Stihl BR 800 - Removing the Flywheel; Installing the Flywheel

BR 800 37
N Fit spark plug boot (9) on the input terminal (12) of the
ZAT 4 ignition system tester 5910 850 4503.
N Connect ZAT 4 output terminal (14) to spark plug
(10).
N Crank the engine quickly with the starter and check
whether a spark is visible in the tester’s window (13).
13.2.2 Testing Ignition Spark with ZAT 3 Ignition Tester
N Preparations, @ 3.1.
N Remove the cover, @ 7.4.
N Pull boot (9) off the spark plug.
N Fit spark plug boot (9) on the terminal (16) of the
ZAT 3 ignition system tester 5910 850 4520.
N Attach terminal (15) of ZAT 3 to the cylinder.
WARNING
High voltages can occur in parts of the ZAT 3 during the
test. This can result in serious or fatal injuries.
Hold the ZAT 3 only by the handle (18) during the test.
N Turn the tester’s adjusting knob (19) to obtain a spark
gap of about 2 mm in the window (17).
N Crank the engine quickly with the starter and check
whether a spark is visible in the tester’s window (17).
13.2.3 Testing Ignition System with MDG 1 Analyzer
N Preparations, @ 3.1.
N Remove the cover, @ 7.4.
N Pull boot (9) off the spark plug.
N Check spark plug (10) and replace if necessary.
N Connect MDG 1 analyzer 5910 840 0210 and test
cables.
N Start diagnosis and follow the steps in the diagnostics
software.
13.3 Removing the Flywheel
N Preparations, @ 3.1.
N Remove the rewind starter, @ 6.2.
N Remove the filter cover, @ 7.2.
N Remove the cover, @ 7.4.
N Pull boot (9) off the spark plug.
N Remove the spark plug (10).
N Fit the locking screw 4282 890 2700 in the spark plug
hole.
N Rotate the flywheel (1) counterclockwise as far as
stop.
The piston is now blocked.
N Unscrew the nut (2).
N Screw puller 5910 893 0801 onto the crankshaft and
then back it off one full turn.
N Tap the puller 5910 893 0801 with the soft-faced
hammer until the flywheel (1) is released from the
crankshaft.
N Unscrew the puller 5910 893 0801.
N Remove the flywheel (1).
N If the flywheel (1) or the magnet poles are damaged
or show signs of turning blue: Replace the flywheel
(1).
13.4 Installing the Flywheel
N Fit the locking screw 4282 890 2700 in the spark plug
hole.
The bore in the flywheel (1) and the crankshaft taper must
be degreased and free from oil.
N Fit the flywheel (1) on the crankshaft so that its spline
(arrow) engages the slot (arrow) in the crankshaft.
N Rotate the flywheel (1) clockwise by hand as far as
stop.
The piston is now blocked.
0000-GXX-6648-A0
12
13
14
16 17 18 19
15
20
0000-GXX-6649-A0
1
0000-GXX-6650-A0