Stihl 2016-07 User manual

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2016-07
STIHL Guide Bars Service Manual

Printed on chlorine-free paper Printing inks contain vegetable oils, paper can be recycled.
© ANDREAS STIHL AG & Co. KG, 2017 RA_025_2016_01_01. VA0.C17. 0000007405_001_GB
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{This service manual is protected by copyright. All rights reserved, especially the rights to reproduce, translate and process with electronic
systems.
Contents
1 About this Service Manual ............................. 2
1.1 Applicable Documentation .............................. 2
1.2 Symbols in Text ..............................................2
2 Safety During Repair Work ............................ 2
2.1 Protective Gloves............................................2
2.2 Safety Glasses................................................ 2
2.3 Spare Parts..................................................... 2
3 Nose Sprocket ............................................... 3
3.1 Overview......................................................... 3
3.2 Tools, Servicing Aids ...................................... 3
3.3 Removing the Nose Sprocket......................... 3
3.4 Installing the Nose Sprocket ........................... 3
4 Guide Bar Nose ............................................. 5
4.1 Overview......................................................... 5
4.2 Tools, Servicing Aids ...................................... 5
4.3 Removing the Guide Bar Nose ....................... 5
4.4 Installing the Guide Bar Nose ......................... 5
5 Guide Bar Body.............................................. 7
5.1 Tools, Servicing Aids ...................................... 7
5.2 Removing Burrs .............................................. 7
5.3 Straightening the Guide Bar ........................... 7
5.4 Opening and Closing the Bar Groove............. 7

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1.1 Applicable Documentation
NPlease observe the following documentation in
addition to this service manual.
–Spare parts documentation
–TI bulletins
–Instruction manual
1.2 Symbols in Text
2.1 Protective Gloves
Sharp or hot components can cause cuts or burns.
NIf sharp or hot components have to be handled during
a repair: Wear protective gloves.
2.2 Safety Glasses
Particles and objects can be thrown into the air at high
speed during a repair. Thrown particles or objects can
cause eye injuries.
NIf there is a risk of particles being thrown during the
repair: Wear safety glasses.
2.3 Spare Parts
If spare parts not approved by STIHL are installed, they
may not fulfill the required function or deactivate safety
devices. This can result in serious or fatal injuries.
NSTIHL recommends the use of genuine STIHL
replacement parts.
1 About this Service Manual
This symbol refers to a chapter in this service
manual.
This symbol refers to an interactive video tuto-
rial for this repair procedure.
This symbol shows the tightening torque for a
screw joint and the procedure after tightening.
In this example: Tightening torque 5 Nm. Then
rotate 1 full turn counterclockwise.
2 Safety During Repair Work
5 Nm
1

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3.1 Overview
3.2 Tools, Servicing Aids
–Twist drill, 6.5 mm
–Pin punch, 4 mm
–Hammer
–STIHL Multispray – 0730 411 7000
3.3 Removing the Nose Sprocket
The nose sprocket can be replaced on STIHL
Rollomatic E and STIHL Rollomatic E Light guide bars.
The nose sprocket cannot be replaced on STIHL
Rollomatic E Mini and STIHL Rollomatic E Mini Light
guide bars.
NCenter-punch the rivet heads (2).
NUse a 6.5 mm drill to drill away the heads of the rivets
(2).
NKnock out the rivets (2) with a 4 mm pin punch.
NPull out the nose sprocket (5) from between the guide
bar’s (1) two side plates.
3.4 Installing the Nose Sprocket
The sprocket nose roller bearing is covered with two
plastic discs (4). The plastic discs (4) are held together by
two clips (3). The plastic discs (4) and clips (3) prevent the
cylindrical rollers dropping out of the bearing.
NHold the guide bar (1) upright.
3 Nose Sprocket
13
2
4
4
5
0000-GXX-1598-A0
0000-GXX-2373-A0

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NRemove the clips (3).
NInsert the nose sprocket (5) in the bar nose (1) from
above. Hold the plastic discs (4) together during this
process.
NPush the nose sprocket (5) into the guide bar. Open
up the bar groove slightly to simplify this process.
NPosition the nose sprocket (5) so that the holes in its
bearing race line up with the holes in the bar nose (1).
NFit the countersunk rivets (2) and form their heads
with a hammer. Each rivet head must completely fill
the hole recess (arrows).
NLubricate the bearing in the nose sprocket (5) with
STIHL Multispray.
44
5
1
5
1
0000-GXX-1599-A0
2
12
0000-GXX-1600-A0

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4.1 Overview
4.2 Tools, Servicing Aids
–Twist drill, 7.5 mm
–Pin punch, 5 mm
–Hammer
4.3 Removing the Guide Bar Nose
The bar nose can be replaced on STIHL Rollomatic ES
and STIHL Rollomatic ES Light guide bars.
NCenter-punch the rivet heads (2).
NUse a 7.5 mm drill to drill away the heads of the rivets
(2).
NKnock out the rivets (2) with a 5 mm pin punch.
NRemove the nose (3) from the guide bar (1).
4.4 Installing the Guide Bar Nose
NPush the new nose (3) onto the guide bar (1). The
nose may be fitted either way round.
NPosition the nose (3) so that its holes line up with the
holes in the guide bar (1).
NFit the countersunk rivets (2) and form their heads.
Each rivet head must completely fill the hole recess
(arrows).
4 Guide Bar Nose
1
3
2
0000-GXX-1601-A0
0000-GXX-2052-A0
2
2
0000-GXX-1602-A0

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NIf the joints (arrows) in the running faces are not the
same height: Grind down the projecting rails.
0000-GXX-1603-A0

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5.1 Tools, Servicing Aids
–Guide bar dresser – 5605 773 4400
–Filing gauge 1/4" P – 0000 893 4005
–Filing gauge 1/4", 3/8" P, .325", 3/8" – 1100 893 4000
–Filing gauge .404", 1/2" – 1106 893 4000
–Groove drift 1.3 mm – 1110 893 9200
–Groove drift 1.6 mm – 1106 893 9200
–Flat file
–Hammer
–Leveling plate
–Spacer that matches groove width
5.2 Removing Burrs
A burr can build up on the outer edge of the guide bar.
NInspect bar body for cracks and damage.
NRemove burr with a belt grinder and/or grinding
wheel.
The burr can also be removed with a flat file or the STIHL
guide bar dresser.
NCheck groove depth with a filing gauge of the right
pitch.
Depending on the pitch, the following minimum groove
depths must be maintained:
NIf the measured groove depth is less than specified:
Replace the guide bar.
5.3 Straightening the Guide Bar
NInspect bar body for cracks and damage.
NSupport the bar in a press or vise at two points
equidistant from the center of the bend (1).
NApply pressure to the apex of the bend (1) until the
bar is straight.
NRelease pressure and check that the bar is still
straight. If the bar is not straight: Repeat the above
procedure.
NUse a hammer to finish straightening on a leveling
plate until it is flat in the rail area.
NInspect bar body for cracks and damage.
5.4 Opening and Closing the Bar Groove
Opening the Groove
NInspect bar body for cracks and damage.
NClamp the center of the guide bar in a vise.
NInsert a groove drift which matches the specified
groove width in the groove at an angle of about 45°.
NUse a hammer to knock the groove drift through the
pinched portion of the groove.
NInspect bar body for cracks and damage.
Closing the Groove
NInspect bar body for cracks and damage.
5 Guide Bar Body
– 1/4" P: 4 mm
– 1/4": 4 mm
– .325": 6 mm
– 3/8" P: 5 mm
– 3/8": 6 mm
– .404": 7 mm
0000-GXX-2226-A0
1
0000-GXX-2374-A0
0000-GXX-2375-A0

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NInsert a spacer that matches the specified groove
width in the wide portion of the groove.
NClamp the affected area of the bar in a vise or
hammer the bar rails against the spacer on a flat
base.
NInspect bar body for cracks and damage.
0000-GXX-2376-A0

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RA_025_2016_01_01
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