1998–2004 STIHL TS 400 Cut-Off Machine Service & Repair Manual with Parts List (P/N 0455 338 0123)

Covers the STIHL TS 400 (4223) cut-off machine, pairing the April 1998 service manual, P/N 0455 338 0123, with the July 2004 illustrated spare parts list. Regional parts listings include USA, Canada, Japan, and Australia configurations.

Text search and navigation: The service manual has no searchable text layer; the spare parts list supports text search. Two PDF bookmarks open the individual documents, without chapter-level navigation. The parts-list bookmark is mislabeled “TS400 - 4203.”

• Engine repair: Cylinder and piston service, crankshaft removal and installation, positive and negative crankcase leakage testing, rotary shaft seal replacement, and decompression valve service.

• Cutting-wheel drive: Bearing-with-guard repair, axial and radial runout checks, V-belt replacement and tensioning, V-belt pulley/clutch drum service, and centrifugal clutch removal.

• Ignition system: Ignition module and flywheel removal, spark plug terminal and ignition lead replacement, stop switch and ground lead routing, and air-gap specifications.

• Fuel system: Diaphragm carburetor leakage testing and adjustment, air filter maintenance, tank vent service, and replacement of fuel hoses, the pick-up body, impulse hose, and manifold.

• Starter and controls: Rewind spring replacement and tensioning, starter wheel service, AV handle system repair, and throttle trigger, interlock, and handle-mount work.

• Parts and workshop data: Exploded assembly views, regional configurations, component-specific serial breaks, tightening torques, runout test tables, and special tool charts with part numbers.

Suited to small-engine repair technicians familiar with two-stroke engine work and equipped for pressure/vacuum testing and crankshaft service.

Engine Repair and Leakage Diagnosis

Engine-core coverage includes cylinder removal, piston and piston-ring installation, crankcase separation, and crankshaft bearing replacement. The crankshaft, connecting rod, and needle bearing form one replacement assembly.

The pressure and vacuum tests help trace air leaks associated with poor idling and hesitation. Illustrated procedures cover pulling rotary shaft seals without splitting the engine case, with a warning that careless extraction can damage the crankshaft stub.

Cutting-Wheel Drive and Runout Checks

The axial runout test sequence connects inspection results with damaged thrust washers, spindle damage, and bearing play. Bearing, flange, and pulley illustrations support cutting-wheel drive repairs, alongside the V-belt clamping mechanism and clutch installation details.

Ignition and Fuel-System Service

The ignition chapter explains fixed ignition timing and limits routine workshop module checks to spark testing. Connection and routing illustrations cover the stop switch lead and ground lead; the electrical coverage uses assembly illustrations and does not include circuit schematics.

The carburetor test discussion connects pressure loss with inlet-needle sealing faults or metering-diaphragm damage. The adjustment section explains the electronic speed limiter and warns that an excessively lean setting can damage the engine without increasing its governed speed.

Parts Variants and Accessory Drawings

The parts list distinguishes HS-274E, earlier HS-274C/HS-274D, HS-279D, and Japan-market HS-301B carburetors. It also identifies earlier starter, tank-vent, crankcase, and ignition arrangements by the serial breaks listed above.

Regional entries separate the Japanese tank housing and 300 mm/350 mm support-with-guard assemblies. Exploded views cover the crankcase, rewind starter, carburetors, and ignition system. Separate drawings identify the water attachment, Cutquik cart and mounting kits, plus water and pressurized water tanks.

Special Tools and Repair Scope

The tool charts identify the carburetor/crankcase tester 1106 850 2905, vacuum pump 0000 850 3501, and crankshaft assembly tool ZS 5910 007 2220. Reference data includes component-specific torque specifications, leakage-test limits, ignition settings, fuel-mix specifications, and cutting-wheel dimensions.

Internal carburetor repair is referred to the separate Carburetor manual. General troubleshooting, clutch disassembly, and certain starter procedures refer to Troubleshooting, standard repairs; those publications are not included.

Consult a qualified technician before major mechanical work. Ignition service involves high voltage, and the cutting wheel presents a rotating-part hazard.

Combined Service Manual and Parts-List PDF

One printable 106-page PDF contains the 54-page English service manual (52 numbered pages plus front and back covers) and the 52-page spare parts list with German, English, and French descriptions. The parts-list contents page and multilingual symbol key are already included in those 52 pages.