STIHL Blower Repair Manual

The STIHL Blower Repair Manual provides comprehensive guidance for troubleshooting, maintenance, and repair of STIHL handheld and backpack blowers. This manual covers safety precautions, common issues, step-by-step repair procedures, parts identification, and specifications for various STIHL blower models. Below are key sections for safety, features, troubleshooting, repair procedures, parts, and maintenance.

1. Safety Precautions 2. Model Identification 3. Common Issues & Symptoms 4. Tools & Equipment Required 5. Engine Troubleshooting 6. Fuel System Repair 7. Ignition System Repair 8. Air Intake & Filter Maintenance 9. Blower Tube & Impeller Repair 10. Parts List & Specifications 11. Maintenance Schedule

Safety Precautions

Before performing any repair, ensure the blower is turned off, cool, and disconnected from any power source. Wear appropriate personal protective equipment (PPE).

Precaution	Description
Work Area	Work in a well-ventilated area away from sparks or open flames
Fuel Safety	Drain fuel before repair; use approved containers
Disconnect Spark Plug	Always disconnect spark plug wire before servicing engine components
Sharp Edges	Wear gloves when handling impeller or metal parts
Eye Protection	Wear safety glasses when cleaning air filters or using compressed air
Stable Surface	Place blower on a stable, flat surface during repair
Original Parts	Use only genuine STIHL replacement parts
Manual Reference	Consult specific model manual for detailed diagrams
Post-Repair Check	Test in a safe area after reassembly
Professional Help	Seek professional service for complex electrical or engine issues

Model Identification

Identify your STIHL blower model using the serial number plate, typically located on the housing or engine block.

Locate serial number: Check rear housing, engine shroud, or handle bracket.
Common models: BR 200, BR 350, BR 400, BR 600, BR 700, and backpack models like BR 800.
Engine type: Most use 2-stroke engine; some newer models may be 4-stroke or battery-powered.
Record model and serial number before ordering parts.

WARNING! Using incorrect parts can cause damage or void warranty. Always verify model compatibility.

Common Issues & Symptoms

Power on blower; observe symptoms to diagnose problems.

Engine won't start: Check fuel, spark plug, air filter, and ignition system.
Loss of power: Clean or replace air filter; check fuel lines and exhaust.
Excessive vibration: Inspect impeller for damage or imbalance.
Unusual noise: Check for loose parts, worn bearings, or debris in housing.
Overheating: Clean cooling fins; ensure proper fuel mixture.

CAUTION! Do not operate a blower that is vibrating excessively or making unusual noises.

Tools & Equipment Required

Basic Tools: Screwdrivers (flathead, Phillips), socket set, Torx bits, pliers, hex keys.
Engine Tools: Spark plug wrench, compression gauge, feeler gauge.
Cleaning Supplies: Carburetor cleaner, compressed air, shop towels.
Safety Gear: Gloves, safety glasses, dust mask.
Specialty Tools: Impeller puller (for specific models), fuel line removal tool.
Diagnostic: Multimeter for electrical testing.
Work Area: Clean, well-lit bench with adequate space.
Parts Storage: Small containers to organize screws and small parts.

Engine Troubleshooting

Access engine components by removing housing screws. Front Panel: Throttle lock, choke lever, primer bulb.

Diagnostic Steps: Check spark, fuel delivery, compression. Use START/RUN/OFF switch.

Fuel: Ensure proper mix (50:1 for most 2-stroke). Air: Clean filter, check for blockages. Spark: Remove plug, check for spark against cylinder. Compression: Should be above 90 PSI. Carburetor: Adjust idle and high-speed screws per manual. Exhaust: Clean spark arrestor screen if equipped.

Fuel System Repair

Fuel Tank: Inspect for cracks. Fuel Lines: Replace if cracked or brittle. Fuel Filter: Replace annually. Carburetor: Clean or rebuild.

Turn off fuel valve (if equipped) and drain tank.
Remove fuel lines, noting routing for reassembly.
Clean carburetor with aerosol cleaner; replace diaphragm and gaskets in rebuild kit.
Reassemble, ensuring all connections are tight and leak-free.

Tip: Always use fresh, properly mixed fuel to prevent carburetor issues.

Ignition System Repair

Supports ignition coil, spark plug, stop switch, wiring.

Disconnect spark plug wire: Remove boot, check for corrosion.
Spark plug: Remove, inspect electrode gap (typically 0.020"), clean or replace.
Ignition coil: Test with multimeter for proper resistance (refer to manual).
Stop switch: Test continuity; replace if faulty.
Wiring harness: Inspect for frayed wires or poor connections.
Flywheel key: Check for shearing if engine timing is off.
Reassembly: Ensure proper gap between coil and flywheel.
Test: Reconnect plug, ground electrode, pull starter to check for spark.

WARNING! Always disconnect spark plug before working on ignition system to prevent accidental starting.

Air Intake & Filter Maintenance

Air Filter: Clean regularly; replace if torn or excessively dirty. Pre-Filter: Wash with soap and water if equipped. Intake Cover: Remove debris.

Blower Tube & Impeller Repair

Unplug spark plug before inspection. Remove tube to access impeller housing.

CAUTION! Impeller blades are sharp. Wear cut-resistant gloves.

Parts List & Specifications

Common replacement parts: Spark plug (BPMR7A), air filter, fuel filter, carburetor kit, impeller, starter rope, vibration mounts. Specifications vary by model. For exact parts, use STIHL parts catalog with model number. Fuel: 50:1 mix with STIHL HP Ultra oil or equivalent. Spark Plug Gap: 0.020 inch. Idle Speed: Typically 2800-3200 RPM. Maximum Speed: Varies by model (e.g., BR 600: ~13,000 RPM). For support, visit www.stihlusa.com or contact authorized STIHL dealer.

Maintenance Schedule

Interval	Task	Details
Before each use	Visual inspection	Check for loose parts, leaks, damage to tube and housing.
Every 10 hours	Air filter cleaning	Remove, tap clean, or wash with soap and water (if foam).
Every 20 hours	Spark plug inspection	Clean, check gap, replace if worn.
Every season	Fuel filter replacement	Replace in-tank fuel filter.
Annually	Carburetor adjustment	Check and adjust idle and high-speed screws.
As needed	Impeller inspection	Check for cracks, imbalance, or debris.
Every 2 years	Fuel line replacement	Replace all fuel lines to prevent cracking.
Storage	Fuel system prep	Drain fuel or add stabilizer; run engine to circulate.

Reset: After repair, reset maintenance reminders if equipped.

Service: For complex repairs, contact authorized STIHL dealer; www.stihlusa.com