Technical Information · issue 24 of 2002
Control Handle with Throttle Cable; Rewind Starter
Model FH 75 Power Scythe – Series 4230
IssueTI 24/2002
Full text
Page 1 of 10
Technical Information
24.2002
Model FH 75 Power Scythe – Series 4230
Model HL 75 Hedge Trimmer – Series 4230
Model HT 70, HT 75 Pole Pruners – Series 4138
Model FC 75, FC 85 Edgers – Series 4137
Model KW 85 PowerSweep – Series 4602
Model KM 85 CombiEngine – Series 4137
Model FS 75, FS 80, FS 85 Brushcutters – Series 4137
Contents
1. Control Handle and Throttle Cable
1.1 Control Handle
1.2 Throttle Cable
1.3 Summary
1.4 Installation, Repairs
2. Rewind Starter
2.1 Starter Rope
2.2 STIHL ElastoStart™
2.3 Rope Rotor
2.4 Rewind Spring
2.5 Rope Rotor with Rewind Spring
2.6 Interchangeability
2.7 Validity of Modifications for Other Models
2.8 Summary
1. Control Handle and Throttle Cable Parts availability
As before, the "control handle" and "throttle cable"
New control handles and throttle cables will be
installed from the serial numbers listed in the are available from the factory only as separate
Summary. The new assemblies will be introduced replacement parts.
on all bike-handled and loop-handled machines. The "throttle cable“ assembly is new. It consists of
See 1.1 and 1.2 for features and construction of the the corrugated tube, microswitch with short-circuit
new parts. wires and throttle cable. The individual parts of the
throttle cable are no longer available as separate
Interchangeability items (see Summary).
The new version of the control handle may be
installed in previous machine versions providing a
connector is retrofitted on the ignition module (see
service notes under 1.4.1) and the new throttle
cable is installed.
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)m~ge 2 Technical Information 24.2002
1.1 Control Handle 1.2 Throttle Cable
3
8
1
7
6
2 1 2
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4
Example: New control handle with throttle cable for
machines with loop handle
Features of the new throttle cables:
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. Two fully insulated short-circuit wires (3) which
go directly from the microswitch (4) to the
New control handles
Top: 4128 790 1301 for bike-handled machines .
connectors on the ignition module.
The new throttle cables can only be installed as
Bottom: 4137 790 1307 for loop-handled machines assemblies.
Gray-shaded areas: non-slip surface
Function of semi-automatic throttle cable
Features of the new control handles:
adjuster
. The new control handles are equipped with a
semi-automatic throttle cable adjuster. For When the throttle trigger (5) is squeezed as far as
description of function see 1.2. The new handles the stop, the tolerances (i.e. any slackness)
can be identified by the slot for the slide (1). between the attachment points of the throttle cable
(6) on the carburetor and the throttle trigger are
. A sealed microswitch is used to switch the corrected.
ignition on and off. It is activated by the slide
control (2). The connection between the The end of the throttle cable sheath (7) is attached
microswitch and short-circuit wire is permanent to the slide (1). During the adjustment of the throttle
and water-tight. The microswitch and short- cable the slide is pulled in the direction of the throttle
circuit wires are included in the "throttle cable" trigger. This causes the detent arm (arrow), held
assembly. under tension by a spring (8), to move along a
notched track in the handle (arrow) until there is no
free play in the throttle cable (see illustration in 1.4.2
under "Installing Slide and Throttle Cable").
Adjusting the throttle cable
The throttle cable has to be adjusted after first-time
installation of a control handle or throttle cable. For
this reason a new chapter, i.e. "Adjusting the
Throttle Cable", has been included in the instruction
manual. For further adjustments see service notes
under 1.4.4.
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Technical Information 24.2002 Page 3
1.3 Summary
Item Part Name Previous New Remarks
All machines
1 Connector (on ignition module) --- 4137 405 1600
Machines with bike handle
FS 80, 85
2 Control handle; 4128 790 1300 --- 1)
including items 4 to 7:
3 Control handle; --- 4128 790 1301
including items 4, 5 and 8 to 10:
4 Handle, right 4128 790 0300 4128 790 0301 1)
5 Detent spring 4128 182 4200 4128 182 4201 1)
6 Contact spring 4128 442 1600 --- 1)
7 Contact spring 4128 442 1605 --- 1)
8 Torsion spring --- 4128 182 4502
9 Slide --- 4128 793 3000
10 Spring --- 4128 791 3100
11 Throttle cable 4137 180 1100 --- 1)
12 Throttle cable; --- 4137 180 1109
including item 13:
13 Microswitch with short-circuit wires --- -*- 2)
All other parts as before
Machines with loop handle
FH 75, HL 75, HT 70, 75, FC 75, 85, KM 85 R, KW 85, FS 75, 80, 85, 85 RT, 85 RX
14 Control handle; 4137 790 1350 --- 1)
including items 16, 17, 19, 20 and
22 to 24:
15 Control handle; --- 4137 790 1307
including items 9, 18, 19 and
21 to 25:
16 Handle molding, inner 4137 790 1101 --- 1)
17 Handle molding, outer 4137 791 0800 --- 1)
18 Handle --- 4137 790 0300
19 Slide control 4137 182 1700 4137 182 1701 1)
20 Contact spring 4137 442 1600 --- 1)
21 Torsion spring --- 4137 182 4505
22 Throttle trigger 4137 182 1000 4137 182 1001 1)
23 Torsion spring 4137 182 4500 4137 182 4504 1)
24 Interlock lever 4137 182 0801 4137 182 0802 1)
25 Torsion spring --- 4128 182 4501
26 Throttle cable 4137 180 1103 --- 1)
27 Throttle cable; 4137 180 1150 --- 3)
including items 16 and 24:
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)m~ge 4 Technical Information 24.2002
Item Part Name Previous New Remarks
28 Throttle cable; --- 4137 180 1107
including item 29:
29 Microswitch with short-circuit wires --- -*- 2)
All other parts as before
Modification to be introduced
USA production FS 80 from serial number 2 55 972 256
FS 85 from serial number 2 55 809 184
HT 75 from serial number 2 55 809 912
KM 85 R since start of production
Other models in progress
Remarks
1) Previous version of part remains available as spare for older machines
2) Part is not available as a separate item
3) Previous version of part remains available from factory up to about 2009
1.4 Installation, Repairs . Connect the black short-circuit wire (1) to the
primary circuit connector (2) on the ignition
Only the most important procedures are described
as follows. module.
. Connect the blue ground wire (3) to the ground
connector (4) on the ignition module.
1.4.1 Instructions for all machines
Connecting wires to ignition module Instructions for earlier machine versions
It is necessary to mount the ground connector (4)
1 on the ignition module as well if the new control
handle with throttle cable is being installed on an
2 3 older machine.
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Technical Information 24.2002 Page 5
Adjusting the tensioner Installing slide and throttle cable
The throttle cable is no longer adjusted at the
tensioner. However, a basic setting has to be 8, 9
carried out on the tensioner for correct operation of
the semi-automatic throttle cable adjuster located in
the control handle.
6 5 11 12 13
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. Press the throttle cable (11) into the slide (12),
the throttle cable ferrule (13) snaps into position
in this process.
. Place the slide (12) in the handle molding so
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that the groove (arrow) is at the end of the slot –
this is the basic setting for adjusting the throttle
cable.
. Rotate the adjusting screw (5) in the tensioner
(6) until the visible lengths of thread are the .
Pay attention to the position of the two wires (8,
same at the top and bottom (arrows). 9) between the channel and corrugated tube
If the automatic throttle cable adjuster does not (see second illustration under 1.4.3 - "Installing
operate satisfactorily with this basic setting, rotate microswitch and wires".
the adjusting screw slightly (see also 1.4.4 -
"Adjustment limits").
1.4.2 Machines with bike handle
Installing microswitch and wires
15
8 9 16
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17 18
. Attach the throttle cable end sleeve (14) to the
throttle trigger (15).
. Position the straight end of the spring (16) in the
throttle trigger, in front of the cable end sleeve
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10 7 (14), and then fit the ring-shaped part of the
spring over the pivot (17) at the lower end of the
throttle trigger.
. Place the microswitch (7) in the handle molding
as shown in the illustration. . Fit the throttle trigger and position the spring
loop around the boss (18) for the screw.
. Push the ground wire (8; blue) into the channel
(10) first and then the short-circuit wire (9; black)
– up to the end of the channel.
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Installing control handle with throttle cable
. Check the correct position of the corrugated
tube and slide.
Important!
Do not squeeze the throttle trigger until instructed
to do so in chapter 1.4.4.
. Screw the handle moldings together, taking care
not to pinch any wires. 19 20
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. Mount the control handle to the handlebar.
. Attach the throttle cable to the carburetor.
. Reassemble the powerhead. . Make sure that both wires are in the channel
. Secure the throttle cable to the throttle cable right up to the end of the handle (neither wire
retainers on the drive tube. may project from the channel).
. Set and secure the handlebar in the required . Place the wires in the recess (20) at the
working position. attachment point for the corrugated tube (19).
The throttle is placed over the recess in a later
. Go to "Adjusting the throttle cable". step.
Installing slide and throttle cable
1.4.3 Machines with loop handle
Installing microswitch and wires
7 11 12 13
10 9
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. Press the throttle cable (11) into the slide (12),
the throttle cable ferrule (13) snaps into position
in this process.
. Place the microswitch (7) in the handle molding . Place the slide (12) in the handle molding so
as shown in the illustration. that the groove (arrow) is at the end of the slot –
. Push the ground wire (8; blue) into the channel this is the basic setting for adjusting the throttle
(10) first and then the short-circuit wire (9; black) cable.
– up to the end of the channel.
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Technical Information 24.2002 Page 7
Installing the throttle trigger 1.4.4 Adjusting the throttle cable (all models)
Important!
Adjust the throttle cable only when the machine is
completely and securely assembled – the handlebar
and control handle must be in the normal operating
14 position.
16
15 This adjustment procedure removes free play from
the throttle cable.
Correct adjustment of the throttle cable is necessary
for correct operation of the machine at full throttle,
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starting throttle and idling. It may therefore be
17 18
necessary to readjust the carburetor after adjusting
the throttle cable.
. Attach the throttle cable end sleeve (14) to the
throttle trigger (15).
Checking throttle cable adjustment
. Push the straight end of the spring (16) under
the end sleeve (14) and then fit the ring-shaped Check the adjustment:
part of the spring over the pivot (17) on the – if the throttle trigger was squeezed accidentally
throttle trigger. while handling or mounting the control handle,
. Fit the throttle trigger and position the spring
loop around the boss (18) for the screw. –
i.e. too early
after servicing or repair work
– before readjusting the carburetor
Installing control handle with throttle cable – on bike-handled machines, after a big change
. Check the correct position of the corrugated in the position of the handlebar (e.g. during
tube and slide. machine set-up)
Important! – after the throttle cable has stretched, or after a
Do not squeeze the throttle trigger until instructed change in the position of the slide as a result of
to do so in chapter 1.4.4. force due to the throttle cable snagging on an
object during operation.
. Screw the handle moldings together, taking care
not to pinch any wires.
. Attach the throttle cable to the carburetor. Adjusting the throttle cable
. Reassemble the powerhead.
12
. Slide the control handle onto the drive tube and
secure the drive tube to the powerhead.
. Line up and secure the control handle.
. Go to "Adjusting the throttle cable".
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. Use a screwdriver to press down the slide (12)
and push it to the end of the slot – this is the
basic setting.
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2. Rewind Starter
21 12
2
1
4
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3
15
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. Press down the throttle trigger interlock (21) and 5
squeeze the throttle trigger (15) all the way (full
throttle position) – the slide (12) now moves Modifications have been carried out on the rewind
away from the end position and the throttle starter in several phases to further improve its
cable is adjusted automatically. operation, standardize parts inventories and simplify
assembly.
. Adjust the carburetor if necessary.
Adjustment limits 2.1 fo
Starter Rope
The starter rope 4123 195 8200 (1; D = 0.105 in /
2.7 mm, L = 31.5 in / 800 mm) used previously in
production and as a replacement was replaced by
an interim version of the same length, i.e.
0000 195 8200 (D = 0.120 in / 3 mm). The interim
version is included in STIHL ElastoStart
0000 190 3400.
In another phase the interim version was
replaced by starter rope 4137 195 8200 (D =
0.105 in / 2.7 mm, L = 35.8 in / 910 mm) which is
393TI055 KN
used in STIHL ElastoStart 0000 190 3403.
22
The limits of adjustment are reached when the slide
butts against the other end of the slot (arrow) after 2.2 STIHL ElastoStart™
carrying out the adjustment, and there is still free
The ElastoStart grip 0000 190 3400 (2) was
play in the throttle cable. Check free play as follows: replaced by the new version 0000 190 3403 in
. Press down the throttle trigger interlock and conjunction with the introduction of the new starter
squeeze the throttle trigger all the way (full rope 4137 195 8200.
throttle position) and check that the lever (22) on
the throttle shaft butts against the carburetor
body (arrow). 2.3 Rope Rotor
If the lever does not butt against the carburetor The previous rope rotor 4133 195 0400 (3) was
body, readjust the tensioner (see 1.4.1) and take up replaced by the interim version 4133 195 0470 in
any slack. If this procedure does not remedy the conjunction with the introduction of a new line of
situation, install a new throttle cable. machines.
In the meantime, however, the interim version of the
rope rotor is no longer available as a separate item.
It is now available from the factory only as an
assembly , i.e. "Rope rotor with rewind spring" (see
2.5).
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Technical Information 24.2002 Page 9
2.4 Rewind Spring 2.6 Interchangeability
The rewind spring 4133 195 1600 (4) is no longer All new parts are fully interchangeable with the parts
available as a separate item. It is now available from in previous machine versions.
the factory only as an assembly, i.e. "Rope rotor with
rewind spring" (see 2.5).
2.7 Validity of Modifications for Other Models
All the modification described also apply to the
2.5 Rope Rotor with Rewind Spring following models: BG 72, BG 75, FC 72, FS 72,
In order to simplify assembly, the parts of the rewind FS 74, FS 76, HS 75, HS 80, HS 85
starter previously supplied as separate items –
The modifications described in 2.1, 2.3, 2.4 and 2.5
"rope rotor" (3) and "rewind spring" (4) – will only be
also apply to the following models: HS 72, HS 74,
available from the factory as an assembly, i.e. "Rope
HS 76
rotor with rewind spring" (5).
2.8 Summary
Item Part Name Previous New Remarks
1 Starter rope, 0.105 in dia. x 31.5 in 4123 195 8200 --- 1) 2)
(Ø 2.7 x 800 mm)
2 Starter rope, 0.120 in dia. x 31.5 in ---
fo 0000 195 8200 2)
(Ø 3.0 x 800 mm)
3 Rope rotor 4133 195 0400 4133 195 0470 2) 3) 4)
4 ElastoStart grip; 0000 190 3400 --- 1) 5)
including item 6:
5 ElastoStart grip; --- 0000 190 3403 5)
including item 7:
6 Starter rope, 0.120 in dia. x 31.5 in 0000 195 8200 --- 1) 5)
(Ø 3.0 x 800 mm)
7 Starter rope, 0.105 in dia. x 35.8 in --- 4137 195 8200 5)
(Ø 2.7 x 910 mm)
8 Rope rotor with rewind spring; --- 4137 190 1100 5)
including items 9 and 10:
9 Rewind spring 4133 195 1600 -*- 3) 5) 6)
10 Rope rotor 4133 195 0470 -*- 3) 5) 6)
All other parts as before
Modification to be introduced: in progress
Remarks
1) Previous version of part remains available for other models
2) Change from earlier to interim version
3) Previous version of part will be supplied from factory only as long as existing stocks last. Thereafter the
"rope rotor with rewind spring" will be supplied as a replacement - see item 8
4) New (interim) version of part is no longer available from the factory
5) Change from interim to new version
6) New version of part is not available as separate item, use item 8.
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)m~ge 10 Technical Information 24.2002
Last Technical Information on models: FC 75, FC 85 32.2001
FH 75 42.2001
FS 75, FS 80, FS 85 32.2001
FS 85 RX 03.2002
HL 75 42.2001
HT 70, HT 75 38.2002
KM 85 R 14.2002
KW 85 32.2001
© 2002 Andreas Stihl AG & Co. Technical Documentation
Waiblingen D1/MTK-na 7811
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Extracted from the manufacturer's 2012 service catalogue. Most of these PDFs embed fonts with a shifted character map, so the text above was recovered rather than copied — read it as a faithful but imperfect transcription, and treat the page image above each block as the authority where the two disagree — the figures exist only there, because they are vector drawings that text extraction cannot keep.