Stihl FS 200 Repair Manual

The Stihl FS 200 is a professional-grade string trimmer/brushcutter designed for demanding clearing and trimming tasks. This manual provides comprehensive repair, maintenance, and troubleshooting guidance for the FS 200's engine, fuel system, cutting head, drivetrain, and electrical components. Below are key sections covering safety, specifications, disassembly, component repair, assembly, and troubleshooting procedures.

1. Safety Precautions 2. Specifications & Technical Data 3. Tools & Workshop Requirements 4. Engine Repair 5. Fuel System Repair 6. Drivetrain & Gearbox Repair 7. Cutting Attachment Repair 8. Electrical System Repair 9. Reassembly & Torque Specifications 10. Maintenance Schedule 11. Troubleshooting Guide

Safety Precautions

Before performing any repair, ensure the unit is off, cool, and the spark plug boot is disconnected. Work in a clean, well-ventilated area.

Hazard	Precaution
Fuel Fire/Explosion	Drain fuel tank before repair. No smoking or open flames.
Sharp Components	Wear cut-resistant gloves when handling cutting blades or line heads.
Spring Force	Use proper tools when disassembling recoil starter or components under tension.
Chemical Exposure	Use safety glasses and gloves when handling fuel, oil, or solvents.
Electrical Shock	Disconnect ignition wire and remove spark plug before working near ignition system.

Specifications & Technical Data

Model: Stihl FS 200
Engine Type: 2-stroke, single-cylinder, air-cooled
Displacement: 31.8 cc
Power Output: 1.3 kW (1.8 hp)
Fuel/Oil Mix: 50:1 (Stihl HP Ultra or equivalent)
Idle Speed: 2,800 rpm
Max Engine Speed: 12,500 rpm
Cutting Attachment: Compatible with PolyCut heads, circular blades, and brush knives
Drive Shaft: Solid, with flexible coupling
Gearbox Ratio: Standard 1.27:1
Weight (without attachment): 5.9 kg (13 lbs)

Tools & Workshop Requirements

Required tools: Stihl special tool set (piston stop, flywheel puller, clutch tool), torque wrench, standard metric socket set, feeler gauges, compression tester, carburetor adjustment tool.

Workspace: Clean, flat bench with adequate lighting.
Parts organization: Use trays or containers to organize screws and small parts.
Manual reference: Keep this manual and Stihl IPL (Illustrated Parts List) accessible.

WARNING! Use only Stihl-approved tools for specific operations (e.g., clutch removal) to avoid damage.

Engine Repair

Cylinder & Piston: Inspect for scoring, carbon buildup. Measure piston clearance (spec: 0.045-0.055 mm). Replace if out of tolerance.

Remove muffler, cylinder cover, and cylinder bolts.
Lift cylinder; inspect piston rings for wear or breakage.
Clean carbon from exhaust port and cylinder head.
Reassemble with new gaskets; torque cylinder bolts to 10 Nm (88 in-lb).

Crankshaft & Bearings: Check for play; replace bearings if rough or noisy. Use puller for flywheel removal.

Fuel System Repair

Carburetor (Zama C1Q-S series): Clean or rebuild if engine runs poorly.

Remove air filter cover and carburetor mounting nuts.
Disconnect fuel lines and throttle linkage.
Disassemble carburetor; clean jets, diaphragm, and gaskets with carb cleaner.
Reassemble with rebuild kit if necessary; adjust idle (LA) and high-speed (H) screws to baseline: LA - 1 turn out, H - 1 turn out.

Fuel Tank & Lines: Inspect for cracks; replace fuel filter and lines annually.

Drivetrain & Gearbox Repair

Drive Shaft: Remove shaft housing; inspect for bends or damage. Lubricate with Stihl grease.

Gearbox: Disassemble to replace worn gears or bearings.

Remove cutting attachment and gearbox cover.
Extract snap ring and output shaft.
Inspect gears for chipping or excessive wear.
Pack with high-temperature grease (Stihl Grease 50) on reassembly.

Clutch: Replace if shoes are worn or springs broken. Use clutch tool for removal.

Cutting Attachment Repair

PolyCut Head: Replace trimmer line spool when line is short. Ensure bump feed mechanism is clean.

Press retainer tabs and remove spool cover.
Remove old spool; wind new line following directional arrows.
Reinstall, ensuring line feeds freely.

Blade Adapter: Inspect for cracks. Tighten blade nut to 40 Nm (30 ft-lb) with proper holder tool.

WARNING! Always wear gloves and ensure unit cannot start when handling blades.

Electrical System Repair

Ignition Module (Coil): Check for spark with tester. Air gap: 0.3 mm (0.012 in). Replace if no spark.

Stop Switch: Test continuity; replace if broken.

Spark Plug: NGK BPMR7A, gap 0.5 mm (0.020 in). Replace if electrodes are worn or fouled.

Reassembly & Torque Specifications

Component	Torque	Notes
Cylinder bolts	10 Nm (88 in-lb)	Crisscross pattern
Muffler bolts	8 Nm (71 in-lb)	Use new gasket
Clutch	40 Nm (30 ft-lb)	Right-hand thread
Flywheel nut	35 Nm (26 ft-lb)	Use piston stop
Gearbox housing screws	6 Nm (53 in-lb)	Apply thread locker
Blade nut	40 Nm (30 ft-lb)	Use blade holder

Maintenance Schedule

Daily: Check for loose fasteners, clean air filter, inspect cutting attachment.
25 Hours: Clean spark arrestor screen, check fuel filter.
50 Hours: Replace spark plug, clean carburetor, grease gearbox.
100 Hours: Inspect piston/cylinder, replace fuel lines, check clutch shoes.
Annual: Full inspection, replace worn bearings and seals.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, flooded carb, fuel issue	Check spark plug, ignition gap; dry plug; clean carburetor.
Loss of power	Clogged air filter, exhaust screen, carb adjustment	Clean/replace filter; clean spark arrestor; adjust H/L screws.
Excessive vibration	Bent drive shaft, unbalanced blade, loose parts	Inspect shaft; balance or replace blade; tighten mounting bolts.
Cutting head doesn't turn	Sheared drive pin, gearbox failure	Replace shear pin; inspect gearbox gears.
Overheating	Lean fuel mix, clogged cooling fins	Adjust carburetor; clean cylinder fins; ensure proper fuel/oil mix.

Technical Support: Stihl authorized service centers only. Use genuine Stihl parts.

Parts Ordering: Refer to Illustrated Parts List (IPL) for part numbers: www.stihlusa.com