Stihl MS 240 Instruction Manual
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Stihl MS 240 Instruction Manual

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STIH)
STIHL MS 240, 260
2013-09

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Summary of Contents for Stihl MS 240

  • Page 1 STIH) STIHL MS 240, 260 2013-09...

  • Page 2: Table Of Contents

    Bar Mounting Studs 10.5 Starter Rope / Grip Carburetor 10.6 Tensioning the Rewind 14.5.1 Basic Setting Spring 14.5.2 Standard Setting 10.7 Replacing the Rewind Spring © ANDREAS STIHL AG & Co. KG, 2013 MS 240, MS 260, MS 260 C...
  • Page 3 Heating Element in the Handlebar 15.7 Removing and Installing the Generator 15.7.1 Handle Heating and Generator Trouble- shooting Chart 15.7.2 Test Connections and Test Values 15.8 Wiring Harness Special Servicing Tools Servicing Aids MS 240, MS 260, MS 260 C...

  • Page 4: Introduction

    4.2 in this example Service manuals and all technical information bulletins are intended exclusively for the use of properly equipped repair shops. They must not be passed to third parties. MS 240, MS 260, MS 260 C...
  • Page 5 This symbol may appear alone on small parts. Storing and disposing of oils and fuels Collect fuel or lubricating oil in a clean container and dispose of it properly in accordance with local environmental regulations. MS 240, MS 260, MS 260 C...

  • Page 6: 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 240, MS 260, MS 260 C...

  • Page 7: Specifications

    Speed-controlled oil pump with reciprocating piston and manual flow control Oil pump without adjustable 7.5 (+/- 2.5) cm /min at delivery rate: 10000 rpm Oil pump with adjustable 4.5...11.5 cm /min at delivery rate: 10000 rpm MS 240, MS 260, MS 260 C...

  • Page 8: Tightening Torquese

    (ignition side) Screw M 5x12 Annular buffer plate/crankcase (ignition side) Screw P 6x19 Annular buffer, tank housing/crankcase (clutch side) Screw M 5x16 Muffler/crankcase/cylinder 10.0 1), 4) (version with catalytic converter and MS 260) MS 240, MS 260, MS 260 C...
  • Page 9 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 240, MS 260, MS 260 C...

  • Page 10: Troubleshooting

    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 240, MS 260, MS 260 C...

  • Page 11: Chain Drive

    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 240, MS 260, MS 260 C...

  • Page 12: Chain Lubrication

    Install new oil intake hose damaged Oil pump delivers insufficient oil Oil pump worn Install new oil pump Oil pump delivery rate set too low Adjust oil pump (only on version with adjustable oil pump) MS 240, MS 260, MS 260 C...

  • Page 13: Rewind Starter

    (containing no chlorinated or windings stick together) halogenated hydrocarbons), then pull rope carefully several times until normal action is restored Decompression valve is not open Open, check and replace decompression valve if necessary MS 240, MS 260, MS 260 C...

  • Page 14: Ignition System

    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 240, MS 260, MS 260 C...
  • Page 15 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 240, MS 260, MS 260 C...

  • Page 16: Carburetor

    Fit a new metering diaphragm shrunk Impulse hose damaged or kinked Install new impulse hose Tank vent faulty Replace tank vent Leak on fuel hose from tank to Seal connections or install new fuel carburetor hose MS 240, MS 260, MS 260 C...
  • Page 17 Reset idle speed screw LA incorrect – throttle shutter correctly completely closed Tank vent faulty Replace tank vent Leak on fuel hose from tank to Seal connections or install new fuel carburetor hose MS 240, MS 260, MS 260 C...
  • Page 18 Impulse hose damaged or kinked Install new impulse hose 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 240, MS 260, MS 260 C...

  • Page 19: Engine

    Close, check and replace decompression valve if necessary 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 240, MS 260, MS 260 C...

  • Page 20: Cutting Attachment

    : Remove the sprocket cover (2) and tensioning gear (3) with guide bar (4). : Take out the screw (arrow). – Reassemble in the reverse – Remove the cover plate (1) and sequence. adjusting wheel (2). MS 240, MS 260, MS 260 C...

  • Page 21: Clutch

    Note that the clutch has a left-hand thread. – Replace any damaged parts. : Unscrew the spark plug (1). Disassembling : Fit the retainers (1). : Use hook (2) 5910 890 2800 to remove the clutch springs (1). MS 240, MS 260, MS 260 C...
  • Page 22 (arrow) faces outwards. : Use the hook (2) 5910 890 2800 to attach the other ends of the springs and press them firmly into the clutch shoes. MS 240, MS 260, MS 260 C...

  • Page 23: Clutch Drum

    If there are signs of serious wear on the inside diameter of the clutch drum (1), check the remaining wall thickness. If it is less than about 80% of the original thickness, install a new clutch drum. MS 240, MS 260, MS 260 C...

  • Page 24: Chain Brake

    : Take out the screw (arrow) and If the chain brake does not operate remove the side plate (1). properly, refer to troubleshooting, b 4.2. : Remove the cover (1). MS 240, MS 260, MS 260 C...
  • Page 25 Install a new brake band if there are reverse sequence. noticeable signs of wear (large areas on inside diameter and/or parts of outside diameter – arrows) and its remaining thickness is less than 0.6 mm. MS 240, MS 260, MS 260 C...

  • Page 26: Brake Lever

    : Take the brake lever (2) out of the lever over the machine until it is hand guard (1). positioned against the pivot pin. – Inspect the brake lever (2) and hand guard (1) and replace if necessary. MS 240, MS 260, MS 260 C...

  • Page 27: Cam Lever

    : Attach the brake spring (1) to the brake lever (arrow). : Disconnect the spring (1) from the anchor pin (arrow). : Fit the E-clip (1). MS 240, MS 260, MS 260 C...

  • Page 28: Pins

    Turn the pin (1) back and forth as necessary. – Position the cam lever (1) so that its cam (arow) faces the cam on the hand guard. : Push the cam lever (1) on to the pivot pin (2). MS 240, MS 260, MS 260 C...

  • Page 29: Side Chain Tensioner

    Pin (2) b =. 3.0 – 3.4 mm : Take out the screw (arrow). – Pull out the tensioner side with adjusting screw, thrust pad and spur gear. : Drive home pins (3, 4 and 5) as specified below. MS 240, MS 260, MS 260 C...

  • Page 30: Front Chain Tensioner

    Always replace the adjusting screw See chapter on cutting attachment, and spur gear as a matching pair. – Lubricate the threads, gears and O-ring with STIHL multipurpose grease, b 17 – Reassemble in the reverse sequence. MS 240, MS 260, MS 260 C...

  • Page 31: Tensioner

    – Fit collar stud and tighten it down down firmly. firmly. – Tightening torques, b 3.5 – Tightening torques, b 3.5 – Reassemble all other parts in the Reassemble all other parts in the reverse sequence. reverse sequence. MS 240, MS 260, MS 260 C...

  • Page 32: Engine

    – Reassemble in the reverse sequence. – Remove the muffler (1), check – Hold the machine upright. and replace if necessary. : Inspect and clean the sealing faces (arrows) and remove any gasket residue. MS 240, MS 260, MS 260 C...

  • Page 33: Leakage Test

    0000 850 1300. : Attach tab (arrow) of the exhaust must be in alignment. casing (1) to the muffler first and then swing it into position. MS 240, MS 260, MS 260 C...

  • Page 34: Preparations

    (1) are in place. (arrow). – Remove the muffler exhaust casing, b 8.1 : Loosen the screws (arrows). : Fit the nuts (arrows) and tighten them down firmly. MS 240, MS 260, MS 260 C...

  • Page 35: Vacuum Test

    – Tighten down the muffler firmly. : Operate the lever (2) until the – Reassemble all other parts in the pressure gauge (arrow) indicates reverse sequence. a vacuum of 0.5 bar. – Tightening torques, b 3.5 MS 240, MS 260, MS 260 C...

  • Page 36: Oil Seals

    : Apply puller (1) 5910 890 4400 with No. 3.1 jaws 0000 893 3706. Clean the crankshaft with a little standard commercial solvent-based degreasant containing no chlorinated or halogenated hydrocarbons. MS 240, MS 260, MS 260 C...

  • Page 37: Removing And

    : Fit the installing sleeve (1) 1118 893 4602. – Apply a thin coating of sealant to : Push out the slotted nut (1) with the outside diameter of the oil insulator. seal (2), b 17 MS 240, MS 260, MS 260 C...

  • Page 38: Cylinder

    11.6 – Screw home the slotted nut as far as stop. – Reassemble all other parts in the reverse sequence. – Inspect the reflector foil (1) and replace it if it is damaged. MS 240, MS 260, MS 260 C...
  • Page 39 (arrows) in the cylinder. – Inspect and clean the sealing face (arrow), b 17 The sealing face must be in perfect condition. Always replace components with damaged sealing faces, b 4.7. MS 240, MS 260, MS 260 C...
  • Page 40 : Slide the cylinder over the piston, the clamping strap moves downwards at the same time. – Turn the hose clamp until the screw head is below the lower cylinder fin (arrow). MS 240, MS 260, MS 260 C...

  • Page 41: Crankshaft

    . Remove the handleber with handle heating, b 11.6 – Remove the cylinder, b 8.5 – Remove the piston, b 8.7 : Take out the screws (arrows). – Remove the flywheel, b 9.5 MS 240, MS 260, MS 260 C...
  • Page 42 : Push the service tool (2) ignition side of the crankcase. 5910 890 2205 over the collar screws, fit the nuts (arrows) and tighten them firmly. MS 240, MS 260, MS 260 C...
  • Page 43 (including the cylinder sealing face) – the sealing faces must not be damaged in any way. : Position the tapered stub of the crankshaft (arrow) above the ball bearing at the ignition side and push it home. MS 240, MS 260, MS 260 C...
  • Page 44 "6", then turn the spindle (1) clockwise. – Install the ignition side of the crankcase as far as stop. : Make sure the pin (1) engages the hole and the gasket is not pinched or twisted. MS 240, MS 260, MS 260 C...
  • Page 45 – Unscrew the mounting nuts. – Unscrew the spindle clockwise and take away the service tool. – Take out the two M5x72 screws. MS 240, MS 260, MS 260 C...

  • Page 46: Bearings / Crankcase

    – See also Troubleshooting, tighten them down firmly in an b 4.7 alternate pattern. – Remove the crankshaft, b 8.6.1 – Tightening torques, b 3.5 – Wear protective gloves to reduce the risk of burn injury. MS 240, MS 260, MS 260 C...
  • Page 47 : Use a suitable punch to carefully drive out the oil seal. – Heat the area of the bearing seat to about 150 °C (300 °F). The bearing (1) drops out as soon as this temperature is reached. MS 240, MS 260, MS 260 C...

  • Page 48: Piston

    8.8 – Install the oil seals, b 8.3 – Reassemble all other parts in the reverse sequence. : Place the assembly drift (1) – Tightening torques, b 3.5 1110 893 4700 in position. MS 240, MS 260, MS 260 C...

  • Page 49: Installing

    : Attach the snap ring (1) to the end (needle cage) and line up the magnet (2) so that the snap ring piston. gap is on the flat side of the tool's shank (arrow). MS 240, MS 260, MS 260 C...

  • Page 50: Piston Rings

    – Tightening torques, b 3.5 : Install the new piston rings in the grooves so that the radii face Make sure the tool shank is held upward (arrows). square on the piston pin axis. MS 240, MS 260, MS 260 C...

  • Page 51: Decompression Valve

    – Fit the decompression valve and screw it home by hand. – Tighten down the decompression valve firmly. – Tightening torques, b 3.5 – Reassemble all other parts in the reverse sequence. MS 240, MS 260, MS 260 C...

  • Page 52: Ignition System

    : Turn twist lock (1) counterclockwise. Since there is no mechanical wear in these systems, ignition timing – Remove the carburetor box cannot get out of adjustment during cover (2). operation. MS 240, MS 260, MS 260 C...
  • Page 53 : Pull the ignition lead (1) out of its wire (arrows) is properly guide (arrow). positioned, b 15.7 : Pull the grommet (1) off the ignition module. : Unscrew the ignition module from the ignition lead (2). MS 240, MS 260, MS 260 C...
  • Page 54 – Fit the wiring harness with short the illustration. circuit wire in position, b 15.8 and b 9.6.2 : Push the ignition module (1) back and hold it thee – the flywheel must turn freely. MS 240, MS 260, MS 260 C...

  • Page 55: Ignition Module

    High voltage – risk of electric shock. spark gap to about 2 mm, see spark window (3). – Crank the engine quickly with the rewind starter and check spark in the tester’s window (2). MS 240, MS 260, MS 260 C...
  • Page 56 – Reassemble all other parts in the reverse sequence. – Unhook the leg spring from the ignition lead. – Pull the boot off the ignition lead. MS 240, MS 260, MS 260 C...

  • Page 57: Flywheel

    – Reassemble all other parts in the of damage, b 15.7. reverse sequence. The flywheel and crankshaft stub – Tightening torques, b 3.5 must be free from grease before assembly. MS 240, MS 260, MS 260 C...

  • Page 58: Short Circuit Wire

    9.7. – Reassemble in the reverse : Pull the wiring harness (1) out of sequence. the guides (arrows). : Pull the pin and socket connector (2) out of the guide and separate MS 240, MS 260, MS 260 C...
  • Page 59 : Inspect the wiring harness (1), is completely covered, b 15.8 contact spring (2), grommet (3) and all connectors, and replace wiring harness if necessary. MS 240, MS 260, MS 260 C...
  • Page 60 (2) into its guide. housing. – Check air gap on ignition module and reset if necessary, b 9.5 : Position the ground wire (1) behind the stop buffer (arrow). MS 240, MS 260, MS 260 C...

  • Page 61: Ground Wire

    : Position the wire (1) behind the pin and socket connector. – Install the carburetor, b 14.2 – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5 – Check operation. MS 240, MS 260, MS 260 C...

  • Page 62: Ignition System Troubleshooting

    – If necessary, install new spark plug boot and/ or leg spring, b 9.4 Test ignition system: with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap see TI 32.94), b 9.3 MS 240, MS 260, MS 260 C...
  • Page 63 – Resistance: spark plug boot to ground: spec. 1.5 – 12 kΩ – Check resistance of ignition lead : spec. < 10 Ω, If necessary, install new spark plug boot and/or ignition lead with module, b 9.4 MS 240, MS 260, MS 260 C...
  • Page 64 Machine runs trouble-free, – Look for fault in fuel system or no further action necessary carburetor – Check engine for leaks – Check position of flywheel on crankshaft, b 8.2, b 9.5 MS 240, MS 260, MS 260 C...

  • Page 65: Rewind Starter

    – screw (1) with sleeve secures the hand guard as well. – Tighten down the screws firmly. – Tightening torques, b 3.5 – Fit the new pawl in the bore (arrow) and lubricate its peg (1), b 17 MS 240, MS 260, MS 260 C...

  • Page 66: Rope Rotor

    – Remove the fan housing, b 10.2 : Pull out the starter rope (1) about 5 cm and hold the rope rotor (2) steady. – Take three full turns of the rope off the rope rotor. MS 240, MS 260, MS 260 C...

  • Page 67: 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 240, MS 260, MS 260 C...

  • Page 68: Tensioning The Rewind Spring

    : Pull rope back until knot (1) : Pull the rope with knot into the locates in recess (arrow) in rope starter grip until it is properly rotor. seated in the grip (small arrow). MS 240, MS 260, MS 260 C...

  • Page 69: Replacing The Rewind

    – the anchor loop (2) must be above the lug (1). : Push the rewind spring with spring housing into its seat (arrow) in the fan housing. The rewind spring may pop out and unwind. MS 240, MS 260, MS 260 C...
  • Page 70 – Install the rope rotor, b 10.4 Distance from the end of the anchor – Reassemble all other parts in the loop to the edge of the spring reverse sequence. housing a = 20 mm. MS 240, MS 260, MS 260 C...

  • Page 71: Servicing The Av System

    – Push the plug into the annular buffer as far as stop. – Use STIHL press fluid to simplify assembly, b 17 : Take out the screw (arrow). – Pry out the annular buffer (1). MS 240, MS 260, MS 260 C...

  • Page 72: Annular Buffer At Ignition Side

    – Push the wiring harness (1) to : Insert screws (arrows) and one side. tighten them down firmly. : Take out the screw (arrow) and remove the washer (2). MS 240, MS 260, MS 260 C...

  • Page 73: Stop Buffer

    14.6.1 bore and make sure it is properly seated. – Pull off the impulse hose, b 14.6.2 – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5 MS 240, MS 260, MS 260 C...

  • Page 74: Handlebar With

    11.5. During all the following procedures: – Remove the carburetor, b 14.2 : To reduce the risk of a short circuit, make sure the insulating tubes completely cover the connections. MS 240, MS 260, MS 260 C...
  • Page 75 : Push the wire with connector sleeve (1) through the hole (arrow) and position it in the guide. : Thread the wiring harness – Install the heater switch, b 15.4 through the hole (arrow). MS 240, MS 260, MS 260 C...
  • Page 76 : Push the wire (1) into the guide (arrow) – position the wire snugly against the housing. : Position the wire (2) behind the fuel hose. MS 240, MS 260, MS 260 C...

  • Page 77: Control Levers

    (1) out of the – Position k = cold start switch shaft. – cold engine is started in this : Push the switch shaft into the position mount (1). MS 240, MS 260, MS 260 C...

  • Page 78: Throttle Trigger/Interlock Lever

    – Check correct position of short circuit wire, b 9.6.2 – Check operation. – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5 : Disconnect the throttle rod (1) from the trigger (2). MS 240, MS 260, MS 260 C...
  • Page 79 – Set the switch shaft to " ". : Attach the torsion spring (1) to the throttle trigger (2) : Remove the throttle trigger (1) – note installed position (arrow). with torsion spring (2). MS 240, MS 260, MS 260 C...
  • Page 80 – Tightening torques, b 3.5 : Push the interlock lever (3) into its pivot mounts (arrows) until it snaps into position – check that torsion spring (4) is in position. The interlock lever may pop out. MS 240, MS 260, MS 260 C...

  • Page 81: Chain Lubrication

    Install the pickup properly. body, b 13.1 – Install the oil pump, adjustable, b 13.5, non-adjustable, b 13.4 – Reassemble all other parts in the reverse sequence. – Tightening torques, b 3.5 MS 240, MS 260, MS 260 C...

  • Page 82: Oil Delivery Hose

    Take care not to damage the bore (arrow). The oil delivery hose with sleeve is damaged during the removal process and has to be replaced – the new hose comes with the sleeve already fitted. MS 240, MS 260, MS 260 C...

  • Page 83: Adjustable Oil Pump

    : Remove the oil pump and disconnect the oil delivery hose (arrow). – Check the oil pump (1) and replace it if necessary – Inspect the oil delivery hose and replace if necessary, b 13.3 MS 240, MS 260, MS 260 C...

  • Page 84: Valve

    – Check adjustment of oil pump and readjust if necessary, b 13.5 : Remove the old valve (1) from the oil tank. : Fit the washer (1) and ring (2). Only on adjustable oil pump. MS 240, MS 260, MS 260 C...
  • Page 85 – note installed depth. : Installed depth of new valve: a = about 2 - 3 mm – Reassemble all other parts in the reverse sequence. MS 240, MS 260, MS 260 C...

  • Page 86: Fuel System

    – Reassemble in the reverse : Remove the fuel hose (1). sequence. – Remove the carburetor, check it and service or replace if necessary. – Check the throttle rod and replace if necessary, b 14.6 MS 240, MS 260, MS 260 C...

  • Page 87: Leakage Test

    1110 141 8600 on to the stop. nipple (2) 0000 855 9200. : Push the fuel hose (1) on to the stub (arrow). : Attach the throttle rod (1) to the trigger (2). MS 240, MS 260, MS 260 C...

  • Page 88: Servicing The Carburetor

    : Push the ring (1) to the right and pump air into the carburetor until the pressure gauge (2) indicates a pressure of about 0.8 bar (80 kPa). : Remove the retainer (1) and thermostatic switch (2). MS 240, MS 260, MS 260 C...
  • Page 89 – Check the metering diaphragm (1) for signs of damage and wear. – Reassemble all other parts in the Install a new gasket. reverse sequence. MS 240, MS 260, MS 260 C...

  • Page 90: Inlet Needle

    (arrow) first, then slide the inlet control lever’s clevis into the groove in the inlet needle (1). : Remove the inlet needle (1). – Remove the spring (2). Inspect and replace if necessary. MS 240, MS 260, MS 260 C...

  • Page 91: Pump Diaphragm

    (arrows). : Use a needle to remove the fuel strainer (1) from the carburetor body. : Carefully remove the gasket with – Reassemble in the reverse pump diaphragm from the end sequence. cover. MS 240, MS 260, MS 260 C...

  • Page 92: Choke Shaft / Choke Shutter

    : Inspect the tip (arrow) for damage or wear and replace the screw (L) if necessary. – Screw down the low speed screw (L) as far as stop. – Continue with high speed screw. MS 240, MS 260, MS 260 C...

  • Page 93: Adjusting The Carburetor

    : Pull out the limiter cap (1). – Reassemble in the reverse sequence. – Take out the high speed screw (H). – Carry out basic setting, b 14.5.1 Always install a new limiter cap. MS 240, MS 260, MS 260 C...

  • Page 94: Standard Setting

    (L) removed for the standard setting. Always perform the following steps 5. Set maximum engine speed before carrying out any with the high speed screw (H) adjustments: (see Specifications), b 3 MS 240, MS 260, MS 260 C...

  • Page 95: Throttle Rod

    Even minor adjustments can noticeably affect engine running behavior. If the setting is made too lean there is a risk of engine damage as a result of lack of lubrication and overheating. MS 240, MS 260, MS 260 C...
  • Page 96 – Coat the manifold flange (2) with – Tightening torques, b 3.5 STIHL press fluid, b 17 – Push on the intake manifold (2) position, line it up and secure it in position, b 8.6 MS 240, MS 260, MS 260 C...

  • Page 97: Impulse Hose

    – Collect the fuel in a clean properly seated. container, b 1 – Coat with STIHL press fluid, – Close the tank cap. b 17 : Pull the impulse hose (1) off the connector (arrow). MS 240, MS 260, MS 260 C...

  • Page 98: Removing And Installing

    – Reassemble in the reverse sequence. : Push the ring (1) to the left and connect the pump (2) 0000 850 1300 to the nipple (arrow) – subject the fuel tank to a vacuum. MS 240, MS 260, MS 260 C...

  • Page 99: Fuel Intake

    : Line up the fuel hose (1) and push it into the housing bore – the flange must butt against the rib (arrow). – Coat with STIHL press fluid, b 17 MS 240, MS 260, MS 260 C...

  • Page 100: Removing And Installing The Tank Housing

    – Take out the annular buffer/tank housing mounting screws. Annular buffer at ignition side, b 11.3. Annular buffer at clutch side, b 11.2 Annular buffer/chain catcher, b 11.1 MS 240, MS 260, MS 260 C...

  • Page 101: Heating System

    – Remove the air filter, b 14.1 : Remove the heating element (1). – Set the ohmmeter to measuring range "Ω". MS 240, MS 260, MS 260 C...

  • Page 102: Thermostatic Switch

    To reduce the risk of a short circuit, make sure the insulating tube completely covers the connectors. : Fit the heating element (1) and heating plate (2). – Fit the nuts (arrows) and tighten them down firmly. MS 240, MS 260, MS 260 C...
  • Page 103 – Install the carburetor, b 14.2 : Push the connector (1) on to the : Fit the new thermostatic switch contact spring (arrow) as far as (1) so that the rping (arrow) faces stop. the carburetor. MS 240, MS 260, MS 260 C...

  • Page 104: Carburetor Heating System Troubleshooting Chart

    (43 °F), but no later than + 13 °C (55 °F)? Carburetor heating system in order Circuit diagram G Generator 1 Handlebar 2 Rear handle 3 Heater switch 4 Heating element (carburetor) 5 Thermostatic switch MS 240, MS 260, MS 260 C...

  • Page 105: Handle Heating System

    10 Ω in measuring range "Ω". it to one side, b 11.5 : Remove the ground wire (1). If no reading is obtained, there is a break in the circuit. : Separate the pin and socket connector. MS 240, MS 260, MS 260 C...

  • Page 106: Heater Switch Ground Wire

    – Check for contact and continuity and replace ground wire if necessary, : Push the connector sleeve (1) into the switch. : Push the grommet (2) over the switch. MS 240, MS 260, MS 260 C...

  • Page 107: Removing And Installing Heating Element In Rear Handle

    – Test the generator and heater switch, b 15.3 – Remove the handle molding, b 12.2 : Push back the insulating tubes (1) in the direction of the wiring harness and separate the pin and socket connectors. MS 240, MS 260, MS 260 C...
  • Page 108 If the heating element is not fitted perfectly flat, heat transfer to the handle will be interrupted and the element may fail as a result of overheating. MS 240, MS 260, MS 260 C...

  • Page 109: In The Handlebar

    Heating element does not operate damage. If damage is found, even though resistance replace the generator. measurement is in order? – Test the generator and heater switch, b 15.3 – Reassemble in the reverse sequence. MS 240, MS 260, MS 260 C...
  • Page 110 To reduce the risk of a short circuit, 1118 893 3500 onto the make sure the insulating tube crankshaft so that the slot completely covers the connector. engages the Woodruff key – the generator is now centered. MS 240, MS 260, MS 260 C...

  • Page 111: Handle Heating And Generator Troubleshooting Chart

    Install new rear handle heating element, b 15.5 Resistance of rear handle heating element about 1.6 Ω? Check generator Resistance between engine ground Install new and generator connection generator, about 0.5-1 Ω? b 15.7 MS 240, MS 260, MS 260 C...
  • Page 112 (contact sleeve against switch housing) heater switch, Closed: about 0Ω? b 15.4 Open: Circuit interrupted, b 15.4 (On machines with carburetor heating, reconnect pin and socket connector to heating element), b 15.1 System in order MS 240, MS 260, MS 260 C...

  • Page 113: Test Connections And Test Values

    Break in wire, Install new heating element handlebar damaged Short circuit – Repair insulation damaged insulation Pull out wire for this purpose MS 240, MS 260, MS 260 C...
  • Page 114 Carburetor and handle heating system G Generator 1 Handlebar 2 Rear handle 3 Heater switch 4 Heating element (carburetor) 5 Thermostatic switch Handle heating system G Generator 1 Handlebar 2 Rear handle 3 Heater switch MS 240, MS 260, MS 260 C...

  • Page 115: Wiring Harness

    : Push back the insulating tube (1) in the direction of the generator in the direction of the heating wire and separate the pin and element and separate the pin and socket connector. socket connector. MS 240, MS 260, MS 260 C...
  • Page 116 – Push the wire (1) and connector – Reassemble all other parts in the (1) into the guides (arrows). reverse sequence. – Tightening torques, b 3.5 : Push the wires with the insulating tube (1) into the guide. MS 240, MS 260, MS 260 C...

  • Page 117: Special Servicing Tools

    Removing and installing piston pin Installing tool 10 5910 890 2210 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 240, MS 260, MS 260 C...
  • Page 118 5910 890 2400 IS-P screws (4 mm) Crimping tool 5910 890 8210 Attaching connectors to electrical wires Pliers DIN 5254-A 19 0811 611 8380 Removing and installing external circlips Remarks: 1) Use for releasing only. MS 240, MS 260, MS 260 C...

  • Page 119: 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 240, MS 260, MS 260 C...
  • Page 120 MS 240, MS 260, MS 260 C...
  • Page 121 MS 240, MS 260, MS 260 C...
  • Page 122 englisch / english 0455 165 0123. VA0.J13. Printed in Germany...

This manual is also suitable for:

Ms 260

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