Stihl TS410 Service Workshop Manual

The Stihl TS410 is a professional-grade cut-off saw designed for demanding construction and demolition work. This service workshop manual provides detailed technical information, maintenance procedures, troubleshooting guides, and repair instructions for certified technicians and experienced users. It covers the TS410's engine, fuel system, cutting system, safety features, and electrical components to ensure proper servicing and optimal performance.

1. Safety Precautions & Warnings 2. Technical Specifications 3. Tools & Equipment Required 4. Engine Service & Overhaul 5. Fuel System Maintenance 6. Cutting System & Guard 7. Ignition System & Electronics 8. Carburetor Adjustment 9. Troubleshooting Flowcharts 10. Torque Specifications 11. Exploded Views & Parts List

Safety Precautions & Warnings

Before performing any service, read all safety instructions. The TS410 is a powerful tool that can cause serious injury or death if mishandled.

Hazard	Precaution
Fuel & Fire	Work in well-ventilated area; no smoking or open flames. Allow engine to cool before servicing.
Sharp Components	Wear cut-resistant gloves when handling the cutting wheel, blade, or drive shaft.
Hot Surfaces	Do not touch muffler, cylinder, or engine immediately after operation.
Electrical Shock	Disconnect spark plug boot before working on ignition or cutting system.
Kickback	Ensure cutting guard is properly installed and undamaged. Use correct wheel type.
Eye & Ear Protection	Always wear safety glasses and hearing protection during testing or operation.

Technical Specifications

Model: Stihl TS410 Cut-Off Saw
Engine Type: 2-stroke, single cylinder, air-cooled
Displacement: 64.1 cm³ (3.91 cu. in.)
Power Output: 3.0 kW (4.0 hp)
Fuel/Oil Mix: 50:1 (Stihl HP Ultra or equivalent)
Idle Speed: 2,800 rpm
Max. Engine Speed: 12,500 rpm
Cutting Wheel Diameter: 300 mm (12 inches) max
Drive System: Direct drive via centrifugal clutch
Ignition System: Electronic, capacitor discharge (CDI)
Weight (without wheel): Approx. 9.5 kg (20.9 lbs)

Tools & Equipment Required

Standard mechanic's tools plus Stihl specialty tools recommended for proper service.

Torque wrench (range: 2-50 Nm)
Spark plug wrench (Stihl 5910 890 4500)
Piston stop tool (Stihl 5910 890 4000)
Flywheel puller (Stihl 5910 890 4100)
Clutch removal tool (Stihl 5910 890 4300)
Compression tester
Feeler gauges
Carburetor adjustment tool (splined)
Clean shop rags and parts cleaning solvent

WARNING! Use only Stihl-approved replacement parts to maintain performance and safety certifications.

Engine Service & Overhaul

Procedures for cylinder, piston, crankshaft, and bearings.

Compression Test: Remove spark plug, install tester, pull starter cord. Minimum: 120 psi (8.3 bar).
Cylinder Inspection: Check for scoring, wear, or carbon buildup. Measure bore diameter.
Piston & Rings: Remove cylinder; inspect piston skirt and ring grooves. Replace if worn.
Crankshaft Seals: Check for leaks (air/fuel). Replace if engine runs lean or has difficulty starting.
Bearings: Check crankshaft bearings for smooth rotation and no play.
Reassembly: Lubricate components with 2-stroke oil during assembly. Follow torque specs.

CAUTION! Label all parts during disassembly. Keep work area clean to prevent contamination.

Fuel System Maintenance

Fuel tank, lines, filter, and cap.

Drain fuel tank completely.
Inspect fuel line for cracks, stiffness, or leaks. Replace if necessary.
Replace in-tank fuel filter (Stihl part # 0000 350 3500).
Clean fuel tank vent in cap. Ensure it is not blocked.
Check fuel pickup and primer bulb (if equipped) for proper operation.
Use only fresh, properly mixed fuel (50:1) after service.

Tip: Old or improperly mixed fuel is the most common cause of starting and performance issues.

Cutting System & Guard

Shaft, spindle, bearing, guard, and wheel.

Component	Service Procedure
Cutting Wheel Shaft	Check for straightness and thread condition. Replace if bent or damaged.
Spindle Bearing	Remove guard and wheel. Check bearing for smooth rotation; replace if rough or noisy.
Centrifugal Clutch	Inspect shoes for wear and springs for tension. Clean drum interior.
Cutting Guard	Inspect for cracks or deformation. Ensure it is securely mounted and aligns with wheel.
Wheel Flange & Nut	Always use the correct flange and tighten nut to specified torque (see Section 10).

WARNING! Never operate the saw without the proper guard installed. Use only wheels rated for the TS410's max RPM.

Ignition System & Electronics

Spark plug, ignition module, stop switch, and wiring.

Spark Plug: Recommended: NGK BPMR7A. Gap: 0.5 mm (0.020 in). Replace if electrode is worn or fouled.
Ignition Module (CDI): Test with Stihl diagnostic tool or multimeter per resistance chart. Replace if no spark.
Stop Switch: Check continuity. Switch should be open (infinite resistance) when in RUN position.
Wiring Harness: Inspect for frayed wires, loose connections, or damage from heat/vibration.
Spark Arrestor (Muffler): Remove and clean screen with wire brush. Reinstall securely.

Carburetor Adjustment

Standard settings and fine-tuning for altitude/temperature.

Initial Settings (screws turned lightly seated):

L (Low Speed Mixture): 1 turn open
H (High Speed Mixture): 1 turn open
LA (Idle Speed Screw): Set to achieve 2,800 rpm idle

Start engine and warm up for 5 minutes.
Adjust idle speed (LA) so cutting wheel does not turn.
Turn L screw for smoothest acceleration from idle (richer if it hesitates).
Under load (cutting), adjust H screw for maximum power without leaning out (4-stroking sound at no-load is normal).
Re-check idle speed after H/L adjustments.

CAUTION! An overly lean H setting can cause engine seizure. Always final-tune under actual load conditions.

Torque Specifications

Fastener	Torque (Nm)	Torque (lb-ft)
Cylinder Head Nuts	20 Nm	14.8 lb-ft
Spark Plug	25 Nm	18.4 lb-ft
Clutch Nut	40 Nm	29.5 lb-ft
Flywheel Nut	50 Nm	36.9 lb-ft
Cutting Wheel Nut	60 Nm	44.3 lb-ft
Muffler Bolts	10 Nm	7.4 lb-ft
Handle Mounting Bolts	15 Nm	11.1 lb-ft

Exploded Views & Parts List

Reference diagrams for ordering correct replacement parts. Key assembly groups:

Engine Group (Cylinder, Piston, Crankshaft)
Fuel System Group (Tank, Cap, Lines, Filter)
Ignition Group (Flywheel, Module, Coil, Switch)
Cutting Group (Shaft, Bearing, Clutch, Guard)
Air Filter & Carburetor Group
Muffler & Exhaust Group
Handle & Control Group

Note: Always use the saw's serial number when ordering parts to ensure compatibility with specific production runs.

Troubleshooting Flowcharts

Problem	Possible Cause	Corrective Action
Engine will not start	No spark, fuel, or compression	1. Check spark plug & boot. 2. Check fuel flow & filter. 3. Test compression.
Engine starts then dies	Fuel starvation, air leak, clogged carb	1. Check tank vent. 2. Inspect fuel line. 3. Check crankcase seals.
Loss of power under load	Clogged air filter, exhaust screen, incorrect carb setting	1. Clean air filter. 2. Clean spark arrestor. 3. Adjust H screw.
Excessive vibration	Bent cutting shaft, unbalanced wheel, loose components	1. Inspect shaft & wheel. 2. Tighten all bolts & nuts. 3. Replace damaged guard.
Cutting wheel does not stop at idle	Idle speed too high, clutch sticking	1. Adjust LA screw. 2. Clean clutch drum & shoes.
Overheating	Lean fuel mix, clogged cooling fins, low oil in fuel	1. Adjust carb richer. 2. Clean cylinder fins. 3. Use proper 50:1 mix.

Service Support: For technical assistance or genuine parts, contact your authorized Stihl dealer or visit www.stihlusa.com.