Stihl MS 440 Service Manual
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Stihl MS 440 Service Manual

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STIH)
STIHL MS 440
2006-05

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  • Page 1 STIH) STIHL MS 440 2006-05...

  • Page 2: Table Of Contents

    12.6 Pickup Body Removing and 12.7 Fuel Hose Installing 12.8 Tank housing Pawls Rope Rotor Starter rope 8.5.1 Tensioning Starter Rope Guide Bushing Replacing the Rewind Spring © ANDREAS STIHL AG & Co. KG, 2006 MS 440, MS 440 C...
  • Page 3 Handle Heating System 14.1 Troubleshooting 14.1.1 Troubleshooting Chart 14.1.2 Test Connections and Test Values 14.2 Heater switch 14.3 Heating element in front handle 14.4 Heating element in front handle 14.5 Generator Special Servicing Tools Servicing Aids MS 440, MS 440 C...

  • Page 4: Introduction

    "Special Servicing Tools" of this procedures for this power tool. manual. Use the part numbers to identify the tools in the "STIHL You should make use of the Special Tools" manual which lists all illustrated parts lists while carrying the special servicing tools currently out repair work.

  • Page 5: Safety Precautions

    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. MS 440, MS 440 C...

  • Page 6: Specifications

    Spark plug (suppressed): Bosch WSR 6F NGK BPMR 7A Electrode gap: 0.5 mm (0.02 in) Chain Lubrication Fully automatic, speed-controlled oil pump with rotary piston Oil delivery rate: 8...18 cm /min (0.49...1.1 cu.in/min) at 10,000 rpm MS 440, MS 440 C...

  • Page 7: Tightening Torques

    8.0 (5.90) Screw assy. IS-M4x16 Hand guard left, fan housing 4.0 (2.95) Remarks: 1) Secure screw with Loctite 270 2) Secure screw with Loctite 242 3) A washer must be fitted under the screw head MS 440, MS 440 C...

  • Page 8: Troubleshooting Chart

    Chain sprocket worn Fit new chain sprocket Saw chain does not stop Brake spring stretched or broken Fit new brake spring immediately when brake is activated Brake band stretched, worn or Fit new brake band broken MS 440, MS 440 C...

  • Page 9: Rewind Starter

    Coat rewind spring with a little becomes viscous at very low standard solvent-based degreasant outside temperatures (spring (containing no chlorinated or windings stick together) halogenated hydrocarbons), then pull rope carefully several times until normal action is restored MS 440, MS 440 C...

  • Page 10: Chain Lubrication

    Install new oil pump Oil pump delivers insufficient oil Adjusting screw and/or control Fit new adjusting screw and/or oil edge on pump piston worn pump Piston bore in pump housing worn Install new oil pump MS 440, MS 440 C...

  • Page 11: Ignition System

    Faulty insulation on ignition lead or short circuit wire. Use ohmmeter to check ignition lead for break. If break is detected or high resistance measured, fit a new ignition lead Leak in crankcase Replace oil seals or crankcase MS 440, MS 440 C...

  • Page 12: Carburetor

    Inlet needle sticking to valve seat Remove inlet needle, clean and refit Diaphragm gasket leaking Fit new diaphragm gasket Metering diaphragm damaged or Fit new metering diaphragm shrunk Impulse hose damaged or kinked Fit new impulse hose MS 440, MS 440 C...
  • Page 13 Main jet bores or ports blocked Clean bores and ports Setting of high speed screw (H) Rotate high speed screw (H) too rich clockwise (leaner), no further than stop Impulse hose damaged or kinked Fit new impulse hose MS 440, MS 440 C...

  • Page 14: Engine

    Decompression valve sticking Replace the decompression valve Engine overheating Insufficient cylinder cooling. Thoroughly clean all cooling air Air inlets in fan housing blocked or openings and the cylinder fins. cooling fins on cylinder very dirty MS 440, MS 440 C...

  • Page 15: Clutch, Chain Drive, Chain Brake And Chain Tensioner

    – b 5.4.2 : Remove the clutch drum (1) with needle cage (2). – Examine the needle cage for signs of damage. : Disengage the chain brake by pulling the hand guard towards the front handle. MS 440, MS 440 C...

  • Page 16: Replacing The

    : Release twist lock (1) on carburetor box cover (2) and lift it off. : On machines with HD air filter, draw air guide (1) off to the rear. MS 440, MS 440 C...
  • Page 17 : Push the locking strip (1) – Pull the clutch shoes off the 0000 893 5903 into the spark carrier. plug hole so that "OBEN-TOP" faces up. Assembly : Slip the retainers onto the clutch shoes. MS 440, MS 440 C...

  • Page 18: Chain Brake

    : Attach one end of each spring (1) to the clutch shoes. : Use the hook (2) 5910 890 2800 to attach other end of the spring and press it firmly into the clutch shoe. MS 440, MS 440 C...

  • Page 19: Removing

    : Unhook the brake band from the – Engage the chain brake by bell crank (2). pushing the hand guard away from the front handle. : Take out the screw (arrow) on the brake band. MS 440, MS 440 C...
  • Page 20 : Carefully pry the hand guard (1) and bell crank (2) off the pivot pins and remove all parts. : Draw the bell crank out of the hand guard. : Take out the screw (1). MS 440, MS 440 C...

  • Page 21: Installing

    STIHL multipurpose grease – b 16. : Slide the bell crank into the opening at the side of the hand guard. The short end of the lever (arrow) faces the upper part of the hand guard. MS 440, MS 440 C...
  • Page 22 : Check that the cam lever is : Hook the brake band into the bell correctly positioned on the sliding crank (arrow). surface (arrow) of the bearing boss. – Route the brake band round behind the stubs on the crankcase. MS 440, MS 440 C...

  • Page 23: Chain Tensioner

    : Take out the screw (2). – Fit the cover. : Remove the cover plate. : Turn in the screws (arrows) and tighten them down – b 3.5 – Fit the clutch drum / chain sprocket – b 5.1 MS 440, MS 440 C...

  • Page 24: Bar Mounting Studs

    – b 16. : Pull out the tensioner slide with adjusting screw and thrust pad. : Check that the O-ring (arrow) is fitted in the spur gear and lubricate it with oil before installing the spur gear. MS 440, MS 440 C...

  • Page 25: Engine

    (except on the MS 440 Magnum). – Clean the spark arresting screen or replace it if necessary. On the MS 440 Magnum, proceed as follows to clean the spark arresting screen: : Take out the screws (arrows). : If there are cracks in the honeycomb structure (1) or if the –...

  • Page 26: Leakage Test

    Loctite – b 16. – Tighten down the screws – b 3.5 When assembling the parts, ensure that size M6x20 screws are fitted at the bottom and size M5x6 screws at the top to secure the exhaust casing. MS 440, MS 440 C...

  • Page 27: Preparations

    : Fit nuts (4) and tighten them down firmly. – Remove the exhaust casing on : Ensure that the sleeve (1) and the muffler – b 6.1 washer (2) are fitted. : Half-remove the screws (arrows) on the muffler. MS 440, MS 440 C...

  • Page 28: Pressure Test

    0000 850 3501 to nipple b 6.2.3 (arrow) of the test flange. : Close the vent screw (1) on the pump. : Operate lever (2) until pressure gauge (3) indicates a vacuum of 0.5 bar (7,25 psi). MS 440, MS 440 C...

  • Page 29: Oil Seals

    – b 16. – Slip the oil seal, open side facing the crankcase, over the crankshaft stub. : Take out the screws (arrows) on machines with handle heating. – Lay the generator aside. MS 440, MS 440 C...
  • Page 30 – b 16. – Free off the oil seal in its seat by crankshaft stub. tapping it with a suitable tube or a : Fit the spacer bush. punch. – Install the oil pump – b 11.3.1 MS 440, MS 440 C...

  • Page 31: Removing The Shroud

    (2). – If a decompression valve is : Take the sleeve (1) out of the installed, check that the cover manifold. (arrow) is correctly seated. : Remove the washer (2) from the stud bolts. MS 440, MS 440 C...
  • Page 32 – Inspect the piston rings and replace if necessary – b 6.6 : Carefully remove the cylinder gasket from the cylinder base. – Pull the cylinder off the piston. – Remove the cylinder gasket. MS 440, MS 440 C...

  • Page 33: Installing

    : Remove the sleeve from : Stand the installing tool, sleeve installing tool 5910 890 2212. downward, on a flat surface (wooden board) and press vertically downwards until the sleeve butts against the tool's shoulder. MS 440, MS 440 C...
  • Page 34 : Fit the hose clamp (1) with the with oil, then place the piston (1) screw head on the right. on the wooden assembly block (2) 1108 893 4800. : Tighten down the clamp so that it closes against the spacer sleeve. MS 440, MS 440 C...
  • Page 35 : Press the manifold down. installed position - ensure it does not break. : Press the sleeve (1) into the manifold. : Fit the washer (2) on the stud bolts. MS 440, MS 440 C...

  • Page 36: Piston Rings

    : Install the new piston rings in the : Take out the screws (arrows). grooves so that the radii at the ends of the rings (arrows) face – Remove the oil pump (1). upward. – Install the piston – b 6.5.2 MS 440, MS 440 C...
  • Page 37 : Remove the screws (arrows) connector (arrow). from the two halves of the crankcase. – Remove the screws from the annular buffers on the clutch side – Draw the reflector foil off the – b 12.8 crankcase. MS 440, MS 440 C...
  • Page 38 If the crankcase has to be replaced, all the components still fitted must be reused. MS 440, MS 440 C...

  • Page 39: Installing The Crankshaft

    : Press the annular buffer (1) out the crankcase half on the fan side. : Unscrew the oil tank cap (2). : Press the cord (3) out of the mount and remove it with the tank cap. MS 440, MS 440 C...
  • Page 40 (arrow) as far as possible into the crankcase by hand with : Press the annular buffer in so that the closed side facing upwards. the circumferential groove (1) engages the edge of the crankcase (2). MS 440, MS 440 C...
  • Page 41 (1) 1118 893 7200 to circumferential groove (1) press home the ball bearing as engages the edge of the far as stop. crankcase (2). MS 440, MS 440 C...
  • Page 42 AS 5910 890 2205. : Hold the spindle steady and : Place new gasket on clutch side rotate the service tool counter- of crankcase. clockwise until the drilled plate butts against the crankcase. MS 440, MS 440 C...
  • Page 43 : Drive the straight pin on the chain : Press the oil seal home with tensioner side home with a size press sleeve (1) 1128 890 3900. 5 mm (1.97 in) drift. The surface must be level and free from burr. MS 440, MS 440 C...

  • Page 44: Decompression Valve

    : Press the oil seal home with press sleeve (1) 1118 893 4602. – Remove the assembly sleeve. – Turn the crankshaft several times after approx. 1 minute. MS 440, MS 440 C...

  • Page 45: Ignition System

    A new ignition module must be installed if no ignition spark is obtained (after checking that wiring and stop switch are in good condition). The electronic ignition system basically consists of an ignition module (1) and flywheel (2). MS 440, MS 440 C...

  • Page 46: Removing And Installing

    Loctite 242 – b 16. Fit the ground wire under the right- hand screw of the ignition module. : Tighten down the screws moderately (arrows). : Take out the screws (arrows). – Remove the ignition module. MS 440, MS 440 C...

  • Page 47: Testing The Ignition System

    : Attach the ground terminal (1) to window (2). the spark plug. Warning! : Use adjusting knob (3) to set the The engine may start and spark gap to 2 mm (0.79 in). accelerate during the test! MS 440, MS 440 C...

  • Page 48: Ignition Lead / Spark Plug Boot

    – b 7.6. : Pull the cover off the spark plug : Pinch the hook of the leg spring boot. into the center of the lead (arrow). MS 440, MS 440 C...

  • Page 49: Flywheel

    – Screw the ignition lead into the ignition module. – Push the grommet over the high voltage output. – Install the ignition module – : Pull off the flywheel. b 7.1.2 – Remove the puller from the flywheel. MS 440, MS 440 C...

  • Page 50: Installation

    : Carefully push the switch : Remove the grommet and wiring housing aside and remove it. from the tank housing. – When fitting the slide control, push it inwards until it clicks into place. MS 440, MS 440 C...

  • Page 51: Testing Wiring Harness

    – b 7.3.2 Replace the ignition module if a fault still cannot be located – b 7.1.2 : Unplug both lines and remove the protective tubing. – Pull the wire out of the grommet. MS 440, MS 440 C...

  • Page 52: Ignition System Troubleshooting

    – Leg spring hook in center of ignition lead? – Boot damaged? If necessary, install new spark plug boot and/or leg spring Test ignition system with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap – see TI 32.94) MS 440, MS 440 C...
  • Page 53 – Spark plug boot: Holes/cracks? – Resistance: spark plug boot to ground: spec. 1.5 – 12kΩ – Check resistance of ignition lead: spec. < 10 Ω, If necessary, install new spark plug boot and/or ignition lead MS 440, MS 440 C...
  • Page 54 Install new ignition module Engine runs Check “#“/“$“ function Look for fault in fuel system on Master Control lever or carburetor, check engine for leaks, separate stop switch check position of flywheel on crankshaft MS 440, MS 440 C...

  • Page 55: Rewind Starter

    Clean all components – b 16. Before installing, lubricate the rewind spring and starter post with : Pull the pawls (1 + 2) out of the STIHL special lubricant – b 16. rope rotor. – Lubricate pegs of new pawls with grease – b 16.

  • Page 56: Rope Rotor

    : Carefully ease the spring (1) off : Thread the new starter rope the starter post with a screwdriver through the top of the starter grip. or pliers. : Remove the rope rotor – b 8.4 MS 440, MS 440 C...

  • Page 57: Tensioning

    : Push the knot into the recess : Grip the rope next to the rotor and (arrow). use it to turn the rope rotor six times clockwise. – Tension the rope rotor – b 8.5.1 MS 440, MS 440 C...

  • Page 58: Starter Rope Guide Bushing

    – b 8.5 mechanism. Reassemble all other parts in the Installing the rope guide bushing reverse sequence. – Install the bushing in the mount in the fan housing with starter mechanism. MS 440, MS 440 C...

  • Page 59: Replacing The Rewind Spring

    – Take the rewind spring out of the fan housing. – Remove any remaining pieces of spring from the fan housing. : Position the anchor loop about 25 mm (0.98 in) from the edge of the spring housing. MS 440, MS 440 C...

  • Page 60: Av Handle System

    The tank housing must be removed in order to remove the other annular buffers – b 12.8 : Press the stop buffer into the guide until the circumferential groove (1) engages the housing rib (2). MS 440, MS 440 C...

  • Page 61: Single Lever Master Control / Handle System

    : Fit the switch housing in the the short-circuit wire (1) and guide before pressing the switch ground wire (2) from the contact shaft into its mount. springs. Reassemble the remaining parts in reverse order. MS 440, MS 440 C...

  • Page 62: Throttle Trigger / Interlock Lever

    : Pull the throttle rod out of the When installing, make sure the : Position the handle moulding so trigger. torsion spring be under the interlock that the lugs (arrow) engage the lever and engage the notch. recess. MS 440, MS 440 C...

  • Page 63: Chain Lubrication

    : Use hook (1) 5910 893 8800 to : Pull the suction hose with pickup pull the pickup body out of the oil body out of the crankcase. tank. Do not stretch the oil hose too much during this operation. MS 440, MS 440 C...

  • Page 64: Valve

    : Use a 7 mm (0.28 in) drift to carefully press home the valve from outside until it is about a = 1 mm (0.04 in) below the housing face. Reassemble all other parts in the reverse sequence. MS 440, MS 440 C...

  • Page 65: Oil Pump

    – Grease the worm with drive ring worm with grease before before installing it – b 16. installing – b 16. Reassemble the other parts in reverse order. : Remove the drive spring from the worm if necessary. MS 440, MS 440 C...

  • Page 66: Fuel System

    : Remove and replace the pre-filter (1). – Thoroughly wash the air filter and blow through with compressed : Remove the air filter (2) and air; it must be replaced if replace the internal filter damaged. cartridge. MS 440, MS 440 C...

  • Page 67: Carburetor

    : Unhook the throttle rod from the throttle shaft. – Thoroughly wash the filter fabric in the filter base in a clean, non- flammable cleaning solution and blow through with compressed air; it must be replaced if damaged. MS 440, MS 440 C...
  • Page 68 – Unplug the lead to the thermostatic switch – b 13.2 : When pushing the carburetor into position, make sure that the impulse hose (1) and fuel hose (2) are correctly seated. MS 440, MS 440 C...

  • Page 69: Leakage Test

    Reassemble all other parts in the reverse sequence. : Push the fuel line with nipple onto : Carefully separate the diaphragm the carburetor’s elbow connector. and gasket. – Examine the diaphragm for signs of damage or wear, replace if necessary. MS 440, MS 440 C...

  • Page 70: Inlet Needle

    (1) faces on the sealing cone of the inlet the inlet control lever (2). needle, a new inlet needle must be fitted because a tight seal is – Fit the end cover. no longer assured. MS 440, MS 440 C...

  • Page 71: Fixed Jet

    (2) from the end cover or carburetor body. – Install the metering diaphragm – b 12.3.1 : Carefully separate the diaphragm and gasket. – Inspect diaphragm for damage and wear, install a new gasket. MS 440, MS 440 C...

  • Page 72: Adjustment (Carburetor Without Limiter Caps)

    – Let the engine warm up. – Adjust engine idle speed. : Place the gasket (1) on the end cover (2). : Wet the pump diaphragm (3) with fuel and place it on the gasket. MS 440, MS 440 C...

  • Page 73: Adjustment (Carburetor With Limiter Cap)

    Starting from the standard setting, set the maximum speed of 13,500 rpm with the high speed screw H: If the setting is made too lean, the engine may become damaged as a result of insufficient lubrication and overheating! MS 440, MS 440 C...

  • Page 74: Basic Setting (Carburetor With Limiter Cap)

    Note: : The lugs of the limiter caps are at – Check chain tension. a right angle to the screwdriver slot. – Warm up the engine. MS 440, MS 440 C...

  • Page 75: Tank Vent

    Pickup body : Use hook (1) 5910 893 8800 to pull the pickup body out of the fuel tank. Do not stretch the fuel hose too much during this operation. MS 440, MS 440 C...

  • Page 76: Fuel Hose

    : The flat edge (1) of the bead must rest against the tank housing. : Pry the flange of the fuel hose out of the fuel tank. MS 440, MS 440 C...

  • Page 77: Tank Housing

    (1) and b 5.2 ground wire (2) from the contact Heat the screw points, but do not springs. : Unscrew the plugs (arrows) from overheat the plastic material. the annular buffers on the clutch side. MS 440, MS 440 C...
  • Page 78 : Unplug the impulse hose (arrow) : Turn a size M6x10 screw with from the connector. washer into the threaded insert. – Screw the threaded insert into the tank housing. MS 440, MS 440 C...
  • Page 79 : Press the manifold down. – Push the ends of the string through the opening in the tank housing. : Mount sleeve (1) in manifold. : Slide washer (2) onto the stud bolts. MS 440, MS 440 C...

  • Page 80: Carburetor Heating

    – Set the ohmmeter to measuring range "Ω". : Clip one of the two test leads to the carburetor body and the other to a cylinder fin (ground). MS 440, MS 440 C...

  • Page 81: Troubleshooting Chart

    Replace thermostatic between +13 °C (55 °F) and switch +6 °C (43 °F)? Does the switch open Replace thermostatic between +6 °C (43 °F) and switch +13 °C (55 °F)? Carburetor heating system in order MS 440, MS 440 C...

  • Page 82: Heating Element With Thermostatic Switch

    – Set ohmmeter to "Ω". Tracing the cause of a fault – Remove the interlock lever – b 10.2 : Remove the protective tubing (arrow) over the plug connecting the lead from the generator to the handle heating element. MS 440, MS 440 C...
  • Page 83 The generator is not connected to the heating element during this time. – After testing, reconnect the leads and slide the protective tubing back over the plug connection. – Install the interlock lever and handle moulding – b 10.2 MS 440, MS 440 C...

  • Page 84: Troubleshooting Chart

    In good condition? Adhesion OK? Replace handle heating element Resistance of rear handle heating element about 1 Ω ? Check generator Resistance between engine ground Install new and black generator generator connection = approx. 0.9 Ω ? MS 440, MS 440 C...
  • Page 85 Check heater switch Install new Closed: about 0 Ω ? heater switch Open: Circuit interrupted (On machines with carburetor heating, refit connector pin of wire from heating element in the round plug) System in order MS 440, MS 440 C...

  • Page 86: Test Connections And Test Values

    Break in wire, Install new front heating element handle damaged Short circuit – Repair damaged insulation insulation Generator Connector Ground 0.6...1.0 Generator OK on wire Pull out the wire for this purpose MS 440, MS 440 C...

  • Page 87: Heater Switch

    – Press the connecting lead into connecting lead out of the heater the mount. switch. – Install the carburetor – b 12.2.1 : Unscrew the nut (arrow) on the heater switch. – Remove the washer. MS 440, MS 440 C...

  • Page 88: Front Handle

    : Pull the leads out of the rubber the handle moulding (2) and grommet. press it into place uniformly from the inside outwards. – Pull the connecting wire out of the heater switch – b 14.2 MS 440, MS 440 C...

  • Page 89: Generator

    – Tighten down the screws – b 3.5 Reassemble the remaining parts in reverse order. : There must not be any cracks or other signs of damage on the generator and poles, otherwise they must be replaced. MS 440, MS 440 C...

  • Page 90: Special Servicing Tools

    Removing crankshaft (clutch side) Screw sleeve 5910 893 2420 Installing crankshaft Service tool ZS (set) 5910 007 2220 Removing crankshaft (starter side) Screw sleeve 5910 893 2409 Pulling crankcase halves together Puller 5910 890 4500 Removing limiter caps MS 440, MS 440 C...
  • Page 91 (clutch side) Press arbor 1120 893 7200 Removing and installing ball bearing (flywheel side) Pliers, DIN 5254-A 19 0811 611 8380 Removing and installing external retaining rings Remarks: 1) Use only for releasing P screws. MS 440, MS 440 C...

  • Page 92: Servicing Aids

    (250 ml (8.25 fl.oz) bottle) High-strength threadlocking 0786 111 1109 adhesive (Loctite 270) (50 ml (1.65 fl.oz) bottle) High-strength threadlocking 0786 110 0126 adhesive (Loctite 649) (50 ml (1.65 fl.oz) bottle) Press Fluid OH 723 0781 957 9000 MS 440, MS 440 C...
  • Page 93 MS 440, MS 440 C...
  • Page 94 englisch / english 0455 175 0123. M0. E6. Printed in Germany...

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