Stihl FS 120, FS 200, FS 300, FS 350, FS 400 and FS 450 series of garden tools repair guide will help with the Starter Rope problems and Rewind mechanism. The FS series of the engine are often found in strimmers, brush cutters, edgers, and other tools. A Service Manual detailing the Starter Rope Rewind procedures including full diagrams, as well as more complete repair information, is available to download. Also, a Stihl FS120, FS200, FS300, FS350, FS400, and FS450 Parts List, Operator Manual, and carburetor manual are also available to view or download as a PDF which can be read on any device or printed.

6.	REWIND STARTER	6.2	Rewind Spring
6.1	General	6.2.1	Replacing

If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not completely, it can be assumed that the starter mechanism is in order but plugged with dirt. At very low outside temperatures the lubricant coating oil on the rewind spring may thicken and cause the spring windings to stick together. This has a detrimental effect on the function of the starter mechanism. In such a case it is sufficient to apply a few drops of paraffin (kerosene) to the rewind spring.

Then carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored.

If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed and disassembled. Take special care when removing the spring.

Wash all parts in paraffin or white spirit.

Lubricate the rewind spring and starter post with STIHL special lubricant, see 13.2, before installing.

Troubleshooting chart – see “Standard Repairs, Trouble- shooting” handbook.

Take out the screws.
Remove fan housing with rewind starter.
Remove the rope rotor – see “Standard Repairs, Troubleshooting” handbook.
Take out the screw and remove any remaining pieces of spring from the fan housing.

Note: The replacement spring comes ready for installation and is secured with a washer.

It should be lubricated with a few drops of STIHL special lubricant before installation – see 13.2.
The washer slips off the rewind spring as it is pushed into the fan housing. Engage the outer spring loop in the recess in the fan housing at the same time.

Caution: The rewind spring may pop out and uncoil during installation.

If the rewind spring has popped out, refit it as follows:

6.2.2 Tensioning

- Engage outer spring loop in the recess and refit rewind spring in fan housing in the counterclockwise direction, starting outside and working inwards.

- Check the position of the inner spring loop. It should be

2 mm (0.08″) away from the hub.

Fit screw and tighten it down to

1.5 Nm (1.1 lbf.ft).

Install the rope rotor – see full manual “Standard Repairs, Troubleshooting” handbook.
Tension the rewind spring – see 6.2.2.
Make a loop in the starter rope.
Grip the rope close to the rotor and use it to turn the rope rotor six full turns counterclockwise.
Hold the rope rotor steady.
Pull out the rope with the starter grip and straighten it out.
Hold the starter grip firmly to keep the rope tensioned.
Let go of the rope rotor and slowly release the starter rope so that it can rewind properly.

Note: The rewind spring is correctly tensioned when the starter grip sits firmly in the rope guide bush without drooping to one side. If this is not the case, tension the spring by one additional turn.

When the starter rope is fully extended, it must still be possible to rotate the rope rotor at least another half turn before maximum spring tension is reached. If this is not the case, pull the rope out, hold the rope rotor steady and take off one turn of the rope.

Do not over tension the rewind spring as this will cause it to break.

Fit fan housing, insert screws and tighten down to 6.0 Nm (4.4 lbf.ft).

6.3 Starter Rope/Starter Grip (ElastoStart)

Remove fan housing with rewind starter – see 6.2.

Starter Rope

Remove rope rotor – see “Standard Repairs, Troubleshooting” handbook.
Remove the starter rope from the rotor.
Pry cap out of starter grip.
Pull the rope out of starter grip.
On FR 350/450, slip tube

(75 mm/2.95″) over the starter rope.

Thread end of new starter rope through the underside of the starter grip.
Secure end of the rope with a simple overhand knot.
Pull the rope back to locate the knot in the starter grip.
Push cap into starter grip.
Secure starter rope to rope rotor.
Install the rope rotor.

Starter grip

The starter grip is supplied with starter rope.

Remove the rope rotor – see “Standard Repairs, Troubleshooting” handbook.
Pull the knot out of the recess in the rope rotor.
Undo the knot and pull the rope out of the rotor and fan housing.
On FR 350/450, slip tube