Stihl TS 500i Service Manual
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Stihl TS 500i Service Manual

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STIH)
STIHL TS 500i
2012-02

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  • Page 1 STIH) STIHL TS 500i 2012-02...

  • Page 2: Table Of Contents

    Control unit 10.2 Throttle trigger / Spark plug boot trigger interlock 7.4.1 Ignition lead Flywheel 7.5.1 Generator Short circuit wire / switch 7.6.1 Testing 7.6.2 Removal and installation Control panel © ANDREAS STIHL AG & Co. KG, 2012 TS 500i...
  • Page 3 11.6.3 Tank vent Removal and installation 11.7 Injection pump 11.7.1 Manual fuel pump 11.7.2 Injection pump 11.8 Fuel intake 11.8.1 Pickup body 11.8.2 Fuel hoses 11.8.3 Fuel tank filler cap 11.9 Tank housing Special tools Service accessories TS 500i...

  • Page 4: Introduction And Safety Precautions

    Servicing and repairs are made "Special Tools Manual". The manual considerably easier if the machine lists all tools supplied by STIHL. is mounted on assembly stand (3) 5910 890 3100. For this purpose, Symbols are included in the text and...

  • Page 5: Safety Precautions

    Exercise extreme caution while carrying out maintenance and repair work on the electronically controlled injection system – STIHL Injection. The high voltages which occur can cause serious or fatal accidents. Keep everything clean when working on the electronically controlled injection system STIHL Injection.
  • Page 6 – fuel hoses can be overstretched when being detached. Mount new fuel hoses dry or using STIHL press fluid – apply press fluid to the ends of the hose and the connectors, b 13. Other press fluids are not permitted and may lead to fuel hose damage.

  • Page 7: Specifications

    Electronic water control The electronic water control makes it possible to feed the optimum amount of water to the abrasive wheel. No water is fed to the abrasive wheel during idling. Engine TS 500i Displacement: 72.2 cm Cylinder bore: 52 mm...

  • Page 8: Tightening Torquese

    Filter cover / tank housing Screw M4x9.6 Spark arresting screen / muffler Screw M5x20 Generator / crankcase Screw P5x16 Handle molding / shroud Screw D5x20 Rubber buffers / support Screw P5x16 Holder / switch / shroud Screw P6x19 Shroud / tank housing TS 500i...
  • Page 9 Muffler / cylinder 1st stage Screw M5x20 Muffler / cylinder 2nd stage 10.0 Screw M5x20 Muffler / crankcase 10.0 Screw G 3/8" Hose connection / solenoid valve Screw M5x21 Guard / cast arm M8x1 Flywheel / crankshaft 33.0 TS 500i...
  • Page 10 Pan head screw / banjo screw 1) Loctite 243 medium strength 2) Easy-slide coating with locking serration 3) Microencapsulated with locking serration 4) Microencapsulated 5) Connection between crankshaft and flywheel must be degreased and oil-free 6) Easy-slide coating TS 500i...

  • Page 11: Troubleshooting

    Loud noises Clutch springs stretched or fatigued Replace all clutch springs Grooved ball bearing on poly V-belt Replace ball bearing pulley / clutch drum damaged Clutch shoe retainer broken Replace holder Clutch shoes and carrier worn Replace clutch TS 500i...

  • Page 12: Cast Arm With Guard

    Check easy movement of throttle cable and replace if necessary Throttle trigger is stiff Check throttle trigger, repair if necessary Throttle shutter does not return Check the throttle shutter stops and automatically replace throttle shutter housing if necessary TS 500i...

  • Page 13: Solenoid Valve

    Problem Cause Remedy No water supply Solenoid valve does not react even Run test with STIHL MDG 1, though the control panel was replace solenoid valve if necessary actuated Banjo screws (water nozzles) are Clean the banjo screws, replace if...
  • Page 14 Control panel damaged Check control panel with STIHL MDG 1, replace if necessary Solenoid valve is damaged or jams Check solenoid valve with STIHL MDG 1, replace if necessary Water hose kinked or damaged – Run water hose so that it is free of...

  • Page 15: Starter

    Lubricating oil on rewind spring Coat rewind spring with a little becomes viscous at very low standard solvent-based degreasant outside temperatures (spring (containing no chlorinated or windings stick together) halogenated hydrocarbons), then pull rope carefully several times until normal action is restored TS 500i...

  • Page 16: Troubleshooting Chart

    Troubleshooting chart STIHL Injection – Carry out diagnosis with STIHL MDG 1 Diagnosis Repair fault shown by STIHL MDG 1 Complaint remedied? – Check starting Trouble- behavior shooting completed Starting Too much starting effort behavior OK? Check decompression Decompression valve...
  • Page 17 Check clutch, replace if tension springs for the necessary, b 5.2 clutch shoes are broken Check throttle cable, repair Throttle cable is jammed if necessary, b 11.2.1 Check throttle trigger, Throttle trigger is stiff repair if necessary, b 10.2 TS 500i...
  • Page 18 6.2, b 6.3 defective Check engine does not Crankcase leaking, leak, b 6.2 faulty Check the throttle shutter Throttle shutter stops stops, replace throttle worn shutter housing if necessary, b 11.2 Injection valve Replace injection valve, mechanically b 11.3 worn TS 500i...
  • Page 19 Use a fuel mixture with the contains too much oil correct mixing ratio Flywheel is cracked, Check flywheel, replace if damaged necessary, b 7.5 Flywheel out of Check woodruff key and adjustment, woodruff key flywheel, replace if has sheared off necessary, b 7.5 TS 500i...
  • Page 20 11.6 Impulse hose damaged Check impulse hose, replace if necessary, kinked b 11.5 Injection pump defective Replace injection pump, (control needle, seal, b 11.7 etc.) Injection valve does not Replace injection valve, close b 11.3 TS 500i...
  • Page 21 Check ignition lead, replace insulation in ignition if necessary, b 7.4 lead Visual inspection of Cable breakage on an electrical component electrical leads Fuel/oil mixture contains Use a fuel mixture with the too much oil correct mixing ratio TS 500i...
  • Page 22 11.2 Muffler, spark arresting Check muffler, replace if screen carbonized necessary, b 6.1 Piston rings worn, Replace piston rings, broken b 6.9 Crankcase leaking, Check engine does not faulty leak, b 6.2 TS 500i...
  • Page 23 Check throttle trigger, Throttle trigger is stiff repair if necessary, b 10.2 Check the throttle shutter Throttle shutter does stops, replace throttle not return shutter housing if automatically necessary, b 11.2 Injection valve Replace injection valve, mechanically b 11.3 worn TS 500i...
  • Page 24 6.3 Check engine does not Crankcase leaking, leak, b 6.2 faulty Check the throttle shutter Throttle shutter stops stops, replace throttle worn shutter housing if necessary, b 11.2 Injection valve Replace injection valve, mechanically b 11.3 worn TS 500i...
  • Page 25 – Check "Switch off engine" Engine cannot be Behavior switched off Check on / off switch with On / off switch STIHL MDG 1, defective clean if necessary or replace – Troubleshooting completed TS 500i...

  • Page 26: Cast Arm With Guard

    (2). – Check banjo screws, O-rings and seal, replace if necessary – Coat O-ring with STIHL press fluid, b 13 : Insert banjo screw (3) – Do not damage O-ring...

  • Page 27: Solenoid Valve

    Installation : Pull insulating tubes with plug connections (1, 2) out of the guides – Starting from the solenoid valve, route the water hose (1) without any tight bends or kinks. – Push hose clip onto water hose TS 500i...
  • Page 28 (arrow) (arrow) – the bushing (3) must be connections in the middle of the completely seated in the mount guides : Check solenoid valve (1), unscrew hose connection (2) if necessary, replace sealing ring (3) and O-ring (4) TS 500i...

  • Page 29: Cast Arm With Guard

    : Fit cover (1) so that the tabs : Take out the collar nuts (arrows). engage in the mounts (arrows) – do not pinch the leads when : Remove starter (1) fitting the cover – Remove ribbed poly V-belt, b 4.5 TS 500i...
  • Page 30 : Remove the axial clamping ring (arrow). : Carefully take out the screws (arrows) – compression springs : Remove the washer (1) and are tensioned. rubber ring (2) : Remove the other thrust washer (1). The flange drops down on the other side. TS 500i...
  • Page 31 – Slide the cast arm into the rubber : Press the rubber ring (1) into the bearing. hole in the guard until it lies flush : Insert the screws with sleeves and springs in the holes (arrows) – Insert and tighten the screws TS 500i...
  • Page 32 – Block the belt pulley : Slide the "cast arm with : Fit the washer, screw on the nut guard" (1) onto the studs (arrow) and tighten it down (arrows) – Left-hand thread The tensioner must point to "0". TS 500i...

  • Page 33: Ball Bearing

    (4) onto the : Press the water hose (1) into the : Drive the ball bearing out of the peg (arrow) guides (arrows) cast arm with press arbor (1) 4224 893 7200 Always use new grooved ball bearings. TS 500i...

  • Page 34: Testing Radial And Axial Truth Of Running

    – Fit the guard on the cast arm, b 4.2 : Position test wheel (1) – Fit the "cast arm with guard", 5910 851 6100 b 4.2 : Fit the thrust washer so that the lugs (1) engage the grooves (arrows) in the shaft TS 500i...

  • Page 35: Test Sequence Data

    Axial truth of running: Axial truth of running is Axial runout none tested with a < 0.15 mm STIHL test wheel or diamond abrasive wheel > 0.15 mm (on 130 mm diameter) Damage or unevenness in Dirt, incorrectly fitted thrust...

  • Page 36: Ribbed Poly V-Belt

    (2) and turn the pulley (2) to draw the belt onto the pulley. : Take the ribbed poly V-belt (1) off : Pull the hose (1) out of the guides the front belt pulley (arrow) (arrows). TS 500i...

  • Page 37: Tensioner

    : Turn the hexagon (1) 1/2 turn clockwise to relax the tensioner : Remove screws (2) : Turn the hexagon (1) on the : Hook the tensioner spring into the tensioner clockwise hole (arrow) of the lever (1) – Fit the cover TS 500i...
  • Page 38 The tensioner must be set to the pre-tensioned position before installing the "cast arm with guard". Turn the hexagon of the tensioner as far as possible counterclockwise to pre-tension the tensioner. – Reassemble remaining parts in reverse order TS 500i...

  • Page 39: Starter Cup / Clutch

    (arrow) – Position as shown. : Remove the spark plug boot (1) : Unscrew nut (1) and pull off starter cup (2) – Examine the starter cup, replace : Unscrew the spark plug (1) if necessary TS 500i...

  • Page 40: Clutch

    (1) to the clutch shoes : Use the hook (2) 5910 890 2800 to attach the other end of the : Slip the retainers (1) onto the spring and press it firmly into the clutch shoes clutch shoe TS 500i...

  • Page 41: Belt Pulley / Clutch Drum

    : Fit the clutch (1) on the : Remove the clutch drum (1) crankshaft stub so that the raised hexagon (arrow) can be seen – Block the piston, b 5.1 : Drive out the ball bearing with the drift pin (1) 4119 893 7200 TS 500i...

  • Page 42: Studs For Securing The

    5910 890 3000 to screw in and tighten the studs : Slide the clutch drum (1) into place – Reassemble remaining parts in reverse order : Slide on the ring (2) – Reassemble remaining parts in reverse order TS 500i...

  • Page 43: Engine

    : Fit cooling plate (1) and muffler and cooling plate (2) pump 0000 850 1300. gasket (2) to muffler (3) and insert screws (4) into cooling plate – Muffler gasket and cooling plate are held in place on the muffler TS 500i...

  • Page 44: Preparations

    4221 025 2200 and screw it tight – Coat O-ring on the plug of the pressure testing tool 5910 890 4100 with STIHL press fluid, b 13 : Press the plug (1) of the pressure testing tool 5910 890 4100 into...

  • Page 45: Testing With Negative Pressure

    – Tighten muffler according to specifications, b 2.5 – Reassemble remaining parts in reverse order : Slide ring (1) to the left : Operate lever (2) until the pressure gauge (arrow) indicates a vacuum of 0.5 bar TS 500i...

  • Page 46: Oil Seals

    (2) no. 6) 0000 893 3711 1122 893 2405 – Clamp the puller arms The seating face must be flat and free from burrs. – Pull out the oil seal Avoid damage to the crankshaft stub. TS 500i...

  • Page 47: Shroud

    4238 893 2400 to install the oil seal (2) The seating face must be flat and free from burrs. : Unhook the throttle cable (1) – Reassemble remaining parts in from the throttle trigger (2), reverse order holding the throttle trigger (2) in place TS 500i...
  • Page 48 : Press the grommet (1) into the mount (arrow) until it is fully home : Check the piece of hose (2), remove and replace if necessary – Examine the throttle trigger and trigger interlock, replace if necessary, b 10.2 TS 500i...

  • Page 49: Engine

    (1) in the direction of the throttle shutter housing – Remove shroud, b 6.4 : Push down the manifold (2) from – Remove control unit, b 7.3 the tank housing support – Remove handlebar, b 9.5 – Remove tank housing, b 11.9 TS 500i...
  • Page 50 : Carefully pull off the cylinder (1) : Pull the bushing (1) and : Unscrew the screws (2) on the generator lead (2) from the bottom and remove long guides (arrows) screw (3) : Remove the clamp (1) TS 500i...
  • Page 51 (arrows) The clamping strap (1) must be fitted in such a way that the piston : Fit the cylinder gasket (1) rings do not protrude beyond the piston sides. : Remove the cylinder gasket (1) TS 500i...
  • Page 52 : Push the hose clip (3) onto the housing until it is in the groove on manifold so that the screw head the circumference is facing the clutch – Push the hose clip over the shoulder of the manifold TS 500i...

  • Page 53: Crankshaft

    "25 / 26" can be reworked as illustrated with the 5.5 mm hole or with the holes 7.5 mm. The drilled plate is shown from : Remove the gasket (1) above in the illustration. Dimensions are given in millimeters. TS 500i...
  • Page 54 : Turn the spindle (1) housing so that the edge number counterclockwise until the "29" (arrow) is at the bottom crankshaft has been forced out of the clutch-side half of the crankcase TS 500i...
  • Page 55 (arrow) always faces upwards 5910 007 2201. towards the cylinder. : Fit the screw sleeve (1) – Remove the assembly tool 5910 893 2420 as far as possible over the fully retracted spindle of the assembly tool (2) 5910 007 2201. TS 500i...
  • Page 56 : Align clutch side half of crankcase (1), press 2 screws M 5x72 (arrows) to act as a guide through the clutch-side half of the crankcase and screw slightly into the threads of the centering sleeves (arrows) – do not tighten TS 500i...
  • Page 57 (arrows) – Coat bushing on the rubber lip with STIHL press fluid, b 13 : Align bushing (1) so that the straight side is flush with the fin (arrow) : Press bushing (1) completely into...

  • Page 58: Ball Bearing / Crankcase

    Those parts which are not supplied with the new crankcase must be removed from the old crankcase halves, examined and replaced if necessary. When fitting a new crankcase, the machine's serial number must be stamped on the crankcase with 2.5 mm figure stamps. TS 500i...

  • Page 59: Piston

    The piston must be held steady – Their installation is the same on during this process to ensure that both sides. jolts are not transmitted to the connecting rod. TS 500i...
  • Page 60 (1) and slide it into the piston : Push the slotted diameter of the sleeve over the magnet (2) and snap ring The inner pin (1) must point towards the flat face of the tool's shank. TS 500i...

  • Page 61: Piston Rings

    6.9 (arrows) face upwards – Install the cylinder, b 6.6 – Reassemble remaining parts in reverse order The snap ring (1) must be fitted so that the gap in the ring (arrow) points upwards. TS 500i...

  • Page 62: Decompression Valve

    – Fit the decompression valve by hand and screw it in – Screw the decompression valve tight – Reassemble remaining parts in reverse order TS 500i...

  • Page 63: Stihl Injection

    (2) and ensures the necessary fuel delivery (impulse). In addition, the manual fuel pump (3) STIHL Injection basically consists of is integrated in the injection a control unit (1), throttle shuttle pump (1). housing (2), injection valve (3),...

  • Page 64: Testing

    – Screw remains in cover cable lug. : Press lock (arrow) downwards by hand and push out plug (1) – Do not pull out the plug (1) by the wires, do not use tools TS 500i...
  • Page 65 : Press plug (1) of the "Injection STIHL MDG 1 must be installed system control unit diagnostic between the spark plug boot and cable" 5910 840 0403 into the the spark plug. socket (2) on the control unit until it snaps into place –...

  • Page 66: Control Unit

    STIHL A power adaptor is supplied with the Injection system are taken into STIHL MDG 1 to power it and it too account and displayed by the is connected with the STIHL program during the test run.
  • Page 67 – Check the control unit, replace if – Coat outside of grommet with necessary STIHL press fluid, : Press the grommet (1) with the thin lip completely into the opening (arrow) in the direction of the air filter – the lip must enclose...

  • Page 68: Spark Plug Boot

    – Pull the boot off the ignition lead – Coat the inside of the spark plug boot with STIHL press fluid, b 13 : Unplug spark plug boot (1) and : Push the ignition lead and torsion...

  • Page 69: Ignition Lead

    7.4.1 Ignition lead – Before twisting in the ignition lead, fill the coil tower with STIHL – Remove control unit, b 7.3 multi-purpose grease, b 13 : Push the spacer (1) 4238 894 1100 onto the screws...
  • Page 70 : Fit the flywheel (1) so that the necessary. woodruff key on the crankshaft stub engages in the groove of the flywheel Flywheel must not touch the generator. : Screw on and tighten the collar nut (2) – Reassemble remaining parts in reverse order TS 500i...

  • Page 71: Generator

    7.5.1 Generator – Check generator with STIHL MDG 1, b 7.1, b 7.2 – Refer also to troubleshooting chart, b 3.5 – Remove the flywheel, b 7.5 : Unscrew the screws (1) and : Push the generator (1) onto the...

  • Page 72: Short Circuit Wire / Switch

    Short circuit wire / switch 7.6.1 Testing – Test the short circuit wire / switch with STIHL MDG 1, b 7.1, b 7.2 : Push the insulating tube (1) onto : Guide the black lead behind the – Refer also to troubleshooting...
  • Page 73 1.1. : Pull the plug connections (1) : Connect the yellow leads (1) and and (2) out of the guides (arrows) green leads (2) completely – Disconnect the plug connections TS 500i...
  • Page 74 (arrow) (arrow) and must be placed underneath the holder (1). : Press the wiring harness (1) of the switch on the inside with the protective tube (2) into the guides (arrows) TS 500i...

  • Page 75: Control Panel

    Control panel – Check the control panel with STIHL MDG 1, b 7.1, b 7.2 – Refer also to troubleshooting chart, b 3.5 – Remove shroud, b 6.4 – Remove switch shaft, b 10.1 : Align the wiring harness (1) of the...
  • Page 76 – the yellow lead must be placed : Place the green and yellow underneath the green lead lead into the guides (arrows) – yellow lead underneath green lead : Guide the leads into the opening (arrow) and carefully fit the control panel (1) TS 500i...
  • Page 77 (arrow) : Press the green lead (1) into the guides (arrows) – the yellow lead must run underneath the green lead – Install the switch, b 7.6 – Reassemble remaining parts in reverse order TS 500i...

  • Page 78: Starter

    Before installing, lubricate the rewind spring and starter post with : Remove starter (1) STIHL special lubricant. If clogged with dirt or pitch, the – Reassemble parts in reverse entire starter mechanism, including order...

  • Page 79: Rope Rotor

    Rope rotor – Coat the hole in the rope rotor Relieve tension of rewind spring with STIHL special lubricant, : Pull the starter rope (1) out b 13 between the recess and rope The system will not be under...

  • Page 80: Starter Rope

    : Press the nipple (1) of the starter – Remove any remaining scraps of rope into the starter grip until it rope from the rope rotor and engages there starter grip. TS 500i...

  • Page 81: Tensioning The Rewind Spring

    : Make the special knot illustrated Hold the tensioned rope rotor firmly, in the end of the rope at the as the rewind spring will be starter grip damaged if it jumps back suddenly. TS 500i...

  • Page 82: Replacing The Rewind Spring

    – Before installation, coat the The replacement spring is supplied rewind spring and washer with a ready for installation and secured in few drops of STIHL special : Let the rope rotor go and slowly a spring housing. lubricant, b 13 rewind the starter rope (1) on the rope rotor.
  • Page 83 – Grease the pegs on the pawl, b 13 – Push spring housing as far as it will go into the mount of the – Tension the rewind spring, b 8.6 starter cover – Reassemble remaining parts in reverse order TS 500i...

  • Page 84: Antivibration Elements

    (arrow) the mount (arrow) with the serration of the bearing plug : Unscrew screw (1) and remove antivibration spring (2) : Fit the antivibration spring with handlebar support (arrow) on the handlebar and hold it in position TS 500i...

  • Page 85: Antivibration Spring In The Support

    : Pull the antivibration spring (1) out of the handlebar : Unscrew screw (1) and remove antivibration spring (2) – Examine the antivibration spring and replace it if necessary – Examine the antivibration spring and replace it if necessary TS 500i...

  • Page 86: Antivibration Spring On Throttle Shutter Housing

    : Screw in the screw (2) and it will go. tighten it : Push the bearing plug (1) into the mount (arrow) and hold it in position : Unscrew the screw (1) TS 500i...

  • Page 87: Handlebar

    (2) engages in the notch (arrow) : Unscrew the screw (1) on the bottom and remove clamp (2) : Fit the clamp (1) onto the handlebar so that the lug (2) engages in the hole (arrow). TS 500i...

  • Page 88: Rubber Buffers / Support

    Bearing plug (1) must be twisted into the antivibration spring as far as it will go. – Coat inside of hose with STIHL : Push the bearing plug (1) into the press fluid, b 13 mount (arrow) and hold it in...

  • Page 89: Support Foot

    : Remove antivibration spring (3), mount (arrow) b 9.2 – Examine the individual parts, replace if necessary : Unscrew screw (1) and raise air baffle (2) – Reassemble the parts in reverse order : Insert and tighten the screws (1) TS 500i...
  • Page 90 : Remove the support foot (1) from : Pry the stop buffer (1) out of the – Apply STIHL press fluid to the the retainers (arrows) and pull it holes of the air baffle (2) guide of the support foot, b 13...

  • Page 91: Wiring Harness Solenoid Valve (Water Connection)

    – Remove the air baffle, b 9.6.2 – Remove the solenoid valve, b 4.1.3 – Apply STIHL press fluid to the : Place the wiring harness (1) into guide of the support foot, b 13 the guides (arrows) so that the...

  • Page 92: Actuating Lever

    (arrows) The peg (arrow) must engage in the – Examine the individual parts, throttle trigger. replace if necessary – Set the switch shaft to position "STOP" or "0" : Remove the screw (arrow) : Remove handle molding (1) TS 500i...

  • Page 93: Trigger Interlock

    "F" if the trigger interlock and throttle trigger are pressed. : Hook the torsion spring (1) into the throttle trigger (2) – Note the installed position (arrow) : Unhook the throttle cable (1) from the throttle trigger (2) TS 500i...
  • Page 94 : Fit the pin (1) and drive it in until it is at the same distance on both sides : Press the trigger interlock (1) into the bearing points (arrows) until it clicks into place TS 500i...

  • Page 95: Fuel System

    – Remove the engine, b 6.5 The mating surfaces on the manifold, throttle shutter housing and cylinder must be in perfect condition and without any damage whatsoever. Parts with damaged mating surfaces. TS 500i...

  • Page 96: 11.2.1 Air Baffle / Throttle Cable

    (arrow) – only push the hose clip onto the shoulder once the tank housing is installed Apply STIHL press fluid to the inside of the manifold – Install the tank housing, b 11.9 – Install the handlebar, b 9.5...

  • Page 97: Injection Valve

    – Reassemble remaining parts in reverse order : Pull the bushing (1) and wiring harness (2) out of the guides (arrows) and set them aside TS 500i...
  • Page 98 (1) guides (arrows) : Check bushing (1) and remove if necessary – Coat bushing with STIHL press : Disconnect the fuel hoses (1) : Unscrew the screws (1) and fluid, b 13 from the connectors (arrows) and...
  • Page 99 (2) as far as possible completely. into the crankcase : Insert and tighten the screws (3) – Use STIHL press fluid to simplify assembly, b 13 : Push impulse hose (1), fuel return line (2) and fuel hose (3)

  • Page 100: Sensor

    (2) tighten it – Install the engine, b 6.5 – Reassemble remaining parts in reverse order : Push the wiring harness (1) and bushing (2) into the guides (arrows) – start with the bushing TS 500i...
  • Page 101 (2) out of the guides sensor out of the guides (arrows) (arrows) and set them aside – Coat the O-ring with STIHL press fluid, b 13 : Position the sensor (1) so that the support (2) engages in the hole...

  • Page 102: Impulse Hose

    "Injection pump", b 11.7.2 into the snap fittings (arrows) until they snap into place : Screw in the screw (2) and tighten it : Push the wiring harness (1) and bushing (2) of the sensor completely into the guides (arrows) TS 500i...

  • Page 103: Leak Testing

    – Coat O-ring on the plug with : Slide ring (1) to the right and regulations, b 1 STIHL press fluid, b 13 connect the pump (2) 0000 850 1300 to the hose – Close the filler cap –...

  • Page 104: 11.6.2 Checking The Tank Vent

    – Before testing with gauge pressure – Complete testing with negative pressure : Close the fuel suction hose (1) with the plug (2) and push the hose (3) of the pump (4) 0000 850 1300 onto the support of the fuel intake TS 500i...

  • Page 105: Tank Vent Removal And Installation

    Installation Installation : Pull the injection pump (1) from the guide (arrow) – Use STIHL press fluid to simplify assembly, b 13 : Insert the compression spring (1) : Examine the bushing (1), pry it into the mount (arrows)

  • Page 106: Injection Pump

    Installation : Fit flange (1) : Insert and tighten the screws (2) : Pull the fuel suction hose (1), – Use STIHL press fluid to simplify impulse hose (2) and fuel assembly, b 13 hose (3) from the connectors on...

  • Page 107: Fuel Intake

    – Reopen the tank and empty it – Dispose of fuel in accordance with regulations, b 1 – Use STIHL press fluid to simplify – Use STIHL press fluid to simplify assembly, b 13 assembly, b 13 : Push the impulse hose (1) onto...

  • Page 108: 11.8.3 Fuel Tank Filler Cap

    If the tank housing is installed again, check the bushing for the : Push down the manifold (2) from connecting element, replace if the tank housing support necessary. – Remove the flywheel, b 7.5 – Remove the generator, b 7.5.1 TS 500i...
  • Page 109 : Pull the hose (1) out of the – Use STIHL press fluid to simplify : Note the position (arrow) of the crankcase (arrow) assembly, b 13 sleeve (1) – Check the hose, replace if : Slide the hose (1) into the recess...
  • Page 110 – Push the hose clip over the shoulder of the manifold Fitting an existing hose Bearing plug (1) must be twisted – Use STIHL press fluid to simplify into the antivibration spring as far as : Align the hose clip (1) on the assembly, b 13 it will go.
  • Page 111 (2) so that the fin (arrow) is between the two tabs : Push the hose holder (1) of the fuel hoses and injection pump (2) into the guides (arrows) – Install the handlebar, b 9.5 TS 500i...

  • Page 112: Special Tools

    New special tools Designation Part No. marks Engine analyzer 5910 840 0200 Check STHIL Injection STIHL MDG 1 – Engine analyzer complete with case "Injection system diagnostic 5910 840 0401 Check STHIL Injection – Connect cable" machine to computer - Injection system generator 5910 840 0402 Included in the kit "Injection system...
  • Page 113 Screw connections (6 to 80 Nm) (with visual and acoustic signaling) Assembly tool 12 5910 890 2212 Fit hookless snap rings in piston - Sleeve 5910 893 1706 For assembly tool, 12 Screwdriver T 27 x 150 5910 890 2400 TS 500i...
  • Page 114 Bit DIN 3124, size 13 5910 893 5608 Unscrew flywheel nut Socket, DIN 3124-S19 x12.5L 5910 893 5613 Removing and installing the clutch Assembly hook 5910 893 8800 Remove pickup body Remarks: 1) Use only for releasing. TS 500i...

  • Page 115: Service Accessories

    Oil seals, sliding and bearing points STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in starter cover STIHL press fluid OH 723 0781 957 9000 Rubber elements antivibration elements STIHL multi-purpose grease 0781 120 1109...
  • Page 116 TS 500i...
  • Page 117 TS 500i...
  • Page 118 englisch / english 0455 753 0123. VA0.B12. Printed in Germany...

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