Ms210 Ms230 Ms250 Service Manual i1l13

STIH)

STIHL MS 210, 230, 250

2003-04

Contents

1.

Introduction

2

2.

Safety Precautions

3

3.

Specifications

4

3.1 3.1.1 3.2 3.3 3.4 3.5

Engine Engine (USA only) Fuel System Ignition System Chain Lubrication Tightening Torques

4 4 5 5 5 6

4.

Troubleshooting Chart

8

4.1 4.2 4.3 4.4 4.5 4.6 5.

5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.5 5.6

Clutch, Chain Drive, Chain Brake, Chain Tensioner Rewind Starter Chain Lubrication Ignition System Carburetor Engine

8 9 10 11 12 14

6.

Engine

6.1

Muffler/Spark Arresting Screen Leakage Test Preparations Pressure Test Vacuum Test Oil Seals Removing and Installing Cylinder Piston Piston Rings Crankshaft Decompression Valve

6.2 6.2.1 6.2.2 6.2.3 6.3 6.4 6.5 6.6 6.7 6.8 6.9

15

Clutch Drum / Chain Sprocket Chain Catcher Clutch Chain Brake Checking Operation Removing Installing Front Chain Tensioner Side Chain Tensioner

15 16 16 18 18 19 20 22 22

23 24 24 25 26 26 28 29 31 33 33 34

10.

Chain Lubrication

54

10.1 10.2

54

10.3 10.4 10.5

Pickup Body Connector/ Suction Hose Valve Worm Oil Pump

11.

Fuel System

58

7.

Ignition System

34

7.1 7.2 7.3

Spark Plug Boot Ignition Module Testing the Ignition Coil Checking the Wiring Harness Ignition Timing Removing and Installing Flywheel Ignition System Troubleshooting

35 35

39

Air Filter Carburetor Leakage Test Removing and Installing 11.2.3 Adjusting (Carburetor without Limiter Cap) 11.2.4 Adjusting (Carburetor with Limiter Cap) 11.2.5 Standard Setting (Carburetor with Limiter Cap) 11.3 Tank Vent 11.4 Pickup Body 11.5 Suction Hose 11.6 Manual Fuel Pump 11.7 Hoses 11.8 Fuel Tank

8.

Rewind Starter

42

12.

8.1 8.2

General Removing and Installing Rope Rotor Segment Starter Rope Elastostart Tensioning Rewind Spring Pawl

42 42 42 44 44 45 46 47 48

AV Handle System/ Handle Housing

48

7.4 7.4.1 7.4.2 7.5 7.6

Clutch, Chain Drive, Chain Brake and Chain Tensioner

23

8.3 8.4 8.5 8.5.1 8.5.2 8.6 8.7 9. 9.1 9.2 9.3 9.4 9.5 9.6

Annular Buffers Front Handle Handle Housing Switch Shaft Spring Throttle Trigger/ Interlock Lever

36 36 37 37 38

11.1 11.2 11.2.1 11.2.2

13.

55 55 56 57

58 59 59 60 61 62 62 63 64 64 65 65 67

Special Servicing Tools

69

Servicing Aids

71

48 49 50 52 52 53

q © ANDREAS STIHL AG & Co. KG, 2007

MS 210, MS 230, MS 250

1

1.

Introduction

This service manual contains detailed descriptions of all the repair and servicing procedures specific to this power tool series. As the design concept of model MS 210, 230 and 250 chainsaws is almost identical, the descriptions and servicing procedures in thus manual generally apply to all three models. Differences are described in detail. You should make use of the illustrated parts lists while carrying out repair work. They show the installed positions of the individual components and assemblies. Refer to the latest edition of the relevant parts list to check the part numbers of any replacement parts. A fault on the machine may have several causes. To help locate the fault, consult the troubleshooting charts for all assemblies and systems in this manual and the "STIHL Service Training System". Refer to the "Technical Information” bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list until a revised edition is issued.

2

The special tools mentioned in the descriptions are listed in chapter "Special Servicing Tools" of this manual. Use the part numbers to identify the tools in the "STIHL Special Tools" manual. The manual lists all special servicing tools currently available from STIHL. Symbols are included in the text and pictures for greater clarity. The meanings are as follows: In the descriptions: : = Action to be taken as shown in the illustration (above the text) – = Action to be taken that is not shown in the illustration (above the text) In the illustrations: A Pointer (short) aDirection of movement (long) b 4.2 = Reference to another chapter, i.e. chapter 4.2 in this example. Service manuals and all technical Information bulletins are intended exclusively for the use of STIHL servicing dealers. They must not be ed to third parties.

Servicing and repairs are made considerably easier if the clamp (1) 5910 890 2000 is used to mount the machine on assembly stand (2) 5910 890 3100 so that one clamp screw engages the outer 10 mm bore (3) in the assembly stand. To service the underside of the machine (e.g. remove the oil pump), turn the machine through 180 degrees and mount it so that one clamp screw engages the inner 10 mm bore (1) in the assembly stand. Note: Pull the hand guard back against the front handle for this purpose. Always use original STIHL replacement parts. They can be identified by the STIHL part number, the STIH) logo and the STIHL parts symbol ( This symbol may appear alone on small parts.

MS 210, MS 230, MS 250

2.

Safety Precautions

If the engine is started up in the course of repairs or maintenance work, observe all local and countryspecific safety regulations as well as the safety precautions and warnings in the owner’s manual. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. Improper handling may result in burns or other serious injuries. Warning! Do not smoke or bring any fire, flame or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately.

MS 210, MS 230, MS 250

3

3.

3.1

Specifications

Engine

Displacement: Bore: Stroke: Engine power to ISO 7293: Max. permissible engine speed (with bar and chain): Idle speed: Clutch: Clutch engages at: Crankcase leakage test at gauge pressure: under vacuum:

3.1.1

MS 230

MS 250

35.2 cm3 40 mm 28 mm 1.6 kW (2.2 HP) at 9,000 rpm

40.2 cm3 40 mm 32 mm 2.0 kW (2.7 HP) at 10,000 rpm

45.4 cm3 42.5 mm 32 mm 2.3 kW (3.1 HP) at 10,000 rpm

12,500 rpm 14,000 rpm 2,800 rpm Centrifugal clutch without linings 4,100 rpm

14,000 rpm

0.5 bar 0.5 bar

Engine (USA only)

Displacement: Bore: Stroke: Engine power to ISO 7293: Max. permissible engine speed (with bar and chain): Idle speed: Clutch: Clutch engages at: Crankcase leakage test at gauge pressure: under vacuum:

4

MS 210

MS 210

MS 230

MS 250

2.15 cu. in 1.57 in 1.10 in 1.5 kW (2.01 HP)

2.45 cu. in 1.57 in 1.26 in 1.9 kW (2.55 HP)

2.77 cu. in 1.67 in 1.26 in 2.2 kW (2.95 HP)

12,500 rpm 14,000 rpm 2,800 rpm Centrifugal clutch without linings 4,100 rpm

14,000 rpm

7.25 psi 7.25 psi

MS 210, MS 230, MS 250

3.2

Fuel System

Carburetor leakage test at gauge pressure: Function of tank vent at gauge pressure: Fuel:

3.3

0.3 bar (4.35 psi) 0.05 bar (0.72 psi) see owner’s manual

Ignition System

Air gap between ignition module and fanwheel: Spark plug (resistor type): Electrode gap:

3.4

0.8 bar (11.6 psi)

0.2 – 0.4 mm (0.008 – 0.015 in) Bosch WSR 6F NGK BPMR 7A 0.5 mm (0.02 in)

Chain Lubrication

Fully automatic speed-controlled oil pump with rotary piston Oil delivery rate:

MS 210, MS 230, MS 250

approx. 7.5 cc/min (0.46 cu in/min) at 10,000 rpm

5

3.5

Tightening Torques

DG screws are used in the polymer and light-alloy components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary without detrimentally affecting the strength of the screwed assembly, providing the specified tightening torque is observed. For this reason always use a torque wrench.

Fastener

Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Collar screw

Collar locknut Collar locknut Collar nut Spline screw

6

Thread size

IS-M4x15 IS-D4x15 IS-P5x16 IS-M4x15 IS-DG5x24 IS-DG5x24 IS-DG5x24 IS-DG5x24 IS-DG5x24 IS-DG5x24 IS-DG5x24 DG 8x18 M12x1 M14x1.25 M5 M5 M8x1 M12x1.5 IS-DG5x16

For component

Cain brake cover Handle molding Connector (engine housing/oil pump) Ground wire (to cylinder) Handle housing/front handle Hand guard Fan housing Buffer (to front handle) Buffer (to engine housing) Ignition module (to engine housing) Cylinder (to engine housing) Guide bar mounting Carrier (clutch) Spark plug Muffler Filter housing/carburetor Flywheel to crankshaft Decompression valve Spiked bumper

Torque

Remarks

kpm

Nm

0.2 0.16 0.4 0.35 0.35 0.35 0.35 0.35 0.35 0.4 0.95 1.6 5.0 2.5 0.8 0.27 2.8 1.4 0.37

2.0 1.6 4.0 3.5 3.5 3.5 3.5 3.5 3.5 4 9.5 16 50 25 8 2.7 28 14 3.7

MS 210, MS 230, MS 250

Use the following procedure to fit a DG screw in an existing thread: – Place the DG screw in the hole and rotate it counterclockwise until drops down slightly. – Tighten the screw clockwise to the specified torque. This procedure ensures that the screw engages properly in the existing thread and does not form a new thread, which would weaken the assembly.

Note: Power screwdriver speed setting for polymer: – DG screws

MS 210, MS 230, MS 250

max. 500 rpm

7

4. 4.1

Troubleshooting Chart Clutch, Chain Drive, Chain Brake, Chain Tensioner

Condition

Cause

Remedy

Saw chain stops under load at full throttle

Clutch shoes badly worn

Install new clutch

Clutch drum badly worn

Install new clutch drum

Brake band stuck

Check freedom of movement and function of brake band

Engine idle speed too high

Readjust with idle speed screw (counterclockwise)

Saw chain rotates at idle speed

Clutch springs stretched or fatigued Replace the clutch springs Clutch spring hooks broken

Loud noises

Chain sprocket wears rapidly

Saw chain does not stop immediately when brake is activated

8

Replace the clutch springs

Clutch springs stretched or fatigued Replace all clutch springs Needle cage damaged

Fit new needle cage

Clutch shoe retainer broken

Fit new retainer

Clutch shoes and carrier worn

Install new clutch

Chain not properly tensioned

Tension chain as specified

Wrong chain pitch

Fit chain of correct pitch

Brake spring stretched or broken

Fit new brake spring

Brake band stretched / worn / broken

Fit new brake band

MS 210, MS 230, MS 250

4.2

Rewind Starter

Condition

Cause

Remedy

Starter rope broken

Rope pulled out too vigorously as far as stop or over edge, i.e. not vertically

Fit new starter rope

Normal wear

Fit new starter rope

Spring overtensioned – no reserve when rope is fully extended

Fit new rewind spring

Very dirty or corroded

Clean or replace rewind spring

Guide peg on pawl or pawl itself is worn

Fit new pawl

Spring clip fatigued

Fit new spring clip

Starter mechanism is very dirty (dusty conditions)

Thoroughly clean complete starter mechanism

Lubricating oil on rewind spring becomes viscous at very low outside temperatures (spring windings stick together)

Apply a few drops of kerosine (paraffin) to spring, then pull rope carefully several times until normal action is restored

Rewind spring broken (rope does not rewind)

Starter rope can be pulled out almost without resistance (crankshaft does not turn)

Starter rope is difficult to pull and rewinds very slowly

MS 210, MS 230, MS 250

9

4.3

Chain Lubrication

Important! In the event of trouble with the chain lubrication system, always investigate the other possible sources of faults before disassembling the oil pump. Condition

Cause

Remedy

Chain receives no oil

Oil tank empty

Fill up with oil

Oil inlet hole in guide bar is blocked

Clean oil inlet hole

Intake hose or pickup body (strainer) clogged or intake hose ruptured

Wash intake hose and pickup body (strainer) in fresh STIHL cleaner or replace if necessary

Valve in oil tank blocked

Clean or replace valve

Oil pump damaged or worn

Install new oil pump

Oil seal leaking

Replace oil seal

Bore in pump housing worn

Install new oil pump

Oil pump worn

Install new oil pump

Machine losing chain oil

Oil pump delivers too little oil

10

MS 210, MS 230, MS 250

4.4

Ignition System

Warning! Exercise extreme caution while carrying out maintenance and repair work on the ignition system. The high voltages which occur can cause serious or fatal accidents! Condition

Cause

Remedy

Engine runs roughly, misfires, temporary loss of power

Spark plug boot is loose

Press boot firmly onto spark plug and fit new spring if necessary

Spark plug sooted, smeared with oil

Clean the spark plug or replace if necessary

Weak spark or no spark

Faulty insulation on ignition lead or short circuit wire. Use ohmmeter to check ignition lead for break. If break is detected or high resistance measured, fit a new ignition lead

Incorrect air gap between ignition coil and flywheel

Set air gap correctly

Flywheel cracked or has other damage

Install new flywheel

Crankcase damaged (cracks)

Install new crankcase

No ignition spark

Check operation of Master Control lever, ignition module and ignition lead

MS 210, MS 230, MS 250

11

4.5

Carburetor

Condition

Cause

Remedy

Carburetor floods; engine stalls

Inlet needle not sealing. Foreign matter in valve seat or cone damaged

Remove and clean or replace the inlet needle, clean the fuel tank, pickup body and fuel line if necessary

Inlet control lever sticking on spindle

Free off inlet control lever

Helical spring not located on nipple of inlet control lever

Remove the inlet control lever and refit it correctly

Perforated disc on diaphragm is deformed and presses constantly against the inlet control lever

Fit a new metering diaphragm

Inlet control lever too high (relative to design position)

Set inlet control lever flush with top edge of housing or bottom of metering chamber

Idle jet too lean

Back off low speed screw (L) slightly

Main jet too lean

Back off high speed screw (H) slightly

Inlet control lever too low (relative to design position)

Set inlet control lever flush with top edge of housing or metering chamber face

Inlet needle sticking to valve seat

Remove inlet needle, clean and refit

Connecting bore to atmosphere blocked

Clean bore

Diaphragm gasket leaking

Fit a new diaphragm gasket

Metering diaphragm damaged or shrunk

Fit a new metering diaphragm

Poor acceleration

12

MS 210, MS 230, MS 250

Condition

Cause

Remedy

Engine will not idle, idle speed too high

Throttle shutter opened too wide by idle speed screw (LA)

Reset idle speed screw (LA) correctly

Engine leaking

Seal the engine

Idle jet bores or ports blocked

Clean jet bores and ports with compressed air

Idle jet too rich

Screw down low speed screw (L) slightly

Setting of idle speed (LA) incorrect – throttle shutter completely closed

Set idle speed screw (LA) correctly

Small plastic plate in valve jet does not close

Clean or renew valve jet

Air filter plugged

Clean or renew the air filter

Tank vent faulty

Clean tank vent or replace if necessary

Leak in fuel line between tank and fuel pump

Seal connections or install new fuel line

Pump diaphragm damaged or fatigued

Fit a new pump diaphragm

Main jet bores or ports blocked

Clean the bores and ports

Fuel pickup body dirty

Clean the pickup body, fit a new filter

Fuel strainers dirty

Clean the fuel strainers

Engine stalls at idle speed

Engine speed drops quickly under load – low power

MS 210, MS 230, MS 250

13

4.6

Engine

Always check and, if necessary, repair the following parts before looking for faults on the engine: – – – –

Air filter Fuel system Carburetor Ignition system

Condition

Cause

Remedy

Engine does not start easily, stalls at idle speed, but operates normally at full throttle

Oil seals in crankcase damaged

Replace the oil seals

Gasket on carburetor spacer flange leaking

Fit a new gasket

Engine pan leaking

Seal the engine pan

Crankcase damaged (cracks)

Replace the crankcase

Muffler leaking

Seal or replace the muffler

Secondary air seepage through leaking gaskets on carburetor spacer flange

Fit new gaskets

Piston rings worn or broken

Fit new piston rings

Muffler / spark arresting screen carbonized

Clean the muffler (inlet and exhaust), replace spark arresting screen

Air filter element dirty

Replace air filter element

Fuel / impulse line severely kinked or damaged

Replace lines or position them free from kinks

Decompression valve sticking

Replace the decompression valve

Insufficient cylinder cooling. Air inlets in fan housing blocked or cooling fins on cylinder very dirty

Thoroughly clean all cooling air openings and the cylinder fins

Engine does not deliver full power or runs erratically

Engine overheating

14

MS 210, MS 230, MS 250

Clutch Drum / Chain Sprocket

143RA007 VA

176RA330 VA

5.1

Clutch, Chain Drive, Chain Brake and Chain Tensioner

143RA004 VA

5.

– Remove the chain sprocket cover.

: Take the needle cage out of the sprocket.

: Disengage the chain brake by pulling the hand guard toward the front handle.

– Clean and inspect the clutch drum / chain sprocket.

: If the clutch drum/chain sprocket is still serviceable, use No. 120 emery paper or emery cloth (grain size approx. 120 µm) to clean and roughen its friction surface. Reassemble in the reverse sequence.

100% 80%

: Remove the E-clip (1).

!

148RA101 VA

1

: Inspect the clutch drum (1) for signs of wear.

– Clean stub of crankshaft. Wash needle cage in clean white spirit and lubricate with grease – b 13. – Replace damaged needle cage. – Rotate clutch drum/chain sprocket and apply slight pressure at the same time until oil pump drive spring engages properly.

: Remove the washer (2). If there are noticeable wear marks on the inside diameter of the clutch drum, check its wall thickness. If it is less than 80% of the original wall thickness, fit a new clutch drum.

– If rim sprocket was fitted, reinstall it with the cavities facing outward.

If the clutch drum has to be replaced, also check the brake band – b 5.4.

– Remove the rim sprocket, if fitted. : Pull off the clutch drum / chain sprocket.

MS 210, MS 230, MS 250

15

5.2

Chain Catcher

5.3

2

Clutch

Troubleshooting chart – b 4.1.

1

– Remove the clutch drum/chain sprocket – b 5.1.

4 3

208RA003 VA

208RA001 VA

– Remove the air filter – b 11.1.

: Sprocket cover with integrally molded chain catcher.

: Oil the cylindrical part (1) of the replacement chain catcher.

If the chain catcher has broken off, repair as follows:

: Push the chain catcher into the AV element (2) and engage the peg (3) in the housing bore (4) at the same time. – Fit the chain bumper strip. Assemble all other parts in the reverse sequence.

2 : Remove the chain bumper strip (1).

208RA000 VA

1

: Take out the shutter. – Pull boot off the spark plug.

: Pry the plug (2) out of the front right-hand AV element.

– Unscrew the spark plug.

135RA022 VA

1

– Close the decompression valve, if fitted. : Push the locking strip (1) 0000 893 5903 into the cylinder.

16

MS 210, MS 230, MS 250

12

: Unscrew the clutch from the crankshaft clockwise (left-hand thread).

: Pull the retainers, if fitted, off the clutch shoes.

2

Disassembling the clutch: : Use hook (2) 5910 890 2800 to remove the clutch springs (1).

208RA032 VA

: On retainers with tabs (1), the narrow side (2) must be next to the series number (3).

1

3

– Clean all parts with STIHL cleaner.

208RA027 VA

208RA026 VA

2

208RA028 VA

1

208RA031 VA

135RA023 VA

3

: Fit the clutch shoes over the arms (1) of the clutch carrier so that the series number (2) is on the same side as the larger hexagon (3).

– Replace any damaged parts.

208RA029 VA

208RA030 VA

– Pull the clutch shoes off the carrier.

Assembling the clutch:

: Clamp the clutch in a vise.

: Slip the retainers onto the clutch shoes.

MS 210, MS 230, MS 250

17

5.4 5.4.1

2

208RA033 VA

250RA008 VA

1

: Attach one end of each spring (1) to the clutch shoes.

– Remove locking strip from the cylinder.

: Use the hook (2) 5910 890 2800 to attach other ends of springs and press them firmly into the clutch shoes.

– Insert spark plug and tighten down to 25 Nm (18.5 lb.ft). : If spark plug has a separate terminal nut, make sure it is properly tightened down.

Chain Brake Checking Operation

The chain brake is one of the most important safety devices on the chainsaw. Its efficiency is measured in of the chain braking time, i.e. the time that elapses between activating the brake and the saw chain coming to a complete standstill. The shorter the braking time, the better the efficiency and protection offered against being injured by the rotating chain. Contamination (with chain oil, chips, fine particles of abrasion, etc.) and smoothing of the friction surfaces of the brake band and clutch drum impair the coefficient of friction. This, in turn, reduces the frictional forces and thus prolongs the braking time. A fatigued or stretched brake spring has the same negative effect.

– Fit boot on the spark plug. – Start the engine.

135RA024 VA

– With the chain brake activated (locked), open throttle wide for a brief period (max. 3 seconds) – the chain must not rotate. – With the chain brake released, open throttle wide and activate the brake manually – the chain must come to an abrupt stop.

: Screw on the clutch and tighten down to 50 Nm (37 lbf.ft).

The braking time is in order if deceleration of the saw chain is imperceptible to the eye.

– Install the clutch drum / chain sprocket – b 5.1.

: Fit the shutter so that its lugs engage the recesses in the handle housing. – Install the air filter – b 11.1.

18

MS 210, MS 230, MS 250

5.4.2

Removing

– Remove the clutch drum / chain sprocket – b 5.1. – Release brake spring tension by pushing hand guard forward.

135RA027 VA

135RA028 VA

– Remove upper bumper strip from the tensioner.

: Remove the screw (arrow) from the hand guard.

: Pry the brake band out of the engine housing.

: Take out the screws.

Install a new brake band if:

– Remove the cover.

– there are noticeable signs of wear (large areas on inside diameter and/or parts of outside diameter) and its remaining thickness is less than 0.6 mm (0.024"). Important! Thickness of brake band must not be less at any point.

135RA029 VA

135RA026 VA

170RA014 VA

– Disconnect the brake band from the bell crank.

: Remove the E-clip.

2

1

: Carefully ease the brake spring off the anchor pin and take it off the bell crank.

135RA030 VA

: If the brake band is still serviceable, use No. 120 emery paper or emery cloth (grain size approx. 120 µm) to clean and roughen its entire friction surface (inside diameter). : Remove strap from bell crank pivot pin (1).

: Push the strap sideways and lift it off the hand guard pivot pin (2).

MS 210, MS 230, MS 250

19

5.4.3

Installing

– Lubricate sliding and bearing points of chain brake with STIHL multipurpose grease or, preferably, molybdenum grease (e.g. Molykote) – b 13.

135RA031 VA

– Install the flat spring.

: Remove the washer.

: Remove the flat spring. – Inspect parts and replace if damaged. – Clean the entire housing recess for the chain brake. – If the groove of the brake spring anchor pin is worn, replace the housing.

: Carefully pry the hand guard (1) and bell crank (2) off their pivot pins and lift away together.

135RA034 VA

2

135RA032 VA

1

: Insert the bell crank in the side of the hand guard so that the short arm of the bell crank points to top of hand guard.

– Pull the bell crank out of the hand guard.

20

MS 210, MS 230, MS 250

: Position the hand guard (1) against the pivot pin and fit the other side of the hand guard over the housing.

135RA038 VA

135RA031 VA

2

208RA109 VA

1

: Hook the brake spring onto the bell crank.

: Fit the washer.

: Position the bell crank (2) against the pivot pin. 2

135RA037 VA

1

: Fit strap on the pivot pin (1) and engage it in the pivot pin's groove.

135RA039 VA

: Push the hand guard and bell crank onto their pivot pins.

: Position the brake band around the clutch and push it into the engine housing.

: Slip the other end of the strap over the bell crank pivot pin (2). – Secure strap with E-clip.

1

: Check that flat spring (1) is properly located on face (2) of hand guard bearing boss.

MS 210, MS 230, MS 250

135RA040 VA

2

135RA036 VA

– Coat the brake band with chain oil (STIHL Bioplus), b 13, to protect it from corrosion and help reduce "snatching" during the first few brake applications.

: Attach the brake spring to the bell crank.

21

5.5

Front Chain Tensioner

5.6

Side Chain Tensioner

2

: Use the hook (2) 1117 890 0900 to attach the brake spring (1) to the anchor pin.

135RA044 VA

135RA041 VA

135RA043 VA

1

– Remove the chain sprocket cover.

– Remove the chain sprocket cover.

: Pull the cover out of the housing.

: Take out the screw. – Pull tensioner assembly out of the engine housing.

1

3

1

2

4

2

3

135RA045 VA

3

143RA052 VA

2

208RA004 VA

1

– Fit the bushing (1) in the hand guard (2).

: Unscrew the nut (1) from the adjusting screw (2).

: Take the thrust pad (1) off the adjusting screw (2).

: Insert M5x24 screw (3) and tighten down to 3.5 Nm (2.6 lbf.ft).

: Take the adjusting screw out of the cover (3).

: Rotate the spur gear (3) until the adjusting screw comes out of the tensioner slide (4).

– Fit the cover.

Reverse the above sequence to install the chain tensioner.

– Tighten screws to 2.0 Nm (1.5 lbf.ft). – Fit upper bumper strip on tensioner. 135RA046 VA

– Install clutch drum/chain sprocket – b 5.1. – Check operation of chain brake – b 5.4.1. : Pull the spur gear out of the cover.

22

MS 210, MS 230, MS 250

6. 6.1

Engine Muffler/Spark Arresting Screen This machine does not have a conventional crankcase. The engine consists of the cylinder, piston, crankshaft and engine pan.

135RA047 VA

135RA051 VA

Troubleshooting chart – b 4.6.

: Pull the tensioner slide off the cover.

: Muffler with push-fit upper and lower casings: Remove the upper casing from the lower casing.

– Take the adjusting screw out of the cover. – Inspect the teeth on the spur gear and adjusting screw. Replace both parts if necessary. Reverse the above sequence to install the chain tensioner.

: Unscrew the nuts.

135RA052 VA

135RA048 VA

– Coat teeth of adjusting screw and spur gear with grease, b 13, before refitting.

208RA006 VA

– Remove the muffler.

: Pull off or lever off the cover plate – depending on type fitted.

1

2

135RA053 VA

: Muffler with push-fit upper and lower casings: If necessary, take the baffle out of the lower casing.

: Remove the gasket (1) and heat shield (2), if fitted.

– Remove spark arresting screen, if fitted. Clean the screen or fit a new one if necessary.

MS 210, MS 230, MS 250

23

6.2

Leakage Test

6.2.1

Preparations

135RA054 VA

Defective oil seals and gaskets or cracks in castings are the usual causes of leaks. Such faults allow supplementary air to enter the engine and upset the fuel-air mixture.

: Remove the screws from the flange. Reassemble in the reverse sequence. – Use a new gasket. – Fit new locknuts and torque down to 8.0 Nm (5.9 lbf.ft).

This makes adjustment of the prescribed idle speed difficult, if not impossible. Moreover, the transition from idle speed to part or full throttle is not smooth. The engine housing can be checked thoroughly for leaks with the carburetor and crankcase tester and the vacuum pump.

– Remove the muffler – b 6.1. : Fit the sealing plate (1) 0000 855 8106 between the mounting screws. The sealing plate must completely fill the space between the two mounting screws. : Slip the flange (2) 1123 855 4200 over the screws. : Fit the sleeves (3) 1123 851 8300 on the screws. : Fit the nuts (4) and tighten down securely. – Remove the carburetor – b 11.2.2.

135RA056 VA

– Set the piston to top dead center (T.D.C.). This can be checked through the inlet port.

: Inspect carburetor gasket and fit a new one if necessary.

24

MS 210, MS 230, MS 250

Pressure Test

208RA007 VA

6.2.2

: Fit the test flange (1) 1118 850 4200 in place of the carburetor.

– Carry out preparations – b 6.2.1. : Connect pressure hose of tester 1106 850 2905 to nipple on test flange.

: However, if the indicated pressure drops, the leak must be located and the faulty part replaced. To find the leak, coat the suspect area with oil and pressurize the engine again. Bubbles will appear if a leak exists. – If the decompression valve is leaking, fit a new one – b 6.9.

1

143RA046 VA

– Repeat the pressure test.

: If decompression valve is fitted, pull out the button.

: Close the vent screw (1) on the rubber bulb.

– Check that spark plug is properly tightened down.

– Pump air into the engine housing with the rubber bulb until the gauge indicates a pressure of 0.5 bar (7.25 psi). If this pressure remains constant for at least 20 seconds, the engine or decompression valve, if fitted, is airtight.

– Carry out the vacuum test – b 6.2.3. – After finishing the test, open the vent screw and disconnect the hose. – Remove the test flange.

– Perform leakage test with tester 1106 850 2905 and vacuum pump 0000 850 3501.

– Install the carburetor – b 11.2.2. – Remove the flange. – Remove the sealing plate. – Install the muffler – b 6.1.

MS 210, MS 230, MS 250

25

6.2.3

Vacuum Test

6.3

Oil seals tend to fail when subjected to a vacuum, i.e. the sealing lip lifts away from the crankshaft during the piston's induction stroke because there is no internal counterpressure. An additional test can be carried out with the vacuum pump to detect this kind of fault.

If the vacuum reading remains constant, or rises to no more than 0.3 bar (4.25 psi) within 20 seconds, it can be assumed that the oil seals are in good condition. However, if the pressure continues to rise (reduced vacuum in the engine housing), the oil seals must be replaced.

Oil Seals

It is not necessary to disassemble the complete engine housing if only the oil seals have to be replaced.

Clutch side: – After finishing the test, open the vent screw and disconnect the hose.

– Carry out the preparations – b 6.2.1.

– Remove the clutch – b 5.3. – Remove the oil pump – b 10.5.

– Remove the test flange. – Install the carburetor – b 11.2.2. – Remove the flange. – Remove the sealing plate.

135RA062 VA

– Install the muffler – b 6.1.

: Connect suction hose of vacuum pump 0000 850 3501 to test flange nipple.

: Ease the retaining ring out of the crankshaft.

3

1

135RA061 VA

2

: Close the vent screw (1) on the pump. : Operate the lever (2) until pressure gauge (3) indicates a vacuum of 0.5 bar (7.25 psi).

26

MS 210, MS 230, MS 250

1

2

1

: Apply puller (1) 5910 890 4400 (jaws 0000 893 3711 with No. 6 profile). – Clamp the puller arms. – Pull out the oil seal. Take care not to damage the crankshaft stub.

: If an oil seal with clamping ring (1) is installed, use puller and No. 3.1 jaws to remove the clamping ring. Pry the sealing ring (2) out of the housing. – Clean sealing face with STIHL cleaner – b 13. If the cylinder and engine pan are assembled, only oil seal 9638 003 1581 (with clamping ring) may be installed. – Lubricate sealing lip of oil seal with grease – b 13.

135RA064 VA

143RA064 VA

135RA063 VA

1

– Place the oil seal in position with the clamping ring faces up. : Use the press sleeve (1) 1123 893 2400 to install the oil seal. – Wait about one minute, then rotate the crankshaft. – Fit a new retaining ring. – Install the oil pump – b 10.5. – Install the clutch – b 5.3.

– Thinly coat the outside diameter of the oil seal with sealant – b 13.

Ignition side: – Remove the flywheel – b 7.5.

135RA065 VA

1

: Apply puller (1) 5910 890 4400 (jaws 0000 893 3711 with No. 6 profile). – Clamp the puller arms. – Pull out the oil seal. MS 210, MS 230, MS 250

27

6.4

Take care not to damage the crankshaft stub.

Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine.

– Remove oil seal with clamping ring as described for clutch side.

If the cylinder and engine pan are assembled, only oil seal 9638 003 1581 (with clamping ring) may be installed. – Lubricate sealing lip of oil seal with grease – b 13.

– Remove the handle housing – b 9.3. – Remove the oil pump – b 10.5.

: Use the press sleeve (1) 1123 893 2400 to install the oil seal. – Wait about one minute, then rotate the crankshaft. – Install the flywheel – b 7.5.

135RA068 VA

– Thinly coat the outside diameter of the oil seal with sealant – b 13.

1 135RA067 VA

– Cleaning sealing face with STIHL cleaner – b 13.

Removing and Installing

: Pull off the worm with drive spring.

2

: Place the oil seal (1) in position with the clamping ring facing up.

135RA069 VA

135RA066 VA

1

: Take out the ground wire fastening screw.

: Screw the guide sleeve (2) 1123 894 7700 onto the crankshaft.

28

MS 210, MS 230, MS 250

: Unscrew the engine pan mounting screws.

135RA072 VA

Cylinder

135RA070 VA

6.5

– Remove the engine – b 6.4.

: Lift the crankshaft and pull the piston out of the cylinder at the same time.

– Take out the spark plug. : Remove baffle plate.

– Inspect ball bearings and oil seals and replace if necessary – b 6.8.

1

135RA073 VA

2

: Remove engine sideways from housing.

: Pull the manifold (1) off the intake port.

– Inspect the cylinder and replace it if necessary.

Install in the reverse sequence.

: Disconnect the impulse hose (2).

: On easy start version, unscrew the decompression valve.

– Tighten down the engine pan mounting screws to 9.5 Nm (7 lbf.ft) and the ground wire fastening screw to 3.5 Nm (2.6 lbf.ft).

– If a new cylinder has to be installed, always fit the matching piston. Replacement cylinders are only supplied complete with piston for this reason.

135RA074 VA

– Thoroughly clean all residue of sealant from the cylinder and engine pan mating faces.

: Pull the engine pan off the cylinder.

MS 210, MS 230, MS 250

– Apply a thin coating of sealant to the outer diameters of the oil seals – b 13. – Lubricate piston and piston ring with oil.

29

2

: Position the piston rings so that the radii at the ring gap meet at the fixing pin in the piston groove when the rings are compressed.

135RA080 VA

1

: Position the crankshaft so that the long crankshaft stub (1) points to the right, looking at exhaust port (2).

: Fit the engine pan so that the seat (1) for the oil pump is at the same side as the long crankshaft stub (2).

135RA079 VA

– Push piston home until ball bearings are seated.

: Slide piston carefully into the cylinder.

: On easy start version, unscrew the plug, screw home the decompression valve and tighten it to 14 Nm (10.3 lbf.ft).

135RA082 VA

The piston rings are compressed by the inner taper of the cylinder.

30

: Apply a thin bead of sealant to the engine pan mating face – b 13.

: Push the manifold on to the intake port so that the straight faces are in alignment.

Follow manufacturer’s instructions for use of sealant.

Assemble all other parts in the reverse sequence.

MS 210, MS 230, MS 250

135RA087 VA

Piston

135RA085 VA

6.6

– Pull the piston out of the cylinder – b 6.5.

: Inspect piston rings and replace if necessary – b 6.7.

: Push the assembly drift, small diameter first, through the piston and small end (needle cage) and line up the piston.

: Fit needle cage (arrow) in the connecting rod (not MS 210).

: Fit the piston pin (1) on the assembly drift (2) and slide it into the piston (the pin slides home easily if the piston is warm).

: Ease the hookless snap rings out of the grooves in the piston bosses.

: Use the assembly drift (2) 1110 893 4700 to push the piston pin (1) out of the piston.

– Oil the needle cage. If the piston pin is stuck, release it by tapping the end of the drift lightly with a hammer. Hold the piston steady during this process to ensure that no jolts are transmitted to the connecting rod.

– Inspect needle cage and replace if necessary.

b

If needle cage is press-fitted, replace the crankshaft. : To ease assembly, heat the piston slightly and push it over the connecting rod. Installed position of piston: 1 = Arrow 2 = Long stub of crankshaft MS 210, MS 230, MS 250

135RA093 VA

a

– Remove the piston from the connecting rod.

: Modify sleeve of the installing tool 5910 890 2210 as shown: a = 16 mm (11/16") b = 8 mm (5/16")

31

: Attach the snap ring (1) to the magnet (2) so that the snap ring gap is on the flat side of the tool's shank.

: Remove the sleeve and slip it onto the other end of the shank. Inner pin must again point toward flat face.

249RA149 VA

1

: Push the large slotted diameter of the sleeve over the magnet and snap ring. Position the sleeve so that the inner pin (1) points toward the flat face (2) of tool's shank.

: Apply the installing tool to the piston boss, hold the piston steady, center the tool shank exactly and press home until the snap ring slips into the groove.

32

249RA150 VA

– Install the piston – b 6.5.

249RA146 VA

2

Fit the snap rings so that their gaps are on the piston's vertical axis (they must point either up or down – see arrow).

249RA148 VA

1

249RA147 VA

249RA144 VA

2

: Stand the installing tool, sleeve downward, on a flat surface (wooden board) and press vertically downwards until the sleeve butts against the tool's shoulder.

249RA145 VA

: Remove the sleeve from the tool.

MS 210, MS 230, MS 250

6.7

Piston Rings

6.8

Crankshaft

– Pull the piston out of the cylinder – b 6.6.

1

2

135RA097 VA

– Remove rings from the piston.

: The crankshaft (1) and connecting rod are an inseparable unit. This means the crankshaft must always be replaced as a complete unit. The needle bearing (2) is replaceable on models MS 230 and MS 250.

: Pull off the oil seals (1) and ball bearings (2).

135RA095 VA

135RA100 VA

When fitting a replacement crankshaft, always install new ball bearings and oil seals.

: Heat ball bearing to approx. 50°C (120°F) and, with closed side facing outwards, push it on to the crankshaft stub as far as stop.

: Use a piece of old piston ring to scrape the grooves clean.

If the crankshaft has been removed, the oil seals used in production (9639 003 1585 with rigid housing) may be installed.

: Install the new piston rings in the grooves so that the radii face upward.

170RA096 VA

135RA096 VA

– Lubricate sealing lips of oil seals with grease – b 13.

– Remove the piston – b 6.6. : Remove the retaining ring (arrow).

– Install the piston – b 6.6.

MS 210, MS 230, MS 250

33

6.9

Decompression Valve

7.

Ignition System

Exercise extreme caution when troubleshooting and carrying out maintenance or repair work on the ignition system. The high voltages which occur can cause serious or even fatal accidents!! 135RA101 VA

Troubleshooting on the ignition system should always begin at the spark plug – b 4.4.

: Slide oil seals over the crankshaft stubs so that their open sides are facing the ball bearings. – Install new retaining ring in crankshaft groove. – Install the piston – b 6.6.

– Remove the front handle – b 9.2. : Use standard 13 mm socket to unscrew the decompression valve. – Install new decompression valve and torque down to 14 Nm (10.5 lbf.ft). – Refit the front handle.

2

135RA106 VA

1

The electronic (breakerless) ignition system basically consists of an ignition module (1) and flywheel (2).

34

MS 210, MS 230, MS 250

7.1

Spark Plug Boot

7.2

Ignition Module

– Remove the air filter – b 11.1. – Pull out the shutter – b 5.3.

The ignition lead is molded to the module. 135RA108 VA

2

: Pinch the hook (arrow) of the leg spring into the center of the lead, i.e. about 10 mm (3/8") from the end of the lead.

1

208RA008 VA

– Pull boot off the spark plug.

The ignition module accommodates all the components required to control ignition timing. There are two electrical connections on the coil body: : the high voltage output with ignition lead (1),

135RA107 VA

171RA146 VA

: the connector tag (2) for the short circuit wire.

: Use pliers to grip the leg spring and pull it out of the spark plug boot.

: Pull the lead back into the boot so that the leg spring locates properly inside it (see arrow).

– Unhook the leg spring from the ignition lead.

If the spark plug has a separate terminal nut, make sure that it is properly tightened down.

– Pull the spark plug boot off the ignition lead. – Coat end of the ignition lead (about 20 mm/3/4") with oil.

Accurate testing of the ignition module is only possible with a special tester. For this reason it is only necessary to carry out a spark test in the workshop. A new ignition module must be installed if no ignition spark is obtained (after checking that wiring and stop switch are in good condition).

– Fit boot on the spark plug. – Fit the shutter – b 5.3. – Install the air filter – b 11.1.

– Fit spark plug boot over the ignition lead. – Use pliers to grip the end of the ignition lead inside the spark plug boot and pull it out.

MS 210, MS 230, MS 250

35

Testing the Ignition Coil

7.4

To test the ignition module, use either the ZAT 4 ignition system tester 5910 850 4503 or the ZAT 3 ignition system tester 5910 850 4520. The ignition test refers only to a spark test, not to ignition timing. Before starting the test, check that the spark plug is in good condition. Test the ignition coil only with the spark plug properly installed in the cylinder.

If the spark plug, ignition lead and spark plug boot are in order, use an ohmmeter to check the short circuit wire, ground wire and spring for a break.

3 ZAT 3

1

Checking the Wiring Harness

5910 850 4520

2

208RA054 VA

7.3

It is necessary to use the ZAT 3 ignition system tester 5910 850 4520 to test the auxiliary spark gap. – Before starting the test, install a new spark plug in the cylinder and tighten it down firmly – b 3.5.

2

3

: Using the ZAT 4 ignition tester 5910 850 4503: Pull the boot off the spark plug and connect it the input terminal (1). Push the tester’s output terminal (3) onto the spark plug. – Pull the rewind starter and check the sparkover in the tester’s window (2).

: Attach ground terminal (1) (alligator clip) to spark plug. Use adjusting knob (3) to set spark gap to about 2 mm. While using the ZAT 3, hold it only by the handle or position it in a safe place. Warning! High voltage – risk of electrocution.

: Pull the short circuit wire (arrow) off the tag on the ignition module. – Connect ohmmeter to ground and the short circuit wire. – Set Master Control lever to "0".

– Crank engine with rewind starter (min. 1,000 rpm) and evaluate spark in spark window. If a spark is visible, the ignition system is in order. If no spark is visible, check the wiring harness and spring – b 7.4.

36

135RA111 VA

1

208RA053 VA

: Pull the boot off the spark plug boot and connect it to terminal (2).

The measured resistance must be about 0 Ohm. If the reading is much higher, there is a break in the wire and the wire or Master Control lever must be replaced. – Set Master Control lever to "1". The measured resistance must be infinitely high. If not, install a new Master Control lever.

MS 210, MS 230, MS 250

7.4.1

– Check flywheel for damage – b 7.4.2. – Check air gap between flywheel and ignition module – b 7.5. If no fault is detected in these areas either, install a new ignition module – b 7.4.2.

7.4.2

Removing and Installing

Ignition timing is not adjustable. Since there is no mechanical wear in these systems, ignition timing cannot get out of adjustment. However, an internal fault in the circuit can alter the switching point in such a way that a spark test will still show the system to be in order although timing is outside the permissible tolerance. This will impair engine starting and running behavior.

135RA111 VA

If no fault is found, perform the following additional checks:

Ignition Timing

– Remove the fan housing – b 8.2.

135RA112 VA

: Pull the short circuit wire off the tag on the ignition module.

: Take out the screws (arrows).

1

208RA110 VA

2

– Pull the ignition module forward a little. : Take the short circuit wire (1) out of the retainer (2).

MS 210, MS 230, MS 250

37

Flywheel

135RA116 VA

7.5

: Push baffle plate (1) in direction of fanwheel and carefully pull out the ignition lead (2).

Removing the flywheel: – Fit the locking strip to block the piston – b 5.3.

Inspect flywheel (1) and magnet poles (2) for cracks or other damage. If you find any damage, install a new flywheel.

– Remove the fan housing – b 8.2.

Installing the flywheel:

– Unscrew the flywheel nut.

Degrease crankshaft stub and bore in flywheel with STIHL cleaner – b 13.

– Pull off the flywheel.

– Fit the flywheel. Check position of slot. Assemble all other parts parts in the reverse sequence. – Tighten the flywheel nut to 28 Nm (20.6 lbf.ft).

– Place the module in position, insert the screws but do not tighten them down yet. : Secure ground wire (1) with outer screw. : Slide the setting gauge (2) 1111 890 6400 between the arms of the ignition module and the flywheel magnet poles.

Reassemble all other parts in the reverse sequence.

1

135RA117 VA

– Press the ignition module against the setting gauge and tighten down the mounting screws to 4 Nm (3 lbf.ft).

If the flywheel cannot be removed by hand, screw on the puller (1) 1116 893 0800 and tap its end to release the flywheel. Remove the puller.

38

MS 210, MS 230, MS 250

7.6

Ignition System Troubleshooting

Engine does not run

Master Control lever/slide control or separate stop switch in position "1"?

Check the spark plug: – Smeared with oil, black? – Sooted? – Electrode gap correct? – s shorted? Clean the plug, reset or replace

Check spark plug boot: Firmly seated on plug (leg spring)? Leg spring hook in center of ignition lead? Boot damaged? If necessary, install new spark plug boot and/or leg spring

Test ignition system with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap – see TI 32.94)

1 MS 210, MS 230, MS 250

39

1

Powerful spark?

yes

no

Check air gap and reset if necessary

Check flywheel: – Have pole shoes turned blue? Install new flywheel

Disconnect short circuit wire from ignition module

Check ignition lead: – Severe chafing? – Spark plug boot: Holes/cracks? – Resistance spark plug boot to ground: spec. 1.5 – 12kΩ – Check resistance of ignition lead: spec. < 10 Ω, If necessary, install new spark plug boot and/or ignition lead

2 40

3 MS 210, MS 230, MS 250

2

3

Check operation of Master Control lever/slide control or separate stop switch – Short circuit wire chafed? – gap ( springs) If necessary, install new ignition lead and/or springs Re-connect short circuit wire

Powerful spark?

yes

no

Install new ignition module

yes

Check ON/STOP function on Master Control lever/ slide contro or separate stop switch

MS 210, MS 230, MS 250

Engine runs

no

Look for fault in fuel system or carburetor, check engine for leaks, check position of flywheel on crankshaft

41

Rewind Starter General

If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not completely, it can be assumed that the starter mechanism is in order but plugged with dirt. At very low outside temperatures the lubricating oil on the rewind spring may thicken and cause the spring windings to stick together. This has a detrimental effect on the function of the starter mechanism. In such a case it is sufficient to apply a few drops of paraffin (kerosine) to the rewind spring. Carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored. If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed and disassembled. Take special care when removing the spring.

8.2

Removing and Installing

8.3

Rope Rotor

Troubleshooting chart – b 4.2. – Remove the fan housing – b 8.2. Relieving tension of rewind spring: 208RA010 VA

8. 8.1

The rewind spring will not be under tension if the starter rope is broken.

: Remove the screws (arrows) from the fan housing and hand guard.

– Pull out the starter rope about 5 cm (2") and hold the rope rotor steady.

– Lift away the fan housing with rewind starter.

– While still holding the rope rotor steady, take three full turns off the rope rotor.

Reassemble in the reverse sequence. – Tighten down screws to 6 Nm (4.4 lbf.ft).

– Pull out the rope with the starter grip and slowly release the rope rotor.

Wash all parts in STIHL cleaner.

208RA034 VA

Lubricate the rewind spring and starter post with STIHL special lubricant, b 13, before installing.

Removing the rope rotor: : Use a screwdriver or suitable pliers to carefully remove the spring clip from the starter post.

42

MS 210, MS 230, MS 250

2 1

Installing the rope rotor:

: Remove the washer (arrow).

Coat bore in rope rotor with STIHL special lubricant – b 13. : Fit the rotor on the starter post so that the lug (1) on the rope rotor slips behind the inner spring loop (2). Check that spring loop has engaged by turning rope rotor slightly and letting it go – it must spin back.

208RA036 VA

249RA141 VA

208RA035 VA

1 2

– Fit washer and push the spring clip into the groove in the starter post. Make sure the spring clip (1) engages the pawl guide peg (2) and points in the clockwise direction. The spring clip must be handled very carefully. If it is bent during disassembly or assembly, the rewind starter may not function properly.

208RA037 VA

– Install the starter rope – b 8.5. – Tension the rewind spring – b 8.5.2.

: Carefully pull the rope rotor off the starter post. – To replace the rope rotor, first remove the starter rope – b 8.5. The rewind spring may pop out and unwind if rope rotor is not removed very carefully.

MS 210, MS 230, MS 250

43

8.4

Segment

– Remove the rope rotor – b 8.3.

8.5

Starter Rope

Remove the rope rotor – b 8.3.

135RA119 VA

– Remove the remaining rope from the rope rotor and the starter grip.

208RA038 VA

208RA0039 VA

: Thread the other end of the rope through the guide bush from inside.

: Use a screwdriver to pry the segment (1) out of the upper retainers (4).

: Thread end of new rope through the hole in the side of the rotor, pull it out.

: Then through the underside of the starter grip and pull it out.

– Pull the segment upwards and remove. Reassemble in the following sequence. : Place the segment (1) in position and push it under the retainer (2).

208RA040 VA

: Engage lugs (3) flush with housing. : Push segment into retainers (4). Reassemble all other parts in the reverse sequence. – Secure the rope with a simple overhand knot. : Pull the rope back until the knot locates in the recess (arrow) in the rope rotor.

44

MS 210, MS 230, MS 250

208RA049 VA

: Tie one of the special knots shown.

Elastostart

208RA052 VA

982RA036 VA

8.5.1

: Pry the nipple of the starter rope out of the starter grip. Pull out the starter rope.

: Thread the other end of the rope, from outside, through the guide bush in the fan housing.

– Pull the rope back into the starter grip.

– Fit the rope in the rope rotor – b 8.5.

– Install the rope rotor – b 8.3. – Install the rope rotor – b 8.3. – Tension the rewind spring – b 8.5.2.

208RA051 VA

– Fit the fan housing – b 8.2.

: Thread new starter rope through the top of the starter grip.

208RA050 VA

1

: Pull out the starter rope until the nipple (1) locates in the starter grip.

MS 210, MS 230, MS 250

45

: Make a loop in the starter rope.

208RA014 VA

: Hold the rope rotor steady. : Pull out the rope with the starter grip and straighten it out. – Hold the starter grip firmly to keep the rope tensioned.

208RA013 VA

– Let go of the rope rotor and slowly release the starter rope so that it can rewind properly.

: Grip the rope next to the rotor and use it to turn the rope rotor six times clockwise.

46

135RA122 VA

Tensioning

208RA012 VA

8.5.2

The rewind spring is correctly tensioned when the starter grip sits firmly in the rope guide bush without drooping to one side. If this is not the case, tension the spring by one additional turn. When the starter rope is fully extended, it must still be possible to rotate the rope rotor at least another half turn before maximum spring tension is reached. If this is not the case, pull the rope out, hold the rope rotor steady and take off one turn of the rope. Do not overtension the rewind spring as this will cause it to break. – Fit the fan housing – b 8.2.

MS 210, MS 230, MS 250

8.6

Rewind Spring

– Remove the rope rotor – b 8.3. a 1

143RA121 VA

The replacement spring comes ready for installation and is secured with a frame.

: Position the anchor loop about 20 mm (3/4") (dimension 'a') from the edge of the assembly tool.

: Push the rewind spring into the fan housing and then remove the assembly tool. – Install the rope rotor – b 8.3.

143RA122 VA

– Tension the rewind spring – b 8.6.

– Lubricate the spring with a few drops of STIHL special lubricant before installation – b 13. : The frame (1) slips off as the rewind spring is pushed into the fan housing. Press the anchor loop (2) into the recess in the fan housing at the same time. The rewind spring may pop out and uncoil during installation.

: Fit the rewind spring in the counterclockwise direction, starting from outside and working inwards. – Place wooden block 1108 893 4800 over the assembly tool to simplify this operation. – Slip the assembly tool with rewind spring over the starter post.

– If the rewind spring has popped out, refit it in the assembly tool 1116 893 4800 as follows:

MS 210, MS 230, MS 250

47

8.7

Pawl

9.

AV Handle System/ Handle Housing 9.1 Annular Buffers Rubber anti-vibration buffers are installed between the handle and engine housing, handle housing and front handle. Damaged rubber buffers (annular buffers) must always be replaced.

2

135RA125 VA

208RA046 VA

1

: Remove the spring clip (1) from the starter post.

Annular buffer in engine housing – Front handle removed.

Do not take the rope rotor off the starter post.

: Pry the annular buffer out of the engine housing.

: Pull the pawl (2) out of the rope rotor. – Coat peg of new pawl with graphite grease – b 13.

208RA016 VA

135RA126 VA

Reassemble in the reverse sequence.

Annular buffers in front handle

: Push annular buffer into the engine housing until its groove engages over the housing rib.

– Remove the front handle – b 9.2.

– Fit the front handle. : Pry both annular buffers out of the front handle.

135RA124 VA

2

135RA127 VA

1

: Push home the annular buffer from inside the front handle until its groove (1) engages over the housing rib (2).

Annular buffer in handle housing – Remove the handle housing – b 9.3. : Ease the plug out of the buffer.

48

MS 210, MS 230, MS 250

: Pry the annular buffer out of the handle housing.

135RA130 VA

: Take the lower mounting screws out of the front handle.

135RA133 VA

Front Handle

135RA128 VA

9.2

: Pull the lower part of the handle housing out of the front handle. – Remove the front handle. Reassemble in the reverse sequence. – Tighten down screws in annular buffers to 3.5 Nm (2.6 lbf.ft).

135RA129 VA

135RA131 VA

1

: Push the annular buffer into the handle housing from outside until its groove (1) engages over the rib (2).

– Remove lower bumper strip from the tensioner.

2

: Ease plugs out of the annular buffers.

– Install the handle housing – b 9.3.

: Take out the screws.

MS 210, MS 230, MS 250

49

9.3

Handle Housing

– Remove the front handle – b 9.2. – Remove the fan housing – b 8.2.

– Remove the carburetor – b 11.2.2.

: Ease the plug out of the annular buffer.

135RA139 VA

135RA136 VA

– Remove the muffler – b 6.1.

: Push the grommet out of the handle housing.

: Disconnect tank vent hose from the stub.

: Pry the annular buffer out of the engine housing.

135RA140 VA

135RA137 VA

– Pull the ground and short circuit wires out of the bore.

: Pull the impulse hose off the stub on the handle housing.

: Pull the ground wire (1) off the spring. : Pull the short circuit wire's sleeve (2) out of the switch shaft.

50

135RA135 VA

2

135RA138 VA

1

: Pull the handle housing slightly forward and push the manifold through the handle housing opening at the same time.

MS 210, MS 230, MS 250

1

: On easy start machines, pull manual fuel pump hose (arrow) out of the fuel tank. – Remove the handle housing.

135RA143 VA

4 2 3

: Place the handle housing in position and the string (1), fuel hose (2), ground wire (3) and short circuit wire (4) through the openings.

: Pull the ends of the string outward.

: Push the grommet for the ground and short circuit wires into the bore from inside.

: Push the annular buffer into the engine housing until its groove engages over the housing rib.

– To replace, remove the annular buffers – b 9.1.

The manifold flange is thus pulled through the handle housing intake opening without any damage to the manifold.

– Remove the switch shaft – b 9.4. – Remove the throttle trigger – b 9.6. 135RA147 VA

– Remove the spring – b 9.5. – On easy start machines, remove the manual fuel pump – b 11.6. Reassemble in the reverse sequence.

135RA142 VA

Reassemble all other parts in the reverse sequence.

: To fit the manifold in the handle housing intake opening, wind a piece of string (about 15 cm / 6" long) around the back of the manifold flange.

MS 210, MS 230, MS 250

: Connect the impulse hose to the stub on the handle housing.

51

9.4

Switch Shaft

– Remove the carburetor box cover – b 11.1. : Pull the sleeve out of the switch shaft.

Spring

: Set the Master Control lever to the horizontal position and pry the switch shaft out of its pivot mount.

– Remove the carburetor – b 11.2.2.

: Pull the switch shaft out of its bore.

: Pull the spring out its seat in the handle housing.

Install in the reverse sequence.

Install in the reverse sequence.

: Pull the ground wire terminal off the spring.

135RA153 VA

: Move the Master Control lever (1) until the slot in the choke shaft (2) and the choke rod (3) are in line.

9.5

: Pull the choke rod out of the switch shaft and the choke shaft.

52

: Lift the spring slightly to install the switch shaft.

MS 210, MS 230, MS 250

208RA048 VA

Throttle Trigger/ Interlock Lever

135RA156 VA

9.6

– Remove the carburetor box cover – b 11.1.

: Use a 4 mm (5/32") drift to drive out the cylindrical pin (1).

: Take out the screw.

: Remove the throttle trigger (2) and torsion spring (3).

: Push the throttle rod into the throttle trigger.

135RA157 VA

135RA161 VA

– Swing the handle molding up and lift it away.

: Take the torsion spring off the throttle trigger.

: Press the interlock lever into the slots. The torsion spring must be under the interlock lever and engage the notch.

208RA047 VA

: Pull the interlock lever out of its seat.

: Remove the throttle rod from the throttle trigger.

: Fit the throttle trigger so that the seat for the throttle rod points upward. : Use a 4 mm (5/32") drift to push home the cylindrical pin.

MS 210, MS 230, MS 250

2

1

135RA162 VA

– Move the Master Control lever to the normal "RUN" position.

: Press the interlock lever (1) downward. : Push the throttle trigger upward and move the Master Control lever (2) to the "Choke" position.

53

Chain Lubrication Pickup Body

Impurities gradually clog the fine pores of the filter with minute particles of dirt. This prevents the oil pump from supplying sufficient oil to the bar and chain. In the event of problems with the oil supply system, first check the oil tank and the pickup body. Clean the oil tank if necessary.

135RA165 VA

135RA163 VA

10. 10.1

Troubleshooting chart – b 4.3. – Unscrew oil filler cap and drain the oil tank.

: Pull the pickup body out of the oil suction hose.

– Insert screw and tighten down to 1.6 Nm (1.2 lbf.ft).

Collect chain oil in a clean container or dispose of it properly at an approved disposal site.

– Wash the pickup body in STIHL cleaner and, if possible, blow out with compressed air.

– Fit the carburetor box cover – b 11.1.

– Observe safety precautions – b 2.

– Replace pickup body if it is damaged.

: Fit the handle molding so that it engages behind the lugs as shown.

– Flush out the oil tank. Install in the reverse sequence.

: Use hook (1) 5910 893 8800 to withdraw the pickup body from the oil tank. Avoid stretching the oil suction hose.

54

MS 210, MS 230, MS 250

10.2

Connector/ Suction Hose

10.3

Valve

A vent valve is installed in the tank wall to keep the internal pressure in the oil tank equal to atmospheric pressure.

135RA166 VA

208RA017 VA

Cleaning the valve

– Remove the front handle – b 9.2.

Install in the reverse sequence. : Fit new O-ring on connector (see arrow).

: Take out the screw.

– Tighten down screw to 4.0 Nm (3.0 lbf.ft).

– Unscrew the oil filler cap. – Drain the oil tank. Collect chain oil in a clean container or dispose of it properly at an approved disposal site. – Observe safety precautions – b 2. – Use compressed air to blow valve clear from the outside inwards. – Flush the oil tank.

135RA167 VA

– Fit the oil filler cap.

: Pull the connector out of the oil pump and suction hose. Replacing the valve

: Pull suction hose with pickup body out of the oil tank.

135RA170 VA

135RA168 VA

– Unscrew the oil filler cap.

: Use a 5 mm (3/16") dia. drift to carefully drive the valve out of the housing from inside the tank.

– Remove the pickup body.

MS 210, MS 230, MS 250

55

10.4

Worm

Reassemble in the reverse sequence.

176RA243 VA

a

: Use a 7 mm (9/32") dia. drift to carefully push home the new valve until dimension 'a' is about 1 mm (3/64").

Fit the cover washer so that the word "TOP" faces outwards.

208RA018 VA

1

– Remove the clutch – b 8. : Remove the cover washer (1).

– Fit the oil filler cap.

: Pull the worm and drive spring (arrow) off the crankshaft stub.

: Take the drive spring off the worm.

56

MS 210, MS 230, MS 250

10.5

Oil Pump

1 2

135RA173 VA

135RA176 VA

3

Removing

: Swing lever (1) down into fork head (2) and secure it with the connecting pin (3).

– Remove the connector – b 10.2.

: Place the fork head (1123/01) with the straight stem (from installing tool) in the oil pump. – Fit lever in fork head and secure in position.

: Pry out the lower annular buffer.

135RA174 VA

135RA177 VA

1

: Fit lever (1) of installing tool 1123 890 2201 in the bore for the annular buffer – from inside.

: Swing lever upward to pull the oil pump out of the housing. – Unscrew the oil pump from the fork head.

: Press the lever down until the fork head butts against the engine housing. The oil pump is now installed at the right depth. – Remove the lever.

: Screw fork head (1123) with threaded stem (from installing tool) into the oil pump.

MS 210, MS 230, MS 250

2

135RA178 VA

135RA175 VA

1

Installing : Place the oil pump in position so that its groove (1) lines up with the square (2) on the housing.

: Push the annular buffer into the housing until its groove engages over the housing rib. – Fit the connector – b 10.2.

57

11. 11.1

Fuel System Air Filter

Dirty air filters reduce engine power, increase fuel consumption and make starting more difficult.

– Close the choke shutter.

Fabric/fleece filter : Place fingers behind the filter, press thumbs against housing, and swing filter toward rear handle.

2

1

208RA023 VA

135RA199 VA

The air filter should always be cleaned when there is a noticeable loss of engine power.

: To remove the filter housing, unscrew the nuts (1 and 2) and lift the filter housing away. Reassemble in the reverse sequence.

– Remove the filter. – Use compressed to blow out filter from the clean air side.

2

208RA019 VA

1

– If the filter is caked with dirt or no compressed air is available, wash the filter in a fresh, nonflammable cleaning solution (e.g. warm soapy water) and then dry.

– Tighten down nuts to 2.7 Nm (2.0 lbf.ft). – Push air filter onto filter housing until it snaps into position.

Replace a damaged air filter.

: Turn twist lock (1) 90 degrees counterclockwise. : Lift off the carburetor box cover (2) vertically. – Remove all loose dirt from around the filter.

58

MS 210, MS 230, MS 250

11.2 Carburetor 11.2.1 Leakage Test Troubleshooting chart – b 4.5. If problems occur on the carburetor or the fuel supply system, always check and clean the tank vent – b 11.3. 208RA020 VA

The carburetor can be tested for leaks with the carburetor and crankcase tester 1106 850 2905. – Remove the carburetor box cover – b 11.1.

: Push fuel line with nipple onto carburetor elbow connector (arrow).

1 2

208RA022 VA

3

: Close the vent screw (1) on the rubber bulb (2) and pump air into the carburetor until the pressure gauge (3) shows a reading of approx. 0.8 bar (11.6 psi). If this pressure remains constant, the carburetor is airtight. However, if it drops, there are two possible causes:

208RA021 VA

1. The inlet needle is not sealing (foreign matter in valve seat or sealing cone of inlet needle is damaged or inlet control lever sticking).

: Pull fuel hose (arrow) off the carburetor's elbow connector.

: Connect the tester's pressure hose to the nipple.

2. The metering diaphragm is damaged. – After completing test, open the vent screw and pull the fuel line off the elbow connector. – Push the fuel hose onto the elbow connector. – Fit the carburetor box cover.

1

143RA172 VA

2

: Push the fuel line (1) 1110 141 8600 onto the nipple (2) 0000 855 9200.

MS 210, MS 230, MS 250

59

11.2.2 Removing and Installing

– Remove the air filter – b 11.1.

: Disconnect fuel hose (1) from the manual fuel pump, if fitted.

: Pull fuel hose (arrow) off the carburetor's elbow connector.

: Remove the grommet with tank vent from the adjusting screws.

: Detach throttle rod from the throttle trigger.

135RA208 VA

135RA191 VA

: Pull the hose (2) off the tank vent.

: Remove the carburetor.

: Slip the gasket off the studs. – If necessary, remove the shim from the studs. Reassemble in the reverse sequence. – Fit the shim with its flat side facing outward. – Install a new gasket.

135RA206 VA

– Tighten down locknuts to 2.5 Nm (1.8 lbf.ft).

: Pull choke rod (1) out of choke shaft (2) and switch shaft (3).

: Take the throttle rod off the throttle shaft.

– On easy start machines, pull carburetor forward a little.

60

MS 210, MS 230, MS 250

11.2.3 Adjusting (Carburetor without Limiter Cap) Standard setting (with tachometer) – Check the air filter and clean or replace as necessary. – Check chain tension. – Warm up the engine. – Adjust idle speed. Standard setting (without tachometer)

3. Use the idle speed screw (LA) to set engine speed again to 3,300 rpm. 4. Set the engine speed to 2,800 rpm with the low speed screw (L). Starting from the standard setting, use the high speed screw (H) to adjust the maximum engine speed to: 12,500 rpm (MS 210) 14,000 rpm (MS 230, 250)

To readjust the carburetor, start with the standard setting.

If the setting is too lean there is a risk of engine damage due to insufficient lubrication and overheating.

– Carefully screw down both adjusting screws (H and L) until they are against their seats. Then make the following adjustments: – Open high speed screw (H) one full turn. – Open low speed screw (L) one full turn. If no tachometer is available, do not turn the high speed screw (H) beyond the standard setting to make the mixture leaner.

Adjusting engine idle speed – Adjust idle speed with a tachometer. Adjust specified engine speeds within tolerance of +/- 200 rpm. 1. Adjust engine speed with idle speed screw (LA) to 3,300 rpm. 2. Turn low speed screw (L) clockwise or counterclockwise to obtain maximum engine speed. If this speed is higher than 3,700 rpm, abort the procedure and start again with step 1.

MS 210, MS 230, MS 250

61

11.2.4 Adjusting (Carburetor with Limiter Cap) Adjusting engine idle speed – Check the air filter and clean or replace as necessary.

11.2.5 Standard Setting (Carburetor with Limiter Cap) The limiter cap needs to be removed from the high speed screw (H) only if it is necessary to replace the high speed screw (H) or clean the carburetor.

– Check chain tension. – Warm up the engine.

After removing the limiter cap it is necessary to carry out the standard setting.

Adjust idle speed with a tachometer. Adjust specified engine speeds within tolerance of +/- 200 rpm. Standard setting

– With this carburetor it is only possible to correct the setting of the high speed screw (H) within fine limits. Make the following adjustments: – Turn high speed screw (H) counter-clockwise (max. 3/4 turn) as far as stop. – Screw low speed screw (L) down onto its seat clockwise, then open it one full turn from that position.

1. Adjust engine speed with idle speed screw (LA) to 3,300 rpm. 2. Turn low speed screw (L) clockwise or counterclockwise to obtain maximum engine speed. If this speed is higher than 3,700 rpm, abort the procedure and start again with step 1. 3. Use the idle speed screw (LA) to set engine speed again to 3,300 rpm.

1 208RA060 VA

Do not remove the limiter cap to carry out the standard setting.

4. Set the engine speed to 2,800 rpm with the low speed screw (L).

: Use suitable pliers to pull off the limiter cap (1). – Carefully screw down both adjusting screws (H and L) clockwise until they are against their seats. Then make the following adjustments:

62

MS 210, MS 230, MS 250

11.3

Tank Vent

Correct operation of the carburetor is only possible if atmospheric pressure and internal fuel tank pressure are equal at all times. This is ensured by the tank vent. If problems occur on the carburetor or the fuel supply system, also check and clean the tank vent.

– Open the high speed screw H (1) one and one half turns. – Open the low speed screw L (2) one full turn.

Check function by performing pressure and vacuum tests on the tank via the fuel hose. – Remove the carburetor box cover – b 11.1.

: Connect vacuum pump 0000 850 3501 (1) to tank vent (2) with hose. – Use vacuum pump to subject vent valve to vacuum. Equalization of pressure in the fuel tank takes place via the tank vent valve. There must be no build-up of vacuum during the test. In the event of a malfunction, wash the vent valve and hose in STIHL cleaner and blow clear with compressed air. Replace components if necessary. Reassemble in the reverse sequence. Make sure the hoses are not kinked.

: Position new limiter cap (1) for the high speed screw (H) so that it is in line with the rich stop (arrow). : Push home limiter cap as far as stop against the carburetor body. Always install a new limiter cap. Limiter caps that have been removed once may be damaged and must not be re-used. – Adjust engine idle speed – b 11.2.4.

: Take the tank vent valve (1) out of the retainer (3) and pull off the hose (2).

MS 210, MS 230, MS 250

63

11.5

The diaphragm pump draws fuel out of the tank and into the carburetor via the fuel hose. Any impurities mixed with the fuel are retained by the pickup body (filter). The fine pores of the filter eventually become clogged with minute particles of dirt. This restricts the age of fuel and results in fuel starvation. In the event of trouble with the fuel supply system, always check the fuel tank and the pickup body first. Clean the fuel tank if necessary. Cleaning the fuel tank

1

Suction Hose

– Use hook (1) 5910 893 8800 to pull the pickup body out of the fuel tank.

135RA217 VA

Pickup Body

135RA215 VA

11.4

– Remove the handle housing – b 9.3. – Remove the pickup body – b 11.4.

Do not stretch the suction hose.

– Pry suction hose flange out of the fuel tank.

Observe safety precautions – b 2.

: Pull out the suction hose.

– Pour a small amount of clean gasoline into the tank.

Reassemble in the reverse sequence.

– Close the tank and shake the saw vigorously.

– Coat the hose flange with a little oil to simplify installation. 135RA216 VA

– Unscrew the filler cap and drain the tank.

– Open the tank again and drain it. Dispose of fuel properly. : Pull the pickup body off the fuel hose. Pickup body – Fit a new pickup body. – Unscrew the fuel filler cap and remove it together with the cap retainer, if fitted.

Reassemble in the reverse sequence.

: Straight side (1) of hose flange must be in line with the tank t (2). Reassemble all other parts in the reverse sequence.

64

MS 210, MS 230, MS 250

11.6

Manual Fuel Pump

11.7

Easy start machines only:

Hoses

The hoses for the tank vent and fuel supply must not be damaged in any way. Replace them if necessary.

– Remove the air filter – b 11.1. – Remove the shutter – b 8.

– Remove the filter housing – b 11.2.2. 135RA221 VA

– Remove the spark plug boot.

: Carefully squeeze the retaining tabs together. – Pump the fuel pump out of its seat in the handle housing. Machines without manual fuel pump:

Reassemble in the reverse sequence.

135RA219 VA

– Push home the fuel pump (short intake stub facing the air filter) until retaining tabs snap into position.

: Carefully push cover, if fitted, with thumb in direction of arrow until it is released from its seat.

– Connect suction hose from carburetor to the short stub on right. – Connect hose from connector to long stub on left. : Remove vent hose from tank. The hoses must not be interchanged.

– Remove the cover.

1

: Disconnect hoses from the connectors.

MS 210, MS 230, MS 250

3

208RA041 VA

135RA220 VA

2

: Push the cover (1) under the upper retaining tab (2) and push the pin (3) into the bore in the handle housing.

65

1 1

3 2

3

: Detach suction hose (2) from retainer (3) on handle housing.

: Pull the connector (1) out of the retainer (2).

: Pull suction hose (2) off the stub on the tank vent (1).

– Pull hose (3) off carburetor stub. – Remove the carburetor – b 11.2.

– Engage the connector (2) in the retainer (3) on the handle housing.

5.7x3.1x166 mm Reassemble in the reverse sequence.

: Push the connector (2) with hose upwards into the handle housing.

2

If hose is damaged, install a new one of the following size:

: When assembling, connect the hose (1) to the thin stub (arrow) of the connector (2) and the manual fuel pump to the long left-hand stub.

4

1

3

Reassemble all other parts in the reverse sequence. 208RA096 VA

– Remove the carburetor – b 11.2.

208RA092 VA

208RA108 VA

2

If hoses are damaged, install new ones of the following size:

Machines with manual fuel pump:

Hose (1): 5.7x3.1x106 mm Hose (2): 5.4x2.2x38 mm Hose (3): 5.7x3.1x51 mm Hose (4): 5.4x2.2x65 mm On non-EU version: Hose (4): 5.4x2.2x100 mm Reassemble in the reverse sequence.

: Remove the vent hose from the tank.

66

MS 210, MS 230, MS 250

11.8

Fuel Tank

Fuel tank and engine housing are a single unit. – Remove the engine – b 8.

1

208RA107 VA

– Remove the chain brake – b 8.

208RA105 VA

– Remove the chain tensioner – b 8.

: Unscrew the fuel filler cap and remove with cap retainer, if fitted.

– Pry the suction hose flange out of the fuel tank.

: Use hook (1) 5910 893 8800 to pull pickup body out of the fuel tank.

: Pull out the suction hose.

Do not stretch the suction hose.

2

135RA230 VA

3

135RA225 VA

2 1

: Disconnect the short circuit wire (1).

: Pull out the oil pump suction hose with pickup body.

: Take out the screws (2).

: Pull the pickup body off the hose.

MS 210, MS 230, MS 250

135RA233 VA

208RA106 VA

: Remove the ignition module (3).

: Remove the spiked bumper, if fitted.

67

Replacement engine housings are supplied with two collar screws of the same length.

: On machines with quick chain tensioner, remove the stiffener (1) and take out the rear collar screw (2).

: To install engine housing in a machine with a quick chain tensioner, use stud puller (1) 5910 893 0501 to slowly unscrew the rear collar screw.

135RA232 VA

Thread in engine housing can be damaged if stud puller is turned too fast.

135RA231 VA

1

135RA234 VA

1

135RA229 VA

2

– Apply a little oil to the thread of the new or original collar screw. : Insert collar screw in the bore of the replacement engine housing and turn it counterclockwise until it engages the thread. – Then screw it home clockwise and torque down to about 8.0 Nm (5.9 lbf.ft). – Tighten down mounting screws on spiked bumper to 3.7 Nm (2.8 lbf.ft). Reassemble all other parts in the reverse sequence.

Reassemble in the reverse sequence. : Position ground wires, short circuit wire and ignition lead in the housing slots. – After assembling, set air gap between ignition module and flywheel – b 8. – Coat the fuel hose flange with a little oil to simplify installation. – Straight side of hose flange must be in line with the tank t.

68

MS 210, MS 230, MS 250

12.

Special Servicing Tools

No.

Part Name

Part No.

Application

1 2 3 4 5 6 7

Locking strip Press sleeve Guide sleeve Puller Jaws (No. 6 profile) Puller Crimping tool

0000 893 5903 1123 893 2400 1123 894 7700 5910 890 4400 0000 893 3711 1116 893 0800 5910 890 8210

8 9

Assembly drift Carburetor and crankcase tester

1110 893 4700 1106 850 2905

10 11 12 13

Nipple Fuel hose Vacuum pump Sealing plate

0000 855 9200 1110 141 8600 0000 850 3501 0000 855 8106

Blocking the crankshaft Installing oil seal(s) Protects oil seal at starter side Removing oil seals Removing oil seals Removing flywheel Attaching connectors to electrical wires Removing and fitting piston pin Testing engine and carburetor for leaks Testing carburetor for leaks Testing carburetor for leaks Testing engine for leaks Sealing exhaust port for leakage test

14 15 16 17

Flange Sleeve (4) Flange Setting gauge

1123 855 4200 1123 851 8300 1118 850 4200 1111 890 6400

18 19 20

Socket, DIN 3124, 13 mm 5910 893 5608 Socket, DIN 3124, 19 mm x12.5L 5910 893 5612 Torque wrench 5910 890 0301

21

Torque wrench

5910 890 0311

22

Spline screw socket T 27 x 150

0812 542 2104

Rem.

1)

Leakage test Setting air gap between ignition module and flywheel Flywheel nut Clutch 0.5 – 18 Nm (0.4 – 13.5 lbf.ft) Alternative: Torque wrench 5910 890 0302 with optical/acoustic signal 6 – 80 Nm (4.4 – 60 lbf.ft) Alternative: Torque wrench 5910 890 0312 with optical/acoustic signal IS-P screws (4 mm)

Remarks: 1) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400.

MS 210, MS 230, MS 250

69

No.

Part Name

Part No.

Application

Rem.

23 24

Hook Installing tool 10

5910 893 8800 5910 890 2210

25 26

1117 890 0900 5910 890 2400

2)

27 28 29 30 31

Assembly tube Spline socket screwdriver T 27 x 150 Stud puller M 8 Installing tool Installing tool Assembly stand Clamping bar

Removing pickup body Installing hookless snap rings in piston Attaching/detaching brake spring IS screws

5910 893 0501 1123 890 2201 1116 893 4800 5910 890 3100 5910 890 2000

32 33

Jaws (No. 3.1 + 4 profile) Sleeve

0000 893 3706 1124 893 7100

Removing guide bar mounting studs Removing/installing oil pump Refitting rewind spring Holds chainsaw for repairs For mounting chainsaw to assembly stand Removing oil seal(s)

Remarks: 2) Only use for releasing DG screws.

70

MS 210, MS 230, MS 250

13.

Servicing Aids

No.

Part Name

Part No.

Application

1

Lubricating grease (370 g / 13 oz tube)

0781 120 1111

Oil seals, oil pump drive, chain sprocket bearing, chain tensioner, cylindrical rollers

2

Press-Fluid lubricant

0781 957 9000

Rubber buffers of AV system

3

STIHL special lubricant

0781 417 1315

Bearing bore in rope rotor, rewind spring in fan housing

4

Dirko sealant (100 g / 3 1/2 oz tube)

0783 830 2120

Engine pan, oil seals (outside)

5

STIHL cleaner

6

STIHL Bioplus (1 ltr./ 34 fl.oz bottle)

7

Molybdenum grease (Molykote)

Sliding and bearing points of brake band

8

Graphite grease

Peg on pawl

9

Hose, 5.4x2.2x1000 mm

0000 930 2800

Fuel/suction hose

10

Hose, 5.7x3.1x1000 mm

0000 930 2801

Fuel/suction hose

MS 210, MS 230, MS 250

Crankshaft stubs and taper on flywheel 0781 516 3331

Protects brake band from corrosion

71

72

MS 210, MS 230, MS 250

englisch / english 0455 208 0123. M0,5. A7. Rei. Printed in