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Stihl MS 200 Service Manual

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STIH)
STIHL MS 200, 200 T
2012-09

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Summary of Contents for Stihl MS 200

  • Page 1 STIH) STIHL MS 200, 200 T 2012-09...

  • Page 2: Table Of Contents

    Bar Mounting Stud 10.1 General 10.2 Removing and Installing 10.3 Pawl 10.4 Rope Rotor 10.5 Starter Rope / Grip 10.6 Tensioning the Rewind Spring 10.7 Replacing the Rewind Spring © ANDREAS STIHL AG & Co. KG, 2012 MS 200, MS 200 T...
  • Page 3 14.7.3 Fuel hose (MS 200) 14.1.2 Removing and Installing Version with multi-part the Filter Base tank vent system (MS 200 T 14.7.4 Fuel hose (MS 200 T) 14.2 Removing and Installing Version with one-part the Carburetor tank vent system (MS 200) 14.7.5 Fuel hose (MS 200 T)

  • Page 4: Introduction

    "Special Servicing Tools" in this STIHL parts symbol K manual. Use the part numbers to This symbol may appear alone on identify the tools in the "STIHL small parts. Special Tools" manual. The manual lists all special servicing tools Storing and disposing of oils and currently available from STIHL.

  • Page 5: Safety Precautions

    All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. Always perform leakage test after working on the fuel system and the engine. MS 200, MS 200 T...

  • Page 6: Specifications

    Spark plug (suppressed): Bosch WSR6F Electrode gap: 0.5 mm Chain Lubrication Speed-controlled oil pump with reciprocating piston and manual flow control Oil pump with adjustable 3.5 - 9.5 cm /min at delivery rate: 10,000 rpm MS 200, MS 200 T...

  • Page 7: Tightening Torques

    Collar screw P 5x25 Handle housing/stop buffer (MS 200) Screw P 6x32.5 Handle housing/front handle (MS 200) Screw P 6x21.5 Handle housing/front handle (MS 200 T) Screw M 5x12 Front handle/annular buffer Screw P 4x14 Handle molding/handle housing Screw P 6x19...
  • Page 8 Coat micro-encapuslated screws with medium strength Loctite 242 or 243 before reinstalling. Power screwdriver setting for polymer: DG and P screws max. 500 rpm Do not use an impact wrench for releasing or tightening screws. Do not mix up screws with and without binding heads. MS 200, MS 200 T...

  • Page 9: Troubleshooting

    Replace the clutch springs Loud noises Clutch springs stretched or fatigued Replace all clutch springs Needle cage damaged Fit new needle cage Clutch shoe retainer broken Fit new retainer Clutch shoes and carrier worn Install new clutch MS 200, MS 200 T...

  • Page 10: Chain Drive, Chain Brake, Chain Tensioner

    Saw chain does not stop Brake spring stretched or broken Fit new brake spring immediately when brake is activated Brake band stretched or worn Fit new brake band Clutch drum worn Install new clutch drum MS 200, MS 200 T...

  • Page 11: Chain Lubrication

    Install new oil pump Oil intake hose damaged Install new oil intake hose Oil pump delivers insufficient oil Oil pump worn Install new oil pump Oil pump delivery rate set too low Adjust oil pump MS 200, MS 200 T...

  • Page 12: Rewind Starter

    Coat rewind spring with a little becomes viscous at very low standard solvent-based degreasant outside temperatures (spring (containing no chlorinated or windings stick together) halogenated hydrocarbons), then pull rope carefully several times until normal action is restored MS 200, MS 200 T...

  • Page 13: Ignition System

    Faulty insulation or break in ignition lead or short circuit wire. Check ignition lead/ignition module and replace ignition module if necessary. Check operation of spark plug. Clean the spark plug or replace if necessary. Crankcase damaged (cracks) Install new crankcase MS 200, MS 200 T...
  • Page 14 Faulty insulation or short in short Check short circuit wire for short circuit wire circuit to ground Break in ignition lead or insulation Check ignition lead and replace if damaged necessary Ignition module faulty Install new ignition module MS 200, MS 200 T...

  • Page 15: Carburetor

    Fit impulse hose correctly or not pushed onto stub below handle replace if necessary housing Tank vent faulty Replace tank vent Leak in fuel hose between tank and Seal connections or install new fuel fuel pump hose MS 200, MS 200 T...
  • Page 16 Setting of idle speed screw LA Reset idle speed screw LA incorrect – throttle shutter correctly completely closed Tank vent faulty Replace tank vent Leak in fuel hose between tank and Seal connections or install new fuel fuel pump hose MS 200, MS 200 T...
  • Page 17 Ignition timing wrong, flywheel out Fit key if necessary and secure of adjustment, key in flywheel is flywheel properly or install new missing or has sheared off flywheel MS 200, MS 200 T...

  • Page 18: Engine

    Fit new hose or position it free from damaged kinks Engine overheating Insufficient cylinder cooling. Air Thoroughly clean all cooling air inlets in fan housing blocked or openings and the cylinder fins cooling fins on cylinder very dirty MS 200, MS 200 T...

  • Page 19: Cutting Attachment

    : Fit the chain sprocket cover. Make sure the peg (arrow) engages the hole. – For adjustment of chain tension see MS 200, MS 200 T instruction manual. – Reassemble all other parts in the reverse sequence. : Unscrew the collar nut (arrow) –...

  • Page 20: Clutch

    0000 893 5903 – wide end first – clutch shoes. – Clamp the clutch in a vise. into the cylinder and then turn it 180°. : Use hook (2) 5910 890 2800 to remove the clutch springs (1). MS 200, MS 200 T...
  • Page 21 – Tightening torques, b 3.5 : Check the clutch – all springs – Remove the locking strip from the (arrows) must be properly cylinder. attached. – Reassemble all other parts in the reverse sequence. MS 200, MS 200 T...

  • Page 22: Clutch Drum

    (arrow). crankshaft stub, b 16 – Install the clutch, b 6 – Lubricate the needle cage and – Reassemble all other parts in the crankshaft stub, b 16 reverse sequence. – Tightening torques, b 3.5 MS 200, MS 200 T...

  • Page 23: Chain Brake

    : Take out the screws (arrows). If the chain brake does not operate properly, refer to troubleshooting, : Swing the brake band (1) b 4.2. outwards and disconnect it from the brake lever (arrow). Do not over-stretch the brake band. MS 200, MS 200 T...

  • Page 24: Brake Lever

    – Reassemble all other parts in the reverse sequence. – Check operation. : Pull the hand guard (1) and brake lever (2) off the pivot pins (arrows) together. : Push the brake band (1) into its guides (arrows). MS 200, MS 200 T...
  • Page 25 7.4 : Push the brake lever (1) into the same time. hand guard recess and line up the holes. – Clean all disassembled parts, b 16 MS 200, MS 200 T...

  • Page 26: Flat Spring

    (arrow). : Pull out the flat spring (1), check it and replace if necessary. : Use the assembly tool (2) 1117 890 0900 to attach the brake spring (1) to the anchor pin (arrow). MS 200, MS 200 T...

  • Page 27: Pins

    : Line up the pin bar – the lug (arrow) must point towards the edge of the cover. – Push the pin bar (1) into its seat in the cover as far as stop. MS 200, MS 200 T...

  • Page 28: Chain Tensioner

    – Fit collar stud and tighten it down firmly. – Tightening torques, b 3.5 – Reassemble all other parts in the reverse sequence. : Use a suitable tool to pull out the complete chain tensioner (1). MS 200, MS 200 T...

  • Page 29: Engine

    – Remove the muffler (1), check and replace if necessary. The muffler must not be opened – the upper and lower casings and screws are bonded in position. – Check the heat shield (1) and replace if necessary MS 200, MS 200 T...

  • Page 30: Leakage Test

    Preparations – Tightening torques, b 3.5 The preparations are the same for : Carefully push the muffler (1) into the MS 200 and MS 200 T even – Remove the muffler, b 8.1 position. though their handle housings and the position of the carburetor are different.

  • Page 31: Vacuum Test

    – After finishing the test, push the ring to the right to vent the pump. – Continue with pressure test, b 8.2.3 : MS 200 T: Take the screw (1) out of the test flange. MS 200, MS 200 T...

  • Page 32: Pressure Test

    : Apply puller (1) 5910 890 4400 MS 200 b 14.2 with jaws 0000 890 3700. – Always carry out the vacuum test MS 200 T b 14.2.1 before the pressure test, b 8.2.2 – Clamp the puller arms. – Remove the flange and sealing : Connect pressure hose (1) of plate.
  • Page 33 – Free off the oil seal in its seat by tapping it with a suitable tube or a punch. : Apply puller (1) 5910 890 4400 with jaws 0000 890 3700. – Clamp the puller arms. – Pull out the oil seal. MS 200, MS 200 T...

  • Page 34: Cylinder

    – Remove the fan housing, b 10.2 – Remove the carburetor, MS 200 b 14.2 MS 200 T b 14.2.1 – Remove the handle housing, MS 200 b 12.4 : Use press sleeve (1) : Carefully lift the cylinder (1) away.
  • Page 35 : Push the retaining plate (3) on as – Pull off the intake manifold (2). far as stop – the edge (arrow) Take care not to displace or damage must be in line with the cylinder the cylinder gasket. fin. MS 200, MS 200 T...
  • Page 36 When installing the handle housing, check that the impulse hose is – Check correct installed position properly fitted on the nipple, MS 200 of rings, b 8.7 b 12.4, MS 200 T b 12.5. – Reassemble all other parts in the Apply the clamping strap (1) so that reverse sequence.

  • Page 37: Crankshaft

    Always install new bearings and oil seals after removing the crankshaft, : Pull out the ignition lead (1) at the – Remove the service tool. b 8.5.2 clutch side. – Pull off the clutch side of the crankcase. MS 200, MS 200 T...
  • Page 38 The crankshaft (1), connecting rod of the crankshaft. (2) and needle bearing form an inseparable unit. – Inspect both halves of the crankcase and replace if necessary, b 8.5.2 – Install new roller bearings, b 8.5.2 MS 200, MS 200 T...
  • Page 39 – Hold the oil suction hose in the crankcase so that it is not pinched during assembly. – Push the clutch side (1) of the crankcase into position as far as stop. MS 200, MS 200 T...

  • Page 40: Bearings / Crankcase

    : Pull out the grommet (1) and take it out of the crankcase with the short circuit wire. – Remove and disconnect the oil tank cap, b 13.1 – Unscrew the annular buffer, b 11.3 MS 200, MS 200 T...
  • Page 41 : Push the grommet (1) – – Heat the area of the bearing seat rectangular opening first – over the connector (2). about 230°C (446°F). MS 200, MS 200 T...

  • Page 42: Piston

    Make sure the impulse hose is properly fitted on the nipples of the : Use a suitable tool to grip the MS 200 T (above right) crankcase and handle housing. snap ring at the recess (arrow) Connector without sleeve, distance and ease it out.

  • Page 43: Installing

    : Place the piston on the – Inspect the piston rings and : Fit the piston pin (2) on the connecting rod. replace if necessary, b 8.7 assembly drift (1) 1114 893 4700 and slide it into the piston. MS 200, MS 200 T...
  • Page 44 Fit the snap ring (1) so that its gap (arrow) points up. : Push the large slotted diameter of the sleeve over the magnet and snap ring. The inner pin must point towards the flat face of the tool's shank. MS 200, MS 200 T...

  • Page 45: Piston Rings

    : Check correct installed position of the piston rings (arrows). – Install the piston, b 8.6.2 – Reassemble all other parts in the reverse sequence. : Use a piece of old piston ring to scrape the grooves clean. MS 200, MS 200 T...

  • Page 46: Ignition System

    – Pull the ignition module (1) out a Since there is no mechanical wear little. in these systems, ignition timing cannot get out of adjustment during operation. : Disconnect the short circuit wire (1) from the retainer (arrow). MS 200, MS 200 T...
  • Page 47 9.3 – The short circuit wire is now held in position and can be – Reassemble in the reverse disconnected again from the sequence. ignition module. – Troubleshooting, b 4.5 MS 200, MS 200 T...

  • Page 48: Testing The Ignition Module

    : Reconnect the short circuit wire (1). The engine may start and accelerate during the test. Make sure the connector is pushed fully on to the tag. – Reassemble all other parts in the reverse sequence. MS 200, MS 200 T...

  • Page 49: Spark Plug Boot / Ignition Lead

    – Use a pointed tool to pierce the center of the new ignition lead’s insulation, about 15 mm from the end of the lead. : Pinch the hook of the leg spring into the center of the lead (arrow). MS 200, MS 200 T...

  • Page 50: Spark Plug Boot

    (arrow) in ignition lead, or replace if the grommet. necessary. – Using STIHL Press Fluid, b 16, : Fit the cable retainer (1) on the simplifies the job of pushing the – Pull the boot off the spark plug.

  • Page 51: Flywheel

    – Tightening torques, b 3.5 (arrow) and not project – there is otherwise a risk of damaging the insulation and causing a short circuit. – Install the flywheel and adjust the air gap, b 9.4, b 9.2.1 MS 200, MS 200 T...

  • Page 52: Short Circuit Wire

    : Make sure the key engages the slot (arrow) in the flywheel. On the MS 200, this test is performed on the short circuit wire – Set the air gap between the and wiring harness. If a fault is...

  • Page 53: Testing The Wiring

    Install a new short circuit wire, b 9.5.3. On a MS 200, a wiring harness if : Take out the screw (arrow). installed to extend the short circuit – Set the switch shaft to "F".
  • Page 54 : Disconnect the short circuit wire from the short circuit wire (2). connector (2). MS 200, MS 200 T MS 200 T : Pry out the grommet (1). : Take out the screws (arrows). – Remove the control lever (1) and handle molding (2).
  • Page 55 – Remove the grommet. – Fit the grommet (1) in the hole the grommet. (arrow) and make sure it is properly seated. MS 200 T (above right) – Check both grommets and Connector without sleeve, distance replace if necessary from grommet a = about 2.5 cm...

  • Page 56: Removing And Installing

    – Disconnect the ground wire (1) from the contact spring. – Reassemble all other parts in the reverse sequence. : Pull the wires out of the guides (arrows). – Tightening torques, b 3.5 MS 200, MS 200 T...
  • Page 57 Perform the contact and continuity terminal first, through the bore test on the ground wire too. (arrow). – Turn the handle housing over. : Push the contact spring (1) on to the peg as far as stop. MS 200, MS 200 T...
  • Page 58 : Connect the wiring harness (1) to the short circuit wire (2). – Push the wiring harness into the handle housing. : Fit the short circuit wire (1) and ground wire (2) in the guides (arrows). MS 200, MS 200 T...

  • Page 59: Ground Wire

    12.3 (arrows). – Remove the annular buffer – Install the annular buffer, (arrow) and ground wire (1), b 11.2.1 b 11.2.1 – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5 MS 200, MS 200 T...

  • Page 60: Ignition System

    – If necessary, install new spark plug boot and/ or leg spring, b 9.3 Test ignition system: with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap see TI 32.94), b 9.2.2 MS 200, MS 200 T...
  • Page 61 Check the flywheel: – Have pole shoes turned blue? – Install new flywheel if necessary, b 9.4 Check short circuit wire: Check MS 200 wiring harness: – Wire damaged? – Connectors firmly seated? – Check continuity, replace wiring harness if necessary, b 9.5.1, b 9.5.2...
  • Page 62 9.2.1 Engine runs – Look for fault in fuel system or Machine runs trouble-free, carburetor no further action necessary – Check engine for leaks – Check position of flywheel on crankshaft, b 8.2, b 9.4 MS 200, MS 200 T...

  • Page 63: Rewind Starter

    : Remove the pawl (1). – Place the fan housing (1) in position. – Fit the new pawl in the bore (arrow) and lubricate its peg (1), b 16 : Fit the metric screws (2) and Plastoform screws (arrows). MS 200, MS 200 T...

  • Page 64: Rope Rotor

    – Remove the spring clip and pawl, – Tension the rewind spring, b 10.3 b 10.6 – Lubricate peg on pawl with grease, b 16 – Reassemble all other parts in the reverse sequence. – Remove the washer (1). MS 200, MS 200 T...

  • Page 65: Starter Rope / Grip

    Do not shorten the starter rope. : Position cap so that its lug (1) engages the slot (arrow) in the starter grip. – Press the cap into the starter grip. MS 200, MS 200 T...

  • Page 66: Tensioning The Rewind Spring

    The rewind spring is now tensioned. Hold the rope rotor steady since it will otherwise spin back and may damage the rewind spring. : Pull rope back until knot locates in recess (arrow) in rope rotor. MS 200, MS 200 T...

  • Page 67: Replacing The Rewind Spring

    (arrow). If the rewind spring has popped out, refit it in the fan housing as follows: : Line up the replacement spring with frame – the anchor loop (2) must be above the lug (1). MS 200, MS 200 T...
  • Page 68 : Apply tool to openings (arrows) to : Fit the rewind spring push the spring into its seat in the counterclockwise in the tool. fan housing. – Hold the spring windings so that they cannot pop out. MS 200, MS 200 T...
  • Page 69 Make sure the starter post does not touch the inner spring loop in this process – the spring may pop out and uncoil. : Push the rewind spring through the frame and into its seat in the fan housing. MS 200, MS 200 T...

  • Page 70: Servicing The Av System

    – Reassemble all other parts in the if necessary. reverse sequence. – Tightening torques, b 3.5 : Take out the screws (arrows). – Pull the annular buffer (1) downwards and out, check it and replace if necessary. MS 200, MS 200 T...

  • Page 71: Annular Buffer On Oil Tank (Ms 200 T)

    : Take out the screws (arrows). – Remove the ground wire (1). : Take out the screw (arrow). – Lift the handle housing slightly and pull out the annular buffer (2). – Check the annular buffer and replace if necessary MS 200, MS 200 T...

  • Page 72: Annular Buffer On Handlebar

    : Remove the screws (arrows) from the annular buffers on the fuel and oil tanks. – Ease the handlebar to one side. – Fit the ground wire (1) in position. : Insert screws (arrows) and tighten them down firmly. MS 200, MS 200 T...

  • Page 73: Handlebar

    – Check the stop buffer and replace if necessary. – Check the handlebar and replace if necessary – Reassemble in the reverse sequence. – Line up the stop buffer (1) so that its tab engages the tank housing. MS 200, MS 200 T...
  • Page 74 – Remove the handle molding and reverse sequence. switch shaft, b 12.1.2 – Tightening torques, b 3.5 : Take out the screw (arrow). – Pulll the handlebar (1) out of the handle housing. Check and replace if necessary. MS 200, MS 200 T...

  • Page 75: Master Control Lever

    : Push the choke lever (1) on to the – Position k = warm start switch shaft so that the lug – warm engine is started in this engages the slot (arrow). – Pull the switch shaft out of the position right-hand mount. MS 200, MS 200 T...

  • Page 76: Removing And Installing (Ms 200 T)

    : Press the switch shaft into the mount (arrow) until it snaps into position. : Pull off the choke lever (1). – Check the choke lever (1) and switch shaft (2) and replace if necessary MS 200, MS 200 T...

  • Page 77: Throttle Trigger/Interlock

    – Install the throttle trigger and the throttle trigger The throttle trigger and interlock interlock lever, b 12.3 – note installed position (arrow). lever may pop out. – Install the choke and throttle rods, b 12.3.2 MS 200, MS 200 T...

  • Page 78: Throttle Trigger/Interlock Lever (Ms 200 T)

    (arrow). : Remove the interlock lever (1) : Take out the screw (arrow). and throttle trigger (2). – Remove the control lever (1). – Check the individual parts and replace if necessary. MS 200, MS 200 T...

  • Page 79: Choke And Throttle Rods (Ms 200)

    : Take the throttle rod (1) out of its guides (arrows). : Attach the interlock lever (1) to the torsion spring (2). – Push the interlock lever (1) with torsion spring into the bore (arrow). MS 200, MS 200 T...

  • Page 80: Choke And Throttle Rods (Ms 200 T)

    – Tightening torques, b 3.5 : Pull the double choke lever (1) – Check operation. out of the handle housing and choke rod. : Attach choke rod (1) to lever (arrow) on choke shaft first. MS 200, MS 200 T...

  • Page 81: The Handle Housing

    – Check the individual parts and replace if necessary. : Attach the short choke rod : Push the long choke rod (1) into (arrow) to the carburetor and the choke lever (arrow). insert it into the handle housing. MS 200, MS 200 T...

  • Page 82: Removing And Installing The Handle Housing (Ms 200)

    : Push the link (1) into the holes (arrows) as far as stop. – Fit the handle molding and switch : Take out the screws (arrows). lever, b 12.1.2 – Remove screw from handlebar. – Tightening torques, b 3.5 – Check operation. MS 200, MS 200 T...
  • Page 83 – Pull out the shutter (1) for position. summer/winter operation, check it and replace if necessary. – Reassemble in the reverse sequence. : Pull the cover (1) out of the handle housing. – Inspect the cover and replace if necessary, MS 200, MS 200 T...

  • Page 84: The Handle Housing

    – Place the handle housing in – Coat the flange of the manifold position. with STIHL Press Fluid, b 16 : Push the tank vent hose (1) and – Position the handle housing fuel hose (2) through the holes against the manifold.

  • Page 85: Removing And Installing The Handle Housing (Ms 200 T)

    12.3.2 properly seated. – Check the switch shaft and : Remove the sleeve (2) and replace if necessary, b 12.1.2 washer (1). – Check shutter for summer/winter operation and replace if necessary, b 14.2.1 MS 200, MS 200 T...
  • Page 86 9.5.3 – Remove the switch shaft, – Coat the flange of the manifold b 12.1.2 with STIHL Press Fluid, b 16 : Take out the screw (arrow). – Position the handle housing against the manifold. – Pull out the handlebar (1), check it and replace if necessary.

  • Page 87: Chain Lubrication

    : Use a suitable tool to pry the connector (1) off the oil pump. : Push the oil suction hose (1), pickup body first, through the – Check the connector (1) and housing bore (arrow). replace if necessary MS 200, MS 200 T...

  • Page 88: Oil Pump

    (arrow) is properly seated in the connector's bore (2). : Turn the oil pump (1) clockwise until the stub (arrow) slips out of : Take out the screws (arrows). the connector (2). – Remove the covers(1 and 2). MS 200, MS 200 T...

  • Page 89: Valve

    – Collect chain oil in a clean : Remove the old valve (1) from container, b 1 the oil tank. – Remove the cover, b 13.4 : Push the worm (1) into te oil pump. MS 200, MS 200 T...
  • Page 90 : Use a 6 mm drift to carefully drive in the new valve (1) from outside – note installed depth. : Installed depth of new valve: a = about 2 - 3 mm – Reassemble all other parts in the reverse sequence. MS 200, MS 200 T...

  • Page 91: Fuel System

    – Remove and install the air filter : Remove the E-clip (1). MS 200 – see MS 200 instruction manual. : Remove the twist lock (2) and – Clean the air filter – see MS 200 spring (3). instruction manual. – Reassemble in the reverse sequence.

  • Page 92: Removing And Installing The Filter Base (Ms 200)

    14.1.2 Removing and Installing 14.2 Removing and Installing the Filter Base (MS 200) the Filter Base (MS 200 T the Carburetor (MS 200) Remove the air filter, b 14.1 Remove the air filter, b 14.1 – Remove the air filter, b 14.1 –...
  • Page 93 (arrow). – Check the choke and throttle rods and replace if necessary, b 12.3.1 Check that the sleeve (1) and washer (2) are in place. MS 200, MS 200 T...

  • Page 94: Removing And Installing The Carburetor (Ms 200 T)

    14.2.1 Removing and Installing the Carburetor (MS 200 T) – Remove the air filter, b 14.1 – Remove the filter base, b 14.1.2 – Open the fuel tank cap and drain the fuel tank. – Collect the fuel in a clean : Disconnect the choke rod (1).

  • Page 95: Leakage Test

    – Remove the carburetor, MS 200 b 14.2, : Push the fuel hose (1) on to the – Install the tank vent (1), b 14.6.4 MS 200 T b 14.2.1 stub (arrow). Choke rod must not be between the carburetor and intake manifold.

  • Page 96: Servicing The Carburetor

    (arrow) first, then the MS 200 b 14.2, (80 kPa). gasket (2). MS 200 T b 14.2.1 If this pressure remains constant, : Take out the screws (arrows). the carburetor is airtight. However, if it drops, there are three possible causes: –...

  • Page 97: 14.4.2 Inlet Needle

    : Take out the screw (arrow). moves freely. – Install the metering diaphragm, b 14.4.1 : If there is an annular indentation (arrow) on the sealing cone of the inlet needle, fit a new inlet needle. MS 200, MS 200 T...

  • Page 98: 14.4.3 Pump Diaphragm

    (2). The diaphragm material is MS 200 b 14.2, subjected to continuous alternating MS 200 T b 14.2.1 stresses and eventually shows signs of fatigue, i.e. the diaphragm : Take out the screw (arrow). distorts and swells and has to be replaced.

  • Page 99: Choke Shaft / Choke

    – Reassemble in the reverse sequence. – Remove the carburetor, MS 200 b 14.2, MS 200 T b 14.2.1 – Turn the choke shaft a little and – Carburetor troubleshooting, take out the shutter (1). b 4.6 MS 200, MS 200 T...

  • Page 100: Throttle Shaft / Throttle Shutter

    Throttle shaft stiff or throttle shutter cannot be closed or opened properly: – Remove the carburetor, MS 200 b 14.2, MS 200 T b 14.2.1 : Push the choke shaft (1) into the – Coat screw with threadlocking – Carburetor troubleshooting, b 4.6 carburetor.
  • Page 101 : Pull out the throttle shaft (1). – Clean the throttle shaft and guides, b 16 : Fit the E-clip (1). Turn leg (2) of spring about one turn clockwise and attach it to the throttle shaft. MS 200, MS 200 T...

  • Page 102: 14.4.6 Accelerator Pump

    – Coat screw with threadlocking adhesive, b 16 : Fit new screw (2) and tighten it moderately. : Close the throttle shutter (1) and center it in the carburetor body’s bore. MS 200, MS 200 T...

  • Page 103: 14.4.7 Adjusting Screws

    – Remove the carburetor and pull off the grommet, MS 200 b 14.2, – Continue with high speed screw. MS 200 T b 14.2.1 – See also carburetor troubleshooting, b 4.6 : Inspect the tip (arrow) for damage or wear and replace the screw (H) if necessary.

  • Page 104: Adjusting The Carburetor

    1. snaps into position. – Install the carburetor, MS 200 b 14.2, MS 200 T b 14.2.1 3. Use the idle speed screw (LA) to set the engine speed again to – Reassemble in the reverse 3,600 rpm.

  • Page 105: Standard Setting

    3/4 turn. – Turn the low speed screw L slowly clockwise as far as stop, then turn it back 1 full turn. Check running behavior: The engine must idle and accelerate smoothly. MS 200, MS 200 T...

  • Page 106: Removing And Installing The Intake Manifold

    – Push the retaining plate (1) over the manifold as far as stop. An angled intake manifold is installed in the MS 200 T, but the procedure for removing and – Install the handle housing, installing is the same as for the MS 200, b 12.4...

  • Page 107: Tank Vent

    : Push the nipple (1) The following preparations describe nipple (arrow). 0000 855 9200 into the fuel hose the MS 200, but also apply to the (arrow). MS 200 T. – Check the impulse hose and – Open the fuel tank cap and drain replace if necessary.

  • Page 108: Removing And Installing (Ms 200)

    5 : Take out the screws (arrows). – Remove the air filter, b 14.1 – Lift the handle housing slightly. : Pry the tank vent (1) out of its seat (arrow). MS 200, MS 200 T...

  • Page 109: Version With One-Part Tank Vent System

    : Fit the stub (1) so that the mushroom valve's rubber nipple Always install a new tank vent – the (arrow) engages the stub's new tank vent is supplied with an opening. installing sleeve. MS 200, MS 200 T...

  • Page 110: Fuel Intake

    – Reassemble in the reverse sequence. – Pour a small amount of clean gasoline into the tank. Close the tank and shake the saw 14.7.2 Fuel hose (MS 200) vigorously. The stub (1) must not project Version with one-part beyond the collar (arrow).

  • Page 111: Fuel Hose (Ms 200) Version With Multi-Part Tank Vent System

    – Remove the chain sprocket – Fit the pickup body, b 14.7.1 cover, bar and chain, b 5 – Close the tank cap. – Remove the tank vent, b 14.6.4 : Disconnect the fuel hose (arrow). MS 200, MS 200 T...
  • Page 112 – Reassemble all other parts in the seated. reverse sequence. : Pry the fuel hose (1) out of its seat (arrow). – Pull the fuel hose (1) out of the tank housing, check it and replace if necessary. MS 200, MS 200 T...

  • Page 113: Version With Multi-Part

    – Remove the handle housing, fuel tank. MS 200, b 12.4 MS 200 T, b 12.5 – Pull the tank housing (1) out of Do not overstretch the fuel hose. the impulse hose.
  • Page 114 – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5 : Push the impulse hose (1) through the hole (arrow). – Line up tank housing (2) with holes. MS 200, MS 200 T...

  • Page 115: Special Servicing Tools

    Removing and installing piston pin Installing tool 9 5910 890 2209 Installing hookless snap rings in piston Clamping strap 0000 893 2600 Compressing the piston rings Wooden assembly block 1108 893 4800 Supporting the piston MS 200, MS 200 T...
  • Page 116 Removing and installing spline socket screws with electric or pneumatic screwdrivers; tighten down screws with torque wrench (4 mm) Screwdriver bit, T 27 x 150 5910 890 2400 IS-P screws (5 mm) Remarks 1) Use for releasing only. MS 200, MS 200 T...

  • Page 117: Servicing Aids

    0786 111 2109 adhesive (Loctite 270) High-strength threadlocking 0786 111 2117 adhesive (Loctite 648) Standard commercial solvent- Cleaning sealing faces and carburetor, based degreasant containing no crankshaft stubs and flywheel taper chlorinated or halogenated hydrocarbons MS 200, MS 200 T...
  • Page 118 englisch / english 0455 161 0123. VA1.J12. Printed in Germany...

This manual is also suitable for:

Ms 200 t

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