Stihl MS 500i

MS 500i 41
22.1 Special Servicing Tools, Servicing Aids
– Socket, T20x125 – 0812 542 2041 or equivalent
– Socket, T27x125 – 0812 542 2104 or equivalent
– Torque wrench – 5910 890 0302 or equivalent
– Screwdriver, T20 – 5910 890 2301 or equivalent
– Screwdriver, T10 – 5910 890 2308 or equivalent
– Screwdriver, T27x200 – 5910 890 2415 or equivalent
– Punch-down tool – 5910 890 4000
– Socket, T20
– Flat nose side cutting pliers
– Loctite 242 (medium-strength threadlocking
adhesive) – 0786 111 2101
22.2 Removing the Generator
N Preparations, @ 3.1.
N Remove the filter cover
N Remove the air filter.
N Remove the shroud.
N Remove the filter base, @ 15.2.
N Remove the throttle body and sleeve, @ 15.4.
N Remove the fan housing with rewind starter, @ 10.2.
N Remove the flywheel, @ 18.2.
N Loosen the screws (4), do not remove them.
The generator (3) hangs loosely on the screws (4).
N Take out the screw (2).
N Remove the air baffle (1).
N Unlock and remove black connector of generator (3)
from controller, @ 19.7.
N Take wires of generator (3) out of the guides.
N Take out the screws (4).
N Remove the generator (3).
22.3 Removing the Sensor
N Preparations, @ 3.1.
N Remove the generator, @ 22.2.
N Remove the injection pump, @ 21.2.
N Remove the handlebar, @ 9.2.
N Remove screw from AV element between tank
housing and crankcase, @ 17.2.
N Unlock and remove blue connector of sensor (6) from
controller, @ 19.7.
22 Generator, Sensor
7
6
1
3
2 M4x12 (1.5 Nm / 13 lbf. in.)
5 M4x12
(3.5 Nm /
31 lbf. in.)
M5x20 4
(6 Nm /
53 lbf. in.)
P3x16 8
(0.8 Nm /
7 lbf. in.)
0000-GXX-5619-A0