Stihl MS200T Repair Manual

The Stihl MS200T is a professional-grade top-handle chainsaw designed for arborists and tree care professionals. This repair manual provides comprehensive instructions for troubleshooting, maintenance, disassembly, and reassembly of the saw. It covers the engine, fuel system, ignition, carburetion, clutch, chain brake, bar, chain, and electrical systems. Always prioritize safety: wear appropriate PPE, disconnect the spark plug before any repair, and use genuine Stihl parts. Below are key sections for safety, specifications, troubleshooting, step-by-step repair procedures, and parts diagrams.

Safety Precautions

Before attempting any repair, ensure the chainsaw is completely cool. Disconnect the spark plug wire to prevent accidental starting. Work in a clean, well-ventilated area. Always wear cut-resistant gloves and safety glasses.

Specifications & Identification

• Model: MS 200 T
• Engine Type: Single cylinder, 2-stroke, air-cooled
• Displacement: 35.2 cc (2.15 cu. in.)
• Power Output: 2.0 kW (2.7 hp)
• Fuel/Oil Mix: 50:1 (Stihl HP Ultra or equivalent ISO-L-EGD)
• Bar Length Range: 12" to 16" (30 cm to 40 cm)
• Chain Pitch/Gauge: 3/8" PMM / .050" (1.3 mm)
• Ignition: Electronic, capacitor discharge (CDI)
• Carburetor: Zama C1Q-S series (adjustable H, L, LA)
• Weight (powerhead): Approx. 4.0 kg (8.8 lbs)
• Serial Number Location: Stamped on crankcase, near rear handle.

Troubleshooting Guide

Routine Maintenance

Daily/Pre-Use Checks: Chain tension, sharpness, bar condition, fasteners tightness. Air filter cleaning (tap out debris, wash if foam). Check fuel filter.

1. Weekly: Clean cooling fins, spark arrestor screen. Inspect clutch drum for wear.
2. Monthly: Clean carburetor external vents. Check fuel lines for cracks. Grease sprocket bearing.
3. Seasonal/100 hrs: Replace spark plug, fuel filter, air filter. Decarbonize exhaust port. Check compression.

WARNING! Never run the saw without the chain brake functioning correctly. Always test brake before use.

Fuel System Repair

Components: Fuel tank, cap, lines, filter, carburetor, tank vent.

1. Drain fuel. Remove top cover and air filter assembly.
2. Disconnect fuel lines from carburetor (note routing). Remove carburetor mounting nuts.
3. Replace in-tank fuel filter by pulling through grommet with wire hook.
4. Carburetor rebuild: Disassemble, clean in solvent, replace diaphragms, gaskets, needle valve. Reassemble.
5. Reinstall, reconnect lines. Adjust idle (L) and high-speed (H) screws to factory specs: Initial setting 1 turn out from lightly seated.
6. Test for leaks and proper operation.

Ignition System Repair

Components: Spark plug, ignition module (coil), stop switch, wiring harness.

1. Remove spark plug, check gap (0.020" / 0.5 mm). Replace if fouled or cracked.
2. Test for spark: Ground plug to cylinder, pull starter. Bright blue spark required.
3. No spark? Check wire integrity. Disconnect stop switch wire from module; retest. If spark returns, switch is faulty.
4. Module resistance test (primary: 0.5-2.0 Ω; secondary: 5-15 kΩ). Replace module if out of spec.
5. Ensure flywheel key is not sheared (timing). Air gap between module and flywheel: 0.3 mm (0.012").

Engine Top-End Rebuild

Required for low compression, scoring, or piston damage.

1. Remove top cover, muffler, carburetor, ignition module, and cylinder cover.
2. Unbolt cylinder base. Carefully lift cylinder off piston. Note orientation.
3. Remove piston pin circlips. Heat piston if necessary. Drive out pin, remove piston.
4. Inspect cylinder: hone if light scoring; replace if deeply scored or port damaged.
5. Replace piston rings. Ensure ring end gaps are staggered. Lubricate with 2-stroke oil.
6. Reassemble in reverse order. Torque cylinder bolts to spec (10-12 Nm).
7. Perform break-in: Run at varied RPMs, avoid prolonged full throttle for first tank.

CAUTION! Label all parts. Use a ring compressor for piston installation.

Clutch & Chain Brake Repair

Clutch: Centrifugal, drum-type. Brake: Band-type, manual/automatic activation.

1. Remove bar, chain, and side cover. Remove clutch nut (left-hand thread). Use clutch holding tool.
2. Inspect clutch shoes for wear, springs for fatigue. Replace if worn.
3. Chain brake: Remove handle-side cover. Inspect brake band for wear, tension spring, and linkage.
4. Test brake function: With saw off, engage brake; band should lock drum firmly.
5. Reassemble. Torque clutch nut to 40-50 Nm. Ensure brake disengages freely.

Bar, Chain & Sprocket Service

• Bar: Clean groove weekly. Flip weekly for even wear. Dress rails with file if burred. Replace if worn, bent, or groove widened.
• Chain: Sharpen regularly with correct file size (4.0 mm round file). Maintain proper depth gauge setting. Replace when stretched beyond adjuster limit or teeth shortened.
• Sprocket: Inspect for hooking or wear. Rim sprockets are replaceable; remove clutch drum to access. Lubricate bearing with high-temperature grease.
• Oil System: Clean oil outlet hole. Adjust oil flow via screw (if equipped). Ensure bar oil hole aligns with saw outlet.

Electrical System

Simple system: Ignition module, stop switch, wiring. No charging system or battery.

1. Check all wire connections for corrosion, breaks, or chafing.
2. Stop switch test: Multimeter continuity check. Switch should be open at "RUN", closed at "STOP".
3. If wiring harness damaged, replace entire harness. Route wires away from hot/moving parts.
4. Ensure ground wire from module to cylinder is clean and tight.

Parts Diagrams & Ordering

Refer to official Stihl MS200T IPL (Illustrated Parts List) for exploded views and part numbers. Common replacement parts:

Ordering: Use serial number when ordering parts. Contact an authorized Stihl dealer or visit www.stihlusa.com.

Service Support: For technical assistance, contact Stihl Technical Service at 1-800-467-8445.