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STIHL MS 192 T - ramcottage.co.uk

1. Install the engine 8 4 2 Reassemble remaining parts in reverse order MS 192 T 8 5 3 Crankshaft Bearing Remove the engine 8 4 1 Remove the crankshaft 8 5 1 217RA118 TG Remove the ball bearing 1 and washer 376RA121 TG Remove the ball bearing 1 and washer oO co a lt x oc 6 N Go The crankshaft 1 connecting rod 2 the needle bearing between them and the needle bearing 3 form an inseparable unit They must always be replaced as a complete unit The deep groove ball bearings and oil seals must always be replaced when installing a new crankshaft Before installing the crankshaft clean it with standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons oO at ise ise lt x oc oS N oO Fit the washer 1 37 376RA122 TG Fit the ball bearing with the closed side arrow facing outwards Heat the inner race of the deep groove ball bearing to approx 150 C 300 F Slip the deep groove ball bearing onto the crankshaft stub as far as the washer The ball bearing must be fitted rapidly as the heat is transmitted to the crankshaft stub and the inner raceway contracts again g amp amp 5 3 If the ball bearing cannot be heated it must be pressed in with a suitable sleeve 1 until the ball bearing rests against the washer 38 3
2. 4 1 Clutch Problem Cause Remedy Saw chain stops under load at full throttle Clutch shoes badly worn Clutch drum badly worn Install new clutch Install new clutch drum Saw chain rotates at idle speed Idle speed too high Clutch springs stretched or fatigued Clutch spring hooks broken Readjust with idle speed screw LA anticlockwise Replace clutch springs or install new clutch Replace clutch springs Loud noises Clutch springs stretched or fatigued Needle cage damaged Clutch shoe retainer broken Clutch shoes and carrier worn Replace all clutch springs Fit new needle cage Fit new retainer Install new clutch MS 192 T 4 2 Chain Drive Chain Brake Chain Tensioner Problem Cause Remedy Chain sprocket wears rapidly Chain not properly tensioned Wrong chain pitch Insufficient chain lubrication Chain sprocket worn Tension chain as specified Fit chain of correct pitch Check chain lubrication Fit new chain sprocket Saw chain stops under load at full throttle Clutch shoes badly worn Clutch drum badly worn Brake band stuck Install new clutch Install new clutch drum Check freedom of movement and function of brake band Saw chain rotates at idle speed Idle speed too high Clutch springs stretched or fatigued Clutch spring hooks broken Readjust with idle speed screw LA anticlockwise Replace clutch springs or install ne
3. Removal Troubleshooting 4 2 Remove the sprocket cover and bar and chain 5 1 Engage the chain brake by pushing the hand guard 1 downwards The brake spring of the brake band is now relaxed o o A ro lt ira N Take out the screws arrows 21 217RA027 TG Remove the cover 1 Carefully ease the brake spring 1 off the anchor pin arrow Unhook the brake spring 1 from the brake lever 2 Disconnect the brake band 1 from the lever arrow and remove it 22 217RA321 TG Install a new brake band if there are noticeable signs of wear large areas on inside diameter and or parts of outside diameter and its remaining thickness is less than 0 6 mm i 217RA030 TG X Remove the E clip arrow fol E a rs lt ita Remove the hand guard 2 with lever 1 from the pivot pins Pull the lever out of the hand guard Draw the hand guard 1 out through the opening in the cover arrow 217RA032 TG Remove the inlay 1 and leaf spring 2 Clean all disassembled parts with a little standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Examine the inlay and leaf spring and replace if necessary MS 192 T Wet the inlay 1 with Loctite before fitting it 16 Press the inlay 1 as far as possible into the opening in the cover Pull the pin
4. Spark present Air gap Check ignition module flywheel Adjust if necessary 9 1 1 Check flywheel Have pole shoes turned blue Replace flywheel if necessary 9 5 Check short circuit wire Replace short circuit wire if necessary 9 6 1 Check ignition lead Severe chafing Spark plug boot holes cracks Resistance of spark plug boot to ground required 1 5 12 KQ Check resistance of ignition lead value required lt 10 Q Replace spark plug boot and or ignition lead with ignition module if necessary 19 4 51 52 Stop switch Check correct operation Short circuit wire chafed Contact springs not in contact with metal pin on switch shaft when in position I Replace short circuit wire if necessary 9 6 2 Spark yes present a Replace ignition module 9 1 1 yes no Engine runs smoothly Look for fault in fuel or carburetor troubleshooting procedure completed system Check power unit for leaks Check position of flywheel on crankshaft 8 2 9 5 MS 192 T 10 Rewind starter 10 1 General If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not completely it may be assumed that the starter mechanism is in order but plugged with dirt At very low outside temperatures th
5. 1 out of the cover with a suitable tool 217RA323 TG 217RA324 TG Carefully drive the pin 1 home tapping lightly until value a approx 4 3 4 7 mm is reached The pin must be driven in squarely Place the leaf spring 1 in the opening arrow Lightly grease both the leaf spring and the pin of the inlay The anchor pin must be replaced if the groove in the brake spring anchor pin is worn Proceed as follows MS 192 T Wet the knurled area of the new pin 1 with Loctite before fitting it 16 Position the new pin 1 in the bore so that the knurling on the pin meshes with the existing Knurling in the bore Turn the pin back and forth as necessary Prise off the bumper strip 1 with a suitable tool Check the bumper strip and replace it if necessary Reassemble parts in reverse order oO fi 9 fe 3S lt ira N Slide the lever 1 through the opening in the cover 23 The forked opening 2 must face towards the brake band Insert the lever 1 in the side of the bearing boss arrow 217RA037 TG Ensure that the holes in the lever inside the hand guard are lined up Slip the bearing boss of the hand guard 1 and lever 2 onto the pivot pins When fitting the parts ensure that the cam arrow on the hand guard is guided past the leaf spring 24 Coat all sliding and bearing points with STIHL multi purpose gr
6. Examine the front handle 1 spring 2 and bearing plug 3 and replace if necessary 217RA164 TG Ensure that the spring 1 has been fully turned into the front handle and bearing plug Reassemble parts in reverse order y Slide the front handle into the hole arrow ensuring that the raised parts of the handle engage the recess of the handle housing 217RA159 TG Insert and tighten down the screw arrow Tightening torques 3 5 Reassemble remaining parts in reverse order 61 11 3 AV Spring between Handle Housing Engine Housing The AV spring is located between handle housing and engine housing to secure the handle housing without transmitting vibrations The replacement spring is supplied complete with bearing plug Remove the sprocket cover and bar and chain 5 1 Open the handle housing 12 1 217RA170 TG Remove the screw arrow o a N qL fia a Prise off the bumper strip 1 with a suitable tool 62 Remove the screw arrow Draw the AV spring out of the recess in the engine housing Examine the AV spring and replace it if necessary Before installing the AV spring ensure that it has been fully turned into the bearing plugs arrows Reassemble parts in reverse order Tightening torques 3 5 217RA169 TG 217RA168 TG 11 4 Clamp To prevent the engine vibrating in the
7. LA 2 Turn the low speed screw L clockwise or anticlockwise to set the highest speed If this speed is more than 3900 rpm stop the adjustment and start again with step 1 3 Setthe speed to 3500 rpm again with the idle speed adjusting screw LA 4 Set the speed to 3000 rpm with the low speed screw L 5 Set the maximum speed of 13 500 rpm with the high speed screw H 6 Fit the limiter cap Always use a new limiter cap Before fitting the limiter cap it must be positioned so that the raised part 1 is below the stop arrow on the carburetor body Then press the limiter cap onto the preset high speed screw Press the limiter cap onto the high speed screw H 83 14 4 2 User Setting o E ra 8 lt ita The limiter cap must not be removed from the high speed screw when making the user setting Standard setting Switch off engine Check the air filter clean or replace if necessary 14 1 Check the chain tension Check the spark arresting screen if installed clean or replace if necessary 8 1 Carefully turn the high speed screw H anticlockwise as far as possible max 3 4 turn Carefully turn the low speed screw L clockwise until it is firmly in its seat Then open it one turn 84 Engine stops when idling Make standard setting Turn the idle speed screw LA clockwise until the saw chain begins to run then back o
8. The handle housing and engine housing are connected by vibration damping rubber buffers and a spring Damaged rubber buffers annular buffers and springs must be replaced 60 11 1 Annular Buffer The rubber buffer is located between handle housing and engine housing to secure the handle housing without transmitting vibrations Remove the carburetor box cover 14 1 Remove the sprocket cover and bar and chain 5 1 1 217RA182 TG Remove the screw arrow Take out the screws arrows Remove the rubber buffer o 2 3 8 lt fia Examine the rubber buffer and replace it if necessary Reassemble parts in reverse order Tightening torques 3 5 MS 192 T 11 2 Front Handle Spring The spring is located between front handle and engine housing to ensure a strong connection between handle housing and engine housing without transmitting vibrations Open the handle housing 12 1 Remove the throttle trigger and throttle trigger interlock 12 1 Remove the switch shaft 12 3 217RA159 TG Remove the screw arrow Remove the screw arrow from underneath the engine housing MS 192 T UN AN x SZ N Pull the front handle 1 out of the upper guide arrow KNOT W Draw the front handle out of the engine housing with the spring facing downwards oO ro 3S lt a
9. engine housing a clamp is fitted on the inside of the engine housing so that the cylinder rests against the clamp Remove the engine 8 4 The following work is made easier by using STIHL Press Fluid 16 217RA184 TG Press the rubber stub arrow out of the engine housing Examine the clamp and replace it if necessary o E 9 Press the clamp 1 into the engine housing from below Reassemble remaining parts in reverse order MS 192 T 12 Actuating Levers Throttle Trigger Interlock Lever Throttle Rod 12 1 217RA186 TG Remove the screw arrow 217RA171 TG Examine the retaining plate and loop and replace them if necessary Fit the loop in the retaining plate arrow and position both parts on the engine housing Insert and tighten down the screw Tightening torques 3 5 MS 192 T 217R Take out the screws arrows Carefully remove the handle moulding 1 Throttle rod and actuating levers may drop out as the handle moulding is removed Remove the throttle rod 1 Remove the interlock lever 1 and throttle trigger 2 N 217RA243 TG Hook the torsion spring 1 into the throttle trigger 2 note the installed position Examine the torsion spring and replace it if necessary Oo d 19 B ita N Place the torsion spring in the fixture arrows
10. fuel can no longer be delivered in sufficient quantities Always check the fuel tank and pick up body first if problems develop in the fuel supply Clean the fuel tank if necessary Lift up the safety latch remove the filler cap 1 and drain the tank Fill a little clean petrol into the tank close the tank and shake it thoroughly Reopen the tank and empty it Ensure that the fuel is disposed of correctly and without harming the environment If cleaning the tank does not remedy the problem clean the pick up body or replace it if necessary Troubleshooting 4 6 or 4 7 89 217RA285 TG Use hook 5910 893 8800 to pull the pick up body 1 out of the fuel tank Take care not to overextend the fuel hose 217RA286 TG Disconnect the pick up body 1 from the fuel hose 2 Check the pick up body and clean or replace it if necessary oO D a lt Slide the connectors of the cleaned or replaced pick up body 1 into the fuel hose 2 90 217RA292 TG Push the pick up body 1 into the tank filler port The pick up body should be positioned at the lowest point inside the tank Reassemble remaining parts in reverse order 14 8 Fuel Hoses Remove the air filter 14 1 Remove the fan cover 9 1 Remove the intake elbow 14 5 Remove the cover 1 o E 2 S cS lt iva N Push the fuel return l
11. lt Push the fuel line with double connector onto the fuel port arrow Push the pressure hose of the tester 1106 850 2905 onto the double connector Close the vent screw 1 on the rubber bulb 2 and pump air into the carburetor until the pressure gauge 3 shows a reading of approx 0 8 bar 80 kPa If this pressure remains constant the carburetor is airtight However if the pressure drops there are two possible causes 1 The inlet valve is not sealing impurities in the valve seat sealing cone of the inlet needle is damaged or inlet control lever is sticking Remove to clean 14 3 2 2 Metering diaphragm damaged replace if necessary EQ 14 3 1 After completing the test open the vent screw 1 and pull the fuel line off the carburetor s elbow connector Push the fuel hose onto the elbow connector Install the carburetor 14 2 Tightening torques 3 5 Reassemble remaining parts in reverse order MS 192 T 14 3 Carburetor Repair 14 3 1 Metering Diaphragm 217RA228 TG Remove the carburetor 14 2 Take out the screws arrows 217RA229 TG The diaphragm material is subjected to continuous alternating stresses and eventually shows signs of fatigue In other words the diaphragm distorts and swells and must be replaced Examine the metering diaphragm for signs of damage and wear replace the gasket 217RA231 TG 217
12. the impulse hose 1 from the stub arrow oO E 19 3 z ira a Remove the screws arrows on the carburetor side 32 Remove the screws arrows from underneath the engine housing 217RA153 TG Lift the handle housing slightly until the manifold flange lifts off the intake stub Pull the engine out of the engine housing Push engine into engine housing 217RA153 TG Lift the handle housing slightly so that the intake stub can be positioned in relation to the manifold when fitting the engine 217RA105 TG Fit the screws arrows and tighten them down only moderately MS 192 T 217RA106 TG Fit the screws arrows and tighten them down only moderately Before tightening the screws down firmly the engine must be centred in relation to the sprocket cover and guide bar oO is K D cS lt a Unscrew the nut arrow and remove the machine from the assembly stand Fit the guide bar MS 192 T 217RA021 TG Guide the peg arrow into the hole and fit the sprocket cover 217RA352 TG The pin 1 must be lined up with the hole arrow when fitting the sprocket cover 217RA351 TG Tighten down the nut arrow and secure the sprocket cover 1 Now tighten down the screws securing the engine Tightening torques 3 5 Remove the sprocket cover again Mount the machine on th
13. the pawl 1 Grease the pegs arrow of the new pawl 16 Reassemble parts in reverse order 54 10 4 Rope Rotor Remove fan housing 10 2 Remove the spring 10 3 Relieve tension of rewind spring 217RA258 TG Pull out the starter rope about 5 cm and hold the rope rotor steady Still holding the rope rotor steady take three full turns off the rope rotor Pull out the rope with the starter grip and carefully release the rope rotor The system will not be under tension if the starter rope or rewind spring is broken Remove the washer 1 Remove the pawl 2 The rewind spring must be relieved 217RA247 TG Carefully remove the rope rotor Remove the starter rope or remaining rope from the rope rotor Examine the rope rotor and replace it if necessary Remove any remaining rope from the fan housing if necessary Install a new starter rope 10 5 Lubricate the hole in the rope rotor with STIHL special lubricant oil 16 MS 192 T Fit the rotor on the starter post so that the inner loop of the spring arrow enters the recess 1 The recess in the hub of the rope rotor acts as carrier for the spring loop Reassemble remaining parts in reverse order MS 192 T LW 217RA251 TG Position the spring 1 so that the loop of the spring encloses the peg of the pawl and the curved part of the spring arrow
14. the piston The clamping strap 1 must be fitted so that the arrow 2 points towards the cylinder exhaust port and is lined up with the arrow arrow at the bottom of the piston Check that the piston rings have been installed correctly oO oO lt a A Align the piston and crankshaft before inserting them in the cylinder The cylindrical crankshaft stub arrow must point towards the cylinder exhaust port For clarity the piston is not shown in this illustration of the clamping strap fitted in the cylinder Insert the clamping strap with piston in the cylinder so that the tab 1 on the clamping strap engages the correspondingly shaped recess arrow When sliding the piston into the cylinder ensure that the clamping strap firmly encloses the piston and that none of the piston rings protrudes risk of breakage 217RA145 TG Slide the piston into the cylinder the clamping strap moves backwards at the same time Remove the clamping strap 35 217RA146 TG Check and clean the mating faces arrows on the cylinder Mating faces must be absolutely clean and undamaged Parts with damaged mating faces must be replaced Whenever the engine pan has been disassembled the mating faces must be cleaned and fresh sealing compound applied QA 16 ir 217RA116 TG Before closing the crankcase ensure that the cylindrical crankshaf
15. the sprocket cover ensuring that the peg arrow engages in the hole Reassemble remaining parts in reverse order Tension the chain 5 2 Tightening torques 3 5 MS 192 T 5 2 Tensioning the Chain 217RA076 TG 5 3 Chain Catcher 5 4 Bumper Spike Turn the screw clockwise to tension the chain Tighten the hex nut arrow 217RA007 TG The chain 1 is correctly tensioned when it rests against the underside of the chain guide arrow and can be pulled over the guide bar by hand when the chain brake is released If the chain is tensioned excessively this may result in damage to the chain guide bar and sprocket as well as its needle bearing MS 192 T Sprocket cover with integrally moulded chain catcher 1 If the chain catcher has broken 2 file down the stub and replace with a replacement chain catcher 3 Remove the sprocket cover and bar and chain 5 1 Remove the screw arrow Remove the chain catcher 3 Reassemble parts in reverse order Remove the sprocket cover and bar and chain 5 1 Remove the chain catcher 5 3 Remove the screw arrow Remove the spiked bumper 1 Reassemble parts in reverse order 17 5 5 Bumper Strips Bumper strips are fitted on the engine housing to guide the saw chain Worn bumper strips must be replaced otherwise the engine housing may be damaged Remove the sprocket cover and bar and
16. 1 must be firmly seated in the hole and the cam arrow must be present oO o lt a Fit the switch shaft 1 pushing the rear contact spring 3 slightly to the side Check operation The contact springs are fitted in the handle housing at different depths The rear contact spring 3 and the front contact spring 2 must make contact with the metal pin of the switch shaft when the switch shaft 1 is in position 0 Reassemble remaining parts in reverse order Tightening torques 3 5 Check correct functioning again 65 12 4 Handle Housing Remove fan housing 10 2 Remove the sprocket cover and bar and chain 5 1 Remove the carburetor 14 2 Push the intake elbow on the carburetor side out of the handle housing 14 5 The handle need not be dismantled when replacing the handle housing as the handle housing is replaced as a complete unit see spare parts list Remove the cover 1 217RA172 TG Remove the bumper strip 1 217RA169 TG Remove the screw arrow Remove the cable guide arrow 217RA320 TG Remove the cable guides arrows Remove the screw arrow 66 Take out the screw arrow and remove the ground wire 2 Remove the short circuit wire 1 Disconnect the spring of the front handle from the engine housing Remove the screw arrow MS 192
17. 5608 Crankshaft nut 33 Combination wrench 1129 890 3401 Spark plug 1 35 Bit T 27 x 125 0812 542 2104 Remove and install spline socket head screws with electric or pneumatic screwdrivers tighten down screws with torque wrench 35 Bit T 20 x 125 0812 542 2041 Remove and install spline socket head screws with electric or pneumatic screwdrivers tighten down screws with torque wrench 36 Screwdriver T 20 x 100 5910 890 2301 1 37 Screwdriver Q SW8x200 5910 890 2420 Carburetor nuts 1 38 Stud puller 41 Crimping pliers 42 Assembly pin 5910 893 0501 5910 890 8210 1114 893 4700 Remove rail mounting studs Cable ties cable lugs etc Remove and install the piston pin Remarks 1 Use only for releasing MS 192 T 95 16 Servicing Aids No Part name Part No Use 1 Lubricating grease 225 g tube 0781 1201111 Oil seals sliding and bearing points 2 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor rewind spring in fan housing 3 Press Fluid OH 723 0781 957 9000 Rubber buffers in AV system 4 STIHL multi purpose grease 0781 120 1109 High voltage output on ignition module 5 Dirko HT red sealant 0783 830 2000 Engine pan oil seals outside 6 High strength thread locking 0786 111 2109 adhesive Loctite 270 7 Standard commercial solvent Cleaning sealing faces and the carburetor based degreasant containing no chlorinated or hydrogenated hydrocarbons cleaning the cran
18. 63 217RA242 TG When installing the interlock lever 1 and throttle trigger 2 ensure that the peg on the interlock lever engages in the guide arrow 217RA308 TG Fit the interlock lever and throttle trigger in the bearing guides arrows oO Ee D se N lt ira a Push the throttle rod into the holes arrows on the throttle trigger and double lever Install the handle moulding fit the screws and tighten them down securely 64 Tightening torques 3 5 Check correct functioning 12 2 Double Lever Remove the air filter 14 1 Remove the air filter base 14 1 1 Remove the handle moulding throttle rod interlock lever and throttle trigger 12 1 Unhook the rod from the carburetor 14 2 217RA244 TG Remove the double lever 1 from the bearing hole arrow o re t lt iva N Install the double lever so that the throttle rod 1 can be fitted in the upper hole arrow and the throttle rod from the carburetor 2 in the lower hole arrow MS 192 T Reassemble parts in reverse order Tightening torques 3 5 Check correct functioning MS 192 T 12 3 Switch Shaft 217RA246 TG Remove the handle moulding throttle rod interlock lever and throttle trigger 12 1 Pull the switch shaft 1 out of the bearing 217RA167 TG Check the switch shaft the metal pin
19. 76RA132 TG Fit the washer 1 oO A lt x oc 6 N oO Fit the ball bearing with the closed side arrow facing outwards Heat the inner race of the deep groove ball bearing to approx 150 C 300 F Slip the deep groove ball bearing onto the crankshaft stub as far as the washer The ball bearing must be fitted rapidly as the heat is transmitted to the crankshaft stub and the inner raceway contracts again If the ball bearing cannot be heated it must be pressed in with a suitable sleeve 1 until the ball bearing rests against the washer Coat the needle bearing with oil Install the piston 8 6 2 Install the crankshaft and oil seals 8 5 2 Install the engine 8 4 2 MS 192 T 8 6 8 6 1 Piston Removal Remove the engine 8 4 1 Remove the crankshaft 8 5 1 e Use a Suitable tool to prise the hookless snap ring out at the recess arrow 217RA124 TG 217RA126 TG Push the piston pin 1 out of the piston with the assembly drift 2 1114 893 4700 If the piston pin is stuck lightly tap the end of the assembly drift with a hammer to loosen it The piston must be held steady during this process to ensure that jolts are not transmitted to the connecting rod 8 6 2 Installation 217RA134 TG Coat the needle cage with oil Align the piston so that the side with the bulge for the snap ring arrow is on the same side as the tapered cra
20. RA232 TG Secure the gasket metering diaphragm and end cover with two screws arrows Remove the end cover 1 If the gasket and diaphragm are stuck to the carburetor they must be removed very carefully 0 Ee Q re N lt ira a Carefully separate the metering diaphragm 1 and gasket 2 MS 192 T Note the order in which the metering diaphragm 2 and gasket 1 are installed Gasket and metering diaphragm must be aligned so that the tab arrow points towards the adjusting nozzles Fit the remaining screws in the secured end cover and tighten down all screws working crosswise 75 14 3 2 Inlet Needle Remove the metering diaphragm 14 3 1 Remove the screw arrow 217RA235 TG Pull the inlet control lever 1 with spindle 2 out of the groove in the inlet needle The spring under the inlet control lever may pop out o FE 8 amp qL ita a Pull out the inlet needle arrow Remove and examine the spring 1 replace it if necessary 76 The sealing cone of the inlet needle must be replaced if a circular indentation arrow is visible on its tip HS Fit the inlet needle 1 Fit spring 2 in bore Position the seat of the inlet control lever 1 with spindle 2 over the spring then slide the fork of the inlet control lever into the groove in the inlet needle 1 Ensur
21. STIHL Contents 1 7 1 7 2 7 3 Introduction Safety Precautions Specifications Engine Fuel System Ignition System Chain Lubrication Tightening Torques Troubleshooting Clutch Chain Drive Chain Brake Chain Tensioner Chain Lubrication Rewind Starter Ignition System Carburetor Engine Chain Spiked Bumper Chain and Chain Guide Tensioning the Chain Chain Catcher Bumper Spike Bumper Strips Clutch Sprocket Clutch Drum Checking Operation of Chain Brake Removing and Installing Chain Tensioner Bar Mounting Stud MS 192 T 20 21 21 26 9 5 9 6 1 9 6 2 9 7 10 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 Engine Muffler Spark Arresting Screen Leakage test Preparations Vacuum test Pressure test Oil Seals Engine Removal Installation Crankshaft Removal Installation Crankshaft Bearing Piston Removal Installation Piston rings Ignition System Ignition Module Removing and installing Ignition Timing Testing the Ignition Module Ignition Lead Spark Plug Boot Flywheel Short Circuit Wire Testing Removing and installing Troubleshooting Ignition System Rewind starter General Removing and Installing Pawls Rope Rotor Starter Rope Grip Tensioning the Rewind Spring Replacing the Rewind Spring Starter Rope Guide Bushing 57 58 59 11 Repairing the AV System Annular Buffer Front Handle Sprin
22. T Pull the front handle with handle housing down slightly Pull the bearing plug out of the engine housing Remove the tank vent 1 Push the fuel return line 1 out MS 192 T Disconnect the tank vent 1 from the fuel hose 2 Draw the fuel hose 2 out through the opening arrow Push the grommet 1 out oO o D A lt a Disconnect the impulse hose 1 from the stub arrow Remove the handle housing 217RA337 TG Unscrew the spring and bearing plug 217RA336 TG Screw the spring 1 and bearing plug 2 into the new front handle Install the complete handle housing in the reverse sequence of steps Tightening torques 3 5 Installation of rubber parts is made easier by using STIHL Press Fluid 16 67 13 Chain Lubrication 13 1 Pick up Body Impurities gradually clog the fine pores of the filter with minute particles of dirt This prevents the oil pump from supplying sufficient oil to the bar and chain Always check the oil tank and pick up body first if problems develop in the oil supply Clean the oil tank if necessary Troubleshooting 4 3 Unscrew the oil tank cap and drain the oil tank Collect chain oil in a clean container or dispose of it properly at an approved disposal site Dy 217RA187 TG Use hook 5910 893 8800 to pull the pick up body 1 out of the oil tank Take care not t
23. chain 5 1 6 Clutch Troubleshooting G2 4 1 Remove the sprocket cover and bar and chain 5 1 Unscrew the spark plug 1 Prise off the bumper strips 1 with a suitable tool Release the twist lock arrow Remove carburetor box cover 1 to the rear Push the locking strip 1 0000 893 5903 into the spark plug hole so that OBEN TOP faces down 217RA083 TG Insert the bumper strips so that the peg is aligned in the recess arrows Reassemble remaining parts in reverse order 18 217RA009 TG Apply a suitable tool to the tab arrow to prise the boot off the spark plug 1 Unscrew the clutch 1 The clutch has a left hand thread MS 192 T 217RA013 TG Disassembly Use hook 2 5910 890 2800 to remove the clutch springs 1 Pull the clutch shoes off the Carrier Pull the retainers 1 off the clutch shoes oO ted lo 5 z ira Clean all parts Replace any damaged parts MS 192 T Slip the retainers 1 onto the clutch shoes Fit the clutch shoes over the arms 1 so that the series number 2 is on the same side as the raised hexagon arrow Clamp the clutch in a vice arrow 217RA016 TG 217RA018 TG 217RA019 TG Attach one end of the clutch spring 1 to the clutch shoes Use the hook 2 5910 890 2800 to attach the other end of the spring and pr
24. circuit wire check ignition lead ignition module and replace if necessary Check operation of spark plug Clean the spark plug or replace if necessary Replace crankcase 12 MS 192 T 4 6 Carburetor Problem Cause Remedy Carburetor floods engine stalls Inlet needle not sealing Foreign matter in valve seat or cone Inlet control lever sticking on spindle Helical spring not located on nipple of inlet control lever Perforated disc on diaphragm is deformed and presses constantly against the inlet control lever Remove and clean inlet needle or clean carburetor Restore easy movement of inlet control lever Remove the inlet control lever and refit it correctly Fit a new metering diaphragm Poor acceleration Idle jet too lean Main jet too lean Inlet control lever too low relative to correct installed position Inlet needle sticking to valve seat Diaphragm gasket leaking Metering diaphragm damaged or shrunk Impulse hose damaged or kinked Turn low speed screw L anticlockwise richer until engine accelerates smoothly Turn high speed screw H anticlockwise richer no further than stop Set inlet control lever flush with top edge of housing Remove inlet needle clean and refit Replace diaphragm gasket Fit new metering diaphragm Fit new impulse hose MS 192 T 13 Problem Cause Remedy Engine will not idle idle speed too high Throttle s
25. de the tank Screw in the filler cap Test for leaks 72 14 Fuel System 14 1 Air Filter Dirty air filters reduce engine power increase fuel consumption and make starting more difficult The air filter should be checked when there is a noticeable loss of engine power Refer also to troubleshooting 4 7 Remove the air filter 1 Knock out the filter or blow it clear with compressed air from the inside outwards Turn the twist lock arrow anticlockwise Remove the carburetor box cover 1 oO E o D i lt a N a Press the tabs arrows together and push the twist lock 1 out of the carburetor box cover Take the foam inlay 1 out of the filter base Clean away loose dirt from around the filter Check the filter and foam inlay and replace them if damaged or dirty Ifsoiled wash all parts of the filter in STIHL universal cleaner or a fresh non flammable cleaning solution e g warm soapy water and allow to dry Do not clean fleece non woven filters with a brush Reassemble parts in reverse order MS 192 T 14 1 1 Air Filter Base 14 2 Carburetor Removing and Installing Remove the air filter 14 1 Remove the filter base 14 1 1 217RA179 TG Remove the air filter 14 1 When fitting the choke lever 1 on the choke shaft 2 ensure that the Unscrew the nuts arrows flat side of the choke shaf
26. dle speed Clutch Clutch engages at Crankcase leakage test at gauge pressure under vacuum MS 192 T 30 1 cm 37 mm 28 mm 1 3 kW 1 8 HP at 9500 rpm 13500 rpm 3000 rpm Centrifugal clutch without linings 4150 rpm 0 5 bar 0 5 bar 3 2 Fuel System Carburetor leakage test at gauge pressure 0 8 bar Operation of tank vent at gauge pressure 0 3 bar Fuel as specified in instruction manual 3 3 Ignition System Air gap between ignition module and fanwheel 0 15 0 35 mm Spark plug Suppressed NGK BPMR 7A Electrode gap 0 5 mm 3 4 Chain Lubrication MS 192 T Fully automatic speed controlled oil pump with rotary piston Oil delivery rate 6 5 8 5 cm at 10 000 rpm 3 5 Tightening Torques DG screws are used in polymer and light metal components These screws form a permanent thread when they are installed for the first time Screws can be removed and installed as often as necessary without impairing the strength of the screwed assembly provided that the specified tightening torque is observed For this reason it is essential to use a torque wrench Fastener Thread size For component Tightening Remarks torque Nm Screw DG 4x15 Chain tensioner cover plate engine 2 5 housing Screw D 6x13 Collar screw for guide bar rear 6 0 Collar screw DG 8x18 Collar screw for guide bar front 16 0 Screw B 4 2x9 5 Cover plate screen muffler 2 0 Screw P 4x12 Cover sprocket cover engine housin
27. double nipple then create a vacuum in the fuel tank Pressure is equalized via the tank vent A negative pressure must not build up inside the tank The tank vent must be replaced if this is not the case Clean the area around the tank vent Replace the tank vent or tank if necessary 14 6 2 or 14 8 3 MS 192 T 14 6 2 Removing and Installing Testing with gauge pressure Close the vent screw 1 Connect the carburetor and crankcase tester 1106 850 2905 1 to the double nipple arrow Pump the rubber bulb until the reading on the pressure gauge shows an excess pressure of 0 5 bar If this pressure remains constant for at least 20 seconds the tank and tank vent are airtight If the pressure drops the leak must be located and the faulty part replaced Reassemble parts in reverse order MS 192 T Remove the air filter 14 1 Remove the filter base 14 1 1 Pull the tank vent 1 out of the holder on the handle housing Oo oO lt c Disconnect the tank vent 1 from the hose 2 Examine the tank vent and replace it if necessary Reassemble parts in reverse order 14 7 Fuel Intake 14 7 1 Pick up Body Impurities which are entrained into the fuel tank with the fuel are trapped by the pick up body With time the fine pores in the pick up body become clogged with very fine dirt particles This reduces the intake diameter and
28. e assembly stand again and continue with the installation procedure Push the manifold 1 onto the intake stub Coat the manifold with STIHL Press Fluid 16 217RA272 TG The tab arrow must point towards the saw chain Press in the supporting plate 1 33 217RA273 TG Ensure that the supporting plate rests securely on the engine housing at all points arrows 217RA156 TG Insert and tighten down the screw 1 Tightening torques 3 5 oO N D lt ira Connect the impulse hose 1 to the stub arrow 34 217RA158 TG Push the insulating plate 1 into the guides arrows until it engages at the bottom Reassemble remaining parts in reverse order 8 5 Crankshaft 8 5 1 Removal 217RA111 TG Take out the screws arrows 217RA112 TG Apply a suitable tool at the projections arrows of the engine pan then tap lightly to release and lift off the engine pan oO B o T N Remove the crankshaft from the bearing seats arrows MS 192 T 217RAI14TG Pull the oil seals arrows off the crankshaft stubs 217RA115 TG Carefully pull the crankshaft and piston out of the cylinder MS 192 T 8 5 2 Installation 217RA142 TG Coat the piston piston rings and inside of cylinder with oil Use the clamping strap 1 1137 893 2600 to compress the rings around
29. e lubricating oil on the rewind spring may thicken and cause the spring windings to stick together This has a detrimental effect on the function of the starter mechanism To clean the rewind spring it is sufficient to apply a few drops of a standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons to the rewind spring Carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored Before installing lubricate the rewind spring and starter post with STIHL special lubricant 16 If clogged with dirt or pitch the entire starter mechanism including the rewind spring must be removed and disassembled Take particular care when removing the spring Clean all components MS 192 T 10 2 Removing and Installing 217RA087 TG Take out the screws arrows Remove the fan housing 1 Press the locking lug arrow together slightly and remove the segment 1 from the fan housing Examine the fan housing and segment replace if necessary Fit the segment 1 in the slits arrows on the fan housing then push it down until the segment engages Reassemble remaining parts in reverse order Tighten down the screws Tightening torques 3 5 53 10 3 Pawls Remove fan housing 10 2 Carefully ease the spring 1 off the starter post 217RA249 TG Remove
30. e test flange Install the carburetor 14 2 Release the muffler and pull out the sealing plate Tighten down the muffler Reassemble remaining parts in reverse order Tightening torques LQ 3 5 Continue with pressure test 8 2 3 MS 192 T 8 2 3 Pressure test Carry out the same preparations as for the vacuum test 8 2 2 217RA067 TG Connect pressure hose 1 of tester 1106 850 2905 to nipple arrow lt gt 2 S Close vent screw 1 on the rubber bulb 0 E o t qL a Pump air into the crankcase with the rubber bulb until the gauge arrow indicates a pressure of 0 5 bar If this pressure remains constant for at least 20 seconds the crankcase is airtight If the pressure drops the leak must be located and the faulty part replaced To find the leak coat the suspect area with oil and pressurize the crankcase Bubbles will appear if a leak exists After finishing the test open the vent screw and disconnect the hose of tester 1106 850 2905 Continue with vacuum test 8 2 2 29 8 3 Oil Seals 217RA085 TG Use oil seal 1 9639 003 1206 for installation on the closed crankcase Use oil seal 2 9639 003 1205 for installation on the open crankcase It is not necessary to disassemble the complete engine in order to replace the oil seals Ignition side Remove fan housing 10 2 Remove the fl
31. e that the spring locates on the nipple of the inlet control lever Press the inlet control lever down and secure it with the screw Check that the inlet control lever moves easily Install the metering diaphragm 14 3 1 MS 192 T 14 3 3 Fixed Jet F Ml 217RA221 T Remove the metering diaphragm 14 3 1 Unscrew the fixed jet 1 with a suitable screwdriver Take care not to damage the jet Examine the fixed jet and replace it if necessary Reassemble parts in reverse order MS 192 T 14 3 4 Pump Diaphragm 217RA222 TG Remove the carburetor 14 2 Remove the screw arrow 217RA223 TG Carefully remove the end cover 1 217RA225 TG Carefully separate the pump diaphragm 1 and gasket 2 The diaphragm material is subjected to continuous alternating stresses and eventually shows signs of fatigue In other words the diaphragm distorts and swells and must be replaced Examine the pump diaphragm for signs of damage and wear replace the gasket Inspect the fuel strainer for contamination and damage clean or replace it if necessary Carefully remove the gasket with pump diaphragm from the carburetor body Pull the fuel strainer 1 out of the carburetor body with a needle and clean or replace it Reassemble parts in reverse order 77 217RA226 TG Fit the gasket 1 and secure it with
32. e the limiter cap 1 off the high speed screw with tool 5910 890 4501 Always fit a new limiter cap 217RA212 TG Take out the high speed screw 1 o o N lt iva Examine the tip arrow for signs of damage or wear Replace the high speed screw if necessary Reassemble parts in reverse order Adjust the high speed screw 14 4 1 MS 192 T 14 4 Carburetor Adjustment 14 4 1 Basic Setting Only necessary if the high speed screw H or low speed screw L has to be replaced or for cleaning and setting the carburetor Remove the limiter cap from the high speed screw 14 3 8 The basic setting must be made after removing the limiter cap oO y D 3 lt c Turn the high speed screw H 1 clockwise until it is firmly in its seat Turn the high speed screw H 1 anticlockwise until it is one turn open Turn the low speed screw L 2 clockwise until it is firmly in its seat Turn the low speed screw L 2 anticlockwise until it is one turn open MS 192 T Check air filter clean or replace if necessary 14 1 Check the chain tension Check the spark arresting screen if installed clean or replace if necessary 8 1 Let the engine warm up Set idle speed with a speed tester Set the specified speeds within the tolerance range of 200 rpm 1 Set the speed to 3500 rpm with the idle speed adjusting screw
33. ease 16 Do not grease the brake band 217RA039 TG Attach the brake band 1 to the brake lever arrow Insert the brake band 1 in the opening arrow o a x S lt x N The turns of the brake spring must lie tightly against one another when relaxed If this is not the case replace the brake spring Check correct position of the protective tube a 31 mm b 44 mm oO f S t S q iva N Attach the brake spring 1 to the brake lever arrow MS 192 T Use the assembly tool 2 1117 890 0900 to attach the brake spring 1 to the anchor pin arrow Reassemble remaining parts in reverse order Before fitting the sprocket cover pull the hand guard up until it engages The chain brake is now open and can be slipped over the sprocket Check operation of the chain brake 7 MS 192 T 7 2 Chain Tensioner Remove the sprocket cover and bar and chain 5 1 Troubleshooting EA 4 2 217RA044 TG Turn the spur gear 2 clockwise until the tensioner slide 1 makes contact on the right and the screw arrow is revealed o o S lt Remove the screw arrow Pull the complete chain tensioner 1 out with a suitable tool 217RA047 TG Examine the thrust pad 1 spur gear 2 adjusting screw 3 and tensioner slide 4 and replace if necessary 217RA048 TG Pull the thrust pad 1 off t
34. er 8 4 1 Disconnect the short circuit line 1 Connect the ohmmeter to ground arrow and the short circuit wire 1 Set the switch shaft to 0 The resistance measured must be about 0 Q If it is much higher the reason is a break in the wire and it must be replaced 9 6 Set the switch shaft to T The resistance measured must be infinitely high otherwise fit a new short circuit wire 9 6 If no fault can be found carry out further checks Check the flywheel 9 5 Check the air gap between flywheel and ignition module 9 1 1 If neither of these checks reveals a fault install a new ignition module 9 1 1 Reassemble parts in reverse order 47 9 6 2 Removing and installing Remove fan housing 10 2 Remove the handle moulding and actuating levers 12 1 Remove the switch shaft 12 3 Remove the cover 1 Take out the screw arrow and remove the ground wire 2 Disconnect the short circuit line 1 48 Remove the cable guide arrow 217RA320 TG Remove the cable guides arrows Ca lt NZ Cesk A SES 217RA318 TG Remove the contact springs arrows from the handle housing 217RA329 TG Examine the wiring harness 1 contact spring 2 contact spring 3 and grommets arrows and replace if necessary For safety reasons contact spring 3 may only be replaced together with the wir
35. ess it firmly into the clutch shoe 217RA020 TG The tips of the retainers arrows must match one another on the side with the raised hexagon and the series numbers must be visible on the clutch shoes 19 217RA084 TG Fit the clutch on the crankshaft stub so that the raised hexagon arrow is visible Screw the clutch 1 with hexagon arrow onto the crankshaft stub and tighten it down Tightening torques GQ 3 5 Pull the locking strip out of the cylinder Reassemble remaining parts in reverse order 20 6 1 Sprocket Clutch Drum 217RA023 TG Remove the clutch 6 Draw the sprocket 1 off the crankshaft stub 217RA024 TG Remove the needle cage 1 from the sprocket Clean the needle cage and crankshaft stub with standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons 148RA101 VA Examine the sprocket 1 for signs of wear If there are distinct signs of wear on the inside diameter of the sprocket 1 the remaining thickness must be measured The sprocket must be replaced if less than 80 of the original thickness remain Reassemble parts in reverse order oO o a 3S lt iva N Grease the needle cage and crankshaft stub 16 Slip the needle cage 1 onto the crankshaft stub MS 192 T 217RA059 TG Slip sprocket 1 onto crankshaft stub
36. ff 1 4 turn Saw chain rotates at idle speed Make standard setting Turn the idle speed screw LA anticlockwise until the saw chain stops then give it another 1 4 turn in the same direction Erratic idling behaviour poor acceleration Make standard setting Idle setting too lean e g at low ambient temperatures Turn the low speed screw L anticlockwise until the engine runs and accelerates smoothly Itis usually necessary to change the setting of the idle speed adjusting screw LA after every correction to the low speed adjusting screw L MS 192 T Correcting the carburetor setting for use at high altitudes The setting may have to be marginally corrected if the engine performance is unsatisfactory at high altitudes Check the standard setting Let the engine warm up Turn the high speed screw H clockwise leaner max up to the stop The screws should be adjusted as little as possible The slightest adjustment produces a tangible difference in engine behaviour If you make the setting too lean it will increase the risk of engine damage through lack of lubrication and overheating If the adjustments do not yield any improvement refer also to the troubleshooting chart for ignition system carburetor and power unit 4 6 MS 192 T 14 5 Intake Elbow Removing and Installing Remove the air filter 14 1 Remove the filter base 14 1 1 Remove the carburet
37. g AV Spring between Handle Housing Engine Housing Clamp Loop 12 Actuating Levers 12 1 Throttle Trigger Interlock Lever Throttle Rod 12 2 Double Lever 12 3 Switch Shaft 12 4 Handle Housing 13 Chain Lubrication 13 1 Pick up Body 13 2 Oil Suction Hose 13 3 Oil Pump 13 4 Valve 13 5 Oil Tank Filler Cap STIHL 60 60 61 62 63 ANDREAS STIHL AG amp Co KG 2005 Contents 14 14 1 14 1 1 14 2 14 2 1 14 3 14 3 1 14 3 2 14 3 3 14 3 4 14 3 5 14 3 6 14 3 7 14 3 8 14 4 14 4 1 14 4 2 14 5 15 16 Fuel System Air Filter Air Filter Base Carburetor Removing and Installing Leakage Test Carburetor Repair Metering Diaphragm Inlet Needle Fixed Jet Pump Diaphragm Choke Shaft Choke Shutter Throttle Shaft Throttle Shutter Accelerator Pump Adjusting screws Carburetor Adjustment Basic Setting User Setting Intake Elbow Removing and Installing Impulse Hose Tank Vent Testing Removing and Installing Fuel Intake Pick up Body Fuel Hoses Fuel Pump Fuel Tank Filler Cap Tank Housing Removing and Installing Special Servicing Tools Servicing Aids 94 96 MS 192 T 1 Introduction This service manual contains detailed descriptions of all the typical repair and servicing procedures for this power tool Refer to the illustrated spare parts lists during all repair work These lists show the installation position and order i
38. g 2 5 tensioner Nut M5 Filter base handle housing 1st stage 1 5 aluminium Nut M5 Filter base handle housing 1st stage 2 0 Nut M5 Filter base handle housing 2nd stage 2 5 aluminium Nut M5 Filter base handle housing 2nd stage 3 5 Screw P 6x19 Handle housing front handle 6 0 Screw P 4x12 Handle moulding handle housing 1 5 Screw P 6x19 Retaining plate loop engine housing 6 0 Screw DG 5x20 Engine pan cylinder 8 0 Screw P 5x16 Bearing plug handle housing 4 0 Screw P 5x16 Bearing plug engine housing sprocket 4 0 side Screw P 5x16 Bearing plug engine housing fan side 4 0 Screw P 5x16 Fan housing engine housing 4 0 M 8x1 L Carrier 25 0 Screw DG 5x20Z Engine housing cylinder 8 0 Screw DG 4x20 Oil pump engine pan 4 5 Screw P 4x12 Annular buffer support engine housing 2 5 Screw P 5x29 6 Annular buffer handle housing 5 0 Screw DG 5x20 Muffler cylinder 9 0 Nut M 8X1 Flywheel crankshaft 18 0 M 14x1 25 Spark plug 25 0 Screw DG 4x20 Ignition module cylinder 4 5 6 MS 192 T Use the following procedure when refitting a DG screw in an existing thread Place the screw in the hole and rotate it anticlockwise until it drops down slightly Tighten the screw clockwise to the specified torque This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly Screwdriver speed when used in plastic material DG screws max 500 rpm MS 192 T 4 Troubleshooting
39. he adjusting screw 25 217RA049 TG Pull the spur gear 1 out of the hole in the cover 2 217RA050 TG Turn the adjusting screw arrow until the tensioner slide has been unwound completely oO E ib 3 lt ira Remove the adjusting screw 1 from the cover 2 26 217RA052 TG Clean all disassembled parts with a little standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Replace any damaged or worn parts Always replace the adjusting screw and spur gear together Ensure that the parts are installed in the correct order Check correct functioning Coat the threads and gear wheels with STIHL multi purpose grease 16 Reassemble remaining parts in reverse order Check correct functioning again 7 3 Bar Mounting Stud 217RA053 TG Remove the sprocket cover and bar and chain 5 1 Fit the stud puller on the collar stud 1 oO st ry q ir N Push the stud puller 1 5910 893 0501 over the collar stud as far as possible and unscrew the collar stud anticlockwise Reassemble parts in reverse order Fit the collar stud and tighten it down firmly Tightening torques 3 5 Reassemble remaining parts in reverse order MS 192 T 8 Engine 8 1 Muffler Spark Arresting Screen Check and if necessary repair the fuel supply carburetor air filter and ignition sys
40. he sealing plate 1 0000 855 8106 between the muffler and cylinder exhaust port and tighten down the screws moderately The sealing plate must fill the full width between the screws Remove the carburetor 14 2 28 pee es Th 217RA063 TG e Ensure that the sleeve 1 and washer 2 are in place 217RA064 TG Remove the socket head screw 1 from the test flange 1128 850 4200 oO o 3 lt fd Fit the test flange 1128 850 4200 1 Screw on the nuts arrows and tighten them down firmly 8 2 2 Vacuum test Oil seals tend to fail when subjected to a vacuum In other words the sealing lip lifts away from the crankshaft during the piston s induction stroke because there is no internal counterpressure An additional test can be carried out with the vacuum pump to detect this kind of fault 217RA067 TG Connect the suction hose 1 of the vacuum pump 0000 850 3501 to the nipple arrow 217RA069 TG Close the vent screw 1 Operate lever 2 until the pressure gauge arrow indicates a vacuum of 0 5 bar MS 192 T If the vacuum reading remains constant or does not decrease by more than 0 3 bar within 20 seconds it may be assumed that the oil seals are in good condition If the vacuum in the crankcase is reduced further the oil seals must be replaced After finishing the test open the vent screw and disconnect the hose Remove th
41. hutter opened too wide by idle speed screw LA Oil seals crankcase leaking Reset idle speed screw LA correctly Seal or replace oil seals crankcase Engine stops when idling Idle jet bores or ports blocked Idle jet too rich or too lean Setting of idle speed screw incorrect throttle shutter completely closed Clean the carburetor Set low speed screw L correctly Reset idle speed screw LA correctly Engine speed drops quickly under load low power Air filter dirty Throttle shutter not opened fully Tank vent faulty Fuel pick up body dirty Fuel strainer dirty Leak in fuel line between tank and fuel pump Setting of high speed screw H too rich Main jet bores or ports blocked Pump diaphragm damaged or fatigued Impulse hose damaged or kinked Clean the air filter Check linkage Clean tank vent or replace if necessary Clean the pick up body or replace if necessary Clean fuel strainer in carburetor or replace if necessary Seal connections or install a new fuel line Turn the high speed screw H clockwise leaner max up to the stop Clean the carburetor Fit new pump diaphragm Fit new impulse hose 14 MS 192 T 4 7 Engine Always check and if necessary repair the following parts before looking for faults on the engine Air filter Fuel system Carburetor Ignition System Problem Cause Remedy Engine does not start easily
42. ignition module 1 and flywheel 2 42 9 1 Ignition Module 217RA325 TG The ignition module accommodates all the components required to control ignition timing There are two electrical connections on the coil body High voltage output 1 with permanently fitted ignition lead Connector tag 2 for the short circuit wire Testing in the workshop is limited to a spark test A new ignition module with ignition lead must be installed if no ignition spark is obtained after checking that the wiring and stop switch are in good condition 9 1 1 Ignition timing is fixed and cannot be adjusted during repair work Since there is no mechanical wear in these systems ignition timing cannot get out of adjustment during operation 9 1 1 Removing and installing 217RA087 TG Take out the screws arrows and remove the fan housing 1 with rewind starter Turn the twist lock arrow anticlockwise to release it and remove the carburetor box cover 1 YY 217RA009 TG Apply a suitable tool to the tab arrow to prise the boot off the spark plug 1 MS 192 T Disconnect the short circuit line 1 Remove the screw arrow Disconnect the ground wire 2 Remove the screw arrow Remove the cable guide arrow MS 192 T 217RA102 TG Remove the ignition module 1 and cable guide arrow for the ignition lead 2 Pull the ig
43. ine 1 out MS 192 T 217RA302 TG Pull the fuel return line 1 out of the guides and flange arrow 217RA349 TG Pull the fuel hose 1 out of the hose on the fuel pump N 217RA307 TG Pull the elbow connectors 3 off the hoses Check the fuel hose 1 fuel return line 2 and elbow connectors 3 and replace them if necessary Reassemble parts in reverse order 217RA287 TG Pull the fuel suction hose 1 out of the tank Examine the fuel suction hose and replace it if necessary 217RA288 TG Push the fuel suction hose 1 into the hole in the fuel tank 217RA303 TG N Pull the fuel hose 1 out of the guides and flange arrow MS 192 T Remove the pick up body 14 7 1 Prise off the flange 1 with a suitable tool Align the flange 1 and press it into the fixture on the housing until it rests against the housing 91 Use hook 5910 893 8800 to pull the fuel suction hose 1 out of the fuel tank Take care not to overextend the fuel hose Fit the pick up body 14 7 1 Reassemble remaining parts in reverse order o Fe a qL a Remove the tank vent 1 92 217RA317 TG Disconnect the tank vent 1 from the hose 2 Pull the hose 2 out through the opening in the handle housing 217RA304 TG 14 8 1 Fuel Pump 217RA304 TG Remove the air filter 14 1 Remove
44. ing harness 217RA319 TG Plug the contact spring 1 into the terminal socket of the wiring harness Place the contact springs in the guides arrows MS 192 T g hd Fit the switch shaft 1 pushing the rear contact spring 3 slightly to the side Check operation The contact springs are fitted in the handle housing at different depths This means that the rear contact spring 3 and the front contact spring 2 must make contact with the metal pin of the switch shaft when the switch shaft 1 is in position 0 Reassemble parts in reverse order Set the air gap between ignition coil and flywheel 9 1 1 Reassemble remaining parts in reverse order Tightening torques 3 5 MS 192 T 49 9 7 50 Troubleshooting Ignition System Engine does not run Stop switch in position Check spark plug Smeared with oil black Sooted Electrode gap correct Contacts shorted Clean adjust or replace the spark plug 9 3 Check spark plug boot Firmly seated on spark plug leg spring Leg spring hook in centre of ignition lead Spark plug boot damaged Replace spark plug boot and or leg spring if necessary 9 4 Check ignition with ZAT 3 or ZAT 4 use ZAT 3 as main spark gap see TI 32 94 9 2 and 9 3 MS 192 T MS 192 T
45. is located in the groove in the starter post Then slide the straight part of the spring over the starter post until it engages in the groove Tension the rewind spring 2 10 6 Grease the pegs of the pawls 16 10 5 Starter Rope Grip Remove the fan housing 10 2 Relieve the tension of the rewind spring and remove the rope rotor 10 4 The rewind spring will not be under tension if the starter rope is broken Remove any remaining scraps of rope from the rope rotor and starter grip Tie one of the two special knots shown above at the end of the rope in the starter grip 55 217RA255 TG Machines with standard starter grip Thread the new rope 1 through the side of the starter grip 217RA256 TG Machines with ElastoStart starter grip Prise off the cap 1 witha suitable tool 217RA354 TG 217RA356 TG Pull the rope 1 with spring and sleeve into the starter grip Press the cap into the starter grip Pull the rope out and continue threading it into the starter grip from the top Pull the rope through the grip until the knot at the end of the rope is in the recess arrow Pull the rope or remaining rope 1 out of the sleeve oO E 19 re cS lt a Pull the rope 1 through the sleeve into the starter grip Tie a special knot in the end of the rope Then thread the rope 1 through the openi
46. kshaft stub and tapers in flywheel 96 MS 192 T
47. n in the illustration Position the anchor loop in the fixture arrow 217RA276 TG Fit the rewind spring 1 ina circular fashion working in clockwise direction Hold the inserted loops securely to prevent them slipping out again MS 192 T 4 Yom cit Arrange the inner loop arrow with suitable pliers so that it is slightly angled against the starter post Install the rope rotor 10 4 Reassemble remaining parts in reverse order MS 192 T 10 8 Starter Rope Guide Bushing Wear on the guide bushing is accelerated by the starter rope being pulled sideways The wall of the bushing eventually wears through and the bushing becomes loose Remove the fan housing 10 2 Relax the rewind spring and remove the starter rope and rope rotor 10 4 Use a suitable tool to remove the damaged guide bushing from the fan housing Place the new guide bushing 1 in the hole in the fan housing Insert the screw spindle 1 of the installing tool 0000 890 2201 through the guide bushing from inside the housing Fit the thrust sleeve 1 and hex nut 2 Tighten down the hex nut steadying the screw 3 until the bushing is firmly seated The installing tool flares the lower end of the rope bushing Remove the installing tool Reassemble remaining parts in reverse order 59 11 Repairing the AV System
48. n the window 3 check the ignition system with the aid of the troubleshooting chart 9 7 MS 192 T 9 4 Ignition Lead Spark Plug Boot The ignition lead cannot be replaced separately as it is permanently connected to the ignition module Remove the ignition module 9 1 1 Pull the spark plug boot 1 with ignition lead arrow out of the engine housing towards the ignition module oO re fez 3 lt a Remove the cover 1 from spark plug boot Use suitable pliers to pull the torsion spring out of the spark plug boot Unhook the torsion spring from the ignition lead Pull the boot off the ignition lead 217RA326 TG Examine the ignition lead 2 ignition module 3 and grommet 1 and replace if necessary Ignition lead and ignition module can only be replaced as a complete unit 45 Use a pointed tool to pierce the centre of the new lead s insulation about 15 mm from the end of the ignition lead Pinch the hook of the torsion spring into the centre of the ignition lead arrow Coat the inside of the spark plug boot with STIHL Press Fluid 16 Push the ignition lead and torsion spring into the spark plug boot 46 217RA327 TG e Ensure that the torsion spring engages in the opening arrow 217RA095 TG Slide the cover 1 over the spark plug boot Do not use either graphite grease or silicone insula
49. n which the individual parts and modules should be assembled Refer to the latest edition of the relevant parts list to check the part numbers of any replacement parts required A fault on the machine may be due to several causes To help locate the fault consult the chapter on Troubleshooting and the STIHL Service Training System for all function groups Refer to the Technical Information bulletins for engineering changes which have been introduced since publication of this service manual Technical information bulletins also supplement the parts list and service manual until an updated edition is issued MS 192 T The special tools mentioned in the descriptions are listed in the chapter Special Servicing Tools of this manual Use the part numbers to identify the tools in the STIHL Special Tools manual It lists all the special servicing tools currently available from STIHL Symbols are included in the text and pictures for greater clarity The meanings are as follows In the text e Action to be taken as shown in the illustration above the text Action to be taken but not shown in the illustration above the text In the illustrations tem pointer short gt Direction of movement long arrow 4 2 Reference to another chapter i e to chapter 4 2 in this case Service manuals and technical information bulletins are intended exclusively for the use of properly equipped re
50. ng arrow Thread the rope 1 into the rope rotor arrows MS 192 T 217RA254 TG Secure the rope 1 with a simple overhand knot Pull the rope into the rope rotor until the knot rests in the recess arrow in the rope rotor Install the rope rotor and tension the rewind spring 10 4 Install the fan housing 10 2 Tightening torques 3 5 MS 192 T 10 6 Tensioning the Rewind Spring 217RA259 TG Remove the fan housing 10 2 Pull out part of the rope 1 between rope rotor 2 and fan housing Turn the rope rotor with rope six times clockwise The rope twists as the rope rotor and 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 oO a lt ira Hold the rope rotor 2 steady Pull out the rope 1 with the starter grip and straighten it out 217RA261 TG Hold the starter grip firmly to keep the rope 1 tensioned Letgo of the rope rotor and let the starter rope rewind slowly oO E o D N lt ira N The rewind spring is correctly tensioned when the starter grip sits firmly in the rope guide bushing arrow without drooping to one side If this is not the case the spring must be tensioned by one additional turn When the starter rope is fully extended it must still be possible t
51. ng the impulse hose ensure that the spring is actually in the hose to prevent it buckling Lubricate the ends of the impulse hose with STIHL Press Fluid 16 217RA348 TG Guide the impulse hose 1 through the opening arrow on the engine housing and push it onto the stub on the handle housing 87 217RA157TG Connect the impulse hose 1 to the stub arrow Reassemble remaining parts in reverse order Ensure that the impulse hose is routed correctly and without kinking 88 14 6 Tank Vent 14 6 1 Testing A pressure equilibrium must always prevail between the inside of the fuel tank and the surrounding atmosphere to permit troublefree operation of the carburetor This is ensured by the tank vent If problems develop in the carburetor or fuel supply the tank vent must always also be tested and replaced if necessary Correct functioning is determined by testing the fuel tank with negative pressure or gauge pressure via the fuel hose Remove the fan housing 10 2 Drain the fuel tank Ensure that the fuel is disposed of correctly and without harming the environment oO o 3S lt ita Remove the cover 1 Disconnect the fuel return line 1 and push the double nipple 2 0000 855 9200 into the flange arrow of the suction hose Testing with negative pressure Close the valve 1 and connect the vacuum pump 2 0000 850 3501 to the
52. nition lead with spark plug boot out of the engine housing A damaged ignition lead can only be replaced together with the ignition module Examine the spark plug boot and replace it if necessary LQ 9 4 Reassemble parts in reverse order Moderately tighten the screws on the ignition module Turn the flywheel until the magnet pole is lined up with the ignition module arrow Slide the setting gauge 1 4118 890 6401 between the arms of the ignition module and the magnet pole of the flywheel Press the ignition module against the setting gauge Tighten down the screws Tightening torques 3 5 Reassemble remaining parts in reverse order 43 9 2 Ignition Timing Ignition timing is fixed and cannot be adjusted during repair work Since there is no mechanical wear in these systems ignition timing cannot get out of adjustment during operation 44 9 3 Testing the Ignition Module To test the ignition module use either the ZAT 4 ignition system tester 5910 850 4503 or the ZAT 3 ignition system tester 5910 850 4520 The ignition test refers only to a spark test not to the ignition timing Using the ZAT 4 ignition system tester 5910 850 4503 Before starting the test install a new spark plug in the cylinder and tighten it down firmly Tightening torques 3 5 Connect the spark plug boot to the input te
53. nkshaft stub 1 Position the piston on the small end Apply the assembly drift 1 1114 893 4700 to the opposite side of the snap ring MS 192 T Remove the piston 1 from the connecting rod Inspect the piston rings and replace if necessary 8 7 Fit the assembly drift 1 1114 893 4700 small diameter first through the piston hole and small end needle cage and line up the piston 39 217RA136 TG Fit the piston pin 2 on the small diameter of the assembly drift 1 and slide it into the piston 217RA137 TG Remove the sleeve 1 from assembly tool 5910 890 2210 oO q oc oO X n Attach the snap ring 1 to the magnet 2 and align it so that the snap ring gap is on the flat side arrow 40 217RA138 TG Push the slotted diameter of the sleeve over the magnet and snap ring The inner pin 1 must point towards the flat face 2 of the tool s shank 217RA139 TG Press the assembly tool down in the sleeve until the magnet is at the end of the guide slits Stand the tool on a suitable surface wooden board Remove the sleeve and push it as far as possible over the opposite end of the assembly tool s shank The inner pin must point towards the flat face 217RA140 TG Apply assembly tool 5910 890 2210 to the piston boss with the taper sleeve hold the piston steady and press the tool shank home until the sna
54. nside of tank Flush out the oil tank Reassemble parts in reverse order The valve must be replaced if it still does not function properly after being cleaned Replacing the valve Remove the sprocket cover and bar and chain 5 1 Remove the oil tank cap Drain the oil tank Collect chain oil in a clean container or dispose of it properly at an approved disposal site MS 192 T 217RA193 TG Carefully drive the valve out of the tank wall into the tank with a drift dia 6 mm 217RA194 TG Remove the old valve from the oil tank 0 pad fey lt ita Ensure that the parts are installed correctly Carefully fit the valve in the hole in the engine housing MS 192 T 217RA196 TG Carefully drive the valve out into the hole in the engine housing with a drift dia 6 mm working from the outside 217RA339 TG e Fit a new valve in the hole a approx 8 10 mm Reassemble remaining parts in reverse order 13 5 Oil Tank Filler Cap 217RA311 TG Lift up the safety latch and unscrew the tank filler cap 1 Wh Prise the nipple out from inside the tank arrow oO o a lt ira a Examine the filler cap 1 cord and sealing ring 2 and replace if necessary The filler cap is supplied complete with cord and sealing ring 71 o E a a Fs a Press the nipple into the mount arrow insi
55. o FE o t qL E a The sprocket must engage the studs arrow of the wormwheel Reassemble remaining parts in reverse order MS 192 T 7 Checking Operation of Chain Brake The chain brake is one of the most important safety devices on the chainsaw Its efficiency is measured in terms of the chain braking time i e the time that elapses between activating the brake and the saw chain coming to a complete standstill The shorter the braking time the better the efficiency and protection offered against being injured by the rotating chain The coefficient of friction is impaired by contamination with chain oil chips fine particles of abrasion etc and smoothing of the friction surfaces on the brake band and clutch drum This in turn reduces the frictional forces and thus prolongs the braking time A fatigued or stretched brake spring has the same negative effect Start the engine With the chain brake activated locked open the throttle wide for a brief period max 3 seconds the chain must not rotate With the chain brake released open the throttle wide and activate the brake manually the chain must come to an abrupt stop The braking time is in order if deceleration of the saw chain is imperceptible to the eye If the chain brake does not operate properly see troubleshooting chart 4 2 7 1 Removing and Installing oO ite A 3 lt x oc a
56. o rotate the rope rotor at least another half turn before the maximum spring tension is reached otherwise the spring tension must be reduced it may break To reduce the spring tension Pull the rope out hold the rope rotor steady and take off one turn of the rope Install the fan housing 10 2 Tightening torques 3 5 57 10 7 Replacing the Rewind Spring Troubleshooting 4 4 The replacement spring is supplied ready for installation and secured in a frame Wear a face shield and protective gloves Remove the fan housing 10 2 Relieve the rewind spring if necessary and remove the rope rotor 10 4 Remove any fragments of the old spring Lubricate the spring with a few drops of STIHL special lubricant before installation 16 oO 2 D cS lt itd E Position the replacement spring with frame the anchor loop must be located over the fixture 1 58 Apply suitable tools screwdriver drift etc to the recesses and push the spring into its seat in the housing the spring slides out of the frame Remove the frame The rewind spring may pop out 217RA284 TG Ensure that the new rewind spring 1 is fitted completely and the anchor loop is positioned in the fixture arrow If the rewind spring pops out during installation fit it in the fan housing as follows 217RA275 TG Arrange the spring 1 as show
57. o overextend the suction hose 68 D 217RA188 TG Hold the suction hose with blunt pliers Pull the pick up body 1 off the suction hose 217RA340 TG D Flush out the oil tank Replace the pick up body Push the pick up body 1 into the suction hose and place it in the oil tank Reassemble remaining parts in reverse order 13 2 Oil Suction Hose Remove the sprocket cover and bar and chain 5 1 Remove the clutch 6 1 Remove the bumper strips 5 5 Unscrew the oil tank cap and drain the oil tank Remove the pick up body 13 1 217RA073 TG Take out the screws arrows Remove the cover 1 pulling the worm 2 off the crankshaft stub at the same time MS 192 T Pull the hose off the connector arrow on the oil pump Pull the suction hose 1 out of the engine housing 217RA192 TG e Use a suitable tool to press in the suction hose until the groove on the suction hose is lined up with the heel on the engine housing Use hook 5910 893 8800 to pull the suction hose 1 out of the oil tank 13 3 Oil Pump Inadequate lubrication of the bar and chain may be due to the oil pump if the pick up body suction hose and valve have been checked and found to be in order Remove the sprocket cover and bar and chain 5 1 Remove the clutch 6 1 Remove the bumper strips 5 5 217RA073 TG Take o
58. on rings 5 Flange 1128 850 4200 Leakage testing 6 Assembly tool 0000 890 2201 Flare the starter rope guide bushing 7 Carburetor and crankcase tester 1106 850 2905 Test crankcase and carburetor for leaks 8 Vacuum pump 0000 850 3501 Test crankcase for leaks test tank vent 9 Connector 0000 855 9200 Test carburetor for leaks 10 Hose for leakage test 1110 141 8600 Test carburetor for leaks 11 Puller 5910 890 4501 Remove limiter cap 12 Puller with No 3 1 jaws 5910 890 4400 Remove oil seals 15 Press sleeve 4112 893 2401 Press in oil seal 16 Assembly tube 1117 890 0900 Hook in clutch spring 17 Assembly hook 5910 890 2800 Detach springs from clutch shoes 19 Assembly tool 10 5910 890 2210 Fit hookless snap rings in piston 20 Setting gauge 4118 890 6401 Set the air gap between ignition module and flywheel 21 Assembly hook 5910 893 8800 Remove pick up body 22 Assembly stand 5910 890 3100 Hold chainsaw for servicing repairs 23 Clamping strip for assembly 5910 890 2000 Clamp machine to assembly stand stand 25 Puller 1116 893 0800 Remove flywheel 27 Ignition system tester ZAT 4 5910 850 4503 Test ignition system 28 Ignition system tester ZAT 3 5910 850 4520 Test ignition system 94 MS 192 T No Part name Part No Use Rem 29 Torque wrench 5910 890 0302 Screw connections 0 5 to 18 Nm 30 Torque wrench 5910 890 0312 Screw connections 6 to 80 Nm 31 Bit size 13 5910 893
59. or 14 2 Unscrew the rubber buffers 11 2 A damaged intake elbow may lead to impaired engine performance Troubleshooting 4 6 or 4 7 Remove the washer 1 Prise off the supporting plate 1 with a suitable tool o Ee o wo 3 lt iva Lift the handle housing and pull the elbow 1 off the cylinder Take the sleeve 1 out of the intake elbow Press the flange of the intake elbow out through the hole in the handle housing towards the cylinder Examine the intake elbow and replace it if necessary 85 217RA267 TG Before installing the intake elbow slide the supporting plate onto the elbow so that the rebate arrow and tab 1 face the carburetor o Ee o a lt ira To draw the elbow flange into the intake port of the tank housing wrap a piece of string 1 approx 15 cm long round the elbow and guide the ends of the string through the intake port Position the elbow on the handle housing 86 217RA269 TG Draw the ends of the string through the intake port with the elbow flange Coat with STIHL Press Fluid 16 In this way the elbow flange is fitted through the intake port of the tank housing without damaging it 217RA270 TG Ensure that the flange is correctly seated in the handle housing The tab on the elbow flange arrow must be aligned so that the hole is lined up wi
60. p ring slips into the groove The tool must be precisely aligned in axial direction of the piston pin o ge c NT The snap ring 1 must be fitted in such a way that the snap ring gap arrow does not coincide with the recess 2 MS 192 T Inspect the piston rings and replace if necessary 8 7 Inspect the ball bearings and replace if necessary LQ 8 5 3 Install the crankshaft 8 5 2 Install the engine 8 4 2 MS 192 T 8 7 Piston rings Remove piston 8 4 1 Remove piston rings from piston 217RA129 TG Use a piece of old piston ring to scrape the grooves clean oO 3 lt a Install the new piston rings in the grooves so that the radii at the ends of the rings arrows face towards the piston head oO E a lt x N Position the piston rings so that the radii at the ring gaps meet at the fixing pins arrows in the piston groove Check the correct installed position of the piston rings again arrows Install the piston 8 4 2 41 9 Ignition System Exercise extreme caution while carrying out maintenance and repair work on the ignition system The high voltages which occur can cause serious or fatal accidents Troubleshooting on the ignition system should always start with the spark plug 4 5 Remove the fan cover 9 1 1 The electronic ignition system basically consists of an
61. pair shops They must not be passed on to third parties oO o lt L oc Nn a Servicing and repairs are made considerably easier if the machine is mounted on assembly stand 3 5910 890 3100 For this purpose secure the clamp 2 5910 890 2000 to the assembly stand with two screws 1 Engage the adjusting screw and stud in the outer holes of the clamp and secure the chainsaw with the nut arrow The sprocket cover and bar and chain must be removed first pull the hand guard back against the front handle for this purpose Always use original STIHL replacement parts They can be identified by the STIHL part number STIHL og0 and the STIHL parts symbol amp 2 The symbol may appear alone on small parts 2 Safety Precautions Specific national safety regulations and the safety instructions in the instruction manual must be observed if the machine has to be started up during maintenance or repair work Petrol is highly inflammable and can also be explosive under certain conditions Improper handling may result in burns and other serious injuries Do not bring any fire flame spark or other source of heat near the fuel All work with fuel must be performed outdoors only Spilled fuel must be wiped away immediately MS 192 T 3 Specifications 3 1 Engine Displacement Bore Stroke Engine power to ISO 7293 Max permissible engine speed with bar and chain I
62. r must line up with the small bore in the carburetor body Tighten down the screw Check correct functioning and easy movement Secure the screw with Loctite 16 14 3 7 Accelerator Pump 217RA360 TG Remove the throttle shaft 14 3 6 Keep a finger over the hole arrow to prevent parts popping out 217RA361 TG Examine the pump piston 1 sealing ring 2 and spring 3 and replace if necessary oO E y 3 lt fd Press the pump piston with spring into the hole arrow before installing the throttle shaft 1 Reassemble remaining parts in reverse order 81 14 3 8 Adjusting screws 217RA197 TG There are three adjusting screws on the carburetor H High speed screw 1 L Low speed screw 2 LA Idle speed screw 3 If the carburetor setting can no longer be adjusted this may also be due to the adjusting screws Only the high speed screw has a limiter cap a new cap must always be used after dismantling the high speed screw Remove the carburetor 14 2 Refer also to troubleshooting on the carburetor 4 6 Low speed screw o FE 2 8 a qL a Take out the low speed screw 1 82 217RA210 TG Examine the tip arrow for signs of damage or wear Replace the low speed screw if necessary Reassemble parts in reverse order Adjust the low speed screw 14 4 High speed screw Pris
63. rd solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Grease the sealing lips of the oil seal 16 MS 192 T 8 4 Engine 8 4 1 Removal 217RA088 TG Apply sealing compound to the outside diameter of the oil seals 16 So that the oil seal can be pressed in as far as possible the flat side of the press sleeve arrow must be aligned with the shoulder on the crankcase Press in the oil seal 2 with press sleeve 1 4112 893 2401 Turn the crankshaft through several times after approx 1 minute Reassemble remaining parts in reverse order MS 192 T The complete engine must be removed before disassembling the piston or cylinder Remove the sprocket cover and bar and chain 5 1 Remove the muffler 8 1 Remove the clutch 6 Remove the oil pump 13 3 Remove fan housing 2 10 2 Remove the ignition module 9 1 Remove the flywheel 9 5 oO ie o 3S lt a Remove the cover 1 Remove the screw arrow Prise off the supporting plate 1 with a suitable tool 217RA109 TG Lift the handle housing 1 slightly and pull the manifold off the intake stub arrow 31 217RA072 TG 217RA106 TG 8 4 2 Installation Pull out the insulating plate 1 pressing the locking lug together at the bottom guide arrow 217RA104 TG Disconnect
64. rminal 1 Push the tester s output terminal 3 onto the spark plug High voltage risk of electrocution Crank the engine quickly with the rewind starter and check sparkover in the window 2 of the ignition system tester The engine may start and accelerate during the test If a spark is visible the ignition system is in order If no spark is visible in the window 2 check the ignition system with the aid of the troubleshooting chart 9 7 376RA134 TG Using the ZAT 3 ignition system tester 5910 850 4520 Before starting the test install a new spark plug and tighten it down firmly Tightening torques 3 5 Connect the spark plug boot to the terminal 2 Attach ground terminal 1 to the spark plug Use adjusting knob 4 to set the spark gap to approx 2 mm see window 3 MS 192 T oO pa o oO lt x oc 6 N oO While using the ZAT 3 hold it only by the handle 4 or position it ina safe place Keep fingers or other parts of your body at least 1 cm away from the spark window 3 high voltage connection 2 ground connection 5 and the ground terminal 1 High voltage risk of electrocution Crank the engine quickly with the rewind starter and check sparkover in the window 3 of the ignition system tester The engine may start and accelerate during the test If a spark is visible the ignition system is in order If no spark is visible i
65. rope cannot be pulled out far enough Rewind spring overtensioned Check rewind spring and reduce tension Starter rope can be pulled out almost without resistance crankshaft does not turn Guide peg on pawls or pawls themselves are worn Spring clip fatigued Fit new pawls Fit new spring clip Starter rope is difficult to pull and rewinds very slowly Starter mechanism is very dirty Thoroughly clean complete starter mechanism MS 192 T 11 4 5 Ignition System Exercise extreme caution while carrying out maintenance and repair work on the ignition system The high voltages which occur can cause serious or fatal accidents Problem Cause Remedy Engine runs roughly misfires temporary loss of power Spark plug boot is loose Spark plug sooted smeared with oil Incorrect air gap between ignition module and flywheel Flywheel cracked or has other damage or pole shoes have turned blue Ignition timing wrong flywheel out of adjustment key in flywheel has sheared off Weak magnetization in flywheel pole shoes have turned blue Irregular spark Crankcase damaged cracks Press boot firmly onto spark plug and fit new spring if necessary Clean the spark plug or replace if necessary Set air gap correctly Install new flywheel Install new flywheel Install new flywheel Check operation of switch shaft and ignition module Faulty insulation on ignition lead or short
66. stalls at idle speed but operates normally at full throttle Oil seals in crankgear damaged Crankcase leaking or damaged cracks Replace the oil seals Seal or replace the crankcase Engine does not deliver full power or runs erratically Piston rings worn or broken Muffler spark arresting screen carbonized Air filter dirty Fuel impulse hose severely kinked or damaged Replace piston rings Clean the muffler inlet and exhaust replace spark arresting screen replace muffler if necessary Replace air filter Fit new hoses and route them without kinks Engine overheating Insufficient cylinder cooling Air inlets in fan housing blocked or cooling fins on cylinder very dirty Thoroughly clean all cooling air openings and the cylinder fins MS 192 T 15 5 Chain Spiked Bumper 5 1 Chain and Chain Guide p 217RA003 TG Wear protective gloves risk of injury Disengage the chain brake by pulling the hand guard 1 towards the front handle until it engages Unscrew the hex nut arrow Turn the screw anticlockwise to relax the chain oO S S T ira Nn a Unscrew the nut arrow and remove the sprocket cover 1 16 217RA002 TG Slide the guide bar 1 towards the clutch and remove the chain from the guide bar Remove the guide bar 1 Remove the chain 2 via the sprocket Reassemble parts in reverse order 217RA021 TG Fit
67. t meshes with the semi circular recess in the choke lever 217RA180 TG Remove the filter base 1 Push out the grommet 1 examine it and replace it if Examine the filter base and necessary replace it if necessary Reassemble parts in reverse Before installing the filter base order lubricate the sealing ring on the carburetor connector with STIHL Press Fluid 16 Reassemble parts in reverse order Ensure that the air filter rests uniformly on the filter base all round oO o E oO wo N N lt lt c ir N N N Pull the choke lever 1 off the Disconnect the fuel hose 1 from choke shaft the carburetor arrow MS 192 T 73 217RA176 TG Carefully draw the carburetor off the fuel return line and stud bolts until the rods appear 217RA177 TG Unhook the rod 1 from the carburetor arrow and remove the carburetor Reassemble parts in reverse order Tightening torques 3 5 Check correct functioning 74 14 2 1 Leakage Test The tank vent must also be checked and cleaned if problems develop with the carburetor or fuel supply 14 6 2 The carburetor can be tested for leaks with the carburetor and crankcase tester 1106 850 2905 Disconnect the fuel hose from the carburetor and remove the carburetor 14 2 143RA172 VA Push the fuel line 1 1110 141 8600 onto the double connector 2 0000 855 9200 oO o R
68. t stub 1 is on the side of the cylinder exhaust port arrow 36 217RA085 TG Use oil seal 1 9639 003 1206 for installation on the closed crankcase Use oil seal 2 9639 003 1205 for installation on the open crankcase 217RA149 TG Slip new oil seals onto the crankshaft stub with the open side facing the crankshaft 217RA150 TG Apply sealing compound to the outside diameter arrows of the oil seals 16 217RA151 TG Fit the crankshaft with bearings and oil seals in the bearing guides on the cylinder taking care to ensure that the oil seals are flush arrow 217RA147 TG Check and clean the mating faces on the engine pan Mating faces must be absolutely clean and undamaged Parts with damaged mating faces must be replaced Apply sealing compound to the groove on the circumference arrows 16 MS 192 T 217RA148 TG Place the engine pan on the sealing surface of the cylinder ensuring that the lug arrow faces the cylindrical crankshaft stub 1 217RA111 TG So that the sealing compound is distributed uniformly fit the screws and gently press the engine pan down Tighten the screws arrows down crosswise Tightening torques 3 5 Avoid damage to the crankshaft stub Clean the crankshaft stub with standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons
69. tem before looking for faults on the engine Troubleshooting G 8 1 Remove the sprocket cover and bar and chain 5 1 217RA055 TG Remove the screw arrow oO Ee o D 3 lt ira a Remove the cover plate 2 and spark arresting screen 1 if fitted Clean the spark arresting screen 1 or replace if necessary MS 192 T Take out the screws arrows Remove and examine the muffler replace if necessary Clean the sealing faces A gasket is not fitted between muffler and cylinder Reassemble parts in reverse order 217RA057 TG 217RA061 TG 8 2 Leakage test Defective oil seals and gaskets or cracks in housing are the usual causes of leaks Such faults allow supplementary air to enter the engine and upset the fuel air mixture This makes adjustment of the prescribed idle speed difficult if not impossible Moreover the transition from idle speed to part or full throttle is not smooth Always start with the vacuum test and then continue with the pressure test The crankcase can be thoroughly checked for leaks with the carburetor and crankcase tester and the vacuum pump 27 8 2 1 Preparations Remove the sprocket cover and bar and chain 5 1 Set the piston to the top dead centre This can be checked through the inlet port Fit the spark plug and tighten it down firmly Undo the screws arrows Fit t
70. th the opening in the handle housing The tab on the elbow flange must not cover the opening in the handle housing otherwise the impulse hose will not operate correctly 217RA263 TG Push the elbow 1 onto the intake port arrow Ensure that the elbow 1 completely encloses the intake port MS 192 T WW 217RA272 TG Fit the supporting plate 1 so that the tab arrow points upwards and towards the chain a oO E o R A lt ira Press the supporting plate home completely until it rests against the engine housing all round arrows Reassemble remaining parts in reverse order Tightening torques 3 5 MS 192 T 14 5 1 Impulse Hose 217RA335 TG A damaged impulse hose may lead to impaired engine performance Remove the fan housing 10 2 Remove the flywheel 9 5 Unscrew the rubber buffers on the handle housing 11 1 Remove the carburetor 14 2 Push the intake elbow out of the handle housing 14 5 Troubleshooting 4 6 or 4 7 The impulse hose is shown on the handle housing after disassembly for clarity 0 foe D A lt a Disconnect the impulse hose 1 from the stub arrow of the handle housing Disconnect the impulse hose 1 from the stub arrow Pull the impulse hose out of the engine housing Examine the impulse hose and replace it if necessary When installi
71. the circlip arrow with a suitable tool 217RA203 TG Before pulling out the throttle shaft secure the pump piston to prevent it popping out 14 3 7 Unhook and relax the torsion spring arrow Pull the throttle shaft 1 with torsion spring out of the carburetor body Clean the throttle shaft and guides Examine the throttle shaft for signs of damage and replace it if necessary Examine the torsion spring and replace it if necessary 217RA204 TG Install the torsion spring Ensure that the torsion spring is fitted correctly arrow 217RA205 TG Turn the torsion spring 1 roughly a half turn in clockwise direction with a suitable tool to prestress it Push the pump piston into the bore of the carburetor with a suitable tool 14 3 7 Push the throttle shaft 2 with prestressed torsion spring into the carburetor body MS 192 T 217RA331 TG Position the prestressed torsion spring so that it rests against the shoulder arrow of the carburetor body 217RA206 TG Install the circlip 217RA207 TG Fit the throttle shutter 1 with the dent 3 on the left and the number 2 visible on the right MS 192 T 217RA208 TG Insert the screw 1 in the flat side of the shaft and tighten it down moderately Close the throttle shutter 2 and centre it in the bore of the carburetor body The notch arrow on the throttle shutte
72. the fan housing 10 2 Disconnect the fuel hose 1 Disconnect the fuel hose 1 from the fuel pump 217RA301 TG Disconnect fuel hose 1 and examine fuel hose 2 replace if necessary Reassemble parts in reverse order Press the tabs arrows together and push the fuel pump 1 out of the housing 217RA306 TG Examine the fuel pump and replace it if necessary Reassemble parts in reverse order MS 192 T 14 8 2 Fuel Tank Filler Cap Lift up the safety latch and unscrew the tank filler cap 1 Prise the nipple out from inside the tank arrow 0 a lt fd Examine the filler cap 1 cord and sealing ring 2 and replace if necessary The filler cap is supplied with cord and sealing ring the sealing ring is available separately MS 192 T Press the nipple into the mount arrow inside the tank Screw in the filler cap Test for leaks Reassemble remaining parts in reverse order 14 8 3 Tank Housing Removing and Installing The tank housing is integrated into the engine housing The complete engine housing must always be replaced if the fuel tank oil tank or engine housing is damaged 93 15 Special Servicing Tools No Part name Part No Use Rem 1 Locking strip 0000 893 5903 Block crankshaft 2 Sealing plate 0000 855 8106 Seal exhaust bore 4 Strap retainer 1137 893 2600 Tension the pist
73. the pegs arrows 217RA227 TG Place the diaphragm 1 over the gasket and secure it with the pegs arrows g o 2 r Position the end cover on the carburetor body from below so that the gasket and pump diaphragm remain secured to the end cover 78 217RA199 TG Turn the throttle shaft lever back and forth so that the end cover with stop pin arrow can be fitted without difficulty Gently move the end cover back and forth until the pegs on the end cover are lined up with the holes in the carburetor body Insert and tighten down the screw Tightening torques 3 5 14 3 5 Choke Shaft Choke Shutter 217RA266 TG Remove the carburetor 14 2 If actuation of the choke shaft is stiff and or the choke shutter cannot be opened or closed properly Remove the choke shaft then clean the shaft and shaft guides with a little standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons 217RA214 TG Remove the screw arrow from the choke shaft The screw thread may be damaged when it is removed Use a new screw MS 192 T Turn the choke shaft anticlockwise with a suitable tool and remove the choke shutter 1 217RA216 TG Take care that the ball and spring do not pop out when removing the choke shaft 1 Wear safety glasses Pull out the choke shaft 1 and clean it with the guides E
74. ting paste Install the ignition module 9 1 Reassemble remaining parts in reverse order 9 5 Flywheel 217RA087 TG Take out the screws arrows and remove the fan housing 1 with rewind starter Block the piston with the locking strip 6 Remove the flywheel nut arrow Remove the flywheel Use the puller if the flywheel is stuck Screw on the puller 1 1116 893 0800 but do not screw it tight and then tap the end of the puller lightly to release the flywheel MS 192 T Unscrew the puller 1 1116 893 0800 from the crankshaft stub Remove the flywheel 1 oO i a D 3 lt ira Flywheel and magnet poles arrows must not show any signs of damage or blue discoloration otherwise the flywheel must be replaced MS 192 T Degrease the crankshaft stub and bore in the flywheel hub with standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Reassemble parts in reverse order 217RA093 TG Ensure that the machined key arrow engages the slot in the crankshaft Set the air gap between ignition coil and flywheel 9 1 1 Reassemble remaining parts in reverse order Tightening torques 3 5 9 6 Short Circuit Wire 9 6 1 Testing Check the short circuit wire if the spark plug and ignition lead with spark plug boot are in order Remove the fan cov
75. ut the screws arrows oO E o lt ira a Push the smaller diameter of the new suction hose 1 into the hole in the engine housing MS 192 T 217RA340 TG Push the pick up body 1 into the suction hose and place itin the oil tank Reassemble remaining parts in reverse order Remove the cover 1 pulling the worm 2 off the crankshaft stub at the same time 69 217RA192 TG Pull the hose off the connector arrow on the oil pump 217RA341 TG Check the oil pump 1 and connector 2 and replace if necessary 217RA079 TG 13 4 Valve Cleaning the valve A valve is installed in the tank wall to keep internal tank pressure equal to atmospheric pressure Remove the sprocket cover and bar and chain 5 1 Remove the oil tank cap Drain the oil tank Collect chain oil in a clean container or dispose of it properly at an approved disposal site Remove the screw arrow oO o R S T ira a Remove the oil pump 1 pulling the connector 2 out of the recess in the engine housing 70 Slip the oil pump 1 over the crankshaft stub and press the nipple on the connector as far as possible into the recess arrow Reassemble remaining parts in reverse order Grease the worm before installing it 2 16 Tightening torques 3 5 Blow the valve arrow clear with compressed air from outside to i
76. w clutch Replace clutch springs Saw chain does not stop immediately when brake is activated Brake spring stretched or broken Brake band stretched worn or broken Clutch drum worn Fit new brake spring Fit new brake band Install new clutch drum MS 192 T 4 3 Chain Lubrication In the event of trouble with the chain lubrication system check and rectify other sources of faults before disassembling the oil pump Problem Cause Remedy Chain receives no oil Oil tank empty Fill up with oil Oil inlet hole in guide bar is blocked Clean oil inlet hole Intake hose or pick up body Fit new intake hose and pick up clogged or intake hose ruptured body Valve in oil tank blocked Clean or replace valve Worm worn Replace worm Oil pump damaged or worn Replace oil pump Machine losing chain oil Oil pump housing defective Replace oil pump Oil pump damaged or worn Replace oil pump Oil pump delivers insufficient oil Oil pump worn Replace oil pump 10 MS 192 T 4 4 Rewind Starter Problem Cause Remedy Starter rope broken Rope pulled out too vigorously as far as stop or over edge i e not vertically Normal wear Fit new starter rope Fit new starter rope Starter rope does not rewind Rewind spring broken Spring insufficiently tensioned Very dirty or corroded Replacing the rewind spring Check rewind spring and increase tension Clean or replace rewind spring Starter
77. xamine the choke shaft for signs of damage and replace it if necessary MS 192 T Examine the ball and spring and replace if necessary Ensure that the spring and ball are correctly fitted before installing the choke shaft Slide the choke shaft 1 into the carburetor body until it engages Turn the choke shaft until the flat area is visible Fit the choke shutter 1 with the hole 2 at the front The choke shutter 3 must be installed so that hole 1 is above and hole 2 axially parallel with the choke shaft Secure the screw with Loctite 16 Fit the new screw arrow in the shaft and tighten it moderately Close the choke shutter 3 and centre it in the bore of the carburetor body Tighten down the screw Check correct functioning and easy movement 79 14 3 6 Throttle Shaft Throttle Shutter If actuation of the throttle shaft is stiff and or the throttle shutter cannot be opened or closed properly Remove the carburetor 14 2 Troubleshooting on the carburetor 4 6 Remove the throttle shaft then clean the shaft and shaft guides with a little standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Remove the screw arrow oO 5 a lt ira a Turn the throttle shaft slightly Pull out the throttle shutter 1 80 Remove
78. ywheel 9 5 o E N N q oc Free off the oil seal in its seat by tapping it with a suitable tube or a punch Apply puller 5910 890 4400 with No 3 1 jaws 0000 893 3706 30 Clamp the puller arms Pull out the oil seal Avoid damage to the crankshaft stub Clean the sealing face with a little standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Grease the sealing lips of the oil seal M 16 Apply sealing compound to the outside diameter of the oil seals 16 Use the press sleeve 2 4112 893 2401 to install the oil sleeve 1 The seating face must be flat and free from burrs Turn the crankshaft through several times after approx 1 minute The crankshaft taper must be free from grease therefore clean it with a little standard solvent based degreasant not containing any chlorinated or halogenated hydrocarbons Reassemble remaining parts in reverse order Clutch side Remove the sprocket cover and bar and chain 5 1 Remove the clutch 6 Remove the oil pump 13 3 217RA070 TG Free off the oil seal in its seat by tapping it with a suitable tube or a punch Apply puller 5910 890 4400 with No 3 1 jaws 0000 893 3706 Clamp the puller arms Pull out the oil seal Avoid damage to the crankshaft stub Clean the sealing face with a little standa

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