Stihl MS 200 Service Manual

1MS 200, MS 200 T
q
© ANDREAS STIHL AG & Co. KG, 2012
RA_161_00_01_05
1. Introduction 3
2. Safety Precautions 4
3. Specifications 5
3.1 Engine 5
3.2 Fuel System 5
3.3 Ignition System 5
3.4 Chain Lubrication 5
3.5 Tightening Torques 6
4. Troubleshooting 8
4.1 Clutch 8
4.2 Chain Drive,
Chain Brake,
Chain Tensioner 9
4.3 Chain Lubrication 10
4.4 Rewind Starter 11
4.5 Ignition System 12
4.6 Carburetor 14
4.7 Engine 17
5. Cutting Attachment 18
5.1 Chain Catcher /
Spiked Bumper 18
6. Clutch 19
6.1 Clutch Drum 21
7. Chain Brake 22
7.1 Checking Operation 22
7.2 Removing and Installing
the Brake Band 22
7.3 Brake Lever 23
7.4 Flat Spring 25
7.5 Pins 26
7.6 Chain Tensioner 27
7.7 Bar Mounting Stud 27
8. Engine 28
8.1 Muffler / Spark Arresting
Screen 28
8.2 Leakage Test 29
8.2.1 Preparations 29
8.2.2 Vacuum Test 30
8.2.3 Pressure Test 31
8.3 Oil Seals 31
8.4 Cylinder 33
8.5 Crankshaft 36
8.5.1 Removing and
Installing 36
8.5.2 Bearings / Crankcase 39
8.6 Piston 41
8.6.1 Removal 41
8.6.2 Installing 42
8.7 Piston Rings 44
9. Ignition System 45
9.1 Ignition Timing 45
9.2 Ignition Module 45
9.2.1 Removing and
Installing 45
9.2.2 Testing the Ignition
Module 47
9.3 Spark Plug Boot /
Ignition Lead 48
9.4 Flywheel 50
9.5 Short Circuit Wire 51
9.5.1 Testing (MS 200,
MS 200 T) 51
9.5.2 Testing the Wiring
Harness (MS 200) 52
9.5.3 Removing and
Installing 52
9.5.4 Removing and Installing
the Wiring Harness
(MS 200) 55
9.5.5 Ground Wire 58
9.6 Ignition System
Troubleshooting 59
10. Rewind Starter 62
10.1 General 62
10.2 Removing and
Installing 62
10.3 Pawl 62
10.4 Rope Rotor 63
10.5 Starter Rope / Grip 64
10.6 Tensioning the
Rewind Spring 65
10.7 Replacing the
Rewind Spring 66
11. Servicing the
AV System 69
11.1 Annular Buffer
on Fuel Tank 69
11.2 Annular Buffer on
Oil Tank (MS 200) 69
11.2.1 Annular Buffer on
Oil Tank (MS 200 T) 70
11.3 Annular Buffer on
Handlebar 71
11.4 Stop Buffer (MS 200) 71
11.5 Handlebar 72
12. Master Control Lever 74
12.1 Switch Shaft / Control
Lever 74
12.1.1 Removing and Installing
(MS 200) 74
12.1.2 Removing and Installing
(MS 200 T) 75
12.2 Throttle Trigger/Interlock
Lever (MS 200) 76
12.3 Throttle Trigger/Interlock
Lever (MS 200 T) 77
12.3.1 Choke and Throttle Rods
(MS 200) 78
12.3.2 Choke and Throttle Rods
(MS 200 T) 79
12.4 Removing and Installing
the Handle Housing
(MS 200) 81
12.5 Removing and Installing
the Handle Housing
(MS 200 T) 84
13. Chain Lubrication 86
13.1 Pickup Body 86
13.2 Oil Suction Hose 86
13.3 Connector /
Oil Pressure 86
13.4 Oil Pump 87
13.5 Valve 88
Contents

Stihl MS 200 Specifications

General

Guide Bar Length	30-40 cm
Chain Oil Capacity	0.22 L
Chain pitch	3/8"
Engine Power	2.0 kW
Displacement	35.2 cc
Weight (without cutting equipment)	4.2 kg