Stihl MS 210 Service Manual
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Stihl MS 210 Service Manual

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STIH)
STIHL MS 210, 230, 250
2003-04

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Summary of Contents for Stihl MS 210

  • Page 1 STIH) STIHL MS 210, 230, 250 2003-04...

  • Page 2: Table Of Contents

    8.5.1 Elastostart 8.5.2 Tensioning Rewind Spring Pawl AV Handle System/ Handle Housing Annular Buffers Front Handle Handle Housing Switch Shaft Contact Spring Throttle Trigger/ Interlock Lever © ANDREAS STIHL AG & Co. KG, 2007 MS 210, MS 230, MS 250...

  • Page 3: Introduction

    Use the part numbers to identify the tools in the "STIHL As the design concept of model Special Tools" manual. MS 210, 230 and 250 chainsaws is The manual lists all special almost identical, the descriptions servicing tools currently available and servicing procedures in thus from STIHL.

  • Page 4: Safety Precautions

    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. MS 210, MS 230, MS 250...

  • Page 5: Specifications

    (with bar and chain): 12,500 rpm 14,000 rpm 14,000 rpm Idle speed: 2,800 rpm Clutch: Centrifugal clutch without linings Clutch engages at: 4,100 rpm Crankcase leakage test at gauge pressure: 7.25 psi under vacuum: 7.25 psi MS 210, MS 230, MS 250...

  • Page 6: Fuel System

    Bosch WSR 6F NGK BPMR 7A Electrode gap: 0.5 mm (0.02 in) Chain Lubrication Fully automatic speed-controlled oil pump with rotary piston Oil delivery rate: approx. 7.5 cc/min (0.46 cu in/min) at 10,000 rpm MS 210, MS 230, MS 250...

  • Page 7: Tightening Torques

    DG 8x18 Guide bar mounting M12x1 Carrier (clutch) M14x1.25 Spark plug Collar locknut Muffler Collar locknut Filter housing/carburetor 0.27 Collar nut M8x1 Flywheel to crankshaft M12x1.5 Decompression valve Spline screw IS-DG5x16 Spiked bumper 0.37 MS 210, MS 230, MS 250...
  • Page 8 This procedure ensures that the screw engages properly in the existing thread and does not form a new thread, which would weaken the assembly. Note: Power screwdriver speed setting for polymer: – DG screws max. 500 rpm MS 210, MS 230, MS 250...

  • Page 9: Troubleshooting Chart

    Fit chain of correct pitch Saw chain does not stop Brake spring stretched or broken Fit new brake spring immediately when brake is activated Brake band stretched / worn / Fit new brake band broken MS 210, MS 230, MS 250...

  • Page 10: Rewind Starter

    Lubricating oil on rewind spring Apply a few drops of kerosine becomes viscous at very low (paraffin) to spring, then pull rope outside temperatures (spring carefully several times until normal windings stick together) action is restored MS 210, MS 230, MS 250...

  • Page 11: Chain Lubrication

    Install new oil pump Machine losing chain oil Oil seal leaking Replace oil seal Bore in pump housing worn Install new oil pump Oil pump delivers too little oil Oil pump worn Install new oil pump MS 210, MS 230, MS 250...

  • Page 12: Ignition System

    Set air gap correctly coil and flywheel Flywheel cracked or has other Install new flywheel damage Crankcase damaged (cracks) Install new crankcase No ignition spark Check operation of Master Control lever, ignition module and ignition lead MS 210, MS 230, MS 250...

  • Page 13: Carburetor

    Inlet needle sticking to valve seat Remove inlet needle, clean and refit Connecting bore to atmosphere Clean bore blocked Diaphragm gasket leaking Fit a new diaphragm gasket Metering diaphragm damaged or Fit a new metering diaphragm shrunk MS 210, MS 230, MS 250...
  • Page 14 Fit a new pump diaphragm fatigued 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 MS 210, MS 230, MS 250...

  • Page 15: Engine

    Decompression valve sticking Replace the decompression valve 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 210, MS 230, MS 250...

  • Page 16: Clutch, Chain Drive

    If the clutch drum has to be replaced, also check the brake band – b 5.4. – Remove the rim sprocket, if fitted. : Pull off the clutch drum / chain sprocket. MS 210, MS 230, MS 250...

  • Page 17: Chain Catcher

    : Pry the plug (2) out of the front right-hand AV element. – Unscrew the spark plug. – Close the decompression valve, if fitted. : Push the locking strip (1) 0000 893 5903 into the cylinder. MS 210, MS 230, MS 250...
  • Page 18 (3). – Pull the clutch shoes off the carrier. Assembling the clutch: : Clamp the clutch in a vise. : Slip the retainers onto the clutch shoes. MS 210, MS 230, MS 250...

  • Page 19: Chain Brake

    – b 5.1. deceleration of the saw chain is imperceptible to the eye. : Fit the shutter so that its lugs engage the recesses in the handle housing. – Install the air filter – b 11.1. MS 210, MS 230, MS 250...
  • Page 20 : Remove strap from bell crank off the anchor pin and take it off pivot pin (1). the bell crank. : Push the strap sideways and lift it off the hand guard pivot pin (2). MS 210, MS 230, MS 250...

  • Page 21: Installing

    (2) off their pivot the hand guard so that the short pins and lift away together. arm of the bell crank points to top of hand guard. – Pull the bell crank out of the hand guard. MS 210, MS 230, MS 250...
  • Page 22 "snatching" during the first few brake applications. : Check that flat spring (1) is : Attach the brake spring to the bell properly located on face (2) of crank. hand guard bearing boss. MS 210, MS 230, MS 250...

  • Page 23: Front Chain Tensioner

    (1.5 lbf.ft). – Fit upper bumper strip on tensioner. – Install clutch drum/chain sprocket – b 5.1. – Check operation of chain brake – b 5.4.1. : Pull the spur gear out of the cover. MS 210, MS 230, MS 250...

  • Page 24: Muffler/Spark

    : Pull off or lever off the cover plate : Remove the gasket (1) and heat – depending on type fitted. shield (2), if fitted. – Remove spark arresting screen, if fitted. Clean the screen or fit a new one if necessary. MS 210, MS 230, MS 250...

  • Page 25: Leakage Test

    – Remove the carburetor – b 11.2.2. – Set the piston to top dead center (T.D.C.). This can be checked through the inlet port. : Inspect carburetor gasket and fit a new one if necessary. MS 210, MS 230, MS 250...

  • Page 26: Pressure Test

    – Remove the flange. pump 0000 850 3501. 20 seconds, the engine or decompression valve, if fitted, is – Remove the sealing plate. airtight. – Install the muffler – b 6.1. MS 210, MS 230, MS 250...

  • Page 27: 6.3 Oil Seals

    0000 850 3501 to test crankshaft. flange nipple. : Close the vent screw (1) on the pump. : Operate the lever (2) until pressure gauge (3) indicates a vacuum of 0.5 bar (7.25 psi). MS 210, MS 230, MS 250...
  • Page 28 Ignition side: – Remove the flywheel – b 7.5. : Apply puller (1) 5910 890 4400 (jaws 0000 893 3711 with No. 6 profile). – Clamp the puller arms. – Pull out the oil seal. MS 210, MS 230, MS 250...

  • Page 29: 6.4 Removing And 5 Installing

    : Place the oil seal (1) in position : Take out the ground wire with the clamping ring facing up. fastening screw. : Screw the guide sleeve (2) 1123 894 7700 onto the crankshaft. MS 210, MS 230, MS 250...

  • Page 30: Cylinder

    – Apply a thin coating of sealant to the outer diameters of the oil seals – b 13. : Pull the engine pan off the – Lubricate piston and piston ring cylinder. with oil. MS 210, MS 230, MS 250...
  • Page 31 : Push the manifold on to the the engine pan mating face – intake port so that the straight b 13. faces are in alignment. Follow manufacturer’s instructions Assemble all other parts in the for use of sealant. reverse sequence. MS 210, MS 230, MS 250...
  • Page 32 5910 890 2210 as shown: the connecting rod. a = 16 mm (11/16") Installed position of piston: b = 8 mm (5/16") 1 = Arrow 2 = Long stub of crankshaft MS 210, MS 230, MS 250...
  • Page 33 Position the sleeve so steady, center the tool shank that the inner pin (1) points exactly and press home until the toward the flat face (2) of tool's snap ring slips into the groove. shank. MS 210, MS 230, MS 250...

  • Page 34: 6.7 Piston Rings

    : Install the new piston rings in the – Remove the piston – b 6.6. grooves so that the radii face upward. : Remove the retaining ring (arrow). – Install the piston – b 6.6. MS 210, MS 230, MS 250...

  • Page 35: Ignition System

    – Install the piston – b 6.6. – Install new decompression valve and torque down to 14 Nm (10.5 lbf.ft). – Refit the front handle. The electronic (breakerless) ignition system basically consists of an ignition module (1) and flywheel (2). MS 210, MS 230, MS 250...

  • Page 36: Spark Plug Boot

    – Install the air filter – b 11.1. – Fit spark plug boot over the ignition lead. – Use pliers to grip the end of the ignition lead inside the spark plug boot and pull it out. MS 210, MS 230, MS 250...

  • Page 37: 7.3 Testing The 10 Ignition Coil

    If no spark is visible, check the – Set Master Control lever to "1". wiring harness and contact spring – b 7.4. The measured resistance must be infinitely high. If not, install a new Master Control lever. MS 210, MS 230, MS 250...

  • Page 38: Removing And Installing

    : Pull the short circuit wire off the tag on the ignition module. : Take out the screws (arrows). – Pull the ignition module forward a little. : Take the short circuit wire (1) out of the retainer (2). MS 210, MS 230, MS 250...

  • Page 39: Flywheel

    Reassemble all other parts in the reverse sequence. If the flywheel cannot be removed by hand, screw on the puller (1) 1116 893 0800 and tap its end to release the flywheel. Remove the puller. MS 210, MS 230, MS 250...

  • Page 40: Ignition System

    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 210, MS 230, MS 250...
  • Page 41 – 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 MS 210, MS 230, MS 250...
  • Page 42 Engine runs Check ON/STOP function Look for fault in fuel system on Master Control lever/ or carburetor, slide contro check engine for leaks, or separate stop switch check position of flywheel on crankshaft MS 210, MS 230, MS 250...

  • Page 43: Rewind Starter

    Lubricate the rewind spring and starter post with STIHL special lubricant, b 13, before installing. Removing the rope rotor: : Use a screwdriver or suitable pliers to carefully remove the spring clip from the starter post. MS 210, MS 230, MS 250...
  • Page 44 : Remove the washer (arrow). Installing the rope rotor: – Fit washer and push the spring clip into the groove in the starter Coat bore in rope rotor with STIHL post. special lubricant – b 13. Make sure the spring clip (1)

  • Page 45: Segment

    Reassemble all other parts in the reverse sequence. – Secure the rope with a simple overhand knot. : Pull the rope back until the knot locates in the recess (arrow) in the rope rotor. MS 210, MS 230, MS 250...

  • Page 46: Elastostart

    – Fit the fan housing – b 8.2. : Thread new starter rope through the top of the starter grip. : Pull out the starter rope until the nipple (1) locates in the starter grip. MS 210, MS 230, MS 250...

  • Page 47: Tensioning

    : Grip the rope next to the rotor – Fit the fan housing – b 8.2. and use it to turn the rope rotor six times clockwise. MS 210, MS 230, MS 250...

  • Page 48: Rewind Spring

    The rewind spring may pop out and rewind spring over the starter uncoil during installation. post. – If the rewind spring has popped out, refit it in the assembly tool 1116 893 4800 as follows: MS 210, MS 230, MS 250...

  • Page 49: Pawl

    Annular buffer in handle housing from inside the front handle until its groove (1) engages over the – Remove the handle housing – housing rib (2). b 9.3. : Ease the plug out of the buffer. MS 210, MS 230, MS 250...

  • Page 50: Front Handle

    (1) engages over the rib (2). : Ease plugs out of the annular buffers. – Install the handle housing – b 9.3. : Take out the screws. MS 210, MS 230, MS 250...
  • Page 51 : Pull the handle housing slightly contact spring. forward and push the manifold through the handle housing : Pull the short circuit wire's opening at the same time. contact sleeve (2) out of the switch shaft. MS 210, MS 230, MS 250...
  • Page 52 : To fit the manifold in the handle : Connect the impulse hose to the housing intake opening, wind a stub on the handle housing. piece of string (about 15 cm / 6" long) around the back of the manifold flange. MS 210, MS 230, MS 250...

  • Page 53: Switch Shaft

    Install in the reverse sequence. Install in the reverse sequence. : Pull the choke rod out of the : Lift the contact spring slightly to switch shaft and the choke shaft. install the switch shaft. MS 210, MS 230, MS 250...

  • Page 54: Throttle Trigger

    : Push the throttle trigger upward : Use a 4 mm (5/32") drift to push and move the Master Control home the cylindrical pin. lever (2) to the "Choke" position. MS 210, MS 230, MS 250...
  • Page 55 Collect chain oil in a clean container – Wash the pickup body in STIHL – Insert screw and tighten down to or dispose of it properly at an cleaner and, if possible, blow out 1.6 Nm (1.2 lbf.ft).

  • Page 56: Connector Suction Hose

    : Pull suction hose with pickup : Use a 5 mm (3/16") dia. drift to body out of the oil tank. carefully drive the valve out of the housing from inside the tank. – Remove the pickup body. MS 210, MS 230, MS 250...
  • Page 57 : Remove the cover washer (1). 1 mm (3/64"). – Fit the oil filler cap. : Pull the worm and drive spring (arrow) off the crankshaft stub. : Take the drive spring off the worm. MS 210, MS 230, MS 250...
  • Page 58 : Place the oil pump in position so over the housing rib. that its groove (1) lines up with the square (2) on the housing. – Fit the connector – b 10.2. MS 210, MS 230, MS 250...
  • Page 59 Replace a damaged air filter. : Turn twist lock (1) 90 degrees counterclockwise. : Lift off the carburetor box cover (2) vertically. – Remove all loose dirt from around the filter. MS 210, MS 230, MS 250...
  • Page 60 – Push the fuel hose onto the elbow connector. – Fit the carburetor box cover. : Push the fuel line (1) 1110 141 8600 onto the nipple (2) 0000 855 9200. MS 210, MS 230, MS 250...
  • Page 61 (1.8 lbf.ft). : Pull choke rod (1) out of choke : Take the throttle rod off the shaft (2) and switch shaft (3). throttle shaft. – On easy start machines, pull carburetor forward a little. MS 210, MS 230, MS 250...
  • Page 62 (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. MS 210, MS 230, MS 250...
  • Page 63 (L). : Use suitable pliers to pull off the limiter cap (1). – Carefully screw down both adjusting screws (H and L) clockwise until they are against their seats. Then make the following adjustments: MS 210, MS 230, MS 250...
  • Page 64 – Adjust engine idle speed – b 11.2.4. : Take the tank vent valve (1) out of the retainer (3) and pull off the hose (2). MS 210, MS 230, MS 250...
  • Page 65 Reassemble in the reverse retainer, if fitted. sequence. : Straight side (1) of hose flange must be in line with the tank joint (2). Reassemble all other parts in the reverse sequence. MS 210, MS 230, MS 250...
  • Page 66 – Remove the cover. : Disconnect hoses from the : Push the cover (1) under the connectors. upper retaining tab (2) and push the pin (3) into the bore in the handle housing. MS 210, MS 230, MS 250...
  • Page 67 Hose (2): 5.4x2.2x38 mm Hose (3): 5.7x3.1x51 mm Hose (4): 5.4x2.2x65 mm Machines with manual fuel pump: On non-EU version: Hose (4): 5.4x2.2x100 mm Reassemble in the reverse sequence. : Remove the vent hose from the tank. MS 210, MS 230, MS 250...
  • Page 68 : Pull out the oil pump suction hose wire (1). with pickup body. : Take out the screws (2). : Remove the ignition module (3). : Pull the pickup body off the hose. : Remove the spiked bumper, if fitted. MS 210, MS 230, MS 250...
  • Page 69 – b 8. – Coat the fuel hose flange with a little oil to simplify installation. – Straight side of hose flange must be in line with the tank joint. MS 210, MS 230, MS 250...

  • Page 70: Special Servicing Tools

    Torque wrench 5910 890 0312 with optical/acoustic signal Spline screw socket T 27 x 150 0812 542 2104 IS-P screws (4 mm) Remarks: 1) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400. MS 210, MS 230, MS 250...
  • Page 71 Clamping bar 5910 890 2000 For mounting chainsaw to assembly stand Jaws (No. 3.1 + 4 profile) 0000 893 3706 Removing oil seal(s) Sleeve 1124 893 7100 Remarks: 2) Only use for releasing DG screws. MS 210, MS 230, MS 250...
  • Page 72 (1 ltr./ 34 fl.oz bottle) Molybdenum grease (Molykote) Sliding and bearing points of brake band Graphite grease Peg on pawl Hose, 5.4x2.2x1000 mm 0000 930 2800 Fuel/suction hose Hose, 5.7x3.1x1000 mm 0000 930 2801 Fuel/suction hose MS 210, MS 230, MS 250...
  • Page 73 MS 210, MS 230, MS 250...
  • Page 74 englisch / english 0455 208 0123. M0,5. A7. Rei. Printed in Germany...

This manual is also suitable for:

Ms 230Ms 250

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