Stihl MS 500i - Page 40

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MS 500i38

N Install the air filter.

N Fit the filter cover.

Main Page

Table of Contents3
About this Service Manual5
Applicable Documentation5
Symbols in Text5
Safety During Repair Work5
Protective Gloves5
Safety Glasses5
Replacement Parts5
Screws5
Preparations for Repair5
Preparations5
Troubleshooting Guide6
Spiked Bumper, Chain Catcher7
Tools, Servicing Aids7
Removing the Chain Catcher7
Installing the Chain Catcher7
Removing the Spiked Bumper7
Installing the Spiked Bumper7
Bar Mounting Studs8
Tools, Servicing Aids8
Removing the Bar Mounting Studs8
Installing the Bar Mounting Studs8
Filter Cover, Shroud9
Tools, Servicing Aids9
Removing the Twist Lock9
Installing the Twist Lock9
Removing the Stop Buffer9
Installing the Stop Buffer9
Removing the Shroud Lock9
Installing the Shroud Lock9
Decompression Valve10
15 8.1 Tools, Servicing Aids10
Removing the Decompression Valve10
Installing the Decompression Valve10
Handle11
Tools, Servicing Aids11
Removing the Handlebar11
Installing the Handlebar11
Rewind Starter13
Tools, Servicing Aids13
Removing the Rewind Starter13
Relieving Tension of Rewind Spring13
Removing the Starter Rope14
Removing the Rope Rotor14
Removing the Rewind Spring14
Installing the Rewind Spring14
Installing the Rope Rotor15
Installing the Starter Rope15
Tensioning the Rewind Spring16
Installing the Rewind Starter16
Clutch17
Tools, Aids17
Removing Clutch17
Checking Clutch Drum17
Disassembling Clutch18
Assembling Clutch18
Installing Clutch18
Chain Tensioner19
Tools, Servicing Aids19
Removing the Chain Tensioner19
Installing the Chain Tensioner19
Chain Brake20
Tools, Servicing Aids20
Removing the Brake Band, Spring and Lever20
Installing the Brake Band, Spring and Lever21
Testing the Chain Brake22
Chain Lubrication23
Tools, Servicing Aids23
Removing Oil Tank Vent Valve23
Installing Oil Tank Vent Valve24
Removing the Worm24
Removing the Oil Pump24
Removing the Hose24
Removing Pickup Body from Oil Tank24
Installing Pickup Body in Oil Tank24
Installing the Hose24
Installing the Oil Pump24
Installing the Worm25
Filter Base, Throttle Body26
Tools, Servicing Aids26
Removing the Filter Base26
Installing the Filter Base26
Removing the Throttle Body26
Installing the Throttle Body26
Throttle Control27
Tools, Servicing Aids27
Removing Trigger Lockout, Throttle Trigger and Throttle Linkage27
Installing Trigger Lockout, Throttle Trigger and Throttle Linkage28
Antivibration Elements29
Tools, Servicing Aids29
Removing the Antivibration Elements29
Installing the Antivibration Elements30
Fly Wheel32
Special Servicing Tools, Servicing Aids32
Removing the Flywheel32
Installing the Flywheel32
Controller, Ignition Lead34
Special Servicing Tools, Servicing Aids34
Testing the Ignition System34
Removing the Ignition Lead34
Disassembling the Ignition Lead35
Assembling the Ignition Lead35
Installing the Ignition Lead35
Removing the Controller35
Installing the Controller36
Fuel Hoses, Impulse Hose37
Tools, Servicing Aids37
Removing Fuel Suction Hose Outside the Tank37
Installing Fuel Suction Hose Outside the Tank37
Removing Fuel Hose37
Installing the Fuel Hose38
Removing the Fuel Return Hose38
Installing the Fuel Return Hose38
Removing the Impulse Hose38
Installing the Impulse Hose39
Injection Pump, Stop Switch41
Special Servicing Tools, Servicing Aids41
Removing the Injection Pump41
Removing the Stop Switch41
Removing Cap and Spring from Injection Pump41
Installing the Injection Pump42
Installing Cap and Spring on Injection Pump42
Installing the Stop Switch42
Generator, Sensor43
Special Servicing Tools, Servicing Aids43
Removing the Generator43
Removing the Sensor43
Installing the Sensor44
Installing the Generator44
Tank Housing46
Tools, Servicing Aids46
Removing Pickup Body from Fuel Tank46
Installing Pickup Body in Fuel Tank46
Removing Tank Vent from Fuel Tank46
Installing Tank Vent in Fuel Tank46
Removing Fuel Suction Hose Inside the Tank47
Installing Fuel Suction Hose Inside the Tank47
Removing Fuel Return Hose Grommet47
Installing Fuel Return Hose Grommet47
Removing the Tank Housing47
Installing the Tank Housing47
Stop Buffer, Grommets49
Tools, Servicing Aids49
Removing Grommet from Airflow Shroud49
Installing Grommet in Airflow Shroud49
Removing Grommets from Crankcase49
Installing Grommets in Crankcase49
Removing Crankcase Stop Buffers49
Installing Crankcase Stop Buffers50
Manifold, Injection Module51
Tools, Servicing Aids51
Removing the Airflow Shroud51
Removing the Manifold51
Installing the Manifold52
Installing the Airflow Shroud52
Removing the Contact Strip52
Installing the Contact Strip52
Removing the Injection Module52
Installing the Injection Module52
Removing the Injection Valve53
Installing the Injection Valve53
Muffler, Heat Shield55
Tools, Servicing Aids55
Removing Muffler and Heat Shield55
Installing Muffler and Heat Shield55
Cylinder, Piston56
Tools, Aids56
Removing the Cylinder56
Removing the Piston57
Installing the Piston57
Installing Cylinder58
Crankcase, Crankshaft, Oil Seals60
Tools, Servicing Aids60
Removing Oil Seals60
Installing the Oil Seals61
Disassembling Crankcase and Removing Crankshaft62
Removing the Ball Bearings63
Installing the Ball Bearings63
Installing Crankshaft and Assembling Crankcase64
Tools, Servicing Aids66
Tools, Aids66

Stihl MS 500i - Page 40

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