STIHL MS 362 Repair Manual
The STIHL MS 362 is a professional-grade chainsaw featuring a 59.0 cc engine, STIHL Quickstop® inertia chain brake, Ematic™ lubrication system, and a decompression valve for easier starting. This manual provides detailed instructions for troubleshooting, maintenance, and repair procedures to ensure optimal performance and safety. Below are key sections covering safety, specifications, disassembly, engine repair, fuel system, ignition, lubrication, and reassembly.
Safety Precautions & Warnings
Before performing any repair, ensure the chainsaw is turned off, spark plug wire disconnected, and all moving parts have stopped. Wear appropriate personal protective equipment (PPE).
| Hazard | Precaution |
|---|
| Fuel & Oil | Work in well-ventilated area; no smoking or open flames |
| Sharp Components | Wear cut-resistant gloves when handling chain, guide bar, or cutter parts |
| Hot Surfaces | Allow engine to cool completely before disassembly |
| Spring-Loaded Parts | Use proper tools; parts under tension can cause injury |
| Electrical Shock | Disconnect spark plug wire before servicing ignition system |
Technical Specifications
- Engine Displacement: 59.0 cc (3.6 cu. in.)
- Power Output: 3.6 kW (4.9 bhp)
- Fuel Tank Capacity: 0.55 L (18.6 fl. oz.)
- Oil Tank Capacity: 0.26 L (8.8 fl. oz.)
- Guide Bar Lengths: 40 cm (16"), 50 cm (20"), 63 cm (25")
- Chain Pitch/Gauge: 3/8" PM / 0.050" (1.3 mm)
- Weight (powerhead): 6.2 kg (13.7 lbs)
- Ignition System: STIHL Electronic Ignition (CDI)
- Carburetor: STIHL Zama C1Q-S267
Tools & Equipment Required
Standard and specialty tools needed for repair.
- STIHL combination wrench or socket set (8mm, 10mm, 13mm)
- Torx screwdrivers (T27, T10)
- Piston stop tool (STIHL 1128 893 4500)
- Flywheel puller (STIHL 1128 893 4503)
- Clutch removal tool (STIHL 1128 893 4505)
- Compression tester (0-300 psi)
- Spark plug gap tool (0.5 mm / 0.020")
- Feeler gauges (0.1-1.0 mm)
- Torque wrench (2-20 Nm)
WARNING! Use only STIHL-approved tools to avoid damage to components.
Troubleshooting Guide
| Symptom | Possible Cause | Corrective Action |
|---|
| Engine will not start | No spark, flooded carburetor, clogged fuel filter | Check spark plug; replace if fouled. Clean air filter. Replace fuel filter. |
| Engine starts then stalls | Dirty carburetor, faulty ignition coil, fuel line leak | Clean carburetor jets. Test ignition coil resistance (4-6 kΩ). Inspect fuel lines. |
| Loss of power | Clogged spark arrestor, worn piston/cylinder, carburetor adjustment | Clean muffler spark arrestor. Check compression (≥120 psi). Adjust H/L screws. |
| Excessive vibration | Loose components, unbalanced clutch, damaged AV mounts | Tighten all fasteners. Inspect clutch drum. Replace anti-vibration mounts. |
| Chain does not oil | Clogged oil passages, faulty oil pump, empty oil tank | Clean oil channels. Test oil pump output. Replace pump if defective. |
Engine Disassembly Procedure
Step-by-step guide to disassemble the powerhead.
- Remove top cover, air filter cover, and air filter.
- Disconnect spark plug wire and remove spark plug.
- Remove carburetor cover and disconnect fuel/oil lines.
- Remove clutch assembly using clutch tool.
- Remove flywheel cover and flywheel using puller.
- Remove cylinder cover and muffler.
- Remove cylinder bolts and lift off cylinder.
- Remove piston pin circlips and push out piston pin.
- Remove crankshaft from crankcase (may require case separation).
CAUTION! Label all parts and fasteners. Note orientation of gaskets and seals.
Cylinder & Piston Inspection
Critical checks for engine wear.
- Cylinder Scoring: Inspect for vertical scratches. Light honing acceptable; replace if deep scoring present.
- Piston Rings: Check ring end gap (0.2-0.4 mm). Replace if gap exceeds 0.8 mm.
- Piston Skirt: Measure skirt diameter (standard: 45.95 mm). Replace if worn or scuffed.
- Crankcase Seals: Check for leaks. Replace seals if hardened or cracked.
- Connecting Rod: Check for side play (max 0.5 mm). Excessive play indicates worn crankshaft bearings.
Fuel System Repair
Carburetor service and fuel line replacement.
- Remove carburetor and disassemble.
- Clean all jets, channels, and diaphragms with compressed air.
- Replace diaphragms, gaskets, and needle valve if hardened.
- Inspect fuel lines for cracks; replace if necessary.
- Reassemble carburetor and set initial adjustments: L screw 1 turn open, H screw 1 turn open.
- Prime and test for leaks.
Tip: Use STIHL carburetor repair kit (1128 007 1060) for best results.
Ignition System Service
Testing and replacing ignition components.
- Check spark plug: Clean or replace if electrode worn. Set gap to 0.5 mm.
- Test ignition coil: Resistance between spark plug wire and ground should be 4-6 kΩ.
- Inspect stop switch wire for continuity; replace if broken.
- Check flywheel magnets for damage; replace if cracked.
- Ensure air gap between flywheel and ignition coil is 0.3 mm.
WARNING! Never crank engine with spark plug removed and wire connected – risk of ignition coil damage.
Chain Brake & Clutch Assembly
Service procedures for safety and drive components.
| Component | Inspection | Action |
|---|
| Chain Brake Band | Check for wear or glazing | Replace if thickness < 1.5 mm |
| Clutch Shoes | Measure shoe thickness | Replace if < 3.0 mm |
| Clutch Springs | Check for stretching/breakage | Replace if deformed |
| Sprocket (Rim/Drum) | Inspect teeth for hooking | Replace if worn unevenly |
| Brake Handle Mechanism | Test engagement and return | Lubricate pivot points |
Lubrication System Maintenance
Ensuring proper chain oil flow.
- Remove oil pump cover and inspect pump gears.
- Clean oil pickup filter in tank.
- Check oil lines for kinks or blockages.
- Test pump output: Should deliver 2-4 ml/min at idle.
- Adjust oil flow via screw on pump (if equipped).
- Replace pump if output is insufficient.
Note: Use only STIHL HP Ultra or equivalent biodegradable chain oil.
Reassembly & Final Checks
Proper reassembly and operational testing.
- Install new crankcase seals and gaskets.
- Reassemble crankshaft, piston, and cylinder with new base gasket.
- Torque cylinder bolts to 10 Nm (88 in-lb) in crisscross pattern.
- Reinstall flywheel and clutch to specified torques (flywheel: 40 Nm, clutch: 35 Nm).
- Reconnect all fuel/oil lines and cables.
- Fill with fresh fuel mix (50:1 STIHL HP Ultra oil) and chain oil.
- Start engine and check for leaks, unusual noises, and proper chain brake function.
- Fine-tune carburetor for smooth acceleration and idle.
Final Verification: Chain tension correct, all guards installed, safety features operational.
Service Support: STIHL USA – 1-800-467-8445 | www.stihlusa.com
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