Stihl FC 75 User manual

STIHL Components4137
FC, FH, FS, HL, KM, KW 2004-06
STIH)
FC 75, FC 85
FH 75
FS 75, FS 80, FS 85
HL 75
KM 85
KW 85
SP 81

1FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
q
© ANDREAS STIHL AG & Co. KG, 2004
Contents
1. Introduction 2
2. Safety Precautions 3
3. Specifications 4
3.1 Fuel System 4
3.2 Tightening Torques 5
4. Troubleshooting 8
4.1 Clutch 8
4.2 Rewind Starter 9
4.3 Fuel System 10
4.4 Engine 12
5. Engine 13
5.1 Shroud 13
5.2 Clutch 13
5.2.1 Removing and
Installing 13
5.2.2 Clutch Drum 15
5.3 Muffler/Spark Arresting
Screen 16
5.4 Removing and Installing
the Engine 17
6. Rewind Starter 17
6.1 General 17
6.2 Removing and
Installing 18
6.3 Rope Rotor/Rewind
Spring 19
6.3.1 Tensioning 20
6.4 Starter Rope 21
6.5 Starter Grip 21
6.6 Carrier/Pawl 22
7. AV System 23
7.1 Repair 23
8. Throttle Control 26
8.1 Control Handle on Loop
Handle up to 1997 26
8.1.1 Throttle Trigger /
Interlock Lever 26
8.1.2 Detent/Torsion Spring 27
8.1.3 Throttle Cable 28
8.2 Control Handle
up to 2002 28
8.2.1 Throttle Trigger/Interlock
Lever 28
8.2.2 Slide Control 29
8.2.3 Throttle Cable 30
8.3 Control Handle
from 2002 31
8.3.1 Throttle Trigger/Interlock
Lever 31
8.3.2 Contact/Detent Spring 32
8.3.3 Throttle Cable 33
8.4 Adjusting the Throttle
Cable 33
8.5 Control Handle on Bike
Handle up to 1997 34
8.5.1 Throttle Trigger/Interlock
Lever 34
8.5.2 Contact / Detent
Spring 35
8.5.3 Throttle Cable 36
8.6 Control Handle on Bike
Handle up to 2002 37
8.6.1 Throttle Trigger/Interlock
Lever 37
8.6.2 Contact / Detent
Spring 38
8.6.3 Throttle Cable 38
8.7 Control Handle on Bike
Handle from 2002 40
8.7.1 Throttle Trigger/Interlock
Lever 40
8.7.2 Contact/Detent Spring 41
8.8 Adjusting the Throttle
Cable 42
9. Fuel System 42
9.1 Air Filter 42
9.2 Carburetor 43
9.2.1 Leakage Test 43
9.2.2 Removing and
Installing 44
9.2.3 Spacer Flange 45
9.3 Servicing the
Carburetor 46
9.3.1 Flange Mounting
with Oval End Cover 46
9.3.2 Flange Mounting with
Square End Cover 47
9.3.3 Metering Diaphragm 47
9.3.4 Inlet Needle 48
9.3.5 Fixed Jet 48
9.3.6 Pump Diaphragm 49
9.4 Adjusting the
Carburetor 49
9.4.1 Carburetor with Two
Adjusting Screws 49
9.4.2 Carburetor with
LD Screw 50
9.4.3 User Adjustment,
Carburetor with
Limiter Cap 51
9.4.4 Service Adjustment,
Carburetor with
Limiter Cap 52
9.5 Tank Vent 54
9.6 Pickup Body 55
9.7 Fuel Tank/
Fuel Hoses 55
10. Drive Tube 57
10.1 Bike Handle 57
10.2 Loop Handle 57
10.2.1 Loop Handle with
Barrier Bar 57
10.2.2 Loop Handle without
Barrier Bar 58
10.2.3 Loop Handle with
Handle Hose 58
10.3 Drive Shaft/Flexible
Liner 59
10.3.1 Drive Shaft in Upper
End of Drive Tube
(KM 85 only) 60
10.4 Drive Tube 62
10.4.1 FS 80, 85, FH 75,
HL 75 62
10.4.2 Split Drive Tube
(KM 85 only) 63
10.5 Bearing Housing
(FS 75 only) 64
11. Special Sevicing
Tools 66
12. Servicing Aids 67

2FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
This service manual contains
detailed descriptions of all typical
repair and servicing procedures for
models FC 75, 85, FH 75,
FS 75, 80, 85, HL 75, KM 85 and
KW 85, which are based on the
series 4137 powerhead.
If there is no specific reference to
individual machines, the procedure
is the same for all machines. The
illustrations may differ depending on
the machine, but the methods used
and the sequence of operations are
identical.
You will find detailed descriptions of
procedures for servicing and
repairing engine components and
associated CombiTools in the
service manual for the “Series 4137
Powerhead“.
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 of any replacement parts.
A fault on the machine may have
several causes. To help locate the
fault, consult the chapter on
"Troubleshooting" in this manual
and the "STIHL Service Training
System" for all assemblies.
Refer to the "Technical Information"
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list until a
revised edition is issued.
The special servicing tools
mentioned in the descriptions are
listed in the chapter "Special
Servicing Tools" 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)
In the illustrations:
Pointer
Direction of movement
b4.2 Reference to another
chapter, i.e. chapter 4.2
in this example.
Service manuals and technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed to third parties.
Servicing and repairs are made
considerably easier if the machine
is mounted on assembly stand (2)
5910 893 3100 with the aid of
clamping fixture (1) 5910 890 8800.
The powerhead can then be
swivelled to the best position for the
VA
249RA!63
2
1
ongoing repair.
Always use original STIHL
replacement parts.
They can be identified by the
STIHL part number,
the STIH) logo and the
STIHL parts symbol (
This symbol may appear alone on
small parts.
1. Introduction

3FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
If the engine is started up in the
course of repairs or maintenance
work, observe all local and country-
specific safety regulations as well
as the safety precautions and
warnings in the instruction 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 bring any fire, flame, spark or
other source of heat near the fuel.
All work with fuel must be performed
outdoors only. Spilled fuel must be
wiped away immediately.
2. Safety Precautions

4FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
3. Specifications
3.1 Fuel System Carburetor: Diaphragm carburetor
Carburetor leakage test at gauge
pressure: 80 kPa (0.8 bar)
Fuel mixture: Regular brand-name gasoline with
min. 90 RON and STIHL 50:1
two-stroke engine oil; see instruction
manual for further details
Rated idle speed: 2,800 rpm
Rated cut-off speed: 10,500 rpm
Operation of tank vent:
- at gauge pressure: 50 kPa (0.5 bar)
- under vacuum: 20 kPa (0.2 bar)

5FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
3.2 Tightening Torques
DG and P (Plastoform) screws are used in polymer and light metal components. These screws form a
permanent thread when they are installed for the first time. They can be removed and installed as often as
necessary without impairing the strength of the screwed assembly, providing the specified tightening torque is
observed.
For this reason it is essential to use a torque wrench.
Fastener Thread size For component Torque Remarks
lbf.ft Nm
Screw IS-P4x16 Control handle/handle molding (outer/inner) 0.75 1.0 1)3)4)5)6)8)
Screw IS-M5x12 Control handle/clamp/drive tube 3.6 5.0 1)3)4)5)6)8)
Screw IS-M5x30 Control handle/handlebar/locknut with
washer (bike handle) 1.5 2.0 2)7)
Screw IS-P4x16 Control handle/handle molding (outer/inner)
(bike handle) 0.75 1.0 2)7)
Screw IS-P4x16 Control handle/handle molding (outer/inner)
(loop handled machine) 0.75 1.0 2)7)
Screw IS-M5x12 Control handle/clamp/right-hand screw
(loop handled machine) 3.6 5.0 2)7)
Screw IS-DG5x16 Loop handle 1.8 2.5 1)3)8)
Screw IS-M6x50 Loop handle/drive tube/nut 2.6 3.5 1)3)8)
Mutter M5 Filter housing/carburetor/flange/screw 3.0 4.0
Screw IS-B4.2x9.5 Spark arresting screen/muffler 0.75 1.0
Screw IS-M5x84 Gearbox housing, left/right 1.1 1.5 6)
Locknut M5 Gearbox housing, left/right
(locknut) 4.4 6.0 6)
Screw IS-M6x20 Gearbox housing/drive tube 7.5 10.0 4)6)
Screw IS-M5x25 Housing, fan side/starter side 7.0 9.5 1)2)3)5)7)8)
Screw IS-DG5x24 Gearbox housing/drive tube 6.6 9.0 2)7)
Screw IS-M5x10 Quadrant/gear housing 5.9 8.0 6)
Screw IS-M4x16 Guard plate/gearbox cover 2.6 3.5 6)
Screw IS-M5x16 Shroud/fan housing 2.6 3.5
Screw IS-M5x16 Shroud/starter cover/crankcase 2.6 3.5
Screw IS-M5x20 AV sleeve (clamp screw) 4.0 5.5

6FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
Fastener Thread size For component Torque Remarks
lbf.ft Nm
Screw IS-DG5x12 AV sleeve/drive tube, location 0.37 0.5
Screw IS-DG5x60 Retainer/deflector/drive tub 1.5 2.0 8)
Screw IS-M6x35 Clamp/clamp block/clamp
(bike handle) 3.3 4.5 2)7)
Tommy screw M6x30 Coupling sleeve/tommy screw
(version with split boom) 4.4 6.0 2)7)
Screw IS-M6x25 Coupling sleeve/clamp nut
(version with split boom) 6.6 9 2)7)
M8 Clutch carrier/flywheel/
crankshaft 19.2 26.0
Screw IS-M5x16 Fan housing/crankcase 5.9 8.0
Screw IS-M6x25 Clamp/loop handle
(loop handled machine) 3.3 4.5 2)4)6)7)
Nut M5 DS270 mm blade/screw 7.0 9.5 6)
M8 Carrier 10.3 14.0
Collar nut P3.5x9.0 Detent spring/slide control/control handle 1.5 1.1 2)7)
Screw IS-M5x22 Clamp/drive tube/harness adjustment
(version with split boom) 2.2 3.0 2)7)
Screw IS-P5.5x12 Rope rotor/starter cover 2.6 3.5
Screw IS-5x33 Clamp/deflector 3.3 4.5 1)
Screw IS-5x16 Muffler/crankcase 7.0 9.5
Screw IS-5x16 Muffler/cylinder 8.5 11.5
Screw IS-M6x14 Clamp/drive tube/harness adjustment 3.3 4.5 2)5)7)
Screw IS-M5x18 Clamp/bearing housing/locknut
4.8 6.5 1)
Screw IS-M5x16 Starter cover/crankcase 4.0 5.5
Screw IS-M5x22 Carrying ring/clamp 2.2 3.0 4)6)
Screw IS-M5x25 Spacer flange/cylinder (with washer) 4.0 5.5
Screw IS-DG5x24 Cylinder/crankcase 7.0 9.5
Spark plug M14x1.25 Spark plug 15.0 20.0
Screw IS-M4x20 Ignition module/cylinder (with washer) 3.3 4.5
Screw IS-M5x25 Spacer flange/cylinder (with washer) 4.0 5.5

7FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
Remarks:
1) FS 75
2) FS 80, 85
3) FC 75
4) HL 75
5) KW 85
6) FH 75
7) KM 85
8) FC 85
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.
Power screwdriver settings for polymer:
Plastoform screws: max. 600 rpm
DG screws: max. 500 rpm
Important:
Do not mix up screws with and without binding head

8FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
4. Troubleshooting
4.1 Clutch
Condition Cause Remedy
Tool stops at full throttle
under load
Clutch shoes badly worn Install new clutch shoes or a new
clutch
Clutch drum badly worn Replace clutch drum
Tool runs at idle speed Idle speed too high Readjust idle speed screw
(counterclockwise)
Clutch springs stretched or
fatigued
Fit new clutch springs
Clutch spring hooks broken Fit new clutch springs
Loud noises Clutch springs stretched or fatigued Replace all clutch springs
Clutch shoe retainer (carrier)
broken
Fit new retainer (carrier) or clutch
Clutch shoes and carrier worn Install a new clutch
Needle cage damaged Install a new needle cage

9FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
4.2 Rewind Starter
Condition Cause Remedy
Starter rope broken Rope pulled out too vigorously as
far as stop or over edge, i.e. not
vertically
Fit new starter rope
Normal wear Fit new starter rope
Rewind spring broken (starter rope
does not rewind)
Spring overtensioned – no reserve
when rope is fully extended
Fit new rewind spring
Very dirty or corroded Clean rewind spring or install new
spring
Starter rope can be pulled out
almost without resistance
(crankshaft does not turn)
Guide peg on pawl or pawl itself
is worn
Fit new pawl
Spring clip fatigued Fit new spring clip
Starter rope is difficult to pull and
rewinds very slowly
Starter mechanism very dirty
(dusty conditions)
Thoroughly clean complete starter
mechanism
Lubricating oil on rewind spring
becomes viscous at very low
outside temperatures (spring
windings stick together)
Coat rewind spring with a standard
solvent-based degreasant
(containing no chlorinated or
halogenated hydrocarbons). Then
pull rope carefully several times
until normal action is restored

10 FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
4.3 Fuel System
Condition Cause Remedy
Engine stalls at idle speed dle jet bores or ports blocked Clean jet bores and ports and blow
clear with compressed air
Idle jet too rich or too lean Reset low speed screw (L)
correctly
Setting of idle speed screw
incorrect – throttle shutter
completely closed
Reset idle speed screw (LA)
correctly
Engine speed drops quickly under
load – low power
Air filter plugged Clean the air filter or replace if
necessary
Tank vent faulty Clean the tank vent of replace if
necessary
Leak in fuel line between tank and
fuel pump
Seal or renew connections and fuel
line
Pump diaphragm damaged or
fatigued
Fit new pump diaphragm
Main jet bores or ports blocked Clean the bores and ports
Fuel pickup body dirty Install new pickup body
Fuel strainer dirty Fit new fuel strainer
Setting of high speed screw (H) too
rich
Reset high speed screw (H)
correctly
Throttle shutter not opened fully Check linkage
Engine will not idle –
idle speed too high
Throttle shutter opened too wide by
idle speed screw
Reset idle speed screw LA
correctly

11FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
Condition Cause Remedy
Poor acceleration Idle jet too lean Turn low speed screw (L) counter-
clockwise (richer), no further than
stop
Main jet too lean Turn high speed screw (H) counter-
clockwise (richer), no further than
stop
Inlet control lever too low
(relative to correct installed
position)
Set inlet control lever flush with top
of carburetor body
Inlet needle sticking to valve seat Remove inlet needle, clean and
refit
Connecting bore to atmosphere
blocked
Clean the bore
Diaphragm gasket leaking Fit new diaphragm gasket
Metering diaphragm damaged or
shrunk
Fit new metering diaphragm
Carburetor floods,
engine stalls
Inlet needle not sealing. Foreign
matter in valve seat or cone
damaged
Remove and clean or replace inlet
needle, clean fuel tank, pickup
body and fuel line if necessary
Inlet control lever sticking on
spindle
Free off inlet control lever
Helical spring not located on nipple
of inlet control lever
Remove inlet control lever and refit
correctly
Perforated disc on diaphragm is
deformed and presses constantly
against inlet control lever
Fit new metering diaphragm
Inlet control lever too low
(relative to correct installed
position)
Fit new inlet control lever

12 FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
4.4 Engine
Always check and, if necessary,
repair the following parts before
looking for faults on the engine:
– Air filter
– Fuel system
–Carburetor
– Ignition system1)
Condition Cause Remedy
Engine does not start easily, stalls
at idle speed, but operates normally
at full throttle
Oil seals in crankcase faulty Install new oil seals 1)
Crankcase leaking / damaged
(cracks)
Seal / replace the crankcase 1)
Muffler leaking Seal / replace the muffler
Engine does not deliver full power
or runs erratically
Piston rings worn or broken Install new piston rings 1)
Muffler / spark arresting screen
carbonized
Clean muffler (inlet and
exhaust openings), replace
spark arresting screen
Air filter element dirty Fit new air filter element
Fuel / impulse line kinked or
cracked
Fit new lines or position
without kinks
Engine overheating Insufficient cylinder cooling.
Air inlets in fan housing
blocked or cooling fins on
cylinder very dirty
Thoroughly clean all cooling air
passages and cooling fins
1) see "Series 4137 Powerhead" service manual“

13FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
:Remove the screw (arrow) from
the starter.
VA
936RA000
:Remove the screw (1) from the
fan housing.
:Remove the shroud (2).
Install in the reverse sequence.
VA
936RA001
12
:Make sure the gaskets on either
side of the cylinder, and the
ignition lead (arrow), are located
in the guides in the shroud.
VA
936RA304
Troubleshooting chart, b4.1.
Removing
– Remove the shroud, b5.1
:Take out the screws (arrows).
– Remove the engine from the fan
housing and put it to one side.
VA
936RA002
:Inspect the clutch drum. There
should be no scores or signs of
excessive wear.
VA
936RA003
:If there are noticeable wear
marks on the inside diameter of
the clutch drum (1), check its wall
thickness. If it is less than about
80% of the original thickness, fit a
new clutch drum, b5.2.2
VA
148RA101
80%
100%
1
!
:Pull off the spark plug boot (1).
:Unscrew the spark plug (2).
VA
936RA004
1 2
5. Engine
5.1 Shroud
5.2 Clutch
5.2.1 Removing and Installing

14 FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
:Push the locking strip (1)
0000 893 5903 into the cylinder.
VA
366AR013
1
:Unscrew the clutch from the
crankshaft counterclockwise.
VA
936RA005
:Use hook (2) 5910 890 2800 to
remove the clutch springs (1).
VA
208RA028
21
– Pull the clutch shoes off the
carrier.
:Pull the retainers off the clutch
shoes.
VA
936RA305
– Clean all parts, b12.
– Replace any damaged parts.
Installing
VA
936RA306
Recommendation:
– If possible, always replace the
clutch as a complete assembly.
:Fit the retainers (1) on the clutch
shoes so that the narrow side (2)
is on the same side as the
number (3).
VA
208RA032
3
1 2
:Push the clutch shoes over the
arms (1) of the carrier so that the
number (2) is on the same side
as the raised hexagon (3).
VA
208RA027
2 1 3
:Clamp the clutch is a vise with
protective jaws.
VA
208RA030

15FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
:Attach one end of each spring (1)
to the clutch shoes.
:Use the hook (2) 5910 890 2800
to attach other ends of springs
and press them firmly into the
clutch shoes.
VA
936RA291
1
2
:Screw the clutch into position
(lower hexagon facing outwards)
and tighten it down firmly, b3.2
VA
936RA006
:Check that the plugs are in
position in the fan housing, fit
them if necessary.
VA
936RA007
:Position the engine against the
fan housing, making sure the
lugs (1) engage the plugs (2).
– Fit fan housing mounting screws
and tighten them down firmly,
b3.2
VA
936RA008
1
2
– Remove the locking strip from the
cylinder.
– Install the spark plug and tighten
it down firmly, b3.2
– Check if spark plug has a
detachable adapter nut. If so,
make sure it is properly fitted and
firmly tightened.
– Fit boot on the spark plug.
– Fit the shroud, b5.1
– Remove the engine, b5.2.1
– Remove the rubber element (AV
system) from the fan housing,
b7.1
:Use pliers (1) 0816 610 1495 to
remove the circlip from the clutch
drum’s output stub.
VA
936RA111
1
:Use drift (1) 4180 893 4400 to
press the clutch drum out of the
ball bearing.
VA
936RA112
1
5.2.2 Clutch Drum

16 FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
:Check the ball bearing (arrow).
If the ball bearing is faulty, the whole
fan housing has to be replaced.
VA
936RA113
:Use drift (1) 1108 893 4700 to
press home the clutch drum as
far as stop.
Assemble all other parts in the
reverse sequence.
VA
936RA114
1
Muffler
– Remove the shroud, b5.1
:Take out the screw (arrow) at the
side of the muffler.
VA
936RA307
:Take out the inner screws
(arrows).
– Remove the muffler with gasket.
936RA308
VA
:Bend up the tab (1) on the
retainer.
:Pull out the gasket (2).
Install in the reverse sequence.
VA
936RA309
2
1
– Bend the tab down again after
fitting the gasket.
– Tighten down the muffler
mounting screws, b3.2
Assemble all other parts in the
reverse sequence.
Spark arresting screen
:Take out the screw (1).
:Pull out the spark arresting
screen (2).
– Clean or replace the spark
VA
936RA310
1
2
arresting screen as necessary.
Install in the reverse sequence.
5.3 Muffler/Spark Arresting
Screen

17FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
– Remove the shroud, b5.1
:Pull the short circuit wire
connector (arrow) off the terminal
on the ignition module.
VA
935RA076
:On machines with two short
circuit wires, pull the connectors
(arrows) off the terminals on the
ignition module.
VA
935RA077
:On machines with one short
circuit wire, remove throttle cable
lug from lower screw (arrow).
936RA430
VA
:Disconnect throttle cable nipple
(1) from slotted pin (2) on
carburetor’s throttle lever.
VA
366RA007
1
2
:Take the throttle cable out of the
tensioner.
VA
936RA229
:Take out the screws (arrows).
– Remove the engine from the
clutch housing.
Install in the reverse sequence.
VA
936RA002
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. This has a
detrimental effect on the function of
the starter mechanism. In such a
case it is sufficient to apply a few
drops of a standard solvent-based
degreasant (containing no
chlorinated or halogenated
hydrocarbons) to the rewind spring,
b12.
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 particular
care when removing the spring.
Clean all parts, b12.
Lubricate the rewind spring and
starter post with STIHL special
lubricant, see b12, before
installing.
5.4 Removing and Installing
the Engine
6. Rewind Starter
6.1 General

18 FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
– Remove the shroud, b5.1
:Take out the screws (arrows).
VA
366RA116
:On machines with one short
circuit wire, remove throttle cable
lug from lower screw (arrow).
– Remove the rewind starter.
Install in the reverse sequence.
936RA430
VA
:Check that the plug (arrow) in the
rewind starter is correctly seated.
Replace if damaged.
VA
936RA037
:Fit the rewind starter so that the
lug (1) engages the plug (2).
VA
936RA038
1
2
:On machines with one short
circuit wire, secure the throttle
cable lug with the lower screw
(arrow).
– Tighten down the screws firmly,
b3.2
936RA430
VA
Assemble all other parts in the
reverse sequence.
6.2 Removing and Installing

19FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85
A replacement rope rotor comes
with a new rewind spring.
– Remove the rewind starter,
b6.2
Relieving tension of rewind
spring
There will be no tension if either the
starter rope or rewind spring is
broken.
– Pull out the starter rope about
30 cm (12“) and hold the rope
rotor steady.
:Engage the rope in the notch
(arrow) in the rotor and make a
loop.
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:Use the loop to rotate the rotor
clockwise until the spring is no
longer under tension.
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:Take out the screw (arrow).
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:Carefully pull the rope rotor off
the starter post.
The rewind spring is installed in the
rope rotor. The spring may pop out
and uncoil if the rope rotor is not
removed very carefully.
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Always wear safety glasses
– Remove the pieces of broken
spring from the rewind starter.
– To replace the rope rotor, remove
the starter rope, b6.4
Install in the reverse sequence.
Pay attention to correct installed
position of the rewind spring.
The rewind spring may pop out of
the rope rotor and uncoil if it is not
installed very carefully. Use the
following procedure to fit the rewind
spring:
:Engage the outer spring loop in
the recess (arrow) and fit the
rewind spring counterclockwise,
starting outside and working
inwards.
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:Check the distance of the inner
spring loop from the bore and
correct if necessary. Dimension
"a" must be 2 mm.
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a
6.3 Rope Rotor/Rewind
Spring