Stihl MS270 Workshop Manual
Transcription
Stihl MS270 Workshop Manual
Contents 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 5.3 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.6 5.7 5.8 7 Ignition System 7.1 7.1.1 7.1.2 Ignition Module Ignition Timing Removing and Installing Testing the Ignition Coil Spark Plug Boot Flywheel Short Circuit Wire/ Ground Wire Stop Contact Ignition System Troubleshooting 7.1.3 7.2 7.3 7.4 17 7.5 7.6 17 18 18 20 20 21 23 25 25 26 28 29 29 8.7 30 AV Handle System 60 9.1 9.2 Handlebar Replacing Annular Buffers Crankcase Tank Housing Spring 60 9.2.1 9.2.2 9.3 10 44 n 5.2 Clutch Drum/Chain Sprocket Replacing the Chain Catcher Clutch Chain Brake Checking Operation Removing Installing Chain Brake with QuickStop Super Removing Installing Checking Play Adjusting Play Brake Cable Checking Operation of Coasting Brake Brake Spring Anchor Pin Chain Tensioner Bar Mounting Studs 6.2 6.2.1 6.2.2 6.2.3 6.3 6.4 6.5 6.5.1 6.5.2 6.6 6.7 6.7.1 6.8 sio 5.1 Clutch, Chain Drive, Chain Brake and Chain Tensioner 8 10 11 12 13 16 33 33 33 34 35 36 37 38 38 39 42 43 43 44 er 5 Clutch, Chain Drive, Chain Brake, Chain Tensioner Rewind Starter Chain Lubrication Ignition System Carburetor Engine Muffler/Spark Arresting Screen Leakage Test Preparations Pressure Test Vacuum Test Oil Seals Shroud Cylinder and Piston Removing Installing Piston Rings Crankcase Crankshaft Decompression Valve 45 45 Master Control/ Handle System 10.1 10.2 Switch Shaft Throttle Trigger/ Interlock Lever 10.2.1 Machines without QuickStop Super 10.2.2 Machines with QuickStop Super 61 61 62 63 64 64 65 65 66 11 Chain Lubrication 67 45 11.1 46 48 48 11.2 11.3 11.4 11.5 Pickup Body/ Suction Hose Delivery Hose Valve Oil Pump Fan Housing 67 68 69 70 70 12 Fuel System 71 12.1 Air Filter 12.2 Carburetor 12.2.1 Removing and Installing 12.2.2 Leakage Test 12.3 Servicing the Carburetor 12.3.1 Metering Diaphragm 12.3.2 Inlet Needle 12.3.3 Fixed Jet 12.3.4 Pump Diaphragm 12.3.5 Accelerator Pump 12.4 Adjusting 12.4.1 Standard Setting 12.5 Tank Vent 12.6 Pickup Body 12.7 Fuel Hose 71 72 49 50 51 8 Rewind Starter 54 8.1 8.2 8.3 8.4 8.5 8.5.1 8.5.2 8.6 General Fan Cover Pawls Rope Rotor Starter Rope ElastoStart Tensioning Starter Rope Guide Bush Replacing the Rewind Spring 54 54 54 55 56 57 57 ev 4.2 4.3 4.4 4.5 4.6 8 lin 4.1 Troubleshooting Chart On 4 6.1 9 rin t 4 33 ep Safety Precautions Engine rr 2 6 fo 3 ot Introduction -n 1 58 59 72 73 73 73 74 75 76 77 79 80 81 82 82 30 31 32 q © 2002 Andreas Stihl AG & Co., Waiblingen MS 270, MS 280 1 Contents 13 83 Servicing Aids 84 On lin ev er sio n -n ot fo rr ep rin t 14 Special Servicing Tools 2 MS 270, MS 280 Introduction The special tools mentioned in the descriptions are listed in chapter "Special Servicing Tools" of this manual. Use the part numbers to identify the tools in the "STIHL Special Tools" manual. The manual lists all special servicing tools currently available from STIHL. This service manual contains detailed descriptions of all the typical repair and servicing procedures for this power tool. You should make use of the illustrated parts lists while carrying out repair work. They show the installed positions of the individual components and assemblies. Refer to the latest edition of the relevant parts list to check the part numbers of any replacement parts. Symbols are included in the text and pictures for greater clarity. The meanings are as follows: = Action to be taken as shown in the illustration (above the text) rr fo Pointer ot In the illustrations: Direction of movement -n Refer to the "Technical Information" bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list until an updated edition is issued. – = Action to be taken that is not shown in the illustration (above the text) ep In the descriptions: A fault on the machine may have several causes. To help locate the fault, consult the troubleshooting charts for all assemblies and systems in this manual and the "STIHL Service Training System". n Service manuals and all technical Information bulletins are intended exclusively for the use of STIHL servicing dealers. They must not be passed to third parties. To service the underside of the machine, turn it upside down and mount it in the assembly stand. Pull the hand guard back against the front handle for this purpose. Always use original STIHL replacement parts. They can be identified by the STIHL part number, the STIH) logo and the STIHL parts symbol ( This symbol may appear alone on small parts. On lin ev er sio Servicing and repairs are made considerably easier if the clamp (1) 5910 890 2000 is used to mount the machine on assembly stand (2) 5910 890 3100 so that one clamp screw engages the outer 10 mm bore (3) in the assembly stand. The chainsaw can then be swivelled to the best position for the ongoing repair. rin t 1 MS 270, MS 280 3 2 Safety Precautions If the engine is started up in the course of repairs or maintenance work, observe all local and countryspecific safety regulations as well as the safety precautions and warnings in the owner’s manual. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. rin t Improper handling may result in burns or other serious injuries. On lin ev er sio n -n ot fo rr ep Warning! Do not smoke or bring any fire, flame or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. 4 MS 270, MS 280 3.1 Specifications Engine Displacement: Bore: Stroke: Engine power to ISO 7293: Max. permissible engine speed (with bar and chain): Idle speed: Clutch: MS 280 49.6 cm3 44.0 mm 32.6 mm 2.6 kW (3.54 HP) at 9,500 rpm 54.2 cm3 46.0 mm 32.6 mm 2.8 kW (3.81 HP) at 9,500 rpm 13,500 ± 150 rpm 2,800 rpm Three-shoe centrifugal clutch without linings 3,300 rpm 13,500 ± 150 rpm 2,800 rpm Three-shoe centrifugal clutch without linings 3,300 rpm ep Clutch engages at: Crankcase leakage test – at gauge pressure: – under vacuum: MS 270 rin t 3 60 kPa (0.6 bar) 40 kPa (0.4 bar) Fuel System Ignition System sio 3.3 ev er Air gap between ignition module and fanwheel: Spark plug (resistor type): Electrode gap: 80 kPa (0.8 bar) 30 kPa (0.3 bar) see owner’s manual 30 kPa (0.3 bar) see owner’s manual 0.20 – 0.30 mm NGK BPMR 7A 0.5 mm 0.20 – 0.30 mm NGK BPMR 7A 0.5 mm Chain Lubrication lin 3.4 80 kPa (0.8 bar) n -n Carburetor leakage test at gauge pressure: Tank vent operates at gauge pressure: Fuel: ot 3.2 fo rr 60 kPa (0.6 bar) 40 kPa (0.4 bar) On Fully automatic speed-controlled oil pump with rotary piston MS 270, MS 280 Oil delivery rate: 10 cc/min at 10,000 rpm 10 cc/min at 10,000 rpm 5 3.5 Tightening Torques DG and P screws (Plastoform) are used in polymer and light-alloy components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary without detrimentally affecting the strength of the screwed assembly, providing the specified tightening torque is observed. For this reason always use a torque wrench. Torque Remarks Nm Spline screw Countersunk screw Spline screw Spline screw Spline screw Collar screw Collar screw Spline screw Decompression valve Collar nut Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw IS-M4x8 IS-PT4x12 IS-B3.9x13 IS-M8x22 IS-P4x10 IS-M10/M8 IS-M8x21.5 IS-DG4x16 Cover plate, chain tensioner/crankcase Cover plate/chain sprocket cover Cover plate/fan cover Brake band/crankcase Brake cable, support/tank housing Guide bar/crankcase Guide bar/crankcase Cover/crankcase IS-M10x1 M5 IS-B4.2x9.5 IS-DG5x24 IS-DG5x24 IS-DG5x24 IS-DG5x18 IS-DG5x18 IS-DG5x24 Decompression valvel Filter base/baffle/carburetor Screen/muffler Hand guard, sleeve/fan cover Shroud/crankcase Shroud/fan housing Chain catcher/crankcase Spiked bumper/crankcase Fan cover/fan housing fo ot 14.0 5.0 2.0 4.0 4.5 4.5 9.0 9.0 4.0 1) 2) 3) 4) 2) 5) 6) 7) 3) 8) 9) sio n -n 3.0 2.5 1.5 10.0 1.0 30.0 23.0 3.0 rin t For component ep Thread size rr Fastener On lin ev er Remarks: 1) Special accessory 2) Only machines with quick chain adjuster 3) Secure screw with Loctite 243 4) Only machines with QuickStop Super 5) Secure screw with Loctite 270 6) With quick chain adjuster 7) Only machines without quick chain adjuster 8) Without quick chain adjuster 9) Only muffler with spark arresting screen 6 MS 270, MS 280 For component Torque Remarks Nm Spline screw Spline screw Clutch carrier Spline screw Nut Pan head screw Collar screw Spline screw Spark plug Spline screw Spline screw IS-DG5x24 IS-DG5x24 M12x1L IS-DG5x18 M8x1 M4x8 M8SK6 IS-M5x28 M14x1.25 IS-DG4x20 IS-DG4x16 Fan housing/crankcase Fan housing/bearing plug Carrier/crankshaft Muffler/cylinder Flywheel/crankshaft Inner side plate Dihedral sleeve/crankcase/bar guide Cylinder/crankcase Spark plug Ignition module/cylinder Oil pump/crankcase 9.0 4.0 50.0 9.0 28.0 3.0 30.0 9.0 25.0 4.0 3.0 1) 1) 6) rin t Thread size ep Fastener fo rr Remarks: 1) Only machines with quick chain adjuster 6) Secure screw with Loctite 270 -n ot Screws secured with adhesive are easier to loosen if the adhesive is heated first with a hot air blower. Exercise caution on polymer components. Use the following procedure to fit a P (Plastoform) screw in an existing thread: sio n – Place the P screw in the hole and rotate it counterclockwise until drops down slightly. – Tighten the screw clockwise to the specified torque. er This procedure ensures that the screw engages properly in the existing thread and does not form a new thread, which would weaken the assembly. On lin – P screws: max. 500 rpm ev Power screwdriver speed setting for polymer: MS 270, MS 280 7 4 4.1 Troubleshooting Chart Clutch, Chain Drive, Chain Brake, Chain Tensioner Cause Remedy Saw chain stops under load at full throttle Clutch shoes badly worn Replace clutch shoes or install new clutch Clutch drum badly worn Install new clutch drum Brake band stuck Check freedom of movement and function of brake band. If necessary, adjust brake cable of QuickStop Super (option) QuickStop Super brake cable broken (option) Replace the brake cable Engine idle speed too high Readjust with idle speed screw (counterclockwise) ep rr Saw chain rotates at idle speed rin t Condition Replace the clutch springs ot Clutch spring hooks broken fo Clutch springs stretched or fatigued Replace the clutch springs Clutch springs stretched or fatigued Replace all clutch springs -n Loud noises n Needle cage damaged sio Clutch shoe retainer broken Chain not properly tensioned ev Chain sprocket wears rapidly er Clutch shoes and carrier worn Fit new retainer Install new clutch Tension chain as specified Fit chain of correct pitch On lin Wrong chain pitch Fit new needle cage 8 MS 270, MS 280 Cause Remedy Saw chain does not stop immediately when brake is activated Brake spring stretched or broken Fit new brake spring Brake band stretched/worn/broken Fit new brake band On lin ev er sio n -n ot fo rr ep rin t Condition MS 270, MS 280 9 4.2 Rewind Starter Cause Remedy Starter rope broken Rope pulled out too vigorously as far as stop or over edge, i.e. not vertically Fit new starter rope Normal wear Fit new starter rope Spring overtensioned – no reserve when rope is fully extended Fit new rewind spring Very dirty or corroded Clean or replace rewind spring Guide peg on pawls or pawls themselves are worn Fit new pawls ep Starter rope can be pulled out almost without resistance (crankshaft does not turn) rr Rewind spring broken (rope does not rewind) rin t Condition Starter mechanism is very dirty ot Starter rope is difficult to pull and rewinds very slowly Fit new spring clip fo Spring clip fatigued Apply a few drops of kerosine (paraffin) to spring, then pull rope carefully several times until normal action is restored On lin ev er sio n -n Lubricating oil on rewind spring becomes viscous at very low outside temperatures (spring windings stick together) Thoroughly clean complete starter mechanism 10 MS 270, MS 280 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. Cause Remedy Chain receives no oil Oil tank empty Fill up with oil Oil inlet hole in guide bar is blocked Clean oil inlet hole Intake hose or pickup body (strainer) clogged or intake hose ruptured Wash intake hose and pickup body (strainer) in fresh STIHL cleaner or replace if necessary ep rin t Condition Clean or replace valve rr Valve in oil tank blocked fo Teeth on pump piston and/or worm worn ot Oil pump hoses blocked/damaged Oil pump hoses porous/ruptured -n Machine losing chain oil Clean or replace hoses Fit new hoses Fit new oil pump Fit new oil pump Oil pump hoses not installed correctly/leaking/ruptured/blocked Check correct installation of hoses or clean/replace hoses Bore in pump housing worn Fit new oil pump sio Pump piston worn On lin ev er Oil pump delivers insufficient oil n Bore in pump housing worn Install new oil pump and/or new worm MS 270, MS 280 11 4.4 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! Cause Remedy Engine runs roughly, misfires, temporary loss of power Spark plug boot is loose Press boot firmly onto spark plug and fit new spring if necessary Spark plug sooted, smeared with oil Clean the spark plug or replace if necessary Weak spark or no spark Faulty insulation on ignition lead or short circuit wire. Use ohmmeter to check ignition lead for break. If break is detected or high resistance measured, fit a new ignition lead Set air gap correctly fo Incorrect air gap between ignition coil and flywheel rr ep rin t Condition -n ot Flywheel cracked or has other damage Clean or replace spark plug, replace faulty parts of ignition system sio n Check operation of spark plug. Inspect Master Control lever, ignition coil/lead for damage insulation and leakage current Install new flywheel Check operation of Master Control lever and ignition module On lin ev er No ignition spark 12 MS 270, MS 280 4.5 Carburetor Cause Remedy Carburetor floods; engine stalls Inlet needle not sealing. Foreign matter in valve seat or cone damaged Remove and clean or replace the inlet needle, clean the fuel tank, pickup body and fuel line if necessary Inlet control lever sticking on spindle Free off inlet control lever Helical spring not located on nipple of inlet control lever Remove the inlet control lever and refit it correctly Perforated disc on diaphragm is deformed and presses constantly against the inlet control lever Fit a new metering diaphragm Inlet control lever too high (relative to correct installed position) Set inlet control lever flush with top edge of housing ep rr fo Idle jet too lean -n ot Poor acceleration n Main jet too lean er sio Inlet control lever too low (relative to correct installed position) ev Inlet needle sticking to valve seat Rotate low speed screw (L) counterclockwise (richer), no further than stop Rotate high speed screw (H) counterclockwise (richer), no further than stop Set inlet control lever flush with top edge of housing Remove inlet needle, clean and refit Diaphragm gasket leaking Fit a new diaphragm gasket Metering diaphragm damaged or shrunk Fit a new metering diaphragm On lin rin t Condition MS 270, MS 280 13 Cause Remedy Engine speed drops quickly under load – low power Air filter dirty Clean the air filter Tank vent faulty Replace tank vent Leak in fuel line between tank and fuel pump Seal connections or install a new fuel line Pump diaphragm damaged or fatigued Fit a new pump diaphragm Main jet bores or ports blocked Clean the bores and ports Fuel pickup body dirty Clean the pickup body, fit a new filter Fuel strainers dirty Clean the fuel strainers -n ot Setting of high speed screw (H) too rich n Throttle shutter not opened fully Reset high speed screw (H) correctly Check linkage Throttle shutter opened too wide by idle speed screw (LA) Reset idle speed screw (LA) correctly Engine leaking Seal the engine On lin ev er sio Engine will not idle, idle speed too high Clean or replace spark arresting screen fo Spark arresting screen dirty rr ep rin t Condition 14 MS 270, MS 280 Cause Remedy Engine stalls at idle speed Idle jet bores or ports blocked Clean jet bores and ports and blow clear with compressed air Idle jet too rich or too lean Set low speed screw (L) correctly Setting of idle speed (LA) incorrect – throttle shutter completely closed Set idle speed screw (LA) correctly Small plastic plate in valve jet does not close Clean or renew valve jet On lin ev er sio n -n ot fo rr ep rin t Condition MS 270, MS 280 15 4.6 Engine Always check and, if necessary, repair the following parts before looking for faults on the engine: – – – – Air filter Fuel system Carburetor Ignition system Cause Remedy Engine does not start easily, stalls at idle speed, but operates normally at full throttle Oil seals in crankcase damaged Replace the oil seals Crankcase leaking or damaged (cracks) Seat or replace the crankcase Muffler leaking Replace the muffler ep rr Piston rings worn or broken Fit new piston rings fo Engine does not deliver full power or runs erratically rin t Condition -n Air filter element dirty ot Muffler/spark arresting screen carbonized sio n Fuel/impulse line severely kinked or damaged Replace air filter element Replace lines or position them free from kinks Decompression valve sticking Replace the decompression valve Insufficient cylinder cooling. Air inlets in fan housing blocked or cooling fins on cylinder very dirty Thoroughly clean all cooling air openings and the cylinder fins On lin ev er Engine overheating Clean the muffler (inlet and exhaust), replace spark arresting screen 16 MS 270, MS 280 5 5.1 Clutch, Chain Drive, Chain Brake and Chain Tensioner Clutch Drum/Chain Sprocket 1 – Remove the bar an chain – wear work gloves to protect your hands from injury. – Inspect the needle cage for damage. 148RA101 VA ! Inspect the clutch drum (1) for signs of wear. If there are noticeable wear marks on the inside diameter of the clutch drum (1), check its wall thickness. If it is less than 80% of the original wall thickness, fit a new clutch drum. ep Pull off the clutch drum (1) with needle cage (2). 80% rin t 1 – Remove the chain sprocket cover. On machines with QuickStop Super: rr Disengage the chain brake by pulling the hand guard towards the front handle. 100% 148RA062 VA 143RA004 VA 2 If the clutch drum has to be replaced, also check the brake band – see 5.4.2. er sio n -n ot fo – Press down the throttle trigger interlock to disengage the coasting brake and then pull off the clutch drum (1) with needle cage (2). lin ev 12 2 138RA003 VA 146RA188 VA On 3 Remove the E-clip (1), washer (2) and, if fitted, the rim sprocket (3). 1 Pull off the chain sprocket (1) or clutch drum (2). – Remove the needle cage. MS 270, MS 280 17 5.2 Replacing the Chain Catcher 5.3 Clutch Troubleshooting chart – see 4.1. 1 – Remove the clutch drum or chain sprocket – see 5.1. 146RA001 VA 2 3 4 Reassemble in the reverse sequence. rin t – Remove the chain sprocket cover. – Remove the bar and chain – wear work gloves to protect your hands from injury. ep If the clutch drum is still serviceable, use No. 120 emery paper or emery cloth (grain size approx. 120 µm) to clean and roughen its friction surface. Take out the slotted screw (1). rr 2 1 fo Take out the screw (3). Remove the chain catcher (4). Release the twist lock (1) and lift away the carburetor box cover (2). 1 146RA003 VA On lin ev er sio 146RA002 VA -n Install in the reverse sequence. n – Rotate clutch drum/chain sprocket and apply slight pressure at the same time until the oil pump drive spring engages the notch (see arrow). Remove the side plate (2). ot Clean stub of crankshaft. Wash needle cage in clean white spirit and lubricate with STIHL multipurpose grease – see 14. Remove the spark plug boot (1). – Unscrew the spark plug. 18 MS 270, MS 280 TOP 1 Take the cover washer (1) off the crankshaft stub. Push the locking strip (1) 0000 893 5903 into the spark plug hole so that "OBEN-TOP" faces up. 208RA026 VA 146RA209 VA – Close the decompression valve, if fitted. – Clean all parts with STIHL cleaner – see 14. rin t 146RA004 VA 1 rr 2 Assembling the clutch n Disassembling the clutch 208RA029 VA 146RA205 VA -n ot fo 1 ep – Replace any damaged parts. Slip the retainers onto the clutch shoes. er sio Use hook (2) 5910 890 2800 to remove the clutch springs (1). 1 3 Unscrew the clutch from the crankshaft clockwise (left-hand thread). MS 270, MS 280 – Pull the clutch shoes off the carrier. 146RA208 VA 208RA031 VA 148RA068 VA On lin ev 2 Fit the clutch shoes (2) over the arms (1) of the clutch carrier (3). Pull the retainers off the clutch shoes. 19 5.4 5.4.1 Clamp the clutch in a vise. 146RA204 VA 146RA206 VA 1 Push cover washer (1), "TOP" (arrow) facing outward, onto the crankshaft. Contamination (with chain oil, chips, fine particles of abrasion, etc.) and smoothing of the friction surfaces of the brake band and clutch drum impair the coefficient of friction. This, in turn, reduces the frictional forces and thus prolongs the braking time. A fatigued or stretched brake spring has the same negative effect. ep Use protective jaws so as not to damage the clutch. 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. rin t TOP Chain Brake Checking Operation rr 2 fo – Start the engine. 135RA024 VA -n 146RA207 VA ot 1 Screw on the clutch and tighten it down – see 3.5. Use the hook (2) 5910 890 2800 to attach other ends of springs and press them firmly into the clutch shoes. – Remove locking strip from the cylinder. sio n Attach one end of each spring (1) to the clutch shoes. – 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. ev er – Screw home spark plug and tighten it down – see 3.5. – With the chain brake activated (locked), open the throttle wide for a brief period (max. 3 seconds) – the chain must not rotate. – Fit boot on the spark plug. lin – Fit the shroud. On – Install clutch drum/chain sprocket – see 5.1. 20 MS 270, MS 280 5.4.2 Removing Troubleshooting chart – see 4.1. 1 – Remove the chain sprocket cover, bar and chain – wear work gloves to protect your hands from injury. 146RA009 VA 146RA006 VA – Remove the clutch drum/chain sprocket – see 5.1. Pry the brake band out of the crankcase. Remove the cover (1). ep – Relieve tension of brake spring by pushing hand guard forward. rr 1 2 rin t Take out the screws (arrows). 2 n 146RA010 VA Remove the brake band (1) from the lugs on the crankcase. Disconnect the brake band from the bell crank (2). 146RA008 VA On lin ev – Engage the chain brake by pushing the hand guard away from the front handle. sio Remove the side plate (2). Carefully ease the brake spring (1) off the anchor pin and take it off the bell crank (2). 1 er Take out the screw (1). -n 138RA004 VA ot 1 146RA007 VA fo 2 Take out the screw (arrow). MS 270, MS 280 21 4 2 146RA202 VA Remove the E-clip (1). rin t Remove the E-clip (arrow). 1 Detach the spring (2). Pull off the cam lever (3). ep 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. 146RA201 VA 146RA200 VA 3 – Inspect parts and replace if damaged. rr Important: Thickness of brake band must not be less at any point. fo – Clean the entire housing recess for the chain brake. – If the groove in the pin (4) is worn, fit a new pin – see 5.6. -n 1 146RA012 VA ot 2 sio n Carefully pry the hand guard (1) and bell crank (2) off their pivot pins and remove them together. er Pull the bell crank out of the hand guard. lin 146RA011 VA On 2 ev 1 Take out the screw (1) together with the bushing (2). 22 MS 270, MS 280 5.4.3 Installing 146RA016 VA Push the bell crank into the side of the hand guard. Check that cam lever is properly located on face (arrow) of hand guard bearing boss. ep The short arm of the bell crank must point to the top of the hand guard. rin t 146RA014 VA If the brake spring anchor pin was removed because it was worn, it must be installed before starting the following operations – see 5.6. rr 1 Push the cam lever (1) into position. 3 sio n Position the bearing boss of the hand guard (1) against the pivot pin and fit the other side of the hand guard over the housing. Fit the E-clip (2). – Coat the brake band with chain oil to protect it from corrosion and help reduce "snatching" during the first few brake applications. Press the cam lever (3) slightly downward and push the hand guard and bell crank onto their pivot pins. ev 2 lin 1 – Tighten down the hand guard mounting screw – see 3.5. 146RA210 VA On 3 Secure bell crank with E-clip. er Position the bell crank (2) against the pivot pin. 146RA017 VA -n 146RA211 VA 2 ot 1 146RA015 VA fo 2 Attach spring (1) to pivot pin (2) and cam lever (3). MS 270, MS 280 23 1 ep – Fit chain brake cover. 1 n Fit the side plate (2) over the collar screws and push it against the crankcase. sio – Coat the screw with Loctite 243 – see 14. Fit the screw (1) and tighten it down firmly. er – Fit the screw and tighten it down firmly – see 3.5. 138RA004 VA -n 146RA019 VA Push brake band into the slot in the crankcase. ev – Install the clutch drum/chain sprocket – see 5.1. – Fit the bar, chain and chain sprocket cover. Tighten down nuts on the chain sprocket cover – see 3.5. 146RA212 VA lin On 2 ot fo Check correct position of protective tube: a = 20 mm b = 32 mm Use assembly tool (2) 1117 890 0900 to attach the brake spring (1) to the anchor pin. rin t Turns of brake spring must be tightly against one another in the relaxed condition. If this is not the case, replace the brake spring. 2 rr Attach the brake band to the bell crank. 176RA046 VA 146RA018 VA b 176RA048 VA a – Check operation of chain brake – see 5.4.1. Hook the brake spring to the bell crank (arrow). 24 MS 270, MS 280 5.5 Chain Brake with QuickStop Super 5.5.1 Removing Troubleshooting chart – see 4.1. 2 – Remove the chain sprocket cover. 1 3 2 fo rr 2 2 Carefully pry the spring (1) off the pivot pin. ep Carefully ease the brake spring (1) off the anchor pin and take it off the brake lever (2). rin t 1 148RA073 VA 148RA071 VA – Remove the clutch drum/chain sprocket – see 5.1. Take out the screw (1). Remove the side plate (2). Pry the brake band (2) out of the crankcase and disconnect it from the brake lever (3). Pull the hand guard (2) and brake lever (1) off their pivot pins. ev er sio n Take out the screw (1). 148RA074 VA 1 1 146RA040 VA -n 138RA004 VA ot 1 1 2 Take out the screw (1). Remove the cover (1). Remove the bushing (2). – Relieve tension of brake spring by pushing hand guard forward. 148RA075 VA 146RA011 VA Take out the screws (arrows). MS 270, MS 280 1 2 146RA006 VA On lin 1 Unhook coasting brake cable (1) from the brake lever (2). – Pull the brake lever out of the hand guard. 25 5.5.2 Installing If the brake spring anchor pin was removed because it was worn, it must be installed before starting the following operations – see 5.6. 1 2 2 4 Attach the coasting brake cable (1) to the hole (arrow) in the brake lever (2). rin t Disconnect spring (1) from lever (2). Clean all disassembled parts in STIHL cleaner – see 14. Replace any damaged or worn parts. rr ep Pry the E-clip (3) off the pin and remove the lever with spring. 1 If the groove in the pin (4) is worn, fit a new pin – see 5.6. fo 1 146RA213 VA -n 3 Fit the lever (2) and spring (1). n Position bearing boss of the hand guard (1) against the pivot pin and fit the other side of the hand guard over the fan cover. sio Fit the E-clip (3). ev er Press the lever (1) slightly downward and push the hand guard and brake lever (2) onto their pivot pins. – Fit hand guard mounting screw at fan cover side and tighten it down firmly – see 3.5. 148RA077 VA lin On 2 ot 2 148RA078 VA 3 148RA075 VA 146RA203 VA 1 Coat all sliding and bearing points with STIHL multipurpose grease – see 14. Do not lubricate the brake band. Push the lever into the side of the hand guard. 26 MS 270, MS 280 a rin t Use the assembly tool 1117 890 0900 to attach the brake spring (1) to the anchor pin. Assemble all other parts in the reverse sequence. ep Check correct position of protective tube: a = 30 mm b = 40 mm 3 n ev Install screw (1) with Loctite 243 and tighten it down firmly – see 3.5. er First attach the brake band (2) to the brake lever (3) and then push it into the slot in the crankcase. sio 1 -n 146RA041 VA ot fo 2 Turns of brake spring must be tightly against one another in the relaxed condition. If this is not the case, replace the brake spring. 1 rr Attach spring (1) to the pivot pin. 176RA046 VA 148RA073 VA b 146RA043 VA 1 1 146RA042 VA On lin 2 Hook the brake spring (1) to the brake lever (2). MS 270, MS 280 27 5.5.3 Checking Play – Pull the hand guard towards the front handle. 1 1 – Remove the chain sprocket cover. 146RA191 VA – Remove the cutting attachment – wear work gloves to protect your hands from injury. A 1 rin t Reassemble in the reverse sequence. fo 3 rr A 4 – Check free travel by slowly squeezing the interlock lever (1). Play must be within the mark (B) at the front end of the interlock lever. The brake lever must not move. If it does, adjust play – see 5.5.4. A 1 2 Take out the screw (1) and remove the side plate (2). ot A -n 146RA179 VA A A 148RA081 VA 3 Let go of the interlock lever (1). ep Press down interlock lever (1) all the way and hold it in that position. 146RA192 VA B sio n The brake band (1) must locate without any play at the points shown (A) in the crankcase. 148RA079 VA 1 On lin ev er Take out the screws (3) and remove the cover (4). The brake cable (1) must hang loosely in the crankcase when the brake is disengaged. 28 MS 270, MS 280 Adjusting Play 5.5.5 Brake Cable Machines with QuickStop Super have an additional brake cable. 2 146RA002 VA 1 – Remove the switch shaft – see 10.1. 2 – Remove brake cable from switch lever – see 10.2.2. 1 148RA075 VA 5.5.4 – Separate crankcase and tank housing – see 9.2.2. Disconnect coasting brake cable (1) from the brake lever (2). 1 2 ep rin t Release twist lock (1) and lift away the carburetor box cover (2). 1 146RA177 VA 146RA178 VA n Reassemble in the reverse sequence. ev Turn wrench to left to increase play. Pull the brake cable (1) out of the crankcase in the direction of the rear handle. sio Turn wrench to right to reduce play. Ease the support (1) upwards and push it in the direction of the cylinder. er Use a 6mm open-end wrench to adjust play on nut (1). -n 146RA038 VA ot fo rr 1 lin Remove the switch shaft (2), see 10.1, if it gets in the way of adjustments. 1 146RA175 VA On Reassemble in the reverse sequence. Pull the cable (1) out of the tank housing in the direction of the cylinder. – Remove the brake spring – see 5.5.1. MS 270, MS 280 29 Checking Operation of Coasting Brake 5.6 Check operation of the brake with the bar and chain mounted. Brake Spring Anchor Pin 1 When starting the machine observe country-specific safety regulations and the safety precautions in the owner’s manual. If the brake does not operate properly, service the sliding and bearing points shown in the illustrations as follows: Lubricate brake lever bearing points (1) with grease – see 14. Coat outside diameter of clutch drum (2) with chain oil – see 14. Removing The anchor pin (1) must be replaced if it is worn or damaged: If lightly contaminated: – Remove the fan cover – see 8.2. – Clean all parts with a brush and STIHL cleaner – see 14. – Remove the chain brake spring – see 5.4.2 or see 5.5.1. If heavily contaminated or clogged with resin: – Remove the shroud – see 6.4. ep The chain must come to a standstill in less than one second. 1 rr – Release the rear handle. 2 146RA194 VA 2 rin t – With the engine running, open the throttle wide. 148RA048 VA 1 fo 5.5.6 ot – Remove the parts concerned and clean in STIHL cleaner – see 14. Use a suitable punch to drive the anchor pin (1) out of the crankcase in the direction of the arrow. -n – Replace worn or damaged parts. sio n – Before re-installing parts, clean machine recesses and seats with STIHL cleaner – see 14. 148RA047 VA On lin ev er If a biological chain oil is preferred, STIHL recommends the use of rapidly biodegradable STIHL Bioplus. To guarantee troublefree operation, use only original STIHL replacement parts as per the latest parts list. Do not drive out the pin in the other direction as this would damage the annular bead which was formed in the crankcase bore when the pin was originally installed. In such a case neither the new anchor pin nor the brake spring would locate properly. Furthermore, the crankcase could be damaged in this way and possibly impair correct operation of the chain brake. Lubricate bearing points (arrows) of interlock and switch levers with Mobilplex grease – see 14. 30 MS 270, MS 280 5.7 Chain Tensioner Installing 2 1 176RA054 VA – Position the new pin in the bore so that the knurling on the pin meshes with the existing knurling in the bore. Turn pin back and forth as necessary. 176RA052 VA – Before installation, coat the knurled area of the new pin with Loctite 243 – see 14. Remove the cover plate. rin t – Remove the inner side plate – see 5.4.2. rr ep Rotate the spur gear clockwise until tensioner slide (1) butts against the thrust pad (2). 176RA055 VA n Pull out the retainer (1). Take out the screw (2). MS 270, MS 280 176RA056 VA 2 176RA053 VA On lin – Fit the shroud – see 6.4. 1 ev – Fit the fan cover – see 8.2. Pull out the spur gear. sio – Coat all sliding and bearing points with STIHL multipurpose grease – see 14. er Carefully tap home the pin squarely to obtain dimension "a" (about 4 mm). -n 176RA036 VA ot fo a Take out the tensioner slide with adjusting screw and thrust pad. 31 5.8 2 Bar Mounting Studs 3 176RA117 VA Wear work gloves to protect your hands from injury. Push stud puller 5910 893 0501 over the collar stud as far as it will go. Use a 15 mm wrench to unscrew the collar stud counterclockwise. – Machines with quick chain adjuster: Before installing, coat thread of collar stud with Loctite 270 – see 14. – Machines without quick chain adjuster: Before installing, coat thread of collar stud with Loctite 243 – see 14. – Install and tighten down the collar studs – see 3.5. On lin ev er sio n -n ot fo Assemble all other parts in the reverse sequence. rin t – Coat teeth of adjusting screw and spur gear with grease, see 14, before refitting. – Remove the chain sprocket cover and cutting attachment. rr The adjusting screw and spur gear must be replaced as a matching pair. When reassembling, check that O-ring (arrow) is fitted in spur gear and coat with oil before fitting the spur gear. ep Inspect the teeth on the spur gear and adjusting screw (1), replace both parts if necessary. To do this, pull off the thrust pad (2) and unscrew the tensioner slide (3). 176RA058 VA 1 176RA057 VA 1 32 MS 270, MS 280 6 6.1 Engine Muffler/Spark Arresting Screen Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine. 6.2 Leakage Test 6.2.1 Preparations Defective oil seals and gaskets or cracks in castings are the usual causes of leaks. Such faults allow supplementary air to enter the engine and upset the fuel-air mixture. Troubleshooting chart – see 4.6. 1 – Remove the decompression valve, if fitted – see 6.8. fo sio 1 2 146RA214 VA On lin Reassemble in the reverse sequence. ev Inspect spark arresting screen (2) for damage, clean or replace if necessary. er Take out the screw (1), if fitted, and pull out the spark arresting screen (2). n Take out the screws (arrows). – Remove the muffler. – Remove the muffler – see 6.1. -n 146RA026 VA 1 – Make sure spark plug is properly tightened down – see 3.5. ot 2 Install plug (1) 1122 025 2200 and tighten down to 25 Nm. ep rr The crankcase can be checked thoroughly for leaks with the carburetor and crankcase tester and the vacuum pump. – Remove the shroud – see 6.4. rin t Moreover, the transition from idle speed to part or full throttle is not smooth. 146RA028 VA This makes adjustment of the prescribed idle speed difficult, if not impossible. Remove the heat shield (1) from the muffler (2). MS 270, MS 280 33 6.2.2 3 Pressure Test 2 1 146RA063 VA Close vent screw (1) on the rubber bulb. Fit sleeves (2) 1124 893 7100. – Pump air into the crankcase with rubber bulb until the gauge indicates a pressure of 0.6 bar. If this pressure remains constant for at least 20 seconds, the crankcase is airtight. Fit nuts (3) and tighten them down firmly. Connect pressure hose of tester 1106 850 2905 to nipple on test flange (arrow). – Remove the carburetor – see 12.2.1. fo rr The sealing plate must completely cover the opening in the heat shield. Fit the test flange 1119 850 4201 (1). rin t Fit sealing plate (1) 0000 855 8106 between the heat shield and cylinder exhaust port and tighten down the heat shield with the muffler mounting screws. ep 1 146RA180 VA 146RA215 VA 1 er sio n -n ot – Set the piston to top dead center (T.D.C.). 146RA031 VA 2 On lin ev 1 Check that the sleeve (1) and washer (2) are in place. 34 MS 270, MS 280 6.2.3 Vacuum Test If the vacuum reading remains constant, or rises to no more than 0.3 bar within 20 seconds, it can be assumed that the oil seals are in good condition. However, if the pressure continues to rise (reduced vacuum in the crankcase), the oil seals must be replaced. 146RA034 VA Oil seals tend to fail when subjected to a vacuum, i.e. the sealing lip lifts away from the crankshaft during the piston's induction stroke because there is no internal counterpressure. An additional test can be carried out with vacuum pump to detect this kind of fault. Carry out the same preparations as for the pressure test – see 6.2.1. If the pressure drops, the leak must be found and the faulty part replaced. – After finishing the test, open the vent screw and disconnect the hose. rin t – Remove the test flange. – Install the carburetor – see 12.2.1. rr ep To find the leak, coat the suspect area with oil and pressurize the crankcase again. Bubbles will appear if a leak exists. -n 146RA033 VA ot fo – Continue with vacuum test – see 6.2.3 – Remove the screws from the cylinder. Remove the sealing plate. – Mount the muffler – see 6.1. – On engines with decompression valve, unscrew the plug from the cylinder, see 6.2.1, and install the decompression valve – see 6.8. 3 2 1 146RA035 VA On lin ev er sio n Connect suction hose (arrow) of vacuum pump 0000 850 3501 to nipple of test flange. Close the vent screw (1) on the pump. Operate lever (2) until the pressure gauge (3) indicates a vacuum of 0.4 bar. MS 270, MS 280 35 6.3 Oil Seals It is not necessary to disassemble the complete crankcase to replace the oil seals. – Install the flywheel – see 7.3. – Clean sealing face with STIHL cleaner – see 14. – Fit the fan cover – see 8.2. – Lubricate sealing lip of oil seal with grease – see 14. Flywheel side – Remove the flywheel – see 7.3. Clutch side – Remove the clutch – see 5.3. 1 fo rr ep rin t – Thinly coat the outside diameter of the oil seal with sealant – see 14. 1 146RA052 VA Remove the drive spring (1) with worm. n Use the press sleeve (1) 1108 893 2405 to install the oil seal. – Remove the oil pump – see 11.4. er – Clamp the puller arms. 146RA047 VA Apply puller (1) 0000 890 4400 with No. 3.1 jaws. – Slip the oil seal, open side facing the crankcase, over the crankshaft stub. sio – Free off the oil seal in its seat by tapping it with a punch. -n 146RA046 VA ot 1 The seating face must be flat and free from burrs. ev – Pull out the oil seal. – Wait about one minute, then rotate the crankshaft several times. 146RA048 VA On lin Take care not to damage the crankshaft stub. Remove the retaining ring (arrow). – Free off the oil seal in its seat by tapping it with a punch. 36 MS 270, MS 280 6.4 Shroud 2 1 1 Apply puller (1) 0000 890 4400 with No. 3.1 jaws. – Slip the oil seal, open side facing the crankcase, over the crankshaft stub. – Clamp the puller arms. Take care not to damage the crankshaft stub. 146RA002 VA rr – Remove the installing sleeve. ep Use press sleeve (1) 1118 893 2405 to install the oil seal. Pull out the oil seal (2). Release twist lock (1) and remove the carburetor box cover (2). – Wait about one minute, then rotate the crankshaft several times. fo – Clean sealing face with STIHL cleaner – see 14. – Lubricate sealing lip of oil seal with grease – see 14. ot – Install retaining ring in crankshaft groove. – Thinly coat the outside diameter of the oil seal with sealant – see 14. 146RA070 VA 2 rin t 146RA049 VA 146RA051 VA 1 -n If the retaining ring is fatigued, fit a new one. n – Install the oil pump – see 11.4. Take out the shroud mounting screws (arrows). – Remove the shroud upwards. Reassemble in the reverse sequence. On 1 146RA050 VA lin ev er sio Reassemble in the reverse sequence. – Pull off the spark plug boot. Fit the installing sleeve (1) 1118 893 4602 on the crankshaft. MS 270, MS 280 37 6.5 6.5.1 Cylinder and Piston Removing – Remove the handlebar – see 9.1. – Remove the muffler – see 6.1. – Remove the shroud – see 6.4. 1 – Remove the carburetor – see 12.2.1. Disconnect the hose (1) from the cylinder. rin t Take out the cylinder base screws through the holes (arrows) in the cylinder. 146RA060 VA 146RA054 VA – Remove the spark plug – see 5.3. ep – Pull the cylinder off the piston. 1 Take the washer (2) off the studs. 146RA059 VA 146RA055 VA Carefully lift the cylinder and, at the same time, push the manifold through the tank housing opening. n Remove the sleeve (1) from the manifold. Unscrew the decompression valve (1), if fitted. sio 2 -n 146RA031 VA ot fo rr 1 Caution: Do not use pointed or sharp-edged tools for this job. 3 Remove the screw (1) with washer and ground wire (2). Disconnect the short circuit wire (3) and take the wires out of the guide (arrow). 2 1 146RA061 VA 146RA053 VA On lin 1 2 ev er – Remove the fan cover. Remove the clamp ring (1). Pull the manifold (2) off the intake port. – Inspect the cylinder for damage and replace it if necessary. 38 MS 270, MS 280 6.5.2 – If a new cylinder has to be installed, always fit a new matching piston. 2 Installing 1 – Remove the clutch – see 5.3. – Remove the flywheel – see 7.3. Use the assembly drift (2) 1108 893 4700 to push the piston pin (1) out of the piston. 176RA077 VA Note installed position of piston: 1 = Arrow 2 = Flywheel The arrow mark must point towards the muffler. rr ep If the piston pin is stuck, tap the end of the drift lightly with a hammer if necessary. Hold the piston steady during this process to ensure that no jolts are transmitted to the connecting rod. 2 rin t – Before removing the piston, decide whether or not the crankshaft has to be removed as well. The crankshaft has to blocked to remove the flywheel and clutch by resting the piston on the wooden assembly block with the cylinder removed or loosened. 176RA075 VA 1 ot fo – Remove the piston from the connecting rod and take the needle cage out of the small end. 2 146RA181 VA 146RA186 VA 1 Remove the hookless snap rings from the piston. Thoroughly clean the gasket seating surface (1). Wear safety glasses to protect your eyes when working with snap rings. Lubricate the needle cage (2) with oil and fit it in the small end. Push the assembly drift 1108 893 4700, small diameter first, through the piston and small end (needle cage) and line up the piston. MS 270, MS 280 176RA074 VA On lin ev er sio n -n – Inspect the piston rings and replace if necessary – see 6.6. 1 39 Push the large slotted diameter of the sleeve over the magnet and snap ring. Position the sleeve so that the inner pin (1) points toward the flat face (2) of tool's shank. 249RA148 VA 249RA146 VA Fit the piston pin (1) on the assembly drift (2) and slide it into the piston. Remove the sleeve and slip it onto the other end of the shank. Inner pin must again point toward flat face. Apply the installing tool 5910 890 2210 to the piston boss, hold the piston steady, center the tool shank exactly and press home until the snap ring slips into the groove. Attach the snap ring (1) to the magnet (2) so that the snap ring gap is on the flat side of the tool's shank. 40 249RA147 VA 1 249RA145 VA 2 On lin ev er sio n Remove the sleeve from installing tool 5910 890 2210. 249RA149 VA -n 249RA144 VA ot fo rr 1 rin t 146RA187 VA 1 ep 2 2 Stand the installing tool, sleeve downward, on a flat surface (wooden board) and press vertically downwards until the sleeve butts against the tool's shoulder. MS 270, MS 280 Wind a piece of string (1) (about 15 cm long) around the back of the manifold flange and pass the ends of the string through the intake opening. rin t – Push the manifold on to the intake port. Fit the clamping ring, note the installed position (arrow). ep Fit the snap rings so that their gaps are on the piston's vertical axis (they must point either up or down – see arrow). 146RA064 VA 249RA150 VA 176RA083 VA 1 Press the manifold down. rr – Make sure the piston rings are properly positioned. -n 146RA216 VA ot fo – Lubricate the inside of the cylinder with oil and line it up so that it is positioned as it will be in the installed condition. Position the piston rings in the grooves so that the radii at the ring gaps engage the fixing pins (arrows) in the piston grooves. upward. MS 270, MS 280 146RA063 VA 146RA065 VA 1 138RA035 VA On lin ev er sio n Coat cylinder sealing face with Dirko red – see 14. Carefully slide the cylinder (1) over the piston. Pull the ends of the string outward. The manifold flange is pulled through the tank housing intake opening without damaging the manifold. 41 6.6 – Make sure the flange is properly seated in the tank housing. Piston Rings – Remove the piston – see 6.5.1. 1 146RA031 VA – Remove the piston rings from the piston. 2 rin t Fit sleeve (1) in the manifold. Push the washer (2) onto the studs. sio Use a piece of old piston ring to scrape the grooves clean. er Fit the cylinder base screws and torque down in a diagonal pattern – see 3.5. n – Line up the cylinder. 176RA091 VA -n 146RA062 VA ot fo rr ep Reassemble all other parts in the reverse sequence. Install and tighten down the decompression valve (1) firmly (if fitted) – see 3.5. 176RA092 VA 146RA059 VA On lin ev 1 Install the new piston rings in the grooves so that the radii at the ends of the rings face upward. – Install the piston – see 6.5.2. 42 MS 270, MS 280 6.7 6.7.1 Crankcase Crankshaft Removing If the ball bearings are damaged, remove them as follows: – Remove the chain catcher – see 5.2. – Drain the oil tank. – remove the oil pump – see 11.4. – Remove the flywheel – see 7.3 fo rr ep Position the piston rings so that the radii at the ring gaps meet at the fixing pins (arrows) in the piston groove when the rings are compressed. – Remove the cylinder – see 6.5.1. rin t 138RA035 VA – Remove the chain brake – see 5.4.2. 2 Heat the ball bearing (arrow) to about 50°C and pull it off the crankshaft. – Pull off the oil seals. The crankshaft and connecting rod form an inseparable unit. This means that the crankshaft must always be replaced as a complete unit in the event of damage to either part. ev er sio n Lift the crankshaft (1) with piston (2) out of the crankcase (3). 1 If the crankshaft has to be replaced, remove the piston – see 6.5.1. 146RA072 VA lin On 135RA100 VA 146RA071 VA -n 1 ot 3 Check the ball bearings (arrows) on crankshaft (1) for damage and replace if necessary. MS 270, MS 280 43 Decompression Valve 7 Exercise extreme caution when troubleshooting or carrying out maintenance and repair work on the ignition system. The high voltages that occur can cause serious or even fatal accidents. 135RA100 VA 146RA059 VA 1 Removing If a new crankshaft has been installed, fit the piston – see 6.5.2. – remove the carburetor box cover and shroud – see 6.4. Heat the ball bearings to about 50°C and push them on, closed side facing outwards, as far as stop. Unscrew the decompression valve (1). 1 rr Installing fo – Fit the decompression valve and tighten it down firmly – see 3.5. – Fit the carburetor box cover and shroud – see 6.4. 2 The electronic ignition system basically consists of an ignition module (1) and flywheel (2). On lin ev er sio n -n – Install the cylinder – see 6.5.2. 146RA073 VA ot – Coat cylinder with 'Dirko red' before installation – see 14. Troubleshooting on the ignition system should always begin at the spark plug – see 4.4. ep Installing Reassemble all other parts in the reverse sequence. Ignition System rin t 6.8 44 MS 270, MS 280 Ignition Module 7.1.1 7.1.2 146RA074 VA – Remove the fan cover with rewind starter – see 8.2. ep The ignition module accommodates all the components required to control ignition timing. There are two electrical connections on the coil body: Since there is no mechanical wear in these systems, ignition timing cannot get out of adjustment. However, an internal fault in the circuit can alter the switching point in such a way that a spark test will still show the system to be in order although timing is outside the permissible tolerance. This will impair engine starting and running behavior. Removing and Installing – Remove the shroud – see 6.4. Ignition timing is permanently set according the design specification cannot be adjusted during repair work. 2 High voltage output with ignition lead (1). 1 fo rr Connector tag (2) for short circuit wire. Pull the short circuit wire (1) off the connector tag on the ignition module. 1 1 146RA076 VA On lin ev er sio n -n ot Testing in the workshop is limited to a spark test. A new ignition module must be installed if no ignition spark is obtained (after checking that wiring and stop switch are in good condition). 146RA075 VA 1 Ignition Timing rin t 7.1 Take out the screws (1) and washers and remove the wires from the guide (arrow). – Remove the ignition module. MS 270, MS 280 45 7.1.3 If the ignition lead is damaged, install a new ignition module. Testing the Ignition Coil 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. If the spark plug boot is damaged, install a new one – see 7.2. 1 146RA078 VA Reassemble in the reverse sequence. The ignition test refers only to a spark test, not to ignition timing. rin t – Rotate the flywheel until the pole shoes are under the ignition module. rr 1 ep Slide the setting gauge (1) 1111 890 6400 between the arms of the ignition module and the flywheel pole shoes. er ev lin On 2 3 208RA053 VA ot -n – Fit the fan cover and tighten down the screws – see 3.5. – Fit the shroud – see 6.4. 46 1 – Connect the short circuit wire. n Use the left-hand screw with washer (arrow) to secure the the ground wire (1). – Remove the setting gauge and use a feeler gauge to check the air gap. It should be 0.2 to 0.3 mm. sio 146RA077 VA fo – Press the ignition module against the flywheel and tighten down the mounting screws – see 3.5. Using the ZAT 4 ignition tester 5910 850 4503 – Before starting the test, install a new spark plug in the cylinder and tighten it down firmly – see 3.5. Pull the boot off the spark plug and connect it to the input terminal (1). Push the tester’s output terminal (3) onto the spark plug. – Crank the engine quickly with the rewind starter (min. 1,000 rpm) and check spark in the tester’s window (2). MS 270, MS 280 Warning! The engine may start and accelerate during the test. If a spark is visible, the ignition system is in order. – Before starting the test, install a new spark plug in the cylinder and tighten it down firmly – see 3.5. If a spark is visible, the ignition system is in order. In case of doubt about the result, perform additional test with ZAT 3. If no spark is visible in the window (2), check the following points: Pull the boot off the spark plug and connect it to the terminal (2). Attach ground terminal (1) to the spark plug. IIf no spark is visible in the window (3), check the following points: Use adjusting knob (3) to set spark gap to about 2 mm. – Check the wiring harness for damage – see 7.4. rin t – Check the wiring harness for damage – see 7.4. – If necessary, check ignition system with aid of the troubleshooting chart – see 7.6. – Check operation of start-stop switch – see 7.5. – Check operation of start-stop switch – see 7.5. ep – Check leg spring – see 7.2. – Check leg spring – see 7.2. -n ot fo rr – If necessary, check ignition system with aid of the troubleshooting chart – see 7.6. er sio n 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). Warning! High voltage – risk of electrocution. lin ZAT 3 ev 3 1 2 208RA054 VA On 5910 850 4520 Using ZAT 3 ignition tester 5910 850 4520 – Crank the engine quickly with the rewind starter (min. 1,000 rpm) and check sparkover in the tester’s window (3). Warning! The engine may start and accelerate during the test. It is necessary to use the ZAT 3 ignition system tester 5910 850 4520 to test the auxiliary spark gap. MS 270, MS 280 47 7.2 Spark Plug Boot 7.3 Flywheel – Remove the fan cover with rewind starter – see 8.2. Use suitable pliers to pull the leg spring out of the spark plug boot. rin t – Remove the shroud – see 6.4. Pinch the hook (arrow) of the leg spring into the center of the lead, i.e. about 15 mm from the end of the lead. ep – Pull boot off the spark plug. 176RA160 VA 176RA159 VA – Block the piston with the locking strip – see 5.3. rr – Unhook the leg spring from the ignition lead. fo – Pull the boot off the ignition lead. Pull the lead back into the boot so that the leg spring locates properly inside it (see arrow). 146RA079 VA Unscrew the flywheel nut (arrow). sio n – Use pliers to grip the end of the ignition lead inside the spark plug boot and pull it out. -n – Fit spark plug boot over the ignition lead. 366RA104 VA ot – Coat end of the ignition lead (about 20 mm) with oil. 146RA080 VA On lin ev er Reassemble in the reverse sequence. 1 If the flywheel cannot be removed by hand, screw on the puller (1) 4133 893 0800 and tap its end to release the flywheel. 48 MS 270, MS 280 Short Circuit Wire/ Ground Wire 1 2 If the insulation of the short circuit wire (1) is damaged it can cause a short circuit to ground and upset or completely interrupt ignition. Replace damaged wires. Pull off the flywheel. To remove the short circuit wire (1) and the ground wire (2), perform the following operations: Reassemble in the reverse sequence. – Remove the fan cover with rewind starter – see 8.2. Degrease crankshaft stub and bore in flywheel with STIHL cleaner – see 14. – Remove the shroud – see 6.4. ot 146RA053 VA -n Remove the screw (1) with washer and ground wire (2). Disconnect the short circuit wire (3) and take the wires out of the guide (arrow). ev er sio n Check position of slot. Assemble all other parts in the reverse sequence. 3 – Remove the air filter/filter base – see 12.1. – Fit the flywheel in position. – Fit the flywheel nut and tighten it down firmly – see 3.5. 1 2 fo rr ep Inspect flywheel and magnet poles for cracks or other damage. If you find any damage, install a new flywheel. Pull the ground wire (1) off the contact spring (2). rin t – Remove the puller from the crankshaft. 1 146RA082 VA 146RA081 VA 2 146RA084 VA 7.4 Pull the connector sleeve of the short circuit wire (1) out of its seat in the switch shaft. 146RA085 VA 1 146RA083 VA On lin 1 Pull the grommet (1) out of the tank housing. – Pull the wires out of the tank housing. MS 270, MS 280 49 7.5 Stop Contact 3 2 Reassemble in the reverse sequence. The contact spring is in order if the short circuit wire makes contact with the connector sleeve when the Master Control lever is in the "STOP" position. Replace the contact spring if it is broken or bent. Replace the contact spring as follows: fo Important: Make sure the wires are properly positioned in the area of the flywheel. ep – Remove the air filter/filter base – see 12.1. rr Remove the wires from the retainers (arrows). rin t 146RA088 VA 146RA087 VA 1 ot Pull the wire (1) off the contact spring (2). -n Pry the contact spring (2) out of the retaining clip (3) and remove it. On lin ev er sio n Reassemble in the reverse sequence. 50 MS 270, MS 280 7.6 Ignition System Troubleshooting Engine does not run ep -n ot fo rr Check the spark plug: – Smeared with oil, black? – Sooted? – Electrode gap correct? – Contacts shorted? Clean the plug, reset or replace rin t Master Control lever/slide control or separate stop switch in position "1"? On lin ev er sio n Check spark plug boot: – Firmly seated on plug (leg spring)? – Leg spring hook in center of ignition lead? – Boot damaged? If necessary, install new spark plug boot and/or leg spring Test ignition system with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap – see TI 32.94) 1 MS 270, MS 280 51 1 Powerful spark? yes rin t no fo rr ep Check air gap and reset if necessary -n ot Check flywheel: – Have pole shoes turned blue? Install new flywheel er sio n Disconnect short circuit wire from ignition module On lin ev Check ignition lead: – Severe chafing? – Spark plug boot: Holes/cracks? – Resistance: spark plug boot to ground: spec. 1.5 – 12kΩ – Check resistance of ignition lead: spec. < 10 Ω, If necessary, install new spark plug boot and/or ignition lead 2 52 3 MS 270, MS 280 2 rr ep Check operation of Master Control lever/slide control or separate stop switch – Short circuit wire chafed? – Contact gap (contact springs) If necessary, install new ignition lead and/or contact springs Re-connect short circuit wire rin t 3 yes ot fo Powerful spark? -n no lin Engine runs no On yes ev er sio n Install new ignition module Check ON/STOP function on Master Control lever/ slide contro or separate stop switch MS 270, MS 280 Look for fault in fuel system or carburetor, check engine for leaks, check position of flywheel on crankshaft 53 8.2 Pawls Removing – Remove the fan cover with rewind starter – see 8.2. rin t Removing Take the screws (arrows) out of the fan cover. ep – Remove the fan cover. 1 fo If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed and disassembled – see 14. rr Wash all parts in STIHL cleaner – see 14. 1 ot 2 Lubricate the rewind spring and starter post with STIHL special lubricant, see 14, before installing. n Installing Use a screwdriver or pliers to carefully remove the spring clip (1) from the starter post. er sio The hand guard is mounted to the fan cover and fan housing with the IS-M5x35 screw (1) and bushing (2). 146RA092 VA Carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored. 8.3 146RA091 VA If the action of the starter rope becomes very stiff and the rope rewinds very slowly or not completely, it can be assumed that the starter mechanism is in order but plugged with dirt. At very low outside temperatures the lubricating oil on the rewind spring may thicken and cause the spring windings to stick together. This has a detrimental effect on the function of the starter mechanism. In such a case it is sufficient to apply a few drops of paraffin (kerosine) to the rewind spring. Fan Cover 146RA011 VA Rewind Starter General -n 8 8.1 On lin Reassemble all other parts in the reverse sequence. 1 2 146RA093 VA ev – Tighten down the screws firmly – see 3.5. – Pull the pawls (1 and 2) out of the rope rotor. 54 MS 270, MS 280 8.4 Rope Rotor – Remove the fan cover with rewind starter – see 8.2. Installing – Coat pegs of new pawls with graphite grease – see 14. Reassemble all other parts in the reverse sequence. Relieving tension of rewind spring: 1 146RA094 VA The rewind spring will not be under tension if the starter rope is broken. – Pull out the starter rope about 5 cm and hold the rope rotor steady. – Carefully pull the rope rotor off the starter post. ep – While still holding the rope rotor steady, take three full turns off the rope rotor. rin t Remove the washer (1) from the starter post. The rewind spring may pop out and unwind if rope rotor is not removed very carefully. – Remove the starter rope from the rotor. – Remove the starter rotor – see 8.5. fo rr – Pull out the rope with the starter grip and slowly release the rope rotor. ot Reassemble in the reverse sequence. -n – Install the starter rope – see 8.5. lin ev er sio n – Coat bore in rope rotor with STIHL special lubricant – see 14. Use a screwdriver or pliers to carefully remove the spring clip (1) from the starter post. 249RA141 VA 146RA092 VA On 1 1 2 Fit the rotor on the starter post so that the lug (1) on the rope rotor slips behind the inner spring loop (2). – Tension the rewind spring – see 8.5.2. MS 270, MS 280 55 8.5 Starter Rope Thread the end of the rope through the hole in the side of the rotor, pull it out. rin t Starter grips without ElastoStart: Thread one end of new rope through the top of the starter grip and tie a simple overhand knot. 146RA229 VA 146RA195 VA – Remove the fan cover with rewind starter – see 8.2. ep – Pull the rope with knot into the starter grip. rr – For ElastoStart grips – see 8.5.1. – Secure the rope with a simple overhand knot. sio n Unclip the segment (1) from the upper retainer in the fan cover and take it out of the lower retainers. Pull the rope back until the knot locates in the recess (arrow) in the rope rotor. er – If the starter rope is broken, remove the remaining rope from the rope rotor, fan cover and starter grip. 146RA230 VA -n 146RA090 VA ot fo 1 ev – Tension the rewind spring – see 8.5.2. – Fit fan cover with rewind starter – see 8.2. 146RA097 VA On lin – If the starter rope is worn, relieve tension of rewind spring, see 8.4, pull the end of the rope out of the rotor and undo the knot. Then pull the worn rope out of the starter grip, fan cover and rotor. Thread the other end of the rope, from outside, through the guide bush in the fan housing. 56 MS 270, MS 280 8.5.1 ElastoStart 8.5.2 – Remove the fan cover with rewind starter – see 8.2. Tensioning – Pull the grip and, if necessary, the spring element off the starter rope. 146RA098 VA – Relieve tension of rewind spring – see 8.4. ep rin t Make a loop in the starter rope. Pry the cap (1) out of the starter grip. 2 sio n Thread end of new starter rope through the grip (1) and the spring element (2) – if removed. Grip the rope next to the rotor (in area of arrow) and use it to turn the rope rotor six times clockwise. er Tie a simple overhand knot in the end of the rope. 146RA099 VA 1 380RA065 VA -n 146RA198 VA ot fo rr 3 1 ev Pull the rope and spring element into the grip and then fit the cap (3). 2 146RA231 VA 1 On lin – Tension the rewind spring – see 8.5.2. – Fit fan cover with rewind starter – see 8.2. Pull starter rope and, if necessary, the spring element (2) out of the grip (1). Undo the knot (arrow) in the starter rope. MS 270, MS 280 57 8.6 Starter Rope Guide Bush When the starter rope is fully extended, it must still be possible to rotate the rope rotor at least another half turn before maximum spring tension is reached. If this is not the case, pull the rope out, hold the rope rotor steady and take off one turn of the rope. 2 1 176RA187 VA ot fo – Let go of the rope rotor and slowly release the starter rope so that it can rewind properly. rin t – Hold the starter grip firmly to keep the rope tensioned. The rewind spring is correctly tensioned when the starter grip sits firmly in the rope guide bush without drooping to one side. If this is not the case, tension the spring by one additional turn. ep Pull out the rope with the starter grip and straighten it out. – Remove the rope rotor – see 8.4. rr Hold the rope rotor steady. 135RA122 VA 146RA100 VA Wear on the guide bush is accelerated by the starter rope being pulled sideways. The wall of the guide bush eventually wears through and the bush becomes loose. -n Do not overtension the rewind spring as this will cause it to break. Pull knot (1) out of recess (2) in the rope rotor. – Undo the knot. Pull starter rope out of the rope rotor and guide bush. On lin ev er sio n – Fit the fan cover – see 8.2. 58 MS 270, MS 280 8.7 Replacing the Rewind Spring Troubleshooting chart – see 4.2. 1 The replacement spring comes ready for installation and is secured in a frame. 1 Important: Wear a face shield and work gloves. – Remove the rope rotor – see 8.4. – Fit the thrust sleeve (1), tapered end first, and the hex nut. Tighten down the hex nut until the bush is firmly seated. The installing tool flares the lower end of the rope bush. Installing the rope bush – Remove the installing tool. rr ep – Use a suitable tool to pry the damaged bush out of the fan cover. rin t If necessary, unclip segment (1) from upper retainer in the fan cover and take it out of the lower retainers. 146RA102 VA 146RA090 VA Removing -n 138RA108 VA ot fo – Place the new bush in its seat in the fan cover. sio n Use suitable pliers to grip the outer spring loop and lift it up. – Take the rewind spring out of the fan cover. lin ev er – Remove any remaining pieces of spring from the fan housing and fan cover. 146RA101 VA 146RA097 VA On 1 Insert the screw spindle (1) of the installing tool 0000 890 2201 through the bush from inside the fan cover. Thread the starter rope through the guide bush from outside and fit it on the rope rotor – see 8.5. – Install the rope rotor – see 8.4. MS 270, MS 280 59 9 9.1 AV Handle System Handlebar 138RA110 VA 146RA196 VA – Remove the shroud – see 6.4. The spring anchor loop must engage the lug in the fan cover. – Fit the spring housing in the fan housing and press the spring loop into the recess at the same time. Place suitable guides on the recesses (arrows) and push the spring into its seat in the fan cover. ot – Tension the rewind spring – see 8.5.2. fo – Install the rope rotor – see 8.4. ep – Position replacement spring with frame in the fan cover. rr – Lubricate the spring with a few drops of STIHL special lubricant before installation – see 14. rin t Fit the rewind spring in the counterclockwise direction, starting from outside and working inwards. Installing Take out the screws (arrows). 1 Position the anchor loop about 25 mm from the edge of the spring housing. 60 146RA105 VA 138RA109 VA On lin ev er sio n -n If the rewind spring has popped out, refit it in the assembly tool 1116 893 4800 as follows: 146RA104 VA Reassemble all other parts in the reverse sequence. Use screwdriver (1) to pry the clip upwards. MS 270, MS 280 9.2 Replacing Annular Buffers 9.2.1 Crankcase Removing Annular rubber buffers and a spring are installed between the tank housing and crankcase to minimize vibrations. Damaged annular buffers must always be replaced. 146RA106 VA – Remove the handlebar – see 9.1. 2 1 Fit an M6 screw (1) in the bushing in the annular buffer (2). ev er sio n Take out the screws (arrows). 146RA217 VA -n 138RA207 VA ot fo rr ep rin t Push the retainer through the handlebar to the outside and remove. 146RA218 VA 1 146RA107 VA On lin 1 Pry plug (1) out of the handlebar to expose the annular buffer. Use the screw to pull out the bushing (1). – Pry the annular buffer out of the handlebar. – Take the screw out of the bushing. Reassemble in the reverse sequence. MS 270, MS 280 61 9.2.2 Tank Housing Removing – Remove the chain sprocket cover. – Remove the cutting attachment – wear work gloves to protect your hands from injury. 146RA220 VA 146RA108 VA 1 1 Use the screw to pull out the bushing (1). rin t Use a screwdriver to pry the annular buffer (1) out of its seat in the crankcase. ep – Take the screw out of the bushing. fo rr 1 Remove the chain catcher (1) – see 5.2. ev Push home the annular buffer until the groove (arrow) engages over the housing rib. Remove the bumper strip (2) and pry the plugs (arrows) out of the annular buffers. er – Coat inside and outside of annular buffer with STIHL installing fluid – see 14. sio n Installing 2 2 3 146RA221 VA 1 146RA109 VA -n 135RA126 VA ot 2 Pull annular buffer (1) out of its seat (3) in the tank housing and the seat (2) in the crankcase. – Repeat the procedure (fitting an M6 in the bushing, pulling bushing out with the screw and then pulling out the annular buffer) on the second annular buffer in the tank housing. lin – Push the bushings, flat end first, home as far as stop. 1 146RA219 VA On Reassemble all other parts in the reverse sequence. Fit an M6 screw (1) in the bushing in the annular buffer (2). 62 MS 270, MS 280 9.3 Spring 1 3 3 146RA228 VA 2 146RA222 VA – Remove the fan housing – see 11.5. Engage bearing plug with spring in the teeth (arrow) in the fan housing. rin t Installing – Coat inside and outside of annular buffer with STIHL installing fluid – see 14. Note the different shapes of annular buffers (1) and (2). Make sure they are not switched during installation. fo – Inspect fan housing, bearing plug and spring for damage and replace if necessary. Reassemble in the reverse sequence. 146RA227 VA -n – Remove the bearing plug from the fan housing. n Apply a screwdriver to the coil end and unscrew the spring (1) together with the bearing plug (2). sio Reassemble all other parts in the reverse sequence. ot 1 Press home the bushings (3), flat end first, as far as stop. rr 2 – Press home annular buffers in crankcase and tank housing until their grooves are properly seated in the housings. Do not use pointed or sharp-edged tools for this job. ep Use pliers to unscrew the spring from the bearing plug. If the spring is too tight on the bearing plug, proceed as follows: 146RA115 VA On lin ev er – To ensure that the teeth on the bearing plug are not damaged during disassembly, unscrew the bearing plug from the spring by hand. When installing the spring, make sure the end of the spring coil butts against the stop (arrow) on the tank housing. MS 270, MS 280 63 10 Master Control/ Handle System 10.1 Switch Shaft – Remove the carburetor – see 12.2.1. Install in the reverse sequence. 146RA189 VA 1 rin t Inspect fan housing gasket (1) and replace if necessary. 146RA089 VA -n sio n Remove the short circuit wire (1) from the switch shaft (2). ev 2 3 1 146RA183 VA On lin Reassemble all other parts in the reverse sequence. 1 er Before fitting the screw (1) above the spring, insert a 5 mm diameter drift or punch in the hole (arrow) to prevent the bearing plug, with spring, slipping out of the tank housing. ot 146RA116 VA fo 1 rr 2 ep – Fit the fan housing and tighten down the screws firmly – see 3.5. Pry the switch shaft (1) out of the tank housing (2). Carefully pull the switch shaft (1) out of the pivot mount (3). 64 MS 270, MS 280 Pull the throttle rod out of the throttle trigger sideways. 176RA216 VA 1 sio n Drive out the pin (3) with a 5 mm drift. Take out the throttle trigger (2) with torsion spring (1). 3 2 146RA121 VA 146RA120 VA -n ot fo rr 3 21 rin t Push the two retainers (arrows) on the underside of the hand guard apart and remove the handle molding upwards. The torsion spring must be installed so that it is under the interlock lever and locates in its seat. ep – Remove the carburetor box cover – see 6.4. 146RA119 VA 146RA117 VA 10.2 Throttle Trigger/Interlock Lever 10.2.1 Machines without QuickStop Super Press down the interlock lever (1). Press the throttle trigger (2) up and the switch shaft (3) to "Choke" position. er Install in the reverse sequence. 146RA118 VA On lin ev 1 – Move the switch shaft to the normal operating position. Pull out the interlock lever (1). MS 270, MS 280 65 10.2.2 Machines with QuickStop Super Press down the end of the handle molding until the retainers snap into position in the handle housing. Push the two retainers (arrows) on the underside of the hand guard apart and remove the handle molding upwards. 148RA100 VA – Remove the carburetor box cover – see 6.4. 1 Use a 4.5 mm drift to drive the bushing (1) out of the interlock lever (2) and then remove the torsion spring (3). rin t 146RA117 VA Fit the handle molding so that the lugs engage the recesses. 2 148RA054 VA -n ot fo rr ep 146RA122 VA 3 1 er sio n To remove the switch lever (1), tilt it back. 2 Ø 1 Use a 3 mm drift to drive the needle roller (2) out of the interlock lever (1). Remove the interlock lever. 66 2 148RA055 VA 148RA099 VA On lin ev 1 Disconnect brake cable (1) from switch lever (2). – Use a 3 mm drift to drive the needle roller out of the switch lever. MS 270, MS 280 – Remove the switch lever. – To remove the throttle trigger, first remove the switch shaft – see 10.1. Chain Lubrication Pickup Body/ Suction Hose Impurities gradually clog the fine pores of the filter with minute particles of dirt. This prevents the oil pump from supplying sufficient oil to the bar and chain. In the event of problems with the oil supply system, first check the oil tank and the pickup body. Clean the oil tank if necessary. 146RA223 VA 11 11.1 1 Troubleshooting chart – see 4.3. ep rin t Disconnect the suction hose (1) from the oil pump. Removing – Take the torsion spring off the throttle trigger. Collect chain oil in a clean container or dispose of it properly at an approved disposal site. n Use a 5 mm drift to drive out the pin (3) and then remove the throttle trigger (2) with torsion spring (1). er – Remove the clutch – see 5.3. When installing, make sure that short arm of torsion spring locates in the throttle trigger. The long arm points toward the carburetor. 2 146RA224 VA 1 – Remove the chain catcher – see 5.2. 146RA124 VA On lin Pull the suction hose (1) with pickup body out of the crankcase. sio Unscrew the oil filler cap (arrow) and drain the oil tank. ev Install in the reverse sequence. 1 146RA197 VA 3 -n 148RA058 VA 1 ot fo rr 2 Pull the pickup body (1) off the suction hose (2). – Inspect the pickup body for damage and dirt and replace if necessary. MS 270, MS 280 67 11.2 As a temporary measure, a dirty pickup body may be washed in STIHL cleaner – see 14. Troubleshooting chart – see 4.3. – Remove the chain sprocket cover and cutting attachment. – Examine suction hose for signs of damage and replace if necessary. 146RA226 VA Wear work gloves to protect your hands from injury. 1 – Remove the clutch drum/chain sprocket – see 5.1. rin t Use a blunt tool to push the grommet (1) into position in the crankcase. Make sure the grommet is properly seated. n sio rr Take out the screw (1). Remove the side plate (2). – Engage the chain brake by pushing the hand guard away from the front handle. On lin ev Insert suction hose, pickup body first, in the crankcase. er Coat grommet (1) on suction hose with a little oil. 1 138RA004 VA -n 146RA225 VA Installing – Push the pickup body into the suction hose. 2 ot fo Reassemble all other parts in the reverse sequence. ep Connect the suction hose to the oil pump. 1 Delivery Hose 68 MS 270, MS 280 11.3 A vent valve is installed in the tank wall to keep the internal pressure in the oil tank equal to atmospheric pressure. 1 1 Valve 146RA130 VA 146RA006 VA Removing 2 – Unscrew the oil filler cap. When installing, make sure the hose is properly positioned (arrows) and not kinked. The hose (1) must be fitted behind the brake band (2). 1 Collect chain oil in a clean container or dispose of it properly at an approved disposal site. Pull the hose (2) off the oil pump (3) and take it out of teh crankcase. Use a suitable tool to carefully press the sleeve (1) into position. 176RA242 VA 146RA131 VA n – Carefully install the hose in the crankcase, making sure the sleeve does not drop out in the process. Use a 3 mm diameter drift to carefully drive the valve out of the housing from inside the tank. Installing ev Install in the reverse sequence. Fit the sleeve (1) in the hose. sio Carefully remove the sleeve (1) from the hose. er 3 -n 146RA129 VA ot fo rr 1 – Drain the oil tank. ep Remove the cover (1). rin t Take out the screws (arrows). 2 – Remove the inner side plate – see 5.4.2. On lin Reassemble all other parts in the reverse sequence. Use a 7 mm diameter drift to carefully push home the valve until it is about 1 mm below the housing face ('a' in illustration). Reassemble in the reverse sequence. MS 270, MS 280 69 11.4 Oil Pump 11.5 Check the suction hose and pickup body before replacing the oil pump. Fan Housing – Drain the oil tank. 1 2 – Remove the flywheel – see 7.3. – Remove the clutch – see 5.3. Dispose oil and fluids properly. 146RA128 VA – Remove the brake band – see 5.4.2. 3 rin t Take out the screws (arrows). Disconnect the delivery hose (2) and suction hose (3). ep Remove the oil pump (1). rr Install in the reverse sequence. Make sure the hoses are free from kinks. fo 1 1 Take out the fan housing mounting screws (arrows). Remove the fan housing (1). lin ev er sio n Pull worm (1) with drive spring off the crankshaft. 146RA069 VA -n 146RA127 VA ot – Lubricate worm with grease before installation – see 14. If necessary, remove the drive spring from the worm. 146RA189 VA 176RA245 VA On 1 Inspect fan housing gasket (1) and replace if necessary. Install in the reverse sequence. 70 MS 270, MS 280 12 12.1 Fuel System Air Filter Dirty air filters reduce engine power, increase fuel consumption and make starting more difficult. 1 Wash air filter thoroughly in STIHL cleaner – see 14. Replace a damaged air filter. 146RA116 VA The air filter should be cleaned when there is a noticeable loss of engine power. rin t – Fit the fan housing and tighten down the screws firmly – see 3.5. ep Before fitting the screw (1) above the spring, insert a 5 mm diameter drift or punch in the hole (arrow) to prevent the bearing plug, with spring, slipping out of the tank housing. rr 2 146RA002 VA -n 146RA133 VA 1 ot fo Reassemble all other parts in the reverse sequence. Unscrew the collar nuts (arrows). Remove the carburetor box cover (2). Pull off the baffle in the direction of the arrow. lin ev er sio n Release the twist lock (1). – Remove all loose dirt from around the filter. Pull air filter (1) away to the rear. MS 270, MS 280 146RA134 VA 1 146RA132 VA On 1 Remove the filter base (1). Install in the reverse sequence. 71 12.2 Carburetor 12.2.1 Removing and Installing – Troubleshooting chart – see 4.5. 1 – Remove the filter base – see 12.1. 146RA031 VA 146RA138 VA – Open the tank cap to release internal pressure. – Close the tank cap. 2 Before fitting the carburetor, check that the sleeve (1) and washer (2) are in position. rin t Fit the air filter and make sure it is correctly seated (arrows). 146RA135 VA -n ot fo rr ep Reassemble in the reverse sequence. 1 146RA136 VA On lin ev er sio n Use a screwdriver to press the throttle shaft down and disconnect the throttle rod. Pull the hose (1) off the carburetor. – Remove the carburetor. 72 MS 270, MS 280 12.2.2 Leakage Test 12.3 Servicing the Carburetor 12.3.1 Metering Diaphragm In the case of problems with the carburetor or fuel supply system, also check and clean or replace the tank vent – see 12.5. 3 – Remove the carburetor – see 12.2.1. 2 1 – Remove the carburetor – see 12.2.1. ep 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 (8 kPa). 1 rr 2 – Connect the tester's pressure hose 1106 850 2905 to the nipple. rin t – Remove the filter base – see 12.1. 249RA012 VA The carburetor can be tested for leaks with the carburetor and crankcase tester 1106 850 2905. -n 143RA172 VA 1. The inlet needle is not sealing (foreign matter in valve seat or sealing cone of inlet needle is damaged or inlet control lever sticking). Remove to clean – see 12.3.2. n Push the fuel line (1) 1110 141 8600 onto the nipple (2) 0000 855 9200. sio 2. Metering diaphragm damaged, replace if necessary – see 12.3.1. 1 146RA142 VA ot fo If this pressure remains constant, the carburetor is airtight. However, if it drops, there are two possible causes: Take out the screws (arrows). Remove the end cover (1). ev er – After completing the test, open the vent screw (1) and pull the fuel line off the carburetor. lin – Push the fuel hose onto the elbow connector. Disconnect fuel hose (1) from the carburetor. Reassemble all other parts in the reverse sequence. 146RA143 VA – Install the carburetor – see 12.2.1. 146RA136 VA On 1 Remove the metering diaphragm and gasket (arrow) from the carburetor body or end cover. – Push the fuel line with nipple onto the carburetor’s elbow connector. MS 270, MS 280 73 12.3.2 Inlet Needle Place the gasket on the carburetor body so that the tab (arrow) points towards the adjusting screws. 146RA147 VA 146RA145 VA If the gasket and diaphragm are stuck to the carburetor, remove them very carefully. rin t – Remove the metering diaphragm – see 12.3.1. Take out the screw (arrow). ep – Remove the inlet control lever with spindle. fo rr Note: There is a small spring under the inlet control lever which may pop out during disassembly. Install in the reverse sequence. 146RA146 VA n sio The gasket and metering diaphragm are held in position by integrally cast pegs. ev The diaphragm, inlet and outlet valves are subjected to continuous alternating stresses and the material eventually shows signs of fatigue, i.e. the diaphragm distorts and swells and has to be replaced. Fit the metering diaphragm (1) on the carburetor body so that the perforated plate faces the inlet control lever and the tab (arrow) points towards the adjusting screws. er Carefully separate the diaphragm and gasket. 1 -n 176RA272 VA ot – Take out the inlet needle. lin – Fit the end cover. Reassemble all other parts in the reverse sequence. 146RA149 VA On – Insert the screws and tighten them down firmly – see 3.5. If there is an annular indentation on the sealing cone of the inlet needle, it will be necessary to replace the inlet needle because it will no longer seal properly. 74 MS 270, MS 280 12.3.3 Fixed Jet Install in the reverse sequence. The upper edge of the inlet control lever must be flush with the top of the carburetor body. 1 – Install the metering diaphragm – see 12.3.1. 146RA150 VA Reassemble all other parts in the reverse sequence. rin t – Remove the metering diaphragm – see 12.3.1. ep Use a suitable screwdriver to unscrew the fixed jet (1). rr 4 fo 3 -n 146RA148 VA 2 Reassemble in the reverse sequence. ot 1 Take care not to damage the fixed jet with the screwdriver when removing and installing. n Fit the inlet needle (1). sio Fit spring (2) in bore. ev – Engage clevis in annular groove on head of the inlet needle. er Insert spindle (3) in the inlet control lever (4). lin – Press the inlet control lever down and secure it with the screw. On Make sure the helical spring locates on the control lever’s nipple. – Check that inlet control lever moves freely. MS 270, MS 280 75 12.3.4 Pump Diaphragm The diaphragm, inlet and outlet valves are subjected to continuous alternating stresses and the material eventually shows signs of fatigue, i.e. the diaphragm distorts and swells and has to be replaced. 146RA144 VA 146RA139 VA 1 1 Place the diaphragm and gasket on the carburetor body so that their tabs (arrow) point towards the elbow connector (1). rin t Take out the screw (arrow). Remove the end cover (1). ep – Fit the end cover on the carburetor body. The pump diaphragm, gasket and end cover are held in position by pegs on the end cover. fo rr 1 1 2 146RA141 VA Reassemble all other parts in the reverse sequence. n Inspect the fuel strainer (1) for contamination and damage. If necessary, use a needle to remove it from the carburetor body and clean or replace. sio Carefully remove the gasket (1) and pump diaphragm (2) from the end cover or carburetor body. -n 146RA140 VA ot – Fit screw and tighten down firmly – see 3.5. 176RA268 VA On lin ev er Install in the reverse sequence. Carefully separate the diaphragm and gasket. – Inspect diaphragm for damage and wear, install a new gasket. 76 MS 270, MS 280 12.3.5 Accelerator Pump – Remove the carburetor – see 12.2.1. 1 – Set the throttle shaft to the full throttle position. Carefully pull the throttle shutter out of the shaft. Remove ball (1), pump piston (2) with sealing ring (3) and spring (4) from the carburetor body. rin t 146RA153 VA 4 146RA155 VA 2 3 146RA154 VA -n 146RA151 VA Use a suitable pointed tool to remove the sealing plug. 1 ot fo rr ep – Inspect parts for damage and wear and replace if necessary. sio n Remove the snap ring (1) from the throttle shaft. Wear safety glasses while installing the accelerator pump/ throttle shaft to protect your eyes from injury if parts suddenly pop out of the carburetor body. Note correct installed sequence of the individual parts of the accelerator pump: First fit the spring (4), then the pump piston (2), with the ball seat (arrow) facing you, and the ball (1). Use a suitable tool to press the ball (1) down and fit the throttle shaft. ev er Hold accelerator pump bore closed with one finger so that the parts of the accelerator pump do not pop out of the carburetor when the throttle shaft is removed. Wear safety glasses. Install in the reverse sequence. On 1 146RA152 VA lin – Pull the throttle shaft out of the carburetor body. Take the screw (1) out of the throttle shutter. MS 270, MS 280 77 Fit the throttle shutter (1) in the shaft. 146RA160 VA 1 1 Check that the center of the notch in the throttle shutter is in line with the hole (arrow) in the carburetor body. rin t Check correct installed position of the spring (1). 146RA159 VA 146RA157 VA 1 ep Tighten the screw (1) moderately. rr – Center the throttle shutter so that it moves freely. fo – Tighten down the screw (1) firmly. 146RA161 VA n Check that the stamped digits face you. sio Use a suitable tool to carefully install a new sealing plug (arrow) in the accelerator pump’s bore. -n 146RA151 VA ot – Check freedom of movement again. 146RA158 VA On a lin ev er The two marks (see arrows) must be parallel to the throttle shaft. Press home sealing plug so that it is recessed 1 mm (dimension 'a') in the accelerator pump’s bore. 78 MS 270, MS 280 12.4 Adjusting Adjustments for operation at high altitude or sea level Chain runs while engine is idling – Turn the idle speed screw (LA) counterclockwise until the chain stops running. Then turn the screw about another full turn in the same direction. – Idle setting too lean. Turn the low speed screw (L) counterclockwise, but no further than stop, until the engine runs and accelerates smoothly. – It is usually necessary to change the setting of the idle speed screw (LA) after every correction to the low speed screw (L). – Open the high speed screw (H) counterclockwise as far as stop. ot fo Make the following adjustments: – Turn high speed screw (H) clockwise (leaner) no further than stop. ep – With this carburetor it is only possible to correct the settings of the high speed screw (H) and low speed screw (L) within fine limits. At high altitude rr Do not remove the limiter cap to carry out the standard setting. – Check standard setting. – Warm up the engine. Erratic idling behavior, poor acceleration although low speed screw is set one quarter turn open. Standard setting A minor correction may be necessary if engine power is not satisfactory when operating at high altitude or at sea level. rin t 146RA162 VA – Set the low speed screw (L) so it is one quarter turn open. – Turn high speed screw (H) counterclockwise (richer) no further than stop. If the setting is made too lean there is a risk of engine damage as a result of insufficient lubrication and overheating. -n – Close the low speed screw (L) clockwise as far as stop, then open it one quarter turn counterclockwise. At sea level Engine stops while idling er – Set the low speed screw (L) so it is one quarter turn open. sio n Adjusting engine idle speed On lin ev – Turn the idle speed screw (LA) clockwise until the saw chain begins to move. Then turn it back one full turn. MS 270, MS 280 79 Adjusting engine idle speed rin t Insert puller 5910 890 4500 in center of limiter caps, apply slight pressure and screw home counterclockwise until the limiter caps come out of the carburetor body. – Check the air filter and clean or replace as necessary. – Check chain tension. ep After removing the limiter cap it is necessary to carry out the standard setting. 146RA166 VA The limiter caps need be removed from the adjusting screws only if it is necessary to replace the high speed screw (H) or low speed screw (L), clean the carburetor or carry out the standard setting. Perform the two following operations: 146RA163 VA 12.4.1 Standard Setting rr – Warm up the engine. fo 1 2 -n n sio On MS 270, make the following adjustment: – Open the high speed screw (H) (1) 1 1/8 turns. ev Turn the right-hand limiter cap (2) of low speed screw (L) clockwise as far as stop. Turn the limiter cap back one quarter turn until its lugs are in line with the carburetor openings. – Screw down both adjusting screws until they are against their seats. er Turn the left-hand limiter cap (1) of high speed screw (H) counterclockwise as far as stop until the limiter cap lugs are in line with the carburetor openings. lin – Open the low speed screw (L) (2) 1 1/4 turns. On MS 280, make the following adjustment: On 146RA167 VA ot 2 146RA167 VA 1 Adjust idle speed with a tachometer. Adjust specified engine speeds within tolerance of +/- 200 rpm. 1. Adjust engine speed with idle speed screw (LA) to 3,300 rpm. 2. Turn low speed screw (L) clockwise or counterclockwise to obtain maximum engine speed. If this speed is higher than 3,700 rpm, abort the procedure and start again with step 1. 3. Use the idle speed screw (LA) to set engine speed again to 3,300 rpm. 4. Set the engine speed to 2,800 rpm with the low speed screw (L). 5. Set engine’s maximum speed to 13,500 rpm with the high speed screw (H). – Open the high speed screw (H) (1) 1 1/4 turns. – Open the low speed screw (L) (2) 1 1/4 turns. 80 MS 270, MS 280 12.5 In the event of trouble with the carburetor or the fuel supply system, always check and clean the tank vent. Check function by performing vacuum test on the tank via the fuel hose. 1 146RA190 VA Limiter caps that have been removed once are damaged and must not be re-used. Correct operation of the carburetor is only possible if atmospheric pressure and internal fuel tank pressure are equal at all times. This is ensured by the tank vent. Equalization of pressure in the fuel tank takes place via the tank vent valve (1). There must be no build-up of vacuum during the test. In the event of a malfunction, use a screwdriver to remove the vent valve (1) and install a new valve with a new sealing ring. rin t 6. Install new limiter caps, noting that the stop lugs on the limiter caps must line up with the openings in the carburetor. Tank Vent – Reassemble in the reverse sequence. fo rr ep – Remove the filter base – see 12.1. -n 146RA136 VA ot 1 2 1 146RA168 VA On lin ev er sio n – Disconnect the fuel hose (1) from the carburetor. Connect vacuum pump (1) 0000 850 3501 to fuel hose (2) and subject fuel tank to vacuum. MS 270, MS 280 81 Pickup Body 12.7 The diaphragm pump draws fuel out of the tank and into the carburetor via the fuel hose. Any impurities mixed with the fuel are retained by the pickup body (filter). The fine pores of the filter eventually become clogged with minute particles of dirt. This restricts the passage of fuel and results in fuel starvation. Fuel Hose – Remove the carburetor – see 12.2.1. – Pull off the pickup body – see 12.6. 1 146RA172 VA 12.6 2 rin t Pickup body ep Use hook (2) 5910 893 8800 to pull the pickup body (1) out of the fuel tank. fo rr Do not stretch the fuel hose too much during this operation. sio n Use a screwdriver to pry the flange of the fuel suction hose out of the fuel tank. er Pull the suction hose (1) with pickup body out of the tank. ev Install in the reverse sequence. Coat the hose flange (2) with a little oil to simplify installation. The straight side of the hose flange must locate against the marking (arrow) on the housing. lin Remove the filler cap (1) and drain the tank. 146RA173 VA On – Pour a small amount of clean gasoline into the tank. Close the tank and shake the saw vigorously. – Open the tank again and drain it. Dispose of fuel properly. 2 146RA174 VA -n 176RA296 VA In the event of trouble with the fuel supply system, always check the fuel tank and the pickup body first. Clean the fuel tank if necessary. Cleaning the fuel tank 1 ot 1 Reassemble all other parts in the reverse sequence. Pull the pickup body off the fuel hose. – Fit a new pickup body. Install in the reverse sequence. 82 MS 270, MS 280 13 Special Servicing Tools Part Name Part No. Application Rem. 1 2 3 4 5 Locking strip Sealing plate Wooden assembly block Socket, DIN 3124, 13 mm Clamping bar 0000 893 5903 0000 855 8106 1108 893 4800 5910 893 5608 5910 890 2000 6 7 Assembly stand Carburetor and crankcase tester 5910 890 3100 1106 850 2905 8 Vacuum pump 0000 850 3501 9 10 11 12 13 14 – Nipple – Fuel line Test flange Press sleeve Assembly drift Installing tool 10 0000 855 9200 1110 141 8600 1119 850 4201 1108 893 2405 1108 893 4700 5910 890 2210 15 16 17 18 19 20 21 Assembly sleeve Ignition system tester, ZAT 4 Ignition system tester, ZAT 3 Puller Stud puller, M8 Installing tool Setting gauge 1118 893 4602 5910 850 4503 5910 850 4520 4133 893 0800 5910 893 0501 0000 890 2201 1111 890 6400 22 23 24 Hook Assembly tube Torque wrench 5910 893 8800 1117 890 0900 5910 890 0301 25 Torque wrench Blocking the crankshaft Sealing exhaust port for leakage test Fitting piston Flywheel nut For mounting chainsaw to assembly stand Holds chainsaw for repairs Testing engine and carburetor for leaks Testing crankcase for leaks, testing tank vent Testing carburetor for leaks Testing carburetor for leaks Leakage test Installing oil seal (starter side) Removing and fitting piston pin Installing hookless snap rings in piston Installing oil seal (clutch side) Checking ignition Checking ignition Releasing flywheel Removing guide bar mounting studs Flaring starter rope guide bush Setting air gap between ignition module and flywhee Removing pickup body Attaching/detaching brake spring 0.5 – 18 Nm (0.4 – 13.5 lbf.ft) Alternative: Torque wrench 5910 890 0302 with optical/acoustic signal 6 – 80 Nm (4.4 – 60 lbf.ft) Alternative: Torque wrench 5910 890 0312 with optical/acoustic signal 5910 890 0311 On lin ev er sio n -n ot fo rr ep rin t No. MS 270, MS 280 83 14 Servicing Aids No. Part Name Part No. Application 1 Lubricating grease (225g tube) 0781 120 1111 2 STIHL special lubricant 0781 417 1315 3 4 5 6 7 Dirko sealant (100g tube) STIHL cleaner Graphite grease Molykote grease Medium-strength threadlocking adhesive (Loctite 243) High-strength threadlocking adhesive (Loctite 270) 0783 830 2000 Oil seals, oil pump drive, chain sprocket bearing, sliding and bearing points of throttle trigger, switch lever, brake lever and interlock lever Bearing bore in rope rotor, rewind spring in fan housing Crankcase, oil seals (outside) Crankshaft stubs Pegs on pawls Sliding and bearing points of brake band rin t 0786 111 1109 On lin ev er sio n -n ot fo rr ep 8 0786 110 0101 84 MS 270, MS 280