STIHL FS 200 Service Manual

The STIHL FS 200 is a professional-grade, lightweight trimmer/brushcutter designed for demanding clearing and trimming work. It features a powerful 2-stroke engine with electronic ignition, a robust gearbox, anti-vibration system, and compatibility with a wide range of cutting attachments. This manual provides essential information for service, maintenance, troubleshooting, and repair procedures to ensure optimal performance and safety.

1. Safety Precautions & Warnings 2. Technical Specifications 3. Engine Overview & Components 4. Fuel System Service 5. Ignition System Service 6. Carburetor Adjustment 7. Gearbox & Drive Shaft 8. Cutting Attachment Maintenance 9. Anti-Vibration System 10. Troubleshooting Guide 11. Torque Specifications

Safety Precautions & Warnings

Before performing any service, read and understand all safety instructions. Failure to follow warnings can result in serious injury or death.

Hazard	Precaution
Fuel Fire/Explosion	Work in well-ventilated area away from sparks or flames. Use only approved fuel containers.
Hot Surfaces	Allow engine and muffler to cool completely before touching or servicing.
Sharp Cutting Tools	Always wear heavy-duty gloves. Ensure cutting attachment is stopped and disconnected.
Rotating Drive Shaft	Disconnect spark plug boot before working on gearbox or drive shaft.
Chemical Exposure	Use gloves when handling fuel, oil, or cleaning solvents. Avoid skin contact.

Technical Specifications

Model: STIHL FS 200
Engine Type: Single cylinder, 2-stroke, air-cooled
Displacement: 30.1 cm³
Power Output: 1.3 kW (1.8 hp)
Fuel/Oil Mix: 50:1 (STIHL HP Ultra oil recommended)
Fuel Tank Capacity: 0.55 liters
Ignition System: Electronic, capacitor discharge (CDI)
Starting System: Rewind starter with decompression valve
Drive System: Flexible drive shaft, spiral bevel gearbox
Standard Cutting Attachment: PolyCut head 2-2 (line trimmer)
Weight (without attachment): 5.2 kg

Engine Overview & Components

Key components: Cylinder, Piston, Crankshaft, Connecting Rod, Muffler, Fan Housing, Rewind Starter.

Cylinder & Piston Inspection: Check for scoring, carbon buildup, and ring wear. Measure piston clearance.
Crankshaft & Bearings: Inspect for play or damage. Replace bearings if rough or noisy.
Muffler: Clean spark arrestor screen regularly to prevent overheating and power loss.
Cooling System: Ensure cooling fins on cylinder and fan housing are clean and unobstructed.

WARNING! Always use genuine STIHL parts for engine repairs to maintain performance and safety certifications.

Fuel System Service

Includes fuel tank, filter, lines, and carburetor.

Fuel Filter: Replace annually or if clogged. Use STIHL fuel filter tool for removal.
Fuel Lines: Inspect for cracks, brittleness, or leaks. Replace both supply and return lines as a set.
Fuel Tank Vent: Check valve in tank cap for proper operation. Clean if blocked.
Carburetor Diaphragms & Gaskets: Service kit includes new diaphragms, needle valve, and gaskets. Replace if engine runs poorly or leaks fuel.

CAUTION! Drain fuel tank before servicing fuel system components. Use only ethanol-resistant fuel lines.

Ignition System Service

Components: Spark plug, Ignition coil (CDI module), Stop switch, Wiring harness.

Spark Plug: Use STIHL recommended type (e.g., BOSCH WSR6F). Gap: 0.5 mm. Replace if electrodes are worn or fouled.

Ignition Coil Air Gap: Adjust to 0.3 mm using a feeler gauge between coil leg and flywheel magnet.

Testing: Use a spark tester. No spark indicates faulty coil, broken wire, or faulty stop switch.

Carburetor Adjustment

STIHL carburetor with H (High), L (Low), and LA (Idle) adjustment screws.

Initial Settings: Gently turn H and L screws clockwise until seated, then back out 1 turn each.
Fine Tuning (Warm Engine):
- Adjust L screw for fastest, smoothest idle.
- Adjust LA screw to set correct idle speed (chain/trimming head should not rotate).
- Adjust H screw for maximum RPM (do not exceed specified max RPM).
Final Check: Engine should accelerate smoothly from idle to full throttle without hesitation.

Note: H screw may have a limiter cap. Do not remove unless performing major service.

Gearbox & Drive Shaft

Spiral bevel gearbox requires periodic lubrication.

Gearbox Grease: Remove fill plug. Inject STIHL gearbox grease until it emerges from the vent.
Drive Shaft: Inspect flexible shaft for kinks or damage. Lubricate with special drive shaft grease during assembly.
Bearing Inspection: Check input and output shaft bearings for smooth rotation and no play.
Seal Replacement: Replace gearbox seals if grease is leaking or moisture is entering.

Cutting Attachment Maintenance

Supports trimmer heads, circular blades, and brush knives.

Trimmer Head (PolyCut): Replace worn cutting line. Ensure head is free of tangled debris.
Metal Blades: Sharpen with a file, maintaining original angle. Check for cracks or damage. Balance blade after sharpening.
Attachment Locking: Use correct combination wrench to secure nut. Ensure cutting tool is properly seated on gearbox output shaft.
Guard Inspection: Never operate without proper guard. Check guard for cracks and secure mounting.

WARNING! Always disconnect spark plug before installing or changing cutting attachments.

Anti-Vibration System

Reduces vibration transmitted to the operator via rubber dampers and spring elements.

Inspection Points:

Front handle rubber isolators.
Spring elements between engine unit and shaft tube.
Rear handle mounting points.

Service: Replace any cracked, hardened, or torn rubber dampers. Ensure all mounting bolts are tightened to specified torque.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, fuel issue	Check spark plug, ignition. Wait if flooded. Check fuel lines, filter, and carburetor.
Engine starts then dies	Clogged fuel filter, tank vent, carburetor	Replace fuel filter. Clean tank vent. Service carburetor diaphragms.
Loss of power	Dirty air filter, clogged muffler, carb adjustment	Clean/replace air filter. Clean spark arrestor. Adjust carburetor.
Excessive vibration	Unbalanced blade, bent shaft, worn AV mounts	Balance blade. Inspect drive shaft. Replace anti-vibration dampers.
Gearbox overheating/noise	Low grease, damaged gears/bearings	Repack with grease. Inspect gears and bearings for wear; replace as needed.

Torque Specifications

Cylinder Head Nuts: 20 Nm (15 ft-lb)
Fan Housing Screws: 4-5 Nm (35-44 in-lb)
Muffler Screws: 10 Nm (7.5 ft-lb)
Carburetor Mounting Nuts: 5 Nm (44 in-lb)
Gearbox Mounting Bolts: 25 Nm (18.5 ft-lb)
Cutting Attachment Nut: 40 Nm (30 ft-lb) - Use locking agent.
Handle Mounting Bolts: 15 Nm (11 ft-lb)

Service Note: Always refer to the latest STIHL service documentation for model-specific updates.

STIHL Support: For technical assistance or genuine parts, contact an authorized STIHL servicing dealer or visit www.stihlusa.com.