STIHL BR 600 Service Manual

The STIHL BR 600 is a professional-grade backpack blower designed for demanding commercial and residential use. This service manual provides comprehensive information for maintenance, troubleshooting, and repair of the BR 600 engine and blower unit. It covers safety procedures, technical specifications, disassembly/assembly instructions, fuel system, ignition system, cooling system, carburetor adjustment, and common fault diagnosis. Below are key sections for safe servicing, specifications, maintenance procedures, and troubleshooting.

Safety Information & Precautions

Before performing any service, read all safety warnings. Engine must be cool. Disconnect spark plug boot. Work in a clean, well-ventilated area.

WARNING! Failure to follow safety procedures can result in serious injury or death. Always use genuine STIHL parts.

Technical Specifications

• Model: STIHL BR 600
• Engine Type: 2-stroke, single cylinder, air-cooled
• Displacement: 64.8 cm³ (3.95 cu in)
• Power Output: 3.6 kW (4.8 bhp) at 7,500 rpm
• Fuel/Oil Mix: 50:1 (STIHL HP Ultra or equivalent)
• Ignition System: Electronic, CDI
• Carburetor: Zama C1Q-S267 or equivalent
• Air Filtration: Multi-stage with foam pre-filter
• Blower Tube Diameter: 57 mm
• Dry Weight: 10.1 kg (22.3 lbs)
• Sound Pressure Level: 112 dB(A)

Maintenance Schedule

Follow intervals based on operating hours or annually, whichever comes first.

1. Daily: Check fuel level, inspect for leaks, clean exterior.
2. Every 25 hours: Clean air filter, check spark plug, inspect cooling fins.
3. Every 50 hours: Replace spark plug, clean fuel filter, check carburetor settings.
4. Every 100 hours: Replace air filter, clean combustion chamber, check all mounts.
5. Annually: Replace fuel filter, inspect fuel lines, check impeller for damage.

Note: Service more frequently under severe conditions (dusty, sandy environments).

Engine Disassembly & Assembly

Required tools: Torx set, socket set, circlip pliers, torque wrench.

1. Remove blower tube and fan housing.
2. Disconnect fuel lines and throttle linkage.
3. Remove cylinder cover and muffler.
4. Remove cylinder head and cylinder.
5. Remove piston pin circlips and pin.
6. Remove crankshaft from crankcase (requires puller).
7. Inspect all parts for wear, scoring, or damage.
8. Reassemble in reverse order using new gaskets.

CAUTION! Mark all parts for reassembly. Do not force components.

Fuel System Service

Components: Fuel tank, filter, lines, carburetor, primer bulb.

1. Drain fuel tank completely.
2. Remove fuel filter through filler neck using hooked wire.
3. Inspect fuel lines for cracks, stiffness, or leaks. Replace if necessary.
4. Clean fuel tank vent.
5. Test primer bulb for proper operation; replace if cracked or not priming.
6. Clean carburetor exterior before removal.

Tip: Use compressed air to clear debris from fuel line connections.

Ignition System Service

Components: Spark plug, ignition coil, flywheel, stop switch, wiring.

1. Check spark plug: Gap 0.5 mm (0.020 in). Replace if electrode worn.
2. Test ignition coil resistance: Primary 0.8-1.2 Ω, Secondary 8-12 kΩ.
3. Inspect flywheel key for shearing; replace if damaged.
4. Check stop switch continuity; should be open when off, closed when pressed.
5. Inspect all wiring for fraying or poor connections.

Note: Weak spark often indicates faulty coil or damaged flywheel magnets.

Cooling System & Air Filter

Clogged cooling fins or air filter cause overheating and power loss.

1. Remove cylinder cover and blower housing.
2. Clean cooling fins on cylinder and cylinder head with brush and compressed air.
3. Remove air filter cover and filter element.
4. Wash foam pre-filter in warm, soapy water. Rinse and air dry.
5. Tap paper filter gently to remove dust. Replace if torn or excessively dirty.
6. Reassemble, ensuring all seals are properly seated.

WARNING! Never operate without air filter. Engine damage will occur.

Carburetor Adjustment

Adjust at operating temperature with clean air filter. Use tachometer.

1. Initial settings: L screw 1 turn open, H screw 1 turn open.
2. Start engine and warm up for 3-5 minutes.
3. Adjust idle speed (LA screw) to 2,800-3,200 rpm.
4. Adjust L (low-speed) screw for smoothest acceleration from idle.
5. Adjust H (high-speed) screw for maximum rpm (no load): 12,500-13,000 rpm.
6. Re-check idle speed and acceleration.

CAUTION! Do not lean out H screw excessively. Engine damage from overheating may result.

Troubleshooting Guide

Torque Specifications

• Spark Plug: 20 Nm (14.8 ft-lb)
• Cylinder Head Nuts: 20 Nm (14.8 ft-lb)
• Muffler Bolts: 10 Nm (7.4 ft-lb)
• Fan Housing Screws: 4 Nm (35 in-lb)
• Crankshaft Nut: 40 Nm (29.5 ft-lb)
• Impeller Nut: 35 Nm (25.8 ft-lb)

Note: Always use a calibrated torque wrench. Do not overtighten.

Exploded Views & Parts List

Refer to official STIHL parts catalog for diagrams and part numbers.

1. Engine Group: Crankcase, cylinder, piston, crankshaft, bearings.
2. Fuel System Group: Tank, carburetor, lines, filter, primer.
3. Ignition Group: Coil, flywheel, spark plug, switch.
4. Air Filtration Group: Filter housing, foam & paper elements.
5. Blower Group: Impeller, housing, tube, throttle linkage.
6. Harness & Controls Group: Throttle lever, stop switch, wiring.

Ordering: Use STIHL part numbers for guaranteed compatibility.

Support: Contact STIHL authorized service center or visit www.stihlusa.com.