stihl ms 192 t - ramcottage.co.uk

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stihl ms 192 t - ramcottage.co.uk
STIH)
STIHL MS 192 T
2005-02
Contents
1.
2.
Introduction
Safety Precautions
3
3.
Specifications
5
3.1
3.2
3.3
3.4
3.5
Engine
Fuel System
Ignition System
Chain Lubrication
Tightening Torques
5
5
5
5
6
4.
Troubleshooting
8
4.1
4.2
Clutch
Chain Drive,
Chain Brake, Chain
Tensioner
Chain Lubrication
Rewind Starter
Ignition System
Carburetor
Engine
8
4.3
4.4
4.5
4.6
4.7
5.
Chain/ Spiked
Bumper
Engine
8.1
8.2
8.2.1
8.2.2
8.2.3
8.3
8.4
8.4.1
8.4.2
8.5
8.5.1
8.5.2
8.5.3
8.6
8.6.1
8.6.2
8.7
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
27
27
28
28
29
30
31
31
32
34
34
35
37
39
39
39
41
11.1
11.2
11.3
9.
Ignition System
9.1
9.1.1
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
4
9
10
11
12
13
15
9.2
9.3
16
9.4
5.1
5.2
5.3
5.4
5.5
Chain and Chain
Guide
Tensioning the Chain
Chain Catcher
Bumper Spike
Bumper Strips
16
17
17
17
18
9.5
9.6
9.6.1
9.6.2
9.7
6.
Clutch
18
6.1
Sprocket /
Clutch Drum
20
7.
7.1
7.2
7.3
Checking Operation
of Chain Brake
21
Removing and
Installing
Chain Tensioner
Bar Mounting Stud
21
25
26
27
11.
8.
11.4
11.5
62
62
63
12.
Actuating Levers
63
12.1
12.2
12.3
12.4
Throttle Trigger /
Interlock Lever /
Throttle Rod
Double Lever
Switch Shaft
Handle Housing
63
64
65
66
42
13.
Chain Lubrication
68
42
13.1
13.2
13.3
13.4
13.5
Pick-up Body
Oil Suction Hose
Oil Pump
Valve
Oil Tank Filler Cap
68
68
69
70
71
42
44
45
46
47
47
48
50
53
10.1
10.2
General
Removing and
Installing
Pawls
Rope Rotor
Starter Rope / Grip
Tensioning the Rewind
Spring
Replacing the Rewind
Spring
Starter Rope Guide
Bushing
53
10.8
60
61
44
Rewind starter
10.7
60
Annular Buffer
Front Handle / Spring
AV Spring between
Handle Housing /
Engine Housing
Clamp
Loop
10.
10.3
10.4
10.5
10.6
Repairing the
AV System
53
54
54
55
57
58
59
q
© ANDREAS STIHL AG & Co. KG, 2005
MS 192 T
1
Contents
14.
Fuel System
72
14.1
Air Filter
14.1.1 Air Filter Base
14.2
Carburetor, Removing
and Installing
14.2.1 Leakage Test
14.3
Carburetor Repair
14.3.1 Metering Diaphragm
14.3.2 Inlet Needle
14.3.3 Fixed Jet
14.3.4 Pump Diaphragm
14.3.5 Choke Shaft / Choke
Shutter
14.3.6 Throttle Shaft /
Throttle Shutter
14.3.7 Accelerator Pump
14.3.8 Adjusting screws
14.4
Carburetor
Adjustment
14.4.1 Basic Setting
14.4.2 User Setting
14.5
Intake Elbow,
Removing and
Installing
14.5.1 Impulse Hose
14.6
Tank Vent
14.6.1 Testing
14.6.2 Removing and
Installing
14.7
Fuel Intake
14.7.1 Pick-up Body
14.8
Fuel Hoses
14.8.1 Fuel Pump
14.8.2 Fuel Tank Filler Cap
14.8.3 Tank Housing,
Removing and
Installing
72
73
15.
16.
2
73
74
75
75
76
77
77
78
80
81
82
83
83
84
85
87
88
88
89
89
89
90
92
93
93
Special Servicing
Tools
94
Servicing Aids
96
MS 192 T
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 in 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.
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:
: = 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:
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.
A Item pointer (short)
a Direction of movement (long
arrow)
b 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 repair shops. They must
not be passed on to third parties.
MS 192 T
2 1 1
3
217RA000 TG
1.
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
STIH) logo
and the
STIHL parts symbol (
The symbol may appear alone on
small parts.
3
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.
4
MS 192 T
3.
3.1
Specifications
Engine
MS 192 T
Displacement:
Bore:
Stroke:
Engine power to ISO 7293
Max. permissible engine speed
(with bar and chain):
Idle speed:
Clutch:
Clutch engages at:
Crankcase leakage test
at gauge pressure:
under vacuum
3.2
30.1 cm3
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
Fuel System
Carburetor leakage test at
gauge pressure:
Operation of tank vent at
gauge pressure:
Fuel:
3.3
0.3 bar
as specified in instruction
manual
Ignition System
Air gap between ignition
module and fanwheel:
Spark plug (suppressed):
Electrode gap:
3.4
0.8 bar
0.15...0.35 mm
NGK BPMR 7 A
0.5 mm
Chain Lubrication
Fully automatic, speed-controlled oil pump with rotary piston
Oil delivery rate:
MS 192 T
6.5 - 8.5 cm³ at 10,000 rpm
5
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
Screw
DG 4x15
Screw
Collar screw
Screw
Screw
D 6x13
DG 8x18
B 4.2x9.5
P 4x12
Nut
M5
Nut
Nut
M5
M5
Nut
Screw
Screw
Screw
Screw
Screw
Screw
M5
P 6x19
P 4x12
P 6x19
DG 5x20
P 5x16
P 5x16
Screw
Screw
P 5x16
P 5x16
M 8x1 L
DG 5x20Z
DG 4x20
P 4x12
P 5x29.6
DG 5x20
M 8X1
M 14x1.25
DG 4x20
Chain tensioner cover plate / engine
housing
Collar screw for guide bar, rear
Collar screw for guide bar, front
Cover plate/ screen/ muffler
Cover/ sprocket cover/ engine housing
tensioner
Filter base/ handle housing, 1st stage
aluminium
Filter base/ handle housing, 1st stage
Filter base/ handle housing, 2nd stage
aluminium
Filter base/ handle housing, 2nd stage
Handle housing/ front handle
Handle moulding/ handle housing
Retaining plate/ loop/ engine housing
Engine pan/ cylinder
Bearing plug/ handle housing
Bearing plug/ engine housing, sprocket
side
Bearing plug/ engine housing, fan side
Fan housing/ engine housing
Carrier
Engine housing/ cylinder
Oil pump/ engine pan
Annular buffer, support/ engine housing
Annular buffer/ handle housing
Muffler / cylinder
Flywheel/ crankshaft
Spark plug
Ignition module/ cylinder
Screw
Screw
Screw
Screw
Screw
Nut
Screw
6
Tightening
torque
Nm
Remarks
2,5
6,0
16,0
2,0
2,5
1,5
2,0
2,5
3,5
6,0
1,5
6,0
8,0
4,0
4,0
4,0
4,0
25,0
8,0
4,5
2,5
5,0
9,0
18,0
25,0
4,5
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
7
4.
4.1
Troubleshooting
Clutch
Problem
Cause
Remedy
Saw chain stops under load at full
throttle
Clutch shoes badly worn
Install new clutch
Clutch drum badly worn
Install new clutch drum
Idle speed too high
Readjust with idle speed screw LA
(anticlockwise)
Saw chain rotates at idle speed
Clutch springs stretched or fatigued Replace clutch springs or install
new clutch
Clutch spring hooks broken
Loud noises
8
Replace clutch springs
Clutch springs stretched or fatigued Replace all clutch springs
Needle cage damaged
Fit new needle cage
Clutch shoe retainer broken
Fit new retainer
Clutch shoes and carrier worn
Install new clutch
MS 192 T
4.2
Chain Drive, Chain Brake, Chain Tensioner
Problem
Cause
Remedy
Chain sprocket wears rapidly
Chain not properly tensioned
Tension chain as specified
Wrong chain pitch
Fit chain of correct pitch
Insufficient chain lubrication
Check chain lubrication
Chain sprocket worn
Fit new chain sprocket
Clutch shoes badly worn
Install new clutch
Clutch drum badly worn
Install new clutch drum
Brake band stuck
Check freedom of movement and
function of brake band
Idle speed too high
Readjust with idle speed screw LA
(anticlockwise)
Saw chain stops under load at full
throttle
Saw chain rotates at idle speed
Clutch springs stretched or fatigued Replace clutch springs or install
new clutch
Saw chain does not stop
immediately when brake is
activated
MS 192 T
Clutch spring hooks broken
Replace clutch springs
Brake spring stretched or broken
Fit new brake spring
Brake band stretched, worn or
broken
Fit new brake band
Clutch drum worn
Install new clutch drum
9
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
Machine losing chain oil
Oil pump delivers insufficient oil
10
Intake hose or pick-up body
clogged or intake hose ruptured
Fit new intake hose and pick-up
body
Valve in oil tank blocked
Clean or replace valve
Worm worn
Replace worm
Oil pump damaged or worn
Replace oil pump
Oil pump housing defective
Replace oil pump
Oil pump damaged or worn
Replace oil pump
Oil pump worn
Replace oil pump
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
Fit new starter rope
Normal wear
Fit new starter rope
Rewind spring broken
Replacing the rewind spring
Spring insufficiently tensioned
Check rewind spring and increase
tension
Very dirty or corroded
Clean or replace rewind spring
Starter 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
Fit new pawls
Spring clip fatigued
Fit new spring clip
Starter mechanism is very dirty
Thoroughly clean complete starter
mechanism
Starter rope does not rewind
Starter rope is difficult to pull and
rewinds very slowly
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
Press boot firmly onto spark plug
and fit new spring if necessary
Spark plug sooted, smeared with oil Clean the spark plug or replace if
necessary
12
Incorrect air gap between ignition
module and flywheel
Set air gap correctly
Flywheel cracked
or has other damage or pole shoes
have turned blue
Install new flywheel
Ignition timing wrong, flywheel out
of adjustment, key in flywheel has
sheared off
Install new flywheel
Weak magnetization in flywheel –
pole shoes have turned blue
Install new flywheel
Irregular spark
Check operation of switch shaft and
ignition module
Faulty insulation on ignition lead or
short circuit wire, check ignition
lead / ignition module and replace if
necessary.
Check operation of spark plug
Clean the spark plug or replace if
necessary
Crankcase damaged (cracks)
Replace crankcase
MS 192 T
4.6
Carburetor
Problem
Cause
Remedy
Carburetor floods; engine stalls
Inlet needle not sealing.
Foreign matter in valve seat or
cone
Remove and clean inlet needle or
clean carburetor
Inlet control lever sticking on
spindle
Restore easy movement of inlet
control lever
Helical spring not located on nipple
of inlet control lever
Remove the inlet control lever and
refit it correctly
Perforated disc on diaphragm is
deformed and presses constantly
against the inlet control lever
Fit a new metering diaphragm
Idle jet too lean
Turn low speed screw L
anticlockwise (richer), until engine
accelerates smoothly
Main jet too lean
Turn high speed screw H
anticlockwise (richer), no further
than stop
Inlet control lever too low (relative
to correct installed position)
Set inlet control lever flush with top
edge of housing
Inlet needle sticking to valve seat
Remove inlet needle, clean and
refit
Diaphragm gasket leaking
Replace diaphragm gasket
Metering diaphragm damaged or
shrunk
Fit new metering diaphragm
Impulse hose damaged or kinked
Fit new impulse hose
Poor acceleration
MS 192 T
13
Problem
Cause
Remedy
Engine will not idle, idle speed too
high
Throttle shutter opened too wide by
idle speed screw LA
Reset idle speed screw LA
correctly
Oil seals / crankcase leaking
Seal or replace oil seals /
crankcase
Idle jet bores or ports blocked
Clean the carburetor
Idle jet too rich or
too lean
Set low speed screw L correctly
Setting of idle speed screw
incorrect – throttle shutter
completely closed
Reset idle speed screw LA
correctly
Air filter dirty
Clean the air filter
Throttle shutter not opened fully
Check linkage
Tank vent faulty
Clean tank vent or replace if
necessary
Fuel pick-up body dirty
Clean the pick-up body or replace if
necessary
Fuel strainer dirty
Clean fuel strainer in carburetor or
replace if necessary
Leak in fuel line between tank and
fuel pump
Seal connections or install a new
fuel line
Setting of high speed screw H too
rich
Turn the high speed screw H
clockwise (leaner) – max. up to the
stop.
Main jet bores or ports blocked
Clean the carburetor
Pump diaphragm damaged or
fatigued
Fit new pump diaphragm
Impulse hose damaged or kinked
Fit new impulse hose
Engine stops when idling
Engine speed drops quickly under
load – low power
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, stalls
at idle speed but operates normally
at full throttle
Oil seals in crankgear damaged
Replace the oil seals
Crankcase leaking or damaged
(cracks)
Seal or replace the crankcase
Piston rings worn or broken
Replace piston rings
Muffler / spark arresting screen
carbonized
Clean the muffler (inlet and
exhaust), replace spark arresting
screen, replace muffler if necessary
Air filter dirty
Replace air filter
Fuel / impulse hose severely kinked
or damaged
Fit new hoses and route them
without kinks
Insufficient cylinder cooling. Air
inlets in fan housing blocked or
cooling fins on cylinder very dirty
Thoroughly clean all cooling air
openings and the cylinder fins
Engine does not deliver full power
or runs erratically
Engine overheating
MS 192 T
15
5.
5.1
Chain/ Spiked Bumper
Chain and Chain Guide
1
– Reassemble remaining parts in
reverse order.
1
– Tension the chain, b 5.2
2
217RA002 TG
217RA003 TG
– Tightening torques, b 3.5
: Slide the guide bar (1) towards
the clutch and remove the chain
from the guide bar.
Wear protective gloves
– risk of injury –
: Disengage the chain brake by
pulling the hand guard (1)
towards the front handle until it
engages.
– Remove the guide bar (1).
– Remove the chain (2) via the
sprocket.
217RA004 TG
– Reassemble parts in reverse
order.
: Unscrew the hex nut (arrow).
: Unscrew the nut (arrow) and
remove the sprocket cover (1).
16
217RA021 TG
1
217RA001 TG
: Turn the screw anticlockwise to
relax the chain.
: Fit the sprocket cover, ensuring
that the peg (arrow) engages in
the hole.
MS 192 T
5.2
Tensioning the Chain
5.3
Chain Catcher
5.4
Bumper Spike
1
2
217RA006 TG
217RA350 TG
217RA076 TG
1
: Turn the screw clockwise to
tension the chain.
Sprocket cover with integrally
moulded chain catcher (1).
– Remove the sprocket cover and
bar and chain, b 5.1
: Tighten the hex nut (arrow).
If the chain catcher has broken (2),
file down the stub and replace with
a replacement chain catcher (3).
– Remove the chain catcher,
b 5.3
: Remove the screw (arrow).
: Remove the spiked bumper (1).
3
217RA005 TG
1
217RA007 TG
– Reassemble parts in reverse
order.
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.
– Remove the sprocket cover and
bar and chain, b 5.1
If the chain is tensioned
excessively, this may result in
damage to the chain, guide bar and
sprocket, as well as its needle
bearing.
– Reassemble parts in reverse
order.
MS 192 T
: Remove the screw (arrow).
: Remove the chain catcher (3).
17
Bumper Strips
6.
Clutch
– Troubleshooting, b 4.1
Bumper strips are fitted on the
engine housing to guide the saw
chain.
– Remove the sprocket cover and
bar and chain, b 5.1
Worn bumper strips must be
replaced, otherwise the engine
housing may be damaged.
Remove the sprocket cover and bar
and chain, b 5.1
217RA010 TG
5.5
1
: Unscrew the spark plug (1).
1
: Prise off the bumper strips (1)
with a suitable tool.
: Release the twist lock (arrow).
: Remove carburetor box cover (1)
to the rear.
217RA011 TG
217RA008 TG
1
217RA071 TG
1
1
: Push the locking strip (1)
0000 893 5903 into the spark
plug hole so that "OBEN-TOP"
faces down.
: Insert the bumper strips so that
the peg is aligned in the recess
(arrows).
: Apply a suitable tool to the tab
(arrow) to prise the boot off the
spark plug (1).
217RA012 TG
1
217RA009 TG
217RA083 TG
1
: Unscrew the clutch (1).
The clutch has a left-hand thread.
– Reassemble remaining parts in
reverse order.
18
MS 192 T
1
2
2
1
Disassembly
: Use hook (2) 5910 890 2800 to
remove the clutch springs (1).
: Slip the retainers (1) onto the
clutch shoes.
217RA019 TG
217RA013 TG
217RA016 TG
1
: 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 press it firmly into the
clutch shoe.
1
2
– Pull the clutch shoes off the
carrier.
: Pull the retainers (1) off the clutch
shoes.
217RA017 TG
217RA014 TG
1
: Fit the clutch shoes over the
arms (1) so that the series
number (2) is on the same side
as the raised hexagon (arrow).
– Clean all parts.
– Replace any damaged parts.
MS 192 T
217RA020 TG
217RA018 TG
: Clamp the clutch in a vice
(arrow).
11
37
217RA015 TG
1137
1137
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
6.1
Sprocket / Clutch Drum
1
: Fit the clutch on the crankshaft
stub so that the raised hexagon
(arrow) is visible.
– Remove the clutch, b 6
: Screw the clutch (1) with
hexagon (arrow) onto the
crankshaft stub and tighten it
down.
: Tightening torques, b 3.5
– Pull the locking strip out of the
cylinder.
: Draw the sprocket (1) off the
crankshaft stub.
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.
217RA024 TG
217RA022 TG
!
80%
– Examine the sprocket (1) for
signs of wear.
1
1
100%
148RA101 VA
217RA023 TG
217RA084 TG
1
: 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.
1
217RA058 TG
– Reassemble remaining parts in
reverse order.
– Grease the needle cage and
crankshaft stub, b 16
: Slip the needle cage (1) onto the
crankshaft stub.
20
MS 192 T
217RA059 TG
1
: Slip sprocket (1) onto crankshaft
stub.
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.
217RA060 TG
– Start the engine.
The sprocket must engage the
studs (arrow) of the wormwheel.
– Reassemble remaining parts in
reverse order.
7.1
Removing and Installing
1
217RA025 TG
7.
Removal
– Troubleshooting, b 4.2
– Remove the sprocket cover and
bar and chain, b 5.1
: Engage the chain brake by
pushing the hand guard (1)
downwards.
The brake spring of the brake band
is now relaxed.
– 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.
217RA026 TG
If the chain brake does not operate
properly, see troubleshooting chart,
b 4.2.
: Take out the screws (arrows).
MS 192 T
21
– Draw the hand guard (1) out
through the opening in the cover
(arrow).
: Remove the cover (1).
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.
1
217RA028 TG
: Carefully ease the brake spring
(1) off the anchor pin (arrow).
2
217RA030 TG
1
217RA032 TG
2
217RA321 TG
217RA027 TG
1
: Remove the inlay (1) and leaf
spring (2).
: Remove the E-clip (arrow).
: Unhook the brake spring (1) from
the brake lever (2).
Clean all disassembled parts with a
little standard solvent-based
degreasant not containing any
chlorinated or halogenated
hydrocarbons.
1
– Examine the inlay and leaf spring
and replace if necessary.
: Disconnect the brake band (1)
from the lever (arrow) and
remove it.
2
217RA031 TG
217RA029 TG
1
: Remove the hand guard (2) with
lever (1) from the pivot pins.
– Pull the lever out of the hand
guard.
22
MS 192 T
1
1
1
217RA324 TG
217RA322 TG
217RA033 TG
Wet the inlay (1) with Loctite before
fitting it, b 16
a
: Pull the pin (1) out of the cover
with a suitable tool.
: Carefully drive the pin (1) home,
tapping lightly, until value "a"
approx. 4.3...4.7 mm is reached.
: Press the inlay (1) as far as
possible into the opening in the
cover.
The pin must be driven in squarely.
1
1
: Place the leaf spring (1) in the
opening (arrow).
– Lightly grease both the leaf
spring and the pin of the inlay.
– Wet the knurled area of the new
pin (1) with Loctite before fitting it,
b 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.
217RA065 TG
: Prise off the bumper strip (1) with
a suitable tool.
– Check the bumper strip and
replace it if necessary.
– Reassemble parts in reverse
order.
1
217RA035 TG
The anchor pin must be replaced if
the groove in the brake spring
anchor pin is worn. Proceed as
follows:
217RA323 TG
217RA034 TG
1
: Slide the lever (1) through the
opening in the cover.
MS 192 T
23
Coat all sliding and bearing points
with STIHL multi-purpose grease,
b 16
1
217RA036 TG
217RA041 TG
Do not grease the brake band.
2
: The turns of the brake spring
must lie tightly against one
another when relaxed. If this is
not the case, replace the brake
spring.
The forked opening (2) must face
towards the brake band.
: Insert the lever (1) in the side of
the bearing boss (arrow).
Check correct position of the
protective tube.
1
1
a = 31 mm
b = 44 mm
Ensure that the holes in the lever
inside the hand guard are lined up.
217RA039 TG
217RA037 TG
2
: Attach the brake band (1) to the
brake lever (arrow).
: Slip the bearing boss of the hand
guard (1) and lever (2) onto the
pivot pins.
1
When fitting the parts, ensure that
the cam (arrow) on the hand guard
is guided past the leaf spring.
24
: Insert the brake band (1) in the
opening (arrow).
217RA042 TG
217RA040 TG
1
217RA038 TG
1
: Attach the brake spring (1)
to the brake lever (arrow).
MS 192 T
7.2
Chain Tensioner
– Remove the sprocket cover and
bar and chain, b 5.1
1
– Troubleshooting, b 4.2
217RA045 TG
217RA043 TG
2
1
: Use the assembly tool (2)
1117 890 0900 to attach the
brake spring (1) to the anchor pin
(arrow).
: Pull the complete chain tensioner
(1) out with a suitable tool.
– Reassemble remaining parts in
reverse order.
1 4 3
2
2
1
217RA044 TG
– Check operation of the chain
brake, b 7
217RA047 TG
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.
: Turn the spur gear (2) clockwise
until the tensioner slide (1) makes
contact on the right and the screw
(arrow) is revealed.
: Examine the thrust pad (1), spur
gear (2), adjusting screw (3) and
tensioner slide (4) and replace if
necessary.
217RA046 TG
217RA048 TG
1
: Remove the screw (arrow).
MS 192 T
: Pull the thrust pad (1) off the
adjusting screw.
25
7.3
: Pull the spur gear (1) out of the
hole in the cover (2).
– Clean all disassembled parts with
a little standard solvent-based
degreasant not containing any
chlorinated or halogenated
hydrocarbons. Replace any
damaged or worn parts.
217RA053 TG
217RA052 TG
1
217RA049 TG
2
Bar Mounting Stud
1
– Remove the sprocket cover and
bar and chain, b 5.1
– Fit the stud puller on the collar
stud (1).
Always replace the adjusting screw
and spur gear together.
– Ensure that the parts are installed
in the correct order.
1
: Turn the adjusting screw (arrow)
until the tensioner slide has been
unwound completely.
– Coat the threads and gear
wheels with STIHL multi-purpose
grease,
b 16
– Reassemble remaining parts in
reverse order.
– Check correct functioning again.
217RA054 TG
217RA050 TG
– Check correct functioning.
: 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.
2
1
– Fit the collar stud and tighten it
down firmly.
217RA051 TG
– Tightening torques, b 3.5
– Reassemble remaining parts in
reverse order.
: Remove the adjusting screw (1)
from the cover (2).
26
MS 192 T
8.2
8.
8.1
Engine
Muffler / Spark Arresting
Screen
Check and if necessary repair the
fuel supply, carburetor, air filter and
ignition system before looking for
faults on the engine.
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.
– Troubleshooting, b 8.1
217RA057 TG
– Remove the sprocket cover and
bar and chain, b 5.1
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.
: Take out the screws (arrows).
Always start with the vacuum test
and then continue with the pressure
test.
: Remove the screw (arrow).
217RA061 TG
217RA055 TG
The crankcase can be thoroughly
checked for leaks with the
carburetor and crankcase tester
and the vacuum pump.
– Remove and examine the
muffler, replace if necessary.
– Clean the sealing faces.
A gasket is not fitted between
muffler and cylinder.
1
2
217RA056 TG
– Reassemble parts in reverse
order.
: 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
27
8.2.1
Preparations
8.2.2
– Remove the sprocket cover and
bar and chain, b 5.1
2
– Set the piston to the top dead
centre. This can be checked
through the inlet port.
1
217RA063 TG
– Fit the spark plug and tighten it
down firmly.
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.
: Ensure that the sleeve (1) and
washer (2) are in place.
1
1
: Undo the screws (arrows).
: Fit the 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 socket head screw
(1) from the test flange
1128 850 4200.
217RA067 TG
217RA062 TG
217RA064 TG
1
: Connect the suction hose (1) of
the vacuum pump
0000 850 3501 to the nipple
(arrow).
1
– Remove the carburetor, b 14.2
0,4
0,6
400
500
0,8
600
300
0,2
200
100
700
0
– Fit the test flange
1128 850 4200 (1).
: Screw on the nuts (arrows) and
tighten them down firmly.
28
217RA069 TG
217RA066 TG
1,0
1 2
: Close the vent screw (1).
: Operate lever (2) until the
pressure gauge (arrow) indicates
a vacuum of 0.5 bar.
MS 192 T
8.2.3
Carry out the same preparations as
for the vacuum test, b 8.2.2
0,4
0,2
0
– After finishing the test, open the
vent screw and disconnect the
hose.
0,8
1,0
: 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.
– Remove the test flange.
– Install the carburetor, b 14.2
– Release the muffler and pull out
the sealing plate.
– Tighten down the muffler.
0,6
217RA068 TG
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.
Pressure test
– If the pressure drops, the leak
must be located and the faulty
part replaced.
1
– Reassemble remaining parts in
reverse order.
217RA067 TG
– Tightening torques, b 3.5
– Continue with pressure test
b 8.2.3
: Connect pressure hose (1) of
tester 1106 850 2905 to nipple
(arrow).
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
b 8.2.2
146RA063 VA
1
: Close vent screw (1) on the
rubber bulb.
MS 192 T
29
8.3
Oil Seals
Clutch side
– Clamp the puller arms.
– Remove the sprocket cover and
bar and chain, b 5.1
– Pull out the oil seal.
2
217RA085 TG
1
– Remove the clutch, b 6
Avoid damage to the crankshaft
stub.
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.
– Clean the sealing face with a little
standard solvent-based
degreasant not containing any
chlorinated or halogenated
hydrocarbons.
– Remove the oil pump, b 13.3
– Grease the sealing lips of the oil
seal, b 16
It is not necessary to disassemble
the complete engine in order to
replace the oil seals.
1
Ignition side
– Remove fan housing, b 10.2
217RA294 TG
– Remove the flywheel, b 9.5
217RA070 TG
2
– Apply sealing compound to the
outside diameter of the oil seals,
b 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.
– 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.
217RA274 TG
– Turn the crankshaft through
several times after approx.
1 minute.
– Free off the oil seal in its seat by
tapping it with a suitable tube or a
punch.
– The crankshaft taper must be
free from grease, therefore clean
it with a little standard solventbased degreasant not containing
any chlorinated or halogenated
hydrocarbons.
– 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, b 16
– Reassemble remaining parts in
reverse order.
: Apply puller 5910 890 4400 with
No. 3.1 jaws 0000 893 3706.
30
MS 192 T
8.4
8.4.1
Engine
Removal
1
217RA088 TG
– Apply sealing compound to the
outside diameter of the oil seals,
b 16
The complete engine must be
removed before disassembling the
piston or cylinder.
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.
– Remove the sprocket cover and
bar and chain, b 5.1
– Reassemble remaining parts in
reverse order.
– Remove the muffler, b 8.1
– Remove the clutch, b 6
– Remove the oil pump, b 13.3
– Remove fan housing,
b 10.2
1
217RA107 TG
– Turn the crankshaft through
several times after approx.
1 minute.
– Remove the ignition module,
b 9.1
– Remove the flywheel, b 9.5
: Prise off the supporting plate (1)
with a suitable tool.
1
217RA103 TG
1
: Remove the cover (1).
MS 192 T
: Remove the screw (arrow).
217RA109 TG
: Press in the oil seal (2) with press
sleeve (1) 4112 893 2401.
217RA108 TG
217RA086 TG
2
: Lift the handle housing (1) slightly
and pull the manifold off the
intake stub (arrow).
31
8.4.2
Installation
: Pull out the insulating plate (1),
pressing the locking lug together
at the bottom guide (arrow).
: Remove the screws (arrows)
from underneath the engine
housing.
217RA152 TG
217RA106 TG
217RA072 TG
1
: Push engine into engine housing.
: Remove the screws (arrows) on
the carburetor side.
: Pull the engine out of the engine
housing.
32
217RA153 TG
217RA105 TG
: Lift the handle housing slightly so
that the intake stub can be
positioned in relation to the
manifold when fitting the engine.
217RA110 TG
: Lift the handle housing slightly
until the manifold flange lifts off
the intake stub.
217RA105 TG
: Disconnect the impulse hose (1)
from the stub (arrow).
217RA153 TG
217RA104 TG
1
: Fit the screws (arrows) and
tighten them down only
moderately.
MS 192 T
– Tightening torques, b 3.5
: Fit the screws (arrows) and
tighten them down only
moderately.
217RA021 TG
217RA106 TG
– Remove the sprocket cover
again.
– Mount the machine on the
assembly stand again and
continue with the installation
procedure.
: Guide the peg (arrow) into the
hole and fit the sprocket cover.
Before tightening the screws down
firmly, the engine must be centred in
relation to the sprocket cover and
guide bar.
217RA352 TG
1
217RA271 TG
1
: The pin (1) must be lined up with
the hole (arrow) when fitting the
sprocket cover.
: Push the manifold (1) onto the
intake stub.
– Coat the manifold with STIHL
Press Fluid, b 16
– Fit the guide bar.
MS 192 T
217RA272 TG
: Unscrew the nut (arrow) and
remove the machine from the
assembly stand.
217RA351 TG
217RA357 TG
1
: Tighten down the nut (arrow) and
secure the sprocket cover (1).
The tab (arrow) must point towards
the saw chain.
– Now tighten down the screws
securing the engine.
: Press in the supporting plate (1).
1
33
8.5
8.5.1
Crankshaft
Removal
: Push the insulating plate (1) into
the guides (arrows) until it
engages at the bottom.
Ensure that the supporting plate
rests securely on the engine
housing at all points (arrows).
217RA111 TG
217RA273 TG
217RA158 TG
1
: Take out the screws (arrows).
: Insert and tighten down the
screw (1).
217RA112 TG
1
217RA156 TG
– Reassemble remaining parts in
reverse order.
: Apply a suitable tool at the
projections (arrows) of the engine
pan, then tap lightly to release
and lift off the engine pan.
– Tightening torques, b 3.5
217RA157 TG
217RA113 TG
1
: Connect the impulse hose (1) to
the stub (arrow).
: Remove the crankshaft from the
bearing seats (arrows).
34
MS 192 T
8.5.2
Installation
1
1
217RA142 TG
: Pull the oil seals (arrows) off the
crankshaft stubs.
– Coat the piston, piston rings and
inside of cylinder with oil.
: Use the clamping strap (1)
1137 893 2600 to compress the
rings around 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.
217RA115 TG
– Check that the piston rings have
been installed correctly.
217RA144 TG
217RA114 TG
2
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 –
MS 192 T
217RA145 TG
217RA143 TG
: Carefully pull the crankshaft and
piston out of the cylinder.
: Align the piston and crankshaft
before inserting them in the
cylinder.
– Slide the piston into the cylinder,
the clamping strap moves
backwards at the same time.
The cylindrical crankshaft stub
(arrow) must point towards the
cylinder exhaust port.
: Remove the clamping strap.
35
: Check and clean the mating
faces (arrows) on the cylinder.
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.
Mating faces must be absolutely
clean and undamaged.
Parts with damaged mating faces
must be replaced.
217RA151 TG
1
217RA085 TG
217RA146 TG
2
: 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).
217RA149 TG
217RA147 TG
Whenever the engine pan has been
disassembled, the mating faces
must be cleaned and fresh sealing
compound applied, b 16
: Slip new oil seals onto the
crankshaft stub with the open
side facing the crankshaft.
– 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)
b 16
217RA116 TG
217RA150 TG
1
Before closing the crankcase,
ensure that the cylindrical
crankshaft stub (1) is on the side of
the cylinder exhaust port (arrow).
: Apply sealing compound to the
outside diameter (arrows) of the
oil seals, b 16
36
MS 192 T
8.5.3
Crankshaft / Bearing
– Remove the engine, b 8.4.1
3
: Place the engine pan on the
sealing surface of the cylinder,
ensuring that the lug (arrow)
faces the cylindrical crankshaft
stub (1).
2
1
376RA128 TG
1
217RA148 TG
– Remove the crankshaft, b 8.5.1
: 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.
217RA111 TG
217RA118 TG
1
So that the sealing compound is
distributed uniformly, fit the screws
and gently press the engine pan
down.
: Remove the ball bearing (1) and
washer.
– Before installing the crankshaft,
clean it with standard solventbased degreasant not containing
any chlorinated or halogenated
hydrocarbons.
: Tighten the screws (arrows)
down crosswise.
– Tightening torques, b 3.5
Avoid damage to the crankshaft
stub.
– Install the engine, b 8.4.2
– Reassemble remaining parts in
reverse order.
MS 192 T
1
376RA133 TG
1
376RA121 TG
– Clean the crankshaft stub with
standard solvent-based
degreasant not containing any
chlorinated or halogenated
hydrocarbons.
: Remove the ball bearing (1) and
washer.
: Fit the washer (1).
37
1
: Fit the ball bearing with the
closed side (arrow) facing
outwards.
: Fit the washer (1).
217RA119 TG
376RA122 TG
376RA132 TG
1
: 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.
– Heat the inner race of the deep
groove ball bearing to approx.
150 °C (300 °F).
– Coat the needle bearing with oil.
– Install the piston, b 8.6.2
– Slip the deep groove ball bearing
onto the crankshaft stub as far as
the washer.
– Install the crankshaft and oil
seals,
b 8.5.2
The ball bearing must be fitted
rapidly as the heat is transmitted to
the crankshaft stub and the inner
raceway contracts again.
376RA120 TG
– Install the engine, b 8.4.2
: 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.
376RA123 TG
1
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.
38
MS 192 T
8.6
8.6.1
Piston
Removal
8.6.2
Remove the engine, b 8.4.1
2
Installation
1
Remove the crankshaft, b 8.5.1
: Push the piston pin (1) out of the
piston with the assembly drift (2)
1114 893 4700.
– 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 crankshaft stub (1).
– Position the piston on the small
end.
217RA124 TG
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.
217RA134 TG
217RA126 TG
1
: Use a suitable tool to prise the
hookless snap ring out at the
recess (arrow).
: Apply the assembly drift (1)
1114 893 4700 to the opposite
side of the snap ring.
: Remove the piston (1) from the
connecting rod.
– Inspect the piston rings and
replace if necessary, b 8.7
MS 192 T
1
217RA127 TG
217RA125 TG
1
217RA135 TG
1
: 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
1
: Fit the piston pin (2) on the small
diameter of the assembly drift (1)
and slide it into the piston.
217RA138 TG
2
: 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.
217RA140 TG
1
217RA136 TG
2
: 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 snap ring
slips into the groove.
: Remove the sleeve (1) from
assembly tool 5910 890 2210.
217RA139 TG
1
217RA137 TG
The tool must be precisely aligned
in axial direction of the piston pin.
: 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).
: Attach the snap ring (1) to the
magnet (2) and align it so that the
snap ring gap is on the flat side
(arrow).
: Remove the sleeve and push it
as far as possible over the
opposite end of the assembly
tool's shank.
2
217RA141 TG
1
376RA111 TG
2
376RA327 TG
1
The snap ring (1) must be fitted in
such a way that the snap ring gap
(arrow) does not coincide with the
recess (2).
The inner pin must point towards
the flat face.
40
MS 192 T
8.7
Piston rings
– Remove piston, b 8.4.1
217RA117 TG
217RA131 TG
– Remove piston rings from piston.
: Position the piston rings so that
the radii at the ring gaps meet at
the fixing pins (arrows) in the
piston groove.
– Inspect the piston rings and
replace if necessary, b 8.7
– Inspect the ball bearings and
replace if necessary, b 8.5.3
: Check the correct installed
position of the piston rings again
(arrows).
– Install the crankshaft, b 8.5.2
– Install the engine, b 8.4.2
217RA129 TG
– Install the piston, b 8.4.2
217RA130 TG
: Use a piece of old piston ring to
scrape the grooves clean.
: Install the new piston rings in the
grooves so that the radii at the
ends of the rings (arrows) face
towards the piston head.
MS 192 T
41
Ignition System
9.1
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.
Ignition Module
9.1.1
Removing and installing
1
1 2
217RA325 TG
Troubleshooting on the ignition
system should always start with the
spark plug, b 4.5
– Remove the fan cover, b 9.1.1
The ignition module accommodates
all the components required to
control ignition timing. There are
two electrical connections on the
coil body:
217RA087 TG
9.
: Take out the screws (arrows) and
remove the fan housing (1) with
rewind starter.
: High-voltage output (1) with
permanently fitted ignition lead
1
: Connector tag (2) for the short
circuit wire.
The electronic ignition system
basically consists of an ignition
module (1) and flywheel (2).
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.
1
217RA008 TG
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),
b 9.1.1
: Turn the twist lock (arrow)
anticlockwise to release it and
remove the carburetor box
cover (1).
217RA009 TG
217RA097 TG
2
1
: Apply a suitable tool to the tab
(arrow) to prise the boot off the
spark plug (1).
42
MS 192 T
1
1
2
: Disconnect the short circuit
line (1).
: Remove the screw (arrow).
217RA100 TG
: Disconnect the ground wire (2).
217RA101 TG
: Remove the screw (arrow).
: Remove the cable guide (arrow).
MS 192 T
– Pull the ignition lead with spark
plug boot out of the engine
housing.
217RA096 TG
217RA102 TG
: Remove the ignition module (1)
and cable guide (arrow) for the
ignition lead (2).
: 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.
A damaged ignition lead can only be
replaced together with the ignition
module.
– Tighten down the screws.
– Examine the spark plug boot and
replace it if necessary, b 9.4
– Reassemble remaining parts in
reverse order.
– Tightening torques, b 3.5
– Reassemble parts in reverse
order.
– Moderately tighten the screws on
the ignition module.
217RA098 TG
1
217RA099 TG
2
: Turn the flywheel until the
magnet pole is lined up with the
ignition module (arrow).
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.
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 engine may start and
accelerate during the test.
The ignition test refers only to a
spark test, not to the ignition timing.
If no spark is visible in the
window (2), check the ignition
system with the aid of the
troubleshooting chart, b 9.7
If a spark is visible, the ignition
system is in order.
2
3
3
4
Using the ZAT 4 ignition system
tester 5910 850 4503
Using the ZAT 3 ignition system
tester 5910 850 4520
– Before starting the test, install a
new spark plug in the cylinder
and tighten it down firmly.
– Before starting the test, install a
new spark plug and tighten it
down firmly.
– Tightening torques, b 3.5
– Tightening torques, b 3.5
: Connect the spark plug boot to
the input terminal (1). Push the
tester's output terminal (3) onto
the spark plug.
: Connect the spark plug boot to
the terminal (2).
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.
44
2
376RA134 TG
1
212RA209 VA
1
: 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
9.4
Ignition Lead / Spark Plug
Boot
The ignition lead cannot be
replaced separately, as it is
permanently connected to the
ignition module.
5
– Remove the ignition module,
b 9.1.1
34
212RA236 VA
2
376RA135 TG
1
: Use suitable pliers to pull the
torsion spring out of the spark
plug boot.
While using the ZAT 3, hold it only
by the handle (4) or position it in a
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).
– Unhook the torsion spring from
the ignition lead.
– Pull the boot off the ignition lead.
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.
217RA094 TG
1
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 (3), check the ignition
system with the aid of the
troubleshooting chart, b 9.7
: Pull the spark plug boot (1) with
ignition lead (arrow) out of the
engine housing towards the
ignition module.
1 2
217RA326 TG
3
217RA095 TG
1
: Remove the cover (1) from spark
plug boot.
– 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.
MS 192 T
45
9.5
Flywheel
– Use a pointed tool to pierce the
centre of the new lead's
insulation about 15 mm from the
end of the ignition lead.
: Ensure that the torsion spring
engages in the opening (arrow).
217RA087 TG
217RA327 TG
1
Take out the screws (arrows) and
remove the fan housing (1) with
rewind starter.
– Block the piston with the locking
strip, b 6
217RA095 TG
376RA136 TG
: Pinch the hook of the torsion
spring into the centre of the
ignition lead (arrow).
: Slide the cover (1) over the spark
plug boot.
: Remove the flywheel nut (arrow).
– Remove the flywheel.
– Install the ignition module, b 9.1
376RA136 TG
– Reassemble remaining parts in
reverse order.
– Coat the inside of the spark plug
boot with STIHL Press Fluid,
b 16
: Push the ignition lead and torsion
spring into the spark plug boot.
Use the puller if the flywheel is
stuck.
1
217RA090 TG
Do not use either graphite grease or
silicone insulating paste.
46
217RA089 TG
1
1
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
9.6
9.6.1
: Unscrew the puller (1)
1116 893 0800 from the
crankshaft stub.
Short Circuit Wire
Testing
– Reassemble parts in reverse
order.
1
217RA328 TG
Degrease the crankshaft stub and
bore in the flywheel hub with
standard solvent-based degreasant
not containing any chlorinated or
halogenated hydrocarbons.
Check the short circuit wire if the
spark plug and ignition lead with
spark plug boot are in order.
– Remove the fan cover, b 8.4.1
: Disconnect the short circuit
line (1).
1
– Connect the ohmmeter to ground
(arrow) and the short circuit
wire (1).
217RA091 TG
217RA093 TG
– Set the switch shaft to "0".
: Ensure that the machined key
(arrow) engages the slot in the
crankshaft.
: Remove the flywheel (1).
– Set the air gap between ignition
coil and flywheel, b 9.1.1
– Reassemble remaining parts in
reverse order.
217RA092 TG
– Tightening torques, b 3.5
Flywheel and magnet poles
(arrows) must not show any signs of
damage or blue discoloration,
otherwise the flywheel must be
replaced.
MS 192 T
The resistance measured must be
about 0 W. If it is much higher, the
reason is a break in the wire and it
must be replaced, b 9.6
– Set the switch shaft to "#".
The resistance measured must be
infinitely high, otherwise fit a new
short circuit wire, b 9.6
If no fault can be found, carry out
further checks:
– Check the flywheel, b 9.5
– Check the air gap between
flywheel and ignition module,
b 9.1.1
– If neither of these checks reveals
a fault, install a new ignition
module, b 9.1.1
– Reassemble parts in reverse
order.
47
9.6.2
Removing and installing
– Remove fan housing,
b 10.2
1
2
3
– Remove the handle moulding
and actuating levers, b 12.1
: Remove the cable guide (arrow).
217RA329 TG
217RA101 TG
– Remove the switch shaft, b 12.3
: 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 wiring harness.
: Remove the cover (1).
217RA320 TG
217RA103 TG
1
: Remove the cable guides
(arrows).
2
: Take out the screw (arrow) and
remove the ground wire (2).
: Disconnect the short circuit
line (1).
48
: Remove the contact springs
(arrows) from the handle
housing.
217RA319 TG
217RA318 TG
1
217RA099 TG
1
– Plug the contact spring (1) into
the terminal socket of the wiring
harness.
: Place the contact springs in the
guides (arrows).
MS 192 T
1
3
217RA166 TG
2
: 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
b 9.1.1
– Reassemble remaining parts in
reverse order.
– Tightening torques, b 3.5
MS 192 T
49
9.7
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
b 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
b 9.4
Check ignition:
with ZAT 3 or ZAT 4
(use ZAT 3 as main spark gap
see TI 32.94)
b 9.2 and b 9.3
1
50
MS 192 T
1
Spark
present?
yes
no
Air gap:
– Check ignition module / flywheel,
– Adjust if necessary, b 9.1.1
Check flywheel:
– Have pole shoes turned blue?
– Replace flywheel if necessary
b 9.5
Check short circuit wire:
– Replace short circuit wire if necessary
b 9.6.1
Check ignition lead:
– Severe chafing?
– Spark plug boot: holes / cracks?
– Resistance of spark plug boot to ground:
required: 1.5...12 kW
– Check resistance of ignition lead:
value required < 10 W,
– Replace spark plug boot and/or ignition lead
with ignition module if necessary
b 9.4
2
MS 192 T
3
51
2
3
Stop switch
Check correct operation:
– Short circuit wire chafed?
– Contact springs not in contact with metal pin
on switch shaft when in position "#"?
– Replace short circuit wire if necessary
b 9.6.2
Spark
present?
yes
no
Replace ignition module
b 9.1.1
yes
Engine runs smoothly,
troubleshooting procedure completed
52
Engine
runs
no
– Look for fault in fuel or carburetor
system
– Check power unit for leaks
– Check position of flywheel on
crankshaft
b 8.2, b 9.5
MS 192 T
Rewind starter
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, the
lubricating oil on the rewind spring
may thicken and cause the spring
windings to stick together. This has
a detrimental effect on the function
of the starter mechanism.
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.
10.2
Removing and Installing
– Tighten down the screws.
– Tightening torques, b 3.5
: Take out the screws (arrows).
– Remove the fan housing (1).
1
– Clean all components.
217RA281 TG
Before installing, lubricate the
rewind spring and starter post with
STIHL special lubricant, b 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.
– Reassemble remaining parts in
reverse order.
1
217RA087 TG
10.
10.1
: 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.
217RA282 TG
1
: Fit the segment (1) in the slits
(arrows) on the fan housing, then
push it down until the segment
engages.
MS 192 T
53
10.3
Pawls
10.4
Rope Rotor
– Remove fan housing, b 10.2
– Remove the spring, b 10.3
1
2
– Remove fan housing, b 10.2
: Remove the washer (1).
: Carefully ease the spring (1) off
the starter post.
: Remove the pawl (2).
Relieve tension of rewind spring
217RA250 TG
217RA283 TG
1
The rewind spring must be relieved.
: Remove the pawl (1).
– Grease the pegs (arrow) of the
new pawl, b 16
– Reassemble parts in reverse
order.
217RA247 TG
217RA258 TG
217RA249 TG
1
: 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.
: 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,
b 10.5
Lubricate the hole in the rope rotor
with STIHL special lubricant oil,
b 16
54
MS 192 T
10.5
Starter Rope / Grip
– Remove the fan housing,
b 10.2
1
217RA248 TG
217RA251 TG
1
: 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.
: 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) is
located in the groove in the
starter post.
– Relieve the tension of the rewind
spring and remove the rope rotor,
b 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.
– Then slide the straight part of the
spring over the starter post until it
engages in the groove.
– Grease the pegs of the pawls,
b 16
982RA036 VA
– Tension the rewind spring,
b 10.6
: Tie one of the two special knots
shown above at the end of the
rope in the starter grip.
MS 192 T
55
1
217RA356 TG
217RA353 TG
217RA255 TG
1
1
Machines with standard starter
grip
Machines with ElastoStart starter
grip
: Pull the rope (1) with spring and
sleeve into the starter grip.
: Thread the new rope (1) through
the side of the starter grip.
: Prise off the cap (1) with a
suitable tool.
– Press the cap into the starter grip.
1
: Pull the rope out and continue
threading it into the starter grip
from the top.
217RA252 TG
217RA354 TG
217RA256 TG
1
: Pull the rope or remaining rope
(1) out of the sleeve.
: Then thread the rope (1) through
the opening (arrow).
1
: Pull the rope through the grip until
the knot at the end of the rope is
in the recess (arrow).
: Pull the rope (1) through the
sleeve into the starter grip.
217RA253 TG
217RA355 TG
217RA257 TG
1
: Thread the rope (1) into the rope
rotor (arrows).
– Tie a special knot in the end of
the rope.
56
MS 192 T
10.6
Tensioning the Rewind
Spring
1
1
217RA261 TG
217RA254 TG
217RA259 TG
2
: Secure the rope (1) with a simple
overhand knot.
– Remove the fan housing,
b 10.2
– Hold the starter grip firmly to keep
the rope (1) tensioned.
– Pull the rope into the rope rotor
until the knot rests in the recess
(arrow) in the rope rotor.
: Pull out part of the rope (1)
between rope rotor (2) and fan
housing.
: Let go of the rope rotor and let the
starter rope rewind slowly.
– Install the fan housing,
b 10.2
– Tightening torques, b 3.5
: 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.
1
Hold the tensioned rope rotor firmly,
as the rewind spring will be
damaged if it jumps back suddenly.
217RA262 TG
– Install the rope rotor and tension
the rewind spring, b 10.4
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 to
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 –
2
217RA260 TG
1
To reduce the spring tension:
Pull the rope out, hold the rope rotor
steady and take off one turn of the
rope.
– Hold the rope rotor (2) steady.
: Pull out the rope (1) with the
starter grip and straighten it out.
MS 192 T
– Install the fan housing,
b 10.2
– Tightening torques, b 3.5
57
Replacing the Rewind
Spring
– Troubleshooting, b 4.4
The replacement spring is supplied
ready for installation and secured in
a frame.
Wear a face shield and protective
gloves.
: 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.
1
– Remove the frame.
217RA275 TG
10.7
The rewind spring may pop out.
– Remove the fan housing,
b 10.2
– Relieve the rewind spring if
necessary and remove the rope
rotor, b 10.4
– Arrange the spring (1) as shown
in the illustration.
: Position the anchor loop in the
fixture (arrow).
– Remove any fragments of the old
spring.
217RA276 TG
1
217RA284 TG
– Lubricate the spring with a few
drops of STIHL special lubricant
before installation, b 16
Ensure that the new rewind spring
(1) is fitted completely and the
anchor loop is positioned in the
fixture (arrow).
1
: Hold the inserted loops securely
to prevent them slipping out
again.
217RA359 TG
If the rewind spring pops out during
installation, fit it in the fan housing
as follows:
: Fit the rewind spring (1) in a
circular fashion, working in
clockwise direction.
: Position the replacement spring
with frame – the anchor loop
must be located over the
fixture (1).
58
MS 192 T
10.8
Starter Rope Guide
Bushing
: Arrange the inner loop (arrow)
with suitable pliers so that it is
slightly angled against the starter
post.
– Install the rope rotor, b 10.4
1
– Remove the fan housing,
b 10.2
– Relax the rewind spring and
remove the starter rope and rope
rotor, b 10.4
217RA279 TG
217RA277 TG
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.
: Insert the screw spindle (1) of the
installing tool 0000 890 2201
through the guide bushing from
inside the housing.
– Reassemble remaining parts in
reverse order.
2
1
1
217RA278 TG
217RA280 TG
3
– 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.
: 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.
MS 192 T
59
Repairing the AV System
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.
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,
b 14.1
217RA309 TG
11.
Remove the sprocket cover and bar
and chain, b 5.1
: Examine the rubber buffer and
replace it if necessary.
– Reassemble parts in reverse
order.
217RA182 TG
– Tightening torques, b 3.5
217RA183 TG
: Remove the screw (arrow).
: Take out the screws (arrows).
– Remove the rubber buffer.
60
MS 192 T
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.
1
– Remove the throttle trigger and
throttle trigger interlock, b 12.1
– Remove the switch shaft,
b 12.3
217RA161 TG
1
– Open the handle housing,
b 12.1
: Pull the front handle (1) out of the
upper guide (arrow).
217RA164 TG
11.2
Ensure that the spring (1) has been
fully turned into the front handle and
bearing plug.
: Remove the screw (arrow).
: Draw the front handle out of the
engine housing with the spring
facing downwards.
217RA165 TG
217RA162 TG
217RA159 TG
– Reassemble parts in reverse
order.
: Slide the front handle into the
hole (arrow), ensuring that the
raised parts of the handle engage
the recess of the handle housing.
: Remove the screw (arrow) from
underneath the engine housing.
2
: Examine the front handle (1),
spring (2) and bearing plug (3)
and replace if necessary.
217RA159 TG
1
217RA163 TG
217RA160 TG
3
: Insert and tighten down the screw
(arrow).
– Tightening torques, b 3.5
– Reassemble remaining parts in
reverse order.
MS 192 T
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.
11.4
To prevent the engine vibrating in
the engine housing, a clamp is fitted
on the inside of the engine housing
so that the cylinder rests against the
clamp.
Remove the engine, b 8.4
217RA169 TG
– Remove the sprocket cover and
bar and chain, b 5.1
– Open the handle housing,
b 12.1
Clamp
– The following work is made
easier by using STIHL Press
Fluid, b 16
: Remove the screw (arrow).
: Remove the screw (arrow).
217RA184 TG
217RA170 TG
217RA168 TG
– Draw the AV spring out of the
recess in the engine housing.
– Examine the AV spring and
replace it if necessary,
: Press the rubber stub (arrow) out
of the engine housing.
: Before installing the AV spring,
ensure that it has been fully
turned into the bearing plugs
(arrows).
– Examine the clamp and replace it
if necessary,
– Reassemble parts in reverse
order.
1
: Prise off the bumper strip (1) with
a suitable tool.
217RA185 TG
217RA172 TG
– Tightening torques, b 3.5
1
: Press the clamp (1) into the
engine housing from below.
– Reassemble remaining parts in
reverse order.
62
MS 192 T
11.5
Loop
12.
12.1
Actuating Levers
Throttle Trigger / Interlock
Lever / Throttle Rod
: Remove the screw (arrow).
217RA241 TG
217RA237 TG
217RA186 TG
1
2
: Remove the interlock lever (1)
and throttle trigger (2).
: Take out the screws (arrows).
1
1
– 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.
217RA243 TG
217RA238 TG
217RA171 TG
2
: Carefully remove the handle
moulding (1).
: Hook the torsion spring (1) into
the throttle trigger (2).
– note the installed position –
Throttle rod and actuating levers
may drop out as the handle
moulding is removed.
– Examine the torsion spring and
replace it if necessary.
– Insert and tighten down the
screw.
: Remove the throttle rod (1).
MS 192 T
217RA240 TG
1
217RA155 TG
– Tightening torques, b 3.5
: Place the torsion spring in the
fixture (arrows).
63
12.2
2
217RA242 TG
1
Double Lever
– Tightening torques, b 3.5
– Remove the air filter, b 14.1
– Check correct functioning.
– Remove the air filter base,
b 14.1.1
– Remove the handle moulding,
throttle rod, interlock lever and
throttle trigger, b 12.1
– Unhook the rod from the
carburetor, b 14.2
: Fit the interlock lever and throttle
trigger in the bearing guides
(arrows).
217RA244 TG
217RA308 TG
When installing the interlock lever
(1) and throttle trigger (2) ensure
that the peg on the interlock lever
engages in the guide (arrow).
1
: Remove the double lever (1) from
the bearing hole (arrow).
: 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
2
217RA245 TG
217RA239 TG
1
: 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
12.3
Switch Shaft
– Reassemble parts in reverse
order.
1
– Tightening torques, b 3.5
217RA246 TG
– Check correct functioning.
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, b 3.5
– Remove the handle moulding,
throttle rod, interlock lever and
throttle trigger, b 12.1
– Check correct functioning again.
: Pull the switch shaft (1) out of the
bearing.
217RA167 TG
1
: Check the switch shaft – the
metal pin (1) must be firmly
seated in the hole and the cam
(arrow) must be present.
1
3
217RA166 TG
2
: Fit the switch shaft (1), pushing
the rear contact spring (3) slightly
to the side.
MS 192 T
65
12.4
Handle Housing
– Remove fan housing, b 10.2
1
– Remove the sprocket cover and
bar and chain, b 5.1
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 –
217RA172 TG
– Push the intake elbow on the
carburetor side out of the handle
housing, b 14.5
217RA101 TG
– Remove the carburetor, b 14.2
: Remove the bumper strip (1).
: Remove the cable guide (arrow).
: Remove the screw (arrow).
: Remove the cover (1).
217RA320 TG
217RA169 TG
217RA103 TG
1
: Remove the cable guides
(arrows).
: Remove the screw (arrow).
66
217RA160 TG
1
217RA099 TG
217RA108 TG
2
: Take out the screw (arrow) and
remove the ground wire (2).
– Disconnect the spring of the front
handle from the engine housing.
: Remove the short circuit wire (1).
: Remove the screw (arrow).
MS 192 T
217RA299 TG
217RA337 TG
1
217RA162 TG
2
– Pull the front handle with handle
housing down slightly.
: Disconnect the tank vent (1) from
the fuel hose (2).
: Pull the bearing plug out of the
engine housing.
– Draw the fuel hose (2) out
through the opening (arrow).
: Unscrew the spring and bearing
plug.
1
: Remove the tank vent (1).
: Push the grommet (1) out.
1
2
217RA336 TG
217RA181 TG
217RA316 TG
1
: 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, b 3.5
1
– Installation of rubber parts is
made easier by using STIHL
Press Fluid, b 16
: Push the fuel return line (1) out.
217RA298 TG
217RA300 TG
1
: Disconnect the impulse hose (1)
from the stub (arrow).
– Remove the handle housing.
MS 192 T
67
Chain Lubrication
Pick-up Body
13.2
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.
– Remove the clutch, b 6.1
– Remove the bumper strips,
b 5.5
– Troubleshooting, b 4.3
– Unscrew the oil tank cap and
drain the oil tank.
– Hold the suction hose with blunt
pliers.
Collect chain oil in a clean container
or dispose of it properly at an
approved disposal site.
Oil Suction Hose
– Remove the sprocket cover and
bar and chain, b 5.1
1
217RA188 TG
13.
13.1
– Unscrew the oil tank cap and
drain the oil tank.
– Remove the pick-up body,
b 13.1
: Pull the pick-up body (1) off the
suction hose.
– Flush out the oil tank.
217RA073 TG
217RA340 TG
1
: Take out the screws (arrows).
– 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.
2
1
: Use hook 5910 893 8800 to pull
the pick-up body (1) out of the oil
tank.
217RA074 TG
217RA187 TG
1
: Remove the cover (1), pulling the
worm (2) off the crankshaft stub
at the same time.
Take care not to overextend the
suction hose.
68
MS 192 T
13.3
Oil Pump
: Pull the hose off the connector
(arrow) on the oil pump.
217RA191 TG
217RA192 TG
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.
: 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.
Remove the sprocket cover and bar
and chain, b 5.1
Remove the clutch, b 6.1
Remove the bumper strips, b 5.5
: Pull the suction hose (1) out of
the engine housing.
: Use hook 5910 893 8800 to pull
the suction hose (1) out of the oil
tank.
217RA340 TG
217RA190 TG
: Push the smaller diameter of the
new suction hose (1) into the hole
in the engine housing.
217RA073 TG
2
1
1
: Take out the screws (arrows).
: Push the pick-up body (1) into the
suction hose and place it in the oil
tank.
1
217RA074 TG
1
217RA077 TG
217RA189 TG
1
: Remove the cover (1), pulling the
worm (2) off the crankshaft stub
at the same time.
– Reassemble remaining parts in
reverse order.
MS 192 T
69
13.4
Valve
Cleaning the valve
1
– Remove the sprocket cover and
bar and chain, b 5.1
: Pull the hose off the connector
(arrow) on the oil pump.
217RA341 TG
A valve is installed in the tank wall to
keep internal tank pressure equal to
atmospheric pressure.
217RA192 TG
2
– Remove the oil tank cap.
– Drain the oil tank.
: Check the oil pump (1) and
connector (2) and replace if
necessary.
Collect chain oil in a clean container
or dispose of it properly at an
approved disposal site.
217RA345 TG
: Slip the oil pump (1) over the
crankshaft stub and press the
nipple on the connector as far as
possible into the recess (arrow).
: Blow the valve (arrow) clear with
compressed air (from outside to
inside of tank).
217RA075 TG
217RA079 TG
1
: Remove the screw (arrow).
– Flush out the oil tank.
– Reassemble remaining parts in
reverse order.
1
– Grease the worm before
installing it, b 16
2
– Tightening torques, b 3.5
– Reassemble parts in reverse
order.
The valve must be replaced if it still
does not function properly after
being cleaned.
217RA078 TG
Replacing the valve
: Remove the oil pump (1), pulling
the connector (2) out of the
recess in the engine housing.
70
– Remove the sprocket cover and
bar and chain, b 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
13.5
Oil Tank Filler Cap
: Remove the old valve from the oil
tank.
217RA311 TG
: Lift up the safety latch and
unscrew the tank filler cap (1).
: Fit a new valve in the hole
a = approx. 8...10 mm.
217RA312 TG
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
: Carefully drive the valve out of
the tank wall into the tank with a
drift dia. 6 mm.
217RA194 TG
217RA193 TG
1
: Prise the nipple out from inside
the tank (arrow).
– Reassemble remaining parts in
reverse order.
Ensure that the parts are installed
correctly.
: Carefully fit the valve in the hole
in the engine housing.
MS 192 T
2
217RA313 TG
217RA195 TG
1
: 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
14.
14.1
Fuel System
Air Filter
Dirty air filters reduce engine power,
increase fuel consumption and
make starting more difficult.
1
217RA314 TG
217RA312 TG
The air filter should be checked
when there is a noticeable loss of
engine power.
– Refer also to troubleshooting,
b 4.7
: Press the nipple into the mount
(arrow) inside the tank.
: Remove the air filter (1).
– Knock out the filter or blow it clear
with compressed air from the
inside outwards.
– Screw in the filler cap.
– Test for leaks.
1
217RA315 TG
217RA008 TG
1
: Turn the twist lock (arrow)
anticlockwise.
: Take the foam inlay (1) out of the
filter base.
– Remove the carburetor box
cover (1).
– Clean away loose dirt from
around the filter.
Check the filter and foam inlay and
replace them if damaged or dirty.
217RA330 TG
1
: Press the tabs (arrows) together
and push the twist lock (1) out of
the carburetor box cover.
72
– If soiled, 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, b 14.1
1
2
217RA174 TG
217RA179 TG
– Remove the filter base, b 14.1.1
– Remove the air filter, b 14.1
When fitting the choke lever (1) on
the choke shaft (2), ensure that the
flat side of the choke shaft meshes
with the semi-circular recess in the
choke lever.
: Unscrew the nuts (arrows).
1
: Remove the filter base (1).
– Examine the filter base and
replace it if necessary,
– Before installing the filter base,
lubricate the sealing ring on the
carburetor connector with STIHL
Press Fluid, b 16
217RA181 TG
217RA180 TG
1
: Push out the grommet (1),
examine it and replace it if
necessary.
– Reassemble parts in reverse
order.
– Reassemble parts in reverse
order.
: Pull the choke lever (1) off the
choke shaft.
MS 192 T
217RA175 TG
1
1
217RA173 TG
Ensure that the air filter rests
uniformly on the filter base all round.
: Disconnect the fuel hose (1) from
the carburetor (arrow).
73
14.2.1 Leakage Test
: Carefully draw the carburetor off
the fuel return line and stud bolts
until the rods appear.
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, b 14.2
2
1
– 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).
1
If this pressure remains constant,
the carburetor is airtight. However, if
the pressure drops, there are two
possible causes:
217RA177 TG
143RA172 VA
1
: Unhook the rod (1) from the
carburetor (arrow) and remove
the carburetor.
3
249RA012 VA
217RA176 TG
The tank vent must also be checked
and cleaned if problems develop
with the carburetor or fuel supply,
b 14.6.2
: Push the fuel line (1)
1110 141 8600 onto the double
connector (2) 0000 855 9200.
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, b 14.3.2
2. Metering diaphragm damaged,
replace if necessary, b 14.3.1
– Reassemble parts in reverse
order.
– After completing the test, open
the vent screw (1) and pull the
fuel line off the carburetor's elbow
connector.
– Tightening torques, b 3.5
– Check correct functioning.
– Push the fuel hose onto the
elbow connector.
217RA178 TG
– Install the carburetor, b 14.2
– Tightening torques, b 3.5
– Reassemble remaining parts in
reverse order.
: Push the fuel line with double
connector onto the fuel port
(arrow).
74
MS 192 T
14.3
Carburetor Repair
14.3.1 Metering Diaphragm
– Examine the metering diaphragm
for signs of damage and wear,
replace the gasket.
– Remove the carburetor, b 14.2
217RA232 TG
217RA228 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.
: Secure the gasket, metering
diaphragm and end cover with
two screws (arrows).
: Take out the screws (arrows).
2
1
: Remove the end cover (1).
– Note the order in which the
metering diaphragm (2) and
gasket (1) are installed.
If the gasket and diaphragm are
stuck to the carburetor, they must
be removed very carefully.
: Gasket and metering diaphragm
must be aligned so that the tab
(arrow) points towards the
adjusting nozzles.
217RA233 TG
– Fit the remaining screws in the
secured end cover and tighten
down all screws, working
crosswise.
2
217RA230 TG
1
217RA231 TG
217RA229 TG
1
: Carefully separate the metering
diaphragm (1) and gasket (2).
MS 192 T
75
14.3.2 Inlet Needle
Ensure that the spring locates on
the nipple of the inlet control lever.
– Press the inlet control lever down
and secure it with the screw.
212RA281 VA
217RA234 TG
– Check that the inlet control lever
moves easily.
– Install the metering diaphragm,
b 14.3.1
: The sealing cone of the inlet
needle must be replaced if a
circular indentation (arrow) is
visible on its tip.
– Remove the metering
diaphragm, b 14.3.1
: Remove the screw (arrow).
2
: Pull the inlet control lever (1) with
spindle (2) out of the groove in
the inlet needle.
217RA219 TG
1
217RA235 TG
1
2
: Fit the inlet needle (1).
: Fit spring (2) in bore.
The spring under the inlet control
lever may pop out.
: Pull out the inlet needle (arrow).
– Remove and examine the spring
(1), replace it if necessary.
76
2 3
217RA220 TG
1
217RA236 TG
1
: 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).
MS 192 T
14.3.3 Fixed Jet
14.3.4 Pump Diaphragm
: Unscrew the fixed jet (1) with a
suitable screwdriver.
217RA222 TG
217RA221 TG
– Remove the metering
diaphragm, b 14.3.1
– Remove the carburetor, b 14.2
: Remove the screw (arrow).
: 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.
Take care not to damage the jet.
– Examine the fixed jet and replace
it if necessary.
2
217RA225 TG
1
1
1
– Examine the pump diaphragm for
signs of damage and wear,
replace the gasket.
217RA223 TG
– Reassemble parts in reverse
order.
– Inspect the fuel strainer for
contamination and damage,
clean or replace it if necessary.
: Carefully remove the end
cover (1).
: Carefully remove the gasket with
pump diaphragm from the
carburetor body.
217RA154 TG
217RA224 TG
1
: Pull the fuel strainer (1) out of the
carburetor body with a needle
and clean or replace it.
– Reassemble parts in reverse
order.
MS 192 T
77
14.3.5 Choke Shaft / Choke
Shutter
: Fit the gasket (1) and secure it
with the pegs (arrows).
: 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.
– Remove the carburetor, b 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.
– Tightening torques, b 3.5
217RA227 TG
1
217RA266 TG
217RA199 TG
217RA226 TG
1
: Position the end cover on the
carburetor body from below so
that the gasket and pump
diaphragm remain secured to the
end cover.
78
217RA214 TG
217RA198 TG
: Place the diaphragm (1) over the
gasket and secure it with the
pegs (arrows).
: 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
217RA363 TG
: Turn the choke shaft
anticlockwise with a suitable tool
and remove the choke
shutter (1).
: Examine the ball and spring and
replace if necessary.
1
217RA217 TG
217RA346 TG
2
1
– Turn the choke shaft until the flat
area is visible.
: Fit the choke shutter (1) with the
hole (2) at the front.
.
1
1
3
: Pull out the choke shaft (1) and
clean it with the guides.
– Examine the choke shaft for
signs of damage and replace it if
necessary.
217RA218 TG
Take care that the ball and spring do
not pop out when removing the
choke shaft (1).
– Wear safety glasses –
2
217RA215 TG
217RA216 TG
1
Ensure that the spring and ball are
correctly fitted before installing the
choke shaft.
The choke shutter (3) must be
installed so that hole (1) is above
and hole (2) axially parallel with the
choke shaft.
: Slide the choke shaft (1) into the
carburetor body until it engages.
– Secure the screw with Loctite,
b 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.
MS 192 T
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 screw (arrow).
: Remove the circlip (arrow) with a
suitable tool.
2
1
– Before pulling out the throttle
shaft, secure the pump piston to
prevent it popping out,
b 14.3.7
: Turn the torsion spring (1)
roughly a half-turn in clockwise
direction with a suitable tool to
prestress it.
: Unhook and relax the torsion
spring (arrow).
– Push the pump piston into the
bore of the carburetor with a
suitable tool, b 14.3.7
217RA205 TG
1
: Pull the throttle shaft (1) with
torsion spring out of the
carburetor body.
1
: Install the torsion spring.
Ensure that the torsion spring is
fitted correctly (arrow).
217RA203 TG
217RA200 TG
– Remove the throttle shaft, then
clean the shaft and shaft guides
with a little standard solventbased degreasant not containing
any chlorinated or halogenated
hydrocarbons.
217RA202 TG
– Troubleshooting on the
carburetor, b 4.6
217RA204 TG
– Remove the carburetor, b 14.2
: Push the throttle shaft (2) with
prestressed torsion spring into
the carburetor body.
217RA201 TG
– Clean the throttle shaft and
guides.
– Turn the throttle shaft slightly.
– Examine the throttle shaft for
signs of damage and replace it if
necessary.
– Examine the torsion spring and
replace it if necessary.
: Pull out the throttle shutter (1).
80
MS 192 T
14.3.7 Accelerator Pump
1
: Position the prestressed torsion
spring so that it rests against the
shoulder (arrow) of the
carburetor body.
: 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.
217RA360 TG
217RA208 TG
217RA331 TG
2
– Remove the throttle shaft,
b 14.3.6
Keep a finger over the hole (arrow)
to prevent parts popping out.
The notch (arrow) on the throttle
shutter must line up with the small
bore in the carburetor body.
: Install the circlip.
– Check correct functioning and
easy movement.
– Secure the screw with Loctite,
b 16
12
217RA361 TG
217RA206 TG
– Tighten down the screw.
3
– Examine the pump piston (1),
sealing ring (2) and spring (3) and
replace if necessary.
s
1
2
: Fit the throttle shutter (1) with the
dent (3) on the left and the
number (2) visible on the right.
217RA362 TG
217RA207 TG
3
Press the pump piston with spring
into the hole (arrow) before
installing the throttle shaft (1).
– Reassemble remaining parts in
reverse order.
MS 192 T
81
14.3.8 Adjusting screws
2
1
There are three adjusting screws on
the carburetor:
H = High speed screw (1)
L = Low speed screw (2)
LA = Idle speed screw (3)
: Examine the tip (arrow) for signs
of damage or wear.
If the carburetor setting can no
longer be adjusted, this may also be
due to the adjusting screws.
– Reassemble parts in reverse
order.
Only the high speed screw has a
limiter cap; a new cap must always
be used after dismantling the high
speed screw.
217RA212 TG
3
217RA210 TG
217RA197 TG
1
: Take out the high speed
screw (1).
– Replace the low speed screw if
necessary.
– Adjust the low speed screw,
b 14.4
217RA213 TG
Remove the carburetor, b 14.2
Refer also to troubleshooting on the
carburetor, b 4.6
: Examine the tip (arrow) for signs
of damage or wear.
– Replace the high speed screw if
necessary.
High speed screw
Low speed screw
– Reassemble parts in reverse
order.
1
: Take out the low speed screw (1).
217RA211 TG
217RA209 TG
1
– Adjust the high speed screw,
b 14.4.1
: Prise the limiter cap (1) off the
high speed screw with tool
5910 890 4501.
Always fit a new limiter cap.
82
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.
– Check air filter – clean or replace
if necessary, b 14.1
– Remove the limiter cap from the
high speed screw, b 14.3.8
– Check the spark arresting screen
(if installed) – clean or replace if
necessary, b 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 LA.
1
2. Turn the
low speed screw L
clockwise or anticlockwise to
set the highest speed.
2
1
217RA347 TG
The basic setting must be made
after removing the limiter cap.
– Check the chain tension.
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.
217RA332 TG
If this speed is more than
3900 rpm, stop the adjustment and
start again with step 1.
3. Set the speed to 3500 rpm again
with the idle speed adjusting
screw LA.
: Turn the high speed screw H (1)
clockwise until it is firmly in its
seat.
4. Set the speed to 3000 rpm with
the low speed screw L.
: 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.
5. Set the maximum speed of
13,500 rpm with the high speed
screw H.
6. Fit the limiter cap.
: Turn the low speed screw L (2)
anticlockwise until it is one turn
open.
MS 192 T
83
14.4.2 User Setting
Engine stops when idling
Erratic idling behaviour, poor
acceleration
– Make standard setting!
217RA334 TG
– Make standard setting!
– Turn the idle speed screw LA
clockwise until the saw chain
begins to run, then back off
1/4 turn.
Idle setting too lean (e.g. at low
ambient temperatures).
Saw chain rotates at idle speed
– Turn the low speed screw L
anticlockwise until the engine
runs and accelerates smoothly.
– Make standard setting!
The limiter cap must not be
removed from the high speed screw
when making the user setting.
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.
It is usually necessary to change the
setting of the idle speed adjusting
screw LA after every correction to
the low speed adjusting screw L.
– Switch off engine
– Check the air filter – clean or
replace if necessary, b 14.1
– Check the chain tension.
– Check the spark arresting screen
(if installed) – clean or replace if
necessary, b 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
MS 192 T
14.5
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.
– Remove the air filter, b 14.1
1
– Remove the filter base, b 14.1.1
– Remove the carburetor, b 14.2
– Unscrew the rubber buffers,
b 11.2
217RA264 TG
Correcting the carburetor setting
for use at high altitudes
Intake Elbow, Removing
and Installing
A damaged intake elbow may lead
to impaired engine performance.
– Troubleshooting, b 4.6 or
b 4.7
: Remove the washer (1).
The screws should be adjusted as
little as possible. The slightest
adjustment produces a tangible
difference in engine behaviour.
1
If you make the setting too lean it
will increase the risk of engine
damage through lack of lubrication
and overheating.
217RA265 TG
1
217RA107 TG
If the adjustments do not yield any
improvement, refer also to the
troubleshooting chart for ignition
system, carburetor and power unit,
b 4.6
: Prise off the supporting plate (1)
with a suitable tool.
: 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.
217RA358 TG
1
: Lift the handle housing and pull
the elbow (1) off the cylinder.
MS 192 T
85
The tab on the elbow flange must
not cover the opening in the handle
housing otherwise the impulse hose
will not operate correctly.
217RA267 TG
217RA269 TG
1
: Before installing the intake elbow,
slide the supporting plate onto
the elbow so that the rebate
(arrow) and tab (1) face the
carburetor.
: Draw the ends of the string
through the intake port with the
elbow flange.
– Coat with STIHL Press Fluid,
b 16
In this way, the elbow flange is fitted
through the intake port of the tank
housing without damaging it.
1
217RA263 TG
217RA268 TG
1
: Push the elbow (1) onto the
intake port (arrow).
: 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.
– Ensure that the flange is correctly
seated in the handle housing.
217RA271 TG
217RA270 TG
1
: Ensure that the elbow (1)
completely encloses the intake
port.
The tab on the elbow flange (arrow)
must be aligned so that the hole is
lined up with the opening in the
handle housing.
86
MS 192 T
14.5.1 Impulse Hose
1
217RA104 TG
: Fit the supporting plate (1) so that
the tab (arrow) points upwards
and towards the chain.
217RA335 TG
217RA272 TG
1
A damaged impulse hose may lead
to impaired engine performance.
: Disconnect the impulse hose (1)
from the stub (arrow).
– Remove the fan housing,
b 10.2
– Pull the impulse hose out of the
engine housing.
– Remove the flywheel, b 9.5
– Examine the impulse hose and
replace it if necessary,
– Unscrew the rubber buffers on
the handle housing, b 11.1
– Remove the carburetor, b 14.2
217RA273 TG
– Push the intake elbow out of the
handle housing, b 14.5
: Press the supporting plate home
completely until it rests against
the engine housing all round
(arrows).
– Troubleshooting, b 4.6 or
b 4.7
When installing 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,
b 16
The impulse hose is shown on the
handle housing after disassembly
for clarity.
– Reassemble remaining parts in
reverse order.
– Tightening torques, b 3.5
1
: Disconnect the impulse hose (1)
from the stub (arrow) of the
handle housing.
MS 192 T
217RA348 TG
217RA298 TG
1
: Guide the impulse hose (1)
through the opening (arrow) on
the engine housing and push it
onto the stub on the handle
housing.
87
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.
: Connect the impulse hose (1) to
the stub (arrow).
– Reassemble remaining parts in
reverse order.
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, b 10.2
2
217RA342 TG
217RA157 TG
1
1
: Disconnect the fuel return line (1)
and push the double nipple (2)
0000 855 9200 into the flange
(arrow) of the suction hose.
– Drain the fuel tank.
Ensure that the impulse hose is
routed correctly and without kinking.
Ensure that the fuel is disposed of
correctly and without harming the
environment.
2
0,4
0,6
400
500
0,8
600
300
0,2
200
100
700
0
217RA344 TG
1,0
1
Testing with negative pressure
: Close the valve (1) and connect
the vacuum pump (2)
0000 850 3501 to the 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.
217RA103 TG
1
: Remove the cover (1).
88
– Clean the area around the tank
vent.
– Replace the tank vent or tank if
necessary, b 14.6.2 or
b 14.8.3
MS 192 T
14.6.2 Removing and Installing
1
146RA063 VA
217RA316 TG
1
Testing with gauge pressure
– Remove the air filter, b 14.1
: Close the vent screw (1).
– Remove the filter base, b 14.1.1
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 fuel can no
longer be delivered in sufficient
quantities.
Always check the fuel tank and pickup body first if problems develop in
the fuel supply. Clean the fuel tank if
necessary.
: Pull the tank vent (1) out of the
holder on the handle housing.
1
0,4
0,2
0
0,6
1
0,8
1,0
217RA317 TG
: Connect the carburetor and
crankcase tester 1106 850 2905
(1) to the double nipple (arrow).
: Disconnect the tank vent (1) from
the hose (2).
– 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.
– Examine the tank vent and
replace it if necessary,
– Reassemble parts in reverse
order.
217RA295 TG
217RA343 TG
2
: 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, b 4.6 or
b 4.7
MS 192 T
89
14.8
Remove the air filter, b 14.1
1
1
Fuel Hoses
Remove the fan cover, b 9.1
: 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.
: 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.
1
: Disconnect the pick-up body (1)
from the fuel hose (2).
217RA103 TG
2
217RA286 TG
1
217RA292 TG
217RA285 TG
Remove the intake elbow,
b 14.5
: Remove the cover (1).
– Check the pick-up body and
clean or replace it if necessary.
: Slide the connectors of the
cleaned or replaced pick-up body
(1) into the fuel hose (2).
90
217RA300 TG
1
2
217RA291 TG
1
: Push the fuel return line (1) out.
MS 192 T
1
1
3
1
217RA287 TG
: Pull the fuel return line (1) out of
the guides and flange (arrow).
217RA307 TG
217RA302 TG
3
: Pull the elbow connectors (3) off
the hoses.
: Pull the fuel suction hose (1) out
of the tank.
– Check the fuel hose (1), fuel
return line (2) and elbow
connectors (3) and replace them
if necessary.
– Examine the fuel suction hose
and replace it if necessary,
2
– Reassemble parts in reverse
order.
217RA288 TG
1
217RA349 TG
1
: Pull the fuel hose (1) out of the
hose on the fuel pump.
: Push the fuel suction hose (1)
into the hole in the fuel tank.
1
: Pull the fuel hose (1) out of the
guides and flange (arrow).
– Remove the pick-up body,
b 14.7.1
: Prise off the flange (1) with a
suitable tool.
MS 192 T
1
217RA289 TG
217RA293 TG
217RA303 TG
1
: Align the flange (1) and press it
into the fixture on the housing
until it rests against the housing.
91
14.8.1 Fuel Pump
1
1
217RA317 TG
: Use hook 5910 893 8800 to pull
the fuel suction hose (1) out of
the fuel tank.
: Disconnect the tank vent (1) from
the hose (2).
Take care not to overextend the fuel
hose.
– Pull the hose (2) out through the
opening in the handle housing.
217RA304 TG
217RA290 TG
2
1
– Remove the air filter, b 14.1
– Remove the fan housing, b 10.2
: Disconnect the fuel hose (1).
– Fit the pick-up body, b 14.7.1
– Reassemble remaining parts in
reverse order.
: Disconnect the fuel hose (1) from
the fuel pump.
: Disconnect fuel hose (1) and
examine fuel hose (2), replace if
necessary.
– Reassemble parts in reverse
order.
92
217RA306 TG
1
217RA316 TG
: Remove the tank vent (1).
: Press the tabs (arrows) together
and push the fuel pump (1) out of
the housing.
217RA301 TG
2
1
217RA305 TG
1
217RA304 TG
1
: Examine the fuel pump and
replace it if necessary,
– Reassemble parts in reverse
order.
MS 192 T
14.8.2 Fuel Tank Filler Cap
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.
: Lift up the safety latch and
unscrew the tank filler cap (1).
217RA310 TG
217RA295 TG
1
: Press the nipple into the mount
(arrow) inside the tank.
– Screw in the filler cap.
– Test for leaks.
217RA296 TG
– Reassemble remaining parts in
reverse order.
1
2
217RA297 TG
: Prise the nipple out from inside
the tank (arrow).
: 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
93
15.
Special Servicing Tools
No.
Part name
Part No.
Use
1
2
4
5
6
7
Locking strip
Sealing plate
Strap retainer
Flange
Assembly tool
Carburetor and crankcase tester
0000 893 5903
0000 855 8106
1137 893 2600
1128 850 4200
0000 890 2201
1106 850 2905
8
9
10
11
12
15
16
17
19
20
Vacuum pump
- Connector
- Hose for leakage test
Puller
Puller (with No. 3.1 jaws)
Press sleeve
Assembly tube
Assembly hook
Assembly tool 10
Setting gauge
0000 850 3501
0000 855 9200
1110 141 8600
5910 890 4501
5910 890 4400
4112 893 2401
1117 890 0900
5910 890 2800
5910 890 2210
4118 890 6401
21
22
23
Assembly hook
Assembly stand
Clamping strip for assembly
stand
Puller
Ignition system tester ZAT 4
Ignition system tester ZAT 3
5910 893 8800
5910 890 3100
5910 890 2000
Block crankshaft
Seal exhaust bore
Tension the piston rings
Leakage testing
Flare the starter rope guide bushing
Test crankcase and carburetor for
leaks
Test crankcase for leaks, test tank vent
Test carburetor for leaks
Test carburetor for leaks
Remove limiter cap
Remove oil seals
Press in oil seal
Hook in clutch spring
Detach springs from clutch shoes
Fit hookless snap rings in piston
Set the air gap between ignition module
and flywheel
Remove pick-up body
Hold chainsaw for servicing / repairs
Clamp machine to assembly stand
1116 893 0800
5910 850 4503
5910 850 4520
Remove flywheel
Test ignition system
Test ignition system
25
27
28
94
Rem.
MS 192 T
No.
Part name
Part No.
Use
29
30
31
33
35
Torque wrench
Torque wrench
Bit size 13
Combination wrench
Bit T 27 x 125
5910 890 0302
5910 890 0312
5910 893 5608
1129 890 3401
0812 542 2104
35
Bit T 20 x 125
0812 542 2041
Screw connections (0.5 to 18 Nm)
Screw connections (6 to 80 Nm)
Crankshaft nut
Spark plug
Remove and install spline socket head
screws with electric or pneumatic
screwdrivers; tighten down screws with
torque wrench
Remove and install spline socket head
screws with electric or pneumatic
screwdrivers; tighten down screws with
torque wrench
36
37
38
41
42
Screwdriver T 20 x 100
Screwdriver Q-SW8x200
Stud puller
Crimping pliers
Assembly pin
5910 890 2301
5910 890 2420
5910 893 0501
5910 890 8210
1114 893 4700
Carburetor nuts
Remove rail mounting studs
Cable ties, cable lugs, etc.
Remove and install the piston pin
Rem.
1)
1)
1)
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 120 1111
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
adhesive (Loctite 270)
0786 111 2109
7
Standard commercial solventbased degreasant containing no
chlorinated or hydrogenated
hydrocarbons
96
Cleaning sealing faces and the carburetor,
cleaning the crankshaft stub and tapers in
flywheel
MS 192 T
englisch / english
0455 217 0123. M5. B5. T. Printed in Germany

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