Small Engines (Lawn Mowers, etc.): Locking lever on Stihl backpack blower, stihl dealer, flat washers

Question
QUESTION: Hi John,

I have a Stihl BR400 backpack blower, which I bought in 1994.  It still runs great, but I'm trying to replace a broken part, and need some help.

Next to the trigger, which controls the throttle, is a plastic locking lever (part number 4).  I have the new part and need to install it.  To take the old lever out, I opened the handle molding and removed the locking washer (the locking washer fits on a pin and keeps the locking lever in place).  After doing that, I removed 3 flat washers, which were sandwiched around a couple of spring washers.

OK, now I have the new locking lever in place, and the washers on the pin, and I need to put the locking washer back on again to keep everything together.  I need to push down on the washers in order to get the locking washer back on, but there is little room to work with, and the locking washer is also difficult to put on.  Is there some trick to doing this?  I'm thinking maybe a special tool is needed.  If so, I will bring the whole thing in to the Stihl dealer, but I just need to know if it's possible to do it myself.

If you are not familiar with this tool, the parts diagram is here:

http://www.smaf-touseau.fr/client/do...0sr400_299.pdf

Look on pages 32-33.  Part 7 is the locking washer that I am trying to put back on.  Thanks!

Bill


ANSWER: Hello Bill:

>>We have a Special Tool that the Company Purchased from Stihl to Install the Throttle Lock Levers.
>>Like you we Tried Several Ways of Installing the Locking Washer and Found it Difficult to Impossible to Assemble without the Special Tool from Stihl.
>>According to my Information, this Tool is NOT Avaliable to Anyone Except Authorized Stihl Service Centers.
>>If you Hit a Snag or this Does Not Correct the Problem,  I Hope to be Here if You Require More Assistance. Hope this Helps. Let me Know What Happens, Please. May the All Mighty Bless You and Yours. Be Safe and Happy. Thanks.

Good Luck

Respectfully

John

PS: I am Allowed to Answer 5 Questions a Day. If you See I am Maxxed Out, then Try Submitting your Question at or Just After 8pm EST (US). My New Day Starts then. Comments and Ratings are Greatly Appreciated. Thanks.

Respectfully

John

---------- FOLLOW-UP ----------

QUESTION: Hi John,

I was able to get the clip onto the throttle lock lever using my own "special tool".  I took a piece of copper tubing bout 2 inches long, and cut a notch in it.  I put it over the pin, with the notch exposing the area where the clip goes.  Then with a helper, I compressed everything with a C-clamp, and slipped the clip on.  It's working fine now.  Thanks for the help.

Bill

Answer
Hello Again Bill:

>>Thanks for the Update.
>>I will Make an Instruction File that has this Information in it for Changing this Locking Lever so Others can Attempt to make the Repair themselves.
>>Have a Happy Holiday Season.
>>Till Next Time. May All Your Mechanical Problems be SMALL ONES and as Always, May the All Mighty Bless You and Yours. Be Safe and Happy.


Best Wishes and Good Luck


Respectfully


jbridger (John)