Stihl FS 160 Manual

The Stihl FS 160 is a professional-grade, straight-shaft grass trimmer/brushcutter designed for demanding clearing and trimming tasks. It features a powerful 2-stroke engine with electronic ignition, a robust gearbox, a bicycle-style handlebar for optimal control, a harness attachment point for operator comfort, and a comprehensive safety system including a throttle trigger lockout and a debris shield. Below are key sections for safety, features, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Safety Instructions 3. Assembly & Preparation 4. Specifications 5. Controls and Components 6. Fuel & Lubrication 7. Starting & Operation 8. Cutting Attachments 9. Maintenance & Storage 10. Warranty Information 11. Troubleshooting

Features at a Glance

Key components: 2-stroke engine, Straight shaft with solid drive rod, Bicycle handlebar, QuickStop® inertia-activated chain brake (if equipped with cutting blade), Throttle trigger lockout, Semi-automatic choke, and Tool-free attachment system for cutting heads.

Feature	Description
Engine Type	2-stroke, single-cylinder, air-cooled
Displacement	30.1 cm³ (1.84 cu. in.)
Powerhead	Ergonomic design with anti-vibration system
Shaft	Straight, solid drive rod for high torque transmission
Handlebar	Bicycle type for two-handed control and maneuverability
Ignition	Electronic, capacitor discharge (CDI)
Starter	Rewind starter with impulse coupling for easy starting
Fuel Tank Capacity	Approx. 0.55 liters (18.6 fl. oz.)
Cutting Attachment	Accepts trimmer heads and metal blades
Weight (powerhead only)	Approx. 6.2 kg (13.7 lbs)

Safety Instructions

Read and understand all instructions before use. Failure to follow warnings can result in serious injury or death.

Personal Protective Equipment (PPE): Always wear safety glasses, hearing protection, sturdy gloves, long pants, and boots.
Clear Work Area: Remove stones, nails, wire, and other debris that could be thrown by the tool.
Fuel Safety: Refuel in a well-ventilated area with the engine stopped and cool. Use only STIHL-approved gasoline/oil mix.
Operation: Keep bystanders and pets at least 15 meters (50 feet) away. Hold the unit firmly with both hands.
Hot Surfaces: Avoid contact with the muffler and cylinder during and immediately after operation.

WARNING! The cutting tool continues to rotate after the throttle is released. Never operate without proper guards in place.

Assembly & Preparation

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

Attach the Shaft: Align the shaft with the powerhead, insert, and tighten the coupling nut securely with the supplied tool.
Install the Handlebar: Slide the handlebar onto the shaft at the desired position and tighten the clamping bolts.
Install the Harness: Connect the harness rings to the attachment points on the powerhead and handlebar.
Install Cutting Attachment: Ensure the engine is off. Fit the chosen trimmer head or blade, securing it with the appropriate retaining nut and guard.
Fuel Mix: Prepare a fresh 50:1 mixture of unleaded gasoline (min. 89 octane) and STIHL 2-stroke engine oil.

CAUTION! Ensure all fasteners are tight before starting the engine. Do not force components during assembly.

Specifications

Model: STIHL FS 160.
Engine Power: 1.3 kW (1.8 bhp).
Idle Speed: 2,800 rpm.
Maximum Power Speed: 9,500 rpm.
Fuel/Oil Ratio: 50:1 (STIHL 2-Stroke Oil).
Recommended Cutting Tools: STIHL PolyCut head, circular grass blades, brush knives.
Drive System:Flexible drive shaft within a rigid tube. Sound Power Level (L_WA)112 dB(A) (measured per EN ISO 22868) Vibration Levels (a_h)Front Handle: 4.5 m/s², Rear Handle: 6.5 m/s²
Warranty: Limited warranty for professional use. See official STIHL warranty statement.

Controls and Components

Familiarize yourself with all controls before starting.

Main Controls: - Throttle Trigger: Located on the rear handle. Squeeze to increase engine speed. - Throttle Trigger Lockout: Must be depressed before the throttle trigger can be engaged. - Stop Switch: Move to "I" (RUN) or "O" (STOP). - Choke Lever: Positions: • = Run, = Half Choke (for cold start), = Full Choke. - Primer Bulb: Press several times to fill carburetor with fuel for cold starts. - Handlebar: Adjustable for operator height and comfort. Includes vibration dampeners.

Safety Features: Debris shield, shoulder harness attachment points, spark arrestor screen in muffler (where required).

Fuel & Lubrication

Use only high-quality, fresh fuel mixture. Old or incorrect fuel is the most common cause of starting and performance problems.

Fuel Mix: Use unleaded gasoline with a minimum octane rating of 89 (AKI). Mix with STIHL 2-Stroke Engine Oil at a 50:1 ratio. Shake container thoroughly.

Refueling: Clean area around fuel cap. Unscrew cap slowly. Use a funnel. Do not overfill. Tighten cap securely.

Gearbox Lubrication: Lubricate the gearbox at the end of the shaft with STIHL Gear Oil before first use and periodically as described in the maintenance schedule.

Air Filter: Check before each use. Clean with compressed air or wash in soapy water if foam type. Re-oil foam filters with STIHL Air Filter Oil.

WARNING! Gasoline is extremely flammable. No smoking. Keep away from sparks and open flame.

Starting & Operation

Follow these steps for safe and reliable starting.

Cold Start: Place unit on clear, flat ground. Set stop switch to "I". Press primer bulb 5-10 times. Move choke lever to full choke .

Starting Procedure: Hold the unit securely with your right hand on the rear handle and your foot in the carrying handle. Pull starter rope briskly until engine fires (usually 1-3 pulls). Immediately move choke lever to half choke . Pull starter rope again to start. Allow to run for a moment, then move choke to • run position.

Warm Start: Choke lever should remain in • run position. Pull starter rope to start.

Operation: Put on harness and adjust. Start with a smooth swinging motion, keeping the cutting attachment parallel to the ground. Do not raise above waist height. Never run at full throttle without a load.

Stopping: Release throttle trigger and allow engine to return to idle. Move stop switch to "O".

CAUTION! Never drop-start or "throw" start the unit. Always keep firm footing.

Cutting Attachments

The FS 160 is compatible with a variety of STIHL trimmer heads and metal blades.

Trimmer Line Heads (e.g., PolyCut): For grass and light weeds. Use correct diameter line. Advance line by tapping head on ground at high idle ("Tap 'n Go").

Circular Grass Blades: 3-tooth or 4-tooth blades for thick grass and saplings.

Brush Knives: 80-tooth or fewer for heavy brush and woody vegetation.

Changing Attachments: Stop engine and ensure it is cool. Use the combination wrench to hold the shaft. Use the appropriate tool to loosen the retaining nut. Always install the correct guard for the attachment.

WARNING! Always use the STIHL guard designed for the specific cutting attachment. Inspect blades for cracks or damage before each use.

Maintenance & Storage

Regular maintenance ensures long life and safe operation.

Daily/Before Use: Check for loose fasteners, damaged parts, and fuel leaks. Clean exterior and air filter. Check cutting attachment security.

Weekly/After Use: Clean under debris shield. Check spark plug condition and gap (0.5 mm / 0.020 in). Clean spark arrestor screen (if equipped).

Long-Term Storage: 1. Drain fuel tank and run carburetor dry. 2. Remove spark plug, add a teaspoon of engine oil into cylinder, pull starter rope slowly to distribute, reinstall plug. 3. Thoroughly clean entire unit. 4. Store in a dry, secure place, protected from dust and moisture.

CAUTION! Disconnect spark plug boot before performing any maintenance other than refueling.

Warranty Information

STIHL FS 160 power tools are backed by a limited warranty for professional use. The warranty period and terms vary by region. Proof of purchase from an authorized STIHL dealer is required. Warranty covers defects in material and workmanship under normal use and proper maintenance. It does not cover wear parts (spark plugs, filters, cutting attachments), damage from misuse, neglect, improper fuel, or unauthorized repairs. For full warranty details and to find your local authorized STIHL service dealer, visit www.stihl.com.

Troubleshooting

Symptom Possible Cause Corrective Action

Engine will not start 1. No fuel.
2. Flooded engine.
3. Choke position incorrect.
4. Spark plug faulty. 1. Refuel with fresh 50:1 mix.
2. Move choke to run, hold throttle wide open, pull starter 10+ times.
3. Follow cold/warm start procedure.
4. Check, clean, gap, or replace plug.

Engine starts but dies 1. Clogged fuel filter/vent.
2. Dirty air filter.
3. Carburetor adjustment. 1. Replace fuel filter. Clean tank vent.
2. Clean or replace air filter.
3. Have carb adjusted by authorized dealer.

Loss of power 1. Clogged air filter.
2. Exhaust screen clogged.
3. Old fuel. 1. Clean air filter.
2. Clean spark arrestor screen.
3. Drain and replace with fresh fuel mix.

Excessive vibration 1. Loose fasteners.
2. Bent drive shaft.
3. Damaged cutting tool. 1. Tighten all nuts and bolts.
2. Inspect shaft, replace if bent.
3. Inspect and replace blade or head.

Cutting head does not advance line 1. Line too short.
2. Line spool jammed.
3. Incorrect line diameter. 1. Pull out more line manually.
2. Disassemble head, clean, rewind spool.
3. Use only STIHL recommended line size.

For Service: Repairs should be performed by an authorized STIHL servicing dealer. Use only genuine STIHL replacement parts.

Customer Support: Contact your local STIHL dealer or visit www.stihl.com for manuals, parts diagrams, and dealer locator.

Stihl FS 160 Manual © - All Rights Reserved 2025

Symptom	Possible Cause	Corrective Action
Engine will not start	1. No fuel. 2. Flooded engine. 3. Choke position incorrect. 4. Spark plug faulty.	1. Refuel with fresh 50:1 mix. 2. Move choke to run, hold throttle wide open, pull starter 10+ times. 3. Follow cold/warm start procedure. 4. Check, clean, gap, or replace plug.
Engine starts but dies	1. Clogged fuel filter/vent. 2. Dirty air filter. 3. Carburetor adjustment.	1. Replace fuel filter. Clean tank vent. 2. Clean or replace air filter. 3. Have carb adjusted by authorized dealer.
Loss of power	1. Clogged air filter. 2. Exhaust screen clogged. 3. Old fuel.	1. Clean air filter. 2. Clean spark arrestor screen. 3. Drain and replace with fresh fuel mix.
Excessive vibration	1. Loose fasteners. 2. Bent drive shaft. 3. Damaged cutting tool.	1. Tighten all nuts and bolts. 2. Inspect shaft, replace if bent. 3. Inspect and replace blade or head.
Cutting head does not advance line	1. Line too short. 2. Line spool jammed. 3. Incorrect line diameter.	1. Pull out more line manually. 2. Disassemble head, clean, rewind spool. 3. Use only STIHL recommended line size.