Manifold, Injection Module; Tools, Servicing Aids; Removing The Airflow Shroud; Removing The Manifold - Stihl MS 500i Service Manual

25 Manifold, Injection Module

5
M4x20 (4 Nm / 35 lbf. in.)
(4 Nm / 35 lbf. in.) M4x20
25.1

Tools, Servicing Aids

Screwdriver – 0000 890 2300 or equivalent
–
Socket, T27x125 – 0812 542 2104 or equivalent
–
Torque wrench – 5910 890 0302 or equivalent
–
Screwdriver, T10 – 5910 890 2308 or equivalent
–
Screwdriver, T27x200 – 5910 890 2415 or equivalent
–
Hook – 5910 890 2800
–
Socket, T10
–
Pin punch, 5 mm
–
STIHL OH 723 press fluid – 0781 957 9000
–
25.2

Removing the Airflow Shroud

Preparations, @ 3.1.
N
Remove the filter cover.
N
Remove the air filter.
N
Remove the shroud.
N
Remove spark plug boot and pull ignition lead out of
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the guides.
Remove the filter base, @ 15.2.
N
Remove the throttle body and sleeve, @ 15.4.
N
Remove the injection pump, @ 21.2.
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Remove the handlebar, @ 9.2.
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Remove screw from AV element between tank
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housing and crankcase, @ 17.2.
MS 500i
4
3
2
M4x12 (2 Nm / 18 lbf. in.)
1
6
7
11
8
10
9
P3x16 (0.8 Nm / 7 lbf. in.)
13
12
6
M4x20
(4 Nm / 35 lbf. in.)
M4x20
(4 Nm / 35 lbf. in.)
Unlock and remove blue connector of sensor from the
N
controller, @ 19.7.
Pull sensor wires out of cable holder on the tank
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housing.
Unlock and remove generator's black connector from
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controller, @ 19.7.
Pull generator's wiring harness out of the guides in
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the tank housing and airflow housing, @ 22.2.
Remove fuel suction hose outside the tank with
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nipple, @ 20.2.
Remove fuel hose from guide in the tank housing, @
N
20.4.
Remove the fuel return hose with nipple, @ 20.6.
N
Remove impulse hose from guide in the tank housing,
N
@ 20.8.
Lift away the tank housing.
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Take out the screws (2) and (5).
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Grip the top edge of the airflow shroud (4) and pull it
N
off of the manifold (1).
If the grommet (3) is damaged: Remove the grommet
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(3) from the airflow shroud (4).
25.3

Removing the Manifold

Remove the airflow shroud (4), @ 25.2.
N
Remove the manifold (1).
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If the muffler (1) or sealing faces of the injection body
N
(12) are damaged: replace the damaged parts.
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