2004 Stihl FS 55 Brushcutter Component Service & Parts Manual Collection with FS 65 and FS 25-4/FS 65-4 Parts Lists
170 Pages • Printable PDF • 5.24 MB • Download
Stihl Models Covered & Key Technical Specifications
Models: FS 55, FS 65, FS 65-4, HS 45, BG 55, BG 65, BG 85, SH 55, SH 85, FC 55, FS 45, FS 46, FS 25-4
Models & Model Codes:
FS 55 — 4140
FS 65 — 4121
FS 65-4 — 4170
FS 25-4 — 4170
Sub-models / Variants: 55 C, 55 R, 55 RC, 55 T, 55 TC, HS 45/450, HS 45/600, FS 65 AVE, FS 65 AVRE
Trade Names: FS 55, HS 45, BG/SH
Model Year: 2004
Coverage: 4140-series component service manual, plus illustrated parts lists for FS 55 (4140), FS 65 (4121), and FS 25-4 / FS 65-4 (4170).
Serial-number references (component-specific parts changes):
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FS 65 / FS 65 AVRE: up to X 13 524 140 for the earlier carburetor and air-filter assembly.
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FS 25-4: up to 1057 792 / from 1057 793 for crankshaft, flywheel, and seal changes; up to 1138 647 for the earlier crankcase; up to 1432 054 for earlier carburetor and intake components.
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FS 65-4: up to 1040 027 / from 1040 028 for crankshaft, flywheel, and seal changes; up to 1205 100 for earlier carburetor and intake components.
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Fuel tank capacity: 0.300 L (4140-series FS models), 0.400 L (BG/SH), 0.225 L (HS 45)
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Starter rope diameter: 3 mm (standard 4140-series starters and FS 25-4 / FS 65-4); 2.7 mm (FS 55 C / FS 55 RC with ErgoStart); 3.5 mm (FS 65)
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Fuel mixture: 1:50 with STIHL two-stroke engine oil (4140-series models)
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Octane rating: At least 90 RON (4140-series models)
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Carburetor type: Diaphragm carburetor
Stihl Manual Features & Selected Content Preview
| Publication | Pages |
|---|---|
| Machine components 4140 — component service for FS 45/46/55, FC 55, HS 45, BG 55/65/85, and SH 55/85 | 50 |
| FS 55 family illustrated parts list (4140), 07/2004 — FS 55, FS 55 C, FS 55 R, FS 55 RC, FS 55 T, and FS 55 TC | 50 |
| FS 65 illustrated parts list (4121), 07/2004 — includes FS 65 AVE and FS 65 AVRE variants | 34 |
| FS 25-4 / FS 65-4 illustrated parts list (4170), 07/2004 | 36 |
The service manual supplies component repair procedures, while the parts lists provide exploded assemblies and numbered replacement-part references. These references help match the machine’s build before replacement parts are selected.
FS 65 and FS 25-4/FS 65-4 coverage consists of parts lists, not model-specific overhaul instructions. Internal engine overhaul and ignition-module air-gap setup are referred to the separate Basic engine 4140 handbook, which is not included.
Searchable Text and Section Bookmarks
Text search and navigation: Searchable PDF text and embedded bookmarks are included. The component manual has chapter and subsection bookmarks; each parts list has a bookmark to its opening page.
One printable 170-page PDF contains all four publications. The three parts-list cover/index pages and three copyright/symbol-key pages are already included in the table totals. The service text is in English; the parts tables include English, German, and French.
Clutch, Fuel-System and Cutting-Drive Service
These selected topics are supplemented by a special-accessory list and fastener notes distinguishing screws with and without underhead locking teeth.
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Clutch and engine removal: Clutch drum inspection, spring replacement, engine removal and installation, and muffler and spark-arresting-screen service.
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Fuel-system diagnosis: Diaphragm-carburetor leakage testing, LD idle adjustment, tank-vent pressure and vacuum checks, and fuel-tank, hose, pickup-body, and air-filter service.
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Starter and throttle controls: Rewind-spring replacement and tensioning, ElastoStart rope and grip replacement, throttle-cable routing, stop switches, and trigger interlocks.
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Shaft and cutting drives: Flexible-shaft replacement, loop- and bike-handle configurations, FS 55/FC 55 gear removal, and HS 45 brake-band and cutting-blade work.
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Blower and vacuum attachments: Fanwheel inspection and removal, SH shredder-blade removal, intake-screen service, and blower-tube, suction-tube, and manifold procedures.
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Parts identification: Exploded views and numbered parts tables for the 4140, 4121, and 4170 models, with carburetor variants and component-specific serial breaks.
The service section was written for STIHL servicing dealers and assumes access to the specified test equipment and special tools.
Engine, Clutch and Starter Repair
The engine chapter covers removal and installation of the power unit and related components. Clutch coverage includes step-by-step procedures for drum and carrier removal, wear inspection, and spring replacement.
Rewind-starter instructions cover the spring, rope, and ElastoStart grip; the manual specifically warns that overtensioning the rewind spring can break it.
Fuel System and Carburetor Variants
If a rough-running engine points to fuel delivery issues, the text outlines leak testing protocols for the diaphragm carburetor. It links pressure loss to inlet-needle sealing or a damaged metering diaphragm.
Tank-vent testing and pickup-body checks help distinguish restricted fuel delivery from a carburetor fault.
The adjustment procedure covers the LD-only carburetor design. The FS 55 parts list separately identifies six C1Q versions, including C1Q-S44A and C1Q-S97, with different adjustment hardware. The FS 65 list includes WT-38B; the 4170 list distinguishes WYL-131/WYL-135 from earlier WYL-62A/WYL-63A units.
General troubleshooting charts and detailed carburetor repair are referenced to separate handbooks rather than supplied here. Observe the manual’s precautions for flammable fuel when servicing the tank or carburetor.
Control Layouts and Cutting Attachments
Separate illustrations show throttle-cable and short-circuit-wire routing for the different control-handle arrangements. FS 55 and FC 55 gear sections cover removal and refitting; internal gear repair is referred to the separate Standard Repairs, Troubleshooting handbook.
HS 45 coverage includes its straight-toothed spur drive, starting-lock checks, brake band, gear housing, and cutting blades. The blade instructions distinguish the insert used on the HS 45/450 assembly.
Exploded Views and Model-Specific Parts
More than 100 technical illustrations include service drawings and exploded component views. FS 55 examples include Crankcase, Cylinder, Ignition system, Clutch, and Gear head, Deflector.
Its parts list distinguishes standard and catalytic mufflers, conventional and ErgoStart starters, and USA/CDN/AUS engine housings. The 4170 Valve timing gear illustration identifies valves, pushrods, rocker arms, and the camshaft.
Serial notes distinguish crankshaft, flywheel, seal, crankcase, and carburetor/intake revisions.
Torque Tables, Tools and Service Aids
The component manual provides exact Plastoform and spline screw torque specifications. Its reassembly notes explain how forming a new thread can weaken an existing screw joint in a polymer housing.
A dedicated service aid table distinguishes Dirko sealant for the engine pan and muffler deflector from Dirko HT red for muffler screws. Listed tools include carburetor/crankcase tester 1106 850 2905, piston locking strip 4221 893 5900, and clutch wrench 4130 890 3600.
Examples of Screw-Speed Limits and Brake-Band Wear Data
For polymer components, the tightening-torque section lists maximum power-screwdriver speeds of 600 rpm for Plastoform screws and 500 rpm for DG screws. These limits accompany fastener-specific torque values and notes on screw reuse.
The HS 45 brake-band section pairs wear assessment with a 0.6 mm minimum remaining wall thickness. Its inspection notes address localized thinning as well as visible wear on the friction surfaces.
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