MS 500i 49
25.1 Tools, Servicing Aids
– Screwdriver – 0000 890 2300 or equivalent
– Socket, T27x125 – 0812 542 2104 or equivalent
– Torque wrench – 5910 890 0302 or equivalent
– Screwdriver, T10 – 5910 890 2308 or equivalent
– Screwdriver, T27x200 – 5910 890 2415 or equivalent
– Hook – 5910 890 2800
– Socket, T10
– Pin punch, 5 mm
– STIHL OH 723 press fluid – 0781 957 9000
25.2 Removing the Airflow Shroud
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 filter base, @ 15.2.
N Remove the throttle body and sleeve, @ 15.4.
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 from the
controller, @ 19.7.
N Pull sensor wires out of cable holder on the tank
housing.
N Unlock and remove generator’s black connector from
controller, @ 19.7.
N Pull generator’s wiring harness out of the guides in
the tank housing and airflow housing, @ 22.2.
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.
N Lift away the tank housing.
N Take out the screws (2) and (5).
N Grip the top edge of the airflow shroud (4) and pull it
off of the manifold (1).
N If the grommet (3) is damaged: Remove the grommet
(3) from the airflow shroud (4).
25.3 Removing the Manifold
N Remove the airflow shroud (4), @ 25.2.
N Remove the manifold (1).
N If the muffler (1) or sealing faces of the injection body
(12) are damaged: replace the damaged parts.
25 Manifold, Injection Module
6
12
7
6
11
8
1
13
3
4
5 M4x20 (4 Nm / 35 lbf. in.)
2 M4x12 (2 Nm / 18 lbf. in.)
10 M4x20
(4 Nm / 35 lbf. in.)
M4x20
(4 Nm / 35 lbf. in.)
9 P3x16 (0.8 Nm / 7 lbf. in.)
(4 Nm / 35 lbf. in.) M4x20
0000-GXX-5635-A0
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