Stihl FS 160 Service Manual

Maintenance Schedule

Access OSD via TV MENU or SETUP (DVD). Front Panel: POWER, OPEN/CLOSE, AUTO/DPMS, MUTE.

Daily/Before Use: Check for loose fasteners, inspect cutting attachment, check fuel for contamination, clean air intake and cooling fins.

Every 50 Hours: Clean spark arrestor screen (if equipped), check fuel filter, inspect spark plug.

Every 100 Hours: Clean carburetor air filter, replace fuel filter, check/replace spark plug, clean cooling system, inspect anti-vibration elements.

Seasonal/Annual: Clean combustion chamber and exhaust ports (decarbonizing), inspect fuel lines and impulse line, grease gearhead, check drive shaft for damage.

Fuel System Service

Components: Fuel tank, filter, lines, carburetor, and fuel cap.

1. Turn off the engine and disconnect the spark plug boot.
2. Drain fuel into an approved container.
3. Remove fuel tank and inspect for cracks. Replace fuel lines if hardened or cracked.
4. Clean or replace the in-tank fuel filter.
5. For carburetor service: Remove, disassemble, clean with compressed air and carburetor cleaner, inspect diaphragms and gaskets, and reassemble. Adjust LA (idle) and H (high-speed) screws to factory settings (typically 1 turn out from lightly seated) as a baseline.

Tip: Always use fresh, properly mixed fuel to prevent varnish and clogging.

Ignition System Service

Supports DVD-Video, audio CDs.

1. Spark Plug: Remove, check electrode gap (0.5 mm / 0.020 in), clean with wire brush, or replace if electrodes are worn or ceramic is cracked.
2. Ignition Module (CDI): Test with a spark tester. Connect tester between spark plug boot and ground. Pull starter rope; a strong blue spark should be visible. No spark indicates a faulty module, stop switch, or wiring.
3. Stop Switch: Test for continuity. The switch should be open (no continuity) in the RUN position and closed (continuity) in the STOP position.
4. Flywheel & Magneto: Check for physical damage, clean magnets, and ensure air gap between flywheel and ignition module is correct (typically 0.3 mm / 0.012 in).

WARNING! Never test for spark by holding the plug against the cylinder. Use a proper spark tester.

Engine Service

Closed Captions: Enable in DVD setup (On/Off). Parental Controls: Block by movie/TV ratings in FEATURES menu (password 9999).

1. Compression Test: Use a compression gauge. Minimum acceptable compression is typically above 100 psi. Low compression indicates worn piston rings, cylinder scoring, or leaking crankcase seals.
2. Crankcase Seals: Inspect for leaks. A leaking seal will cause a lean air-fuel mixture, leading to engine damage. Replace if oil residue is present around the seal or if a pressure/vacuum test fails.
3. Piston & Cylinder: Remove muffler to inspect piston through exhaust port. Look for scoring, scuffing, or carbon buildup. Severe scoring requires cylinder honing or replacement.
4. Muffler & Spark Arrestor: Remove and clean carbon deposits from the muffler and spark arrestor screen (if equipped) to prevent overheating.

Drive Shaft & Gearhead

Unplug before cleaning. Use dry cloth only; no liquids or aerosols.

1. Drive Shaft: Inspect for bends or damage. Remove by detaching from the engine clutch and gearhead. Lubricate with STIHL drive shaft grease during reassembly.
2. Gearhead: Remove cutting attachment. Clean exterior. Remove cover plate, clean old grease, inspect gears for wear or damage. Repack with STIHL gear grease (approx. 30 ml). Ensure seals are intact to prevent grease loss and dirt ingress.
3. Clutch: Inspect clutch shoes for wear and springs for tension. A worn clutch will cause slipping under load.

CAUTION! Always secure the drive shaft or clutch when loosening the gearhead nut to prevent rotation.

Cutting Attachments

FCC Part 15: Class B digital device; complies with interference limits for residential use. Copyright © 2006 Insignia; trademarks of Best Buy Enterprise Services, Inc. Macrovision: Incorporates copy protection technology. For support, visit www.insigniaproducts.com or contact 1-877-467-4289.

1. Trimmer Head: For nylon line. Ensure line is wound correctly and does not exceed recommended length. Replace worn bump feed head if necessary.
2. Metal Blades: Circular blades or brush knives. Inspect for cracks, nicks, or dullness. Sharpen with a file or replace damaged blades. Ensure the blade is balanced before installation.
3. Installation: Use the correct washer and nut sequence. Always use the STIHL combination wrench to secure the attachment. The nut has a left-hand thread (tighten clockwise to loosen, counter-clockwise to tighten when viewed from the blade side).
4. Guard: Always use the appropriate cutting attachment guard. Never operate the machine without a properly installed guard.

Troubleshooting

Reset: For electronic ignition modules, no reset is required. Ensure all connections are secure.

Service: For technical support and genuine STIHL parts, contact an authorized STIHL servicing dealer or visit www.stihlusa.com.