STIHL KM 90 Owner's Manual

STIHL KM 90

STIH)

Instruction Manual Manual de instrucciones

Warning!

For safe operation follow all safety precautions in Instruction Manual - improper use can cause serious injury.

Advertencia!

Para su seguridad durante el manejo de este producto, siga siempre las precauciones de seguridad dadas en el manual de instrucciones - el uso indebido puede causar lesiones graves.

Contents

English / USA

KombiSystem ................................... 2

Guide to Using this Manual .............. 3

Safety Precautions and

Working Techniques ......................... 4

Approved KombiTools .................... 11

Mounting the Bike Handle .............. 11

Adjusting the Throttle Cable ........... 13

BA_SE_182_004_01_07.fmPrinted on chlorine-free paper.

Mounting the Loop Handle ............. 14

4-MIX Engine .................................. 15

Fuel ................................................ 16

Fueling ............................................ 17

Starting / Stopping the Engine ........ 18

Operating Instructions .................... 21

Cleaning the Air Filter ..................... 21

Motor Management ........................ 21

Adjusting the Carburetor ................ 22

Spark Arresting Screen in Muffler ... 23

Checking the Spark Plug ................ 24

Replacing Starter Rope

and Rewind Spring ......................... 25

Storing the Machine ........................ 28

Inspections and Maintenance

by Dealer ........................................ 28

Maintenance Chart ......................... 29

Parts and Controls .......................... 30

Specifications ................................. 32

Printing inks contain vegetable oils; paper can be recycled.

Special Accessories ....................... 32

Maintenance and Repairs ............... 33

STIHL Incorporated Federal Emission Control

Warranty Statement ........................ 34

STIHL Incorporated California Exhaust and Evaporative Emissions

Control Warranty Statement ........... 36

Trademarks .................................... 39

Allow only persons who understand the manuals of the KombiEngine and the KombiTool to operate your power tool.

To receive maximum performance and satisfaction from your STIHL power tool, it is important that you read and understand the maintenance and safety precautions, starting on page 4, before using your power tool.

Contact your STIHL dealer or the STIHL distributor for your area if you do not understand any of the instructions in the two manuals.

STIHl

0458 465 8621 A. M8,3. B9. CP. Printed in USA

1KM 90, KM 90 R

English / USA

!Warning!

Because this power tool is a high-speed working tool, some special safety precautions must be observed to reduce the risk of personal injury. Careless or improper use may cause serious or even fatal injury.

STIHL's philosophy is to continually improve all of its products. As a result, engineering changes and improvements are made from time to time. Therefore, STIHL cannot be responsible for changes, modifications or improvements not covered in this manual. If the operating characteristics or the appearance of your power tool differs from those described in the two manuals, please contact your STIHL dealer for information and assistance.

KombiSystem

In the STIHL KombiSystem a number of different KombiEngines and KombiTools can be combined to produce a power tool. In this instruction manual the functional unit formed by the KombiEngine and KombiTool is referred to as the power tool.

The KombiEngine and KombiTool come with separate instruction manuals.

Always read and make sure you understand both instruction manuals before starting and using your machine. Keep the manuals in a safe place for later reference.

002BA159 KN

KM 90, KM 90 R

Guide to Using this Manual

English / USA

Pictograms

All the pictograms attached to the machine are shown and explained in this manual.

The operating and handling instructions are supported by illustrations.

Symbols in text

The individual steps or procedures described in the manual may be marked in different ways:

: A bullet marks a step or procedure

without direct reference to an illustration.

A description of a step or procedure that refers directly to an illustration may contain item numbers that appear in the illustration. Example:

Loosen the screw (1)

Lever (2) ...

In addition to the operating instructions, this manual may contain paragraphs that require your special attention. Such paragraphs are marked with the symbols described below:

Warning where there is a risk of an accident or personal injury or serious damage to property.

Caution where there is a risk of damaging the machine or its individual components.

Note or hint which is not essential for using the machine, but may improve the operator’s understanding of the situation and result in better use of the machine.

Note or hint on correct procedure in order to avoid damage to the environment.

Equipment and features

This instruction manual may refer to several models with different features. Components that are not installed on all models and related applications are marked with an asterisk (*). Such components may be available as special accessories from your STIHL dealer.

Engineering improvements

STIHL’s philosophy is to continually improve all of its products. As a result, engineering changes and improvements are made from time to time. If the operating characteristics or the appearance of your machine differ from those described in this manual, please contact your STIHL dealer for assistance.

Therefore some changes, modifications and improvements may not be covered in this manual.

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Safety Precautions and Working Techniques

Because this KombiEngine is the engine for a high-speed, power tool, special safety precautions must be observed to reduce the risk of personal injury.

It is important that you read, fully understand and observe the following safety precautions and warnings. Read the

instruction manuals and the safety precautions of your KombiEngine and KombiTool periodically. Careless or improper use may cause serious or fatal injury.

Have your STIHL dealer show you how to operate your power tool. Observe all applicable local safety regulations, standards and ordinances.

!Warning!

Do not lend or rent your power tool without the instruction manuals. Be sure that anyone using it understands the information contained in these manuals.

!Warning!

Minors should never be allowed to use this power tool. Bystanders, especially children, and animals should not be allowed in the area where it is in use.

!Warning!

To reduce the risk of injury to bystanders and damage to property, never let your power tool run unattended. When it is not in use (e.g. during a work break), shut it off and make sure that unauthorized persons do not use it.

Most of these safety precautions and warnings apply to the use of all STIHL power tools. Different models may have different parts and controls. See the appropriate section of your KombiEngine and KombiTool instruction manuals for a description of the controls and the function of the parts of your model.

Safe use of a KombiEngine involves

1. the operator

2. the power tool

3. the use of the power tool.

THE OPERATOR

Physical Condition

You must be in good physical condition and mental health and not under the influence of any substance (drugs, alcohol, etc.) which might impair vision, dexterity or judgment. Do not operate this machine when you are fatigued.

!Warning!

Be alert – if you get tired, take a break. Tiredness may result in loss of control. Working with any power tool can be strenuous. If you have any condition that might be aggravated by strenuous work, check with your doctor before operating this machine.

!Warning!

Prolonged use of a power tool (or other machines) exposing the operator to vibrations may produce whitefinger disease (Raynaud's phenomenon) or carpal tunnel syndrome.

These conditions reduce the hand's ability to feel and regulate temperature, produce numbness and burning sensations and may cause nerve and circulation damage and tissue necrosis.

KM 90, KM 90 R

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All factors which contribute to whitefinger disease are not known, but cold weather, smoking and diseases or physical conditions that affect blood vessels and blood transport, as well as high vibration levels and long periods of exposure to vibration are mentioned as factors in the development of whitefinger disease. In order to reduce the risk of whitefinger disease and carpal tunnel syndrome, please note the following:

– Most STIHL power tools are

available with an anti-vibration (“AV”) system designed to reduce the transmission of vibrations created by the engine to the operator's hands. An AV system is recommended for those persons using power tools on a regular or sustained basis.

– Wear gloves and keep your hands

warm.

– Keep the AV system well

maintained. A power tool with loose components or with damaged or worn AV buffers will tend to have higher vibration levels.

– Maintain a firm grip at all times, but

do not squeeze the handles with constant, excessive pressure. Take frequent breaks.

All the above-mentioned precautions do not guarantee that you will not sustain whitefinger disease or carpal tunnel syndrome. Therefore, continual and regular users should closely monitor the condition of their hands and fingers. If any of the above symptoms appear, seek medical advice immediately.

!Warning!

The ignition system of the STIHL unit produces an electromagnetic field of a very low intensity. This field may interfere with some pacemakers. To reduce the risk of serious or fatal injury, persons with a pacemaker should consult their physician and the pacemaker manufacturer before operating this tool.

Proper Clothing

!Warning!

To reduce the risk of injury, the operator should wear proper protective apparel.

!Warning!

Power tool noise may damage your hearing. Wear sound barriers (ear plugs or ear mufflers) to protect your hearing.

Continual and regular users should have their hearing checked regularly.

Be particularly alert and cautious when wearing hearing protection because your ability to hear warnings (shouts, alarms, etc.) is restricted.

For further instructions on proper clothing see the safety precautions in the instruction manual of the KombiTool you are using.

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THE POWER TOOL

For illustrations and definitions of the power tool parts see the chapter on “Main Parts and Controls.”

!Warning!

Never modify this power tool in any way. Only attachments supplied by STIHL or expressly approved by STIHL for use with the specific STIHL KombiEngine model are authorized. Although certain unauthorized attachments are useable with STIHL power tools, their use may, in fact, be extremely dangerous.

If this tool is subjected to unusually high loads for which it was not designed (e.g. heavy impact or a fall), always check that it is in good condition before continuing work. Check in particular that the fuel system is tight (no leaks) and that the controls and safety devices are working properly. Do not continue operating this machine if it is damaged. In case of doubt, have it checked by your STIHL servicing dealer.

THE USE OF THE POWER TOOL

Transporting the Power Tool

!Warning!

Always switch off the engine and make sure the working tool has stopped before putting a power tool down. When transporting your power tool in a vehicle, properly secure it to prevent turnover, fuel spillage and damage to the power tool.

Fuel

Your STIHL power tool uses an oilgasoline mixture for fuel (see the chapter on “Fuel” of your instruction manual).

!Warning!

Gasoline is an extremely flammable fuel. If spilled and ignited by a spark or other ignition source, it can cause fire and serious

burn injury or property damage. Use extreme caution when handling gasoline or fuel mix. Do not smoke or bring any fire or flame near the fuel or the power tool. Note that combustible fuel vapor may escape from the fuel system.

Fueling Instructions

!Warning!

Fuel your power tool in well-ventilated areas, outdoors. Always shut off the engine and allow it to cool before refueling. Gasoline vapor pressure may build up inside the fuel tank depending on the fuel used, the weather conditions and the tank venting system.

In order to reduce the risk of burns and other personal injury from escaping gas vapor and fumes, remove the fuel filler cap on your power tool carefully so as to allow any pressure build-up in the tank to release slowly. Never remove the fuel filler cap while the engine is running.

Select bare ground for fueling and move at least 10 feet (3 m) from the fueling spot before starting the engine. Wipe off any spilled fuel before starting your machine.

!Warning!

Check for fuel leakage while refueling and during operation. If fuel leakage is found, do not start or run the engine until the leak is fixed and any spilled fuel has been wiped away. Take care not to get fuel on your clothing. If this happens, change your clothing immediately.

Different models may be equipped with different fuel caps.

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Cap with grip

!Warning!

In order to reduce the risk of fuel spillage and fire from an improperly tightened fuel cap, correctly position and tighten the fuel cap in the fuel tank opening.

To do this with this STIHL cap, raise the grip on the top of the cap until it is upright at a 90° angle. Insert the cap in the fuel

tank opening with the triangular marks on the grip of the cap and on the fuel tank opening lining up. Using the grip, turn the cap firmly clockwise as far as it will go (approx. a quarter turn).

Fold the grip flush with the

top of the cap. If the grip

does not lie completely

flush with the cap and the

detent on the grip does

not fit in the corresponding recess in the filler neck, the cap is not properly seated and tightened and you must repeat the above steps.

Screw cap

!Warning!

Unit vibrations can cause an improperly tightened fuel filler cap to loosen or come off and spill quantities of fuel. In order

to reduce the risk of fuel spillage and fire, tighten the fuel filler cap by hand as securely as possible.

Before Starting

!Warning!

Always check your KombiEngine for proper condition and operation before starting, particularly the throttle trigger, throttle trigger interlock, stop switch and working tool. The throttle trigger (if applicable) must move freely and always spring back to the idle position. Never attempt to modify the controls or safety devices.

!Warning!

Never use a power tool that is damaged or not properly maintained.

Keep the handles clean and dry at all times; it is particularly important to keep them free of moisture, pitch, oil, grease or resin in order for you to maintain a firm grip and properly control your power tool.

Starting

Start the engine at least 10 feet (3 meters) from the fueling spot, outdoors only.

For specific starting instructions, see the appropriate section of your KombiEngine and KombiTool manuals. Place the power tool on firm ground or other solid surface in an open area. Maintain good balance and secure footing.

!Warning!

To reduce the risk of injury from loss of control, be absolutely sure that the working tool is clear of you and all other obstructions and objects, including the ground, because when the engine starts at starting-throttle, engine speed will be fast enough for the clutch to engage and move the working tool.

!Warning!

Check that the spark plug boot is securely mounted on the spark plug – a loose boot may cause arcing that could ignite combustible fumes and cause a fire.

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!Warning!

Your power tool is a one-person machine. Do not allow other persons in the general work area, even when starting.

!Warning!

To reduce the risk of injury from loss of control, do not attempt to “drop start” your power tool.

!Warning!

When you pull the starter grip, do not wrap the starter rope around your hand. Do not let the grip snap back, but guide the starter rope to rewind it properly. Failure to follow this procedure may result in injury to your hand or fingers and may damage the starter mechanism.

See also the safety precautions on Starting in the instruction manual of the KombiTool.

Important Adjustments

!Warning!

To reduce the risk of personal injury from loss of control or contact with the running working tool, do not use a power tool with incorrect idle adjustment. At correct idle speed, the working tool should not move. For directions on how to adjust idle speed, see the appropriate section of your instruction manual. If you cannot set the correct idle speed, have your STIHL dealer check your power tool and make proper adjustments and repairs.

During Operation

Holding and controlling the power tool

Always hold the unit firmly with both hands on the handles while you are working. Wrap your fingers and thumbs around the handles.

Working conditions

Operate and start your power tool only outdoors in a well ventilated area. Operate it under good visibility and daylight conditions only. Work carefully.

!Warning!

As soon as the engine is running, this product generates toxic exhaust fumes containing chemicals (such as

unburned hydrocarbons and carbon monoxide) known to cause respiratory problems, cancer, birth defects, or other reproductive harm. Some of the gases (e.g. carbon monoxide) may be colorless and odorless. To reduce the risk of serious or fatal injury/illness from inhaling toxic fumes, never run the machine indoors or in poorly ventilated locations.

Operating instructions

!Warning!

Do not operate your power tool using the starting throttle lock, as you do not have control of the engine speed.

In the event of an emergency, switch off the engine immediately – move the slide control / stop switch to 0 or STOP.

002BA057 KN

Your right hand should grip the rear handle. This also applies to left-handers.

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!Warning!

The muffler and other parts of the engine (e.g. fins of the cylinder, spark plug) become hot during operation and remain hot for a while after stopping the engine. To reduce risk of burns do not touch the muffler and other parts while they are hot.

!Warning!

To reduce the risk of fire and burn injury, keep the area around the muffler clean. Remove excess lubricant and all debris such as pine needles, branches or leaves. Let the engine cool down sitting on concrete, metal, bare ground or solid wood (e.g. the trunk of a felled tree) away from any combustible substances.

!Warning!

Never modify your muffler. The muffler could be damaged and cause an increase in heat radiation or sparks, thereby increasing the risk of fire and burn injury. You may also permanently damage the engine. Have your muffler serviced and repaired by your STIHL servicing dealer only.

Catalytic converter

!Warning!

Some STIHL power tools are equipped with a catalytic converter, which is designed to reduce the exhaust emissions of the

engine by a chemical process in the muffler. Due to this process, the muffler does not cool down as rapidly as conventional mufflers when the engine returns to idle or is shut off. To reduce the risk of fire and burn injuries, the following specific safety precautions must be observed.

!Warning!

Since a muffler with a catalytic converter cools down less rapidly than conventional mufflers, always set your power tool down in the upright position and never locate it where the muffler is near dry brush, grass, wood chips or other combustible materials while it is still hot.

!Warning!

An improperly mounted or damaged cylinder housing or a damaged/ deformed muffler shell may interfere with the cooling process of the catalytic converter. To reduce the risk of fire or burn injury, do not continue work with a damaged or improperly mounted cylinder housing or a damaged/ deformed muffler shell.

Your catalytic converter is furnished with screens designed to reduce the risk of fire from the emission of hot particles. Due to the heat from the catalytic reaction, these screens will normally stay clean and need no service or maintenance. If you experience loss of performance and you suspect a clogged screen, have your muffler maintained by a STIHL servicing dealer.

9KM 90, KM 90 R

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MAINTENANCE, REPAIR AND STORING

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any nonroad engine repair establishment or individual. However, if you make a warranty claim for a component which has not been serviced or maintained properly or if nonapproved replacement parts were used, STIHL may deny coverage.

!Warning!

Use only identical STIHL replacement parts for maintenance and repair. Use of non STIHL parts may cause serious or fatal injury.

Strictly follow the maintenance and repair instructions in the appropriate section of your KombiEngine and KombiTool instruction manuals. Please refer to the maintenance charts respectively the maintenance notes in these manuals.

!Warning!

Always stop the engine and make sure that the working tool is stopped before doing any maintenance or repair work or cleaning the power tool. Do not attempt any maintenance or repair work not described in your KombiEngine and KombiTool instruction manuals. Have such work performed by your STIHL servicing dealer only.

!Warning!

Use the specified spark plug and make sure it and the ignition lead are always clean and in good condition. Always press spark plug boot snugly onto spark plug terminal of the proper size. (Note: If terminal has detachable SAE adapter nut, it must be attached.) A loose connection between spark plug boot and the ignition wire connector in the boot may create arcing that could ignite combustible fumes and cause a fire.

!Warning!

Never test the ignition system with the ignition wire boot removed from the spark plug or with a removed spark plug, since uncontained sparking may cause a fire.

!Warning!

Do not operate your power tool if the muffler is damaged, missing or modified. An improperly maintained muffler will increase the risk of fire and hearing loss. If your muffler was equipped with a spark-arresting screen to reduce the risk of fire, never operate your power tool if the screen is missing or damaged. Remember that the risk of forest fires is greater in hot or dry weather.

Store the power tool in a dry and high or locked location out of reach of children.

Before storing for longer than a few days, always empty the fuel tank. See chapter "Storing the machine" in this manual.

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Approved KombiTools

The following STIHL KombiTools may be mounted on the KombiEngine

KombiTool Purpose FS-KM Brushcutter with

mowing head

FS-KM

Brushcutter with grass cutting blade

HL-KM 0/90°

1) 2)

Hedge trimmer, adjustable

HL-KM 135°

1) 2)

Hedge trimmer,

adjustable HL-KM 0° FH-KM HT-KM BF-KM FCB-KM

FCS-KM KB-KM KW-KM

Barrier bar must be mounted on

Hedge trimmer

Power scythe

Pole pruner

Pick tine cultivator

Power edger

Bristle brush

PowerSweep

loop handle

Unsuitable or not approved for

KombiEngines with bike handle

Mounting the Bike Handle

Removing Clamp Moldings

: Hold the lower clamp (1) and upper

clamp (2) firmly.

: Release the wing screw (3).

The clamps are loose once the wing screw has been released. They are pushed apart by the two springs (4 and 5).

: Pull out the wing screw.

Washer (6) remain at the tommy screw .

: Separate the clamps.

Springs (4) and (5) remain in the lower clamp.

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Mounting the Handlebar

: Place the handlebar (7) in the lower

clamp (1) so that distance A is no more than 6 in (15 cm).

: Place the upper clamp in position

and hold both clamps together.

: Push the wing screw, with washer,

through the two clamps as far as stop – hold all parts together and secure them.

250BA046 KN

: Place the secured assembly on the

handle support (8) with the wing screw at the engine side.

: Push the wing screw into the handle

support as far as stop and then screw it down – but do not finally tighten yet.

: Line up the handlebar at a right

angle to the drive tube – check dimension A again.

: Tighten down the wing screw firmly

002BA234 KN

Mounting the Control Handle

: Loosen the screw (9). The nut (10)

remains in the control handle (11).

: Push the control handle – throttle

trigger (12) must point toward the gearbox – onto the handlebar (7) so that the holes (13) line up.

: Insert screw and tighten down

firmly.

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Adjusting the Throttle Cable

A properly adjusted throttle cable is the precondition for correct operation in the full throttle, starting throttle and idle positions.

Adjust the throttle cable only after the unit is fully assembled – the control handle must be in the normal operating position.

Fitting the Throttle Cable

Do not kink the throttle cable or lay it in tight radii – make sure the throttle trigger moves freely.

: Press the throttle cable (14) into the

retainers (15).

Throttle Cable Adjustment

On control handles with slide: : Go to chapter "Adjusting the

Throttle Cable".

* see "Guide to Using this Manual"

250BA002 KN

Swiveling the Handlebar

Transport position:

: Release the wing screw (3) and

unscrew it until the handlebar (7) can be turned clockwise.

: Turn the handlebar 90° and then

swing the handles down.

: Tighten down the wing screw firmly.

Working position:

: Reverse the sequence described

above to swing the handles up and turn the handlebar counterclockwise.

002BA163 KN

: Use a suitable tool to push the slide

to the bottom of the slot (see illustration).

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Mounting the Loop Handle

STOP

: Press down the trigger interlock (1)

and squeeze the throttle trigger (2) (full throttle) – this sets the throttle cable correctly.

249BA017 KN

Loop handle with barrier bar

: Insert square nuts (1) in the

barrier bar (2).

: Line up the holes.

002BA098 KN

: Place the clamp (3) in the loop

handle (4) and position them both against the drive tube (5).

: Fit the clamp (6) and place the

barrier bar (2) in position.

Note correct position.

: Line up the holes. : Insert screws (7) in holes and screw

them into the barrier bar as far as stop.

: Go to “Securing the loop handle”.

002BA099 KN

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4-MIX Engine

The STIHL 4-MIX engine features gas

8 7

oil lubrication and must be run on a fuel mixture of gasoline and engine oil.

It operates otherwise on the 4-stroke principle.

Loop handle without barrier bar

: Place the clamp (3) in the loop

handle (4) and position them both against the drive tube (5).

: Fit the clamp (6) and line up the

holes.

: Fit washers (7) on screws (8). : Insert screws (8) in holes and screw

on the square nuts (1) as far as stop.

: Go to “Securing the loop handle”.

002BA136 KN

Securing the loop handle

: Secure the loop handle (4)

approx. 8”/20cm (A) forward of the control handle (9).

: Line up the loop handle. : Tighten down the screws firmly –

lock the nuts if necessary.

10= Sleeve*

002BA147 KN

* see “Guide to Using this Manual”

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Fuel

This engine is certified to operate on unleaded gasoline and the STIHL twostroke engine oil at a mix ratio of 50:1.

Your engine requires a mixture of highquality gasoline and quality two-stroke air cooled engine oil.

Use mid-grade unleaded gasoline with a minimum octane rating of 89 (R+M/2). If the octane rating of the mid-grade gasoline in your area is lower, use premium unleaded fuel.

Fuel with a lower octane rating may increase engine temperatures. This, in turn, increases the risk of piston seizure and damage to the engine.

The chemical composition of the fuel is also important. Some fuel additives not only detrimentally affect elastomers (carburetor diaphragms, oil seals, fuel lines, etc.), but magnesium castings and catalytic converters as well. This could cause running problems or even damage the engine. For this reason STIHL recommends that you use only nationally recognized high-quality unleaded gasoline!

Use only STIHL two-stroke engine oil or equivalent high-quality two-stroke engine oils that are designed for use only in air cooled two-cycle engines.

We recommend STIHL 50:1 two-stroke engine oil since it is specially formulated for use in STlHL engines.

Do not use BIA or TCW rated (twostroke water cooled) mix oils or other mix oils that state they are for use in both water cooled and air cooled engines (e.g., outboard motors, snowmobiles, chainsaws, mopeds, etc.).

Take care when handling gasoline. Avoid direct contact with the skin and avoid inhaling fuel vapor. When filling at the pump, first remove the canister from your vehicle and place the canister on the ground before filling. Do not fill fuel canisters that are sitting in or on a vehicle.

The canister should be kept tightly closed in order to avoid any moisture getting into the mixture.

The machine‘s fuel tank and the canister in which fuel mix is stored should be cleaned as necessary.

Fuel mix ages

Only mix sufficient fuel for a few days work, not to exceed 3 months of storage. Store in approved fuel-canisters only. When mixing, pour oil into the canister first, and then add gasoline. Close the canister and shake it vigorously by hand to ensure proper mixing of the oil with the fuel.

Gasoline

US gal. US fl.oz

12.6 2 1/2 6.4

512.8

Dispose of empty mixing-oil canisters only at authorized disposal locations.

Oil (STIHL 50:1 or equivalent high-quality oils)

KM 90, KM 90 R

Fueling

English / USA

Before fueling, clean the filler cap and the area around it to ensure that no dirt falls into the tank.

Always thoroughly shake the mixture in the canister before fueling your machine.

In order to reduce the risk of burns or other personal injury from escaping gas vapor and fumes, remove the fuel filler cap carefully so as to allow any pressure build-up in the tank to release slowly.

Opening the cap

: Raise the grip until it is upright.

: Turn the cap counterclockwise

(approx. a quarter turn).

: Remove the filler cap.

Closing the cap

: Fit the cap – grip upright –marks

must line up.

: Turn the cap clockwise as far as

stop (approx. a quarter turn).

: Fold the grip flush with the top of the

cap.

: If the grip does not lie completely

flush with the cap and the detent on the grip does not engage the recess in the filler neck, the cap is not properly seated and tightened and you must repeat the above steps.

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Starting / Stopping the Engine

STOP-

START

STOP

Controls

Control handle on bike handle

Throttle trigger interlock (1), throttle trigger (2) and slide control (3).

STOP

002BA182 KN

Control handle on drive tube

Throttle trigger interlock (1), throttle trigger (2) and slide control (3).

Positions of Slide Control

STOP-O (4) – engine off – the ignition is

switched off # – normal run position (5) – the engine

is running or can start

START (6) – the ignition is switched on, the engine can start

5 6

STOP-

START

002BA181 KN

Symbol on slide control

h (7) – stop symbol and arrow – to stop the engine, push the slide control in the direction of the arrow on the stop symbol (h) to STOP-O.

Starting Procedure

: Hold down the throttle trigger

interlock and squeeze the throttle trigger.

: While holding both levers in this

position, move the slide control to START and hold it there.

: Now release the throttle trigger,

slide control and throttle trigger interlock in that order. This is the

starting throttle position.

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: Set the choke knob (8):

For cold start to For warm start to e

Also use this setting if engine has been running but is still cold.

: Press the fuel pump bulb (9) at least

five times, even if the bulb is still filled with fuel.

249BA007 KN

: Place the unit on the ground: It must

rest securely on the engine support . Check that the tool is not touching the ground or any other obstacles – see also chapter "Starting/Stopping the Engine" in the KombiTool instruction manual.

: Make sure you have a firm footing. : Hold the unit with your left hand and

press it down firmly – your thumb should be under the fan housing.

Do not stand or kneel on the drive tube!

: Pull the starter grip slowly with your

right hand until you feel it engage and then give it a brisk strong pull. Do not pull out the starter rope all the way – it might otherwise break.

: Do not let the starter grip snap back.

Guide it slowly and vertically into the housing so that the starter rope can rewind properly.

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: Crank engine until it begins to fire.

After no more than five attempts, turn the choke knob to e and continue cranking.

As soon as engine runs

: Blip the throttle trigger so that the

slide control moves to the normal run position # and the engine settles down to idle speed.

Make sure the carburetor is correctly adjusted – the tool must not move when the engine is idling.

Your machine is now ready for operation.

To shut down the engine:

: Push the slide control in the

direction of the arrow on the stop symbol ( ) to STOP-O.

At very low outside temperatures:

As soon as engine runs: : Blip the throttle trigger to disengage

the starting throttle positiion – the slide control moves to the run position # – and the engine settles down to idle speed.

: Open the throttle part way and warm

up engine for a brief period.

If the engine does not start

If you did not turn the choke knob to e quickly enough after the engine began to fire, the combustion chamber has flooded.

: Turn the choke knob to e. : Set slide control, interlock lever and

throttle trigger to starting throttle position.

: Start the engine by pulling the

starter rope firmly. 10 to 20 pulls may be necessary.

If the engine still does not start:

: Push the slide control to STOP-O. : Pull off the spark plug boot (10).

: Unscrew and dry off the spark plug.

: Open the throttle wide. : Crank the engine several times with

the starter to clear the combustion chamber.

: Refit the spark plug and connect the

spark plug boot – push it down firmly.

: Set the slide control to START : Set choke knob to e – even if

engine is cold.

: Now start the engine.

Throttle cable adjustment

: Check adjustment of the throttle

cable – see "Adjusting the Throttle Cable".

Fuel tank run until dry

: After refueling, press the fuel pump

bulb at least five times – even if

249BA008 KN

bulb is still filled with fuel.

: Set choke knob according to engine

temperature.

: Now start the engine

KM 90, KM 90 R

English / USA

Operating Instructions Cleaning the Air Filter

During break-in period

A factory new machine should not be run at high revs (full throttle off load) for the first three tank fillings. This avoids unnecessary high loads during the break-in period. As all moving parts have to bed in during the break-in period, the frictional resistances in the engine are greater during this period. The engine develops its maximum power after about 5 to 15 tank fillings.

During operation

After a long period of full-throttle operation, allow engine to run for a while at idle speed so that the heat in the engine can be dissipated by flow of cooling air. This protects enginemounted components (ignition, carburetor) from thermal overload.

After finishing work

Wait for engine to cool down. Drain the fuel tank. Store the machine in a dry place. Check tightness of nuts and screws (not adjusting screws) at regular intervals and retighten as necessary.

Dirty air filters reduce engine power, increase fuel consumption and make starting more difficult.

If there is a noticeable loss of engine power:

: Set the choke knob to g. : Take out the screw (1) and remove

the filter cover (2).

: Clean away loose dirt from around

the filter.

: Grip the filter element (3) at the

notch (arrow) in the filter housing (4) and take it out.

: Fit a new filter element. As a

temporary measure you can knock it out on the palm of your hand or blow it out. Do not wash.

: Replace any damaged parts. : Install filter element in the filter

housing.

: Refit the filter cover. : Insert the screw and tighten it down

firmly.

Motor Management

Exhaust emissions are controlled by the design of the fundamental engine parameters and components (e.g. carburation, ignition, timing and valve or port timing) without the addition of any

major hardware.

266BA009 KN

21KM 90, KM 90 R

English / USA

Adjusting the Carburetor

The carburetor comes from the factory with a standard setting.

This setting provides an optimum fuel-air mixture under most operating conditions.

With this carburetor it is only possible to adjust the engine idle speed within fine limits.

Standard Setting

: Shut off the engine. : Assemble the KombiTool with the

attachment mounted.

: Check the air filter and replace if

necessary.

: Check adjustment of throttle cable

and readjust if necessary - see "Adjusting the Throttle Cable"

: "Check the spark arresting screen

(not installed in all countries) and clean or replace if necessary.

: Carefully turn both adjusting screws

counterclockwise as far as the stop:

The high speed screw (H) and low

266BA008 KN

speed screw (L) are now 3/4 turn open.

: Start and warm up the engine. : Adjust idle speed with the idle speed

screw (LA) so that the tool does not move.

Fine Tuning

A slight correction of the setting of the high speed screw (H) may be necessary if engine power is not satisfactory when operating at high altitude or at sea level.

Rule of thumb

Rotate the high speed screw (H) about

1/4 turn for every 3300 ft (1000 meter)

change in altitude

: Carry out the standard setting. : Warm up engine for about

3 minutes.

KM 90, KM 90 R

English / USA

Spark Arresting Screen in Muffler

At high altitudes

: Turn the high speed screw (H)

clockwise (leaner) no further than stop until there is no noticeable increase in engine speed.

At sea level

: Turn the high speed screw (H)

counterclockwise (richer) no further than stop until there is no noticeable increase in engine speed

It is possible that maximum engine speed will already be reached with the standard setting in each case.

Adjusting Idle Speed

It is usually necessary to change the setting of the idle speed screw (LA) after every correction to the low speed screw (L).

: Warm up engine

Engine stops while idling

: Turn idle speed screw (LA) slowly

clockwise until the engine runs smoothly – tool must not move.

Tool moves when engine is idling

: Turn idle speed screw (LA) slowly

counterclockwise until tool stops moving and then turn the screw about another 1/2 to 3/4 turn in the same direction.

Erratic idling behavior, engine stops even though setting of LA screw is correct, poor acceleration

Idle setting too lean:

: Turn low speed screw (L)

counterclockwise until the engine runs and accelerates smoothly.

Erratic idling behavior

Idle setting too rich:

: Turn low speed screw (L) clockwise

(no further than stop) until the engine runs and accelerates smoothly.

The spark arresting screen is an option that is not fitted in all machines.

: If the engine is low on power, check

the spark arresting screen in the muffler.

: Wait for muffler to cool down.

: Move slide control to STOP-O. : Remove the screw (1).

249BA033 KN

249BA034 KN

: Remove the screws (2). : Lift away the shroud (3).

23KM 90, KM 90 R

English / USA

: Remove the screw (4). : Lift spark arresting screen (5) and

pull it out.

: Clean spark arresting screen if

necessary – if screen is damaged or coked up, fit a new one.

: Refit the spark arresting screen. : Insert screw and tighten down. : Fit the shroud.

Checking the Spark Plug

Wrong fuel mix (too much engine oil in the gasoline), a dirty air filter and unfavorable running conditions (mostly at part throttle etc.) affect the condition of the spark plug. These factors cause deposits to form on the insulator nose which may result in trouble in operation.

If engine is down on power, difficult to start or runs poorly at idling speed, first check the spark plug.

: Remove spark plug as described

in chapter "Starting / Stopping the Engine".

: Clean dirty spark plug. : Check the electrode gap (A) and

readjust if necessary – see "Specifications".

: Use only resistor type spark plugs

of the approved range.

Rectify problems which have caused fouling of spark plug:

: Too much oil in fuel mix. : Dirty air filter.

000BA002 KN

: Unfavorable running conditions,

e.g. operating at part load.

Fit a new spark plug after approx. 100 operating hours

or earlier if the electrodes are badly eroded.

KM 90, KM 90 R

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