MS200T STIHL Repair Manual

The STIHL MS200T is a professional-grade top-handle chainsaw designed for arborists and tree care professionals. This repair manual covers essential procedures for maintenance, troubleshooting, and repair of the engine, fuel system, ignition, chain brake, clutch, guide bar, and cutting chain. Below are key sections for safety, specifications, disassembly, component repair, reassembly, and troubleshooting.

1. Safety Precautions 2. Specifications & Technical Data 3. Tools Required 4. Engine Disassembly 5. Cylinder & Piston Service 6. Carburetor Adjustment & Repair 7. Ignition System 8. Chain Brake & Clutch Assembly 9. Guide Bar & Chain Maintenance 10. Reassembly Instructions 11. Troubleshooting Guide

Safety Precautions

Before performing any repair, ensure the chainsaw is completely cool, the spark plug wire is disconnected, and all fuel has been drained. Always wear cut-resistant gloves and safety glasses.

Hazard	Precaution
Fuel & Oil	Work in well-ventilated area; no open flames.
Sharp Components	Handle cutting chain and guide bar with extreme care.
Spring-Loaded Parts	Clutch and brake springs are under tension; use proper tools.
Electrical	Disconnect spark plug before working on ignition or engine.
Fasteners	Use correct torque values to avoid stripping or breakage.

Specifications & Technical Data

Engine Type: Single-cylinder, 2-stroke, air-cooled.
Displacement: 35.2 cc (2.15 cu in).
Power Output: 2.2 kW (3.0 hp).
Fuel/Oil Ratio: 50:1 (STIHL HP Ultra or equivalent).
Idle Speed: 2,800 RPM.
Maximum Power Speed: 13,500 RPM.
Ignition System: Electronic, non-adjustable.
Carburetor: Zama C1Q-S series.
Chain Pitch/Gauge: 1/4"P / .043" (1.1 mm).
Weight (powerhead): 3.9 kg (8.6 lbs).

Tools Required

Standard and STIHL-specific tools needed for repair.

Torx screwdrivers (T10, T15, T27).
Socket set (8mm, 10mm, 13mm).
Feeler gauge set (0.10mm, 0.15mm).
Piston stop tool (STIHL 1129 893 4500).
Clutch holding tool (STIHL 1129 893 4501).
Compression tester (0-300 psi).
Spark tester.
Vacuum/pressure pump for fuel system testing.

WARNING! Use genuine STIHL tools or equivalents to prevent damage.

Engine Disassembly

Step-by-step procedure to disassemble the powerhead.

Remove top cover, air filter, and carburetor cover.
Disconnect fuel line and impulse line from carburetor.
Remove muffler and spark plug.
Install piston stop; remove clutch and flywheel.
Separate crankcase halves after removing all screws.
Extract crankshaft, connecting rod, and bearings.

CAUTION! Mark all components and fasteners for correct reassembly.

Cylinder & Piston Service

Inspection and repair of cylinder, piston, rings, and wrist pin.

Component	Inspection	Service Limit
Cylinder Bore	Check for scoring, wear	Max diameter 35.24 mm
Piston Skirt	Measure diameter	Min diameter 35.00 mm
Piston Rings	Check end gap in cylinder	0.15-0.30 mm
Wrist Pin	Check for play	Replace if loose
Cylinder Compression	Test with gauge	Minimum 120 psi

Note: Replace cylinder and piston as a matched set if damaged.

Carburetor Adjustment & Repair

Zama C1Q-S carburetor adjustment and diaphragm replacement.

Remove carburetor from engine.
Disassemble: Remove cover, diaphragm, metering lever, and gaskets.
Clean all passages with carburetor cleaner; inspect for wear.
Set metering lever height flush with carburetor body.
Reassemble with new diaphragm and gasket kit.
Adjust idle (L) and high-speed (H) screws: Initial setting 1 turn open from lightly seated.
Fine-tune with tachometer: Idle 2,800 RPM, max 13,500 RPM.

Tip: Always pressure-test carburetor after repair.

Ignition System

Testing and replacement of ignition module, spark plug, and wiring.

Spark Plug: NGK BPMR7A, gap 0.020" (0.5 mm).
Ignition Module: STIHL 1140 400 0801. Test with multimeter: Primary resistance 0.8-1.2 Ω.
Stop Switch: Ensure continuity when off; open when on.
Testing: Use spark tester; minimum spark jump 6 mm.

WARNING! Never crank engine with spark plug removed and wire connected.

Chain Brake & Clutch Assembly

Disassembly, inspection, and reassembly of the chain brake and clutch.

Remove side cover, chain, and guide bar.
Use clutch holding tool to remove clutch (left-hand thread).
Inspect clutch drum, shoes, and springs for wear.
For chain brake: Remove handle, inspect band, spring, and mechanism.
Replace band if thickness below 1.5 mm.
Reassemble with new grease on bearings.

CAUTION! Clutch springs are under tension; wear eye protection.

Guide Bar & Chain Maintenance

Maintaining and servicing the guide bar and cutting chain.

Guide Bar: Clean groove weekly; file rails if uneven; rotate regularly.
Chain Sharpening: Use 4.0 mm round file; maintain 30° cutters, 10° depth gauges.
Tension Adjustment: Chain should snap back when lifted from bar.
Lubrication: Ensure oiler port is clear; use STIHL chain oil.

Note: A dull chain increases wear and risk of kickback.

Reassembly Instructions

Critical steps for reassembling the MS200T powerhead.

Install crankshaft bearings with proper sealant.
Join crankcase halves; torque screws to 10 Nm (88 in-lb).
Install piston with arrow toward exhaust; use ring compressor.
Mount cylinder; ensure piston rings seat properly.
Install flywheel and clutch to specified torques.
Reconnect fuel system; prime carburetor.
Final check: All fasteners tight, no fuel leaks.

WARNING! Perform compression test after reassembly.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel, or compression	Check spark, fuel lines, carburetor, compression.
Engine runs poorly	Clogged filter, bad diaphragm	Clean air filter; rebuild carburetor.
Loss of power	Exhaust clog, air leak	Clean spark arrestor; pressure test crankcase.
Chain won't turn	Clutch, sprocket, or brake issue	Inspect clutch shoes, drum, and brake band.
Excessive vibration	Unbalanced flywheel, loose parts	Check flywheel key; tighten all mounts.
Oil leakage	Seals, gaskets, oil line	Replace crank seals; check oil line connections.

Service Note: For technical support, contact STIHL at 1-800-467-8445 or visit www.stihlusa.com.