stihl ts410 workshop manual pdf

The STIHL TS 410 is a professional-grade cut-off saw designed for heavy-duty concrete, asphalt, and masonry cutting. This workshop manual provides comprehensive technical information for maintenance, repair, and troubleshooting. It covers the TS 410's engine system (2-stroke, single-cylinder), fuel system, cutting system, safety features, electrical system, and detailed assembly/disassembly procedures. Below are key sections for specifications, maintenance schedules, troubleshooting, and parts diagrams.

1. Features at a Glance 2. Safety Information 3. Technical Specifications 4. Maintenance Schedule 5. Engine System 6. Fuel System 7. Cutting System 8. Electrical System 9. Disassembly & Assembly 10. Troubleshooting 11. Parts Diagrams

Features at a Glance

Key components: 2-stroke engine, anti-vibration system, quick-release cutting head guard, electronic ignition (CDI), diaphragm carburetor, and ergonomic handles.

Feature	Description
Engine Type	STIHL single-cylinder 2-stroke engine
Displacement	64.1 cm³ (3.91 cu. in.)
Power Output	3.0 kW (4.0 hp)
Fuel Tank Capacity	1100 ml (37.2 fl. oz.)
Cutting Depth (max)	125 mm (4.9 in.) with 300 mm blade
Idle Speed	2800 rpm
Ignition System	Electronic CDI ignition
Carburetor	Diaphragm carburetor with manual choke
Vibration Damping	Integrated anti-vibration system
Weight (without blade)	Approx. 10.5 kg (23.1 lbs)

Safety Information

Always wear appropriate PPE: safety glasses, hearing protection, gloves, and steel-toed boots.

Read manual: Understand all instructions before operation.
Inspect saw: Check for damage, loose parts, and blade condition before each use.
Fuel safety: Use only STIHL-approved gasoline/oil mix (50:1). Refuel in well-ventilated area, engine off and cool.
Cutting precautions: Ensure workpiece is secure. Keep bystanders at a safe distance.

WARNING! Never operate a damaged or improperly maintained saw. Risk of serious injury or death.

Technical Specifications

Model: STIHL TS 410 Cut-off Saw.
Engine: Air-cooled, single-cylinder 2-stroke.
Bore x Stroke: 48 mm x 35.4 mm.
Powerhead Weight: 10.5 kg (23.1 lbs).
Recommended Blade Diameter: 300 mm (12 in.).
Max. Cutting Depth: 125 mm (4.9 in.).
Fuel/Oil Ratio: 50:1 (STIHL HP Ultra or equivalent).
Spark Plug: NGK BPMR 7A (gap 0.5 mm / 0.020 in.).
Warranty: Refer to STIHL warranty terms.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily/Before Use: Check fuel level, inspect blade and guard, check for loose fasteners, clean air filter if necessary.

Every 50 Hours: Clean spark arrestor screen, check spark plug condition and gap.

Every 100 Hours: Clean/replace air filter, check fuel filter, inspect carburetor settings.

Annually or 300 Hours: Clean combustion chamber, check piston and cylinder for wear, replace fuel lines if cracked.

Engine System

Disassembly: Remove muffler, cylinder head, and cylinder. Inspect piston rings, cylinder walls for scoring.

Compression check: Should be above 120 psi (8.3 bar).
Crankcase seals: Inspect for leaks; replace if damaged.
Ignition timing: Fixed by CDI unit; check flywheel key for shearing.

Note: Use STIHL special tools for engine work (piston stop, flywheel puller).

Fuel System

Components: Fuel tank, filter, lines, carburetor (Zama C1Q-S series).

Fuel filter: Replace if clogged; located inside tank.
Carburetor adjustment: Use H and L screws for high/low speed mixture (initial setting: 1 turn open from lightly seated).
Diaphragm: Check for cracks or stiffness; replace kit if necessary.

Tip: Always use fresh fuel mix to prevent carburetor varnishing.

Cutting System

Includes blade, guard, spindle, and drive system.

Blade mounting: Ensure blade is compatible (diamond abrasive for masonry). Use correct flange and nut (tighten clockwise).
Guard: Quick-release mechanism for easy blade changes. Ensure it rotates freely.
Spindle bearings: Check for play or roughness; replace if worn.
Drive belt: Inspect for cracks/wear; adjust tension per manual.

WARNING! Always use blade guard. Never use a damaged or warped blade.

Electrical System

CDI ignition, stop switch, spark plug wire.

Testing: Use multimeter to check coil resistance (primary: 0.5-1.5 Ω, secondary: 8-15 kΩ). Ensure stop switch circuit is not grounded when in RUN position.

Disassembly & Assembly

General sequence: Remove external covers, fuel tank, carburetor, cylinder, piston, crankshaft.

CAUTION! Label parts and organize fasteners. Refer to torque specifications for reassembly.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel issue, flooded	Check spark plug, fuel mix, choke operation. Clean air filter.
Engine runs poorly/lacks power	Clogged fuel filter, dirty carburetor, exhaust blocked	Replace fuel filter, clean carburetor, clean spark arrestor screen.
Excessive vibration	Unbalanced blade, loose components, engine mount worn	Balance or replace blade, tighten all fasteners, inspect mounts.
Blade doesn't spin	Drive belt broken, clutch faulty, spindle seized	Inspect belt and clutch assembly, check spindle bearings.
Overheating	Lean fuel mixture, clogged cooling fins, low oil in fuel	Adjust carburetor, clean fins, ensure correct fuel/oil mix.

Reset: For electronic issues, disconnect spark plug wire and pull starter 5 times to clear flood.

Service: Authorized STIHL servicing dealers only. Use genuine STIHL parts.

Parts Diagrams

Refer to official STIHL parts catalog for exploded views and part numbers for:

Engine Assembly (Cylinder, Piston, Crankshaft)
Fuel System (Tank, Carburetor, Lines)
Cutting Attachment (Spindle, Guard, Blade Flange)
Ignition System (Flywheel, Coil, Stop Switch)
Anti-Vibration System (Handles, Mounts)

Note: Always use part numbers from the latest parts list when ordering.