Stihl TS 500i - Default Chapter; Table of Contents; Stihl Mdg

1TS 500i
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© ANDREAS STIHL AG & Co. KG, 2012
RA_753_00_01_01
1. Introduction and
safety precautions 3
1.1 Introduction 3
1.2 Safety precautions 4
2. Specifications 6
2.1 Engine 6
2.2 Fuel system 6
2.3 Spark plug 6
2.4 Abrasive wheels 6
2.5 Tightening torquese 7
3. Troubleshooting 10
3.1 Clutch 10
3.2 Cast arm with guard 11
3.3 Solenoid valve /
Water system 12
3.4 Starter 14
3.5 Troubleshooting chart
STIHL Injection 15
4. Cast arm with guard 25
4.1 Water system 25
4.1.1 Nozzles 25
4.1.2 Water hose 25
4.1.3 Solenoid valve 26
4.2 Cast arm with guard 28
4.2.1 Ball bearing 32
4.3 Testing radial and
axial truth of running 33
4.4 Test sequence data 34
4.5 Ribbed poly V-belt 35
4.6 Tensioner 36
5. Starter cup / clutch 38
5.1 Starter cup 38
5.2 Clutch 39
5.3 Belt pulley /
clutch drum 40
5.4 Studs for securing the
"cast arm with guard" 41
6. Engine 42
6.1 Muffler / spark
arresting screen 42
6.2 Leak testing 42
6.2.1 Preparations 43
6.2.2 Testing with negative
pressure 44
6.2.3 Pressure test 44
6.3 Oil seals 45
6.4 Shroud 46
6.5 Engine 48
6.6 Cylinder 48
6.7 Crankshaft 52
6.7.1 Ball bearing /
crankcase 57
6.8 Piston 58
6.9 Piston rings 60
6.10 Decompression valve 61
7. STIHL Injection 62
7.1 Testing 63
7.1.1 Checking the screw
connection and plug 63
7.1.2 Connect the injection
system diagnostic
cable 63
7.2 Testing with
STIHL MDG 1 65
7.3 Control unit 65
7.4 Spark plug boot 67
7.4.1 Ignition lead 68
7.5 Flywheel 68
7.5.1 Generator 70
7.6 Short circuit wire /
switch 71
7.6.1 Testing 71
7.6.2 Removal and
installation 71
7.7 Control panel 74
8. Starter 77
8.1 General 77
8.2 Removal and
installation 77
8.3 Pawl 77
8.4 Rope rotor 78
8.5 Starter rope /
starter grip 79
8.6 Tensioning the
rewind spring 80
8.7 Replacing the
rewind spring 81
9. Antivibration
elements 83
9.1 Antivibration spring
on handlebar 83
9.2 Antivibration spring
in the support 84
9.3 Antivibration spring
at the bottom of the
crankcase 84
9.4 Antivibration spring
on throttle shutter
housing 85
9.5 Handlebar 86
9.6 Rubber buffers /
support 87
9.6.1 Support 87
9.6.2 Support foot 88
9.6.3 Wiring harness
solenoid valve
(water connection) 90
10. Actuating lever 91
10.1 Switch shaft 91
10.2 Throttle trigger /
trigger interlock 92
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