Stihl MS 362, MS 362 C Chainsaw Full Service & Repair Manual

STIH) STIHL MS 362, 362 C 2009-08

1 MS 362, MS 362 C q © ANDREAS STIHL AG & Co. KG, 2009 RA_553_00_01_02 1. Introduction and Safety Precautions 3 1.1 Introduction 3 1.2 Safety Precautions 4 2. Specifications 5 2.1 Motor 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 12 3.6 Carburetor 13 3.7 Engine 16 4. Clutch 17 4.1 Clutch Drum 18 5. Chain Brake 20 5.1 Checking Operation 20 5.2 Brake Band 20 5.3 Brake Lever 22 5.4 Brake Lever on Machines with QuickStop Super 23 5.4.1 Adjusting the Brake Cable 25 5.4.2 Brake Cable 26 5.5 Cam Lever 28 5.6 Pins 29 5.7 Chain Tensioner 30 5.7.1 Quick Chain Tensioner 31 5.8 Bar Mounting Studs 31 6. Engine 33 6.1 Muffler 33 6.2 Leakage Test 34 6.2.1 Preparations 34 6.2.2 Vacuum Test 35 6.2.3 Pressure Test 35 6.3 Oil Seals 36 6.4 Shroud 37 6.5 Cylinder 37 6.6 Crankshaft 39 6.6.1 Bearings / Crankcase 44 6.7 Piston 46 6.8 Piston Rings 48 6.9 Decompression Valve 48 7. Ignition System 49 7.1 Ignition Timing 49 7.2 Preseparator 49 7.3 Ignition Module 49 7.4 Testing the Ignition Module 51 7.5 Spark Plug Boot / Ignition Lead 52 7.6 Flywheel 53 7.7 Short Circuit Wire 54 7.7.1 Testing 54 7.7.2 Removing and Installing 55 7.7.3 Ground Wire 56 7.7.4 Contact Spring 57 7.8 Ignition System Troubleshooting 58 8. Rewind Starter 61 8.1 General 61 8.2 Fan housing 61 8.3 Pawls 61 8.4 Rope Rotor 62 8.5 Starter Rope / Grip 63 8.6 Tensioning the Rewind Spring 64 8.7 Replacing the Rewind Spring 65 9. Servicing the AV System 67 9.1 Buffer on Oil Tank 67 9.2 AV Spring on Oil Tank 67 9.2.1 AV Spring on Oil Tank - Machines with Heating 67 9.3 AV Spring on Fuel Tank 68 9.4 AV Spring on Handlebar 69 9.4.1 Machines with Heating 70 9.5 Annular and Stop Buffers 70 9.6 Handlebar 71 9.7 Handlebar with Heating 72 10. Control Levers 78 10.1 Master Control Lever 78 10.1.1 Removing and Installing 78 10.2 Throttle Trigger/ Interlock Lever 79 10.3 Throttle Trigger/ Interlock Lever – QuickStop Super 80 10.3.1 Switch Lever – QuickStop Super 82 10.3.2 Interlock Lever – QuickStop Super 82 10.3.3 Choke Rod 83 10.3.4 Throttle Rod 84 11. Chain Lubrication 85 11.1 Pickup Body 85 11.2 Oil Suction Hose 85 11.3 Oil Pump 86 11.4 Valve 87 Contents

2 MS 362, MS 362 C Contents 12. Fuel System 88 12.1 Air Filter 88 12.2 Baffle 88 12.3 Filter Base 88 12.4 Air Guide Shroud 89 12.5 Carburetor 92 12.5.1 Leakage Test 94 12.6 Servicing the Carburetor 94 12.6.1 Metering Diaphragm 94 12.6.2 Inlet Needle 95 12.6.3 Pump Diaphragm 96 12.6.4 Air Valve 97 12.6.5 Levers on Throttle Shaft 98 12.6.6 Adjusting Screws 99 12.7 Adjusting the Carburetor 100 12.7.1 Basic Setting 100 12.7.2 Standard setting 101 12.8 Carburetor Carrier 102 12.9 Intake Manifold 103 12.10 Tank Vent 104 12.10.1 Testing 104 12.10.2 Removing and Installing 105 12.11 Fuel Intake 106 12.11.1 Pickup Body 106 12.11.2 Fuel Hose 106 12.11.3 Tank Housing 107 13. Heating System 109 13.1 Carburetor Heating 109 13.1.1 Testing the Complete System 109 13.1.2 Testing the Heating Element 109 13.1.3 Thermostatic Switch 110 13.2 Carburetor Heating System Troubleshooting Chart 111 13.3 Handle Heating System 112 13.3.1 Troubleshooting 112 13.4 Heater Switch 112 13.5 Heating Element in Rear Handle 113 13.6 Heating Element in Handlebar 114 13.7 Generator 115 13.7.1 Handle Heating and Generator Troubleshooting Chart 117 13.7.2 Test Connections and Test Values 119 13.8 Wiring Harness 121 14. Special Servicing Tools 123 15. Servicing Aids 125

3 MS 362, MS 362 C 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 that is 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 aDirection 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 3100. 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. The above operation is not necessary with the new assembly stand 5910 890 3101 since the mounting plate is already fitted. 1 2 3 219RA000 TG

4 MS 362, MS 362 C Engage the bar mounting studs in the outer bores in the mounting plate and secure the saw in position with the nuts (arrows). Preparations for servicing Remove the chain sprocket cover, saw chain and guide bar before carrying out repairs or mounting the machine to the assembly stand. 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. 216RA000 TG 1.2 Safety Precautions If the power tool 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. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. 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. 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. Damaged parts must always be replaced in order to avoid consequential damage. Run the chain saw only with the shroud mounted in position – there is otherwise a risk of injury from the fanwheel and a risk of engine damage due to overheating. 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, b 15. Other press fluids are not approved and may result in damage to the fuel hoses. Coat the ends of the hoses and the connectors with STIHL press fluid and then push the new hoses onto the hose barbs, b 15.

5 MS 362, MS 362 C 2. Specifications 2.1 Motor MS 362 Displacement: 59 cm 3 Bore: 47.0 mm Stroke: 34.0 mm Engine power to ISO 7293: 3.4 kW (4.6 bhp) at 9,500 rpm Maximum permissible engine speed with bar and chain: 14,000 rpm Idle speed: 2,800 rpm Clutch: Centrifugal clutch without linings Clutch engages at: 3,500 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 Operation of tank vent at gauge pressure: 0.5 bar Fuel: refer to instruction manual 2.3 Ignition System Air gap between ignition module and fanwheel: 0.20...0.30 mm Spark plug (suppressed): NGK BPMR 7 A BOSCH WSR6F Electrode gap: 0.5 mm 2.4 Chain Lubrication Speed-controlled oil pump with reciprocating piston and manual flow control Oil delivery rate: Ematic oil pump 9.5 (+/- 2.5) cm³/min at 10,000 rpm Oil delivery rate: Adjustable oil pump 5.5...15.0 (+/- 3.0) cm³/min at 10,000 rpm

6 MS 362, MS 362 C 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 4x8 Chain tensioner cover plate/crankcase 3.0 Screw P 6x21.5 Cover, handlebar/tank housing (VW, R) 6.0 Screw M 7x12.5 Starter post/fan housing 12.0 Screw M 4x12 Brake band/crankcase 3.0 1), 4) Screw P 4x12 Brake cable retainer/tank housing (Q) 2.0 Collar screw M 8x21.5 Collar stud for bar 23.0 1) Collar stud M 8/ M 10 Bar mounting, quick chain tensioner 30.0 3) Screw M 4x12 Cover, chain brake/crankcase 3.0 4) M 10x1 Decompression valve 14.0 Screw B 2.9x9.5 Spark arresting screen/muffler 2.0 Screw M 4x12 Generator/crankcase (VW) 3.0 1) Screw M 6x19.5 Handlebar/stiffener (VW, R) 10.0 Screw P 5x16 Handlebar/plug, AV spring 3.0 Screw M 5x16 Handlebar/plug, AV spring (VW) 6.0 4) Screw P 6x26.5 Handlebar/tank housing 7.0 Screw P 6x40 Handlebar/tank housing (VW, R) 8.0 Screw M 5x35 Hand guard/fan housing/crankcase 6.0 4) Screw P 6x28 Chain catcher/crankcase/bearing plug 6.0 Screw M 5x12 Spiked bumper/crankcase/upper locknut 8.0 4) Screw M 5x16 Spiked bumper/crankcase, bottom 8.0 Screw M 4x12 Manifold/cylinder 4.0 4) Screw M 5x25 Crankcase, sprocket side/fan side, 1st stage 4.0 4) Screw M 5x25 Crankcase, sprocket side/fan side, 2n stage 10.0 4) Screw P 6x21.5 Bearing plug/crankcase 6.0 Screw M 5x16 Bearing plug/cylinder 10.0 4) Screw M 5x20 Fan housing/crankcase 6.0 4) Screw M 4x12 Air guide shroud/crankcase 4.0 4) Carrier M 14x1 Carrier/crankshaft 50.0

7 MS 362, MS 362 C Fastener Thread size For component Torque Nm Remarks Screw M 4x12 Oil pump/crankcase 3.0 4) Screw M 5x25 Muffler/crankcase 10.0 Screw M 5x16 Muffler / cylinder 10.0 4) Nut M 12x0.75 Switch/handle housing (VW) 6.0 Screw M 4x10 Guard/tank housing 1.5 Nut M 8x1 Flywheel/crankshaft 33.0 5) Screw M 4x8 Side plate/crankcase 3.0 Nut M 5 Carburetor/collar stud 3.5 Screw M 4x12 Preseparator/crankcase 3.0 1), 4) Screw M 5x20 Elbow/handlebar (R) 7.0 4) Screw D 4x15 Cover plate/fan housing 3.0 M 14x1.25 Spark plug 25.0 Screw M 5x20 Ignition module/crankcase 8.0 4) Screw M 5x25 Cylinder/crankcase, 1st stage 4.0 4) Screw M 5x25 Cylinder/crankcase, 2nd stage 10.0 4) Screw P 6x26.5 Crankcase/bearing plug (R) 5.0 Remarks: 1) Loctite 242 or 243, medium strength 2) Loctite 649, high strength 3) Loctite 270, high strength 4) Screws with binding head 5) Degrease crankshaft/flywheel and mount oil-free VW) Carburetor and handle heating system R) Wrap-around handle Q) QuickStop Super 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. Coat micro-encapsulated screws with medium strength Loctite 242 or 243 before reinstalling. 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 362, MS 362 C 3. Troubleshooting 3.1 Clutch Condition Cause Remedy Saw chain stops under load at full throttle 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 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 Loud noises Clutch springs stretched or fatigued Replace all clutch springs Needle cage damaged Fit new needle cage Clutch shoe retainer broken Install new retainer or clutch Clutch shoes and carrier worn Install new clutch

9 MS 362, MS 362 C 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 Chain sprocket worn Fit new chain sprocket Saw chain stops under load at full throttle 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 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 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

Stihl MS 362, MS 362 C Chainsaw Full Service & Repair Manual

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