Stihl FS 160 Brush Cutter Manual

The Stihl FS 160 is a professional-grade, straight-shaft brush cutter designed for clearing dense vegetation, grass, and light brush. It features a powerful 2-stroke engine, loop handle for two-handed operation, modular design for easy attachment of various cutting heads (e.g., nylon line, metal blades), anti-vibration system, and a reliable starting mechanism. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Assembly & Preparation 3. Starting & Stopping 4. Specifications 5. Controls and Settings 6. Attaching Cutting Tools 7. Operating Instructions 8. Maintenance Schedule 9. Storage & Transport 10. Safety Information 11. Troubleshooting

Features at a Glance

Key components: 2-stroke engine, straight drive shaft, loop handle with controls, anti-vibration mounts, modular attachment interface, and fuel tank.

Feature	Description
Engine Type	2-stroke, single-cylinder, air-cooled
Displacement	30.1 cc
Power Output	1.3 kW (1.8 hp)
Fuel Tank Capacity	0.55 liters
Drive Shaft	Straight, solid
Handle System	Loop handle with throttle trigger and stop switch
Anti-Vibration	Integrated dampeners in handle and shaft
Cutting Attachment	Modular interface for trimmer heads or blades
Starter	Rewind starter with decompression valve
Weight (without tool)	Approx. 6.2 kg

Assembly & Preparation

Unpack and inspect all parts. Assemble on a clean, flat surface.

Attach the handle: Align handle with shaft, secure with provided bolts and wrench.
Install cutting tool: Ensure engine is off. Attach trimmer head or blade to drive shaft, secure with retaining nut using appropriate wrench.
Fuel mixture: Use STIHL 2-stroke engine oil mixed with unleaded gasoline (50:1 ratio). Fill fuel tank.
Check controls: Verify throttle trigger moves freely and stop switch functions.

WARNING! Always wear protective equipment: safety glasses, gloves, ear protection, long pants, and sturdy boots. Ensure cutting attachment is securely fastened before operation.

Starting & Stopping

Follow proper starting procedure to avoid injury and engine damage.

Cold Start: Set stop switch to "I" (On). Set choke lever to closed position. Press decompression valve (if equipped). Pull starter cord briskly until engine fires. Move choke lever to open position. Pull starter cord again to start.
Warm Start: Choke open. Pull starter cord.
Stopping: Release throttle trigger. Press and hold stop switch until engine stops.

CAUTION! Never start the engine without the cutting tool properly attached and clear of obstructions. Keep bystanders at a safe distance.

Specifications

Model: FS 160
Engine: STIHL 2-MIX engine technology
Fuel/Oil Ratio: 50:1 (STIHL HP Ultra oil recommended)
Idle Speed: 2,800 rpm
Max. Power Speed: 9,000 rpm
Sound Pressure Level: Approx. 96 dB(A)
Vibration Level (handle): Left: 4.5 m/s², Right: 5.5 m/s²
Cutting Tools: Compatible with PolyCut heads, circular grass blades, brush knives
Warranty: Limited warranty; see dealer for terms.

Controls and Settings

Main controls located on the loop handle.

Handle: Throttle trigger (variable speed), throttle trigger lockout (must be depressed to engage throttle), stop switch ("I"=On, "0"=Off).

Engine Area: Choke lever (for cold starts), decompression valve (eases starting), air filter cover, spark plug.

Adjustments: Handle can be rotated for user comfort. Idle speed and carburetor adjustments should be performed by authorized STIHL dealer only.

Attaching Cutting Tools

Ensure engine is OFF and spark plug boot is disconnected.

Place brush cutter on its side.
Align drive tang of cutting attachment with clutch drum.
Secure with the appropriate retaining nut (right-hand thread). Tighten firmly with wrench.
For trimmer line heads: Follow specific head instructions for loading line.
For metal blades: Ensure blade is sharp, undamaged, and correctly oriented.

Tip: Use only STIHL-approved cutting attachments. Always check for secure mounting before each use.

Operating Instructions

Technique is critical for safety and efficiency.

Starting Position: Place unit on clear, flat ground. Hold handle firmly, place foot on shaft guard.
Swing Technique: Use a smooth, sweeping motion from right to left (for right-handed users), keeping cutting tool parallel to ground.
Cutting Height: Avoid hitting soil, rocks, or fences to prevent kickback and tool damage.
Slopes: Work across the slope, not up and down. Maintain secure footing.
Fatigue: Take frequent breaks. The anti-vibration system reduces but does not eliminate fatigue.

WARNING! Beware of kickback! Never use a metal blade for trimming near solid objects. Always inspect work area for hidden wires, rocks, or debris.

Maintenance Schedule

Regular maintenance ensures long life and safe operation.

Interval	Task
Before each use	Check for loose fasteners, fuel leaks, damaged parts. Inspect cutting tool.
Every 25 hours	Clean air filter. Check spark plug condition.
Every 50 hours	Clean spark arrestor screen (if equipped). Check fuel filter.
Every 100 hours	Replace air filter. Have carburetor adjustment checked by dealer.
Annually	Replace fuel filter. Inspect drive shaft and gearhead grease.

CAUTION! Use only genuine STIHL parts. Disconnect spark plug before performing any maintenance.

Storage & Transport

Drain fuel tank for storage over 30 days. Run engine until it stops to empty carburetor.

Store in a cool, dry place, out of reach of children. Secure cutting tool with a guard during transport.

CAUTION! Fuel is highly flammable. Store fuel in approved container away from sparks or flame.

Safety Information

Read and understand manual before use. This is a powerful tool that can cause serious injury.

Always wear Personal Protective Equipment (PPE).
Keep bystanders and pets at least 15 meters away.
Never operate the tool fatigued, or under the influence of drugs/alcohol.
Be aware of your surroundings, especially overhead obstacles and uneven terrain.
Use the correct cutting tool for the job.
Carry the brush cutter with the engine stopped and cutting tool guarded.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No fuel, flooded, spark plug faulty	Check fuel, open choke, dry spark plug, check for spark.
Engine runs poorly/dies	Dirty air filter, old fuel, clogged fuel filter	Clean/replace air filter, use fresh fuel mix, replace fuel filter.
Excessive vibration	Damaged blade, loose cutting attachment	Stop engine! Inspect blade for damage/balance. Tighten attachment.
Cutting tool does not spin	Drive shaft failure, clutch worn	Stop engine. Inspect for debris. Contact authorized STIHL dealer.
Loss of power	Clogged exhaust, carburetor issue	Clean spark arrestor screen. Have carburetor serviced by dealer.

Service: For repairs beyond basic maintenance, contact an authorized STIHL servicing dealer.

Support: STIHL Incorporated, www.stihlusa.com or contact your local STIHL dealer.