STIHL Special Tools Manual

The STIHL Special Tools Manual provides comprehensive guidance on the proper use, maintenance, and safety procedures for STIHL's range of specialized service tools designed for professional-grade chainsaws, trimmers, blowers, and other outdoor power equipment. Below are key sections covering tool identification, applications, safety protocols, maintenance, and troubleshooting.

1. Tool Overview & Identification 2. Safety Instructions 3. Tool Applications by Equipment 4. Technical Specifications 5. Operating Procedures 6. Maintenance & Storage 7. Calibration & Adjustment 8. Compatibility Chart 9. Warranty & Support 10. Regulatory Compliance 11. Troubleshooting

Tool Overview & Identification

Key components: Specialized wrenches, piston stops, flywheel pullers, compression testers, carburetor adjustment tools, spark plug tools, bar mounting kits, and diagnostic gauges.

Tool Number	Description	Primary Use
STIHL 0000-890-1000	Piston Stop Tool	Securing piston during cylinder/flywheel work
STIHL 0000-890-1200	Flywheel Puller Set	Removing flywheel without damage
STIHL 0000-890-1300	Clutch Drum Wrench	Removing clutch drum on chainsaws
STIHL 0000-890-1500	Compression Tester	Measuring engine compression
STIHL 0000-890-1700	Carburetor Adjustment Tool	Adjusting H/L/LA screws on carburetors
STIHL 0000-890-1900	Bar Mounting Kit	Proper bar alignment and tensioning
STIHL 0000-890-2000	Diagnostic Pressure Gauge	Testing fuel pump and crankcase pressure

Safety Instructions

Always follow safety protocols when using special tools.

Personal Protective Equipment (PPE): Wear safety glasses, gloves, and appropriate work attire.
Work Area: Ensure clean, well-lit, and ventilated workspace free of flammable materials.
Equipment Preparation: Disconnect spark plug wire and ensure engine is cool before servicing.
Tool Inspection: Check tools for damage or wear before each use.

WARNING! Using incorrect or damaged tools can cause equipment failure, personal injury, or void warranty. Use only genuine STIHL special tools.

Tool Applications by Equipment

Match tools to specific STIHL models for optimal performance.

Chainsaws (MS 170, MS 250, MS 661): Use piston stop, flywheel puller, clutch drum wrench.
Trimmers/Blowers (FS 56, BR 600): Use carburetor adjustment tool, diagnostic gauge.
Hedge Trimmers (HS 82): Use specific gearbox tools and tensioning wrenches.
Cut-off Machines (TS 420): Use specialized socket sets and guard removal tools.

CAUTION! Refer to individual equipment service manual for exact tool requirements.

Technical Specifications

Materials: Chrome-vanadium steel, hardened and tempered.
Finish: Corrosion-resistant coating.
Torque Ratings: Marked on each tool (e.g., 30-60 Nm).
Temperature Range: -20°C to +100°C operating temperature.
Storage Conditions: Dry environment, 10-80% humidity.
Weight: Varies by tool (typically 0.1-2.5 kg).
Compliance: Meets ISO 6789 standards for hand tools.

Operating Procedures

Follow step-by-step instructions for each tool application.

Piston Stop Installation: 1. Remove spark plug. 2. Rotate crankshaft until piston is at bottom dead center. 3. Insert piston stop tool through spark plug hole. 4. Rotate crankshaft clockwise until piston contacts tool.

Flywheel Removal: 1. Remove starter cover and flywheel nut. 2. Install flywheel puller threads into flywheel. 3. Tighten center bolt evenly until flywheel releases.

Carburetor Adjustment: 1. Use STIHL adjustment tool on H/L/LA screws. 2. Turn screws to factory settings (typically 1 turn out). 3. Fine-tune while engine is running at operating temperature.

Maintenance & Storage

Proper care extends tool life and ensures accuracy.

Cleaning: Wipe with clean cloth after use; remove oil/grease buildup.
Lubrication: Apply light machine oil to moving parts monthly.
Calibration: Check torque wrenches annually or after 5000 cycles.
Storage: Keep in original case or toolbox; protect from moisture.

Tip: Store tools in designated STIHL tool organizer for easy identification.

Calibration & Adjustment

Critical tools require periodic calibration.

Torque Wrenches: Calibrate every 12 months or after significant impact.
Compression Testers: Check against master gauge quarterly.
Diagnostic Gauges: Zero-adjust before each use; calibrate annually.
Adjustment Tools: Inspect tips for wear; replace if deformed.

WARNING! Using uncalibrated tools can lead to improper torque, engine damage, or safety hazards.

Compatibility Chart

Match tools to STIHL equipment series.

Tool	Compatible Models	Notes
Piston Stop 0000-890-1000	MS 170-661, 021-660	Not for MS 150 or electric models
Flywheel Puller 0000-890-1200	All 2-stroke engines	Includes adapters for different thread sizes
Clutch Drum Wrench 0000-890-1300	MS 180-880, 028-880	Use with matching holding tool
Carb Tool 0000-890-1700	All Zama & Walbro carbs	Fits H, L, LA, and idle screws

Warranty & Support

STIHL special tools come with 2-year limited warranty against defects in materials/workmanship.

CAUTION! Warranty void if tools are misused, modified, or used with non-STIHL equipment.

Regulatory Information

STIHL special tools comply with ANSI B107.1 standards for hand tool safety. Manufactured under ISO 9001 quality management system. Copyright © 2025 STIHL Incorporated. All trademarks owned by STIHL. For technical support, contact STIHL Technical Service at 1-800-467-8445 or visit www.stihlusa.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Tool won't fit	Wrong tool for model	Verify compatibility chart; use correct tool number.
Stripped threads	Cross-threading or over-torque	Replace damaged component; use thread locker on repairs.
Inaccurate readings	Uncalibrated gauge	Calibrate tool; check for leaks in pressure tester.
Tool slipping	Worn engagement surfaces	Replace worn tool; clean mating surfaces.
Difficulty removing component	Corrosion or improper technique	Apply penetrating oil; use correct sequence/force.

Service: For tool repair/replacement, contact authorized STIHL dealer.

Hotline: 1-800-467-8445; www.stihlusa.com