Stihl Ts500i Service Manual-Stihl

7/23/2019 Stihl Ts500i Service Manual-Stihl

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STIH)

STIHL TS 500i 2012-02



1TS 500i

q © ANDREAS STIHL AG & Co. KG, 2012 R

A_

7 5 3_

0 0_

0 1_

0 1

1. Introduction andsafety precautions 3

1.1 Introduction 31.2 Safety precautions 4

2. Specifications 6

2.1 Engine 62.2 Fuel system 62.3 Spark plug 62.4 Abrasive wheels 62.5 Tightening torquese 7

3. Troubleshooting 10

3.1 Clutch 103.2 Cast arm with guard 11

3.3 Solenoid valve /Water system 123.4 Starter 143.5 Troubleshooting chart

STIHL Injection 15

4. Cast arm with guard 25

4.1 Water system 254.1.1 Nozzles 254.1.2 Water hose 254.1.3 Solenoid valve 26

4.2 Cast arm with guard 284.2.1 Ball bearing 324.3 Testing radial and

axial truth of running 334.4 Test sequence data 344.5 Ribbed poly V-belt 354.6 Tensioner 36

5. Starter cup / clutch 38

5.1 Starter cup 385.2 Clutch 395.3 Belt pulley /

clutch drum 405.4 Studs for securing the

"cast arm with guard" 41

6. Engine 42

6.1 Muffler / sparkarresting screen 42

6.2 Leak testing 426.2.1 Preparations 436.2.2 Testing with negative

pressure 446.2.3 Pressure test 446.3 Oil seals 45

6.4 Shroud 466.5 Engine 486.6 Cylinder 486.7 Crankshaft 526.7.1 Ball bearing /

crankcase 576.8 Piston 586.9 Piston rings 606.10 Decompression valve 61

7. STIHL Injection 62

7.1 Testing 637.1.1 Checking the screwconnection and plug 63

7.1.2 Connect the injectionsystem diagnosticcable 63

7.2 Testing withSTIHL MDG 1 65

7.3 Control unit 657.4 Spark plug boot 677.4.1 Ignition lead 687.5 Flywheel 687.5.1 Generator 70

7.6 Short circuit wire /switch 71

7.6.1 Testing 717.6.2 Removal and

installation 717.7 Control panel 74

8. Starter 77

8.1 General 778.2 Removal and

installation 778.3 Pawl 778.4 Rope rotor 78

8.5 Starter rope /starter grip 798.6 Tensioning the

rewind spring 808.7 Replacing the

rewind spring 81

9. Antivibrationelements 83

9.1 Antivibration springon handlebar 83

9.2 Antivibration springin the support 849.3 Antivibration spring

at the bottom of thecrankcase 84

9.4 Antivibration springon throttle shutterhousing 85

9.5 Handlebar 869.6 Rubber buffers /

support 879.6.1 Support 879.6.2 Support foot 88

9.6.3 Wiring harnesssolenoid valve(water connection) 90

10. Actuating lever 91

10.1 Switch shaft 9110.2 Throttle trigger /

trigger interlock 92

Contents



2 TS 500i

Contents

11. Fuel system 94

11.1 Air filter 9411.2 Throttle shutter housing /

Intake manifold 9411.2.1 Air baffle /

throttle cable 95

11.3 Injection valve 9611.4 Sensor 9911.5 Impulse hose 10111.6 Leak testing 10211.6.1 Checking the fuel tank /

fuel system 10211.6.2 Checking the

tank vent 10311.6.3 Tank vent

Removal andinstallation 104

11.7 Injection pump 10411.7.1 Manual fuel pump 104

11.7.2 Injection pump 10511.8 Fuel intake 10611.8.1 Pickup body 10611.8.2 Fuel hoses 10611.8.3 Fuel tank filler cap 10711.9 Tank housing 107

12. Special tools 111

13. Serviceaccessories 114



3TS 500i

1. Introduction and safety precautions

1.1 Introduction

This Service Manual containsdetailed descriptions of all thetypical repair and servicingprocedures for this power tool.

Refer to the illustrated spare partslists during all repair work. Theselists show the installation positionand order in which the individualparts and modules should beassembled.

Refer to the latest edition of therelevant spare parts list to check thepart numbers of any spare partsrequired.

A fault on the machine may be due

to several causes. To help locatethe fault, consult the chapter on"Troubleshooting" and the"STIHL Service Training System"for all functional groups.

Refer to the "Technical Information"bulletins for engineering changeswhich have been introduced sincepublication of this Service Manual.The "Technical informationbulletins" also supplement the spareparts list and Service Manual until

an updated edition is issued.

The special tools mentioned in thedescriptions are listed in the chapter"Special Servicing Tools" of thismanual. The tools can be identifiedaccording to part number in the"Special Tools Manual". The manuallists all tools supplied by STIHL.

Symbols are included in the text andpictures for greater clarity.The meanings are as follows:

In the text:

: = Action to be takenas shown in the illustrationabove the text

– = Action to be taken

but not shown in the illustrationabove the text

In the illustrations:

A Item pointer (short)

aDirection of movement(long arrow)

b 4.2 = Reference to another chapter, in this case toChapter 4.2

Service Manuals and "Technicalinformation bulletins" are intendedexclusively for the use of properlyequipped repair shops. They mustnot be passed on to third parties.

Servicing and repairs are madeconsiderably easier if the machineis mounted on assembly stand (3)5910 890 3100. For this purpose,secure the mount (2)5910 850 1650 to the assembly

stand with two screws (1).

For the assembly block5910 890 3101 theabovementioned mountingstep is dropped since themount is already attached.

1

2

3

2 1 9 R A 0 0 0 T G

The screws must not protrude, asthey may damage the housingswhen clamping the machine,depending on the model.

The clamping plate (1)4238 890 2100 is secured to themount (2) using two screwsM8x20 (3) and washers.

Preparing to make repairs

In order to be able to clamp themachine for the repair work on theassembly stand, the "cast arm withguard" must be removed 4.2.

The machine is guided by thetwo front studs on the crankcasethrough the bushings of the

clamping plate and is securedwith the nuts (arrows).

3

1 2

3

3 7 0 R A 0 0 0 T G

3 7 0 R A 0 0 1 T G



4 TS 500i

Always use originalSTIHL replacement parts.They can be identified by theSTIHL part number,the logoSTIand theSTIHL parts symbol(

The symbol may appearalone on small parts.

Storage or disposal of fuel

Collect fuel in a clean container anddispose of it in accordance withenvironmental regulations.

Plug connections on electricalleads

The insulating tube must beoriented so that it is centered overthe plug connection and completelyenclose the plug connection– danger of short-circuiting.

The plug connection is completelyplugged together when it has a totallength of a = max. 30 mm.

Routing the leads

In principle, press all electrical leadsinto the guides using the wiring tool5910 890 4000.

5 9 0 2 R A 2 9 9 T G

a

1.2 Safety precautions

Specific national safety regulationsand the safety instructions in theinstruction manual must beobserved if the machine has to bestarted up during maintenance or

repair work.

Fuel is highly inflammable and canalso be explosive under certainconditions.

Do not bring any fire, flame, spark orother source of heat near the fuel.

All work with fuel must be performedoutdoors only. Spilled fuel must bewiped away immediately.

Test for leakage after all work on the

fuel system and engine.

Exercise extreme caution whilecarrying out maintenance and repairwork on the electronically controlledinjection system – STIHL Injection.The high voltages which occur cancause serious or fatal accidents.

Keep everything clean whenworking on the electronicallycontrolled injection system STIHLInjection.

Suitable gloves must be wornwithout fail if parts are heated forassembly/disassembly purposes.

Improper handling may result inburns and other serious injuries.

Always replace damaged parts.Check dismantled parts for wearand damage before installation,replace if necessary.

Only use the machine with the fancover mounted – otherwise therotating flywheel poses a risk ofinjury and there is a risk of enginedamage due to overheating.

Only start engine with built-in

throttle shutter housing.

The chapter "Tightening Torques"lists all components of this machinethat must be tightened with thespecified tightening torques orcoated with thread-lockingadhesive. These specificationsmust be observed throughout theService Manual when tighteningscrews and nuts as well as otherfasteners.



5TS 500i

Fuel system – barbed connectors

Pull or push the fuel hoses, by handwhenever possible, in the directionof the connector in order to ensureleakproofness of the fuel system.

Avoid damaging the barbedconnectors – sharp-edged pliers, screwdrivers,etc., may not be used.

Also, do not cut open fuel hoseswith a knife or similar aids.

Do not reuse fuel hoses afterdisassembly, but instead alwaysreplace them with new hoses

– fuel hoses can be overstretchedwhen being detached.

Mount new fuel hoses dry or usingSTIHL press fluid – apply press fluidto the ends of the hose and theconnectors, 13.

Other press fluids are not permittedand may lead to fuel hose damage.



6 TS 500i

2. Specifications

2.1 Engine

STIHL InjectionControl unit with load dependent, characteristic-curve-driven ignition timing adjustment and fuel injection.

Electronic water controlThe electronic water control makes it possible to feed the optimum amount of water to the abrasive wheel. Nowater is fed to the abrasive wheel during idling.

TS 500i

Displacement: 72.2 cm3

Cylinder bore: 52 mm

Stroke: 34 mm

Engine 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 rpmIdle speed: 2500 rpm

Clutch: Centrifugal clutch withoutlinings

Clutch engages at: 4000 rpm

Crankcase leakage test

at gauge pressure: pü = 0.5 bar

under vacuum pu = 0.5 bar

2.2 Fuel system Fuel system leakage test at

gauge pressure:pü = 0.8 bar

Operation of tank ventat gauge pressure: pü = 0.3 bar

Fuel: as specified in instructionmanual

2.3 Spark plug Spark plug (suppressed): Bosch WSR6FNGK BPMR 7 A

Electrode gap: 0.5 mm

2.4 Abrasive wheels

Composite and diamond cutting wheels Diameter 350 mm

Cutting depth 125 mm



7TS 500i

2.5 Tightening torquese

P and DG screws are fitted in plastic and light alloy metal parts. These screws form a permanent thread whenthey are installed for the first time. The material is permanently deformed. Screws can be removed and installedas often as necessary without impairing the strength of the screwed assembly, provided that the specifiedtightening torque is observed.For this reason it is essential to use a torque wrench.

When inserting DG and P screws into an existing screw thread:

Insert the DG or P screw in the hole and turn counterclockwise until it gently drops into the hole in axial directionand engages the existing threads. 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 threadand weaken the assembly.

For the microencapsulated screw, before renewed assembly, clean both threads (insert tap in the internal threadby hand and then blow out the threaded hole, brush off the exterior thread), coat the cleaned screw withmedium-strength Loctite 242 or 243.

Screwdriver speed when used in plastic material: P and DG screws max. 500 rpm.Do not use an impact wrench to release or tighten screw connections.

Screws with and without locking serration must not be confused.

Fastener Thread size For component Tighteningtorques

Comment

Nm

Screw P4x16 Limit stop / cast arm 1.8

Screw M8 Stop pin / cast arm 5.0

Screw M6x28 Cast arm / flange 8.0 2)

Collar nut M8 Cast arm / rewind starter / stud 20.0Screw M5x17 Cover / shroud (service cover) 4.5

Screw P6x19 Cap / solenoid valve / tank housing 6.0

M10x1 Decompression valve 14.0

Screw M4x20 Injection valve / crankcase 3.0 2)

Screw M5x20 Filter cover / tank housing 6.0

Screw M4x9.6 Spark arresting screen / muffler 2.0

Screw M5x20 Generator / crankcase 6.0 2)

Screw P5x16 Handle molding / shroud 4.0

Screw D5x20 Rubber buffers / support 6.0 6)

Screw P5x16 Holder / switch / shroud 4.0

Screw P6x19 Shroud / tank housing 6.0



8 TS 500i


Comment

Nm

Screw M5x17 Cap, spark plug cover / shroud 4.5

Nut M10x1 L V-belt pulley, front 45.0

Screw P6x40 Clamp / handlebar / tank housing 6.0Screw P6x26 Clamp / tank housing 6.0

Screw D5x45 Clamp / antivibration system / handlebarholder

6.0 2)

Screw M5x35x22 Manifold / throttle shutter housing /cylinder

6.0 2

Screw P6x19 Crankcase / bearing plug antivibrationsystem

6.0

Screw M5x32x22 Crankcase / cylinder 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 / tankhousing 4.0

Screw M5x20 Fan cover / crankcase 6.0 2)

Screw P6x19 Air baffle / tank housing 6.0

Screw M5x20 Air guide shroud / crankcase 3.0 2)

Screw M4x12 Ground wire / cover / crankcase 4.0 3)

M12x1 L Carrier 40.0

Screw P3x6 Rewind spring / starter cover 0.5

Screw M5x20 Muffler / cylinder 1st stage 2.5 2)

Screw M5x20 Muffler / cylinder 2nd stage 10.0 2)

Screw M5x20 Muffler / crankcase 10.0 2)

Screw G 3/8" Hose connection / solenoid valve 2.0Screw M5x21 Guard / cast arm 6.0

Nut M8x1 Flywheel / crankshaft 33.0 5)



9TS 500i


Comment

Nm

Screw M4x12 Sensor / crankcase 2.0 3)

Screw M3x20 Hose clamp, manifold / cylinder 0.5

Screw D5x24 Clamping lever / cast arm 4.0 2)Nut M8x1 Starter cup / crankshaft 33.0

Screw M8x53 Stud / crankcase 21.0 4)

Screw P6x50 Support / clamp / handlebar / tankhousing

6.0

Screw P6x19 Support / bearing plug antivibrationsystem

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 M8x17 Adjusting lever / guard / square nut 4.0M14x1.25 Spark plug 25.0

Screw M4x8 Pan head screw / banjo screw 3.0

1) Loctite 243 medium strength2) Easy-slide coating with locking serration3) Microencapsulated with locking serration4) Microencapsulated5) Connection between crankshaft and flywheel must be degreased and oil-free6) Easy-slide coating



10 TS 500i

3. Troubleshooting

3.1 Clutch

Problem Cause Remedy

Cutting wheel stops under load atfull throttle

Clutch shoes badly worn Replace clutch

Clutch drum badly worn Replace clutch drum

Cutting wheel rotates at idle speed Clutch springs stretched or fatigued Replace clutch springs or replaceclutch

Anchor loops of the clutch springhooks are broken

Replace clutch springs

Throttle cable is jammed Check easy movement of throttlecable and replace if necessary

Throttle trigger is stiff Check throttle trigger, repair ifnecessary

Throttle shutter does not returnautomatically

Check the throttle shutter stops andreplace throttle shutter housing ifnecessary

Loud noises Clutch springs stretched or fatigued Replace all clutch springs

Grooved ball bearing on poly V-beltpulley / clutch drum damaged

Replace ball bearing

Clutch shoe retainer broken Replace holder

Clutch shoes and carrier worn Replace clutch



11TS 500i

3.2 Cast arm with guard


Cutting wheel does not runsmoothly or vibrates

Axial or radial runout Set axial or radial true running,replace cutting wheel if necessary

Ribbed poly V-belt is loose Check and tension ribbed poly

V-belt, replace ribbed poly V-belt ortensioner if necessary

Grooved ball bearing of the frontpoly V-belt pulley is worn

Replace ball bearing

Cutting wheel stops under load atfull throttle

Clutch shoes badly worn Replace clutch

Clutch drum badly worn Replace clutch drum

Ribbed poly V-belt not properlytensioned

Tension ribbed poly V-belt, replaceif necessary

Cutting wheel rotates at idle speed Clutch springs stretched or fatigued Replace clutch springs or replaceclutch

Anchor loops of the clutch springhooks are broken

Replace clutch springs

Throttle cable is jammed Check easy movement of throttlecable and replace if necessary

Throttle trigger is stiff Check throttle trigger, repair ifnecessary

Throttle shutter does not returnautomatically

Check the throttle shutter stops andreplace throttle shutter housing ifnecessary



12 TS 500i

3.3 Solenoid valve / Water system


No water supply Solenoid valve does not react eventhough the control panel wasactuated

Run test with STIHL MDG 1,replace solenoid valve if necessary

Banjo screws (water nozzles) arevery dirty

Clean the banjo screws, replace ifnecessary

Control panel damaged Run test with STIHL MDG 1,replace control panel if necessary

Water volume too low even thoughit has been increased via thecontrol panel

Banjo screws (water nozzles) arevery dirty

Clean the banjo screws, replace ifnecessary

Water hose kinked or damaged –also check water supply hose

Check hose clips, water hose andseals, replace if necessary

Manifold for hose connection isclogged

Check manifold and clean (rinsescreen), replace if necessary

Control panel damaged Check control panel with STIHLMDG 1, replace if necessary

Water supply even though machinehas been switched off

Solenoid valve is damaged or jams – solenoid valve no longer closes

Check solenoid valve, replace ifnecessary

Leaks in the water system O-ring and / or seal on waterattachment damaged

Replace O-ring and seal, replacewhole water attachment ifnecessary

Hose clips open or damaged orhose damaged

Close hose clips, replace ifnecessary, replace damaged hose



13TS 500i


Abrasive wheel runs dry eventhough water control has beenswitched on

Manifold for hose connection isclogged

Check manifold and clean (risenscreen), replace if necessary

Nozzles are clogged Clean nozzles, replace if necessary

Control panel damaged Check control panel with STIHLMDG 1, replace if necessary

Solenoid valve is damaged or jams Check solenoid valve with STIHLMDG 1, replace if necessary

Water hose kinked or damaged –also check water supply hose

Run water hose so that it is free ofkinks, replace damaged water hose



14 TS 500i

3.4 Starter


Starter rope broken Rope pulled out too vigorously asfar as stop or over edge, i.e. notvertically

Replace starter rope

Normal wear Replace starter rope

Starter rope does not rewind Very dirty or corroded Clean or replace rewind spring

Spring insufficiently tensioned Check rewind spring and increasetension

Rewind spring broken Replace rewind spring

Starter rope cannot be pulled outfar enough

Rewind spring overtensioned Check rewind spring and reducetension

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

Guide peg on pawls or pawlsthemselves are worn

Replace pawls

Spring clip fatigued Replace spring clip

Loose starter cup Tighten starter cup, replace ifnecessary

Starter rope is difficult to pull orrewinds very slowly

Starter mechanism is very dirty Thoroughly clean complete startermechanism

Lubricating oil on rewind springbecomes viscous at very lowoutside temperatures (spring

windings stick together)

Coat rewind spring with a littlestandard solvent-based degreasant(containing no chlorinated or

halogenated hydrocarbons), thenpull rope carefully several timesuntil normal action is restored



15TS 500i

3.5 Troubleshooting chart STIHL Injection

DiagnosisOK?

no

– Carry out diagnosis with STIHL MDG 1

Repair fault shown by STIHL MDG 1

Decompression valveleaking, faulty

yes

Oil sealsdefective

Crankcase leaking,faulty

– Check startingbehavior

Check decompressionvalve, replace if necessary,

6.10

Check oil seals, replaceif necessary, 6.2,

6.3

Check engine does notleak, 6.2

Complaintremedied?

no

Startingbehavior OK?

no

yes

Trouble-shooting

completed

yes

Too much starting effort

Decompression valveleaking, faulty

Spark plug defective

Break or damagedinsulation in ignition lead

Check decompressionvalve, replace if

necessary, 6.10

Replace spark plug

Check ignition lead, replaceif necessary, 7.4

Engine does not start

21 3



16 TS 500i

Clutch springs stretchedor fatigued

Anchor loops of the

tension springs for theclutch shoes are broken

Throttle cable is jammed

– Check idle behaviorafter start

Check clutch, replace ifnecessary, 5.2

Check fuel system does notleak, 11.6

Check throttle cable, repairif necessary, 11.2.1

Idlebehavior OK?

no

yes

Idle speed toohigh, abrasive wheel

runs

54 7

Cable breakage on anelectrical component(control unit, sensor,

injection valve, on / offswitch

Fuel systemleaking


Visual inspection ofelectrical leads

Check clutch, replace if

necessary, 5.2


21 3

Throttle trigger is stiff Check throttle trigger,repair if necessary, 10.2

Pickup body soiled Check pickup body, replace

if necessary, 11.8.1

Flywheel out ofadjustment, woodruff key

has sheared off

Check woodruff key andflywheel, replace ifnecessary, 7.5

Injection pump hasmechanical fault

Replace injection pump, 11.7

6



17TS 500i

Throttle shutter stopsworn

Oil sealsdefective


Check the throttle shutter

stops, replace throttleshutter housing if

necessary, 11.2


Idle speedtoo low

98 10

Check oil seals, replace ifnecessary, 6.2, 6.3


Check the throttle shutterstops, replace throttle

shutter housing ifnecessary, 11.2

Injection valvemechanically

worn

Replace injection valve,11.3

54 7

Engine stallswhen idle

Throttle shutter does notreturn automatically



6

Pickup body soiled Check pickup body, replace

if necessary, 11.8.1


Replace injection pump,11.7


worn




18 TS 500i

Spark plug bootis loose on the

spark plug

Spark plug sooted,smeared with oil

Ignition lead loose oncontrol unit

Press boot firmly ontospark plug, replace torsionspring if necessary, 7.4

Secure ignitionlead, 7.4

Idle speed unstable,erratic

11

Clean spark plug, replaceif necessary

Fuel / oil mixturecontains too much oil

Use a fuel mixture with thecorrect mixing ratio

Flywheel is cracked,damaged

Check flywheel, replace ifnecessary, 7.5

98 10

Flywheel out ofadjustment, woodruff key

has sheared off

Check woodruff key andflywheel, replace ifnecessary, 7.5



19TS 500i

Spark plug defective

Pickup body soiled

Fuel hose kinked

–Check acceleration

Replace spark plug

Run fuel hoseso that it is free of kinks,

11.8

AccelerationOK?

no

Poor acceleration /engine stalls while

accelerating

12

Check pickup body, replaceif necessary, 11.8.1

Fuel system leaking Check fuel system doesnot leak, 11.6

Impulse hose damagedor

kinked

Check impulse hose,replace if necessary,

11.5

Injection pump defective(control needle, seal,

etc.)


11

yes

Injection valve does notclose




20 TS 500i

Air filter dirty

Decompression valvedoes not close

Spark plug bootis loose on the

spark plug

– Check behavior whileworking

Replace air filter, 11.1

Press boot firmly ontospark plug, replace torsion

spring if necessary,7.4

BehaviorOK?

no

Loss of power, maximumengine speed not

reached,Engine stops

13

Check decompressionvalve, replace if necessary,

6.10

Spark plug sooted,smeared with oil

Clean spark plug, replaceif necessary

Ignition lead loose oncontrol unit

Secure ignition lead, 7.4

Break or damagedinsulation in ignition

lead

Check ignition lead, replaceif necessary, 7.4

12

yes

Cable breakage on anelectrical component

Visual inspection ofelectrical leads

1514

Fuel/oil mixture containstoo much oil

Use a fuel mixture with thecorrect mixing ratio



21TS 500i

Fuel hosekinked

Impulse hose damagedorkinked


Run fuel hoseso that it is free of kinks,

11.8

Check throttle cable, repairif necessary,

11.2.1

16

Check impulse hose,replace if necessary,

11.5





Muffler, spark arrestingscreen carbonized

Check muffler, replace ifnecessary, 6.1

13

Piston rings worn,

broken Replace piston rings,6.9

1817



14 15

Pickup body soiled

Fuel system leaking

Tank vent faulty

Check pickup body, replaceif necessary, 11.8.1

Check tank vent, replace ifnecessary, 11.6

Check fuel system does not

leak, 11.6



22 TS 500i

Clutch springs stretchedor fatigued

Anchor loops of thetension springs for the

clutch shoes are broken


– Check idle behaviorafter work completed


Check woodruff key and

flywheel, replace ifnecessary, 7.5


11.2.1

BehaviorOK?

no

yes

Engine won't go into idlespeed

2019 21

Flywheel is cracked,damaged

Flywheel out of

adjustment, woodruff keyhas sheared off


Check flywheel, replace ifnecessary, 7.5




Throttle shutter doesnot return

automatically




worn


16 18

Injection valve hasmechanical fault


17



23TS 500i

Throttle shutter does notreturn automatically

Oil sealsdefective





Engine delays going intoidle speed

22

Check oil seals, replace if

necessary, 6.2,6.3





worn


2019 21

Engine speed drops,engine stops



11.2.1




24 TS 500i

On / off switch

defective

– Check "Switch offengine"

Check on / off switch withSTIHL MDG 1,

clean if necessary orreplace

BehaviorOK?

noEngine cannot be

switched off

22

yes

– Troubleshootingcompleted



25TS 500i

4. Cast arm with guard

4.1 Water system

4.1.1 Nozzles

: Take out banjo screws (arrow) onboth sides – the square nutsinside the guard drop down.

: Take out and examine the waterhose (1), replace if necessary

– Check banjo screws, O-rings andseal, replace if necessary

: Remove screw (1)

: Guide the adjusting lever (2) overthe lift-off lugs (arrow) with agentle turning movement andremove it.

1

3 7 0 R A 0 0 3 T G

3 7 0 R A 0 0 4 T G

2 1

Installation

When fitting the adjusting lever, it issimply pushed into place until itengages.

– Insert and tighten the screw

: Fit the connector (1) with waterhose and align it at a right angleto the adjusting lever (2).

– Coat O-ring with STIHL pressfluid, 13

: Insert banjo screw (3) – Do not damage O-ring

Opposite side

: Push gasket (1) onto banjoscrew (2)

– Coat O-ring with STIHL pressfluid, 13

: Insert banjo screw (2) – Do not damage gasket orO-ring

1 3 0 7 R A 3 6 4 T G

2

3

1

1 3 0 7 R A 0 0 0 T G

1

2

: Fit the square nuts (1) in theguides (arrows) inside the guardon both sides and hold it.

: Hold the square nuts (1) in placeand screw in and tighten banjoscrews on both sides

4.1.2 Water hose

: Apply a screwdriver to the hoseclip (arrow) and turn slightly toopen the clip.

: Remove water hose (1)

3 7 0 R A 0 0 6 T G

1

3 7 0

R A 0 0 7 T G

1



26 TS 500i

: Pull the water hose (1) out of theguides (arrows).

: Apply a screwdriver to the hoseclip (arrow) and turn slightly toopen the clip.

: Pull off the hose (1).

Installation

– Push hose clip onto water hose

3 7 0 R A 0 1 3 T G

1

1 3 0 7 R A 0 0 1 T G

1

1 3 0 7 R A 0 0 2 T G

12

: Push water hose (1) as far aspossible onto the support of thesolenoid valve, then align thehose clip (2)

: Press the tabs (arrows) on thehose clip (2) together until they

engage

– Push hose clip onto water hose

: Push water hose (1) as far aspossible onto the support of thenozzle, then align the hoseclip (2)

: Press the tabs (arrows) on thehose clip (2) together until theyengage

– Starting from the solenoid valve,route the water hose (1) withoutany tight bends or kinks.

1 3

0 7 R A 0 1 5 T G

21

3 7 0 R A 0 4 4 T G

1

: Press the water hose (1) into theguides (arrows)

4.1.3 Solenoid valve

– Troubleshooting, 3.3

– Disconnect the water hose fromthe solenoid valve, 4.1.2

: Remove screw (1) on the bottomof the machine and remove thecover (2)

: Pull insulating tubes with plugconnections (1, 2) out of theguides

1 3 0 7 R A 0 0 3 T G

1

2

1

2 1 3 0 7 R A 0 0 4 T G



27TS 500i

: Push insulating tubes (1) off theplug connections (2, 3)

: Disconnect plugconnections (2, 3)

– Pull insulating tubes off the wiringharness

: Pull solenoid valve (1) from thebushing (2) and remove, pullwiring harness (3) through theopening (arrow)

: Check solenoid valve (1),unscrew hose connection (2) ifnecessary, replace sealingring (3) and O-ring (4)

1 3 0 7 R A 0 0 5 T G

2

31

1

1 3 0 7 R A 0 0 6 T G

1

32

1 3 0 7 R A 0 1 6 T G

34 2

1

Installation

: Orient solenoid valve (1) so thatthe raised parts (arrows) engagein the profiles (arrows)

: Push wiring harness (2) into theopening (3)

: Pull wiring harness (1) throughthe opening and fit solenoidvalve (2), pushing thebushing (3) into the mount(arrow) – the bushing (3) must becompletely seated in the mount

1 3 0 7 R A 0 0 7 T G

1

2

3

1 3 0 7 R A 0 0 8 T G

2

13

: Push insulating tubes (1)into place and completelypush together the plugconnections (2, 3)

– Leads can be interchanged

: Slide insulating tubes (1) over theplug connections, 1.1

: Press insulating tubes with plugconnections (1, 2) completelyinto the guides (arrows)

– Align insulating tubes with plugconnections in the middle of theguides

1 3 0 7 R A 0 1 0 T G

2

31

1

1 3 0 7 R A 0 1 1 T G

1

2



28 TS 500i

: Press the wiring harness (1) intothe guide so that the protectivetube (2) is flush with the edge(arrow)

: Press leads into the guide (arrow)

: Fit cover (1) so that the tabsengage in the mounts (arrows) –do not pinch the leads whenfitting the cover

1 3 0 7 R A 0 1 2 T G

2

1

1 3 0 7 R A 0 1 3 T G

1 3 0 7 R A 0 1 4 T G

1


– Fit the water hose to the solenoidvalve, 4.1.2

4.2 Cast arm with guard

– Unscrew the banjo screw on theadjusting lever and remove theconnector with water hose,

4.1.1

: Unscrew collar nuts (arrows).

: Relax the ribbed poly V-belt byturning the hexagon (1) on thetensioner counterclockwise untilthe arrow points to "0" (arrow).

3 7 0 R A 0 1 0 T G

3 7 0 R A 0 1 1 T G

1

: Pull the hose (1) out of the guides(arrows).

: Remove the screw (arrow).

: Remove the belt guard (1).

: Take out the collar nuts (arrows).

: Remove starter (1)

– Remove ribbed poly V-belt,4.5

3 7 0 R A 0 1 3 T G

1

3 7 0 R A 0 1 4 T G

1

1 3 0 7 R A 0 0 9 T G

1



29TS 500i

: Remove "cast arm withguard" (1)

– Block the belt pulley.

: Remove screw (1)

: Remove thrust washer (2).

: Remove the axial clamping ring(arrow).

: Remove the other thrustwasher (1).

3 7 0 R A 0 1 7 T G

1

1 3 0 7 R A 3 6 6 T G

2 1

3 7 0 R A 0 1 6 T G

1

: Block the belt pulley (arrow).

: Unscrew the nut (left-handthread) and 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 springsare tensioned.

The flange drops down on the otherside.

3 7 0 R A 0 1 8 T G

1

1

3 7 0 R A 0 1 9 T G

3 7 0 R A 0 2 0 T G

: Remove the cast arm (1)

: Remove the sleeves (2) andcompression springs (3)

: Check the stop pin (1), unscrewand replace if necessary

– Reassemble parts in reverseorder

: Remove the washer (1) andrubber ring (2)

3 7 0 R A 0 2 1 T G

2

3

1

1 3 0 7 R A 0 1 7 T G

1

3 7 0 R A 0 2 2 T G

1

2



30 TS 500i

: Remove the washer (1) andrubber ring (2) on the other side

: Examine guard (3), replace ifnecessary

– also check the stops (arrows)

– Examine the individual parts,

replace if necessary

Installation

: Align the rubber ring so that thelug (1) engages in the opening(arrow)

: Press the rubber ring (1) into thehole in the guard until it lies flush

1 3 0 7 R A 0 1 8 T G

1

2

3

3 7 0 R A 0 2 4 T G

1

– Rotate guard

: Align the rubber ring (2) so thatthe lug (1) engages in theopening (arrow)

: Press the rubber ring (2) into thehole in the guard until it lies flush.

The profile of the rubber ringmust engage in the mount of theguard

: Place washer (1) on the outsideof the guard on the rubber ring (2)

– Slide the cast arm into the rubberbearing.

1 3 0 7 R A 0 1 9 T G

2

1

3 7 0 R A 0 3 1 T G

1

2

: Place washer (1) on theflange (2)

: Fit flange (2) on the opposite sideand align so that the threadedholes in the flange (2) line up withthe holes in the cast arm

– Fit sleeves (1) and springs (2)over the screws (3)

: Insert the screws with sleevesand springs in the holes (arrows)

– Insert and tighten the screws

3 7 0 R A 0 3 2 T G

1

2

3 7 0 R A 0 3 3 T G

2

1 3

3 7 0 R A

0 3 4 T G



31TS 500i

: Slide the shaft (1) into the ballbearings from the flange side (2)

– Turn the "cast arm with guard"and hold the shaft

: Slide the belt pulley (1) onto theshaft with the longer collar

(arrow) first so that the polygonalprofile is aligned

– Block the belt pulley

: Fit the washer, screw on the nut(arrow) and tighten it down

– Left-hand thread

1

3 7 0 R A 0 3 5 T G

2

1 3 0 7 R A 3 6 5 T G

1

3 7 0 R A

0 3 7 T G

: Fit the thrust washer (2) so thatthe groove (arrow) engages thelug (1) on the shaft

– Fit the axial clamping ring

: Fit the thrust washer so that thelugs (1) engage the grooves

(arrows) in the shaft

– Fit screw

: Slide the "cast arm withguard" (1) onto the studs(arrows)

The tensioner must point to "0".

3 7 0 R A 0 3 8 T G

1

2

3 7 0 R A 0 3 9 T G

1

1

3 7 0 R A 0 4 0 T G

1

– Fit the ribbed poly V-belt, 4.5

: Position the guard (1)

: Insert and tighten the screw(arrow)

: Slide the starter (1) onto the

studs

: Screw in the collar nuts (arrows) – do not tighten

– Tension the ribbed poly V-belt,4.5

– Screw all three collar nuts tight

3 7 0 R A 0 4 1 T G

1

3 7 0 R A 0 4 2 T G

1



32 TS 500i

– Fit the connector (1) with waterhose and align it at a right angleto the adjusting lever (2).

: Insert square nut on the inside,screw in banjo screw (3) andtighten

: Starting from the solenoid valve,route the water hose (1) so thatthere are no tight bends or kinks

: Press the water hose (1) into theguides (arrows)

1 3 0 7 R A 3 6 4 T G

2

3

1

3 7 0 R A 0 4 4 T G

1

4.2.1 Ball bearing

– Remove the "cast arm withguard", 4.2

– Remove the guard on the castarm, 4.2

: Remove the circlips (1) on bothsides

: Drive the ball bearing out of thecast arm with press arbor (1)4224 893 7200

Always use new grooved ballbearings.

1 3 0 7 R A 3 6 3 T G

1

3 7 0 R A 0 2 7 T G

1

Installation

: Fit a circlip (1) as stop in the castarm

– Align the press arbor (1)4224 893 7200 – the ball bearingand ring are pushed onto the longpeg (arrow)

: Slide the first grooved ballbearing (2), ring (3) and secondgrooved ball bearing (4) onto thepeg (arrow)

1 3 0 7 R A 3 6 2 T G

1

1 3 0 7 R A 0 3 6 T G

11 2

3 4



33TS 500i

: Position the grooved ballbearing (2) with press arbor (1)4224 893 7200 and press it as faras possible against the circlip

Do not press too hard, otherwise thecirclip which has been fitted as astop will be jammed.

– Take out the press arbor

– Fit the second circlip in thegroove in the cast arm

The seal on the deep groove ballbearing must not be damaged.

– Fit the guard on the cast arm,4.2

– Fit the "cast arm with guard",4.2

3 7 0 R A 0 3 0 T G

1

2

4.3 Testing radial and axialtruth of running

Since the radial truth of running ofthe cutting wheel changes if theshaft diameter changes (due toscoring, etc.), it is sufficient to

carefully inspect the shaft aroundthe mount for the cutting wheel.

The axial truth of running, on theother hand, depends on thecondition of several parts andshould therefore be determined bymeasurement.

– Undo the screw and remove thethrust washer, see 4.2

: Position test wheel (1)

5910 851 6100

: Fit the thrust washer so that thelugs (1) engage the grooves(arrows) in the shaft

3 7 0 R A 0 4 5 T G

1

3 7 0 R A 0 3 9 T G

1

1


: Secure a dial gauge holder (1)5910 850 6000 with fitted dialgauge (2) 0000 890 9100 on theguard so that the axial truth ofrunning can be determined for adiameter of approx. 130 mm over

one full revolution of the wheel,see test table.

– Remove the test equipment aftertesting.

3 7 0 R A 0 4 7 T G

21



34 TS 500i

4.4 Test sequence data

Test sequence Actual condition Possible causes Activities

Radial truth of running:

Visual inspectionSpindle (shaft)

Wear marks or scoringaround the mount for thecutting wheel

Operation with loosefastening screw, use of thewrong cutting wheels(mount dia. > 20mm)

Replace spindle (shaft),use correct cuttingwheel

Axial truth of running: Axial truth of running istested with aSTIHL test wheel ordiamond abrasive wheel(on 130 mm diameter)

Axial runout< 0.15 mm

> 0.15 mmDamage or unevenness inthe mating faces of the

thrust washers (particularlythe inner thrust washer),mating faces are not plane,use of parts which are notoriginal STIHL parts

Dirt, incorrectly fitted thrustwashers or cutting wheel,

use of force when cutting orduring transport

none

Replace the thrustwashers

Spindle (shaft) damaged Incorrect handling, use offorce

Replace spindle (shaft)

Tangible radial backlash inthe bearing seat→ spindlebearing faulty

Grooved ball bearingsdamaged by dust and/orbearing seat worn at thespindle

Replace spindle andgrooved ball bearings



35TS 500i

4.5 Ribbed poly V-belt

: Unscrew collar nuts (arrows).

: Relax the ribbed poly V-belt byturning the hexagon (1) on thetensioner counterclockwise untilthe arrow points to "0" (arrow).

: Pull the hose (1) out of the guides(arrows).

3 7 0 R A 0 1 0 T G

3 7 0 R A 0 1 1 T G

1

3 7 0 R A 0 4 4 T G

1

: Remove the screw (arrow)

: Remove the belt guard (1).

: Take out the collar nuts (arrows).

: Remove starter (1)

: Take the ribbed poly V-belt (1) offthe front belt pulley (arrow)

3 7 0 R A 0 1 4 T G

1

1 3 0 7 R A 0 0 9 T G

1

3 7 0 R A 0 4 8 T G

1

: Take the ribbed poly V-belt (1) offthe belt pulley on the clutch side

– Check the ribbed poly V-belt,replace if necessary

: Insert ribbed poly V-belt (1) firstonto rear belt pulley (clutch)

: Then fit the ribbed poly V-belt (1)over the front belt pulley (2) andturn the pulley (2) to draw the beltonto the pulley.

3 7 0 R A 0 4 9 T G

1

3 7 0 R A 0 4 9 T G

1

2



36 TS 500i

: Fit the belt guard (1)

: Insert and tighten the screw(arrow)

: Slide the starter (1) onto thestuds

: Screw in the collar nuts (arrows) – do not tighten

: Turn the hexagon (1) on thetensioner clockwise

3 7 0 R A 0 4 1 T G

1

3 7 0 R A 0 4 2 T G

1

3 7 0 R A 0 5 1 T G

1

– After roughly 1/8 of a turn, thetensioner is caught by the force ofthe spring. The hexagon is nowturned further by the springtension until the ribbed polyV-belt is tensioned.

The hexagon must not be forced, asthe belt tension is obtained throughthe spring tension.

– Screw all three collar nuts tight

– Insert the water hose in theguides, starting from the solenoidvalve

4.6 Tensioner


: Turn the hexagon (1) 1/2 turnclockwise to relax the tensioner

: Remove screws (2)

1 3 0 7 R A 0 2 0 T G

2

1 2

: Remove the completetensioner (1)

: Remove the cover (1)

– Unhook the tensioner spring fromthe clamping lever

– Examine the parts and replacethem if necessary

: Hook the tensioner spring into thehole (arrow) of the lever (1)

– Fit the cover

1 3 0 7 R A 1 6 6 T G

1

3 7 0 R A 0 5 4 T G

1

3 7 0 R A 0 5 5 T G

1



37TS 500i

: Fit the complete tensioner (1)


The tensioner must be set to thepre-tensioned position beforeinstalling the "cast arm with guard".

Turn the hexagon of the tensioneras far as possible counterclockwiseto pre-tension the tensioner.

– Reassemble remaining parts inreverse order

1 3 0 7 R A 1 6 7 T G

1



38 TS 500i

5. Starter cup / clutch

5.1 Starter cup


: Remove the screw (arrow) – Screw remains in cap

: Remove the cap (1) with screw

: Remove the spark plug boot (1)

: Unscrew the spark plug (1)

1 3 0 7 R A 0 5 0 T G

1

1

1 3 0 7 R A 0 5

1 T G

1 3 0 7 R A 0 5 2 T G

1

Decompression valve must berelieved.

: Insert locking strip (1)0000 893 5903 in the cylinder

Locking strip (1) 0000 893 5903must rest against the cylinder wall(arrow) – Position as shown.

: Unscrew nut (1) and pull offstarter cup (2)

– Examine the starter cup, replaceif necessary

1 3 0 7 R A 0 5 3 T G

1

1 3 0 7 R A 0 5 4 T G

1 3 0 7 R A 0 5 5 T G

1

2

: Align the starter cup (1) so thatthe hexagon (arrow) engageshexagon (2) of the clutch

– Slide the starter cup into placeand screw on the nut

– Block the piston and screw the

nut tight


1 3 0 7 R A 0 5 6 T G

1

2



39TS 500i

5.2 Clutch


– Remove starter cup, 5.1

– Block the piston, 5.1

: Unscrew the clutch (1) withhexagon (arrow)


: Use hook (2) 5910 890 2800 toremove the clutch springs (1)

3 7 0 R A 0 6 5 T G

1

3 7 0 R A 0 6 6 T G

21

– Pull the clutch shoes off thecarrier

: Pull the retainers (1) off the clutchshoes

– Clean the individual parts, 13

– replace any damaged parts – Always replace clutch shoes insets

: Slip the retainers (1) onto theclutch shoes

3 7 0 R A 0 6 7 T G

1

3 7 0 R A 0 6 8 T G

3 7 0 R A 0 6 9 T G

1

: Slide the clutch shoes (2) overthe legs (1)

: Clamp the clutch in a vise (arrow)

Hook the springs into the oppositeside of the raised hexagon.

: Attach one end of the clutchspring (1) to the clutch shoes

: Use the hook (2) 5910 890 2800to attach the other end of thespring and press it firmly into theclutch shoe

3 7 0 R A 0 7 0 T G

1 2

1 3 0 7 R A 3 6 7 T G

3 7 0 R A 0 7 2 T G

1

2



40 TS 500i

: Examine the clutch – all springs(arrows) must be hooked inproperly

Ring (1) must be in place.

: Fit the clutch (1) on thecrankshaft stub so that the raisedhexagon (arrow) can be seen

– Block the piston, 5.1

3 7 0 R A 0 7 3 T G

1 3 0 7 R A 0 5 7 T G

1

3 7 0 R A 0 7 5 T G

1

: Turn the clutch (1) with hexagon(arrow) onto the crankshaft stuband screw it tight – left-handthread

– Pull the locking strip out of thecylinder


5.3 Belt pulley / clutch drum

– Remove the clutch, 5.2

: Remove the ring (arrow)

: Remove the clutch drum (1)

1

3 7 0 R A 0 0 2 T G

1 3 0 7 R A 0 5 8 T G

1

– Examine the clutch drum (1) forsigns of wear

The remaining thickness must bemeasured if there are distinct signsof wear on the inside diameter of theclutch drum (1). The clutch drummust be replaced if the remaining

thickness is less than approx. 80 %of the original thickness.

: Remove the circlip (1)

: Drive out the ball bearing with thedrift pin (1) 4119 893 7200

!80%

100%

5 9 0 2 R A 0 1 8 T G

1

3 7 0 R

A 0 7 6 T G

1

3 7 0 R A 0 7 7 T G

1



41TS 500i

: Press the ball bearing fully homewith press arbor (1)4224 893 7200

: Fit the circlip (1)

: Slide the clutch drum (1) intoplace

: Slide on the ring (2)


3 7 0 R A 0 7 8 T G

1

3 7 0 R A 0 7 9 T G

1

1 3 0 7 R A 0 5 9 T G

1

2

5.4 Studs for securing the"cast arm with guard"


: Fit the stud puller (1)5910 893 0501 over the studs

(arrows) as far as possible andunscrew

: Coat the thread (arrows) of thestuds with Loctite before fittingthem, 13

– Use the stud driver5910 890 3000 to screw in andtighten the studs

– Reassemble remaining parts in

reverse order

1 3 0 7 R A 0 6 0 T G

1

1 3 0 7 R A 0

6 1 T G



42 TS 500i

6. Engine

6.1 Muffler / spark arrestingscreen

– Refer also to troubleshootingchart, 3.5

– Remove the "cast arm with

guard", 4.2

To keep dirt particles from enteringthe cylinder, move piston to topdead center before removing themuffler.

: Take out the screws (arrows)

: Take out and examine themuffler (1), replace if necessary

: Remove the muffler gasket (1)and cooling plate (2)

1

3 7 0 R A 0 8 3 T G

2

1

3 7 0 R A 0 8 4 T G

– Installing and removing the sparkarresting screen, see InstructionManual

– Cover exhaust bore and removeany fouling on the cylinder andexhaust bore

: Examine and clean the matingsurfaces (arrows) on the exhaustbore, cooling plate and muffler,remove any gasket residues ifnecessary – there must not beany gasket residues or dirtparticles in the exhaust bore,

13

Parts with damaged mating facesmust be replaced.

: Fit cooling plate (1) and mufflergasket (2) to muffler (3) andinsert screws (4) into coolingplate

– Muffler gasket and cooling plateare held in place on the muffler

3 7 0 R A 0 8 6 T G

1 3 0 7 R A 0 6 2 T G

1

2

3

4

: Carefully fit muffler (1) withmuffler gasket and cooling plate

: Fit the screws (arrows) and checkthat the cooling plate and gasketare correctly positioned

: Insert the screws (arrows) and

tighten them according tospecifications, 2.5

6.2 Leak testing

Defective oil seals and gaskets orcracks in housing are the usualcauses of leaks. Such faults allowsupplementary air to enter theengine and upset the fuel-airmixture.

This can above all affect the idlespeed.Moreover, it is possible that thetransition from idle speed to part orfull throttle is not smooth.

Always start with the vacuum testand then continue with the pressuretest.

The engine can be thoroughlychecked for leaks under vacuum

and at gauge pressure using thepump 0000 850 1300.

1

3 7 0 R A 0 8 8 T G



43TS 500i

6.2.1 Preparations

– Remove shroud, 6.4

The spark plug (2) must be screwedtight.

– Remove the decompressionvalve, 6.10

: Fit the stopper (1)4221 025 2200 and screw it tight

: Undo the screws (arrows)

3 7 0 R A 0 8 9 T G

2

1

1 3 0 7 R A 0 6 3 T G

: Fit a sealing plate (1)0000 855 8106 between thecylinder exhaust port and coolingplate, then tighten the screwsgently

The sealing plate must fill the fullwidth between the screws.

– Remove the air filter, 11.1

1 3 0 7 R A 0 6 4 T G

1

– Coat O-ring on the plug of thepressure testing tool5910 890 4100 with STIHL pressfluid, 13

: Press the plug (1) of the pressuretesting tool 5910 890 4100 intothe intake duct so that the recessis on the raised part (arrow)

: Push the plug (1) 5910 890 4100as far as possible into the intakeduct

1 3 0 7 R A 0 6 5 T G

1

1



44 TS 500i

: Push the suction hose (1) ofpump 0000 850 1300 onto theconnector (arrow)

6.2.2 Testing with negativepressure

Oil seals tend to fail when subjectedto a vacuum. In other words, thesealing lip lifts away from thecrankshaft during the piston'sinduction stroke because there is nointernal counterpressure.

This kind of fault can be detected bytesting with pump 0000 850 1300.

During this test procedure, the oilseals in the crankcase and in thethrottle shutter housing are

checked.

: Slide ring (1) to the left

: Operate lever (2) until thepressure gauge (arrow) indicatesa vacuum of 0.5 bar

1 3 0 7 R A 0 6 6 T G

1

1 3

0 7 R A 0 6 7 T G

1

2

If the vacuum reading remainsconstant, or does not decreaseby more than 0.3 bar within20 seconds, it may be assumed thatthe oil seals are in good condition.If the negative pressure continuesto drop, the leak must be located

and the faulty part replaced.

– If the oil seals in the crankcaseare defective, replace the oilseals, 6.3

– If the oil seals in the throttleshutter housing are defective,replace the throttle shutterhousing, 11.2

– After testing, slide the ring on thepump back to the right to vent the

pump

– Continue with pressure test,6.2.3

6.2.3 Pressure test

The same preparatory steps arerequired as for the vacuum test,

6.2.1.

– Before testing with gaugepressure

– Complete testing with negativepressure 6.2.2

: Slide ring (1) to the right

: Actuate the lever (2) until thepressure gauge (arrow) shows apressure of 0.5 bar. If thispressure remains constant for atleast 20 seconds, the crankcaseis airtight.

– If the pressure drops, the leakmust be located and the faultypart replaced.

To find the leak, coat the suspectarea with soapy water andpressurize the crankcase. Bubbleswill appear if a leak exists.

– After testing, slide the ring on thepump to the left to vent the pump

– disconnect the hose.

– Remove pressure testing tool

– Fit air filter, 11.1

– Release the muffler and pull outthe sealing plate

– Tighten muffler according tospecifications, 2.5


1 3 0 7 R A 0 6 8 T G

1

2



45TS 500i

6.3 Oil seals

It is not necessary to disassemblethe complete engine in order toreplace the oil seals.


: Remove fan cover (1)

– Remove the flywheel, 7.5

– Remove the generator, 7.5.1

– Free the oil seal in its seat bytapping it with a suitable tube or apunch.

: Apply the puller (1)

5910 890 4400 with jaws (profileno. 6) 0000 893 3711

– Clamp the puller arms

– Pull out the oil seal

Avoid damage to the crankshaftstub.

1 3 0 7 R A 0 6 9 T G

1

1 3 0 7 R A 0 7 0 T G

1

Installation

– Clean the mating surface, 13

– Grease the sealing lips of thenew oil seal, 13

: Fit the assembly sleeve (1)1141 893 4600

: Slide the oil seal (2) over theassembly sleeve with the sealinglip facing the crankcase

– Remove the assembly sleeve

: Align press sleeve (2) so that theshoulder faces the oil seal (1)

: Press the new oil seal (1) fullyhome with press sleeve (2)1122 893 2405

The seating face must be flat andfree from burrs.

1 3 0 7 R A 0 7 1 T G

2

1

1 3 0 7 R A 0 7 2 T G

2

1

– Clean the cone of the crankshaftto ensure it is completely grease-free, 13


Clutch side


– Remove the clutch, 5.2

– Remove the clutch drum, 5.3

– Free the oil seal in its seat bytapping it with a suitable tube or a

punch.

: Apply the puller (1)5910 890 4400 with jaws (profileno. 3.1) 0000 893 3706

– Clamp the puller arms

– Pull out the oil seal


1 3 0 7 R A 0 7 3 T G

1



46 TS 500i

Installation

– Clean the mating surface, 13

– Grease the sealing lips of thenew oil seal, 13

– Fit the assembly sleeve (1)1118 893 4602.

: Slide the oil seal (2) over theassembly sleeve with the sealinglip facing the crankcase

– Remove the assembly sleeve

: Use the press sleeve (1)4238 893 2400 to install the oilseal (2)

The seating face must be flat andfree from burrs.


1 3 0 7 R A 0 7 4 T G

1

2

1 3 0 7 R A 0 7 5 T G

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)

1 3 0 7 R A 0 5 0 T G

1

1 3 0 7 R A 0 7 6 T G

1

2

– Remove dirt from around the plugon the control unit beforeremoving it

: Press lock (arrow) downwards byhand and push out plug (1)

– Do not pull out the plug (1) bythe wires, do not use tools

: Unscrew screw (1) and removehandle molding (2)

: Unhook the throttle cable (1)from the throttle trigger (2),holding the throttle trigger (2) inplace

1 3 0 7 R A 0 7 7 T G

1

1 3 0 7 R A 0 7 8 T G

1

2

1 3 0 7 R A 0 7 9

T G

1

2



47TS 500i


: Remove the shroud (1)

: Check bushing (1), pull out ofmount (arrow) if necessary andreplace

: Check rubber buffer (1), pull outof mount (arrow) if necessary andreplace

: Check the piece of hose (2),remove and replace if necessary

– Examine the throttle trigger andtrigger interlock, replace ifnecessary, 10.2

1 3 0 7 R A 0 8 0 T G

1

1 3 0 7 R A 0 8 1 T G

1

1 3 0 7 R A 0 8 2 T G

1

2

– Check short circuit wire, controlpanel and switch, replace ifnecessary, 7.6, 7.7

Installation

: Push rubber buffer (1) with lug

into the hole (arrow) as far as itwill go

Piece of hose (2) mustbe pushed on

– Piece of hose (2) acts as holddown for the injection pump.

: Lift plug (1) out of opening

: Guide the shroud (2) over theinjection pump and position sothat the lugs (arrows) engage in

the mounts – Do not pinch theplug (1)

1 3 0 7 R A 0 8 3 T G

1

2

1 3 0 7 R A 0 8 4 T G

2

1

: Insert and tighten the screws(arrows)

: Hook the throttle cable (1) intothe throttle trigger (2)

: Move throttle cable (2) towardsfull-throttle until the nipple of the

throttle cable engages in thethrottle trigger

: Press the grommet (1) into themount (arrow) until it is fully home

1 3 0 7 R A 0 8 5 T G

1 3 0 7 R A 0 8 6 T G

1

2

1 3 0 7 R A 0 8 7 T G

1



48 TS 500i

: First slide the pegs (arrows) onthe cap (1) into the mount, thenpress it home


: Push the plug (1) into the socketon the control unit until it snaps

into place

– Fit cover

6.5 Engine

Removal


– Empty the fuel tank, 1


– Remove control unit, 7.3

– Remove handlebar, 9.5

– Remove tank housing, 11.9

3 7 0 R A 1 1 6 T G

1

1 3 0 7 R A 1 8 9 T G

1

To remove the engine, you do notneed to disconnect the fuel hoses.

: Remove hose clip (1)

Installation

: Push the hose clip (1) onto themanifold (2) so that the screwhead is facing the clutch

– Apply press fluid to the inside ofthe manifold, 13

– Install the tank housing, 11.9


1 3 0 7 R A 0 8 8 T G

1

1 3 0 7 R A 0 8 9 T G

1

2

6.6 Cylinder

Before removing the cylinder,decide whether or not thecrankshaft is to be removed.

With the cylinder in place:

The piston must be blocked toprevent the crankshaft turning inorder to remove the clutch, 5.2

With the cylinder removed:To dismantle the clutch, block thecrankshaft by placing the piston onthe wooden assembly block.


– Empty the fuel tank, 1



– Remove muffler, 6.1

– Remove air baffle, 11.2.1

– Remove fan cover, 6.3

: Loosen the screw and push thehose clip (1) in the direction of thethrottle shutter housing

: Push down the manifold (2) fromthe tank housing support

1 3 0 7 R A 2 2 4 T G

1

2



49TS 500i

: Unscrew the screw (1)

: Remove the ground wire (2) andcover (3)

: Unscrew the screw (1) andremove the cable holder (2)

: Pull the bushing (1) andgenerator lead (2) from theguides (arrows)

1 3 0 7 R A 0 9 0 T G

1

3

2

1 3 0 7 R A 0 9 1 T G

1

2

1

1 3 0 7 R A 0 9 2 T G

2

: Pull bushing (1) with wiringharness (2) of the sensors andbushing (3) with wiringharness (4) of the injection valvefrom the guides (arrows)

: Unscrew the screw (1) andremove the air guide shroud (2)

: Unscrew the screws (2) on thebottom and remove longscrew (3)

: Remove the clamp (1)

1 3 0 7 R A 0 9 3 T G

3

1

4

2

1 3 0 7 R A 0 9 4 T G

1

2

1 3 0 7 R A 3 3 7 T G

2

3

2

1

: For a pan head screw on thebottom, guide the tool throughthe hose (2) and unscrew the panhead screw – the pan head screwstays in the hose (2)

: Unscrew the other three panhead screws (1)

: Carefully pull off the cylinder (1)

1 3 0 7 R A 3 6 8 T G

1

1

2

1

1 3 0 7 R A 1 0 0 T G

1



50 TS 500i

: Examine and clean the matingsurface, remove any gasketresidues if necessary

– Also check the mating surface onthe cylinder exhaust port andintake port

The mating surfaces must be inperfect condition and without anydamage whatsoever. A new cylindermust be used if the mating surfacesare damaged.

– For a new cylinder, check"throttle shutter housing / intakemanifold", spark plug anddecompression valve andreconfigure if OK, 11.2,

6.10

: Remove the cylinder gasket (1)

1 3 0 7 R A 1 0 4 T G

1

1 3 0 7 R A 1 0 1 T G

– Examine and clean the matingsurface (arrow).

The mating surface must be inperfect condition and without anydamage whatsoever. Parts withdamaged mating faces must bereplaced.

Always use a new cylinder gasketafter removing the cylinder.

: Position the cylinder gasket (1)so that the holes engage in thecentering sleeves (arrows)

: Fit the cylinder gasket (1)

1 3 0 7 R A 1 0 2 T G

1

1 3 0 7 R A 1 0

3 T G

: Place wooden assemblyblock (1) 1108 893 4800between piston and crankcase

– Coat piston, piston rings andinside of cylinder with oil, 13

– Ensure that piston rings are

correctly positioned, 6.9

: Fit clamping strap (1)0000 893 2600 aroundpiston and piston rings

The clamping strap (1) must befitted in such a way that the pistonrings do not protrude beyond thepiston sides.

1

1 3 0 7 R A 1 0 5 T G

1

1 3 0 7 R A 1 0 6 T G



51TS 500i

: Position cylinder (1) so that themanifold (3) is facing the injectionvalve (2)

When fitting the cylinder over thepiston, ensure that the clampingstrap securely encloses the pistonand that none of the piston rings

protrudes – danger of breakage.

: Slide the cylinder (1) over thepiston; the clamping strap ispushed downwards at the sametime

: Remove clamping strap (1) andwooden assembly block (2)

Ensure that the cylinder gasket iscorrectly positioned.

: Push the hose clip (3) onto themanifold so that the screw headis facing the clutch

1

1 3 0 7 R A 1 0 7 T G

2

3

1 3 0 7 R A 1 0 8 T G

3

1

2

– Push cylinder as far as possibleover the centering sleeves andhold

For the pan head screw in thehose (2), the tool is guided throughthe hose to screw in the pan headscrew.

: Screw in all pan head screws (1)from the bottom – do not tighten

– Check the position of the cylindergasket

: Tighten all pan head screws (1)crosswise

: Push the manifold (1) completelyand evenly onto thesupports (arrow) of the tank

housing until it is in the groove onthe circumference

– Push the hose clip over theshoulder of the manifold

1 3 0 7 R A 3 6 8 T G

1

1

2

1

1 3 0 7 R A 2 3 6 T G

1

: Align the hose clip (1) on themanifold (3) so that the clampinggap lines up with the fin (arrow)

: Screw in the screw (2) andtighten it


reverse order

1 3 0 7 R A 2 3 7 T G

1

2

3



52 TS 500i

6.7 Crankshaft

– Remove the engine, 6.5

– Remove the clutch drum, 5.3

– Remove the cylinder, 6.6

– Remove the piston, 6.8

If one of the fuel hoses isdisconnected, the fuel hose unitmust be replaced, 11.7.

: Disconnect the impulse hose (1),fuel return line (2) and fuelhose (3)

– Remove the injection valve,

11.3

– Remove the sensor, 11.4

Always replace ball bearings and oilseals when removing thecrankshaft.

1 3 0 7 R A 1 0 9 T G

123

: Take out the needle bearing (1),examine and clean it, replace ifnecessary

Fan-side half of the housing

: Unscrew the screws (arrows)

Washer 5910 893 2103 withoutholes "25 / 26" can be reworked asillustrated with the 5.5 mm hole orwith the holes 7.5 mm.

The drilled plate is shown fromabove in the illustration.

Dimensions are given in millimeters.

1 3 0 7 R A 1 1 3 T G

1

1 3 0 7 R A 1 1 4 T G

1 4 , 4

2124,4

2 3 , 2

14,8

1 4 , 7

26

26

25

2 5 / 2 6

5,5 mm7,5 mm

1 3 0 7 R A 1 1 5 T G

– Unscrew spindle (1) of theservice tool kit 5910 007 2201until the washer rests against thehalf of the housing


: Align the assembly tool with thewasher (2) 5910 893 2103

against the fan-side half of thehousing so that the edge number"25 / 26" (arrow) is at the bottom

: Insert three M5x30 screws (3)through the holes marked "25"and "26" and screw them as faras possible into the crankcasehalf

: Turn spindle anticlockwise untilthe fan-side half of the crankcaseis pulled off

– Replace ball bearings and oilseals, 6.7.1

: Remove the gasket (1)

1 3 0 7 R A 1 1 7 T G

2

3

25/26

1

1 3 0 7 R A 1 1 8 T G

1



53TS 500i

Clutch side half of crankcase

Washer 5910 893 2101 withoutholes "29" can be reworked asillustrated with 5.5 mm holes.

The hole 20 (arrow) is also part ofhole circle 29, therefore only addthe number 29. The two otherholes 29 must be drilled.

The drilled plate is shown fromabove in the illustration.

Dimensions are given in millimeters.

: Unscrew spindle (1) of theservice tool kit 5910 007 2201until the washer rests against thehalf of the housing


: Align the assembly tool with thewasher (2) 5910 893 2101against the clutch-side half of thehousing so that the edge number"29" (arrow) is at the bottom

36,1

1 3 0 7 R A 1 1 6 T G

7 , 2

2 3 , 8

43,0

1 3 0 7 R A 1 1 9 T G

3

2

3

13

: Insert three M5x55 screws (3)through the holes marked "29"

: Push the screws (1) through theholes in the crankcase half

: Fit washers and nuts (arrows)

: Tighten the nuts (arrows)

: Turn the spindle (1)counterclockwise until thecrankshaft has been forced out ofthe clutch-side half of thecrankcase

1 3 0 7 R A 1 2 0 T G

1

1

1

1 3 0 7 R A 1 2 1 T G

1 1 3 0 7 R A 1 2 2 T G

: Pry out bushing (1)

– Check the crankcase halves,replace if necessary

– Replace oil seals and ballbearings, 6.3, 6.7.1

– Before installation, clean thecrankshaft, 13

Installation



Examine and clean the matingsurfaces of the fan-side half of thecrankcase (including the cylindersealing surface) – The matingsurfaces must be without anydamage whatsoever.

1 3 0 7 R A 1 3 6 T G

1



54 TS 500i

: Orient the crankshaft (1) with theconical crankshaft stub (arrow)facing the fan-side ball bearing

– Heat the inner race of the ballbearing to approx. 150 °C(300 °F)

Push the crankshaft home until thecrankshaft stub makes contact.

The crankshaft must be fittedrapidly, as the heat is transmitted tothe crankshaft stub and the innerbearing race contracts.

If the inner race cannot be heated,the crankshaft can be drawn into thecrankcase with the assembly tool5910 007 2201.

: Fit the screw sleeve (1)5910 893 2420 as far as possibleover the fully retracted spindle ofthe assembly tool (2)5910 007 2201.

1 3 0 7 R A 1 2 3 T G

1

3 7 0 R A 1 4 6 T G

1

2

– Coat the conical crankshaft stubwith oil

: Align the crankshaft with theconical crankshaft stub (arrow)facing the fan-side ball bearingand push it home

: Fit the screw sleeve (1) over thethread of the conical crankshaftstub (2) and screw it on

1 3 0 7 R A 1 2 5 T G

1 3 0 7 R A 1 2 6 T G

21

: By turning the spindle screw (1),fit the washer (2) to the fan-sidehalf of the crankcase

: Fit the assembly tool with threeM5x30 screws (3) through theholes marked "25" and "26" onthe washer (2) and secure it to

prevent it twisting; screw in thespindle screw (1) clockwise

– Pull the crankshaft as far aspossible into the fan-side half ofthe crankcase

The crankshaft also turns when it isdrawn in with the assembly tool. Forthis reason, ensure that the rod eye(arrow) always faces upwardstowards the cylinder.

– Remove the assembly tool

1 3 0 7 R A 1 2 7 T G

2

3

25/26

1

1 3 0 7 R A 1 2 8 T G



55TS 500i

: Fit a new gasket (1) and secure itwith the centering sleeves(arrows)


Avoid damage to the crankshaft

stub.

Examine and clean the matingsurfaces of the clutch-side half ofthe crankcase (including thecylinder sealing surface) – Themating surfaces must be withoutany damage whatsoever.

– Coat the cylindrical crankshaftstub with oil

– Heat the inner race of the ball

bearing to approx. 150 °C(300 °F)

: Align clutch side half ofcrankcase (1), press 2 screwsM 5x72 (arrows) to act as a guidethrough the clutch-side half of thecrankcase and screw slightly intothe threads of the centeringsleeves (arrows) – do not tighten

1 3 0 7 R A 1 2 9 T G

1

1 3 0 7 R A 1 3 0 T G

1

: Push in clutch-side half of thecrankcase (1) as far as it will go

The clutch-side half of thecrankcase must be fitted rapidly, asthe heat is transmitted to thecrankshaft stub and the inner

bearing race contracts.

Ensure that the sleeves (arrows)enter the holes and that the housinggasket is not jammed or buckled.

If the inner race cannot be heated,the crankshaft can be drawn into thecrankcase with the assembly tool5910 007 2201.

: Fit the screw sleeve (1)5910 893 2420 as far as possibleover the fully retracted spindle ofthe assembly tool kit (2)5910 007 2201.

1

3 0 7 R A 1 3 1 T G

3 7 0 R A 1 4 6 T G

1

2

– Coat the cylindrical crankshaftstub with oil

: Push the clutch-side half ofcrankcase (1) over the cylindricalcrankshaft stub and align so thatthe holes line up with thecentering sleeves (arrows)

: Place the threaded sleeve (1)over the thread (2) of thecylindrical crankshaft stub andscrew it on

1 3 0 7 R A 1 3 3 T G

1

2

1 3 0 7 R A 1 3 4 T G

2

1



56 TS 500i

: Fit the washer (1) onto thecrankcase half

: Push the 2 screws M5x72 (2) inthe top holes "29" through thewasher and crankcase half andscrew slightly into the threads ofthe centering sleeves – do not

tighten

Ensure that the centering sleeves(arrows) enter the holes and that thehousing gasket is not jammed orbuckled.

: Turn the spindle screw (1)clockwise

1 3 0 7 R A 1 3 5 T G

1

2

2

1

3 0 7 R A 1 3 1 T G

1 3 0 7 R A 1 3 7 T G

1

– Draw the clutch-side half of thecrankcase in as far as possible

The crankshaft also turns when it isdrawn in with the assembly tool. Forthis reason, ensure that the rod eye(arrow) always faces towards the

cylinder.

– Remove the assembly tool

: Insert the screws (arrows) andtighten them crosswise

– Cut off the protruding gasket – Do not damage the matingsurface

– Coat bushing on the rubber lipwith STIHL press fluid, 13

: Align bushing (1) so that thestraight side is flush with the fin(arrow)

: Press bushing (1) completely intothe opening

1 3 0 7 R A 1 1 4 T G

1 3 0 7 R A 1 7 5 T G

1

The bushing must enclose theopening (arrows) completely on thefan side.

– Install injection valve, 11.3

– Install sensor, 11.4

– Replace fuel hoses, 11.7

: Push impulse hose (1), fuelreturn line (2) and fuel hose (3)completely onto the connectors(arrows)

1 3 0 7 R A 1 7 6 T G

1 3 0 7 R A 1 3 8 T G

123



57TS 500i

: Coat the needle cage (1) with oil

: Push the needle cage (1) into therod eye

– Examine and install the piston,6.8

– Examine and install the cylinder,6.6

– Install the clutch drum, 5.3

– Install the engine, 6.5


6.7.1 Ball bearing / crankcase

The two halves of the crankcasecan be replaced individually if theyare defective.

New crankcases are delivered withthe relevant components pre-assembled – see spare parts list.Those parts which are not suppliedwith the new crankcase must beremoved from the old crankcasehalves, examined and replaced if

necessary.

When fitting a new crankcase, themachine's serial number must bestamped on the crankcase with2.5 mm figure stamps.

1 3 0 7 R A 1 3 9 T G

1

If the old crankcase is reused, theoil seals and ball bearings must bereplaced, all gasket residuesremoved and the mating surfacescleaned thoroughly. The matingsurfaces must be absolutely cleanto guarantee a perfect seal.

Examine both halves of thecrankcase for cracks and check allmating surfaces for signs ofdamage.


– Remove crankshaft, 6.7


: Carefully drive the oil seal outwith a suitable punch

– Examine and clean thecrankcase half, replace ifnecessary

Replace the ball bearings if thecrankcase half is in good condition.

1 3 0 7 R A 1 4 3 T G

– Heat the area around the bearingseat to approx. 150 °C (300 °F)

The bearing (1) drops out of its ownaccord when this temperature isreached.


: Press the ball bearing home asfar as possible

The ball bearing must be fittedrapidly, as it absorbs heat andexpands.

1 3 0 7 R A 1 4 4 T G

1

1 3 0 7 R A 1 4 5 T G



58 TS 500i


: Carefully drive the oil seal outwith a suitable punch

– Examine and clean thecrankcase half, replace ifnecessary

Replace the ball bearings if thecrankcase half is in good condition.


The bearing (1) drops out of its ownaccord when this temperature isreached.

1 3 0 2 R A 1 4 6 T G

1 3 0 7 R A 1 4 7

T G

1


: Press the ball bearing home asfar as possible

The ball bearing must be fittedrapidly, as it absorbs heat and

expands.

– Install crankshaft, 6.7

– Install oil seals, 6.3


6.8 Piston

Before removing the cylinder,decide whether the crankshaft is tobe removed, 6.7

– Remove the cylinder, 6.6

Two snap rings are fitted, but onlyone need be removed in order toremove the piston pin

– Their installation is the same onboth sides.

1 3 0 2 R A 1 4 8 T G

: Pry the hookless snap ring out ofthe recess (arrow) on the fan sidewith a suitable tool

: Fit the assembly drift (1)0000 893 4700 on the clutch side

The assembly drift can be inserted

through the fitted snap ring.

: Drive the piston pin (2) out of thepiston with the assembly drift (1)0000 893 4700

If the piston pin is stuck, tap the endof the drift gently with a hammer toloosen it.The piston must be held steadyduring this process to ensure that

jolts are not transmitted to theconnecting rod.

1 3 0 7 R A 1 3 2 T G

1 3 0 7 R A 0 2 2 T G

1

2



59TS 500i

: Remove the piston (1) from theconnecting rod

– Examine the piston rings andreplace if necessary, 6.9

Installation

: Take out the needle cage (1),examine and clean it, replace ifnecessary

: Coat the needle cage (1) with oiland insert it in the rod eye

1 3 0 7 R A 1 4 9 T G

1

1 3 0 7 R A 3 5 7 T G

1

: Line up the piston (1) so that thearrow (arrow) in the piston basepoints towards the abrasivewheel or cylinder exhaust port

: Position the piston (1) on the rodeye

: Push assembly drift (1)0000 893 4700 with the stub endfirst through piston hole and rodeye (needle cage) and secure thepiston

– Coat the piston pin with oil

: Fit the piston pin (2) on the stubof the assembly drift (1) and slideit into the piston

1 3 0 7 R A 1 5 0 T G

1

1 3 0 7 R A 1 4 0 T G

1

2

: Remove the sleeve (1)5910 893 1706 from theassembly tool (2) 5910 890 2212

: Attach the snap ring (1) to themagnet (2) and align it so that thesnap ring gap is on the flat side(arrow)

: Push the slotted diameter of thesleeve over the magnet (2) andsnap ring

The inner pin (1) must point towardsthe flat face of the tool's shank.

12 1 3 0 7 R A 0 2 3 T G

2 4 4 2 R A 4 0 6 T G

1

1 3 0 7 R A 0 2 9 T G

2 1



60 TS 500i

: Press the assembly tool down inthe sleeve until the magnet is atthe end of the guide slits

Stand the tool on a suitable surface.

: Remove the sleeve and push itover the opposite end of theassembly tool's shank. The innerpin (arrow) must point towardsthe flat face.

The snap ring (1) must be fitted sothat the gap in the ring (arrow)points upwards.

1 3 0 7 R A 0 2 8 T G

1 3 0 7 R A 1 9 5 T G

1 3 0 7 R A 0 2 4 T G

1

Align the assembly tool so that thegap in the snap ring faces upwards.

: Fit the assembly tool5910 890 2212 with the tapersleeve on the piston boss, holdthe piston steady and press thetool shank home until the snapring slips into the groove

The tool must be precisely alignedin axial direction of the piston pin.

– Examine the piston rings andreplace if necessary, 6.9

– Install the cylinder, 6.6


1 3 0 7 R A 0 3 0 T G

1 3 0 7 R A 0 2 5 T G

6.9 Piston rings

– Remove the piston, 6.8

– Remove piston rings from piston

: Use a piece of old piston ring toscrape the grooves clean(arrows)

: Align the new piston rings so thatthe radii at the ends of the ring(arrows) face upwards

1 3 0 7 R A 1 2 4 T G

1 3 0 7 R A 0 2

6 T G



61TS 500i

: Install the piston rings so that theradii at the ring gaps meet at thefixing pins (arrows) in the pistongroove

: Check the correct installedposition of the piston rings again(arrows)

– Install the piston, 6.8


1 3 0 7 R A 0 2 7 T G

6.10 Decompression valve

– Remove cap and bushing, 6.4

: Unscrew the decompressionvalve (1) with socket, 13 mm,long reach, 5910 893 2804

: Examine the sealing cone(arrow) on the decompressionvalve for signs of damage

Use a new decompression valve ifthe sealing cone on thedecompression valve does not sealtightly or is damaged.

– Fit the decompression valve byhand and screw it in

– Screw the decompression valvetight


1 3 0 7 R A 1 9 6 T G

1

3 7 6 R A 3 3 7 T G



62 TS 500i

7. STIHL Injection

In this chapter the components areshown without the shroud and tankhousing for a better view.

STIHL Injection basically consists ofa control unit (1), throttle shuttlehousing (2), injection valve (3),injection pump (4), sensor (5),generator (6) and flywheel (7).

The control unit (1) is responsiblefor central control of all enginefunctions and contains an ignitionmodule with high ignition energy.

1 3 0 7 R A 2 5 5 T G

2

5

126 4

3

7

8

The control unit (1) is powered withvoltage generated by the magnetring on the flywheel (7) and thegenerator (6). In addition, thegenerator (6) provides the speedsignal and the position of thecrankshaft to the control unit (1).

This information is required todetermine the ignition timing andthe injection timing.

The throttle shutter (8) in the throttleshutter housing (2) is actuated viathe throttle cable, thus regulatingthe inflow of air. The sensor (5)provides the pressure andtemperature in the crankcase to thecontrol unit (1), which, on this basis,determines the air mass introducedand ultimately the required amount

of fuel from the characteristic curve.This amount of fuel is injected intothe crankcase via the injectionvalve (3).

The injection pump (1) maintains aconstant pressure for the injectionvalve (2) and ensures thenecessary fuel delivery (impulse). Inaddition, the manual fuel pump (3)is integrated in the injectionpump (1).

The pickup body (4) with magneticseparator (5) eliminates tinymetallic particles and protects theinjection valve (2).

Troubleshooting and testprocedures are described in thefollowing chapters, Testing, 7.1,Troubleshooting, 7.6.

1 3 0 7 R A 3 7 2 T G

2

3

1

5

4



63TS 500i

7.1 Testing

7.1.1 Checking the screwconnection and plug

There must be a reliable connectionfor communication between controlunit, injection valve and sensor. Ifcommunication between controlunit, injection valve and sensor isinterrupted or faulty, the control unitdoes not initiate an ignition spark.

– In the event of a malfunction or ifthere is no ignition spark, firstcheck the firm seat of the plugson the control unit, then the screwconnection of the ground wireand the seat of the spark plugboot, 7.4

: Unscrew screw (1) and removecover (2)

– Screw remains in cover

1 3 0 7 R A 0 7 6 T G

1

2

The plugs (1, 2, 3, 4, 5) must beseated completely in the bushingsof the control unit and must besnapped into place.


: Screw (1) must be tight.

The ground wire (arrow) must beseated completely and firmly in thecable lug.

1 3 0 7 R A 2 5 7 T G

1

3 5

42

1 3 0 7 R A 2 5 6 T G

1

7.1.2 Connect the injectionsystem diagnostic cable

: Unscrew screw (1) andremove cover (2)

– Screw remains in cover

– Remove dirt from around the plug

on the control unit beforeremoving it

: Press lock (arrow) downwards byhand and push out plug (1)

– Do not pull out the plug (1) bythe wires, do not use tools

1 3 0 7 R A 0 7 6 T G

1

2

1 3 0 7 R A 2 5 9 T G

1



64 TS 500i

: Press plug (1) of the "Injectionsystem control unit diagnosticcable" 5910 840 0403 into thesocket (2) on the control unit untilit snaps into place

: Press plug (1) of the generatorinto the socket (2) of the"Injection system control unitgenerator" 5910 840 0402 until itsnaps into place

1 3 0 7 R A 2 6 0 T G

2

1

1 3 0 7 R A 2 6 1 T G

12

STIHL MDG 1 must be installedbetween the spark plug boot andthe spark plug.

– Unplug the spark plug boot

: Push plug (1) in spark plug bootand socket (2) onto the spark

plug

– Run test, 7.2

1 3 0 7 R A 2 6 2 T G

21



65TS 500i

7.2 Testing with STIHLMDG 1

Run tests with STIHL engineanalyzer MDG 1.

The STIHL engine analyzer MDG 1

can be used in conjunction with acomputer to test the STIHL Injectionsystem.

A program must be installed on thecomputer for the analyzer. A"Bluetooth" device must be pluggedinto the USB port of the computer.The "Bluetooth" device ensures thedata transmission between STIHLMDG 1 and the computer.

When used, the diagnostic program

runs step by step and interactivelythrough the whole test run. Faultsand error sources of the STIHLInjection system are taken intoaccount and displayed by theprogram during the test run.

6 1 6 1 R A 3 5 8 T G

The STIHL engine analyzer MDG 1is now switched to the ignition circuitand connected to the control unitand generator via the test lead.

A power adaptor is supplied with theSTIHL MDG 1 to power it and it toois connected with the STIHLMDG 1.

There is an electronic unit in theSTIHL MDG 1 that ensures the datatransmission to the "Bluetooth"device on the computer.The engine analyzer is suppliedtogether with the diagnosticprogram for the computer on a datacarrier from the factory. A databaseis part of the diagnostic program inwhich the data of different devicesand machines is stored for the testrun.

1 3 0 7 R A 2 6 3 T G

It is possible, depending on theseries status of the STIHL MDG 1and the device to be tested, that thedatabase in the diagnostic programis not yet up-to-date for the deviceto be tested. In this case, it ispossible to download the latest

version of the program from theInternet.

Additional and detailed informationabout the STIHL MDG 1 can befound in the instruction manual forthe STIHL MDG 1 and in the"Technical Information" for theintroduction of the STIHL MDG 1.

7.3 Control unit

– Check control unit with STIHLMDG 1, 7.1, 7.2



– Remove dirt from around the plugon the control unit beforeremoving it

: Press locks (arrow) downwardsby hand and push outplug (1, 2, 3, 4)

– Do not pull out theplug (1, 2, 3, 4) by the wires, donot use tools

1 3 0 7 R A 2 6 4 T G

1

2

3

4



66 TS 500i

: Unplug spark plug boot (1) andpull ignition lead (2) from cableguide (arrow)

: Lift control unit (1) slightly on thecylinder and pull out of mount(arrow)

: Check the thrust piece (2),replace if necessary

– Check the control unit, replace ifnecessary

1 3 0 7 R A 2 6 5 T G

1

2

1 3 0 7 R A 2 6 6 T G

2

1

: Pry out grommet (1) in thedirection of the cylinder

– Check ignition lead, replace ifnecessary, 7.4.1

– Examine the spark plug boot andreplace it if necessary, 7.4

Installation

– Coat outside of grommet withSTIHL press fluid,

: Press the grommet (1) with thethin lip completely into theopening (arrow) in the direction ofthe air filter – the lip must enclosethe opening completely on theopposite side

1 3 0 7 R A 2 6 7 T G

1

1 3 0 7 R A

2 6 8 T G

1

: Slide the control unit (1) with thelug (2) into the grommet (arrow)and position

: Place the thrust piece (1) in theframe (arrows) and press

: Push the spark plug boot (1) ontothe spark plug so that it is facingthe flywheel and press theignition lead (2) into the cableguide (arrow)

1 3 0 7 R A 2 6 9 T G

2

1

1 3 0 7 R A 2 7 0 T G

1

1 3 0 7 R A 2 7 1 T G

1

2



67TS 500i

: Push the plugs (1), (2), (3)and (4) into the sockets of thecontrol unit (5) until they engage

– The shape and color of theplugs and sockets ensures thatthey cannot be mixed up


reverse order

7.4 Spark plug boot


: Unplug spark plug boot (1) andpull ignition lead (2) from cableguide (arrow)

1 3 0 7 R A 2 7 2 T G

1

2

3

4

5

1 3 0 7 R A 2 6 5 T G

1

2

: Remove the cover (1) from thespark plug boot

: Use suitable pliers to pull thetorsion spring out of the sparkplug boot

– Unhook the torsion spring from

the ignition lead

– Pull the boot off the ignition lead

1 3 0 7 R A 0 3 7 T G

1

3 7 0 R A 2 0 1 T G

Installation

– With a new ignition module, use apointed tool to pierce the centerof the new lead's insulationapprox. 15 mm from the end ofthe ignition lead

:Pinch the hook of the torsionspring into the center of theignition lead (arrow)

– Coat the inside of the spark plugboot with STIHL press fluid,

13

: Push the ignition lead and torsionspring into the spark plug boot

3 7 6 R A 1 3 6 T G

3 7 6 R A 1 3 6 T G



68 TS 500i

: Slide the cover (1) over the sparkplug boot (2) and align

: Ensure that the torsion spring(arrow) is located in the recess


7.4.1 Ignition lead


: Push the grommet (1) off thecontrol unit (2)

: Unscrew the ignition lead (3)from the control unit (2)

– Check the control unit andignition lead, replace if necessary

1 3 0 7 R A 1 4 1 T G

1

2

1 3 0 7 R A 2 5 8 T G

3

2

1

– Examine the spark plug boot andreplace it if necessary, 7.4

Installation

: Use a pointed tool to pierce thecenter of the end of the new

ignition lead, which is to betwisted into the control unit.

– Before twisting in the ignitionlead, fill the coil tower with STIHLmulti-purpose grease, 13

: Push grommet (1) onto ignitionlead

: Twist ignition lead (2) completelyinto the control unit

: Push on the grommet (1)

– Install control unit, 7.3


1 6 5 R A 1 9 1 T G

1 3 0 7 R A 2 7 3 T G

2

1

7.5 Flywheel

– Remove fan cover, 6.3

– Block piston, 5.1

: Unscrew the flywheel nut (1)

: Push the spacer (1)4238 894 1100 onto the screwsof the puller (2) 5910 890 4504so that the larger diameters of theholes face the puller

1 3 0 7 R A 3 5 6 T G

1

1 3 0 7 R A 2 7 4 T G

21



69TS 500i

: Fit puller (1) 5910 890 4504 withspacer (2) 4238 894 1100 andscrew in the screws uniformly inthe threaded holes of the flywheel

: Turn screw (3) clockwise until theflywheel comes off the crankshaftstub

– Take out the screws and removethe puller and spacer from theflywheel

Check the magnet ring (arrow) inthe flywheel (1) for cracks or otherdamage. Replace flywheel ifnecessary.

1 3 0 7 R A 2 7 5 T G

1

2

3

1 3 0 7 R A 2 7 6 T G

1

: Check the woodruff key (1),replace if necessary

: Make sure that the woodruffkey (1) is properly seated (arrow)

: Check groove (arrow), replaceflywheel if necessary – if the

groove is worn, replace theflywheel

Ensure that the woodruff keyengages in the groove (arrow).

1 3 0 7 R A 2 7 7 T G

1

1 3 0 7 R A 2 7 8 T G

Installation

The hole in the flywheel hub andcrankshaft stub must be completelygrease-free, clean if necessarybefore installing the flywheel, 13.

The generator lead (1) must beseated completely in theguide (arrow).

The flywheel must not touchthe generator lead

– power supply can be interrupted.

: Fit the flywheel (1) so that thewoodruff key on the crankshaftstub engages in the groove of theflywheel

Flywheel must not touch thegenerator.

: Screw on and tighten the collarnut (2)


1 3 0 7 R A 2 7 9 T G

1

1 3 0 7 R A 2 8 0 T G

1

2



70 TS 500i

7.5.1 Generator

– Check generator with STIHLMDG 1, 7.1, 7.2


– Remove the flywheel, 7.5

: Remove the insulating tubes (1)with plug connections from theguide (arrow)

: Push the insulating tubes (1)towards the wiring harness (2)and disconnect the plugconnections (3) and (4)

1 3 0 7 R A 2 8 1

T G

1

1

1 3 0 7 R A 2 8 2 T G

1

12

3

4

: Unscrew the screws (1) andremove the generator (2)

– Examine the generator, replace ifnecessary

Installation

Use the wiring tool 5910 890 4000to press the leads completely intothe guides, 1.1.

: Press the blue lead (1)completely into the guide (arrow)

1 3 0 7 R A 2 8 3 T G

2

1

1

1 3 0 7 R A 2 8 4 T G

1

: Push the generator (1) onto thecentering sleeves with the leadconnection facing the crankcase,placing the generator lead (2)into the guide (arrow)

– Do not pinch the generator lead


: Push the insulating tube (1) ontothe blue lead (5) of the wiringharness

: Take the plug (2) and terminalsocket (3) of the blue leads (4)and (5) completely push together

1 3 0 7 R A 2 8 5 T G

2

1

1 3 0 7 R A 2 8 6 T G

1

5

3

2

4



71TS 500i

: Push the insulating tube (1) ontothe black lead (5) of the wiringharness

: Take the plug (2) and terminalsocket (3) of the black lead (5)and yellow lead (4) andcompletely push together

: Slide insulating tubes (1) over themiddle of the plug connections,

1.1

: Guide the blue lead behind theinsulating tube (1) and press theplug connection into the middle ofthe guide (arrow) – the blue leadmust run underneath theinsulating tube

1 3 0 7 R A 2 8 7 T G

1

5

3 2

4

1 3 0 7 R A 2 8 8 T G

1

1

1 3 0 7 R A 2 8 9 T G

1

: Guide the black lead behind theinsulating tube (1) and press theplug connection into the middle ofthe guide (arrow) – the black leadmust run underneath theinsulating tube

: Press the leads completely intothe guides (arrows)

The lead (1) must be seatedcompletely in the guide (arrow).

The flywheel must not touch thegenerator lead

– power supply can be interrupted.

1 3 0 7 R A 2 9 0 T G

1

1 3 0 7 R A 2 9 1 T G

1 3 0 7 R A 2 7 9 T G

1


7.6 Short circuit wire / switch

7.6.1 Testing

– Test the short circuit wire / switchwith STIHL MDG 1, 7.1,

7.2


7.6.2 Removal and installation

The switch, short circuit wire and

ground wire form a single unit. Thecomplete switch must be replaced ifthere is any sign of damage.


– Remove switch shaft, 10.1

– Remove interlock lever andthrottle trigger, 10.2

: Pull the wiring harness (1) of theswitch on the inside out of theguides (arrows)

1 3 0 7 R A 2 9 2 T G

1



72 TS 500i

: Unscrew the screw (1) and lift theholder (2) and switch out of themount

: Pull the blue and black lead out ofthe guides (arrows)

: Pull the plug connections (1)and (2) out of the guides (arrows)

– Disconnect the plug connections

1 3 0 7 R A 2 9 3 T G

2 1

1 3 0 7 R A 2 9 4 T G

1 3 0 7 R A 2 9 5 T G

1 2

: Pull the wiring harness (1) of theswitch out of the opening (arrow)

: Remove the retainer (1)

: Check the switch (2), replace ifnecessary

– Check the control panel, replaceif necessary, 7.7

Installation


1 3 0 7 R A 2 9 6 T G

1

1 3 0 7 R A 2 9 7 T G

1

2

: Press the switch (1) into theholder (2) until it engages

: Push the wiring harness (1) of theswitch with the plug through theopening (arrow)

: Connect the yellow leads (1) andgreen leads (2) completely

1 3 0 7 R A 2 9 8 T G

2

1

1 3 0 7 R A 2 9 9 T G

1

1 3 0 7 R A 3 0 0 T G

1

1

2

2



73TS 500i

: Press the plug connection (1) ofthe yellow lead into the guide(arrow)

: Press the yellow lead (1) into theguides (arrows)

– the yellow lead must be placedunderneath the green lead

: Press the plug connection (1) ofthe green lead into the guide(arrow)

1 3 0 7 R A 3 0 1 T G

1

1 3 0 7 R A 3 0 2 T G

1

1 3 0 7 R A 3 0 3 T G

1

: Press the green lead (1) into theguides (arrows)

– the yellow lead must rununderneath the green lead

: Fit the holder (1) into the mountso that the tab (2) engages in thefin (arrow)

The yellow and green lead of thecontrol panel must be in the guide(arrow) and must be placedunderneath the holder (1).

1 3 0 7 R A 3 0 4 T G

1

1 3 0 7 R A 3 0 5 T G

1

2

1 3 0 7 R A 3 0 6 T G

1


: Push the black and blue lead inthis order into the guides (arrows)

– the black lead must rununderneath the blue lead

: Push the black lead (1) and bluelead (2) into the guide (arrow)and place between dome (3) andfin (4)

: Press the wiring harness (1) ofthe switch on the inside with theprotective tube (2) into the guides(arrows)

1 3 0 7 R A 3 0 7 T G

1

1 3 0 7 R A 1 9 4 T G

1

3

2

4

1 3 0 7 R A 3 0 8 T G

2

1



74 TS 500i

: Align the wiring harness (1) of theswitch so that the mark on theprotective tube lines up with theguide (arrow) and the plug (2) isoutside of the opening

– Install interlock lever and throttletrigger, 10.2

– Install switch shaft, 10.1

: Check correct functioning – The stop switch must actuatethe contact springs (arrow) of theswitch when in position "STOP" or "0" and close the contact – thiscan be heard as a clicking noisefrom the micro switch

The switch shaft can only be set toposition "F" if the trigger interlock

and throttle trigger are pressed.


1 3 0 7 R A 3 0 9 T G

12

1 3 0 7 R A

3 1 0 T G

7.7 Control panel

– Check the control panel withSTIHL MDG 1, 7.1, 7.2



– Remove switch shaft, 10.1

– Remove interlock lever andthrottle trigger, 10.2

: Unscrew the screw (1) and lift theholder (2) and switch out of themount

: Pull the blue and black lead out ofthe guides (arrows) and set asidethe switch

1 3 0 7 R A 2 9 3 T G

2 1

1 3 0 7 R A 2 9 4 T G

: Pull the plug connections (1)and (2) out of the guides (arrows)

– Disconnect the plug connections

: Pull the green and yellow lead outof the guides (arrows)

: Unhook the yellow and greenlead out of the guides (arrows) onthe inside

1 3 0 7 R A 2 9 5 T G

1 2

1 3 0 7 R A 3 1 1 T G

1 3 0 7 R A 3 1 2 T G



75TS 500i

: Unlock the control panel (1) onthe wide tab (arrow) and removeit

: Pull the control panel (1) with theleads out of the opening (arrow)and examine it, replace ifnecessary

Installation


: Guide the leads into the opening(arrow) and carefully fit thecontrol panel (1)

1 3 0 7 R A 3 1 3 T G

1

1 3 0 7 R A 3 1 4 T G

1

1 3 0 7 R A 3 1 5 T G

1

: Press in the control panel (1)until the wide tab (2) engages

– narrow tab (arrow) engages inthe opening

: Hook the green and yellowlead into the guides (arrows)

– green lead underneath yellowlead

: Place the green and yellowlead into the guides (arrows)

– yellow lead underneath greenlead

1 3 0 7 R A 3 1 6 T G

2

1

1 3 0 7 R A 3 1 2 T G

1 3 0 7 R A 3 1 7 T G

: Connect the yellow leads (1) andgreen leads (2) completely

: Press the plug connection (1) ofthe yellow lead into the guide(arrow)

: Press the yellow lead (1) intothe guides (arrows)

– the yellow lead must be placedunderneath the green lead

1 3 0 7 R A 3 0 0 T G

1

1

2

2

1 3 0 7 R A 3 0 1 T G

1

1 3 0 7 R A 3 0 2 T G

1



76 TS 500i

: Press the plug connection (1) ofthe green lead into the guide(arrow)

: Press the green lead (1) into theguides (arrows)

– the yellow lead must rununderneath the green lead

– Install the switch, 7.6


1 3 0 7 R A 3 0 3 T G

1

1 3 0 7 R A 3 0 4 T G

1







79TS 500i

: Fit the rotor on the starter post sothat the inner loop of thespring (1) enters the recess(arrow).

The recess (arrow) in the hub of therope rotor acts as carrier for theanchor loop.

– Fit the washer.

– Install the pawl and spring,8.3

– Install starter rope, 8.5

– Tension the rewind spring, 8.6

– Grease the pegs on the pawl,13


8.5 Starter rope / starter grip

– Remove starter, 8.2

– Relieve the tension of the rewindspring, 8.4

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

– Remove any remaining scraps ofrope from the rope rotor andstarter grip.

1 3 0 7 R A 0 3 9 T G

1

The starter rope must not beshortened.

– Remove the rope rotor, 8.4

: Pull out starter rope (1) on therope rotor (2) and undo the knot

– Pull starter rope from rope rotorand starter cover

: Pry the nipple on the rope (1) outwith a suitable tool

1 3 0 7 R A 0 4 0 T G

1

2

1

3 7 0 R A 2 2 9 T G

: Pull the rope (1) or remainingrope out of the starter grip,examine the various parts,replace if necessary.

– Remove any remaining rope fromthe rope rotor if necessary

: Thread the new starter rope (1)into the starter grip from above

: Press the nipple (1) of the starterrope into the starter grip until itengages there

3 7 0 R A 2 3 0 T G

1

3 7 0 R A 2 3 1 T G

1

3 7 0 R A

2 3 2 T G

1



80 TS 500i

: Then thread the starter rope (1)through the rope guide (arrow)

: Slide the starter rope (1) into therope rotor (arrow)

: Make the special knot illustratedin the end of the rope at thestarter grip

3 7 0 R A 2 3 3 T G

1

1

3 7 0 R A 2 3 4 T G

1 3 0 7 R A 0 4 1 T G

: Thread starter rope (1) into roperotor

: Press the knot into the mount(arrow) of the rope rotor.

– Install the rope rotor and tensionthe rewind spring, 8.4, 8.6

– Fit starter, 8.2

8.6 Tensioning the rewindspring

Pawl and spring must be installed.

1 3 0 7 R A 0 4 2 T G

1

3 7 0 R A 2 3 6 T G

: Hold the rope rotor (1) so that therecess (arrow) faces towards therope guide.

: Pull the starter rope (2) outbetween the recess and ropeguide (arrow) with assemblyhook (3) 5910 893 8800.

– Do not damage the starter rope

: Secure the starter rope (1) in therecess (arrow) and give the roperotor (2) six turnscounterclockwise.

The starter rope twists as the roperotor and starter rope are turned –the rewind spring is now tensioned.

Hold the tensioned rope rotor firmly,as the rewind spring will be

damaged if it jumps back suddenly.

2

3

3 7 0 R A 2 3 7 T G

1

1

3 0 7 R A 0 4 3 T G

2

1



81TS 500i

: Hold the rope rotor (2) steady

: Pull out the twisted rope (1) withthe starter grip and straighten itout.

: Hold the starter grip firmly tokeep the starter rope (1)

tensioned

: Let the rope rotor go and slowlyrewind the starter rope (1) on therope rotor.

The starter grip must sit firmly in therope guide bushing (arrow) withoutdrooping to one side. If this is notthe case, the spring must betensioned by one additional turn.

1 3 0 7 R A 0 4 4 T G

2

1

3 7 0 R A 2 4 0 T G

1

3 7 0 R A 2 4 1 T G

When the rope is fully extended, itmust still be possible to rotate therope rotor at least another half turnbefore the maximum spring tensionis reached. If not, the spring tensionmust be reduced, otherwise it willbreak.

Reduce spring tension

– Pull out the starter rope and turnthe rope rotor with starter ropeback one turn.

– Pull the twisted rope out with thestarter grip and tidy it.

– Keep the starter rope tensionedwith the starter grip.

– Let go of the rope rotor and let thestarter rope rewind slowly on tothe rope rotor

– Fit starter, 8.2

8.7 Replacing the rewindspring


The replacement spring is suppliedready for installation and secured ina spring housing.

Wear a face shield and protectivegloves.

– Remove starter, 8.2

– Relieve the rewind spring ifnecessary, remove the rope rotorand set it aside along with the

starter rope, 8.4

: Unscrew screws (1) and carefullyremove spring housing (2), ifnecessary remove any fragmentsof the spring

: Examine the washer (1) andclean or replace it if necessary

– Before installation, coat therewind spring and washer with afew drops of STIHL speciallubricant, 13

Ensure that the inner spring loop (1)can be seen through the hole(arrow) so that it can subsequentlybe aligned.

1 3 0 7 R A 0 4 5 T G

1

12

1 3 0 7 R A 0 4 6 T G

1

1 3 0 7 R A 0 4 7 T G

1



82 TS 500i

Washer (1) must be fitted.

: Align spring housing (2) withreplacement spring so that it linesup with the mounts (arrow)

: Press spring housing (1) as far asit will go into the mount of thestarter cover

: Insert and tighten the screws (2)

– Install the rope rotor, 8.4

– Install the pawl, 8.3




1 3 0 7 R A 0 4 8 T G

2

1

1 3 0 7 R A 0 4 9 T G

1

2

2

If the rewind spring pops outduring installation, fit it in thespring housing as follows:

: Arrange the spring (1) as shownin the illustration

: Position the spring loop in the

fixture (arrow) in the springhousing

: Fit the rewind spring (1)completely in a circular fashion,working in clockwise direction

– Secure the spring so that itcannot pop out

– Push spring housing as far as itwill go into the mount of thestarter cover

1 3 0 7 R A 3 1 8 T G

1

1 3 0 7 R

A 3 1 9 T G

1

– Secure the rewind spring so thatit cannot pop out

: If necessary, align the innerspring loop (arrow) with suitablepliers so that it rests against thestarter post at a slight angle

– Install the rope rotor, 8.4

– Install the pawl, 8.3




1 3 0 7 R A 3 2 0 T G



83TS 500i

9. Antivibration elements

The handle frame, tank housing andengine housing are connected byvibration-damping springs.

Damaged springs must be replacedas a matter of principle.

9.1 Antivibration spring onhandlebar

The antivibration spring is locatedbetween handlebar and crankcaseon the clutch side and must bereplaced if defective.

– Remove the muffler, 6.1

: Unscrew screw (1) and removeclamp (2)

: Unscrew screw (1) and removeantivibration spring (2)

1 3 0 7 R A 0 2 1 T G

2

1

1 3 0 7 R A 0 3 1 T G

1

2

: Unscrew handlebar support (1)

– Examine the spring, handlebarsupport and clamp, replace ifnecessary

Installation

: Screw the handlebar support (1)into the antivibration spring (2) asfar as possible (arrow)

: Fit the antivibration spring withhandlebar support (arrow) on thehandlebar and hold it in position

1

3 7 0 R A 2 5 3 T G

1

3 7 0 R A 2 5 4 T G

2

3 7 0 R A 2 5 5 T

G

: Fit the clamp (1) on the oppositeside so that the guide (arrow) ison the inside of the handlebar

: Insert a screw (2) through theclamp and handlebar, and screwit tightly into the oppositehandlebar support (3)

: Push antivibration spring (1) intothe mount (arrow) with theserration of the bearing plug

1 3 0 7 R A 0 3 2 T G

2

3

1

1 3 0 7 R A 0 3 3 T G

1



84 TS 500i


– Fit the muffler, 6.1

9.2 Antivibration spring inthe support

The antivibration spring is locatedbetween support and crankcaseand must be replaced if defective.

– Remove the support, 9.6

: Unscrew screw (1) and removeantivibration spring (2)

– Examine the antivibration springand replace it if necessary

1 3 0 7 R A 0 3 4 T G

1

1 3 0 7 R A 3 2 3 T G

1

2

Installation

: Push antivibration spring (1) asfar as possible into the mount(arrow ) and hold it in position

– antivibration spring is securedagainst twisting


– Install the support, 9.6

1 3 0 7 R A 3 2 4 T G

1

1 3 0 7 R A 3 2 5 T G

1

9.3 Antivibration spring atthe bottom of thecrankcase

The antivibration spring is securedunderneath the machine and mustbe replaced if defective.

: Remove screw (1)

– Remove front handlebar, 9.5

: Pull the antivibration spring (1)out of the handlebar

– Examine the antivibration springand replace it if necessary

1 3 0 7 R A 3 2 6 T G

1

1

3 7 0 R A 2 6 2 T G



85TS 500i

Installation

: Push the antivibration spring (1)into the handlebar so that thetab (2) engages in the notch(arrow)

– Mount the handlebar on the

machine, 9.5

Bearing plug (1) must be twistedinto the antivibration spring as far asit will go.

: Push the bearing plug (1) into themount (arrow) and hold it inposition

1

3 7 0 R A 2 6 3 T G

2

1 3 0 7 R A 3 2 7 T G

1


– Install handlebar, 9.5

9.4 Antivibration spring onthrottle shutter housing

The antivibration spring is locatednear the throttle shutter housingbetween tank housing andcrankcase, and must be replaced ifdefective.




1 3 0 7 R A 3 2 6 T G

1

1 3 0 7 R A 3 2 8 T G

1


: Remove the antivibrationspring (2) and examine it,replace if necessary

Installation

: Push the antivibration spring (1)into the mount (arrow)


1 3 0 7 R A 3 2 9 T G

12

1 3 0 7 R A 3 3 0 T G

21



86 TS 500i





1 3 0 7 R A 3 3 1 T G

1

1 3 0 7 R A 3 2 8 T G

1

9.5 Handlebar

– Remove the support, 9.6

: Unscrew screw (1) and removeclamp (2)


: Unscrew the screw (1) on thebottom and remove clamp (2)

1 3 0 7 R A 0 2 1 T G

2

1

1 3 0 7 R A 3 2 6 T G

1

1 3 0

7 R A 3 3 3 T G

1

1

1

2

: Remove handlebar (1) and pullout antivibration spring (2)

: Remove the clamp (3)

– Examine the individual parts,replace if necessary

Installation

: Push the antivibration spring (1)into the handlebar so that thetab (2) engages in the notch(arrow)

: Fit the clamp (1) onto thehandlebar so that the lug (2)engages in the hole (arrow).

1 3 0 7 R A 3 3 4 T G

2 13

1

3 7

0 R A 2 6 3 T G

2

1

2

3 7 0 R A 2 7 2 T G



87TS 500i

: Position the handlebar (1) overthe machine and push into themounts (arrows)




1 3 0 7 R A 3 3 5 T G

1

1 3 0 7 R A 3 3 6 T G

1

1 3 0 7 R A 3 2 6 T G

1

– Mount the support, 9.6

: Fit the clamp (1) so that the pegengages in the hole (arrow). Thissecures the antivibration springin the handlebar.

– Coat inside of hose with STIHL

press fluid, 13

: Fit clamp (1), the peg mustengage in the hose (arrow)


: Insert and tighten the longscrew (3)

3 7 0 R A 2 7 6 T G

1

1 3 0 7 R A 3 3 7 T G

2

3

2

1

: Fit the clamp (1) on the oppositeside so that the guide (arrow) ison the inside of the handlebar

: Insert screw (2) through theclamp and handlebar, and screwit tightly into the oppositeclamp (3)

9.6 Rubber buffers / support

9.6.1 Support

: Remove screws (1) and (2)

1 3 0 7 R A 0 3 5 T G

2

3

1

1 3 0 7 R A 3 3 8 T G

2

1



88 TS 500i

: Unscrew screws (1) and removesupport (2)

: Unscrew screws (1) and removerubber buffers (2)

– The rubber buffers on thesupport must be replaced in pairs

: Remove antivibration spring (3),9.2


– Reassemble the parts in reverseorder

1 3 0 7 R A 3 3 9 T G

1 21

1 3 0 7 R A 3 4 0 T G

1

22

1

3

Installation

: Position the pre-assembledsupport (1) underneath themachine so that it engages in thepegs (arrows).

: Push the bearing plug of theantivibration spring into themount (arrow)


1 3 0 7 R A 3 4 1 T G

1

3 7 0 R A 2 8 3 T G

1 3 0 7 R

A 3 4 2 T G

11

: Insert the long screw (1) in thehole (arrow) and tighten it


9.6.2 Support foot

– Remove filter cover and air filter,11.1

: Unscrew screw (1) and raise airbaffle (2)

3 7 0 R A 2 8 5 T G

1

2

1 3 0 7 R A 3 4 3 T G

1

2



89TS 500i

: Remove the support foot (1) fromthe retainers (arrows) and pull itout of the guide on the tankhousing on the side of the tankfiller port

: Remove support foot (1) with airbaffle (2)

: Pull support foot (1) out of theguide (arrow) of the air baffle (2)and examine it, replace ifnecessary

1 3 0 7 R A 3 4 4 T G

1

1 3 0 7 R A 3 4 5 T G

1

2

1 3 0 7 R A 3 4 6 T G

2

1

: Pry the stop buffer (1) out of theholes of the air baffle (2)

– Check the wiring harness of thesolenoid valve, replace ifnecessary, 9.6.3

Installation

– Apply STIHL press fluid to thepeg of the stop buffer, 13

: Push stop buffer (1) into theholes of the air baffle (2) anddrawing in on the pegs (arrows)until they enclose the holescompletely

1 3 0 7 R A 3 4 7 T G

1

2

2

1

1 3 0 7 R A 3 4 8 T G

– Apply STIHL press fluid to theguide of the support foot, 13

: Push the support foot (1) into theguide (arrow) of the air baffle (2)

: Position the air baffle (1) andsupport foot (2) so that the

peg (3) engages behind theopening and the tab (4) is overthe guide of the wiring harness

– Do not pinch wiring harness

1 3 0 7 R A 3 4 9 T G

2

1

1 3 0 7 R A 3 5 0 T G

1

2

3

4



90 TS 500i

– Apply STIHL press fluid to theguide of the support foot, 13

: Push the support foot (1) into theguide on the tank housing on theside of the tank filler port

: Then press the support foot (1)

into the retainers (arrows)



1 3 0 7 R A 3 5 1 T G

1

1 3 0 7 R A 3 5 2 T G

1

9.6.3 Wiring harness solenoidvalve (water connection)

– Remove the air baffle, 9.6.2

– Remove the solenoid valve,4.1.3

: Pull the wiring harness (1) out ofthe guides (arrows)

Installation

Using the wiring tool5910 890 4000, press the leadscompletely into the guides, 1.1.

: Orient the wiring harness (1) sothat the plug (2) is located at thetop guide (arrow)

– Install the solenoid valve,4.1.3

1 3 0 7 R A 3 5 3 T G

1

1 3 0 7 R A 3 5 4 T G

2

1

: Place the wiring harness (1) intothe guides (arrows) so that theprotective tube (2) protrudes onthe bottom guide (3) 35 mm

The air baffle (1) must engage withthe tab (2) via the guide of the wiringharness – Do not pinch the wiringharness.

– Fit the air baffle, 9.6.2


1 3 0 7 R A 3 5 5 T G

3 5

m m

2 3

1

1 3 0 7 R A 3 6 0 T G

2

1





92 TS 500i

: Lay the leaf spring (1) on thecams of the switch shaft (2) andpress it into the mount (arrow)

– Hook the torsion spring into thetrigger interlock

: Set the switch shaft (1) to

position "STOP" or "0".

– Checking correct functioning – in position "STOP" or "0" theswitch shaft must actuate theswitch

The switch shaft can only be set toposition "F" if the trigger interlockand throttle trigger are pressed.

1 3 0 7 R A 2 4 4 T G

21

1 3 0 7 R A 2 4 5 T G

1

: Guide the handle molding (1) intoposition under the pegs (arrows)


10.2 Throttle trigger / triggerinterlock

– Remove the handle molding,10.1

: Unhook the torsion spring (1)from the trigger interlock (arrow)and remove the triggerinterlock (2)

: Unhook the throttle cable (1)from the throttle trigger (2)

3 7 0 R A 3 0 3 T G

1

1 3 0 7 R A 2 4 6 T G

2

1

1 3 0 7 R A 0 8 6 T G

1

2

: Drive the pin (arrow) out with adrift

: Take out the throttle trigger (1)and torsion spring (2)


: Hook the torsion spring (1) intothe throttle trigger (2)

– Note the installed position(arrow)

1 3 0 7 R A 2 4 7 T G

1 3 0 7 R A 2 4 8 T G

2

1

3 7 0 R A 3 0 7 T G

12



93TS 500i

: Guide the throttle trigger (1) pastthe switch shaft (arrow) and placeit in the shroud with the torsionspring

: Insert the drift in the hole (arrow)to secure the throttle trigger withtorsion spring

: Fit the pin (1) and drive it in untilit is at the same distance on bothsides

: Press the trigger interlock (1) intothe bearing points (arrows) until itclicks into place

1 3 0 7 R A 2 4 9 T G

1

1 3 0 7 R A 2 5 0 T G

1

1 3 0 7 R A 2 5 1 T G

1

: Hook the torsion spring (1) intothe trigger interlock (arrow)

– Install the handle molding,10.1

– Checking correct functioning – in position "STOP" or "0" the

switch shaft must actuate theswitch

The switch shaft can only be set toposition "F" if the trigger interlockand throttle trigger are pressed.

1 3 0 7 R A 2 5 2 T G

1



94 TS 500i

11. Fuel system

11.1 Air filter

Only replace the air filter if engineperformance deteriorates.


: Unscrew the screws (arrows) andremove the filter cover (1)

– Replace the air filter and auxiliaryfilter – see Instruction manual


11.2 Throttle shutter housing /

Intake manifold

Only start engine with built-inthrottle shutter housing.

Oil seals are built into the throttleshutter housing.

– Check for leaks, 6.2

If the oil seals in the throttle shutterhousing are defective, the throttle

shutter housing must be replaced.


1 3 0 7 R A 1 5 1 T G

1

: Remove the hose clip (1)

: Unscrew the screws (2) andremove the manifold (3) withthrottle shutter housing (4)

: Remove gasket (1) – alwaysinsert a new gasket

: Unscrew the screws (2) andremove the manifold (3)

– Examine the manifold,replace if necessary

– Engine operation may beimpaired even by the slightestdamage

– Clean the mating surface,remove any gasket residues if

necessary

The mating surfaces on themanifold, throttle shutter housingand cylinder must be in perfectcondition and without any damagewhatsoever. Parts with damagedmating surfaces.

1 3 0 7 R A 1 5 2 T G

2

2

3

4

1

1 3 0 7 R A 1 5 3 T G

3

1

2

2

: Pull bushing (1) out of themount (2) and unhook the throttlecable from the throttle shutterlever (arrow)

– Check the throttle shutterhousing, clean or replace ifnecessary

Installation

: Hook brass ball of the throttlecable (1) into the throttle shutterlever (arrow) and pull it until itclicks into place

: Push the bushing (2) into themount (3)

1 3 0 7 R A 1 5 4 T G

1

2

1 3 0 7 R

A 1 5 5 T G

2

3 1



95TS 500i

: Position the manifold (1) so thatthe lug (arrow) lines up with thethrottle shutter housing (2)

: Insert screws (3) – Manifold is secured to thethrottle shutter housing

: Push the new gasket (1) on theopposite side of the throttleshutter housing (2) over thescrews

: Align the screws (1) so that theyonly protrude slightly on thethrottle shutter housing (2)

1 3 0 7 R A 1 5 6 T G

1

3

3

2

1 3 0 7 R A 1 5 7 T G

1

2

1 3 0 7 R A 1 5 8 T G

21

1

: Fit throttle shutter housing (1)with gasket and manifold (2) andinsert screws (3)

– Check and adjust the position ofthe gasket if necessary


: Push the hose clip (1) onto themanifold (2) so that the screwhead is on the clutch side

: Slide the hose clip (1) overthe shoulder (arrow)

– only push the hose clip onto theshoulder once the tank housing isinstalled

Apply STIHL press fluid to the inside

of the manifold

– Install the tank housing, 11.9

– Install the handlebar, 9.5

– Install the control unit, 7.3

1 3 0 7 R A 1 5 9 T G

2

3 1

3

1 3 0 7 R A 1 6 0 T G

1

2

– Fit the shroud, 6.4

– Check correct functioning – the throttle cable must moveeasily and when the throttletrigger is in the full throttleposition, the throttle shutter must

be open all the way


11.2.1 Air baffle / throttle cable



: Unhook the throttle cable (1)from the mount (arrow)

: Raise the retaining tab (2) slightlyand pull out air baffle (3)

1 3 0 7 R A 1 6 1 T G

1

23



96 TS 500i

: Pull bushing (1) of the throttlecable out of the mount (2) andunhook the ball of the throttlecable from the throttle shutterlever (arrow)

– Examine the throttle cable,replace if necessary

Installation

: Hook ball of the throttle cable (1)into the throttle shutter lever(arrow) and pull it until it clicksinto place

: Push the bushing (2) into themount (3)

1 3 0 7 R A 1 6 2 T G

1

2

1 3 0 7 R

A 1 6 3 T G

2

3 1

: Align the air baffle (1) so that thepegs (arrows) engage in theprofile of the tank housing

: Press the air baffle (1) until thetab (2) snaps into place

: Push the bushing (1) into the

mount (arrow)

– Install the control unit, 7.3

– Fit the shroud, 6.4

– Check correct functioning – the throttle cable must moveeasily and when the throttletrigger is in the full throttleposition, the throttle shutter mustbe open all the way


1 3 0 7 R A 1 6 4 T G

2

1

1 3 0 7 R A 1 6 5 T G

1

11.3 Injection valve





: Pull the bushing (1) and wiringharness (2) out of the guides(arrows) and set them aside

1 3 0 7 R A 0 9 0 T G

1

3

2

1 3 0 7

R A 0 9 1 T G

1

2

1

1 3 0 7 R A 0 9 2 T G

2



97TS 500i

: Pull out bushing (1) and (2) andpull wiring harnesses (3) and (4)out of the guides (arrows)

: Press the snap fittings (arrows)and open the cover (1)

: Disconnect the fuel hoses (1)from the connectors (arrows) andremove injection pump withconnecting element

Replace fuel hose unit which hasbeen removed.

1 1 3 0 7 R A 1 6 8 T G

2 4

3

1 3 0 7 R A 1 6 9 T G

1

1 3 0 7 R A 1 7 0 T G

1

: Pull the wiring harness (1) of thesensor out of the guides (arrows)

: Pull the wiring harness (1) of theinjection valve (2) out of theguides (arrows)

: Unscrew the screws (1) andremove the injection valve (2)with air baffle (3)

1 3 0 7 R A 1 7 1 T G

1

1 3 0 7 R A 1 7 2 T G

1

2

1 3 0 7 R A 1 7 3 T G

1

3

12

: Press injection valve (1) out ofthe air baffle (2) and remove – donot disassemble the injectionvalve any further

– Check air baffle, injection valve orO-ring, replace damagedcomponent if necessary

Installation

Using the wiring tool5910 890 4000, press the leadscompletely into the guides, 1.1.

: Check bushing (1) and remove ifnecessary

– Coat bushing with STIHL pressfluid, 13

: Press new bushing (1) into thehole so that the straight edge isflush with the fin (arrow)

1 3 0 7 R A 1 7 4 T G

2

1

1 3 0 7 R A 1 7 5 T G

1





99TS 500i

: Place the wiring harness (1) andbushing (2) of the sensorcompletely into the guides(arrows)

: Place the wiring harness (1) andbushing (2) of the injection valvecompletely into the guides(arrows)

: Push the wiring harness (1) andbushing (2) into the guides(arrows) – start with the bushing

1 3 0 7 R A 1 8 4 T G

12

1 3 0 7 R A 1 8 5 T G

12

1 3 0 7 R A 1 8 6 T G

1

2

: Position cable holder (1) so that itengages over the bushing(arrow) – do not pinch the leads


: Fit the cover (1) and guide the

cable lug of the ground wire (2)between the tabs (arrows)




1 3 0 7 R A 1 8 7 T G

2

1

1 3 0 7 R A 1 8 8 T G

3

1

2

11.4 Sensor





1 3 0 7 R A 0 9 0 T G

1

3

2

1 3 0 7

R A 0 9 1 T G

1

2





101TS 500i

: Place the wiring harness (1) ofthe sensor into the guides(arrows) – the wiring harness ofthe injection valve must beunderneath

: Close the cover (1) and pressinto the snap fittings (arrows)until they snap into place

: Push the wiring harness (1) andbushing (2) of the sensorcompletely into the guides(arrows)

1 3 0 7 R A 1 8 1 T G

1

1 3 0 7 R A 1 8 3 T G

1

2 1 3 0 7 R A 1 9 3 T G

1

: Place the wiring harness (1) andbushing (2) in the guides(arrows) – start with the bushing

: Position the cable holder (1) sothat it engages over the bushing(arrow) – do not pinch the leads


1 3 0 7 R A 1 8 6 T G

1

2

1 3 0 7 R A 1 8 7 T G

2

1

: Fit the cover (1) and guide thecable lug of the ground wire (2)between the tabs (arrows)




11.5 Impulse hose

The impulse hose forms one unitwith the fuel hoses. Installation andremoval is described in the chapter"Injection pump", 11.7.2

1 3 0 7 R A 1 8 8 T G

3

1

2



102 TS 500i

11.6 Leak testing

11.6.1 Checking the fuel tank /fuel system

On testing the fuel system underpressure using the pressure testingtool 5910 890 4100, a quick first testcan be carried out.

– Open the filler cap and drain thefuel tank in accordance withregulations, 1

– Close the filler cap

– Remove the shroud, 6.4

– Remove the control unit, 7.3


– Remove the tank vent, 11.6.3

: Push the hoses (1)1127 358 7600 onto connectingelement (2) 5910 895 0200

1 3 0 7 R A 1 9 9 T G

2 11

1

– Coat O-ring on the plug withSTIHL press fluid, 13

: Press the plug (1) of the pressuretesting tool 5910 890 4100 as faras it will go into the hole (arrow)

– Pull injection pump from the

guide

: Push hoses (1) 1127 358 7600onto the plug (2) of the pressuretesting tool 5910 890 4100 andinjection pump (3)

1

1 3 0 7 R A 3 7 0 T G

1 3 0 7 R A 3 7 1 T G

1

2

3

1

: Slide ring (1) to the right andconnect the pump (2)0000 850 1300 to the hose

– Build up gauge pressure in thefuel tank

Actuate the pump until the pressuregauge shows a pressure of 0.8 bar.

If this pressure remains constant forat least 20 seconds, the tank isairtight. If the pressure drops, theleak must be located and the faultypart replaced.

– After testing, slide the ring on thepump to the left to vent the pump

– disconnect the hose.

– Remove pressure testing tool

– If the fuel tank is airtight, continue

with tank vent test, 11.6.2



1 3 0 7 R A 3 6 9 T G

1

2



103TS 500i

11.6.2 Checking the tank vent

Test preparations

– Open the filler cap and drain thefuel tank in accordance withregulations, 1

– Close the filler cap




: Pull off the fuel suction hose (1)at the connector (arrow)

: Close the fuel suction hose (1)with the plug (2) and push thehose (3) of the pump (4)0000 850 1300 onto thesupport of the fuel intake

1 3 0 7 R A 2 0 3 T G

1

1 3 0 7 R A 2 0 4 T G

2

3 4

1

Testing with negative pressure

: Slide ring (1) to the left andconnect the pump (2)0000 850 1300 to the fuel tankwith negative pressure

Pressure is equalized via the tank

vent. A negative pressure must notbuild up inside the tank.

– Clean the area around the tankvent

– Replace tank vent if necessary,11.6.3

– Continue with "Testing withgauge pressure"

Testing with gauge pressure

The same preparatory steps arerequired as for the testing withnegative pressure.

– Before testing with gaugepressure – Complete testingwith negative pressure

1 3 0 7 R A 2 0 5 T G

1

2

: Slide ring (1) to the right andconnect the pump (2)0000 850 1300 to the fuel tankwith overpressure

Actuate the pump until the pressuregauge shows a pressure of 0.3 bar.If this pressure remains constant for

at least 20 seconds, the tank ventand tank are airtight. If the pressuredrops, replace the tank vent.

– After testing, slide the ring on thepump to the left to vent the pumpand disconnect the hose from thesupport of the connectingelement.

– Replace the fuel suction hosebetween the injection pump andconnecting element, 11.7.2



1 3 0 7 R A 2 0 5 T G

1

2



104 TS 500i

11.6.3 Tank vent Removal andinstallation


: Pry out the tank vent (1)

Always fit a new tank vent.

Installation

– Use STIHL press fluid to simplifyassembly, 13

: Examine the bushing (1), pry itout and replace if necessary

: Install the bushing (1) so that therubber lip encloses the holecompletely

: Align the new tank vent (2) sothat the connector (arrow) pointsdownwards

: Push the new tank vent (2) as faras possible into the bushing

1 3 0 7 R A 2 0 7 T G

1

1 3 0 7 R A 2

0 8 T G

1 2


11.7 Injection pump

11.7.1 Manual fuel pump

After the injection pump has beenremoved, replace the fuel hose unit.First, check if only the manual fuelpump needs to be replaced.

The manual fuel pump can berepaired with the fuel hoses stillattached.



: Pull the injection pump (1) fromthe guide (arrow)

1 3 0 7 R A 2 0 9 T G

1

: Remove screws (1) – The two other screws (2)guarantee the function preset atthe factory and must thereforenot be loosened or unscrewed

: Remove flange (3), cap (4) andcompression spring (5)


Installation

: Insert the compression spring (1)into the mount (arrows)

1 3 0 7 R A 2 1 0 T G

15 4 32

12

1 3 0 7 R A 2 1 1 T G

1



105TS 500i

: Press the cap (1) into the grooveon the circumference (arrow)

: Fit flange (1)


: Push the injection pump (1) with

the lug and support into theguides (arrows)


1 3 0 7 R A 2 1 2 T G

1

1 3 0 7 R A 2 1 3 T G

1 2

2

1 3 0 7 R A 2 1 4 T G

1

11.7.2 Injection pump


: Pull the impulse hose (1), fuelreturn line (2) and fuel hose (3)from the connectors

: Remove the injection pump (4)with the fuel hoses andconnecting element (5)

: Pull the fuel suction hose (1),impulse hose (2) and fuelhose (3) from the connectors onthe injection pump

1 3 0 7 R A 2 1 5 T G

1

23

4

5

1 3 0 7 R A 2 1 6 T G

1

2

3

: Disconnect the fuel suctionhose (1) and fuel return line (2)from the connectors of theconnecting element (3)

: Examine the connectingelement (3), replace if necessary

: Replace the fuel suction hose (1)

: Replace the fuel hose unit (4)

Installation


: Slide the fuel return line (1) ontothe short connectors (arrow) ofthe connecting element (2) and

slide the fuel hose (3) onto theconnectors (arrow) of theinjection pump (4)

1 3 0 7 R A 2 1 7 T G

1

4

2 3

1 3 0 7 R A 2 1 8 T G

4

2

3

1



106 TS 500i


: Push the impulse hose (1) ontothe connectors (arrow) of theinjection pump (2)

– Use STIHL press fluid to simplify

assembly, 13

: Slide the fuel suction hose (1)onto the connectors (arrow) ofthe connecting element (2) andonto the connectors (arrow) ofthe injection pump (3)

1 3 0 7 R A 2 1 9 T G

1

2

1

2

3 1 3 0 7 R A 2 2 0 T G


: Push impulse hose (1), fuelreturn line (2) and fuel hose (3)onto the connectors (arrows)



11.8 Fuel intake

11.8.1 Pickup body

Impurities which are entrained intothe fuel tank with the fuel aretrapped by the pickup body. Withtime, the fine pores in the pickupbody become clogged with very finedirt particles. This reduces theintake diameter and fuel can nolonger be delivered in sufficientquantities.

Always check the fuel tank andpickup body first if problemsdevelop in the fuel supply.


Clean the fuel tank if necessary.

1 3 0 7 R A 2 2 1 T G

2

1

3

– Open the filler cap and drain thetank.

– Fill a little clean gasoline into thetank, close the tank and shake itthoroughly.

– Reopen the tank and empty it

– Dispose of fuel in accordancewith regulations, 1

– Open the filler cap

: Pull the pickup body (1) out of thefuel tank with assembly hook (2)5910 893 8800

Take care not to overextend the fuel

hose (3).

: Pull the pickup body (1) off thefuel hose (3), examine it andclean or replace it if necessary


11.8.2 Fuel hoses

– The installation or removal of thefuel hoses is described in thechapter "Injection pump",

11.7.2

1 3 0 7 R A 1 4 2 T G

2

3

1





108 TS 500i

: Pull the hose (1) out of thecrankcase (arrow)

– Check the hose, replace ifnecessary

Installation

: Push the hose clip (1) over theshoulder of the manifold (2) in thedirection of the throttle shutterhousing so that the screw headfaces the clutch side

– Apply STIHL press fluid to theinside of the manifold, 13

1 3 0 7 R A 3 6 1 T G

1

1 3 0 7 R A 2 2 7 T G

1

2


: Slide the hose (1) into the recess(arrow) in the crankcase and thenpush it into the opening (2) in theside of the fan-side half of thecrankcase.

: Check that the hose is correctlyseated

– On the fan side, the hose(arrows) must enclose theopening completely

: Slide the sleeve (1) into theopening (arrow) in the hoseuntil it lies flush

1 3 0 7 R A 1 1 0 T G

1

2

1 3 0 7 R A 2 2 8 T G

1 3 0 7 R A 2 2 9 T G

1

: Note the position (arrow) of thesleeve (1)

Fitting a new hose


: Position the tank housing (1) onthe crankcase from below

: Guide the hose (2) through theopening (arrow) in the tankhousing with the tab

– Hold the tank housing in place

1 3 0 7 R A 2 3 0 T G

1

1 3 0 7 R A 2 3 1 T G

2

1













114 TS 500i

13. Service accessories

No. Designation Part No. Use

1 Grease (225 g tube) 0781 120 1111 Oil seals, sliding and bearing points

2 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring instarter 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-lockingadhesive (Loctite 242)

0786 111 2101

8 Standard solvent-baseddegreasant not containing anychlorinated or halogenatedhydrocarbons

Cleaning mating surfaces and the carburetor,cleaning the crankshaft stub and tapers inflywheel





116 TS 500i



Documents

Stihl Ts500i Service Manual-Stihl