Stihl MS 290 Manual
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Stihl MS 290 Manual

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STIH)
STIHL MS 290, 310, 390
2004-11

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Summary of Contents for Stihl MS 290

  • Page 1 STIH) STIHL MS 290, 310, 390 2004-11...

  • Page 2: Table Of Contents

    Muffler/Spark 9.3.3 Front Handle/Engine Arresting Screen Housing Leakage Test Switch Shaft 6.2.1 Preparations Throttle Trigger/ 6.2.2 Pressure Test Interlock Lever 6.2.3 Vacuum Test Oil Seals Shroud © ANDREAS STIHL AG & Co. KG, 2004 MS 290, MS 310, MS 390...

  • Page 3: Introduction

    Use the part numbers to identify the tools in the "STIHL As the design concept of models Special Tools" manual which lists all MS 290, MS 310 and MS 390 is the special servicing tools currently almost identical, the descriptions available from STIHL.

  • Page 4: Safety Precautions

    Warning! Do not bring any fire, flame, spark or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. MS 290, MS 310, MS 390...

  • Page 5: Specifications

    12,500 rpm 13,000 rpm 13,000 rpm Idle speed: 2,800 rpm Clutch: Centrifugal clutch without linings Clutch engages at: 3,500 rpm Engine leakage test at gauge pressure: 7.25 psi under vacuum: 7.25 psi MS 290, MS 310, MS 390...

  • Page 6: Fuel System

    Spark plug (suppressed): Bosch WSR 6F NGK BPMR 7 A Electrode gap: 0.5 mm Chain Lubrication Fully automatic, speed-controlled oil pump with rotary piston Oil delivery rate: 8 – 18 cm at 10,000 rpm MS 290, MS 310, MS 390...

  • Page 7: Tightening Torques

    Locknut Muffler cover/cylinder/screw M8x1 Flywheel/crankshaft 28.0 Carburetor/handle housing/screw 0.33 Spark plug M14x1.25 Spark plug 25.0 Screw DG5x24 Ignition module/engine housing 0.48 Screw DG4x15 Oil pump Remarks: 1) Loctite 243, medium strength 2) with sleeve MS 290, MS 310, MS 390...

  • Page 8: Troubleshooting Chart

    Chain does not stop immediately Brake spring stretched or broken Fit new brake spring when brake is activated Brake band stretched / worn / Fit new brake band broken Clutch drum worn Install new clutch drum MS 290, MS 310, MS 390...

  • Page 9: Rewind Starter

    Coat rewind spring with a standard becomes viscous at very low 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 290, MS 310, MS 390...

  • Page 10: Chain Lubrication

    Oil pump damaged or worn Fit new oil pump Oil pump delivers insufficient oil Control screw and/or control edge Replace control screw and/or oil on pump piston worn pump Oil pump worn Fit new oil pump MS 290, MS 310, MS 390...

  • Page 11: Ignition System

    Check operation of spark plug. Clean or replace spark plug, Inspect Master Control lever, replace faulty parts of ignition ignition coil/lead for damage system insulation and leakage current. Engine pan damaged (cracks) Replace engine pan MS 290, MS 310, MS 390...

  • Page 12: Carburetor

    Inlet needle sticking to valve seat Remove inlet needle, clean and refit Diaphragm gasket leaking Fit new diaphragm gasket Metering diaphragm damaged or Fit new metering diaphragm shrunk Impulse hose damaged or kinked Fit new impulse hose MS 290, MS 310, MS 390...
  • Page 13 Setting of high speed screw (H) Rotate high speed screw (H) too rich clockwise (leaner), no further than stop Main jet bores or ports blocked Clean the carburetor Pump diaphragm damaged or Fit new pump diaphragm fatigued MS 290, MS 310, MS 390...

  • Page 14: Engine

    Replace lines or position them free or damaged from 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 290, MS 310, MS 390...

  • Page 15: Clutch, Chain Drive, Chain Brake And Chain Tensioner

    13. 100% – Replace damaged needle cage. : Inspect the clutch drum (1) for – If a rim sprocket is fitted, pull it off. signs of wear. : Remove the clutch drum/chain sprocket. MS 290, MS 310, MS 390...

  • Page 16: Chain Catcher

    : Take out the screw (1). – Take out the screws (arrows). : Remove the chain catcher (2). : Remove the spiked bumper (1). Install in the reverse sequence. Install in the reverse sequence. Check correct installed position. MS 290, MS 310, MS 390...

  • Page 17: Collar Stud

    – Coat thread of the DG 9 collar stud with Loctite 648, b 13. – Install the collar stud squarely. : Push the locking strip (1) 0000 893 5903 into the spark plug hole so that "TOP" faces up. MS 290, MS 310, MS 390...
  • Page 18 Clutches marked 1127/00 on the carrier must be installed with cover washer. : Use hook (2) 5910 890 2800 to remove the clutch springs (1). – Pull the clutch shoes off the carrier. MS 290, MS 310, MS 390...

  • Page 19: Chain Brake

    : Carefully ease the brake spring detachable adapter nut, make off the anchor pin. sure it is tightened down firmly. – If the groove in the anchor pin is worn, install a new pin, b 5.7.1 MS 290, MS 310, MS 390...
  • Page 20 (2). : Disconnect the brake band (1) : Take the screw (1) together with : Remove the washer (arrow). from the bell crank (2). the bushing (2) out of the hand guard. MS 290, MS 310, MS 390...
  • Page 21 – If necessary, pull the bell crank out of the hand guard. Install in the reverse sequence. : Use assembly tool (2) 1117 890 0900 to attach the brake spring (1) to the anchor pin. MS 290, MS 310, MS 390...

  • Page 22: Replacing Pins

    : Use a 2 mm drift to remove the : Use a 4 mm drift to remove the pin by driving it outwards. pin by driving it outwards. – Installing, b 5.7.2 – Installing, b 5.7.2 MS 290, MS 310, MS 390...

  • Page 23: Installing

    “a” is 4.6 ± 0.2 mm Hand guard pivot pin Lever pivot pin : Drive home pin (1) until : Drive home pin (1) until dimension “a” is 12 ± 0.2 mm dimension “a” is 9.1 ± 0.2 mm MS 290, MS 310, MS 390...

  • Page 24: Chain Tensioner

    Install in the reverse sequence. – Coat teeth of adjusting screw and spur gear with grease, b 13, before refitting. : Remove the conical spring washers (arrows). : Remove the cover (1). MS 290, MS 310, MS 390...
  • Page 25 3.5. – Remove the screw sideways from the flange. Install in the reverse sequence. Install new gaskets. : Remove the gasket (1). MS 390 (US version only) : Remove the exhaust gasket (1). MS 290, MS 310, MS 390...

  • Page 26: Leakage Test

    – Vacuum test, b 6.2.3 When fitting the test flange, make sure the pin (3) locates properly in the impulse hose (4). : Check that the sleeve (1) and washer (2) are properly seated. MS 290, MS 310, MS 390...

  • Page 27: Pressure Test

    : Close the vent screw (1) on the necessary. pump. – After finishing the test, open the vent screw and disconnect the : Operate lever (2) until pressure hose. gauge (3) indicates a vacuum of 0.5 bar. MS 290, MS 310, MS 390...

  • Page 28: Oil Seals

    9639 003 1743. crankshaft stub. Install hard oil seals as described in b 6.7 – Clean sealing face with standard solvent-based degreasant Install in the reverse sequence. containing no chlorinated or halogenated hydrocarbons, b 13. MS 290, MS 310, MS 390...
  • Page 29 9639 003 1743. – Install the oil pump, b 10.4.1 Install hard oil seals as described in b 6.7 Install all other parts in the reverse sequence. Install in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 30: Shroud

    Install all other parts in the reverse sequence. : Take out the screws (arrows). : Lift the shroud (1) up a little and remove it to the rear. : If necessary, unclip the shutter (1). Install in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 31: Removing And Installing The Engine

    : Take out the screw (1). must be replaced before installing the cylinder. Perform the following : Remove the ground wires operations to replace the engine (arrows). pan: : Take out the screws (arrows). MS 290, MS 310, MS 390...

  • Page 32: Cylinder

    : Push oil seals (1) into position. : Pull the manifold (2) off the intake – Apply a thin coating of sealant to port. the outer diameters of the oil seals, b 13. : Disconnect the impulse hose (3). MS 290, MS 310, MS 390...
  • Page 33 6.5 If a new cylinder is installed, also install a new piston, b 6.5.2 : Position the crankshaft so that the long crankshaft stub (1) points to the right, looking at exhaust port (2). MS 290, MS 310, MS 390...

  • Page 34: Piston

    : If necessary, modify the sleeve of connecting rod. the installing tool 5910 890 2210 as shown: Installed position of piston: a = 16 mm 1 = Mark (arrow) b = 8 mm 2 = Long stub of crankshaft MS 290, MS 310, MS 390...
  • Page 35 : 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 290, MS 310, MS 390...

  • Page 36: Piston Rings

    : Install the new piston rings in the : Pull off the oil seals (1) and ball grooves so that the radii face bearings (2). upward. Install in the reverse sequence. – Install the piston, b 6.5.1 MS 290, MS 310, MS 390...

  • Page 37: Ignition System

    The “soft” oil seals must be used if the crankshaft is in the installed condition. – Lubricate sealing lips of oil seals The electronic (breakerless) ignition with grease, b 13. system basically consists of an ignition module (1) and flywheel (2). MS 290, MS 310, MS 390...

  • Page 38: Ignition Module

    A new ignition module must be installed if no ignition spark is obtained (after checking that wiring and stop switch are in good condition).. : Take out the screw (1) and remove the ground wires (arrows). MS 290, MS 310, MS 390...
  • Page 39 : Push short circuit wire into wire the module. retainer (arrow). – Press the ignition module against – Remove the ignition module. the setting gauge. If the ignition lead or spark plug boot is damage, install new parts, b 7.2 MS 290, MS 310, MS 390...

  • Page 40: Testing The Ignition Module

    (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). Warning! The engine may start and accelerate during the test. MS 290, MS 310, MS 390...

  • Page 41: Spark Plug Boot

    : Attach ground terminal (1) to the spark plug. : Use adjusting knob (4) to set spark gap to about 2 mm. : If a spark is visible in window (3), the ignition system is in order. MS 290, MS 310, MS 390...

  • Page 42: Ignition Lead

    : Use a pointed tool to pierce the plug boot so that the leg spring center of the other end of the locates properly inside it (arrow). ignition lead which screws into the module. MS 290, MS 310, MS 390...

  • Page 43: Flywheel

    : If the flywheel cannot be removed : The flywheel (1) and magnet by hand, screw the puller (1) poles (2) must not be damaged 1116 893 0800 onto the or have turned blue. Replace crankshaft stub. flywheel if necessary. MS 290, MS 310, MS 390...

  • Page 44: Contact Spring

    Install in the reverse sequence. : When fitting, make sure the : Pull the wire (1) out of the contact spring is under the guide retainer (arrow). pin (1) and locates in the housing recess (arrows). MS 290, MS 310, MS 390...
  • Page 45 (arrows). guide lugs (arrows) and line them : Position the cable lug against the : Fit the screw (1) and tighten it cylinder with its crimping facing down firmly, b 3.5 the cylinder. MS 290, MS 310, MS 390...

  • Page 46: Ignition System Troubleshooting

    – 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) MS 290, MS 310, MS 390...
  • Page 47 – Spark plug boot: Holes/cracks? – Resistance: spark plug boot to ground: spec. 1.5 – 12kW – Check resistance of ignition lead: spec. < 10 W, If necessary, install new spark plug boot and/or ignition lead MS 290, MS 310, MS 390...
  • Page 48 Check #" / $ function on Look for fault in fuel system Master Control lever/ or carburetor, switch shaft check engine for leaks, or separate stop switch check position of flywheel on crankshaft MS 290, MS 310, MS 390...

  • Page 49: Rewind Starter

    – Pull the pawl (1) out of the rope STIHL special lubricant, b 13. rotor. – Lubricate peg of new pawl with grease, b 13. Install in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 50: Rope Rotor

    : Remove the washer (1) from the : Tie one of the special knots starter post. shown in the end of the starter rope. – Carefully pull the rope rotor off the starter post. MS 290, MS 310, MS 390...
  • Page 51 – Remove remaining rope from the starter grip. : Thread end of rope through hole in the side of the rotor, pull it out. MS 290, MS 310, MS 390...

  • Page 52: Tensioning

    (arrow) without drooping to one side. If this is not the case, tension the spring by one additional turn. MS 290, MS 310, MS 390...

  • Page 53: Starter Rope Guide Bushing

    – Remove any remaining pieces of spring from the fan housing. : Insert the screw spindle (1) of the installing tool 0000 890 2201 through the bushing from inside the fan housing. MS 290, MS 310, MS 390...

  • Page 54: Av Handle System/Handle Housing

    Install all other parts in the reverse sequence. : Pry out the plugs (arrows). : Position the anchor loop about : Take out the screws (arrows). 20 mm (dimension ’a’) from the edge of the installing tool (1). MS 290, MS 310, MS 390...

  • Page 55: Handle Housing

    (2) together and push it into buffers, b 9.3.1 the handle housing. Install in the reverse sequence. : Pull the ground wire (1) off the contact spring. : Pull the ground wire out of the retainers (arrows). MS 290, MS 310, MS 390...
  • Page 56 : Ease the annular buffer out of the : Pull the ends of the string handle housing. outward and remove the string from the manifold (1). – Remove the handle housing. Install all other parts in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 57: Annular Buffers

    STIHL Press Fluid OH 723, b 13. : Push the annular buffer into the front handle until its groove (1) engages over the housing rib (2). Install all other parts in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 58: Front Handle/Engine Housing

    – Coat the new annular buffer with STIHL Press Fluid OH 723, b 13. : Push the annular buffer into the engine housing from the inside so that its groove (arrow) engages over the housing rib. MS 290, MS 310, MS 390...

  • Page 59: Switch Shaft

    (arrow). : Use a suitable tool to ease the : Lift the contact spring (1) slightly switch shaft (1) upwards and out to install the switch shaft. of the handle housing. shaft (2). MS 290, MS 310, MS 390...

  • Page 60: Throttle Trigger/Interlock Lever

    : Press the interlock lever into the – Move switch shaft to “RUN” position. the throttle trigger. slots. The torsion spring must be under the interlock lever and : Take out the interlock lever. engage the notch. MS 290, MS 310, MS 390...

  • Page 61: Chain Lubrication

    : Ease the suction hose (1) off the : Pull the pickup body (1) out of the oil pump. suction hose (2). – Replace the pickup body if it is damaged or very dirty. MS 290, MS 310, MS 390...

  • Page 62: Valve

    Install all other parts in the reverse sequence. : Use a 7 mm drift the carefully drive the valve out of its seat and into the engine housing. – Remove the faulty valve from inside the tank. MS 290, MS 310, MS 390...

  • Page 63: Tank Cap

    : Use a suitable tool to push the Machines from 1998 hose (2) down and off the pump. : Carefully disconnect nipple (1) of cap retainer from the guide (2) in : Take out the screws (1). the engine housing. MS 290, MS 310, MS 390...

  • Page 64: Servicing

    Install all other parts in the reverse Install in the reverse sequence. sequence. When fitting the cover washer, make sure the word “TOP” faces outwards. : Fit new O-ring (arrow) on engine housing nipple. Install in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 65: Fuel System

    Install all other parts in the reverse sequence. : Insert blade of screwdriver Machines from 2002 between the lugs. : Turn the twist lock (1) 90 degrees to the left (counterclockwise). : Remove the carburetor box cover to the rear. MS 290, MS 310, MS 390...

  • Page 66: Carburetor

    Do not clean fleece filters with a brush. Replace damaged air filter elements. : Disconnect the throttle rod (1) Install in the reverse sequence. from the throttle shaft (2). MS 290, MS 310, MS 390...

  • Page 67: Leakage Test

    : Check that the washer (1) and : Push the fuel line with nipple onto sleeve (2) are in place and the carburetor’s elbow connector. correctly seated. Install all other parts in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 68: Servicing The Carburetor

    – Install the carburetor, b 11.2.1 Reassemble all other parts in the reverse sequence. : Carefully separate the diaphragm Carburetor with limiter caps and gasket. : Take out the screws (arrows). : Remove the end cover (1). MS 290, MS 310, MS 390...

  • Page 69: Inlet Needle

    (arrow) points towards the adjusting screws. MS 290, MS 310, MS 390...

  • Page 70: Fixed Jet

    – Install the metering diaphragm, b 11.3.1 Install all other parts in the reverse sequence. : Carefully separate the diaphragm and gasket. – Inspect diaphragm for damage and wear, fit a new gasket. MS 290, MS 310, MS 390...
  • Page 71 Install all other parts in the reverse sequence. : Check fuel strainer (1) for contamination and damage. If necessary, use a needle to take it out of the carburetor and clean or replace. Install in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 72: Adjusting Carburetor

    13,000 rpm (MS 310, 390) – Check chain tension. If the setting is too lean there is a – Warm up the engine. risk of engine damage due to insufficient lubrication and – Adjust idle speed. overheating. MS 290, MS 310, MS 390...

  • Page 73: User Adjustment (Carburetor With Limiter Caps)

    – Open the low speed screw L one quarter of a turn. – Turn the idle speed screw LA clockwise until the chain begins to run – then turn the screw back one quarter of a turn. MS 290, MS 310, MS 390...

  • Page 74: Basic Setting (Carburetor With Limiter Caps)

    Limiter caps that have been removed once may be damaged – Check the air filter and clean or and must not be re-used. replace as necessary. – Check and clean or replace spark arresting screen (if fitted). MS 290, MS 310, MS 390...

  • Page 75: Tank Vent

    Check correct installed position of tank vent in the handle housing. Install all other parts in the reverse sequence. : Use a 3 mm drift to push the grub screws (1) out of the vent hose (2). MS 290, MS 310, MS 390...

  • Page 76: Machines From 2002

    : Connect vacuum pump : Pry the grommet (1) out of the 0000 850 3501 (1) with hose to handle housing. tank vent (2). : Take the hose (2) out of the retainer (arrow). MS 290, MS 310, MS 390...

  • Page 77: Fuel Tank

    – Use hook (1) 5910 893 8800 to pull the pickup body out of the line with the rib. fuel tank. Install all other parts in the reverse Do not stretch the suction hose. sequence. MS 290, MS 310, MS 390...

  • Page 78: Tank Cap

    : Pry the bumper strip (1) out of the Machines from 1998 housing. : Carefully disconnect nipple (1) of cap retainer from the guide (2) in : Use stud puller 5910 893 0501 to the engine housing. remove the collar stud (2). MS 290, MS 310, MS 390...
  • Page 79 – Remove the chain tensioner, b 5.8 – Remove the wiring harness, b 7.5 – Remove engine with engine pan, b 6.5 – Remove the tank caps, b 10.3 and b 11.6.3 Install in the reverse sequence. MS 290, MS 310, MS 390...

  • Page 80: Special Servicing Tools

    5910 890 0301 0.5 to 18 Nm Alternative: Torque wrench 5910 890 0302 with optical/acoustic signal Torque wrench 5910 890 0311 6 to 80 Nm Alternative: Torque wrench 5910 890 0312 with optical/acoustic signal MS 290, MS 310, MS 390...
  • Page 81 T-handle screwdriver, T 27 x 150 5910 890 2400 IS-P screws (4 mm) Remarks: 1) Use for releasing P screws only. MS 290, MS 310, MS 390...

  • Page 82: Servicing Aids

    0786 111 1101 adhesive (Loctite 242) High-strength threadlocking 0786 111 1109 adhesive (Loctite 270) High-strength threadlocking 0786 110 0126 adhesive (Loctite 649) STIHL Press Fluid OH 723 (50ml) 0781 957 9000 Installing annular buffers MS 290, MS 310, MS 390...
  • Page 83 MS 290, MS 310, MS 390...
  • Page 84 MS 290, MS 310, MS 390...
  • Page 85 MS 290, MS 310, MS 390...
  • Page 86 englisch / english 0455 209 0123. M7. L4. Fi. Printed in Germany...

This manual is also suitable for:

Ms 310Ms 390

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