Stihl MS 500i

MS 500i 47
24.1 Tools, Servicing Aids
– Combination wrench – 1129 890 3401
– Extension – 4180 893 4400
– Punch-down tool – 5910 890 4000
– STIHL multipurpose grease – 0781 120 1110
– STIHL OH 723 press fluid – 0781 957 9000
24.2 Removing Grommet from Airflow Shroud
N Preparations, @ 3.1.
N Remove the filter cover
N Remove the shroud.
N Remove the decompression valve, @ 8.2.
N Remove the grommet (5) sideways out of the airflow
shroud (6).
24.3 Installing Grommet in Airflow Shroud
N Fit the grommet (5) into the guide in the airflow
shroud (6) as far as stop.
N Install the decompression valve, @ 8.3.
N Mount the shroud.
N Fit the filter cover.
24.4 Removing Grommets from Crankcase
N Preparations, @ 3.1.
N Remove the filter cover.
N Remove the shroud.
N Use extension 4180 893 4400 to pry out the
grommets (4).
24.5 Installing Grommets in Crankcase
Grommets may be damaged during removal. The shroud
and crankcase may be damaged If a damaged grommet
is re-installed.
Always install new grommets.
N Coat tapered ends of grommets (4) with press fluid.
N Use extension 4180 893 4400 to push grommets (4)
into their seats in the crankcase, making sure they
engage in position.
N Mount the shroud.
N Fit the filter cover.
24.6 Removing Crankcase Stop Buffers
N Preparations, @ 3.1.
N Remove the filter cover.
N Remove the air filter.
N Remove the shroud.
N Remove spark plug boot and pull ignition lead out of
the guides.
N Remove the fan housing with rewind starter, @ 10.2.
N Remove the filter base, @ 15.2.
N Remove the throttle body and sleeve, @ 15.4.
N Remove the injection pump, @ 21.2.
N Remove the stop switch, @ 21.3.
N Remove the handlebar, @ 9.2.
N Remove screw from AV element between tank
housing (2) and crankcase, @ 17.2.
N Unlock and remove blue connector of sensor from the
controller, @ 19.7.
N Pull sensor wires out of cable holder on the tank
housing.
N Remove fuel suction hose outside the tank with
nipple, @ 20.2.
N Remove fuel hose from guide in the tank housing, @
20.4
N Remove the fuel return hose with nipple, @ 20.6.
N Remove impulse hose from guide in the tank housing,
@ 20.8.
24 Stop Buffer, Grommets
3
6
5
1
4
4
2
0000-GXX-5634-A0