Stihl MS 500i

MS 500i54
27.1 Tools, aids
– Screwdriver – 0000 890 2300 or equivalent tool
– Clamping strap – 0000 893 2600
– Socket T27x125 – 0812 542 2104 or equivalent tool
– Torque wrench – 5910 890 0302 or equivalent tool
– Screwdriver T27x200 – 5910 890 2415 or equivalent
tool
– Piston support – 5910 893 5301
– Assembly drift – 1108 893 4700
– Assembly tool - 5910 890 2212
– STIHL press-in fluid OH 723 – 0781 957 9000
– Two-stroke engine-oil
27.2 Removing the cylinder
N Prepare for repair, @ 3.1.
N Remove the filter cover.
N Remove air filter.
N Remove shroud.
N Unplug spark plug boot and pull ignition lead out of
the guides.
N Remove the spark plug.
N Remove starter, @ 10.2.
N Remove filter base, @ 15.2.
N Remove throttle shutter housing and sleeve, @ 15.4.
N Detach injection pump,@ 9.2.
N Remove the front handle, @ 9.2
N Unscrew the AV element screw between the tank
housing (2) and the crankcase, @ 17.2.
N Insert black plug of the generator on the control unit
and engage, @ 19.7.
N Pull the generator wiring harness out of the guides on
the tank housing and on the air guide hood,@ 22.2.
N Insert blue plug of the sensor on the control unit and
engage, @ 19.7.
N Pull the sensor cables out of the cable holder on the
tank housing.
N Remove the sensor wiring harness from the injection
module, @ 22.3.
N Remove fuel hose, @ 20.4.
N Remove fuel return hose, @ 20.6.
N Remove the impulse hose from the guide in the tank
housing and pull it off the crankcase, @ 20.8.
N Remove tank housing.
N Remove manifold, @ 25.3.
N Remove air guide shroud, @ 25.2.
N Remove injection module,@ 25.8.
N Remove muffler and heat shield,@
26.2.
N If necessary, remove the hood lock, @ 7.6.
N If necessary, remove the decompression valve, @
8.2.
27 Cylinder, Piston
1 M6x28 (15 Nm / 133 lbf. in.)
4
3
2
10
9
5
6
7
8
4
0000-GXX-5640-A0