press the jet home until it is flush

with the metering chamber.

Page 64

64 034, 036, 036 QS

 Fit the inlet needle (1).  Fit spring (2) in bore.  Insert spindle (3) in the inlet

control lever (4).

– Engage clevis in annular groove

915RA051

on head of the inlet needle.

– Press the inlet control lever down

and secure with the round head screw.

Note:

Make sure the helical spring locates on the control lever’s nipple.

Important:

The upper edge of the inlet control lever must be flush with the top of the carburetor body . If this is not th e case, install a new inlet control lever.

138RA189

– Place the gasket on the

carburetor body.

 Fit the metering gasket with the

perforated plate (1) facing the inlet control lever.

– Fit the end cover.

138RA228

Note:

The gasket, metering diaphragm and end cover are held in position by the pegs (arrow) on the carburetor body.

– Insert the collar screws and

tighten them down firmly.

 Insert the fuel strainer at the

pump side.

– Fit the pump diaphragm, gasket

and end cover and tighten down firmly.

138RA182

Note:

The pump diaphragm and gasket are held in position by the pegs (arrow) on the cover.

138RA191

 Thoroughly clean the high spee d

screw (1) and low speed screw (2). Coat threads of screws (not the first two or three turns) with LOCTITE 221, see 13.2.

Caution:

Do not apply adhesive to the first

148RA059

1 2

two or three turns of the screw threads. Adhesive must not enter the carburetor.

– Fit adjusting screws in the

carburetor.

– Carry out leakage test after

installing carburetor.

Page 65

65034, 036, 036 QS

Removing the throttle shaft:

 Unscrew the throttle shutter

fastening screw and pull the shutter out of the throttle shaft.

138RA200

 Ease the E-clip off the throttle

shaft.

138RA192

 Pull the throttle shaft out of the

carburetor. – Remove the torsion spring.  Take out the idle speed screw (1).

138RA193

 Fit the throttle shaft with torsion

spring and secure with E-clip.

 Fit the idle speed screw and

check that torsion spring is correctly positioned.

138RA194

 Fit the throttle shutter, round

notch first, in the throttle shaft.

Note:

Whole circumference of throttle shutter must locate against choke tube wall.

138RA195

– Coat the throttle shutter faste ning

screw with LOCTITE 270, see

13.2, and tighten down firmly.

Removing the choke shaft:

 Unscrew the choke shutter

fastening screw.

138RA196

 Ease the E-clip off the choke

shaft and pull the shaft out of the carburetor.

– Remove the torsion spring.

138RA197

 After fitting the choke shaft,

check that torsion spring is correctly positioned.

– Fit the E-clip.

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Page 66

66 034, 036, 036 QS

 Fit the choke shutter , round notch

first, with the small bore facing the choke lever.

Note:

When choke shutter is closed, its whole circumference must locate against choke tube wall.

138RA199

– Coat the fastening screw with

LOCTITE 270, see 13.2, and tighten down firmly.

– Install the carburetor - see 12.3

1 = Idle speed screw 2 = Low speed screw 3 = High speed screw

Note:

Carry out carburetor adjustments only after warming up the engine and cleaning the air filter.

138RA201

The carburetor comes from the factors with a standard setting.

This is the optimum setting of the high speed screw under the barometric pressure and climatic conditions at the factory (300 m above sea level). It ensures the machine will deliver maximum power, be fuel efficient and operate reliably.

Standard sett ing H =High speed screw opened

1 full turn. L = Low speed screw opened 1 full turn.

– If the carburetor has to be

adjusted from scratch, first carry out the standard setting.

If it is not possible to check the maximum permissible engine speed (13,000 rpm with bar and properly tensioned chain), do not turn the high speed screw beyond the standard setting to make the mixture leaner.

Caution:

The setting of the high speed adjusting screw affects not only the engine's performance but also its maximum off-load speed. If the setting is too lean (adjusting screw turned too far clockwise), the maximum permissible engine speed

will be exceeded and increase the risk of engine damage due to a lack of lubricant and overheating.

If the saw is used at high altitudes (mountains) or near sea l evel it may be necessary to correct the setting. Carry out the correction with the two adjusting screws:

– Turn clockwise (leaner) at high

altitudes.

– Turn counterclockwise (richer) at

sea level.

Caution:

Even slight changes to the adjusting screws have a noticeable effect on engine running behavior.

Adjusting idle speed Engine stops while idling:

– Turn idle speed screw clockwise

until the chain begins to move.

– Then back off the screw one

quarter turn.

Chain runs while engine is idling:

– Turn idle speed screw co unter-

clockwise until the chain stops running.

– Then turn the screw about

another quarter turn in the same direction.

12.5 Adjusting the Carburetor

Page 67

67034, 036, 036 QS

Erratic idling behavior, poor acceleration:

– Idle setting too lean. Turn the low

speed screw counterclockwise

until the engine runs and

accelerates smoothly.

Exhaust smokes at idle speed:

– Idle setting too rich. Turn the low

speed screw clockwise until

engine speed drops. – Then turn it back one quarter turn

from that position. – Check that the engine

accelerates smoothly when the

throttle is opened.

Correct operation of the carburetor is only possible if atmospheric pressure and internal fuel tank pressure are equal at all times. This is ensured by the tank vent.

Important:

In the event of trouble with the carburetor or the fuel supply system, always check and clean the tank vent.

– Remove the air filter - see 12.1

 On older t ank housings (up to

serial number

X 32 185 626) remove the original type tank vent (arrow) by pulling it upwards.

138RA202

 Take out the pan head screw (1)

and the grub screw (2). When assembling the tank vent, make sure the grub screw is fitted squarely.

138RA203

 On machines from serial number

X 32 185 626, pull of f the cap

(3) and filter (2) vertically.

 Inspect previous valve (1), or new

valve (4), for damage and, if necessary, replace as follows:

148RA096

Pull the previous valve (1) out of the tank housing from outside and install it from outside.

In case of new valve (4), first drain the fuel tank. Then pull the valve out of the tank housing fr om inside. Install new valve from inside the fuel tank, and carefully pull the stem from outside until the valve is properly seated.

– Wash all parts in clean gasoline

and blow clear with compressed air.

Reassemble in the reverse sequence.

Note:

Overpressure may occur in the fuel tank (e.g. due to heat build-up or exposure to sunlight). Always open the tank cap carefully so as to allow any pressure build-up to release slowly.

12.6 Tank Vent

Page 68

68 034, 036, 036 QS

The diaphragm pump draws fuel out of the tank and into the carburetor via the fuel hose. Any impurities mixed with the fuel are retained by the pickup body (filter). The fine pores of the filter eventually become clogged with minute particles of dirt. This restricts the

138RA204

passage of fuel and results in fuel starvation.

Important:

In the event of trouble with the fuel supply system, always check the fuel tank and the pickup body first. Clean the fuel tank if necessary.

Cleaning the fuel tank:

 Unscrew the filler cap and drain

the tank.

– Pour a small amount of clean

gasoline into the tank.

– Close the tank and shake the saw

vigorously.

– Open the tank again and drain it.

Removing and installing the pickup body:

 Use the hook 5910 893 8800 to

pull the pickup body out through the fuel tank filler opening.

138RA225

 Pull the pickup body of f the fuel

hose.

 Replace the new type pickup

body (once piece).

148RA044

 In case of original type pickup

bodies, remove the cap (4) from the pickup body (1) and take out the weight (3).

 T ake the f ilter (2) out of the pickup

body.

138RA205

Caution:

The fine mesh strainer on the pickup body must not be damaged. It can be washed in white spirit.

Note:

It is not advisable to clean the filter (2) - always fit a new one. The foam filter must be fitted without creases or twists.

Install in the reverse sequence.

Removing the suction hose:

– Remove the carburetor -

see 12.3.

– Pull the pickup body off the

suction hose.

148RA045

 Pull the suction hose out of the

tank housing.

Install in the reverse sequence.

Note:

Coat the hose flange with a little oil to simplify installation. The flat face of the hose flange must be seated on the tank housing.

12.7 Fuel Filter and Fuel Hose

Page 69

69034, 036, 036 QS

– Drain the tank housing.

 Remove mounting screws from

side of front handle.

138RA206

 Remove mounting screws from

underside of front handle. Lift away the handle.

Note:

To remove front handle on machines with handle heating

see 10.4.

138RA207

– Remove the carburetor -

see 12.3.

– Remove the shroud - see 4.3.

 Pull the washer (1) off the studs

and remove the sleeve (2) from the manifold.

138RA023

 Pull the connector sleeves of the

short circuit wire (2) and ground wire (1) off the contact springs.

138RA208

– Remove the fan housing - see

6.4.1.

 Pry the plug (1) out of the annular

buffer at the ignition side.

138RA209

 Remove the annula r buffer

mounting screw.

– Remove the chain catcher -

see 4.2.

138RA210

 Pry the plugs out of the annula r

buffers at the starter side.

– Remove annular buffer moun ting

screws.

138RA115

 Pull the grommet with g round and

short circuit wires out of the crankcase.

138RA149

12.8 Tank Housing

12.8.1 Removing and Installing

Page 70

70 034, 036, 036 QS

 Pull the impulse hose off the

nipple.

138RA216

 Pull the t ank housing forward and

push the manifold flange out of the tank housing intake opening at the same time.

138RA212

 Pry out the rubbe r buffer on the

inside of the crankcase.

Reassemble in the reverse sequence.

138RA213

Note:

If a screw thread is stripped in one of the mounting holes for special self-threading screws, the tank housing can be repaired by installing a thread insert. The stripped thread must be drilled out to a diameter of 8.5 mm and a depth

138RA214

8,5mm

15mm

of 15 mm.

Important:

Do not exceed the specified hole depth of 15 mm.

– Fit M6x10 screw with washer in

the thread insert.

 Screw the thread insert into the

tank housing. Use an M6x18 p an head screw in place of the original special self-threading screw.

138RA215

In order not to damage the manifold when fitting it through the tank housing intake opening, use the following procedure:

 Wind a piece of string (approx.

15 cm long) around the back of the manifold flange, then press

138RA041

the manifold downward and pass the ends of the string through the intake opening.

 Push the tank housing against

the manifold and pull the ends of the string outward at the same time.

138RA042

Page 71

71034, 036, 036 QS

13 Special Servicing Tools and Aids

13.1 Special Servicing Tools

No. Part Name Part No. Application 1 Locking strip 0000 893 5903 Blocking the crankshaft 2 Press sleeve 1118 893 2401 Installing oil seal (clutch side) 3 Press sleeve 1121 893 2400 Installing oil seal (ignition side) 4 Puller 5910 890 4400 Removing oil seals 5 - Jaws (No. 3.1 + 4) 0000 893 3706 (for clutch side only) 6 Assembly sleeve 1118 893 4602 Oil seal (clutch side) 7 Puller 1110 890 4500 Removing flywheel 8 Crimping tool 5910 890 8210 Attaching connectors to electric wires 9 Assembly drift 1110 893 4700 Fittin g the piston pin 10 Clamping strap 0000 893 2600 Compressing piston rings 11 Wooden assembly block 1108 893 4800 Fitting piston 12 Carburetor and crankcase

tester

1106 850 2905 Test ing crankcase and carburetor

for leaks 13 Vacuum pump 0000 850 3501 Testing crankcase for leaks 14 - Nipple 0000 855 9200 15 - Hose 1110 141 8600 16 Sealing plate 0000 855 8106 Sealing exhaust port for leakage test 17 Flange for leakage test 1128 850 4200 Lea kage test 18 Setting gauge 1111 890 6400 Setting air gap between ignition modu le

and flywheel 19 Socket, 13 mm 5910 893 5608 Crankshaft nut 20 Socket, 19 mm 5910 893 5612 21 Torque wrench 5910 890 0301 22 Torque wrench 5910 890 0311 23 Screwdriver bit T27x125 0812 542 2104 IS (spline socket head) screws 24 Assembly hook 5910 893 8800 Removing pickup bodies 25 Installing tool 5910 890 2210 Fitting hookless snap rings in piston 26 Press arbor 1120 893 7200 Removing crankshaft bearing at

ignition side 27 Press arbor 1118 893 7200 Insta lling crankshaft bearings 28 Assembly hook 5910 890 2800 Detaching springs from clutch shoes 29 Installing tool 0000 890 2201 Flaring rope guide bush 30 Assembly tube 1117 890 0900 Att aching the brake spring 31 Centering tool 1118 893 3500 Centering the heating generator 32 Service tool AS (set) 5610 007 2205 Removing the crankshaft (clutch side) 33 Service tool ZS (set) 5910 007 2200 Removing the crankshaft (ignition side) 34 T-handle screwdriver

QI-5x150

5910 890 2400 For all IS screws

35 Stud puller MS 5910 893 0501 Removing bar mounting studs 36 Puller 1107 890 4500 Removing generator centering tool 37 Ohmmeter 38 Thrust piece (sleeve) 1107 894 1000 Protecting crankshaft thread

Page 72

72 034, 036, 036 QS

13.2 Servicing Aids

No. Part Name Part No. Application

1 Lubricating grease

(Mobilplex)

0781 120 1111 Oil seals, oil pump drive,

chain sprocket bearing, bearing and sliding points of throttle trigger, switch lever, brake lever and interlock lever

2 Medium-strength threadlocking

adhesive (LOCTITE 243)

0786 110 0101 Securing screws,

see "Tightening Torques"

3 High-strength threadlocking

adhesive (LOCTITE 270)

0786 110 0109 Securing screws,

see "Tightening Torques"

4 High-strength threadlocking

adhesive up to 250°C (LOCTITE 272)

0786 110 0128 Securing screws,

see "Tightening Torques"

5 High-strength threadlocking

adhesive (LOCTITE 649)

0786 110 0126 Securing screws,

see "Tightening Torques"

6 Standard commercial, solvent

based degreasant containing no chlorinated or halogenated hydrocarbons

Cleaning crankshaft stub

7 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor,

rewind spring

8 Electrician’s repair kit 5910 007 1050 Electrical system

9 Sealing paste 0783 810 1101 Manifold, crankcase ga sket

10 Sealant

(LOCTITE 221)

High speed and low speed adjusting screws

11 Graphite grease Pawls in rewind starter

12 Molybdenum grease

(e.g. Molykote)

Sliding and bearing points of brake levers

13 Ignition lead HTR (10 m) 0000 930 2251

Stihl 034 Series, 036 Series, 036 QS Series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual