MS 500i

Serial number
Engine Ignition system, Fan Fuel injection system,
housing Tank housing, Handlebar
MS 500i-Z

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Smart Connector

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (4) 01.04.2021

 MS 500i

Description Technical Information

Engine

Ignition system, Fan housing

Fuel injection system, Tank housing, Handlebar MS 500i-

Z

Serial number

Smart Connector

Tools

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (5) 01.04.2021

 Engine

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (6) 01.04.2021

 Engine

Referen Item number Qty Description Contains

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1 1147 020 2601 1 Crankcase, fan side (4) 2 - 8, 10, 11

2 0000 988 8600 4 Sleeve (4)

3 0000 988 5211 1 Connector (4)

4 9523 003 4280 1 Grooved ball bearing 15x37,7x11 (4)

5 1141 791 5902 1 Stop buffer (4)

6 9640 003 1560 1 Oil seal 15x22x4 (4)

7 9022 500 1051 5 Spline screw IS-M5x27 (4)

8 1147 080 1701 2 Grommet (4)

9 9022 346 0658 2 Spline screw IS-M4x12 (4)

10 0000 350 0533 1 Filler cap (4) 11

11 9645 948 7734 1 O-ring 25x3.5 (4)

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12 1147 020 2902 1 Crankcase (4) 7, 13 - 22

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13 1120 162 5200 1 Pin (4)

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14 1121 162 5200 1 Pin (4)

15 1121 162 5205 1 Pin (4)

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16 1128 162 5200 1 Pin (4)

17 9523 003 4282 1 Grooved ball bearing 15x37,7x13 (4)

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18 0000 664 2406 2 Collar screw M8 (4)

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19 1128 640 9100 1 Valve (4)

20 0000 974 1200 1 Notched pin 2.6x8 (4)

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21 1141 791 5902 1 Stop buffer (4)

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22 9640 003 1604 1 Oil seal DIN3760-BS15x31,5x4 (4)

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23 1147 020 9700 1 Gasket (4) 7

24 1147 030 0405 1 Crankshaft (4) 7

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25 9468 621 1520 1 Circlip 15x1 (4)

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26 1117 640 3800 1 Pickup body (4)

27 1122 647 9400 1 Hose (4)

28 1147 021 1100 1 Cover (4)

29 1147 021 1101 1 Cover (4)

30 1147 007 1600 1 Set of gaskets (4) 6, 7, 22, 23,

37, 87, 93

31 1147 020 1200 1 Cylinder with piston Ø 54 mm (4) 32 - 36

32 1147 030 2003 1 Piston Ø 54 mm (4) 33 - 36

33 1147 034 3001 2 Piston ring Ø 54x1,2 mm (4)

34 1147 034 1501 1 Piston pin 12x8x39 (4)

35 9512 003 3146 1 Needle cage 12x16.2x15 (4)

36 9463 650 1200 2 Snap ring 12x1 (4)

37 1147 029 2300 1 Cylinder gasket (4)

(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (7) 01.04.2021

 Engine

Referen Item number Qty Description Contains

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38 9022 341 1358 4 Spline screw IS-M6x28 (4)

39 1142 020 9400 1 Decompression valve (4)

40 0000 400 7011 1 Spark plug NGK CMR6H (4)

41 9022 313 0660 2 Spline screw IS-M4x12 (4)

42 1125 664 1400 1 Thrust pad (4)

43 1125 640 1900 1 Tensioner slide (4)

44 1125 007 1021 1 Spur gear / chain adjusting screw kit (4) 45

45 9646 945 0490 1 O-ring 7x1.5 (4)

46 1122 664 2200 1 Cover plate (4)

47 1122 664 4500 1 Support (4)

48 9022 313 0633 2 Spline screw IS-M4x8 (4)

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49 1122 649 5000 1 Sealing ring B4x2 (4)

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50 1142 640 3200 1 Oil pump (4) 51 - 57

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51 0000 958 0518 2 Washer (4)

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52 0000 997 0615 1 Compression spring (4) pr
53 1142 647 0600 1 Pump piston (4)
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54 1125 641 9400 1 Bearing bushing (4)

or

55 9646 945 0160 2 O-ring 4x2 (4)

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56 1142 647 4800 1 Control bolt (4)

no

57 9380 620 1090 1 Roll pin 2x10 (4)

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59 9022 341 0983 1 Spline screw IS-M5x16 (4)

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60 9022 341 0960 1 Spline screw IS-M5x12 (4)

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61 1128 664 1000 1 Inner side plate (4)

62 1142 640 1701 1 Chain sprocket cover (4) 63 - 67, 97, 98

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63 1121 648 6610 2 Bumper strip (4)

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64 1142 656 1501 1 Guard (4)

65 0000 995 0803 2 Collar nut M8 (4)

66 1122 650 7702 1 Chain catcher (4)

67 9214 320 0700 2 Lock nut M5 (4)

68 1122 664 0506 1 Bumper spike (4)

69 9214 320 0700 1 Lock nut M5 (4)

71 1147 640 7110 1 Worm gear (4) 72

72 1128 647 2400 1 Spring (4)

73 1122 162 1000 1 Cover washer 52 mm (4)

74 1147 160 2002 1 Clutch (4) 76 - 78

76 1128 162 3000 3 Retainer (4)

77 0000 997 5611 3 Tension spring (4)

78 1147 162 0801 3 Clutch shoe (4)

(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (8) 01.04.2021

 Engine
Referen Item number Qty Description Contains
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79 9512 933 2380 1 Needle cage 10x16x12 (4)

80 1128 007 1017 1 Rim sprocket kit 3/8" 7T (4) 81 - 83

81 0000 642 1223 1 Rim sprocket 3/8" 7T (4)

82 0000 958 1032 1 Washer Ø 27 mm (4)

83 9460 624 0801 1 E-clip 8x1.3 (4)

84 1147 080 1501 1 Shroud lock (4) 85

85 1147 084 7401 1 Grommet (4)

86 1147 141 3200 1 Cooling plate (4)

87 1147 149 0600 1 Muffler gasket (4)

88 1147 140 0603 1 Muffler Z (4) 89 - 93

89 1147 141 9001 1 Screen (4)

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90 1147 145 0800 1 Exhaust casing (4)

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91 9022 399 1020 4 Spline screw IS-M5x20 (4)

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92 9022 341 0911 2 Spline screw IS-M5x6 (4)

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93 1147 149 0500 1 Gasket (4) pr
94 1147 080 1602 1 Shroud (4) 95, 96
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95 1147 084 7100 1 Cap (4)

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96 1147 084 2200 1 Guard (4)

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97 1122 664 0501 1 Bumper spike (4)

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98 9008 345 0960 2 Hexagon head screw M5x12 (4)

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (9) 01.04.2021

 Ignition system, Fan housing

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (10) 01.04.2021

 Ignition system, Fan housing

Referen Item number Qty Description Contains

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1 1147 080 2101 1 Fan housing with rewind starter (2,4) 2 - 8, 10 - 13

2 1147 080 1800 1 Fan housing (2,4) 3

3 1110 084 9102 1 Bushing (2,4)

4 1147 967 1500 1 Model plate MS 500i (2,4)

5 1135 190 0600 1 Rewind spring (2,4)

6 1128 195 0400 1 Rope rotor (2,4)

7 1128 190 3400 1 Starter grip ElastoStart Ø 3,5 mm (2,4) 8

8 1128 190 2900 1 Starter rope Ø 3.5 mm (2,4)

9 0000 930 2267 1 Starter rope Ø 3.5 mm / 28 pieces (B) (2,4)

10 1125 195 7200 2 Pawl (2,4)

11 0000 958 0923 1 Washer (2,4)

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12 1128 195 3500 1 Spring (2,4)

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13 1147 084 7800 1 Segment (2,4)

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14 1147 400 1201 1 Flywheel (2,4)

15 0000 955 0802 1 Collar nut M8x1 (2,4)

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16 1147 400 5801 1 Sensor (2,4) 17

17 1147 139 0101 1 Gasket (2,4)

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18 9022 313 0658 2 Spline screw IS-M4x12 (2,4)

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19 1147 400 4000 1 Generator (2,4)

20 1147 404 7800 2 Screw M5 (2,4)

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21 1147 141 6301 1 Air baffle (2,4)

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22 9022 346 0658 2 Spline screw IS-M4x12 (2,4)

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23 1147 790 9100 1 Hand guard (2,4) 24, 25

24 0000 967 3915 1 Instruction label (2,4)

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25 1141 790 6100 1 Screw assy. M5 (2,4)

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26 1147 160 5400 1 Brake band (2,4)

27 1128 160 5000 1 Lever (2,4)

28 9460 624 0400 2 E-clip 4 (2,4)

29 1121 162 5010 1 Lever (2,4)

30 0000 997 0628 1 Spring (2,4)

31 1141 160 5502 1 Tension spring (2,4) 32

32 1141 162 8000 1 Hose (2,4)

33 9022 371 1020 3 Spline screw IS-M5x20 (2,4)

34 1147 080 7501 1 Cover plate (B) (2,4) 35

35 9022 313 0660 2 Spline screw IS-M4x12 (B) (2,4)

(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (11) 01.04.2021

 Fuel injection system, Tank housing, Handlebar MS 500i-Z

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (12) 01.04.2021

 Fuel injection system, Tank housing, Handlebar MS 500i-Z

Referen Item number Qty Description Contains

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1 1147 130 0102 1 Injection module (4) 2-8

2 1147 130 4504 1 Injection housing (4) 3, 8

3 1147 139 0100 1 Gasket (4)

4 1147 431 7002 1 Contact plate (4)

5 9074 477 2311 1 Pan head self-tapping screw IS P3x16 (4)

6 0000 130 3307 1 Injection valve (4) 7, 8

7 1147 007 1001 1 Sealing ring kit (4)

8 1147 007 2000 1 Hose kit (4)

9 1147 131 3801 1 Support (4)

10 1147 132 0100 2 Screw (4)

11 0000 121 2702 1 Cap (4)

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12 0000 132 0200 1 Spring (4)

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13 1147 130 0302 1 Injection pump (4) 8 - 12

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14 1147 430 0512 1 Switch (4)

15 1147 432 1700 1 Cover (4)

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16 1147 131 3800 1 Support (4)

17 9074 477 2995 2 Pan head self-tapping screw IS-P4x12 (4)

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18 9022 371 0710 4 Spline screw IS-M4x20 (4)

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19 1147 141 2200 1 Manifold (4)

20 1147 141 1805 1 Sleeve (4)

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21 1147 080 0901 1 Air guide shroud (4) 22

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22 1147 080 1700 1 Grommet (4)

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23 1147 141 8600 1 Impulse hose (4)

24 9022 313 0660 1 Spline screw IS-M4x12 (4)

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25 1147 120 6901 1 Throttle shutter housing (4) 26

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26 9022 500 1020 2 Screw IS-M5x22 (4)

27 1147 140 1202 1 Air filter base (4) 26, 28

28 1144 129 0900 1 Gasket (4)

29 1144 140 4402 1 Air filter HD2 (4)

30 1147 140 1000 1 Filter cover (4) 31

31 1144 141 2300 1 Twist lock (4)

34 1147 182 1000 1 Throttle trigger (4)

35 1138 182 4500 1 Torsion spring (4)

36 9371 470 2630 1 Cylindrical pin (DIN7)-5m6x22 (4)

37 1141 182 0800 1 Lockout lever (4)

38 1147 182 1500 1 Throttle rod (4)

39 1147 791 0600 1 Handle molding (4)

40 1147 791 1900 1 Handlebar support (4)

(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (13) 01.04.2021

 Fuel injection system, Tank housing, Handlebar MS 500i-Z

Referen Item number Qty Description Contains

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41 1147 790 1700 1 Handlebar (4) 51, 52

42 9074 478 4675 4 Pan head self-tapping screw IS-P6x32.5 (4)

43 1141 791 2802 1 Stop buffer (4)

44 1144 791 3102 1 Spring (4)

45 1147 792 2904 1 AV mount (4)

46 1147 790 8303 1 AV spring (4)

47 9022 341 0983 1 Spline screw IS-M5x16 (4)

48 9022 371 1020 1 Spline screw IS-M5x20 (4)

49 1147 790 8302 1 AV spring (4)

50 9074 477 4130 1 Pan head self-tapping screw IS-P5x16 (4)

51 0000 791 7904 1 Bushing (4)

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52 1141 791 6100 1 Collar screw (4)

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53 1147 350 0803 1 Tank housing CDN (4) 8, 54 - 62, 71,

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72

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54 1147 350 0801 1 Tank housing (4) 8, 55 - 62

55 0000 350 5800 1 Tank vent (4)

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56 1139 358 7700 1 Hose (4)
or

57 1141 989 0600 1 Grommet (4)

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58 0000 350 3518 1 Pickup body (4)

no

59 1147 448 1200 1 Lead retainer (4)

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60 0000 350 0533 1 Filler cap (4) 61

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61 9645 948 7734 1 O-ring 25x3.5 (4)

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62 0000 967 7247 1 Warning pictogram MS (4)

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63 1147 435 2700 1 Cover (4)

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64 1147 400 4702 1 Control unit (4) 65 - 68

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65 1147 405 1000 1 Spark plug boot (4)

on

66 0000 998 0618 1 Torsion spring (4)

67 0000 405 0600 1 Ignition lead 1 m (B) (4)

67 0000 930 2251 1 Ignition lead 10 m (B) (4)

68 0000 989 1002 1 Grommet (4)

69 1147 798 3600 1 Deflector (B) (4)

70 4148 353 2700 1 Connector (4)

71 0000 967 4066 1 Warning Spark arresting screen CDN (4)

72 0000 967 3596 1 Instruction label CDN (4)

(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (14) 01.04.2021

 Serial number

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (15) 01.04.2021

 Serial number

Referen Qty Description

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1 1 Position of serial number

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (16) 01.04.2021

 Tools

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (17) 01.04.2021

 Tools

Referen Item number Qty Description

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1 1142 890 3401 1 Combination wrench

2 0812 370 1000 1 Screwdriver T27x120x70

3 0000 891 0810 1 Tool roll

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(1) MS 500i, (2) MS 500i-RZ, (3) MS 500i-W, (4) MS 500i-Z

Copyright ANDREAS STIHL AG & Co. KG 2021 (18) 01.04.2021

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