Stihl MS 191 Service Manual Download | Manualshive

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STIH)

STIHL MS 311, 391

2009-06

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Summary of Contents for MS 191

Page 1: ...STIH STIHL MS 311 391 2009 06 ...

Page 2: ...Piston Rings 38 6 9 Decompression Valve 38 7 Ignition System 39 7 1 Ignition Timing 39 7 2 Preseparator 39 7 3 Ignition Module 39 7 4 Testing the Ignition Module 41 7 5 Spark Plug Boot Ignition Lead 42 7 6 Flywheel 43 7 7 Short Circuit Wire 44 7 7 1 Testing 44 7 7 2 Removing and Installing 44 7 7 3 Ground Wire 46 7 7 4 Contact Spring 46 7 8 Ignition System Troubleshooting 48 8 Rewind Starter 51 8 ...

Page 3: ...phragm 74 12 6 4 Air Valve 76 12 6 5 Levers on Throttle Shaft 76 12 6 6 Adjusting Screws 77 12 7 Carburetor Adjustment 79 12 7 1 Basic Setting 79 12 7 2 Standard Setting 80 12 8 Carburetor Carrier 81 12 9 Intake Manifold 82 12 10 Tank Vent 83 12 10 1 Testing 83 12 10 2 Removing and Installing 84 12 11 Fuel Intake 84 12 11 1 Pickup Body 84 12 11 2 Fuel Hose 85 12 11 3 Fuel Suction Hose 86 12 11 4 T...

Page 4: ...ual Use the part numbers to identify the tools in the STIHL Special Tools manual The manual lists all special servicing tools currently available from STIHL Symbols are included in the text and pictures for greater clarity The meanings are as follows In the descriptions N Action to be taken as shown in the illustration above the text Action to be taken that is not shown in the illustration above t...

Page 5: ...fuel 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 Always replace damaged parts Check disassembled parts for wear or damage before re installing replace as necessary Run the machine only with the shroud mounted in position there is otherwise a risk of injury from the fanwhee...

Page 6: ...pm Engine housing leakage test at gauge pressure 0 5 bar under vacuum 0 5 bar 2 2 Fuel System Carburetor leakage test at gauge pressure 0 8 bar Operation of tank vent at gauge pressure 0 5 bar Fuel as specified in instruction manual 2 3 Ignition System Air gap between ignition module and fanwheel 0 20 0 30 mm Spark plug resistor type NGK BPMR 7 A BOSCH WSR6F Electrode gap 0 5 mm 2 4 Chain Lubricat...

Page 7: ...ndlebar plug AV spring 3 0 Screw P 6x26 5 Handlebar tank housing right polymer 7 0 Screw P 6x26 5 Handlebar tank housing bottom polymer 7 0 Screw P 6x25 Hand guard fan housing 8 0 Screw M 6x30 Shroud engine housing 10 0 Screw P 6x38 Chain catcher bearing plug 6 0 Screw P 5x16 Spiked bumper engine housing 4 0 Screw M 4x12 Manifold cylinder 4 0 3 Screw P 6x21 5 Bearing plug engine housing 6 0 Screw ...

Page 8: ... the hole and rotate it counterclockwise until it drops down slightly Tighten the screw clockwise to the specified torque Coat micro encapsulated screws with medium strength threadlocking adhesive before re installing 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 setting for polymer DG and P sc...

Page 9: ...h Readjust with idle speed screw LA counterclockwise Clutch springs stretched or fatigued Replace the clutch springs or install new clutch Clutch spring hooks broken Replace the clutch springs or install new clutch Loud noises Clutch springs stretched or fatigued Replace the clutch springs or install new clutch Needle cage damaged Fit new needle cage Clutch shoe retainer broken Install new retaine...

Page 10: ...ll new clutch Clutch drum badly worn Install new clutch drum Brake band blocked Check freedom of movement and operation of brake band Saw chain rotates at idle speed Engine idle speed too high Readjust with idle speed screw LA counterclockwise Clutch springs stretched or fatigued Replace the clutch springs or install new clutch Clutch spring hooks broken Replace the clutch springs Saw chain does n...

Page 11: ...ake hose and pickup body Valve in oil tank blocked Clean or replace valve Teeth on worm worn Install new worm Worm drive spring broken Install new worm Oil pump damaged or worn Install new oil pump Machine losing chain oil Oil pump body damaged Install new oil pump Oil pump damaged or worn Install new oil pump Oil intake hose connection damaged Install new oil intake hose Oil pump delivers insuffi...

Page 12: ...rter rope can be pulled out almost without resistance crankshaft does not turn Guide peg on pawl or pawl itself is worn Fit new pawl Spring clip on pawl fatigued Fit new spring clip 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 spr...

Page 13: ...ch oil Use correct mixture of fuel and oil Incorrect air gap between ignition module and flywheel Set air gap correctly Flywheel cracked or damaged or pole shoes have turned blue Install new flywheel Ignition timing out of adjustment flywheel warped machined key in flywheel sheared Install new flywheel check crankshaft stub for damage and replace crankshaft if necessary Weak magnetization in flywh...

Page 14: ...isc on diaphragm is deformed and presses constantly against the inlet control lever Fit a new metering diaphragm Metered diaphragm deformed Fit a new metering diaphragm Poor acceleration Setting of low speed screw too lean Check basic carburetor setting correct if necessary Setting of high speed screw too lean Check basic carburetor setting correct if necessary Inlet needle sticking to valve seat ...

Page 15: ...le jet bores or ports blocked Clean the carburetor Low speed screw too rich or too lean Reset low speed screw L correctly Setting of idle speed screw LA incorrect throttle shutter completely closed Reset idle speed screw LA correctly Tank vent faulty Replace tank vent Leak on fuel hose from tank to carburetor Seal connections or install new fuel hose Saw chain rotates at idle speed Engine idle spe...

Page 16: ...res or ports blocked Clean the carburetor Pump diaphragm damaged or fatigued Fit new pump diaphragm Ignition timing wrong flywheel out of adjustment key in flywheel has sheared off Fit key if necessary and secure flywheel properly or install new flywheel Engine running extremely rich has no power and a very low maximum speed Air valve does not open Check the carburetor and service or replace if ne...

Page 17: ...ot deliver full power or runs erratically Piston rings worn or broken Fit new piston rings Muffler spark arresting screen carbonized Clean the muffler inlet and exhaust replace spark arresting screen replace muffler if necessary Air filter dirty Replace air filter Fuel impulse hose severely kinked or damaged Fit new hoses or position them free from kinks Decompression valve is not closed Close che...

Page 18: ...cylinder wall arrow as shown Apply wrench to hexagon arrow and unscrew the clutch 1 Note that the clutch has a left hand thread Disassembling Use hook 2 5910 890 2800 to remove the clutch springs 1 4903RA106 TG 1 1 4903RA003 TG 4903RA004 TG 2 1 Pull the clutch shoes off the carrier Remove the retainers 1 Clean all parts b 14 Replace any damaged parts If the clutch is noticeably worn replace all th...

Page 19: ...ing 1 to the clutch shoes Use the hook 2 5910 890 2800 to attach the other ends of the springs and press them firmly into the clutch shoes Check the clutch all springs arrows must be properly attached 4903RA010 TG 1 2 4903RA011 TG Make sure the washer 1 is in place Installed position is correct when TOP arrow faces outwards Position the clutch on the crankshaft stub so that the raised hexagon arro...

Page 20: ...ll the clutch drum see instruction manual Pull off the needle cage 1 Clean the needle cage and crankshaft stub b 14 Lubricate the needle cage and crankshaft stub b 14 Inspect the clutch drum 1 for signs of wear 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 ...

Page 21: ... a brief period max 3 seconds the chain must not rotate With the chain brake released open the throttle wide and activate the brake manually the chain must come to an abrupt stop The braking time is in order if deceleration of the saw chain less than a second is imperceptible to the eye If the chain brake does not operate properly refer to troubleshooting b 3 2 5 2 Brake Band Remove the clutch dru...

Page 22: ... brake lever 2 and then swing it in the direction of its seat 4903RA020 TG 2 1 219RA049 TG 4903RA021 TG 2 1 Position the brake band 1 it the guide arrow first Disengage the chain brake Push the brake band 1 over the guide lugs arrows and into its seat Push the brake band 1 into its seat arrow as far as stop 4903RA022 TG 4903RA023 TG 1 4903RA024 TG 1 Fit the screw 1 on the underside of the machine ...

Page 23: ... disconnect the brake spring 1 from the anchor pin arrow Remove the brake spring from the brake lever Remove the shroud b 6 4 Take out the screws arrows Remove the sleeve 1 Lift the hand guard a little and remove the fan housing 4903RA027 TG 1 4903RA119 TG Remove the E clip 1 Lift and turn the strap 1 slightly push it towards the hole arrow and remove it Remove the spacer sleeve 2 from the brake l...

Page 24: ...p the holes 4903RA032 TG 1 2 4903RA033 TG 1 Push the hand guard with brake lever 1 over the machine until they are positioned against the pivot pins arrows Lift the bearing boss of the hand guard and the brake lever a little and position them over the pivot pins arrows Turn the cam lever 1 to one side until the cam of the hand guard arrow slips passed it Push the hand guard bearing boss and the br...

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