Stihl BR 500 - Default Chapter; Table of Contents

1BR 500, BR 550, BR 600
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© ANDREAS STIHL AG & Co. KG, 2009
Contents
1. Introduction 2
2. Safety Precautions 2
3. Specifications 3
3.1 Engine 3
3.2 Ignition System 3
3.3 Fuel System 3
3.4 Tightening Torques 4
4. Troubleshooting 6
4.1 Rewind Starter 6
4.2 Ignition System 7
4.3 Carburetor 8
4.4 Engine 10
5. Rewind Starter /
Shroud 11
5.1 General 11
5.2 Removing
and Installing 11
5.3 Pawl 11
5.4 Rope Rotor 12
5.5 Starter Rope/Grip 13
5.6 Rope Guide Bushing 14
5.7 Replacing
the Rewind Spring 14
5.8 Tensioning
the Rewind Spring 15
5.9 Shroud 16
6. Fuel System 17
6.1 Air Filter 17
6.2 Carburetor 19
6.2.1 Leakage Test 19
6.2.2 Removing
and Installing 20
6.3 Servicing
the Carburetor 20
6.3.1 Metering Diaphragm 20
6.3.2 Inlet Needle 21
6.3.3 Pump Diaphragm 22
6.3.4 Accelerator Pump 23
6.4 Adjusting
the Carburetor 25
6.4.1 User Adjustment 25
6.4.2 Basic Setting in
Service Shop 26
6.5 Tank Vent 27
6.6 Fuel Hoses/
Pickup Body 28
6.7 Fuel Tank 29
7. Engine 29
7.1 Compression
Pressure 29
7.2 Checking / Adjusting
Valve Clearances 30
7.3 Rocker Arms /
Pushrods 31
7.4 Cam Followers 32
7.5 Cam Gear 33
7.5.1 Decompression
System 33
7.6 Muffler/Spark
Arresting Screen 34
7.7 Flywheel 35
7.8 Testing for Leaks 35
7.8.1 Preparations 36
7.8.2 Vacuum Test 36
7.8.3 Pressure Test 37
7.9 Crankshaft 38
7.9.1 Oil Seals 38
7.9.2 Crankcase,
Lower Half 39
7.9.3 Crankshaft 40
7.9.4 Piston 40
7.9.5 Piston Rings 42
7.9.6 Valves / Valve
Springs 43
7.9.7 Upper Half of
Crankcase
with Cylinder 43
8. Ignition System 44
8.1 Ignition Module 45
8.2 Ignition Timing 45
8.3 Testing the
Ignition Module 45
8.4 Removing and
Installing 46
8.5 Spark Plug Boot 47
8.6 Testing the
Wiring Harness 48
8.7 Ignition System
Troubleshooting 49
9. Control Handle 52
9.1 Throttle Trigger/
Interlock Lever 52
9.2 Setting Lever 52
9.3 Throttle Cable 53
9.3.1 Removing and
Installing 53
9.3.2 Adjusting 53
10. AV System 54
10.1 Spring Elements 54
10.2 Backplate 54
11. Fan 55
11.1 Outer Fan Housing 55
11.2 Inner Fan Housing 56
11.3 Fanwheel 56
11.4 Antistatic Wire 57
12. Special
Servicing Tools 58
13. Servicing Aids 59
RA_452_00_01_02
RA_452_00_01_02.book Seite 1 Donnerstag, 16. Februar 2012 11:52 11