Stihl BR 500 Service Manual
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Stihl BR 500 Service Manual

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STIH)
STIHL BR 500, 550, 600
2009-05

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  • Page 1 STIH) STIHL BR 500, 550, 600 2009-05...

  • Page 2: Table Of Contents

    Oil Seals Servicing Aids 7.9.2 Crankcase, Lower Half 7.9.3 Crankshaft 7.9.4 Piston 7.9.5 Piston Rings 7.9.6 Valves / Valve Springs 7.9.7 Upper Half of Crankcase with Cylinder © ANDREAS STIHL AG & Co. KG, 2009 BR 500, BR 550, BR 600...

  • Page 3: Introduction

    In the descriptions: as the safety precautions and As the design concept of models warnings in the instruction manual. BR 500, BR 550 and BR 600 is : = Action to be taken as almost identical, the descriptions shown in the illustration...

  • Page 4: Specifications

    0.8 bar 0.8 bar 0.8 bar Operation of tank vent at gauge pressure: 0.3 bar 0.3 bar 0.3 bar Fuel: as specified in as specified in as specified in instruction manual instruction manual instruction manual BR 500, BR 550, BR 600...

  • Page 5: Tightening Torques

    15.0 20.0 Locknut IS-M5 Rocker arm mounting Screw IS-M5x18 Starter cover/shroud/engine pan Screw IS-M5x18 Starter cover/shroud/cylinder Remarks: 1) Install with high-strength Loctite 270 2) Do not lubricate with grease 3) Tighten in crosswise pattern BR 500, BR 550, BR 600...
  • Page 6 This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly. Power screwdriver settings for polymer: Plastoform screws max. 600 rpm DG screws max. 500 rpm Important: Do not mix up screws with and without binding head BR 500, BR 550, BR 600...

  • Page 7: Troubleshooting

    (spring (containing no chlorinated or windings stick together) halogenated hydrocarbons). Then pull rope carefully several times until normal action is restored. When installing, coat rewind spring and starter post with STIHL special lubricant BR 500, BR 550, BR 600...

  • Page 8: Ignition System

    Use ohmmeter to check ignition lead for break. If break is detected or resistance is high, fit new ignition lead Replace or clean spark plug, replace damaged parts of ignition system BR 500, BR 550, BR 600...

  • Page 9: 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 BR 500, BR 550, BR 600...
  • Page 10 Setting of high speed screw (H) too Turn high speed screw (H) 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 BR 500, BR 550, BR 600...

  • Page 11: Engine

    Fuel / impulse line kinked or Fit new lines or position cracked without kinks Pump diaphragm torn Install new pump diaphragm Decompression lever sticking Install new cam gear Engine pan defective (cracks) Replace engine pan BR 500, BR 550, BR 600...

  • Page 12: Rewind Starter / Shroud

    13. the rewind spring, must be removed and disassembled. Take particular care when removing the spring. Lubricate the rewind spring and starter post with STIHL special lubricant, b 13, before installing. BR 500, BR 550, BR 600...

  • Page 13: Rope Rotor

    (2). Install all other parts in the reverse sequence. : Remove the washer (1). : Carefully remove the rope rotor (2) from the starter post – Remove worn or broken starter rope, b 5.5 BR 500, BR 550, BR 600...

  • Page 14: Starter Rope/Grip

    : Thread the rope through the rope top of the starter grip from above. rotor. – Pull the rope with knot into the – Tie a simple overhand knot in the starter grip. end of the rope. BR 500, BR 550, BR 600...

  • Page 15: Rope Guide Bushing

    (arrow). Install in the reverse sequence. If the rewind spring pops out and uncoils during installation, refit it in special tool 1116 893 4800 as follows: BR 500, BR 550, BR 600...

  • Page 16: The Rewind Spring

    – To simplify this operation, place counterclockwise. the assembly block 1108 893 4800 across the top of the special tool. BR 500, BR 550, BR 600...

  • Page 17: Shroud

    : Lay the unit on its back. The starter grip must sit firmly in the rope guide bushing without drooping to one side. If this is not the case, tension the spring by one additional turn. BR 500, BR 550, BR 600...

  • Page 18: Fuel System

    : Remove the air filter (1). bond a soundproofing liner (1) in position. The filter element cannot be washed and must be replaced if it is Install all other parts in the reverse heavily loaded. sequence. BR 500, BR 550, BR 600...
  • Page 19 : Pry the grommet (1) out to the mounting (arrow). rear. : Pull out the throttle cable (2). – Take the filter housing (1) out of Install in the reverse sequence. the machine. Replace damaged hoses. BR 500, BR 550, BR 600...

  • Page 20: Carburetor

    Install all other parts in the reverse sequence. – Check tension of throttle cable, adjust if necessary, b 9.3.2 : Push the hose (1) 1110 141 8600 onto the nipple (2) 0000 855 9200. BR 500, BR 550, BR 600...

  • Page 21: Removing And Installing

    Install all other parts in the reverse Always install new gaskets. sequence. Carefully separate the diaphragm and gasket. If the gasket and diaphragm are stuck to the carburetor, remove and separate them very carefully. BR 500, BR 550, BR 600...

  • Page 22: Inlet Needle

    (arrow) on the sealing cone of the perforated sheet (2) faces the inlet needle, replace the inlet inlet control lever (3). needle because it will no longer seal properly. BR 500, BR 550, BR 600...

  • Page 23: Pump Diaphragm

    – Install the metering diaphragm, b 6.3.1 Install all other parts in the reverse sequence. : Remove the gasket (1) with pump : Remove the gasket (1) with pump diaphragm (2). diaphragm (2). BR 500, BR 550, BR 600...

  • Page 24: Accelerator Pump

    : Remove the sleeve (2). out of the carburetor body and clean or replace. Install in the reverse sequence. Note correct installed position of throttle shutter. : Take out the screw (1). : Remove the throttle shutter (2). BR 500, BR 550, BR 600...
  • Page 25 Use a suitable tool to carefully hold down the pump piston and then push the throttle shaft fully home. : Take the pump piston (1) with sealing ring (2) and spring (3) out of the carburetor body. BR 500, BR 550, BR 600...

  • Page 26: Adjusting The Carburetor

    – do not clean. – Check adjustment of throttle cable, b 9.3.2 – Check the spark arresting screen (if fitted), b 7.6 – Start the engine and allow it to warm up. – Adjust engine idle speed. BR 500, BR 550, BR 600...

  • Page 27: Basic Setting In Service Shop

    – Warm up the engine. If the setting is too lean, there is a body. Pry off the limiter cap. risk of engine damage due to insufficient lubrication and overheating. BR 500, BR 550, BR 600...

  • Page 28: Tank Vent

    (L). Use the high speed screw (H) to adjust the maximum engine speed to: 5,500 rpm on the BR 500 6,100 rpm on the BR 550 7,200 rpm on the BR 600 : Push the caps onto the screws until dimension “a”...

  • Page 29: Fuel Hoses

    : Fit a new O-ring (2). before installing, b 13. – Press home the tank vent squarely as far as stop – it must snap audibly into position. Install all other parts in the reverse sequence. BR 500, BR 550, BR 600...

  • Page 30: Fuel Tank

    The high voltages that occur can cause an electric shock. : Disconnect the tank cap cord (1) from the slot (2). – Remove the fuel tank cap. Install in the reverse sequence. BR 500, BR 550, BR 600...

  • Page 31: Checking / Adjusting

    7.5.1. : Take out the screws (arrows) – Rotate the crankshaft until the tip (arrow) of the flywheel lines up : Remove the air guide shroud (1). with the ignition module as shown. BR 500, BR 550, BR 600...

  • Page 32: Rocker Arms / Pushrods

    The feeler gauge must slip through with a certain resistance. Inlet valve (2) = 0.10 ± 0.02 mm Exhaust valve (3) = 0.10 ± 0.02 mm : Remove the sleeve (1). BR 500, BR 550, BR 600...

  • Page 33: Cam Followers

    13. : Take out the pushrod (1). Follow maker's instructions. : Take out the screws (1). : Carefully pry off the cover (2) in a crosswise pattern at the points shown (arrows). BR 500, BR 550, BR 600...

  • Page 34: Cam Gear

    – Install the cam followers, b 7.4 : Rotate the crankshaft until the tip (arrow) of the flywheel lines up with the ignition module as shown. BR 500, BR 550, BR 600...

  • Page 35: Muffler/Spark

    : Take out the screws (arrows) : Carefully fit the spark arresting screen (1) in position. : Remove the muffler (1). Guide lug on spark arresting screen must engage the scoop. BR 500, BR 550, BR 600...

  • Page 36: Flywheel

    8.4 Install all other parts in the reverse sequence. : Screw home the puller 1116 893 0800 (1). – Tap the puller until the flywheel (2) is released from its seat. BR 500, BR 550, BR 600...

  • Page 37: Preparations

    0000 855 8106 (1) between the pump. muffler and cylinder exhaust port. : Operate the lever (2) until the – Tighten the muffler mounting pressure gauge (3) indicates a screws moderately. vacuum of 0.5 bar. BR 500, BR 550, BR 600...

  • Page 38: Pressure Test

    7.6 : Close the vent screw (1) on the rubber bulb. : Pump air into the crankcase with rubber bulb (2) until the gauge (3) indicates a pressure of 0.5 bar. BR 500, BR 550, BR 600...

  • Page 39: Crankshaft

    1108 893 2405 to press home the 1118 893 4602 over the end of oil seal (1) until it is flush with the the crankshaft. crankcase. Install all other parts in the reverse sequence. BR 500, BR 550, BR 600...

  • Page 40: Crankcase, Lower Half

    13. : Use the press sleeve (1) 1108 893 2405 (2) to press home the oil seal until it is flush with the crankcase. Install all other parts in the reverse sequence. BR 500, BR 550, BR 600...

  • Page 41: Crankshaft

    – Align the flywheel and fit the cam gear, b 7.5 Install all other parts in the reverse sequence. : Use the assembly drift (2) 1110 893 4700 to push the piston pin (1) out of the piston. BR 500, BR 550, BR 600...
  • Page 42 (1) points : Remove the sleeve from the tool. towards the flat face (2) of the tool’s shank. : The arrow stamped in the piston crown (arrow) points towards the exhaust port. BR 500, BR 550, BR 600...

  • Page 43: Piston Rings

    Inner pin must point towards flat face. Fit the snap ring so that its gap is on the piston’s vertical axis (it must point either up or down). Install all other parts in the reverse sequence. BR 500, BR 550, BR 600...

  • Page 44: Valves / Valve Springs

    : Check valve heads (1 and 2) for : Loosen the clamp (3) and remove damage. the manifold (2) with flange (1). : Check valve springs (3) for : Pull off the impulse hose (4). damage. BR 500, BR 550, BR 600...

  • Page 45: Ignition System

    The solid state (breakerless) ignition system basically consists of an ignition module (1) and flywheel (2). : When installing, check that the groove in the manifold is properly seated in the fan housing (arrow). BR 500, BR 550, BR 600...

  • Page 46: 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. BR 500, BR 550, BR 600...

  • Page 47: Removing And Installing

    : Pull the boot off the spark plug troubleshooting chart, b 8.7. and connect it to terminal (2). : Attach ground terminal (1) to the spark plug. : Use adjusting knob (4) to set spark gap to about 2 mm. BR 500, BR 550, BR 600...

  • Page 48: Spark Plug Boot

    : Check that the wires are correctly : Pinch the hook of the leg spring positioned in the air guide into the center of the lead, i.e. shroud (arrow). about 15 mm from the end of the lead. BR 500, BR 550, BR 600...

  • Page 49: Testing The Wiring Harness

    If no fault is found, carry out the following checks: – Examine flywheel for damage, b 7.7 – Check air gap between flywheel and ignition module, b 8.4 BR 500, BR 550, BR 600...

  • Page 50: 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) BR 500, BR 550, BR 600...
  • Page 51 – Spark plug boot: Holes/cracks? 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 BR 500, BR 550, BR 600...
  • Page 52 Install new ignition module Engine runs Check “#“/“0“ function on Look for fault in fuel system setting lever or carburetor, or separate check engine for leaks, stop switch check position of flywheel on crankshaft BR 500, BR 550, BR 600...

  • Page 53: Control Handle

    : Remove the torsion spring (1). – Make sure the teeth of the setting lever mesh with those of the cam. : Remove the throttle trigger (2) with lever (3). – Disconnect the throttle cable. BR 500, BR 550, BR 600...

  • Page 54: Throttle Cable

    : Turn the grub screw (arrow) with the fixing pins (arrows). a suitable tool until the throttle lever butts against the carburetor – Adjust the throttle cable, b 9.3.2 cover. – Check idle position. BR 500, BR 550, BR 600...

  • Page 55: Av System

    – Remove the tank, b 6.7 : Screw home the springs and BR 500 only bearing plugs as far as stop (arrows). : Remove soundproofing (arrows). Install all other parts in the reverse sequence. BR 500, BR 550, BR 600...

  • Page 56: Fan

    Install all other parts in the reverse sequence. : Disconnect the lower half of the antistatic wire (1) from the upper half (2). – Take the powerhead off the backplate, b 10.2 BR 500, BR 550, BR 600...

  • Page 57: Inner Fan Housing

    Do not lubricate the thread of the positioned. fanwheel. Install all other parts in the reverse sequence. : Unscrew the fanwheel (1) counterclockwise. Right-hand thread. Very high release torques may be necessary after long periods of operation. BR 500, BR 550, BR 600...

  • Page 58: Antistatic Wire

    : Make sure the sleeve on the crimping (arrow) on the cable lug antistatic wire is always clipped faces outwards. into the retainer (arrow). Install all other parts in the reverse Install all other parts in the reverse sequence. sequence. BR 500, BR 550, BR 600...

  • Page 59: Special Servicing Tools

    Ignition tester, ZAT 3 5910 890 4520 Testing the ignition system Ignition tester, ZAT 4 5910 850 4503 Testing the ignition system Puller 5910 890 4501 Removing limiter caps Screwdriver, T 27 x 200 5910 890 2415 BR 500, BR 550, BR 600...

  • Page 60: Servicing Aids

    Dirko sealant (100 g tube) 0783 830 2120 Crankcase sealing faces Standard commercial solvent- Cleaning crankshaft stub based degreasant containing no chlorinated or halogenated hydrocarbons Loctite 270 (50 ml bottle) 0786 111 1109 High-strength threadlocking adhesive BR 500, BR 550, BR 600...
  • Page 61 BR 500, BR 550, BR 600...
  • Page 62 englisch / english 0455 452 0123. VA0.B12.FST. Printed in Germany...

This manual is also suitable for:

Br 550Br 600

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