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MS 661
Stihl MS 661 User Manual
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ST
I
H)
STIHL MS 661, 661 C-M
2013-07
2
Table of Contents
Default Chapter
2
Table of Contents
2
Testing with STIHL MDG
2
1 Introduction and Safety Precautions
4
2 Specifications
6
Engine
6
Fuel System
6
Ignition System
6
Chain Lubrication
6
Tightening Torquese
7
3 Troubleshooting
9
Clutch
9
Chain Drive, Chain Brake, Chain
10
Chain Lubrication
11
Rewind Starter
12
Ignition System
13
Carburetor
14
Engine
18
4 Clutch
19
Clutch Drum
19
5 Chain Brake
20
Checking Operation
20
Brake Band
20
Brake Lever
21
Cam Lever
22
Pins
22
Chain Tensioner
23
Bar Mounting Studs
24
Collar Nuts for
24
Sprocket Cover
24
6 Engine
25
Muffler
25
Leakage Test
26
Preparations
26
Vacuum Test
27
Pressure Test
27
Oil Seals
27
Ignition Side
27
Clutch Side
28
Shroud
29
Cylinder
29
Crankshaft
32
Bearings / Crankcase
36
Piston
37
Piston Rings
39
Decompression Valve
39
7 Ignition System
40
Ignition Timing on All Models
40
Ignition Module / Control Unit
40
Removing and
40
Installing
40
Testing the
40
Ignition Module
42
Testing Ignition Module
42
With MDG 1 Engine Analyzer
42
Spark Test
43
Spark Plug Boot
44
Ignition Lead
44
Flywheel
45
Testing Wiring
46
Testing Wiring Harness
46
Without M-Tronic
46
Testing Wiring Harness
47
With M-Tronic
47
Testing Ground Wire
47
Short Circuit Wire
47
Without M-Tronic
47
Removing and Installing
47
Short Circuit Wire / with M-Tronic Removing and Installing
49
Short Circuit Wire / with M-Tronic and
51
Heating
52
Installing
53
Contact Spring
55
Ignition System
57
8 M-Tronic
61
Calibrating the Control Unit
61
Testing
62
Preparations
62
Connecting Test Cables
63
Testing Screw and
63
Checking the Solenoid Valve
64
Checking Detection of Start Conditions
65
Testing the Wiring
66
Harness
66
Wiring Harness
67
Switch Unit
67
Solenoid Valve
69
Troubleshooting Chart
70
Circuit Diagram
70
Tronic Troubleshooting Chart
70
Engine Does Not Start
71
In Position
72
Engine Speed Drops under Load - Engine down on Power
73
Ignition - no Spark
74
Engine Stops Suddenly
75
Cut-Off Engine Speed Is Not Reached
76
9 Rewind Starter
77
General
77
Rewind Starter Removing and Installing
77
Pawls
77
Rope Rotor
78
Starter Rope / Grip
78
Tensioning the Rewind Spring
79
Replacing the Rewind Spring
79
Segment
80
10 AV Elements
81
Stop Buffer at
81
Clutch Side
81
Antivibration Element
81
Tank Housing
81
Fuel Tank
82
AV Element on Handlebar
84
Stop Buffer at Ignition Side
84
Handlebar
84
Handlebar / Wrap Around Handlebar with Heating
86
11 Control Levers
89
Switch Shaft
89
Removing and Installing
89
Throttle Trigger
91
Lockout Lever
91
Throttle Rod
92
Choke Rod Models Without M-Tronic
94
12 Chain Lubrication
95
Pickup Body
95
Oil Pump
95
12.3.1 Adjusting Uprated
97
Valve
97
13 Fuel System
98
Air Filter
98
Baffle
98
Filter Base
98
Carburetor
99
13.4.1 Leakage Test
102
Servicing the Carburetor
102
Disassembling and Cleaning the
102
Carburetor
103
Assembling the Carburetor
103
13.5.3 Metering Diaphragm
103
Inlet Needle
104
13.5.5 Pump Diaphragm
105
13.5.6 Lever on Throttle Shaft
106
Lever on
107
Choke Shaft
107
13.5.7 Lever on Choke Shaft
107
Switch Unit
107
Models with M-Tronic
107
Adjusting the Carburetor, Models with M-Tronic
108
Adjusting the Carburetor, Models Without M-Tronic
108
13.7.1 Adjusting Screws
108
Adjusting the Carburetor
110
13.8.1 Basic Setting
110
13.8.2 Setting
110
13.8.3 Standard Setting
111
Manifold
112
13.9.1 Impulse Hose
113
Tank Vent
114
13.10.1 Testing
114
Removing and 16. Installing
114
Fuel Intake
115
13.11.1 Pickup Body
115
Fuel Suction Hose in Tank Housing
115
Fuel Suction Hose on Carburetor
116
13.11.4 Tank Housing
116
14 Heating System
119
Carburetor Heating
119
Testing the Complete System
119
Testing the Heating Element
119
14.1.3 Thermostatic Switch
120
Carburetor Heating System Troubleshooting Chart
121
Handle and Carburetor Heating System
122
14.3.1 Troubleshooting
122
Heater Switch
123
Heating Element in Rear Handle
124
Heating Element in Handlebar
125
Generator
125
14.7.1 Handle Heating and Generator Troubleshooting Chart
127
14.7.2 Test Connections and Test Values
129
Heating Element Connecting Wires
131
Connecting Wire between Rear Handle and Handlebar
131
Connecting Wire between Rear Handle and Generator
132
15 Special Servicing Tools
135
Servicing Aids
137
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Stihl MS 661 Specifications
General
Displacement
91.1 cc
Chain Pitch
3/8"
Engine Power
5.4 kW
Fuel Capacity
825 ml
Chain Oil Capacity
360 ml
Guide Bar Lengths
90 cm
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