Stihl TS 500i User manual

STIH)
STIHL TS 500i 2012-02

1TS 500i
q
© ANDREAS STIHL AG & Co. KG, 2012
RA_753_00_01_01
1. Introduction and
safety precautions 3
1.1 Introduction 3
1.2 Safety precautions 4
2. Specifications 6
2.1 Engine 6
2.2 Fuel system 6
2.3 Spark plug 6
2.4 Abrasive wheels 6
2.5 Tightening torquese 7
3. Troubleshooting 10
3.1 Clutch 10
3.2 Cast arm with guard 11
3.3 Solenoid valve /
Water system 12
3.4 Starter 14
3.5 Troubleshooting chart
STIHL Injection 15
4. Cast arm with guard 25
4.1 Water system 25
4.1.1 Nozzles 25
4.1.2 Water hose 25
4.1.3 Solenoid valve 26
4.2 Cast arm with guard 28
4.2.1 Ball bearing 32
4.3 Testing radial and
axial truth of running 33
4.4 Test sequence data 34
4.5 Ribbed poly V-belt 35
4.6 Tensioner 36
5. Starter cup / clutch 38
5.1 Starter cup 38
5.2 Clutch 39
5.3 Belt pulley /
clutch drum 40
5.4 Studs for securing the
"cast arm with guard" 41
6. Engine 42
6.1 Muffler / spark
arresting screen 42
6.2 Leak testing 42
6.2.1 Preparations 43
6.2.2 Testing with negative
pressure 44
6.2.3 Pressure test 44
6.3 Oil seals 45
6.4 Shroud 46
6.5 Engine 48
6.6 Cylinder 48
6.7 Crankshaft 52
6.7.1 Ball bearing /
crankcase 57
6.8 Piston 58
6.9 Piston rings 60
6.10 Decompression valve 61
7. STIHL Injection 62
7.1 Testing 63
7.1.1 Checking the screw
connection and plug 63
7.1.2 Connect the injection
system diagnostic
cable 63
7.2 Testing with
STIHL MDG 1 65
7.3 Control unit 65
7.4 Spark plug boot 67
7.4.1 Ignition lead 68
7.5 Flywheel 68
7.5.1 Generator 70
7.6 Short circuit wire /
switch 71
7.6.1 Testing 71
7.6.2 Removal and
installation 71
7.7 Control panel 74
8. Starter 77
8.1 General 77
8.2 Removal and
installation 77
8.3 Pawl 77
8.4 Rope rotor 78
8.5 Starter rope /
starter grip 79
8.6 Tensioning the
rewind spring 80
8.7 Replacing the
rewind spring 81
9. Antivibration
elements 83
9.1 Antivibration spring
on handlebar 83
9.2 Antivibration spring
in the support 84
9.3 Antivibration spring
at the bottom of the
crankcase 84
9.4 Antivibration spring
on throttle shutter
housing 85
9.5 Handlebar 86
9.6 Rubber buffers /
support 87
9.6.1 Support 87
9.6.2 Support foot 88
9.6.3 Wiring harness
solenoid valve
(water connection) 90
10. Actuating lever 91
10.1 Switch shaft 91
10.2 Throttle trigger /
trigger interlock 92
Contents

2TS 500i
Contents
11. Fuel system 94
11.1 Air filter 94
11.2 Throttle shutter housing /
Intake manifold 94
11.2.1 Air baffle /
throttle cable 95
11.3 Injection valve 96
11.4 Sensor 99
11.5 Impulse hose 101
11.6 Leak testing 102
11.6.1 Checking the fuel tank /
fuel system 102
11.6.2 Checking the
tank vent 103
11.6.3 Tank vent
Removal and
installation 104
11.7 Injection pump 104
11.7.1 Manual fuel pump 104
11.7.2 Injection pump 105
11.8 Fuel intake 106
11.8.1 Pickup body 106
11.8.2 Fuel hoses 106
11.8.3 Fuel tank filler cap 107
11.9 Tank housing 107
12. Special tools 111
13. Service
accessories 114

3TS 500i
1. Introduction and safety precautions
1.1 Introduction
This Service Manual contains
detailed descriptions of all the
typical repair and servicing
procedures for this power tool.
Refer to the illustrated spare parts
lists during all repair work. These
lists show the installation position
and order in which the individual
parts and modules should be
assembled.
Refer to the latest edition of the
relevant spare parts list to check the
part numbers of any spare parts
required.
A fault on the machine may be due
to several causes. To help locate
the fault, consult the chapter on
"Troubleshooting" and the
"STIHL Service Training System"
for all functional groups.
Refer to the "Technical Information"
bulletins for engineering changes
which have been introduced since
publication of this Service Manual.
The "Technical information
bulletins" also supplement the spare
parts list and Service Manual until
an updated edition is issued.
The special tools mentioned in the
descriptions are listed in the chapter
"Special Servicing Tools" of this
manual. The tools can be identified
according to part number in the
"Special Tools Manual". The manual
lists all tools supplied by STIHL.
Symbols are included in the text and
pictures for greater clarity.
The meanings are as follows:
In the text:
:= Action to be taken
as shown in the illustration
above the text
– = Action to be taken
but not shown in the illustration
above the text
In the illustrations:
AItem pointer (short)
aDirection of movement
(long arrow)
b4.2 = Reference to another
chapter, in this case to
Chapter 4.2
Service Manuals and "Technical
information bulletins" are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed on to third parties.
Servicing and repairs are made
considerably easier if the machine
is mounted on assembly stand (3)
5910 890 3100. For this purpose,
secure the mount (2)
5910 850 1650 to the assembly
stand with two screws (1).
For the assembly block
5910 890 3101 the
abovementioned mounting
step is dropped since the
mount is already attached.
1
2
3
219RA000 TG
The screws must not protrude, as
they may damage the housings
when clamping the machine,
depending on the model.
The clamping plate (1)
4238 890 2100 is secured to the
mount (2) using two screws
M8x20 (3) and washers.
Preparing to make repairs
In order to be able to clamp the
machine for the repair work on the
assembly stand, the "cast arm with
guard" must be removed b4.2.
The machine is guided by the
two front studs on the crankcase
through the bushings of the
clamping plate and is secured
with the nuts (arrows).
3
12
3
370RA000 TG370RA001 TG

4TS 500i
Always use original
STIHL replacement parts.
They can be identified by the
STIHL part number,
the logo STIH)
and the
STIHL parts symbol (
The symbol may appear
alone on small parts.
Storage or disposal of fuel
Collect fuel in a clean container and
dispose of it in accordance with
environmental regulations.
Plug connections on electrical
leads
The insulating tube must be
oriented so that it is centered over
the plug connection and completely
enclose the plug connection
– danger of short-circuiting.
The plug connection is completely
plugged together when it has a total
length of a = max. 30 mm.
Routing the leads
In principle, press all electrical leads
into the guides using the wiring tool
5910 890 4000.
5902RA299 TG
a
1.2 Safety precautions
Specific national safety regulations
and the safety instructions in the
instruction manual must be
observed if the machine has to be
started up during maintenance or
repair work.
Fuel is highly inflammable and can
also be explosive under certain
conditions.
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.
Test for leakage after all work on the
fuel system and engine.
Exercise extreme caution while
carrying out maintenance and repair
work on the electronically controlled
injection system – STIHL Injection.
The high voltages which occur can
cause serious or fatal accidents.
Keep everything clean when
working on the electronically
controlled injection system STIHL
Injection.
Suitable gloves must be worn
without fail if parts are heated for
assembly/disassembly purposes.
Improper handling may result in
burns and other serious injuries.
Always replace damaged parts.
Check dismantled parts for wear
and damage before installation,
replace if necessary.
Only use the machine with the fan
cover mounted – otherwise the
rotating flywheel poses a risk of
injury and there is a risk of engine
damage due to overheating.
Only start engine with built-in
throttle shutter housing.
The chapter "Tightening Torques"
lists all components of this machine
that must be tightened with the
specified tightening torques or
coated with thread-locking
adhesive. These specifications
must be observed throughout the
Service Manual when tightening
screws and nuts as well as other
fasteners.

5TS 500i
Fuel system – barbed connectors
Pull or push the fuel hoses, by hand
whenever possible, in the direction
of the connector in order to ensure
leakproofness of the fuel system.
Avoid damaging the barbed
connectors
– sharp-edged pliers, screwdrivers,
etc., may not be used.
Also, do not cut open fuel hoses
with a knife or similar aids.
Do not reuse fuel hoses after
disassembly, but instead always
replace them with new hoses
– fuel hoses can be overstretched
when being detached.
Mount new fuel hoses dry or using
STIHL press fluid – apply press fluid
to the ends of the hose and the
connectors, b13.
Other press fluids are not permitted
and may lead to fuel hose damage.

6TS 500i
2. Specifications
2.1 Engine
STIHL Injection
Control unit with load dependent, characteristic-curve-driven ignition timing adjustment and fuel injection.
Electronic water control
The electronic water control makes it possible to feed the optimum amount of water to the abrasive wheel. No
water is fed to the abrasive wheel during idling.
TS 500i
Displacement: 72.2 cm3
Cylinder bore: 52 mm
Stroke: 34 mm
Engine power to ISO 7293: 3.9 kW (5.3 HP)
at 9500 rpm
Cut-off speed: 9800 rpm
Max. spindle speed to ISO 19432: 4780 rpm
Idle speed: 2500 rpm
Clutch: Centrifugal clutch without
linings
Clutch engages at: 4000 rpm
Crankcase leakage test
at gauge pressure: pü= 0.5 bar
under vacuum pu= 0.5 bar
2.2 Fuel system Fuel system leakage test at
gauge pressure:
pü= 0.8 bar
Operation of tank vent
at gauge pressure: pü= 0.3 bar
Fuel: as specified in instruction
manual
2.3 Spark plug Spark plug (suppressed): Bosch WSR6F
NGK BPMR 7 A
Electrode gap: 0.5 mm
2.4 Abrasive wheels
Composite and diamond cutting wheels Diameter 350 mm
Cutting depth 125 mm

7TS 500i
2.5 Tightening torquese
P and DG screws are fitted in plastic and light alloy metal parts. These screws form a permanent thread when
they are installed for the first time. The material is permanently deformed. Screws can be removed and installed
as often as necessary without impairing the strength of the screwed assembly, provided that the specified
tightening torque is observed.
For this reason it is essential to use a torque wrench.
When inserting DG and P screws into an existing screw thread:
Insert the DG or P screw in the hole and turn counterclockwise until it gently drops into the hole in axial direction
and engages the existing threads. Tighten the screw clockwise to the specified torque.
This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.
For the microencapsulated screw, before renewed assembly, clean both threads (insert tap in the internal thread
by hand and then blow out the threaded hole, brush off the exterior thread), coat the cleaned screw with
medium-strength Loctite 242 or 243.
Screwdriver speed when used in plastic material: P and DG screws max. 500 rpm.
Do not use an impact wrench to release or tighten screw connections.
Screws with and without locking serration must not be confused.
Fastener Thread size For component Tightening
torques
Comment
Nm
Screw P4x16 Limit stop / cast arm 1.8
Screw M8 Stop pin / cast arm 5.0
Screw M6x28 Cast arm / flange 8.0 2)
Collar nut M8 Cast arm / rewind starter / stud 20.0
Screw M5x17 Cover / shroud (service cover) 4.5
Screw P6x19 Cap / solenoid valve / tank housing 6.0
M10x1 Decompression valve 14.0
Screw M4x20 Injection valve / crankcase 3.0 2)
Screw M5x20 Filter cover / tank housing 6.0
Screw M4x9.6 Spark arresting screen / muffler 2.0
Screw M5x20 Generator / crankcase 6.0 2)
Screw P5x16 Handle molding / shroud 4.0
Screw D5x20 Rubber buffers / support 6.0 6)
Screw P5x16 Holder / switch / shroud 4.0
Screw P6x19 Shroud / tank housing 6.0

8TS 500i
Fastener Thread size For component Tightening
torques
Comment
Nm
Screw M5x17 Cap, spark plug cover / shroud 4.5
Nut M10x1 L V-belt pulley, front 45.0
Screw P6x40 Clamp / handlebar / tank housing 6.0
Screw P6x26 Clamp / tank housing 6.0
Screw D5x45 Clamp / antivibration system / handlebar
holder
6.0 2)
Screw M5x35x22 Manifold / throttle shutter housing /
cylinder
6.0 2
Screw P6x19 Crankcase / bearing plug antivibration
system
6.0
Screw M5x32x22 Crankcase / cylinder 9.0 2)
Screw M5x20 Crankcase clutch side / fan side 8.0 2)
Screw M5x35x22 Crankcase clutch side / fan side 8.0 2)
Screw P5x16 Bearing plug antivibration system / tank
housing
4.0
Screw M5x20 Fan cover / crankcase 6.0 2)
Screw P6x19 Air baffle / tank housing 6.0
Screw M5x20 Air guide shroud / crankcase 3.0 2)
Screw M4x12 Ground wire / cover / crankcase 4.0 3)
M12x1 L Carrier 40.0
Screw P3x6 Rewind spring / starter cover 0.5
Screw M5x20 Muffler / cylinder 1st stage 2.5 2)
Screw M5x20 Muffler / cylinder 2nd stage 10.0 2)
Screw M5x20 Muffler / crankcase 10.0 2)
Screw G 3/8" Hose connection / solenoid valve 2.0
Screw M5x21 Guard / cast arm 6.0
Nut M8x1 Flywheel / crankshaft 33.0 5)

9TS 500i
Fastener Thread size For component Tightening
torques
Comment
Nm
Screw M4x12 Sensor / crankcase 2.0 3)
Screw M3x20 Hose clamp, manifold / cylinder 0.5
Screw D5x24 Clamping lever / cast arm 4.0 2)
Nut M8x1 Starter cup / crankshaft 33.0
Screw M8x53 Stud / crankcase 21.0 4)
Screw P6x50 Support / clamp / handlebar / tank
housing
6.0
Screw P6x19 Support / bearing plug antivibration
system
6.0
Screw P6x40 Support / tank housing 6.0
Screw M10x18 Abrasive wheel 30.0
Screw M5x30 Adjusting lever / guard 6.0 2)
Screw M8x24 Adjusting lever / guard / square nut 4.0
Screw M8x17 Adjusting lever / guard / square nut 4.0
M14x1.25 Spark plug 25.0
Screw M4x8 Pan head screw / banjo screw 3.0
1) Loctite 243 medium strength
2) Easy-slide coating with locking serration
3) Microencapsulated with locking serration
4) Microencapsulated
5) Connection between crankshaft and flywheel must be degreased and oil-free
6) Easy-slide coating

10 TS 500i
3. Troubleshooting
3.1 Clutch
Problem Cause Remedy
Cutting wheel stops under load at
full throttle
Clutch shoes badly worn Replace clutch
Clutch drum badly worn Replace clutch drum
Cutting wheel rotates at idle speed Clutch springs stretched or fatigued Replace clutch springs or replace
clutch
Anchor loops of the clutch spring
hooks are broken
Replace clutch springs
Throttle cable is jammed Check easy movement of throttle
cable and replace if necessary
Throttle trigger is stiff Check throttle trigger, repair if
necessary
Throttle shutter does not return
automatically
Check the throttle shutter stops and
replace throttle shutter housing if
necessary
Loud noises Clutch springs stretched or fatigued Replace all clutch springs
Grooved ball bearing on poly V-belt
pulley / clutch drum damaged
Replace ball bearing
Clutch shoe retainer broken Replace holder
Clutch shoes and carrier worn Replace clutch

11TS 500i
3.2 Cast arm with guard
Problem Cause Remedy
Cutting wheel does not run
smoothly or vibrates
Axial or radial runout Set axial or radial true running,
replace cutting wheel if necessary
Ribbed poly V-belt is loose Check and tension ribbed poly
V-belt, replace ribbed poly V-belt or
tensioner if necessary
Grooved ball bearing of the front
poly V-belt pulley is worn
Replace ball bearing
Cutting wheel stops under load at
full throttle
Clutch shoes badly worn Replace clutch
Clutch drum badly worn Replace clutch drum
Ribbed poly V-belt not properly
tensioned
Tension ribbed poly V-belt, replace
if necessary
Cutting wheel rotates at idle speed Clutch springs stretched or fatigued Replace clutch springs or replace
clutch
Anchor loops of the clutch spring
hooks are broken
Replace clutch springs
Throttle cable is jammed Check easy movement of throttle
cable and replace if necessary
Throttle trigger is stiff Check throttle trigger, repair if
necessary
Throttle shutter does not return
automatically
Check the throttle shutter stops and
replace throttle shutter housing if
necessary

12 TS 500i
3.3 Solenoid valve / Water system
Problem Cause Remedy
No water supply Solenoid valve does not react even
though the control panel was
actuated
Run test with STIHL MDG 1,
replace solenoid valve if necessary
Banjo screws (water nozzles) are
very dirty
Clean the banjo screws, replace if
necessary
Control panel damaged Run test with STIHL MDG 1,
replace control panel if necessary
Water volume too low even though
it has been increased via the
control panel
Banjo screws (water nozzles) are
very dirty
Clean the banjo screws, replace if
necessary
Water hose kinked or damaged –
also check water supply hose
Check hose clips, water hose and
seals, replace if necessary
Manifold for hose connection is
clogged
Check manifold and clean (rinse
screen), replace if necessary
Control panel damaged Check control panel with STIHL
MDG 1, replace if necessary
Water supply even though machine
has been switched off
Solenoid valve is damaged or jams
– solenoid valve no longer closes
Check solenoid valve, replace if
necessary
Leaks in the water system O-ring and / or seal on water
attachment damaged
Replace O-ring and seal, replace
whole water attachment if
necessary
Hose clips open or damaged or
hose damaged
Close hose clips, replace if
necessary, replace damaged hose

13TS 500i
Problem Cause Remedy
Abrasive wheel runs dry even
though water control has been
switched on
Manifold for hose connection is
clogged
Check manifold and clean (risen
screen), replace if necessary
Nozzles are clogged Clean nozzles, replace if necessary
Control panel damaged Check control panel with STIHL
MDG 1, replace if necessary
Solenoid valve is damaged or jams Check solenoid valve with STIHL
MDG 1, replace if necessary
Water hose kinked or damaged –
also check water supply hose
Run water hose so that it is free of
kinks, replace damaged water hose

14 TS 500i
3.4 Starter
Problem Cause Remedy
Starter rope broken Rope pulled out too vigorously as
far as stop or over edge, i.e. not
vertically
Replace starter rope
Normal wear Replace starter rope
Starter rope does not rewind Very dirty or corroded Clean or replace rewind spring
Spring insufficiently tensioned Check rewind spring and increase
tension
Rewind spring broken Replace rewind spring
Starter rope cannot be pulled out
far enough
Rewind spring overtensioned Check rewind spring and reduce
tension
Starter rope can be pulled out
almost without resistance
(crankshaft does not turn)
Guide peg on pawls or pawls
themselves are worn
Replace pawls
Spring clip fatigued Replace spring clip
Loose starter cup Tighten starter cup, replace if
necessary
Starter rope is difficult to pull or
rewinds very slowly
Starter mechanism is very dirty Thoroughly clean complete starter
mechanism
Lubricating oil on rewind spring
becomes viscous at very low
outside temperatures (spring
windings stick together)
Coat rewind spring with a little
standard solvent-based degreasant
(containing no chlorinated or
halogenated hydrocarbons), then
pull rope carefully several times
until normal action is restored

15TS 500i
3.5 Troubleshooting chart STIHL Injection
Diagnosis
OK?
no
– Carry out diagnosis
with STIHL MDG 1
Repair fault shown by STIHL MDG 1
Decompression valve
leaking, faulty
yes
Oil seals
defective
Crankcase leaking,
faulty
– Check starting
behavior
Check decompression
valve, replace if necessary,
b6.10
Check oil seals, replace
if necessary, b6.2,
b6.3
Check engine does not
leak, b6.2
Complaint
remedied?
no
Starting
behavior OK?
no
yes
Trouble-
shooting
completed
yes
Too much starting effort
Decompression valve
leaking, faulty
Spark plug defective
Break or damaged
insulation in ignition lead
Check decompression
valve, replace if
necessary, b6.10
Replace spark plug
Check ignition lead, replace
if necessary, b7.4
Engine does not start
2
13

16 TS 500i
Clutch springs stretched
or fatigued
Anchor loops of the
tension springs for the
clutch shoes are broken
Throttle cable is jammed
– Check idle behavior
after start
Check clutch, replace if
necessary, b5.2
Check fuel system does not
leak, b11.6
Check throttle cable, repair
if necessary, b11.2.1
Idle
behavior OK? no
yes
Idle speed too
high, abrasive wheel
runs
5
47
Cable breakage on an
electrical component
(control unit, sensor,
injection valve, on / off
switch
Fuel system
leaking
Crankcase leaking,
faulty
Visual inspection of
electrical leads
Check clutch, replace if
necessary, b5.2
Check engine does not
leak, b6.2
2
13
Throttle trigger is stiff Check throttle trigger,
repair if necessary, b10.2
Pickup body soiled Check pickup body, replace
if necessary, b11.8.1
Flywheel out of
adjustment, woodruff key
has sheared off
Check woodruff key and
flywheel, replace if
necessary, b7.5
Injection pump has
mechanical fault
Replace injection pump,
b11.7
6

17TS 500i
Throttle shutter stops
worn
Oil seals
defective
Crankcase leaking,
faulty
Check the throttle shutter
stops, replace throttle
shutter housing if
necessary, b11.2
Check engine does not
leak, b6.2
Idle speed
too low
9
810
Check oil seals, replace if
necessary, b6.2, b6.3
Throttle shutter stops
worn
Check the throttle shutter
stops, replace throttle
shutter housing if
necessary, b11.2
Injection valve
mechanically
worn
Replace injection valve,
b11.3
5
4 7
Engine stalls
when idle
Throttle shutter does not
return automatically
Check the throttle shutter
stops, replace throttle
shutter housing if
necessary, b11.2
6
Pickup body soiled Check pickup body, replace
if necessary, b11.8.1
Injection pump has
mechanical fault
Replace injection pump,
b11.7
Injection valve
mechanically
worn
Replace injection valve,
b11.3

18 TS 500i
Spark plug boot
is loose on the
spark plug
Spark plug sooted,
smeared with oil
Ignition lead loose on
control unit
Press boot firmly onto
spark plug, replace torsion
spring if necessary, b7.4
Secure ignition
lead, b7.4
Idle speed unstable,
erratic
11
Clean spark plug, replace
if necessary
Fuel / oil mixture
contains too much oil
Use a fuel mixture with the
correct mixing ratio
Flywheel is cracked,
damaged
Check flywheel, replace if
necessary, b7.5
9
810
Flywheel out of
adjustment, woodruff key
has sheared off
Check woodruff key and
flywheel, replace if
necessary, b7.5

19TS 500i
Spark plug defective
Pickup body soiled
Fuel hose kinked
–Check acceleration
Replace spark plug
Run fuel hose
so that it is free of kinks,
b11.8
Acceleration
OK?
no
Poor acceleration /
engine stalls while
accelerating
12
Check pickup body, replace
if necessary, b11.8.1
Fuel system leaking Check fuel system does
not leak, b11.6
Impulse hose damaged
or
kinked
Check impulse hose,
replace if necessary,
b11.5
Injection pump defective
(control needle, seal,
etc.)
Replace injection pump,
b11.7
11
yes
Injection valve does not
close
Replace injection valve,
b11.3