Stihl TS 500i, Service Manual

Page 1: ...STIH STIHL TS 500i 2012 02...

Page 2: ...5 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...

Page 3: ...101 11 6 Leak testing 102 11 6 1 Checking the fuel tank fuel system 102 11 6 2 Checking the tank vent 103 11 6 3 Tank vent Removal and installation 104 11 7 Injection pump 104 11 7 1 Manual fuel pump...

Page 4: ...the text and pictures for greater clarity The meanings are as follows In the text Action to be taken as shown in the illustration above the text Action to be taken but not shown in the illustration ab...

Page 5: ...ar the fuel All work with fuel must be performed outdoors only Spilled fuel must be wiped away immediately Test for leakage after all work on the fuel system and engine Exercise extreme caution while...

Page 6: ...pliers screwdrivers etc may not be used Also do not cut open fuel hoses with a knife or similar aids Do not reuse fuel hoses after disassembly but instead always replace them with new hoses fuel hoses...

Page 7: ...ne power to ISO 7293 3 9 kW 5 3 HP at 9500 rpm Cut off speed 9800 rpm Max spindle speed to ISO 19432 4780 rpm Idle speed 2500 rpm Clutch Centrifugal clutch without linings Clutch engages at 4000 rpm C...

Page 8: ...re renewed assembly clean both threads insert tap in the internal thread by hand and then blow out the threaded hole brush off the exterior thread coat the cleaned screw with medium strength Loctite 2...

Page 9: ...inder 9 0 2 Screw M5x20 Crankcase clutch side fan side 8 0 2 Screw M5x35x22 Crankcase clutch side fan side 8 0 2 Screw P5x16 Bearing plug antivibration system tank housing 4 0 Screw M5x20 Fan cover cr...

Page 10: ...ring plug antivibration system 6 0 Screw P6x40 Support tank housing 6 0 Screw M10x18 Abrasive wheel 30 0 Screw M5x30 Adjusting lever guard 6 0 2 Screw M8x24 Adjusting lever guard square nut 4 0 Screw...

Page 11: ...eplace clutch springs Throttle cable is jammed Check easy movement of throttle cable and replace if necessary Throttle trigger is stiff Check throttle trigger repair if necessary Throttle shutter does...

Page 12: ...utch shoes badly worn Replace clutch Clutch drum badly worn Replace clutch drum Ribbed poly V belt not properly tensioned Tension ribbed poly V belt replace if necessary Cutting wheel rotates at idle...

Page 13: ...s replace if necessary Water hose kinked or damaged also check water supply hose Check hose clips water hose and seals replace if necessary Manifold for hose connection is clogged Check manifold and c...

Page 14: ...n replace if necessary Nozzles are clogged Clean nozzles replace if necessary Control panel damaged Check control panel with STIHL MDG 1 replace if necessary Solenoid valve is damaged or jams Check so...

Page 15: ...duce tension Starter rope can be pulled out almost without resistance crankshaft does not turn Guide peg on pawls or pawls themselves are worn Replace pawls Spring clip fatigued Replace spring clip Lo...

Page 16: ...alve replace if necessary b 6 10 Check oil seals replace if necessary b 6 2 b 6 3 Check engine does not leak b 6 2 Complaint remedied no Starting behavior OK no yes Trouble shooting completed yes Too...

Page 17: ...e breakage on an electrical component control unit sensor injection valve on off switch Fuel system leaking Crankcase leaking faulty Visual inspection of electrical leads Check clutch replace if neces...

Page 18: ...k the throttle shutter stops replace throttle shutter housing if necessary b 11 2 Injection valve mechanically worn Replace injection valve b 11 3 5 4 7 Engine stalls when idle Throttle shutter does n...

Page 19: ...essary b 7 4 Secure ignition lead b 7 4 Idle speed unstable erratic 11 Clean spark plug replace if necessary Fuel oil mixture contains too much oil Use a fuel mixture with the correct mixing ratio Fly...

Page 20: ...cceleration engine stalls while accelerating 12 Check pickup body replace if necessary b 11 8 1 Fuel system leaking Check fuel system does not leak b 11 6 Impulse hose damaged or kinked Check impulse...

Page 21: ...t reached Engine stops 13 Check decompression valve replace if necessary b 6 10 Spark plug sooted smeared with oil Clean spark plug replace if necessary Ignition lead loose on control unit Secure igni...

Page 22: ...Throttle shutter stops worn Check the throttle shutter stops replace throttle shutter housing if necessary b 11 2 Muffler spark arresting screen carbonized Check muffler replace if necessary b 6 1 13...

Page 23: ...21 Flywheel is cracked damaged Flywheel out of adjustment woodruff key has sheared off Injection pump has mechanical fault Check flywheel replace if necessary b 7 5 Check clutch replace if necessary...

Page 24: ...g into idle speed 22 Check oil seals replace if necessary b 6 2 b 6 3 Throttle shutter stops worn Check the throttle shutter stops replace throttle shutter housing if necessary b 11 2 Injection valve...

Page 25: ...TS 500i On off switch defective Check Switch off engine Check on off switch with STIHL MDG 1 clean if necessary or replace Behavior OK no Engine cannot be switched off 22 yes Troubleshooting complete...

Page 26: ...engages Insert and tighten the screw Fit the connector 1 with water hose and align it at a right angle to the adjusting lever 2 Coat O ring with STIHL press fluid b 13 Insert banjo screw 3 Do not dama...

Page 27: ...hose clip onto water hose Push water hose 1 as far as possible onto the support of the nozzle then align the hose clip 2 Press the tabs arrows on the hose clip 2 together until they engage Starting fr...

Page 28: ...ed parts arrows engage in the profiles arrows Push wiring harness 2 into the opening 3 Pull wiring harness 1 through the opening and fit solenoid valve 2 pushing the bushing 3 into the mount arrow the...

Page 29: ...e to the solenoid valve b 4 1 2 4 2 Cast arm with guard Unscrew the banjo screw on the adjusting lever and remove the connector with water hose b 4 1 1 Unscrew collar nuts arrows Relax the ribbed poly...

Page 30: ...remove the washer Pull off the belt pulley 1 Draw the shaft 1 out on the other side Carefully take out the screws arrows compression springs are tensioned The flange drops down on the other side 370R...

Page 31: ...opening arrow Press the rubber ring 2 into the hole in the guard until it lies flush The profile of the rubber ring must engage in the mount of the guard Place washer 1 on the outside of the guard on...

Page 32: ...rust washer 2 so that the groove arrow engages the lug 1 on the shaft Fit the axial clamping ring Fit the thrust washer so that the lugs 1 engage the grooves arrows in the shaft Fit screw Slide the ca...

Page 33: ...ll bearing Remove the cast arm with guard b 4 2 Remove the guard on the cast arm b 4 2 Remove the circlips 1 on both sides Drive the ball bearing out of the cast arm with press arbor 1 4224 893 7200 A...

Page 34: ...eter changes due to scoring etc it is sufficient to carefully inspect the shaft around the mount for the cutting wheel The axial truth of running on the other hand depends on the condition of several...

Page 35: ...rasive wheel on 130 mm diameter Axial runout 0 15 mm 0 15 mm Damage or unevenness in the mating faces of the thrust washers particularly the inner thrust washer mating faces are not plane use of parts...

Page 36: ...belt guard 1 Take out the collar nuts arrows Remove starter 1 Take the ribbed poly V belt 1 off the front belt pulley arrow 370RA014 TG 1 1307RA009 TG 1 370RA048 TG 1 Take the ribbed poly V belt 1 of...

Page 37: ...ed The hexagon must not be forced as the belt tension is obtained through the spring tension Screw all three collar nuts tight Insert the water hose in the guides starting from the solenoid valve 4 6...

Page 38: ...screws The tensioner must be set to the pre tensioned position before installing the cast arm with guard Turn the hexagon of the tensioner as far as possible counterclockwise to pre tension the tensio...

Page 39: ...cking strip 1 0000 893 5903 in the cylinder Locking strip 1 0000 893 5903 must rest against the cylinder wall arrow Position as shown Unscrew nut 1 and pull off starter cup 2 Examine the starter cup r...

Page 40: ...n the individual parts b 13 replace any damaged parts Always replace clutch shoes in sets Slip the retainers 1 onto the clutch shoes 370RA067 TG 1 370RA068 TG 370RA069 TG 1 Slide the clutch shoes 2 ov...

Page 41: ...inder Reassemble remaining parts in reverse order 5 3 Belt pulley clutch drum Remove the clutch b 5 2 Remove the ring arrow Remove the clutch drum 1 1 370RA002 TG 1307RA058 TG 1 Examine the clutch dru...

Page 42: ...A079 TG 1 1307RA059 TG 1 2 5 4 Studs for securing the cast arm with guard Remove the cast arm with guard b 4 2 Fit the stud puller 1 5910 893 0501 over the studs arrows as far as possible and unscrew...

Page 43: ...ed mating faces must be replaced Fit cooling plate 1 and muffler gasket 2 to muffler 3 and insert screws 4 into cooling plate Muffler gasket and cooling plate are held in place on the muffler 370RA086...

Page 44: ...nder exhaust port and cooling plate then tighten the screws gently The sealing plate must fill the full width between the screws Remove the air filter b 11 1 1307RA064 TG 1 Coat O ring on the plug of...

Page 45: ...fective replace the oil seals b 6 3 If the oil seals in the throttle shutter housing are defective replace the throttle shutter housing b 11 2 After testing slide the ring on the pump back to the righ...

Page 46: ...00 Slide the oil seal 2 over the assembly sleeve with the sealing lip facing the crankcase Remove the assembly sleeve Align press sleeve 2 so that the shoulder faces the oil seal 1 Press the new oil s...

Page 47: ...n reverse order 1307RA074 TG 1 2 1307RA075 TG 1 2 6 4 Shroud Remove the screw arrow Screw remains in cap 1 Remove the cap 1 with screw Unscrew screw 1 and remove cover 2 Screw remains in cover 2 1307R...

Page 48: ...ation Push rubber buffer 1 with lug into the hole arrow as far as it will go Piece of hose 2 must be pushed on Piece of hose 2 acts as hold down for the injection pump Lift plug 1 out of opening Guide...

Page 49: ...nside of the manifold b 13 Install the tank housing b 11 9 Reassemble remaining parts in reverse order 1307RA088 TG 1 1307RA089 TG 1 2 6 6 Cylinder Before removing the cylinder decide whether or not t...

Page 50: ...wiring harness 4 of the injection valve from the guides arrows Unscrew the screw 1 and remove the air guide shroud 2 Unscrew the screws 2 on the bottom and remove long screw 3 Remove the clamp 1 1307R...

Page 51: ...arrow The mating surface must be in perfect condition and without any damage whatsoever Parts with damaged mating faces must be replaced Always use a new cylinder gasket after removing the cylinder P...

Page 52: ...3 1307RA108 TG 3 1 2 Push cylinder as far as possible over the centering sleeves and hold For the pan head screw in the hose 2 the tool is guided through the hose to screw in the pan head screw Screw...

Page 53: ...with the 5 5 mm hole or with the holes 7 5 mm The drilled plate is shown from above in the illustration Dimensions are given in millimeters 1307RA113 TG 1 1307RA114 TG 14 4 21 24 4 23 2 14 8 14 7 26...

Page 54: ...tom 36 1 1307RA116 TG 7 2 23 8 43 0 1307RA119 TG 3 2 3 1 3 Insert three M5x55 screws 3 through the holes marked 29 Push the screws 1 through the holes in the crankcase half Fit washers and nuts arrows...

Page 55: ...2 Coat the conical crankshaft stub with oil Align the crankshaft with the conical crankshaft stub arrow facing the fan side ball bearing and push it home Fit the screw sleeve 1 over the thread of the...

Page 56: ...lf of the crankcase 1 as far as it will go The clutch side half of the crankcase must be fitted rapidly as the heat is transmitted to the crankshaft stub and the inner bearing race contracts Ensure th...

Page 57: ...th the assembly tool For this reason ensure that the rod eye arrow always faces towards the cylinder Remove the assembly tool Insert the screws arrows and tighten them crosswise Cut off the protruding...

Page 58: ...crankcase is reused the oil seals and ball bearings must be replaced all gasket residues removed and the mating surfaces cleaned thoroughly The mating surfaces must be absolutely clean to guarantee a...

Page 59: ...e remaining parts in reverse order 6 8 Piston Before removing the cylinder decide whether the crankshaft is to be removed b 6 7 Remove the cylinder b 6 6 Two snap rings are fitted but only one need be...

Page 60: ...e Push assembly drift 1 0000 893 4700 with the stub end first through piston hole and rod eye needle cage and secure the piston Coat the piston pin with oil Fit the piston pin 2 on the stub of the ass...

Page 61: ...upwards Fit the assembly tool 5910 890 2212 with the taper sleeve on the piston boss hold the piston steady and press the tool shank home until the snap ring slips into the groove The tool must be pre...

Page 62: ...0 Decompression valve Remove cap and bushing b 6 4 Unscrew the decompression valve 1 with socket 13 mm long reach 5910 893 2804 Examine the sealing cone arrow on the decompression valve for signs of d...

Page 63: ...ignition timing and the injection timing The throttle shutter 8 in the throttle shutter housing 2 is actuated via the throttle cable thus regulating the inflow of air The sensor 5 provides the pressu...

Page 64: ...the spark plug boot b 7 4 Unscrew screw 1 and remove cover 2 Screw remains in cover 1307RA076 TG 1 2 The plugs 1 2 3 4 5 must be seated completely in the bushings of the control unit and must be snapp...

Page 65: ...plug 1 of the generator into the socket 2 of the Injection system control unit generator 5910 840 0402 until it snaps into place 1307RA260 TG 2 1 1307RA261 TG 1 2 STIHL MDG 1 must be installed between...

Page 66: ...ensures the data transmission to the Bluetooth device on the computer The engine analyzer is supplied together with the diagnostic program for the computer on a data carrier from the factory A databa...

Page 67: ...d replace it if necessary b 7 4 Installation Coat outside of grommet with STIHL press fluid Press the grommet 1 with the thin lip completely into the opening arrow in the direction of the air filter t...

Page 68: ...he spark plug boot Use suitable pliers to pull the torsion spring out of the spark plug boot Unhook the torsion spring from the ignition lead Pull the boot off the ignition lead 1307RA037 TG 1 370RA20...

Page 69: ...tion Use a pointed tool to pierce the center of the end of the new ignition lead which is to be twisted into the control unit Before twisting in the ignition lead fill the coil tower with STIHL multi...

Page 70: ...eck groove arrow replace flywheel if necessary if the groove is worn replace the flywheel Ensure that the woodruff key engages in the groove arrow 1307RA277 TG 1 1307RA278 TG Installation The hole in...

Page 71: ...rator replace if necessary Installation Use the wiring tool 5910 890 4000 to press the leads completely into the guides b 1 1 Press the blue lead 1 completely into the guide arrow 1307RA283 TG 2 1 1 1...

Page 72: ...t run underneath the insulating tube Press the leads completely into the guides arrows The lead 1 must be seated completely in the guide arrow The flywheel must not touch the generator lead power supp...

Page 73: ...out of the opening arrow Remove the retainer 1 Check the switch 2 replace if necessary Check the control panel replace if necessary b 7 7 Installation Use the wiring tool 5910 890 4000 to press the l...

Page 74: ...mount so that the tab 2 engages in the fin arrow The yellow and green lead of the control panel must be in the guide arrow and must be placed underneath the holder 1 1307RA304 TG 1 1307RA305 TG 1 2 1...

Page 75: ...are pressed Reassemble remaining parts in reverse order 1307RA309 TG 1 2 1307RA310 TG 7 7 Control panel Check the control panel with STIHL MDG 1 b 7 1 b 7 2 Refer also to troubleshooting chart b 3 5...

Page 76: ...Press in the control panel 1 until the wide tab 2 engages narrow tab arrow engages in the opening Hook the green and yellow lead into the guides arrows green lead underneath yellow lead Place the gree...

Page 77: ...1 of the green lead into the guide arrow Press the green lead 1 into the guides arrows the yellow lead must run underneath the green lead Install the switch b 7 6 Reassemble remaining parts in reverse...

Page 78: ...arbons to the rewind spring Carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored Before installing lubricate the rewind spring and starte...

Page 79: ...then hold the rope rotor 2 steady The recess arrow must point towards the rope guide Pull the starter rope 1 out between the recess and rope guide arrow with assembly hook 2 5910 893 8800 Hold the ro...

Page 80: ...rter rope is broken Remove any remaining scraps of rope from the rope rotor and starter grip 1307RA039 TG 1 The starter rope must not be shortened Remove the rope rotor b 8 4 Pull out starter rope 1 o...

Page 81: ...the rewind spring Pawl and spring must be installed 1307RA042 TG 1 370RA236 TG Hold the rope rotor 1 so that the recess arrow faces towards the rope guide Pull the starter rope 2 out between the rece...

Page 82: ...ope back one turn Pull the twisted rope out with the starter grip and tidy it Keep the starter rope tensioned with the starter grip Let go of the rope rotor and let the starter rope rewind slowly on t...

Page 83: ...ollows Arrange the spring 1 as shown in the illustration Position the spring loop in the fixture arrow in the spring housing Fit the rewind spring 1 completely in a circular fashion working in clockwi...

Page 84: ...7RA031 TG 1 2 Unscrew handlebar support 1 Examine the spring handlebar support and clamp replace if necessary Installation Screw the handlebar support 1 into the antivibration spring 2 as far as possi...

Page 85: ...stallation Push antivibration spring 1 as far as possible into the mount arrow and hold it in position antivibration spring is secured against twisting Screw in the screw 1 and tighten it Install the...

Page 86: ...rew 1 and tighten it Install handlebar b 9 5 9 4 Antivibration spring on throttle shutter housing The antivibration spring is located near the throttle shutter housing between tank housing and crankca...

Page 87: ...w screw 1 and remove clamp 2 Unscrew the screw 1 Unscrew the screw 1 on the bottom and remove clamp 2 1307RA021 TG 2 1 1307RA326 TG 1 1307RA333 TG 1 1 1 2 Remove handlebar 1 and pull out antivibration...

Page 88: ...g engages in the hole arrow This secures the antivibration spring in the handlebar Coat inside of hose with STIHL press fluid b 13 Fit clamp 1 the peg must engage in the hose arrow Insert and tighten...

Page 89: ...A340 TG 1 2 2 1 3 Installation Position the pre assembled support 1 underneath the machine so that it engages in the pegs arrows Push the bearing plug of the antivibration spring into the mount arrow...

Page 90: ...f the solenoid valve replace if necessary b 9 6 3 Installation Apply STIHL press fluid to the peg of the stop buffer b 13 Push stop buffer 1 into the holes of the air baffle 2 and drawing in on the pe...

Page 91: ...1 3 Pull the wiring harness 1 out of the guides arrows Installation Using the wiring tool 5910 890 4000 press the leads completely into the guides b 1 1 Orient the wiring harness 1 so that the plug 2...

Page 92: ...w arrow Remove handle molding 1 1307RA050 TG 1 1307RA358 TG 1 Unhook the torsion spring on the trigger interlock Pry the leaf spring 1 out of the mount arrow Pull the switch shaft 1 out of the bearing...

Page 93: ...the handle molding 1 into position under the pegs arrows Insert and tighten the screw 10 2 Throttle trigger trigger interlock Remove the handle molding b 10 1 Unhook the torsion spring 1 from the trig...

Page 94: ...istance on both sides Press the trigger interlock 1 into the bearing points arrows until it clicks into place 1307RA249 TG 1 1307RA250 TG 1 1307RA251 TG 1 Hook the torsion spring 1 into the trigger in...

Page 95: ...e manifold 3 with throttle shutter housing 4 Remove gasket 1 always insert a new gasket Unscrew the screws 2 and remove the manifold 3 Examine the manifold replace if necessary Engine operation may be...

Page 96: ...manifold 2 so that the screw head is on the clutch side Slide the hose clip 1 over the shoulder arrow only push the hose clip onto the shoulder once the tank housing is installed Apply STIHL press flu...

Page 97: ...ess the air baffle 1 until the tab 2 snaps into place Push the bushing 1 into the mount arrow Install the control unit b 7 3 Fit the shroud b 6 4 Check correct functioning the throttle cable must move...

Page 98: ...ion valve 2 out of the guides arrows Unscrew the screws 1 and remove the injection valve 2 with air baffle 3 1307RA171 TG 1 1307RA172 TG 1 2 1307RA173 TG 1 3 1 2 Press injection valve 1 out of the air...

Page 99: ...the crankcase Insert and tighten the screws 3 Place the wiring harness 1 of the injection valve 2 into the guides arrows Place the wiring harness 1 of the sensor into the guides arrows the wiring harn...

Page 100: ...2 Position cable holder 1 so that it engages over the bushing arrow do not pinch the leads Screw in the screw 2 and tighten it Fit the cover 1 and guide the cable lug of the ground wire 2 between the...

Page 101: ...1 and pull out the sensor 2 Examine the sensor and O ring replace if necessary Do not clean the sensor using cold cleaner compressed air or sharp edged tools 1307RA171 TG 1 1307RA192 TG 1 1 2 Installa...

Page 102: ...s 1 and bushing 2 in the guides arrows start with the bushing Position the cable holder 1 so that it engages over the bushing arrow do not pinch the leads Screw in the screw 2 and tighten it 1307RA186...

Page 103: ...as it will go into the hole arrow Pull injection pump from the guide Push hoses 1 1127 358 7600 onto the plug 2 of the pressure testing tool 5910 890 4100 and injection pump 3 1 1307RA370 TG 1307RA371...

Page 104: ...the tank vent Replace tank vent if necessary b 11 6 3 Continue with Testing with gauge pressure Testing with gauge pressure The same preparatory steps are required as for the testing with negative pr...

Page 105: ...in reverse order 11 7 Injection pump 11 7 1 Manual fuel pump After the injection pump has been removed replace the fuel hose unit First check if only the manual fuel pump needs to be replaced The manu...

Page 106: ...nd connecting element 5 Pull the fuel suction hose 1 impulse hose 2 and fuel hose 3 from the connectors on the injection pump 1307RA215 TG 1 2 3 4 5 1307RA216 TG 1 2 3 Disconnect the fuel suction hose...

Page 107: ...dy become clogged with very fine dirt particles This reduces the intake diameter and fuel can no longer be delivered in sufficient quantities Always check the fuel tank and pickup body first if proble...

Page 108: ...push the hose clip 1 in the direction of the throttle shutter housing Push down the manifold 2 from the tank housing support 1307RA222 TG 1 2 1307RA223 TG 1 2 3 1307RA224 TG 1 2 Unscrew the screw 1 a...

Page 109: ...in the crankcase and then push it into the opening 2 in the side of the fan side half of the crankcase Check that the hose is correctly seated On the fan side the hose arrows must enclose the opening...

Page 110: ...using with the ends of the string 2 until the hose completely encloses the opening arrow Remove the string Bearing plug 1 must be twisted into the antivibration spring as far as it will go Push the ta...

Page 111: ...e holder 1 of the fuel hoses and injection pump 2 into the guides arrows Install the handlebar b 9 5 1307RA238 TG 1 2 1307RA239 TG 2 1 1307RA240 TG 2 1 Pull the fuel suction hose 1 out of the fuel tan...

Page 112: ...sting tools 5910 890 4100 Engine and fuel system leak test Hose 210 mm 1127 358 7600 Engine and fuel system leak test Plug 5910 890 3800 Engine and fuel system leak test Connector 5910 895 0200 Engine...

Page 113: ...r cut off machine 4238 890 2100 Mount cut off machine on assembly stand 18 Press sleeve 4238 893 2400 Install oil seal on clutch side 19 Spacer 4238 894 1100 Release flywheel in combination with extra...

Page 114: ...No 3 1 0000 893 3706 Remove oil seal on clutch side Jaws No 6 0000 893 3711 Remove oil seal on fan side 32 Puller 5910 890 4504 Removing flywheel 33 Stud puller M8 5910 893 0501 Unscrew studs for att...

Page 115: ...cover 3 STIHL press fluid OH 723 0781 957 9000 Rubber elements antivibration elements 4 STIHL multi purpose grease 0781 120 1109 High voltage output on control unit 5 Medium strength thread locking a...

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Page 118: ...englisch english 0455 753 0123 VA0 B12 Printed in Germany...