Stihl MS 500i Service Manual
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Stihl MS 500i Service Manual

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STIHL MS 500i
Service Manual
2020-01

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  • Page 1 STIHL MS 500i Service Manual 2020-01...

  • Page 3: Table Of Contents

    Removing the Rewind Spring 17.3 Installing the Antivibration Elements 10.7 Installing the rewind spring 10.8 Installing the Rope Rotor This service manual is protected by copyright. All rights reserved, especially the rights to reproduce, translate and process with electronic systems. MS 500i...
  • Page 4 Removing Fuel Suction Hose Inside the Tank 45 23.7 Installing Fuel Suction Hose Inside the Tank 23.8 Removing Fuel Return Hose Grommet 23.9 Installing Fuel Return Hose Grommet 23.10 Removing the Tank Housing 23.11 Installing the Tank Housing MS 500i...

  • Page 5: About This Service Manual

    Wear safety glasses. Replacement Parts Preparations If replacement parts not approved by STIHL are installed, Drain the fuel tank into a container approved for fuels. they may not fulfill the required function or deactivate Remove the chain and guide bar.

  • Page 6: Troubleshooting Guide

    The guide describes symptoms and possible causes as well as the following tests to locate the problem: Testing fuel system for leaks and correct operation. Testing engine for leaks. Testing fuel tank and tank vent for leaks. Calibrating the saw. MS 500i...

  • Page 7: Spiked Bumper, Chain Catcher

    Fit the chain sprocket cover. Installing the Chain Catcher Fit the chain catcher (1). If the original screw (4) is re-used: Coat thread of screw (2) with Loctite 242. Insert and tighten down the screw (2). Fit the chain sprocket cover. MS 500i...

  • Page 8: Bar Mounting Studs

    Use stud puller 5910 893 0501 to remove the collar stud (1). Installing the Bar Mounting Studs Coat threads of collar studs (1) with Loctite 270. Use stud puller 5910 890 3000 to fit and tighten down the collar studs (1). Fit the chain sprocket cover. MS 500i...

  • Page 9: Filter Cover, Shroud

    Fit the filter cover (2), . Preparations, @ 3.1. Remove the shroud (3). Pull off the stop buffer (4). Installing the Stop Buffer Push stop buffer (4) onto peg in shroud as far as the stop. Mount the shroud (3). MS 500i...

  • Page 10: Decompression Valve

    – Removing the Decompression Valve Preparations, @ 3.1. Remove the shroud. Unscrew the decompression valve (1). Installing the Decompression Valve Screw decompression valve (1) into place by hand. Tighten decompression valve (1) to specified torque. Mount the shroud. MS 500i...

  • Page 11: Handle

    Take out the screw (4). Installing the Handlebar Insert and tighten down the screw (4). Push bushing (10) onto the screw (4) so that it snaps into place. Fit the handlebar (2) over the hand guard from the front. MS 500i...
  • Page 12 Push holes in handlebar (2) onto the screw bosses on the handlebar mount (9) (arrows). Place the handlebar (2) in the guide (7). Insert and tighten down the screws (1). Insert and tighten down the screws (5). Insert and tighten down the screw (3). MS 500i...

  • Page 13: Rewind Starter

    Torque wrench – 5910 890 0302 or equivalent – Screwdriver, T27x200 – 5910 890 2415 or equivalent – Pin punch, 2 mm – STIHL multipurpose grease – 0781 120 1110 – STIHL gear grease – 0781 417 1315 – 10.2 Removing the Rewind Starter Grip the segment (6) by the lug and pull it out of the Preparations, @ 3.1.

  • Page 14: Removing The Starter Rope

    Relieve tension of rewind spring, @ 10.3. Remove the starter rope, @ 10.4. Remove the spring (11). Remove the pawls (10). Remove the washer (9). Pull off the rope rotor (8). The rewind spring (7) may pop out and unwind. MS 500i...

  • Page 15: Installing The Rope Rotor

    Thread the starter rope (5) through the bushing (18). Thread the starter rope (5) through the rope rotor (8). Secure the end of the rope (5) with a simple overhand knot. Push the rope (5) into the recess (arrow). MS 500i...

  • Page 16: Tensioning The Rewind Spring

    It must be possible to turn the rotor (8) another half turn. If the rope rotor (8) cannot be turned any further: Hold the rotor (8) steady and take one turn of the rope off the rotor (8). MS 500i...

  • Page 17: Clutch

    Remove needle cage (5). Remove shroud. Examine the clutch drum (4) for signs of wear. Remove the spark plug. If distinct wear marks are visible on the inner diameter of the clutch drum (4): Measure wall thickness a. MS 500i...

  • Page 18: Disassembling Clutch

    Engage chain brake. Calibrate the chain saw, @ 4. Hook clutch springs (10) onto the side with the hexagon (arrow) using the hook 5910 890 2800. The control unit is optimally adjusted to the mechanical and mechatronic components. MS 500i...

  • Page 19: Chain Tensioner

    Screwdriver, T27x200 – 5910 890 2415 or equivalent – Coat teeth of adjusting screw (8) with multipurpose grease. STIHL multipurpose grease – 0781 120 1110 – Screw the adjusting screw (8) a few turns into the 12.2 Removing the Chain Tensioner tensioner slide (9).

  • Page 20: Chain Brake

    Flat nose side cutting pliers – If the turns of the brake spring (8) are not tightly against one another, install a new spring. STIHL multipurpose grease – 0781 120 1110 – Remove the E-clip (12). Loctite 242 (medium-strength threadlocking –...

  • Page 21: Installing The Brake Band, Spring And Lever

    Swing lever (9) in direction of arrow until the hand Fit the chain sprocket cover. guard (15) and lever (13) can be pushed into place as far as stop. Check operation of chain brake, @ 3.1. Fit the E-clip (12). MS 500i...

  • Page 22: Testing The Chain Brake

    Mount one of the cutting attachment combinations listed in the instruction manual. Start the engine. Disengage the chain brake. Open throttle wide and engage brake manually. The chain brake is operating properly if the chain comes to a stop without any noticeable delay. MS 500i...

  • Page 23: Chain Lubrication

    – Flat nose side cutting pliers – Pin punch, 6 mm – STIHL OH 723 press fluid – 0781 957 9000 – Loctite 242 (medium-strength threadlocking – adhesive) – 0786 111 2101 Use a 6 mm punch to drive out the valve (7) from Chain oil inside the tank.

  • Page 24: Installing Oil Tank Vent Valve

    (4) and face (9) locates against the sealing ring (5). Pull off the pickup body. If the original screws (2) are re-used: Coat threads of screws (2) with Loctite 242. Insert and tighten down the screws (2) firmly. Install the worm gear, @ 14.11. MS 500i...

  • Page 25: Installing The Worm

    14.11 Installing the Worm Coat worm (1) with chain lubricant. Push home the worm (1) as far as stop. Install the clutch, @ 11.6. Fit the chain sprocket cover. Close the tank cap. MS 500i...

  • Page 26: Filter Base, Throttle Body

    Push seal (2) onto flange of filter base (4) as far as stop. Fit the air filter (1). Fit the filter cover. If a new air filter (1) has been fitted: Calibrate the saw, @ 4. MS 500i...

  • Page 27: Throttle Control

    Take out the throttle lever (4) together with the torsion Remove the throttle body and sleeve, @ 15.4. spring (3). Take the torsion spring (3) off the throttle trigger (4). Hold the handle molding (1) steady. Disengage the retaining lugs on the handle molding (1). MS 500i...

  • Page 28: Installing Trigger Lockout, Throttle Trigger And Throttle Linkage

    (6) in the handle housing so that the torsion spring (3) is under the lever’s pivot. Swing the lockout lever (6) towards the handle housing. Attach torsion spring (3) to the guide (arrow) on the lockout lever (6). MS 500i...

  • Page 29: Antivibration Elements

    – Screwdriver, T27x200 – 5910 890 2415 or equivalent – Punch-down tool – 5910 890 4000 – STIHL OH 723 press fluid – 0781 957 9000 – Loctite 242 (medium-strength threadlocking – adhesive) – 0786 111 2101 Take out the screw (2).

  • Page 30: Installing The Antivibration Elements

    Position the tank housing on the crankcase so that the bearing plug (14) is in its seat in the crankcase. Insert and tighten down the screw (10). Position the annular buffer (6) in its seat in the crankcase. MS 500i...
  • Page 31 Place the AV spring (8) in position. If the original screw (9) is re-used: Coat thread of screw (9) with Loctite 242. Insert and tighten down the screw (9). Insert and tighten down the screw (7). Mount the shroud. Fit the filter cover. MS 500i...

  • Page 32: Fly Wheel

    Push the locking strip 0000 893 5904 into the spark The piston is now blocked. plug hole and hold it there. Unscrew the nut (4). Pull the locking strip 0000 893 5904 out of the spark plug hole. MS 500i...
  • Page 33 Install the fan housing with rewind starter, @ 10.11. Mount the shroud. Remove the filter cover Calibrate the saw, @ 4. The controller is optimally adjusted to suit the mechanical and mechatronic components. MS 500i...

  • Page 34: Controller, Ignition Lead

    – Connect saw to MDG 1 analyzer. Pin punch, 5 mm – Start STIHL diagnostic software and follow the instructions. STIHL OH 723 press fluid – 0781 957 9000 – 19.3 Removing the Ignition Lead 19.2 Testing the Ignition System Preparations, @ 3.1.

  • Page 35: Disassembling The Ignition Lead

    (6) as far as stop. the connectors (12, 13, 14). Push the grommet (5) onto the controller (6). Unlock and remove the white connector (12). Push the ignition lead (4) into the guide (arrow). Unlock and remove the blue connector (13). MS 500i...

  • Page 36: Installing The Controller

    The engine can be seriously damaged. If the controller has to be replaced, perform the following steps: Connect the saw to the STIHL MDG 1 analyzer. – Start STIHL diagnostic software. –...

  • Page 37: Fuel Hoses, Impulse Hose

    Punch-down tool – 5910 890 4000 – Install a new fuel suction hose (3). STIHL OH 723 press fluid – 0781 957 9000 – Coat both ends of nipple (2) with press fluid. Push the nipple (2) into the fuel suction hose (3) as far 20.2...

  • Page 38: Installing The Fuel Hose

    Remove the filter base, @ 15.2. The fuel return hose (8) may be damaged during removal. Fuel may escape. Remove the throttle body and sleeve, @ 15.4. Install a new fuel return hose (8). Take out the screw (7). Remove the bracket (6). MS 500i...

  • Page 39: Installing The Impulse Hose

    Insert and tighten down screw on AV element between tank housing and crankcase, @ 17.3. Install the handlebar, @ 9.3. Fit the bracket (6). Insert and tighten down the screw (7) firmly. Install sleeve and throttle body, @ 15.5. Install the filter base, @ 15.3. MS 500i...
  • Page 40 Install the air filter. Fit the filter cover. MS 500i...

  • Page 41: Injection Pump, Stop Switch

    Take wires of stop switch (8) out of the guides. Remove the spring (4). Pull out the injection pump (3) together with the stop 21.5 Removing the Injection Pump switch (8) and cover (9). Preparations, @ 3.1. Remove the injection pump (3), @ 21.2. MS 500i...

  • Page 42: Installing The Injection Pump

    Installing the Injection Pump Fit the stop switch (8), @ 21.8. Fit the injection pump (3) together with the stop switch (8) and cover (9). Fit the stop switch wires so that they are under the throttle linkage. MS 500i...

  • Page 43: Generator, Sensor

    Remove the throttle body and sleeve, @ 15.4. Remove the fan housing with rewind starter, @ 10.2. Remove the flywheel, @ 18.2. Loosen the screws (4), do not remove them. The generator (3) hangs loosely on the screws (4). MS 500i...

  • Page 44: Installing The Sensor

    Pass the wiring harness (13) through the opening in the crankcase. Place the generator (3) in position. If the original screws (4) are re-used: Coat threads of screws (4) with Loctite 242. Insert the screws (4) but do not tighten them down yet. MS 500i...
  • Page 45 Push the wiring harness (9) into the cable holder (11). Install throttle body and sleeve, @ 15.5 Install the flywheel, @ 18.3. Install the fan housing with rewind starter, @ 10.11. Mount the shroud. Install the air filter. MS 500i...

  • Page 46: Tank Housing

    Remove the filter base, @ 15.2. – Punch-down tool – 5910 890 4000 – Hook – 5910 893 8800 – STIHL OH 723 press fluid – 0781 957 9000 – 23.2 Removing Pickup Body from Fuel Tank Preparations, @ 3.1. Open the tank cap (1).

  • Page 47: Removing Fuel Suction Hose Inside The Tank

    Pry the grommet (11) out of the tank housing (2). Install the fuel return hose (9) with nipple (10), @ 20.7. Fit fuel hose in the guide in the tank housing, @ 20.5. Install the fuel suction hose (7) with nipple (6), @ 20.3. MS 500i...
  • Page 48 Install the controller, @ 19.8. Install sleeve and throttle body, @ 15.5. Install the filter base, @ 15.3. Fit the ignition lead and spark plug boot, @ 19.6. Mount the shroud. Install the air filter. Fit the filter cover. MS 500i...

  • Page 49: Stop Buffer, Grommets

    – Remove the air filter. STIHL multipurpose grease – 0781 120 1110 – Remove the shroud. STIHL OH 723 press fluid – 0781 957 9000 – Remove spark plug boot and pull ignition lead out of the guides. 24.2 Removing Grommet from Airflow Shroud Remove the fan housing with rewind starter, @ 10.2.

  • Page 50: Installing Crankcase Stop Buffers

    Install sleeve and throttle body, @ 15.5. Install the filter base, @ 15.3. Install the fan housing with rewind starter, @ 10.11. Fit the ignition lead and spark plug boot, @ 19.6. Mount the shroud. Install the air filter. Fit the filter cover. MS 500i...

  • Page 51: Manifold, Injection Module

    Remove fuel hose from guide in the tank housing, @ Pin punch, 5 mm – 20.4. STIHL OH 723 press fluid – 0781 957 9000 – Remove the fuel return hose with nipple, @ 20.6. Remove impulse hose from guide in the tank housing, 25.2...

  • Page 52: Installing The Manifold

    Insert and tighten down the screws (6) firmly. Remove the airflow shroud (4), @ 25.2. Fit cable lug of sensor’s red wire, @ 22.4. Take out the screw (9). If the manifold (1) has been removed: Install the manifold (1), @ 25.4. MS 500i...

  • Page 53: Removing The Injection Valve

    (7). The sleeve (7) may remain on the injection valve (8) or get stuck in the injection body (12) during removal. If the O-rings on the injection valve are damaged: Install new O-rings on injection valve (8). MS 500i...
  • Page 54 Fit cable lug of sensor’s red wire, @ 22.4. Install the airflow shroud (4), @ 25.5. Test the fuel system for leaks and correct operation, @ 4. Calibrate the saw, @ 4. The controller is optimally adjusted to suit the mechanical and mechatronic components. MS 500i...

  • Page 55: Muffler, Heat Shield

    Remove the muffler gasket (7). Insert and tighten down the screws (1). Remove the heat shield (8). Install the spark arrestor (if fitted). Calibrate the saw, @ 4. The controller is optimally adjusted to suit the mechanical and mechatronic components. MS 500i...

  • Page 56: Cylinder, Piston

    Pull the sensor cables out of the cable holder on the tank housing. Assembly tool - 5910 890 2212 – Remove the sensor wiring harness from the injection STIHL press-in fluid OH 723 – 0781 957 9000 – module, @ 22.3. Two-stroke engine-oil –...

  • Page 57: Removing The Piston

    Pull needle cage (6) out of connecting rod. Remove compression rings (9 and 10). If the compression rings (9 and 10) are damaged: Replace compression rings (9 and 10). The snap ring (8) does not need to be removed. MS 500i...

  • Page 58: Installing Cylinder

    Insert screws (1) and tighten. Turn the crankshaft counterclockwise until the piston Attach antivibration element to the cylinder,@ 17.3. (4) is firmly seated on the piston support 5920 893 Install the decompression valve, @ 8.3. 5301 (14). Install hood lock,@ 7.7. MS 500i...
  • Page 59 Press ignition cable into the guides and plug in the ignition cable plug. Install shroud. Install air filter. Attach filter cover. Calibrate the chain saw, @ 4. The control unit is optimally adjusted to the mechanical and mechatronic components. MS 500i...

  • Page 60: Crankcase, Crankshaft, Oil Seals

    Screwdriver – 0000 890 2300 or equivalent – Pin punch, 3 mm – Jaws (No. 3.1 + 4) – 0000 893 3706 – STIHL multipurpose grease – 0781 120 1110 – Jaws (No. 6) – 0000 893 3711 – Solvent-based degreasant containing no chlorinated –...

  • Page 61: Installing The Oil Seals

    Degrease the crankshaft stub and sealing faces. If the seating faces are not flat and free from burrs: Replace the crankcase (4, 9) or the crankshaft (6). Lubricate lips of oil seals (3 and 11) with multipurpose grease. MS 500i...

  • Page 62: Disassembling Crankcase And Removing Crankshaft

    Back off the spindle (20) of puller 5910 890 4505. Remove the fuel return hose, @ 20.6. Remove impulse hose from guide in tank housing and pull it off the crankcase, @ 20.8. Remove the tank housing, @ 23.8. MS 500i...

  • Page 63: Removing The Ball Bearings

    Use press sleeve 1113 893 4600 to remove the ball bearing (3). If the ball bearing (5) does not drop out of its own accord: Use press sleeve 4119 893 2400 to remove the ball bearing (5). MS 500i...

  • Page 64: Installing Crankshaft And Assembling Crankcase

    Install the airflow shroud, @ 25.5. Install the tank housing, @ 23.8. Install the impulse hose, @ 20.9. Install the fuel return hose, @ 20.7. Install the fuel hose, @ 20.5. Install the controller, @ 19.8. Install the sensor, @ 22.4. MS 500i...
  • Page 65 Fit the chain sprocket cover. Install the spark plug. Fit the spark plug boot. Mount the shroud. Install the air filter. Fit the filter cover. Calibrate the saw, @ 4. The controller is optimally adjusted to suit the mechanical and mechatronic components. MS 500i...

  • Page 66: Tools, Servicing Aids

    Removing oil seals 5910 890 4504 Puller Removing the flywheel 5910 890 4505 Puller Remove crankshaft 5910 893 0501 Stud driver M8 Unscrewing collar screws 5910 893 2804 Insert 13 mm long or equivalent tool Removing, installing decompression valve MS 500i...
  • Page 67 0781 417 1315 STIHL special lubricant Installing rewind spring 0781 957 9000 STIHL press fluid OH 723 Installing rubber elements 0786 111 2101 Loctite 242 (thread-locking adhesive, medium Securing screw on chain catcher; pivot pin in strength)
  • Page 68 RA_004_2018_01_01 englisch www.stihl.com...

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