Stihl MS201, MS201T Chainsaw Full Service & Repair Manual
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STIH)
STIHL MS 201, MS 201 T
2012-01
1 MS 201, MS 201 C, MS 201 T, MS 201 TC
q
© ANDREAS STIHL AG & Co. KG, 2012
RA_577_00_01_02
1. Introduction and
Safety Precautions 3
1.1 Introduction 3
1.2 Safety Precautions 4
2. Specifications 5
2.1 Engine 5
2.2 Fuel System 5
2.3 Ignition System 5
2.4 Chain Lubrication 5
2.5 Tightening Torques 6
3. Troubleshooting 8
3.1 Clutch 8
3.2 Chain Drive,
Chain Brake, Chain
Tensioner 9
3.3 Chain Lubrication 10
3.4 Rewind Starter 11
3.5 Ignition System 13
3.6 Carburetor 14
3.7 Engine 17
4. Clutch 18
4.1 Clutch 18
4.2 Clutch Drum 19
5. Chain Brake 20
5.1 Checking Operation 20
5.2 Brake Band 20
5.3 Brake Lever 21
5.4 Flat Spring 23
5.5 Pins 23
5.6 Chain Tensioner 24
5.6.1 Chain Catcher 25
5.7 Bar Mounting Stud 25
5.8 Collar Nut for
Sprocket Cover 25
6. Engine 27
6.1 Muffler 27
6.1.1 Insulating Plate 28
6.2 Leakage Test 29
6.2.1 Preparations 29
6.2.2 Vacuum Test 30
6.2.3 Pressure Test 31
6.3 Oil Seals 31
6.3.1 Ignition Side 31
6.3.2 Clutch Side 32
6.4 Cylinder 33
6.5 Crankshaft /
Crankcase 34
6.5.1 Roller Bearings /
Crankcase 37
6.6 Piston 38
6.7 Piston Rings 41
7. Ignition System 42
7.1 Ignition Timing 42
7.2 Ignition Module 42
7.3 Testing the
Ignition Module 45
7.4 Spark Plug Boot /
Ignition Lead 46
7.5 Flywheel 47
7.6 Short Circuit Wire 48
7.6.1 Testing 48
7.6.2 Removing and
Installing (MS 201) 48
7.6.3 Removing and
Installing (MS 201 T) 51
7.6.4 Ground Wire 52
7.6.5 Contact Spring
(MS 201) 53
7.6.6 Contact Springs
(MS 201 T) 54
7.7 Ignition System
Troubleshooting 56
8. Rewind Starter 59
8.1 General 59
8.2 Fan Housing 59
8.3 Pawls 60
8.4 Rope Rotor 61
8.4.1 Rope Rotor with
ErgoStart 61
8.5 Starter Rope / Grip 62
8.6 Tensioning the
Rewind Spring 64
8.7 Replacing the
Rewind Spring 65
9. AV Elements 67
9.1 Annular Buffer on Fuel
Tank (MS 201) 67
9.1.1 Annular Buffer on Fuel
Tank (MS 201 T) 67
9.2 AV Spring on Oil Tank
(MS 201) 68
9.2.1 AV Spring on Oil Tank
(MS 201 T) 69
9.3 Front Handle /
AV Spring (MS 201) 70
9.3.1 Front Handle /
AV Spring (MS 201 T) 71
9.4 Stop Buffer on Handle
Housing (MS 201) 72
9.5 Stop Buffer on Tank
Housing (MS 201) 73
10. Control Levers 74
10.1 Master Control Lever 74
10.1.1 Switch Shaft (MS 201) 74
10.1.2 Switch Shaft
(MS 201 T) 75
10.2 Throttle Trigger /
Lockout Lever
(MS 201) 76
10.3 Throttle Trigger /
Lockout Lever
(MS 201 T) 77
10.3.1 Choke and Throttle
Rods (MS 201) 78
10.3.2 Choke and Throttle
Rods (MS 201 T) 80
10.4 Handle Housing
(MS 201) 82
10.5 Handle Housing
(MS 201 T) 86
11. Chain Lubrication 89
11.1 Pickup Body 89
11.2 Oil Suction Hose 89
11.3 Connector /
Oil Pressure 89
11.4 Oil Pump 90
11.5 Valve 91
Contents
2 MS 201, MS 201 C, MS 201 T, MS 201 TC
Contents
12. Repair fuel system 93
12.1 Air Filter 93
12.2 Baffle 93
12.3 Filter Base (MS 201) 93
12.3.1 Filter Base
(MS 201 T) 94
12.4 Carburetor (MS 201) 94
12.5 Carburetor (MS 201 T) 96
12.5.1 Leakage test 98
12.6 Servicing the
Carburetor 99
12.6.1 Metering Diaphragm 99
12.6.2 Inlet Needle 100
12.6.3 Pump Diaphragm 101
12.6.4 Lever on
Throttle Shaft 102
12.6.5 Levers on
Choke Shaft 102
12.6.6 Adjusting Screws 103
12.7 Adjusting the
Carburetor 105
12.7.1 Basic Setting 105
12.7.2 Standard Setting 107
12.8 Intake Manifold 108
12.8.1 Impulse Hose 109
12.9 Tank Vent 110
12.9.1 Testing 110
12.9.2 Tank Vent (MS 201) 111
12.9.3 Tank Vent
(MS 201 T) 112
12.10 Fuel Intake 112
12.10.1 Pickup Body 112
12.10.2 Fuel Suction Hose 112
12.10.3 Tank Vent Hose 114
12.10.4 Manual Fuel Pump
with Fuel Hoses 116
12.11 Tank Housing
Removing and
Installing 118
13. Special Servicing
Tools 120
14. Servicing Aids 122
3 MS 201, MS 201 C, MS 201 T, MS 201 TC
1. Introduction and Safety Precautions
1.1 Introduction
This service manual contains
detailed descriptions of all the repair
and servicing procedures specific to
this power tool.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual
components and assemblies.
Refer to the latest edition of the
relevant parts list to check the part
numbers of any replacement parts.
A fault on the machine may have
several causes. To help locate the
fault, consult the chapter on
"Troubleshooting" and the
"STIHL Service Training System"
for all assemblies.
Refer to the “Technical Information”
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list until a
revised edition is issued.
The special tools mentioned in the
descriptions are listed in the chapter
on "Special Servicing Tools" in this
manual. 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:
: Action to be taken as shown in
the illustration above the text
– Action to be taken that is not
shown in the illustration above
the text
In the illustrations:
A Pointer
a Direction of movement
@ 4.2 =Reference to another
chapter, i.e. chapter 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.
Servicing and repairs are made
considerably easier if the machine
is mounted to assembly stand (3)
5910 890 3101. To do this, secure
the mounting plate (2)
5910 850 1650 to the assembly
stand with two screws (1) and
washers.
The screws must not project since
they, depending on the machine,
may damage housings when the
machine is clamped in position.
2710RA320 TG
2
3
1
Preparations for servicing
Remove the chain sprocket cover,
saw chain, guide bar and clutch
drum before carrying out repairs
– the chain brake must be
disengaged.
Mount the machine to the assembly
stand for servicing and repair work.
Engage the bar mounting stud in the
outer bore in the mounting plate and
secure the machine in position with
the M 8 nut (arrow).
The machine is held in position on
the mounting plate by the screw
head on the crankcase.
Always use original STIHL
replacement parts.
They can be identified by the STIHL
part number,
the {
logo and the
STIHL parts symbol K. 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.
7013RA000 TG
4 MS 201, MS 201 C, MS 201 T, MS 201 TC
1.2 Safety Precautions
If the machine is started up in the
course of repairs or maintenance
work, observe all local and country-
specific safety regulations as well
as the safety precautions and
warnings in the instruction manual.
Fuel is extremely flammable and
can be explosive in certain
conditions.
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.
Always perform leakage test after
working on the fuel system and the
engine.
Exercise extreme caution while
carrying out maintenance and repair
work on the ignition system. The
high voltages which occur can
cause serious or fatal accidents.
Always wear suitable protective
gloves for operations in which
components are heated for
assembly or disassembly.
Improper handling may result in
burns or other serious injuries.
Always replace damaged parts.
Check disassembled parts for wear
or damage before re-installing –
replace as necessary.
Run the machine only with the fan
housing mounted in position – there
is otherwise a risk of injury from the
flywheel and a risk of engine
damage due to overheating.
The chapter on tightening torques
lists all machine components that
have to be tightened to a specific
torque or coated with threadlocking
adhesive. The specifications must
be maintained when tightening
down screws, nuts and other
fasteners in all the procedures
described in this service manual.
Fuel system – hose barb
connectors
Pull off or push on fuel hoses in line
with the connector, preferably by
hand, to ensure the tightness of the
fuel system.
Avoid damaging the hose barb
– do not use sharp-edged pliers,
screwdrivers, etc.
Do not cut open fuel hoses with a
knife or similar tool.
Do not re-use fuel hoses after
removal. Always install new hoses
– fuel hoses can be overstretched
during removal.
Install new fuel hoses either dry or
with the aid of STIHL press fluid
– coat the ends of hoses and the
connectors, b 14.
Other press fluids are not approved
and may result in damage to the fuel
hoses.
5 MS 201, MS 201 C, MS 201 T, MS 201 TC
2. Specifications
2.1 Engine
MS 201 MS 201 T
Displacement: 35.2 cm
3
35.2 cm
3
Bore: 40.0 mm 40.0 mm
Stroke: 28.0 mm 28.0 mm
Engine power to ISO 7293: 1.8 kW (2.4 bhp)
at 9,500 rpm
1.8 kW (2.4 bhp)
at 9,500 rpm
Cut-off speed
with bar and chain: 14000 rpm 14000 rpm
Idle speed: 3,000 rpm 3,000 rpm
Clutch: Centrifugal clutch without
linings
Centrifugal clutch without
linings
Clutch engages at: 3,700 rpm 3,700 rpm
Crankcase 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 0.8 bar
Operation of tank vent at gauge pressure: 0.5 bar 0.5 bar
Fuel: as specified in instruction
manual
as specified in instruction
manual
2.3 Ignition System
Air gap between the ignition module and
flywheel: 0.30 (+ 0.05/- 0.10) mm 0.30 (+ 0.05/- 0.10) mm
Spark plug (resistor type): NGK CMR 6 H NGK CMR 6 H
Electrode gap: 0.5 mm 0.5 mm
2.4 Chain Lubrication
Speed-controlled oil pump with reciprocating piston and manual flow control or Ematic
Settings for oil delivery rate:
min.:
max.:
Ematic:
3.5 (+/1.0) cm
3
/min
at 7,000 rpm
9.5 (+/2.0) cm
3
/min
at 10,000 rpm
6.5 (+/1.5) cm
3
/min
at 10,000 rpm
3.5 (+/1.0) cm
3
/min
at 7,000 rpm
9.5 (+/2.0) cm
3
/min
at 10,000 rpm
6.5 (+/1.5) cm
3
/min
at 10,000 rpm
6 MS 201, MS 201 C, MS 201 T, MS 201 TC
2.5 Tightening Torques
DG and P (Plastoform) screws are used in polymer and light metal components. These screws form a
permanent thread when they are installed for the first time. They can be removed and installed as often as
necessary without impairing the strength of the screwed assembly, providing the specified tightening torque is
observed.
For this reason it is essential to use a torque wrench.
Fastener Thread size For component Torque
Nm
Remarks
Screw M 4x12 Chain tensioner cover / crankcase 1.8 2) 4)
Screw M 4x16 Antivibration element on oil tank / crankcase 4.0 3)
Collar stud M 8 Collar stud for bar 22.0 1)
Screw P 4x14 Cover / chain sprocket cover 1.5
Screw M 4x12 Cover, oil pump / crankcase 2.0 2) 4)
Screw M 4x9.6 Spark arresting screen / muffler 2.0
Screw P 6x19 Handle housing / front handle (MS 201) 6.0
Screw P 6x19 Handle housing / front handle (MS 201 T) 3.5
Screw M 4x16 Handlebar / crankcase 4.0 3)
Screw P 4x14 Handle molding / handle housing 1.5
Screw P 6x19 Retainer, ring / tank housing 6.0
Screw P 4x10 Clamp, wiring harness / handle housing
(MS 201)
1.8
Screw P 4x10 Clamp, ignition lead 1.8
Screw M 5x16 Chain catcher / spiked bumper / crankcase 10.0 2) 4)
Screw M 5x16 Spiked bumper / crankcase 10.0 2) 4)
Screw M 4x12 Manifold / cylinder 3.0 2) 4)
Screw M 4x16 Crankcase, sprocket side/fan side 4.5 2) 4)
Screw P 5x16 Bearing plug / handle housing 3.0
Screw M 4x16 Fan housing / crankcase 4.0 2) 4)
Screw P 5x16 Fan housing / tank housing 4.0
Carrier M 8x1 L Carrier / crankshaft 25.0
Screw M 4x12 Oil pump / crankcase 3.5 2)
Screw P 5x29.5 Annular buffer / handle housing 3.0
Screw P 4x14 Annular buffer / tank housing 1.5
Screw P 4x10 Rewind spring retainer 1.5
Screw M 5x16 Muffler / cylinder, stage 1
(tightening first screw)
2.5 2) 3)
Screw M 5x16 Muffler / cylinder, stage 2
(tightening second screw)
10.0 2) 3)
Screw M 5x16 Muffler / cylinder, stage 3
(tightening first screw)
10.0 2) 3)
Collar stud M 5x18 Bar mounting / crankcase 7.0 2) 3)
Nut M 8x1 Flywheel / crankshaft 23.0 6)
Screw P 4x10 Insulating plate (MS 201) 1.5
7 MS 201, MS 201 C, MS 201 T, MS 201 TC
Fastener Thread size For component Torque
Nm
Remarks
Screw M 4x16 Tank housing / crankcase 4.5 2) 4)
Screw M 5x43 Carburetor / handle housing, stage 1 0.8 5)
Screw M 5x43 Carburetor / handle housing, stage 2 3.0 5)
M 10x1 Spark plug / cylinder 12.0
Screw M 4x20 Ignition module / crankcase 4.0 3)
Screw M 5x20 Cylinder / crankcase 10.0 2) 4)
Remarks:
1) Loctite 272, high strength up to 250 °C (482 °F)
2) Screws with binding head
3) Micro-encapsulated screws
4) Waxed screws
5) Bright and waxed screws
6) Degrease crankshaft/flywheel and mount oil-free
Use the following procedure when refitting a DG or P screw in an existing thread:
Place the screw in the hole and rotate it counterclockwise until it drops down slightly.
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.
Before reinstalling a micro-encapsulated screw, clean both threads (screw tap into female thread by hand and
then blow out with compressed air, clean male thread with brush), coat clean screw with medium strength
Loctite 242 or 243.
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.
8 MS 201, MS 201 C, MS 201 T, MS 201 TC
3. Troubleshooting
3.1 Clutch
Condition Cause Remedy
Saw chain stops under full load Clutch shoes badly worn Install new clutch
Clutch drum badly worn Install new clutch drum
Saw chain rotates at idle speed Engine idle speed too high Readjust idle speed screw LA
Clutch springs stretched Replace the clutch springs or install
new clutch
Clutch springs broken Replace the clutch springs
Loud noises Clutch springs stretched Replace all clutch springs
Clutch shoe retainer broken Install new retainer or clutch
Clutch shoes and carrier worn Install new clutch
Needle cage damaged Fit new needle cage
9 MS 201, MS 201 C, MS 201 T, MS 201 TC
3.2 Chain Drive, Chain Brake, Chain Tensioner
Condition Cause Remedy
Chain sprocket wears rapidly Chain not properly tensioned Tension chain as specified
Wrong chain pitch Fit chain of correct pitch
Insufficient chain lubrication Check chain lubrication
Saw chain stops under full load Clutch shoes badly worn Install 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 idle speed screw LA
Clutch springs stretched Replace the clutch springs or install
new clutch
Clutch springs broken Replace the clutch springs
Saw chain does not stop
immediately when brake is
activated
Brake spring stretched or broken Fit new brake spring
Brake band stretched or worn Fit new brake band
Clutch drum worn Install new clutch drum
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