MS311, MS391 SM

STIH)
STIHL MS 311, 391 2009-06

Contents
1. Introduction and 6. Engine 27 9. Servicing the

Safety Precautions 3 AV System 57
6.1 Muffler 27
1.1 Introduction 3 6.2 Leakage Test 28 9.1 Buffer on Oil Tank 57
1.2 Safety Precautions 4 6.2.1 Preparations 28 9.2 AV Spring on Oil Tank 57
6.2.2 Vacuum Test 29 9.3 AV Spring on
6.2.3 Pressure Test 29 Fuel Tank 57
2. Specifications 5 6.3 Oil Seals 30 9.4 AV Spring on
6.4 Shroud 31 Front Handle 58
2.1 Engine 5 6.5 Cylinder / Crankshaft 32 9.5 Stop Buffer at
2.2 Fuel System 5 6.6 Bearings / Crankshaft 35 Clutch Side 59
2.3 Ignition System 5 6.7 Piston 36 9.6 Annular Buffer at
2.4 Chain Lubrication 5 6.8 Piston Rings 38 Ignition Side 59
2.5 Tightening Torques 6 6.9 Decompression Valve 38 9.7 Handlebar 59
3. Troubleshooting 8 7. Ignition System 39 10. Control Levers 61
3.1 Clutch 8 7.1 Ignition Timing 39 10.1 Master Control Lever 61

3.2 Chain Drive, 7.2 Preseparator 39 10.2 Throttle Trigger/Interlock
Chain Brake, 7.3 Ignition Module 39 Lever 61
Chain Tensioner 9 7.4 Testing the 10.2.1 Choke Rod 63
3.3 Chain Lubrication 10 Ignition Module 41 10.2.2 Throttle Rod 64
3.4 Rewind Starter 11 7.5 Spark Plug Boot /
3.5 Ignition System 12 Ignition Lead 42
3.6 Carburetor 13 7.6 Flywheel 43 11. Chain Lubrication 65
3.7 Engine 16 7.7 Short Circuit Wire 44
7.7.1 Testing 44 11.1 Pickup Body 65
7.7.2 Removing and 11.2 Oil Suction Hose 65
4. Clutch 17 Installing 44 11.3 Oil Pump 66
7.7.3 Ground Wire 46 11.4 Valve 67
4.1 Clutch Drum 19 7.7.4 Contact Spring 46
7.8 Ignition System
Troubleshooting 48
5. Chain Brake 20
5.1 Checking Operation 20 8. Rewind Starter 51

5.2 Brake Band 20
5.3 Brake Lever 22 8.1 General 51
5.4 Cam Lever 24 8.2 Fan housing 51
5.5 Pins 25 8.2.1 Segment 51
5.6 Chain Tensioner 25 8.3 Pawls 51
5.7 Bar Mounting Studs 26 8.4 Rope Rotor 52
8.5 Starter Rope / Grip 53
8.6 Tensioning the
Rewind Spring 54
8.7 Replacing the
Rewind Spring 55
RA_542_00_01_01
q
© ANDREAS STIHL AG & Co. KG, 2009
MS 311, MS 391 1
Contents
12. Fuel System 68
12.1 Air Filter 68

12.2 Baffle 68
12.3 Filter Base 68
12.4 Air Guide Shroud 69
12.5 Carburetor 71
12.5.1 Leakage Test 71
12.6 Servicing the
Carburetor 72
12.6.1 Metering Diaphragm 72
12.6.2 Inlet Needle 73
12.6.3 Pump Diaphragm 74
12.6.4 Air Valve 76
12.6.5 Levers on
Throttle Shaft 76
12.6.6 Adjusting Screws 77
12.7 Carburetor
Adjustment 79
12.7.1 Basic Setting 79
12.7.2 Standard Setting 80
12.8 Carburetor Carrier 81
12.9 Intake Manifold 82
12.10 Tank Vent 83
12.10.1 Testing 83
12.10.2 Removing and
Installing 84
12.11 Fuel Intake 84
12.11.1 Pickup Body 84
12.11.2 Fuel Hose 85
12.11.3 Fuel Suction Hose 86
12.11.4 Tank Housing 87
13. Special Servicing

Tools 88
14. Servicing Aids 90
2 MS 311, MS 391
1. Introduction and Safety Precautions
1.1 Introduction The special tools mentioned in the

descriptions are listed in the chapter 1
on "Special Servicing Tools" in this 3
This service manual contains
detailed descriptions of all the repair manual. Use the part numbers to
and servicing procedures specific to identify the tools in the
"STIHL Special Tools" manual. The 2
this power tool.
manual lists all special servicing
tools currently available from
You should make use of the
219RA000 TG
STIHL.
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual Symbols are included in the text and
components and assemblies. pictures for greater clarity.
The meanings are as follows: Servicing and repairs are made
considerably easier if the machine
Refer to the latest edition of the is mounted to assembly stand (3)
In the descriptions:
relevant parts list to check the part 5910 890 3100. To do this, secure
numbers of any replacement parts. the mounting plate (2)
N Action to be taken as shown in
the illustration above the text 5910 850 1650 to the assembly
A fault on the machine may have stand with two screws (1) and
several causes. To help locate the washers.
fault, consult the chapter on – Action to be taken that is not
"Troubleshooting" and the shown in the illustration above
The screws must not project since
"STIHL Service Training System" the text
they, depending on the machine,
for all assemblies. may damage housings when the
In the illustrations: machine is clamped in position.
Refer to the “Technical Information”
bulletins for engineering changes A Pointer The above operation is not
which have been introduced since necessary with the new assembly
publication of this service manual. a Direction of movement stand 5910 890 3101 since the
Technical information bulletins also mounting plate is already fitted.
supplement the parts list until a @ 4.2 =Reference to another
revised edition is issued. 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.
MS 311, MS 391 3
1.2 Safety Precautions The chapter on tightening torques
lists all machine components that
have to be tightened to a specific
If the machine is started up in the
course of repairs or maintenance torque or coated with threadlocking
work, observe all local and country- adhesive. The specifications must
be maintained when tightening
specific safety regulations as well
down screws, nuts and other
as the safety precautions and
fasteners in all the procedures
216RA000 TG warnings in the instruction manual.
described in this service manual.
Gasoline is an extremely flammable
fuel and can be explosive in certain
conditions. Fuel system – hose barb
Engage the bar mounting studs in connectors
the outer bores in the mounting
plate and secure the machine in Always wear suitable protective
Pull off or push on fuel hoses in line
position with the nuts (arrows). gloves for operations in which
with the connector, preferably by
components are heated for
assembly or disassembly. hand, to ensure the tightness of the
Preparations for servicing fuel system.
Remove the chain sprocket cover, Improper handling may result in

Avoid damaging the hose barb
saw chain and guide bar before burns or other serious injuries.
– do not use sharp-edged pliers,
carrying out repairs or mounting the screwdrivers, etc.
machine to the assembly stand. Do not smoke or bring any fire,
flame or other source of heat near Do not cut open fuel hoses with a
the fuel. All work with fuel must be knife or similar tool.
Always use original STIHL
replacement parts. performed outdoors only. Spilled
Do not re-use fuel hoses after
They can be identified by the STIHL fuel must be wiped away
removal. Always install new hoses
part number, the { logo immediately.
– fuel hoses can be overstretched
and the STIHL parts symbol K during removal.
This symbol may appear alone on Always perform leakage test after
small parts. working on the fuel system and the
Install new fuel hoses either dry or
engine.
with the aid of STIHL press fluid,
Storing and disposing b 14.
of oils and fuels Always replace damaged parts.
Check disassembled parts for wear
or damage before re-installing – Other press fluids are not approved
Collect fuel or lubricating oil in a and may result in damage to the fuel
clean container and dispose of it replace as necessary.
hoses.
properly in accordance with local
environmental regulations. Run the machine only with the
Coat the ends of the hoses and the
shroud mounted in position – there
connectors with STIHL press fluid
is otherwise a risk of injury from the
fanwheel and a risk of engine and then push the new hoses on to
damage due to overheating. the hose barbs, b 14.
4 MS 311, MS 391
2. Specifications
2.1 Engine
MS 311 MS 391
Displacement: 59 cm3 64.1 cm3

Bore: 47 mm 49 mm
Stroke: 34 mm 34 mm
Engine power to ISO 7293: 3 kW (4 bhp) 3.2 kW (4.4 bhp)
at 9,500 rpm at 9,500 rpm
Maximum permissible engine speed
with guide bar and chain: 13,000 rpm 13,000 rpm
Idle speed: 2,800 rpm 2,800 rpm
Clutch: Centrifugal clutch without Centrifugal clutch without
linings linings
Clutch engages at: 3,500 rpm 3,500 rpm
Engine housing leakage test
at gauge pressure: 0.5 bar
under vacuum: 0.5 bar
2.2 Fuel System
Carburetor leakage test at 0.8 bar

gauge pressure:
Operation of tank vent at 0.5 bar
gauge pressure:
Fuel: as specified in instruction
manual
2.3 Ignition System
Air gap between ignition

module and fanwheel: 0.20...0.30 mm
Spark plug (resistor type): 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: 11.5 (+2.5) cm3/min

Ematic oil pump at 10,000 rpm
Oil delivery rate: 6.0 (+/-2.0)...17.5 (+3.0 / -4.5)

Adjustable oil pump cm3/min at 10,000 rpm
MS 311, MS 391 5
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 Remarks

Nm
Screw P 4x14 Chain tensioner cover/engine housing 1.5

Screw P 4x12 Brake band/engine housing 2.0
Collar screw M 10 Collar stud for bar / engine pan 30.0 1)
Collar screw D 8x24 Collar stud for bar / engine housing 16.0
Screw P 5x16 Cover, chain brake / engine housing 4.0
M 10x1 Decompression valve 14.0
Screw P 5x16 Handlebar/plug, AV spring 3.0
Screw P 6x26.5 Handlebar / tank housing, right (polymer) 7.0
Screw P 6x26.5 Handlebar / tank housing, bottom (polymer) 7.0
Screw P 6x25 Hand guard / fan housing 8.0
Screw M 6x30 Shroud / engine housing 10.0
Screw P 6x38 Chain catcher / bearing plug 6.0
Screw P 5x16 Spiked bumper / engine housing 4.0
Screw M 4x12 Manifold/cylinder 4.0 3)
Screw P 6x21.5 Bearing plug / engine housing 6.0
Screw M 5x16 Bearing plug/cylinder 10.0 4)
Screw P 5x20 Fan housing / engine housing 4.0
Screw P 4x12 Air baffle / engine housing 2.0
Carrier M 12x1 LH Carrier / crankshaft 50.0
Screw M 6x25 Engine housing / cylinder, stage 1 4.0 3)
Screw M 6x25 Engine housing / cylinder, stage 2 12.0 3)
Screw D 4x18 Oil pump 4.0 3)
Screw M 5x16 Muffler / cylinder 10.0 1) 3)
Screw M 8x1 Flywheel/crankshaft 33.0 5)
Nut M5 Carburetor/collar stud 3.5
Screw P 4x14 Pre-separator / engine housing 2.0
Screw P 4x12 Cover plate/fan housing 2.0
Spark plug M 14x1.25 Spark plug 25.0
Screw D 4x18 Ignition module / engine pan 4.0 3)
6 MS 311, MS 391
Remarks:
1) Loctite 242 or 243, medium strength

2) Loctite 648, high strength
3) Screws with antifricton coated binding head
4) Screws with micro-encapsulated binding head
5) Degrease crankshaft/flywheel and mount oil-free
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.
Coat micro-encapsulated screws with medium-strength threadlocking adhesive before re-installing.
This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.
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.
MS 311, MS 391 7
3. Troubleshooting
3.1 Clutch
Condition Cause Remedy
Saw chain stops under load at full Clutch shoes badly worn Install new clutch
throttle
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 or install

new clutch
Loud noises Clutch springs stretched or fatigued Replace the clutch springs or install
new clutch
Needle cage damaged Fit new needle cage
Clutch shoe retainer broken Install new retainer or clutch
Clutch shoes and carrier worn Install new clutch
8 MS 311, MS 391
3.2 Chain Drive, Chain Brake, Chain Tensioner
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 Clutch shoes badly worn Install new clutch
throttle
Clutch drum badly worn Install new clutch drum
Brake band blocked Check freedom of movement and

operation of brake band

new clutch
Clutch spring hooks broken Replace the clutch springs
Saw chain does not stop Brake spring stretched or broken Fit new brake spring
immediately when brake is
activated
Brake band stretched or worn Fit new brake band
Clutch drum worn Install new clutch drum
MS 311, MS 391 9
3.3 Chain Lubrication
In the event of trouble with the

chain lubrication system, check and .
rectify other sources of faults
before disassembling the oil pump.
Chain receives no oil Oil tank empty Fill up with oil and check setting of
oil pump if necessary
Oil inlet hole in guide bar is blocked Clean oil inlet hole
Intake hose or pickup body clogged Fit new intake hose and pickup
or intake hose ruptured body
Valve in oil tank blocked Clean or replace valve
Teeth on worm worn Install new worm
Worm drive spring broken Install new worm
Oil pump damaged or worn Install new oil pump
Machine losing chain oil Oil pump body damaged Install new oil pump
Oil pump damaged or worn Install new oil pump
Oil intake hose connection Install new oil intake hose

damaged
Oil pump delivers insufficient oil Oil pump worn Install new oil pump
Worm drive spring not engaged in Engage drive spring in notch in

clutch drum clutch drum
Oil pump delivery rate set too low Adjust oil pump
(only on version with adjustable oil
pump)
10 MS 311, MS 391
3.4 Rewind Starter
Starter rope broken Rope pulled out too vigorously as Fit new starter rope
far as stop or over edge,
i.e. not vertically
Normal wear Fit new starter rope
Starter rope does not rewind Very dirty or corroded Clean or replace rewind spring
Insufficient spring tension Check rewind spring and increase

tension
Rewind spring broken Fit new rewind spring
Starter rope cannot be pulled out Spring overtensioned Check rewind spring and reduce
far enough tension
Starter rope can be pulled out Guide peg on pawl or pawl itself is Fit new pawl
almost without worn
resistance (crankshaft does not
turn)
Spring clip on pawl fatigued Fit new spring clip
Starter rope is difficult to pull or Starter mechanism is very dirty Thoroughly clean complete starter
rewinds very slowly mechanism
Lubricating oil on rewind spring Coat rewind spring with a small

becomes viscous at very low amount of standard solvent-based
outside temperatures (spring degreasant (containing no
windings stick together) chlorinated or halogenated
hydrocarbons), then pull rope
carefully several times until normal
action is restored
Decompression valve is not open Open, check and replace

decompression valve if necessary
MS 311, MS 391 11
3.5 Ignition System
Exercise extreme caution while

carrying out maintenance and
repair work on the ignition system.
The high voltages which occur can
cause serious or fatal accidents.
Engine runs roughly, misfires, Spark plug boot is loose Press boot firmly onto spark plug
temporary loss of power and fit new spring if necessary
Spark plug sooted, smeared with oil Clean the spark plug or replace if
necessary.
If sooting keeps recurring, check air
filter
Ignition lead loose in ignition Secure ignition lead properly

module
Fuel/oil mixture Use correct mixture of fuel and oil

– too much oil
Incorrect air gap between ignition Set air gap correctly

module and flywheel
Flywheel cracked or Install new flywheel

damaged or pole shoes have
turned blue
Ignition timing out of adjustment, Install new flywheel, check

flywheel warped, machined key in crankshaft stub for damage and
flywheel sheared replace crankshaft if necessary
Weak magnetization in flywheel Install new flywheel
Irregular spark Check operation of switch shaft/

contact springs and ignition
module.
Faulty insulation or break in ignition
lead or short circuit wire. Check
ignition lead/ignition module and
replace ignition module if
necessary.
Check operation of spark plug.
Clean the spark plug or replace if
necessary.
Engine housing damaged (cracks) Install new engine housing
12 MS 311, MS 391
3.6 Carburetor
Carburetor floods; engine stalls Inlet needle not sealing Remove and clean the inlet needle,
– foreign matter in valve seat or clean the carburetor
cone
Inlet needle worn Replace the inlet needle
Inlet control lever sticking on Check the inlet control lever and
spindle replace if necessary.
Helical spring not located on nipple Remove the inlet control lever and
of inlet control lever refit it correctly
Perforated disc on diaphragm is Fit a new metering diaphragm

deformed and presses constantly
against the inlet control lever
Metered diaphragm deformed Fit a new metering diaphragm
Poor acceleration Setting of low speed screw too lean Check basic carburetor setting,
correct if necessary
Setting of high speed screw too Check basic carburetor setting,

lean correct if necessary
Inlet needle sticking to valve seat Remove inlet needle, clean and
refit
Diaphragm gasket leaking Fit new diaphragm gasket
Metering diaphragm damaged or Fit a new metering diaphragm

shrunk
Tank vent faulty Replace tank vent
Leak on fuel hose from tank to Seal connections or install new fuel
carburetor hose
MS 311, MS 391 13
Engine will not idle, idle speed too Throttle shutter opened too wide by Reset idle speed screw LA
high idle speed screw LA correctly
Oil seals/engine housing leaking Seal or replace oil seals/engine

housing
Throttle shutter does not close Replace throttle shutter and shaft
Air valve does not close Replace end cover with air valve.
Engine stops while idling Idle jet bores Clean the carburetor
or ports blocked
Low speed screw too rich or Reset low speed screw L correctly
too lean
Setting of idle speed screw LA Reset idle speed screw LA

incorrect – throttle shutter correctly
completely closed
carburetor hose

new clutch
Clutch spring hooks broken Replace the clutch springs
14 MS 311, MS 391
Engine speed drops quickly under Air filter dirty Clean air filter or replace if
load – low power necessary
Throttle shutter not opened fully Check throttle cable and rod
Fuel pickup body dirty Install new pickup body
Fuel strainer dirty Clean fuel strainer in carburetor,

replace if necessary
carburetor hose
Setting of high speed screw H too Check basic carburetor setting,

rich correct if necessary
Main jet bores or ports blocked Clean the carburetor
Pump diaphragm damaged or Fit new pump diaphragm

fatigued
Ignition timing wrong, flywheel out Fit key if necessary and secure
of adjustment, key in flywheel has flywheel properly or install new
sheared off flywheel
Engine running extremely rich, has Air valve does not open Check the carburetor and service
no power and a very low maximum or replace if necessary.
speed
Engine running too rich, loss of Air valve does not open fully in full Check the carburetor and service
power and maximum speed too low throttle position or replace if necessary.
Erratic idle – too lean Air valve does not close completely Check the end cover with air valve
and replace if necessary
Intake manifold faulty Install new intake manifold
MS 311, MS 391 15
3.7 Engine
Always check and, if necessary,

repair the following parts before
looking for faults on the engine:
- Air filter
- Fuel system
- Carburetor
- Ignition system
Engine does not start easily, stalls Oil seals in engine housing Replace the oil seals
at idle speed, but operates normally damaged
at full throttle
Engine housing leaking/ Seal or replace the engine housing

damaged (cracks)
Engine does not deliver full power Piston rings worn or broken Fit new piston rings
or runs erratically
Muffler / spark arresting screen Clean the muffler (inlet and

carbonized exhaust), replace spark arresting
screen, replace muffler if necessary
Air filter dirty Replace air filter
Fuel/impulse hose severely kinked Fit new hoses or position them free
or damaged from kinks
Decompression valve is not closed Close, check and replace

decompression valve if necessary
Engine overheating Insufficient cylinder cooling. Air Thoroughly clean all cooling air
inlets in fan housing blocked or openings and the cylinder fins
cooling fins on cylinder very dirty
16 MS 311, MS 391
4. Clutch
– Troubleshooting, b 3.1
1
– Remove the shroud, b 6.4.
1
– Remove the clutch drum, b 4.1
4903RA106 TG
4903RA005 TG
: The locking strip (1) – Pull the clutch shoes off the
0000 893 5903 must butt against carrier.
the cylinder wall (arrow) as
shown. : Remove the retainers (1).
4903RA001 TG
: Pull boot (1) off the spark plug.
– Unscrew the spark plug.
1
4903RA003 TG
4903RA006 TG
1 : Apply wrench to hexagon (arrow) – Clean all parts, b 14
and unscrew the clutch (1).
– Replace any damaged parts.
4903RA002 TG
Note that the clutch has a left-hand

thread.
If the clutch is noticeably worn,
replace all three clutch shoes at the
: Push the locking strip (1) same time – not individual shoes –
Disassembling
0000 893 5903 into the spark since runout may otherwise affect
plug hole, wide end first, so that correct operation of the clutch.
"OBEN-TOP" faces up. 1 2
4903RA004 TG
: Use hook (2) 5910 890 2800 to

remove the clutch springs (1).
MS 311, MS 391 17
1 2
1 1
4903RA007 TG
4903RA010 TG
4903RA012 TG
: Fit the retainers (1). Attach the springs (1) on the side Make sure the washer (1) is in
with the raised hexagon (arrow). place.
: Attach one end of each spring (1) Installed position is correct when
1 2 to the clutch shoes. TOP (arrow) faces outwards.
: Use the hook (2) 5910 890 2800

to attach the other ends of the
springs and press them firmly into
the clutch shoes.
4903RA008 TG
4903RA013 TG
: Fit the clutch shoes (2) over the
arms (1).
: Position the clutch on the

crankshaft stub so that the raised
4903RA011 TG
hexagon (arrow) faces outwards.
: Check the clutch – all springs

(arrows) must be properly
attached.
4903RA009 TG
: Clamp the clutch in a

vise (arrow).
18 MS 311, MS 391
4.1 Clutch Drum
– Remove and install the clutch

drum, see instruction manual.
1
4903RA014 TG
: Screw the clutch (1) on to the
crankshaft stub and tighten down
the hexagon (arrow) firmly – left-
4903RA015 TG
hand thread.
– Remove the locking strip from the

cylinder.
: Pull off the needle cage (1).
– Reassemble all other parts in the

– Clean the needle cage and
reverse sequence.
crankshaft stub, b 14
– Lubricate the needle cage and

crankshaft stub, b 14
100%
165RA029 TG
80% !
– Inspect the clutch drum (1) for

signs of wear.
If there are signs of serious wear on

the inside diameter of the clutch
drum (1), check the remaining wall
thickness. If it is less than about
80% of the original thickness, install
a new clutch drum.
– Install the clutch drum.
MS 311, MS 391 19
5. Chain Brake
5.1 Checking Operation 5.2 Brake Band
The chain brake is one of the most – Remove the clutch drum, b 4.1
important safety devices on the 1
machine. Its efficiency is measured – Troubleshooting, b 3.2
in terms of the chain braking time,
i.e. the time that elapses between
activating the brake and the saw
4903RA018 TG
chain coming to a complete 1
standstill.
Contamination (with chain oil, – Engage the chain brake.

chips, fine particles of abrasion,
etc.) and smoothing of the friction
The brake band is now tensioned.
surfaces of the brake band and
clutch drum impair the coefficient of
4903RA016 TG
friction, which prolongs the braking : Remove the screw (1) from the
time. A fatigued or stretched brake underside of the machine.
spring has the same negative effect.
: Pull off the bumper strip (1).
– Starting the engine
– With the chain brake

activated (locked), open the 1 1
throttle wide for a brief
period (max. 3 seconds) – the
chain must not rotate.
4903RA019 TG
– With the chain brake released,
open the throttle wide and
4903RA017 TG
activate the brake manually – the

chain must come to an abrupt : Pry the brake band (1) out of its
stop. seat (arrow).
: Take out the screws (arrows).
The braking time is in order if – Remove the brake band (1).
deceleration of the saw chain (less
than a second) is imperceptible to – Remove the cover (1).
Do not overstretch the brake band.
the eye.
– Pull the hand guard towards the
If the chain brake does not operate handlebar to simplify assembly of
properly, refer to troubleshooting, the brake band.
b 3.2.
20 MS 311, MS 391
2
1
1
4903RA020 TG
4903RA022 TG
4903RA018 TG
: Turn the brake band (1) to one : Position the brake band (1) it the : Fit the screw (1) on the underside
side and disconnect it from the guide (arrow) first. of the machine and tighten it
brake lever (2). down firmly.
– Disengage the chain brake.
4903RA025 TG
219RA049 TG
4903RA023 TG
1 1
Install a new brake band if there are : Engage the cover (1) in the slots
noticeable signs of wear (large : Push the brake band (1) over the (arrows) first and then swing it
areas on inside diameter and/or guide lugs (arrows) and into its into position.
parts of outside diameter – arrows) seat.
and its remaining thickness is less
than 0.6 mm.
Installing
1
2
1
4903RA024 TG
4903RA021 TG
: Push the brake band (1) into its

seat (arrow) as far as stop.
: Hold the brake band (1)

sideways, attach it to the brake
lever (2) and then swing it in the
direction of its seat.
MS 311, MS 391 21
5.3 Brake Lever
1
4903RA026 TG
4903RA029 TG
4903RA027 TG
: Insert the screws (arrows) and : Remove the E-clip (1).
tighten them down firmly.
– Troubleshooting, b 3
– Fit the bumper strip.
1
– Remove the brake band, b 5.2
– Install the clutch drum, b 4.1
– Engage the chain brake.
– Check operation, b 5.1
The brake spring is now relaxed.
2
4903RA030 TG
reverse sequence. : Use the assembly tool
1117 890 0900 to disconnect the
brake spring (1) from the anchor
pin (arrow).
: Lift and turn the strap (1) slightly,
push it towards the hole (arrow)
– Remove the brake spring from
and remove it.
the brake lever.
: Remove the spacer sleeve (2)

from the brake lever.
1
4903RA119 TG
4903RA031 TG
– Remove the shroud, b 6.4

: Pull the hand guard (1) and brake
lever (2) off the pivot pins
– Remove the sleeve (1). (arrows) together.
– Lift the hand guard a little and – Remove the hand guard and
remove the fan housing. brake lever.
22 MS 311, MS 391
1 2 1
4903RA032 TG
4903RA034 TG
4903RA272 TG
: Take the brake lever (2) out of the : Push the hand guard with brake : Fit the spacer sleeve (1).
hand guard (1). lever (1) over the machine until
they are positioned against the
– Inspect the pivot pins and replace pivot pins (arrows).
if necessary, b 5.5 1
– Inspect the cam lever and

replace if necessary, b 5.4
2
Installing
4903RA037 TG
1
4903RA035 TG
– Fit the strap (1).
: Fit the E-clip (2).

: Lift the bearing boss of the hand
guard and the brake lever a little
and position them over the pivot
4903RA033 TG
pins (arrows).
– Clean all disassembled parts,

b 14
: Hold the brake lever (1) so that

the brake spring attachment point
(arrow) is at the top.
1
4903RA036 TG
: Push the brake lever (1) into the

hand guard recess and line up
the holes.
: Turn the cam lever (1) to one side

until the cam of the hand
guard (arrow) slips passed it.
– Push the hand guard bearing

boss and the brake lever on to
the pivot pins.
MS 311, MS 391 23
2
4903RA038 TG
1
4903RA040 TG
4903RA042 TG
1
The turns of brake spring must be : Check the cam lever (1) and : Fit the E-clip (1).
tightly against one another in the spring (2) and replace if
relaxed condition. If this is not the necessary.
case, replace the brake spring.
: Check the condition of the cam 2
– Position the protective tube so contour (arrow) and replace the
that it leaves the first two hand guard if necessary.
turns (arrow) free.
1
– If the groove in the spring's Installing
anchor pin is worn, install a new
4903RA043 TG
pin, b 5.5
3 1
5.4 Cam Lever

: Attach the spring (1) to the cam
lever so that the open side of the
The cam lever defines the locked spring hook (arrow) points away
position of the hand guard. from the housing.
4903RA041 TG
– Remove the brake lever, b 5.3 2

If the groove in the spring's anchor
pin is worn, install a new pin, b 5.5
– Position the cam lever (1) so that : Attach the spring (1) to the
its cam (arrow) faces the pin (3). anchor pin (2).
2
1
: Push the cam lever (1) on to the The cam lever is not yet under
pivot pin (2). tension – the spring may become
detached.

4903RA039 TG
3 reverse sequence.
– Lubricate the cam lever, b 14

: Disconnect the spring (1) from
the anchor pin (2).
: Remove the E-clip (3).
– Pull off the cam lever.
24 MS 311, MS 391
5.5 Pins Turn pin back and forth as
necessary.
a
The anchor pins secure the springs. 3
Worn pins must be replaced – the
springs may otherwise become 5
2 1
detached and pop out.
c
The pins must be driven home 4
4903RA049 TG
squarely.
b
For greater clarity, all parts have
been removed from the pins in the
4903RA046 TG
: Pin (3) a = about 11.6 - 11.8 mm
following illustrations. Pin (4) b = about 4.6 - 4.8 mm
Pin (5) c = about 9.1 - 9.3 mm
2 3 1 5 : Drive home the pins (1 and 2) as

shown in the illustrations. 5.6 Chain Tensioner
4 a
4903RA044 TG
2
1
2
: Use suitable tool to remove the
4903RA047 TG
pins (1 - 5).
b
3
4903RA050 TG
Installing : Pin (1) a = about 2.9 - 3.3 mm
1
Pin (2) b = about 4.3 - 4.7 mm
: Turn the spur gear (2) clockwise
until the tensioner slide (1) butts
3 5 against the right-hand end and
the screw (3) is visible.
: Take out the screw (3).

4903RA045 TG
4903RA048 TG
4
– Before installing the new pin, coat
its knurled shank with
threadlocking adhesive, b 14
: Drive home pins (3, 4 and 5) as
specified below.
: Position the new pin in the
bore (arrow) so that the knurling
on the pin meshes with the
existing knurling in the bore.
MS 311, MS 391 25
5.7 Bar Mounting Studs
1 2
2 2
4903RA052 TG
4903RA054 TG
: Pull out the spur gear (1) and 1
tensioner slide (2).
: Push stud puller 5910 893 0501
(1) over the collar studs (2) as far
as it will go and unscrew the
2 2 4 studs counterclockwise.
1 2
533RA058 TG
1 3
– Inspect the thrust pad (3),

4903RA055 TG
support (4), tensioner slide (1),

spur gear set (2) and replace as
necessary.
: Before installing, coat threads (1)
– Clean all disassembled parts, and (2) of collar studs with
b 14 threadlocking adhesive, b 14
– Lubricate thread with STIHL – Fit the collar studs and tighten
multipurpose grease, b 14 them down firmly.
– Reassemble in the reverse – Reassemble all other parts in the

sequence. reverse sequence.
26 MS 311, MS 391
6. Engine
6.1 Muffler
1
Always check and, if necessary,
repair the fuel system, carburetor,
air filter and ignition system before
looking for faults on the engine.
0001RA076 TG
0001RA080 TG
– Remove the shroud, b 6.4 1
Before removing the muffler, set the : Remove the exhaust gasket (1). – Position the exhaust gasket (1)
piston to top dead center to ensure so that the warts (arrows) point
that no dirt falls into the cylinder. – Remove and install the spark towards the cylinder.
arresting screen – see instruction
manual. : Fit the exhaust gasket (1) and
line it up with the warts (arrows)
1 1 against the cylinder exhaust port.
Installing
2 2
4903RA056 TG
1
: Pry the plug (1) out of the drive
0001RA079 TG
0001RA081 TG
tube.
– Do not refit old plugs, always fit
new ones.
– Hold the machine upright. : Carefully place the muffler (1) in
position.
1 1 : Inspect and clean the sealing
faces (arrows) and remove any : Check the position of the gasket
gasket residue. and fit the screws (2).
2
Always replace components with – Fit and tighten down the screws
damaged sealing faces. (2) firmly.
4903RA057 TG
– Fit new plugs.
: Take out the screws (1).
: Remove the muffler (2).
MS 311, MS 391 27
6.2 Leakage Test 6.2.1 Preparations
1 1
Defective oil seals and gaskets or
cracks in castings are the usual 1
causes of leaks. Such faults allow
supplementary air to enter the
engine and upset the fuel-air
mixture.
4903RA053 TG
This makes adjustment of the
0001RA083 TG
prescribed idle speed difficult, if not
impossible. – Pry out the plugs.
2
– Do not refit old plugs, always fit
Moreover, the transition from idle new ones.
speed to part or full throttle is not – Remove the shroud, b 6.4
smooth.
– Pull off the boot and unscrew the : Loosen the screws (1).
Always perform the vacuum test spark plug.
first and then the pressure test.
– Set the piston to top dead center.
The engine can be checked This can be checked through the
thoroughly for leaks with the pump spark plug hole.
0000 850 1300. 1
– Remove the decompression
valve, b 6.9
0001RA085 TG
: Fit the plug (1) 1122 025 2200
and tighten it down firmly.
: Fit the spark plug (2) and tighten

: Fit the sealing plate (1)
it down firmly.
0000 855 8107 between the
cylinder exhaust port and muffler
and tighten down the screws
moderately.
The sealing plate must completely

fill the space between the two
screws.
– Remove the carburetor, b 12.5
28 MS 311, MS 391
2 4 3 2
3
1
4903RA225 TG
4903RA238 TG
4903RA239 TG
1 2 1
: Check that the sleeve (1) and : Connect suction hose (1) of : Push ring (1) to the right.
washer (2) are in place. pump 0000 850 1300 to the
nipple (arrow). : Operate the lever (2) until the
pressure gauge (3) indicates a
: Push ring (2) to the left. pressure of 0.5 bar. If this
2 pressure remains constant for at
: Operate the lever (3) until the least 20 seconds, the engine
pressure gauge (4) indicates a housing is airtight.
vacuum of 0.5 bar.
1 – If the pressure drops, the leak
If the vacuum reading remains must be located and the faulty
constant, or rises to no more than part replaced.
4903RA237 TG
2 0.3 bar within 20 seconds, it can be

assumed that the oil seals are in To find the leak, coat the suspect
good condition. However, if the area with oil and pressurize the
– Line up the flange (1) pressure continues to rise (reduced engine housing again. Bubbles will
1140 890 1200 and fit it over the vacuum in the engine), the oil seals appear if a leak exists.
studs must be replaced, b 6.3.
– After finishing the test, push the
– After finishing the test, push the ring to the left to vent the pump –
: Fit the test flange (1)
ring to the right to vent the pump. disconnect the hose.
1140 890 1200.
– Continue with pressure test, – Remove the flange.

: Fit the nuts (2) and tighten them
b 6.2.3
down firmly.
– Loosen the screws on the muffler
and pull out the sealing plate.
6.2.3 Pressure Test
6.2.2 Vacuum Test
– Tighten down muffler screws
Carry out the same preparations as firmly and fit new plugs.
Oil seals tend to fail when subjected
for the vacuum test, b 6.2.2
to a vacuum, i.e. the sealing lip lifts
away from the crankshaft during the – Install the carburetor, b 12.5
piston's induction stroke because
there is no internal counterpressure. – Reassemble all other parts in the
reverse sequence.
A test can be carried out with pump
0000 850 1300 to detect this kind of
fault.
MS 311, MS 391 29
6.3 Oil Seals : Apply puller (1) 5910 890 4400 Degrease the crankshaft taper,
with No. 3.1 jaws 0000 893 3706. b 14
– Clamp the puller arms. – Reassemble all other parts in the

reverse sequence.
– Pull out the oil seal.
2 Clutch side
Take care not to damage the
crankshaft stub.
– Remove the clutch, b 4
4903RA275 TG
1 – Clean the sealing face, b 14

– Remove the oil pump, b 11.3
– Lubricate sealing lips of new oil
Use oil seal (1) 9638 003 1581 for seal with grease, b 14
replacement on closed engine.
Use oil seal (2) 9639 003 1585 for
replacement on opened engine. Installing
It is not necessary to disassemble 1

the engine to replace the oil seals. 1
4903RA063 TG
Ignition side
– Remove the fan housing, b 8.2

2
: Remove the E-clip (1).
4903RA062 TG
– Remove the flywheel, b 7.6
1 – Slip the oil seal, open side (snap

ring) facing outwards, over the
crankshaft stub.
: Use press sleeve (2)

1122 893 2405 to install the oil
seal (1).
4903RA061 TG
The seating face must be flat and

free from burrs.
– Free off the oil seal in its seat by – Wait about one minute, then
tapping it with a suitable tube or a rotate the crankshaft several
punch. times.
30 MS 311, MS 391
Installing
1
1 1
4903RA064 TG
4903RA067 TG
4903RA065 TG
– Free off the oil seal in its seat by : Fit the E-clip (1).
tapping it with a suitable tube or a
punch. : Fit the installing sleeve (1) – Wait about one minute, then
1122 893 4600. rotate the crankshaft several
: Apply puller (1) 5910 890 4400 times.
with No. 3.1 jaws 0000 893 3706. – Slip the oil seal, open side (snap
ring) facing outwards, over the – Reassemble all other parts in the
– Clamp the puller arms. installing sleeve. reverse sequence.
– Pull out the oil seal. – Remove the installing sleeve (1).
6.4 Shroud
The crankshaft stub and oil pump
spur gear must not be damaged. – Set the Master Control lever to
2
"0".
– Clean the sealing face, b 14
– Push the front hand guard
– Lubricate sealing lips of new oil 1 forwards to engage the chain
seal with grease, b 14 brake.
4903RA276 TG
: Use press sleeve (1)

1122 893 2405 to install the oil 1
seal (2).
The seating face must be flat and

free from burrs. 4903RA068 TG
: Remove the shroud (1).
MS 311, MS 391 31
6.5 Cylinder / Crankshaft
1
1
– Pull off the boot and unscrew the
spark plug,
4903RA069 TG
4903RA073 TG
– Remove the filter base, b 12.3

: Use a suitable drift (1) to drive out : Use the lug (arrow) to pry the
the screws (arrow). – Remove the carburetor, b 12.5 cylinder (1) upwards.
– Remove the manifold, b 12.9 – Remove the cylinder with

Installing crankshaft.
– Remove the muffler, b 6.1
– Remove the decompression

2 valve, b 6.9
– Remove AV spring from 1

handlebar, b 9.4
1
4903RA071 TG
4903RA074 TG
: Use a suitable drift (2) to drive
home the screws (1). : Pull the crankshaft (1) out of the
bearing seats (arrows).
– Reassemble in the reverse
sequence. : Carefully pull the crankshaft (1)
4903RA072 TG
with piston out of the cylinder.
– Check the crankshaft and ball

: Take out the screws (arrows). bearings and replace if
necessary, b 6.6
– Inspect the piston and piston

rings and replace if necessary,
b 6.7, b 6.8
32 MS 311, MS 391
1
4903RA081 TG
533RA098 TG
533RA107 TG
1
: Remove the E-clip (1). – Inspect and clean the sealing : Fit the installing sleeve (1)
faces (arrows) and remove any 1118 893 4602.
gasket residue, b 14
: Push the new oil seals, open side
The sealing faces must be in perfect facing inwards, on to the
condition. Always replace crankshaft stubs.
components with damaged sealing
faces.
1
Installing
533RA099 TG
: Pull the oil seals (arrows) off the

crankshaft stubs.
533RA098 TG
2
4903RA275 TG
1 : Fit the E-clip (1).
Use oil seal (1) 9638 003 1581 for

replacement on closed engine.
Use oil seal (2) 9639 003 1585 for
replacement on opened engine.
MS 311, MS 391 33
1
4903RA076 TG
4903RA078 TG
533RA104 TG
– Lubricate the piston, piston rings When properly aligned, the piston – Inspect and clean the sealing
and cylinder wall with oil. rings are compressed by the face on the engine housing and
cylinder's taper. remove any gasket residue,
: Position the piston rings so that b 14
the radii at the ring gap meet at : Carefully push the piston with
the fixing pin in the piston groove crankshaft (1) into the cylinder. The sealing faces must be in perfect
(arrows) – there is otherwise a condition. Always replace
risk of ring breakage. components with damaged sealing
faces.
: Apply sealant to the groove in the

sealing face, b 14
1
4903RA090 TG
4903RA075 TG
2
– Place the crankshaft with
bearings and oil seals in the
bearing seats, making sure the oil
4903RA079 TG
– Line up the piston with crankshaft
before fitting them in the cylinder. seals are firmly against their
stops (arrows) in the cylinder. 1
Viewed from the exhaust
port (arrow), the long crankshaft – Hold the crankshaft (1) steady.
stub (1) must be on the right.
: Fit the cylinder (2) with
crankshaft (1) in the engine
housing.
34 MS 311, MS 391
1 1
4903RA072 TG
4903RA083 TG
4903RA085 TG
: Fit the screws (arrows). : Pull the ball bearing (1) off the – Heat the bearing inner race to
straight crankshaft stub. about 150°C (300°F).
: Tighten down the screws
(arrows) in an alternate pattern. : Push the ball bearing onto the
straight crankshaft stub as far as
– Reassemble all other parts in the stop.
reverse sequence.
2
6.6 Bearings / Crankshaft

1
4903RA084 TG
– Remove the cylinder, b 6.5
1
– Remove the crankshaft and pull
off the oil seals, b 6.5
: The crankshaft (1), connecting
4903RA086 TG
rod (2) and needle bearing form
– Remove the piston, b 6.7 an inseparable unit.
When fitting a replacement – Heat the bearing inner race to

crankshaft, always install new ball about 150°C (300°F).
bearings and oil seals.
: Push the ball bearing onto the
Before installing, clean the tapered crankshaft stub as far as
crankshaft, b 14 stop.
1
Heated ball bearings must be
– Lubricate the needle bearing with
installed quickly because the
4903RA082 TG
oil.
crankshaft stubs absorb heat and
expand.
– Install the piston, b 6.7
: Pull the ball bearing (1) off the
– Install the crankshaft and oil
tapered crankshaft stub.
seals, b 6.5
MS 311, MS 391 35
6.7 Piston If the piston pin is stuck, release it
by tapping the end of the drift lightly 1
with a hammer.
– Remove the cylinder, b 6.5
Hold the piston steady during this
process to ensure that no jolts are
The snap ring at the clutch side transmitted to the connecting rod.
cannot be removed.
– Remove the piston.
533RA125 TG
– Inspect the piston rings and
: Push the assembly drift (1)
1108 893 4700, small diameter
first, through the piston and small
end (needle cage) and line up the
piston.
4903RA087 TG
1 2
: At the ignition side, use a suitable
4903RA252 TG
tool at the recess (arrow) to
remove the hookless snap ring
from the piston boss. 1
: Pull out the needle cage (1),

check it and replace if necessary,
533RA126 TG
1 b 14
Installing – Lubricate the piston pin (2) with

oil.
1
: Fit the piston pin (2) on the
533RA121 TG
assembly drift (1) and slide it into

the piston.
: Push the assembly drift (1)

1108 893 4700 through the
4903RA088 TG
installed snap ring.
: Use the assembly drift (1)

1108 893 4700 to push the piston
– Lubricate the needle cage with oil
pin out of the piston.
and push it into the connecting
rod.
0001RA481 TG
– Position the piston as shown so 2 1

that the mark (arrow) points to
the rear and the long crankshaft
: Remove the sleeve (1) from the
stub (1) is on the right.
installing tool (2) 5910 890 2212.
– Place the piston on the

connecting rod.
36 MS 311, MS 391
0001RA483 TG
4903RA089 TG
165RA153 TG
2 1
: Attach the snap ring (1) to the : Press the installing tool : Apply the installing tool
magnet (2) so that the snap ring downwards into the sleeve until 5910 890 2212 with the sleeve’s
gap is on the flat side of the tool's the magnet butts against the end taper against the piston boss,
shank (arrow). of the guide slot. hold the piston steady, center the
tool shank exactly and press
Use a suitable base. home until the snap ring slips into
the groove.
2 1
Make sure the tool shank is held
square on the piston pin axis.
0001RA482 TG
216RA178 TG
: Push the large slotted diameter of

the sleeve over the magnet and 1
0001RA329 TG
snap ring. : Remove the sleeve and slip it
onto the other end of the shank –
The inner pin (1) must point towards the inner pin must point towards
the flat face (2) of the tool's shank. the flat face.
Fit the snap ring (1) so that its
gap (arrow) points either up or
down.
MS 311, MS 391 37
6.9 Decompression Valve
533RA136 TG
533RA134 TG
4903RA091 TG
– Inspect the piston rings and : Install the new piston rings in the 1
replace if necessary, b 6.8 grooves so that the radii face
upward (arrows).
– Check the oil seals and ball
bearings and replace if : Unscrew the decompression
necessary, b 6.5 valve (1).
– Install the cylinder, b 6.5

reverse sequence. 533RA137 TG
6.8 Piston Rings
– Remove the piston, b 6.7
165RA164 TG
: Position the piston rings so that
the radii at the ring gap meet at
– Remove the piston rings from the the fixing pin in the piston
piston. groove (arrows).
: Check the sealing cone (arrow)
on the decompression valve for
: Check correct installed position damage.
of the piston rings (arrows).
– If the sealing cone does not close
– Install the piston, b 6.7
completely or shows signs of
damage, install a new
– Reassemble all other parts in the decompression valve.
reverse sequence.
– Fit the decompression valve and
533RA135 TG
tighten it down firmly.

: Use a piece of old piston ring to reverse sequence.
scrape the grooves (arrows)
clean.
38 MS 311, MS 391
7. Ignition System
Exercise extreme caution when 7.2 Preseparator Testing in the workshop is limited to
troubleshooting and carrying out a spark test. A new ignition module
maintenance or repair work on the must be installed if no ignition spark
ignition system. The high voltages is obtained (after checking that
which occur can cause serious or wiring and stop switch are in good
fatal accidents.
2 condition).
Troubleshooting on the ignition

system should always begin at the 1 Removing
spark plug, b 2.3
– Remove the shroud and pull off
4903RA254 TG
– Remove the fan housing, b 8.2 the spark plug boot, b 6.4

1 – Remove the preseparator, b 7.2
: Remove the preseparator (2).

1
2
4903RA253 TG
sequence.
7.3 Ignition Module

The electronic (breakerless) ignition
4903RA215 TG
system basically consists of an
ignition module (1) and flywheel (2).
1
: Pull the ignition lead (1) out of the
7.1 Ignition Timing
cable channel (arrows).
Ignition timing is fixed and cannot

be adjusted during repair work.
4903RA092 TG
3
Since there is no mechanical wear
in these systems, ignition timing 2
cannot get out of adjustment during
operation. The ignition module accommodates
all the components required to
control ignition timing. There are 2 2
two electrical connections on the
4903RA255 TG
coil body:
1
– High voltage output (1) with
ignition lead : Disconnect the short circuit
wire (1).
– The connector tag (2) for the
short circuit wire : Take out the screws (2).
: Remove the ground wire (3).
– Remove the ignition module.
MS 311, MS 391 39
– Check operation – rotate the
3 4 2 flywheel and make sure it does
not touch the ignition module.
1
4903RA273 TG
4903RA095 TG
1
The ignition module (1) and ignition : Push the ignition module back
lead (2) form a unit. and slide the setting gauge (1)
4903RA259 TG
1111 890 6400 between the
– Before installing, check that the arms of the ignition module and 1
sleeve (4) is on the ignition the flywheel magnet.
lead (2) and its opening (arrow) is : Connect the short circuit wire
pointing in the same direction as terminal (1) – the terminal must
the spark plug boot. be pushed fully home.
– Inspect the spark plug boot (3)

and replace if necessary, b 7.5
1
4903RA258 TG
Installing
4903RA097 TG
1 The setting gauge is not shown in
the illustration.
– Push the ignition module (1) back : Starting at the ignition module,
3 and hold it there push the ignition lead into the
cable channel.
– the flywheel must move freely.
4903RA256 TG
2 : Rotate the flywheel until the

magnet poles (arrows) are next to
: Fit the ignition module (1) and the ignition module (1).
insert the screw (arrow)
– do not tighten down yet. – Press the ignition module (1)
against the setting gauge.
: Fit the ground wire (3) and insert
the screw (2) – do not tighten Hold the ground wire terminal
down yet. steady – it must point towards the
cable guide.
Crimped side of terminal must face
the screw head. – Tighten down the screws firmly.
– Remove the setting gauge.
40 MS 311, MS 391
Using the ZAT 4 ignition tester Using the ZAT 3 ignition tester
1 5910 850 4503 5910 850 4520
2
a
4903RA277 TG
1
165RA183 TG
165RA184 TG
: Fit the boot (1) on the spark plug.
1 2 3 2 3 4
: Line up the sleeve (2) – distance
'a' about 3 mm to the edge of the – Before starting the test, install a – Before starting the test, install a
housing and its open side (arrow) new spark plug in the cylinder new spark plug in the cylinder
facing the cylinder. and tighten it down firmly. and tighten it down firmly.
– Reassemble all other parts in the : Connect the spark plug boot to : Connect spark plug boot to the
reverse sequence. the input terminal (1) and push terminal (2).
the tester's output terminal (3)
onto the spark plug. : Attach the ground terminal (1) to
7.4 Testing the Ignition the spark plug.
Module High voltage – risk of electric shock.
: Use adjusting knob (4) to set the
– Crank the engine quickly with the spark gap to about 2 mm,
To test the ignition module, use rewind starter and check spark in see window (3).
either the ZAT 4 ignition system the tester’s window (2).
tester 5910 850 4503 or the ZAT 3
ignition system tester
The engine may start and
5910 850 4520.
accelerate during the test.
The ignition test refers only to a
If a spark is visible, the ignition
spark test, not to ignition timing.
system is in order.
– If no spark is visible in the

window (2), check the ignition
system with the aid of the
troubleshooting chart, b 7.8
MS 311, MS 391 41
7.5 Spark Plug Boot / Installing
Ignition Lead
Do not shorten the ignition lead.
5
The ignition module (1) and ignition
lead (2) form a unit. A new ignition
module must be installed if the
1 ignition lead is damaged.
165RA185 TG
2 3 4
While using the ZAT 3, hold it only

by the handle (4) or position it in a
165RA188 TG
safe place. Keep fingers or other
parts of your body at least 1 cm
away from the spark window (3),
high voltage connection (2), ground – Use a pointed tool to pierce the
4903RA227 TG
connection (5) and the ground center of the new ignition lead’s
terminal (1). insulation, about 15 mm from the
end of the lead.
High voltage – risk of electric shock.
: Pinch the hook of the leg spring
– Crank the engine quickly with the into the pierced hole in the center
rewind starter and check spark in : Use suitable pliers to pull the leg
of the lead (arrow).
the tester’s window (3). spring out of the spark plug boot.
The engine may start and – Unhook the leg spring from the
accelerate during the test. ignition lead.
If a spark is visible in the window (3), – Pull the boot off the ignition lead.
the ignition system is in order.
– Remove the sleeve.
– If no spark is visible in the
window (3), check the ignition
system with the aid of the
4903RA228 TG
troubleshooting chart, b 7.8
– Coat the inside of the spark plug

boot with
STIHL press fluid, b 14
: Hold the ignition lead and leg

spring together and push them
into the spark plug boot.
42 MS 311, MS 391
2
1
1
0001RA165 TG
0001RA168 TG
4903RA229 TG
3
: Make sure the leg spring (arrow) : Fit the puller (3) 1135 890 4500 Make sure the key (arrow) engages
locates properly inside the spark on the flywheel and tighten the the slot in the crankshaft.
plug boot. screws (1) as far as stop.
– Tighten the screws uniformly. – Set the air gap between the
Do not use either graphite grease or ignition module and flywheel,
silicone insulating paste. : Screw home the thrust bolt (2) b 7.3
clockwise until the flywheel is
– Reassemble all other parts in the released from the crankshaft. – Reassemble all other parts in the
reverse sequence. reverse sequence.
– Remove the puller (3)
1135 890 4500 from the flywheel.
7.6 Flywheel
– Use locking strip to block the

piston, b 4
0001RA167 TG
1
The flywheel and magnet poles
(arrows) must not be damaged or
have turned blue. Replace flywheel
0001RA165 TG
if necessary.
The flywheel and crankshaft stub

must be free from grease before
: Unscrew the flywheel nut (1). assembly.
MS 311, MS 391 43
7.7 Short Circuit Wire 7.7.2 Removing and Installing
2
7.7.1 Testing
– Pull the boot off the spark plug.
2 – Remove the shroud, b 6.4
4903RA101 TG
– Disconnect the choke rod, 1
b 10.2.1
4903RA263 TG
: Pull the short circuit wire (1) out

– Remove the contact spring, of the guides (arrows).
1 b 7.7.4
– Pull the ring terminal (2) off the
If the spark plug, ignition lead and The ground and short circuit wires pin.
spark plug boot are in order, check are combined in a wiring harness.
the short circuit wire.
: Disconnect the short circuit

wire (1). 3
1
– Connect the ohmmeter to
ground (2) and the short circuit
4903RA102 TG
wire (1). 2
4903RA099 TG
1 2
– Set the Master Control lever to
"0".
: Lift the ring terminal (1) a little
: Pull the ignition lead (3) out of the
and pull it off the pin (2) .
The resistance measured must be guide (arrows).
about 0 Ω. If it is much higher, the
reason is a break and the wiring – Remove the filter base, b 12.3
: Remove the connector (1).
harness has to be replaced, b 7.7.
: Take out the screw and remove
– Set the Master Control lever to the ground wire (2).
"F". 1
The resistance measured must be

infinitely high. If not, fit a new short
circuit wire, b 7.7.
1
Perform the contact and continuity
4903RA264 TG
test on the ground wire too.
– If no fault can be found, check the

ignition system with the aid of the
4903RA100 TG
: Pull the short circuit wire (1) out

troubleshooting chart, b 7.8. of the guides (arrows).

sequence. : Pull the wiring harness (1) out of
the guides (arrows).
44 MS 311, MS 391
Installing Position the short circuit wire so that
1 it forms a loop and can move along
with the switch shaft.
4903RA103 TG
1
4903RA104 TG
The wire must be laid straight and fit
4903RA109 TG
snugly against the housing.
: Position the short circuit wire so
that the yellow mark lines up with : Push the short circuit wire (1) into
the edge (arrow). the guides (arrows).
: Check that short circuit wire is
– Push the wiring harness (1) into properly seated, push it fully into
the guide. the guide (arrow) if necessary.
1
1
4903RA107 TG 1
4903RA110 TG
4903RA105 TG
– Install the filter base, b 12.3

2
– Position the ring terminal (1) so
: Position the protective tube (2) that its crimped side faces up. – Position the ring terminal (1) so
so that it is in line with the yellow that its crimped side faces up.
mark (arrow). : Push the ring terminal (1) onto
the pin (arrow) as far as stop. : Fit the ring terminal (1) of the
: Push the protective tube (2) with ground wire on the pin (2) and
short circuit wire (1) into the swing it down.
guide (centered as shown).
4903RA261 TG
: Push the short circuit wire (1) into

the guides (arrows).
MS 311, MS 391 45
7.7.3 Ground Wire
A faulty ground wire may impair or

prevent operation of the short circuit
1 wire.
The ground wire is combined with

4903RA111 TG the short circuit wire in a wiring
4903RA114 TG
harness. If damaged, the wiring
2 harness must be replaced 1
: The ring terminal (1) must locate – Check for contact and continuity : Lift the contact spring (1) over the
behind the lug (2). and lug (arrow) and pull it out.
replace the wiring harness,
b 7.7
– Check the ground wire ring
terminal and replace it if
1 necessary, b 7.7.3
7.7.4 Contact Spring
– Remove the shroud, b 6.4 Installing
– Remove the choke rod,

b 10.2.1
4903RA112 TG
– Fit the contact spring, b 7.7.4 2
4903RA115 TG
: Push the ground wire (1) into the
guide (arrow).
1
– Install the ignition lead, b 7.3
– Place the contact spring (1) in
4903RA113 TG
position at a slight angle.

– Reconnect the choke rod,
b 10.2.1 1
: Push the contact spring (1) onto
: Move the switch shaft (1) the pins (arrows) as far as stop.
reverse sequence. towards the tank housing until the
contact spring (2) is free.
46 MS 311, MS 391
4903RA116 TG
Make sure the lug (arrow) locks the
contact spring in position.
1
4903RA117 TG
: Lift the contact spring (1) and

push it over the switch shaft.
4903RA118 TG
: Check operation.
– short circuit wire's connector
must touch the contact spring
(arrow) in position "0".

reverse sequence.
MS 311, MS 391 47
7.8 Ignition System Troubleshooting
Machine does not run
Stop switch:
– in position "F"?
Check the spark plug:

– Smeared with oil, black?
– Sooted?
– Electrode gap correct?
– Contacts shorted?
– Clean, readjust or replace the plug, b 7.4
Check the spark plug boot:

– Firmly seated on plug (leg spring)?
– Leg spring hook in center of ignition lead?
– Boot damaged?
– If necessary, install new spark plug boot and/
or leg spring,
b 7.5
Test ignition system:

with ZAT 3 or ZAT 4
(use ZAT 3 as main spark gap
see TI 32.94),
b 7.4
48 MS 311, MS 391
1
Powerful yes
spark?
no
Air gap:
– Check ignition module/flywheel,
– reset if necessary, b 7.3
Check the flywheel:

– Have pole shoes turned blue?
– Install new flywheel if necessary,
b 7.6
Check short circuit wire:

– Wire damaged?
– Connectors firmly seated?
– Check continuity, replace wiring harness if
necessary, b 7.7.2
Check the ignition lead:

– Severe chafing?
– Spark plug boot: Holes/cracks?
– Resistance: spark plug boot to ground:
spec. 1.5 – 12 kΩ
– Check resistance of ignition lead (spark plug
boot and ignition module removed)
Spec.: < 10 Ω,
If necessary, install new spark plug boot and/or
ignition lead with module,
b 7.3
2 3
MS 311, MS 391 49
2 3
Check operation
of switch shaft:
– Short circuit wire chafed?
– Function between contact spring and switch
shaft contact:
– Position "F" = no connection
– Position "0" = connection
– Install new short circuit wire if necessary,
b 7.7.2
Powerful yes
spark?
no
Install new ignition

b 7.3
yes Engine no
runs?
Machine runs trouble-free, – Look for fault in fuel system or

no further action necessary carburetor
– Check engine for leaks
– Check position of flywheel on
crankshaft,
b 7.6, b 6.5
50 MS 311, MS 391
8. Rewind Starter
8.1 General 8.2 Fan housing Installing
If the action of the starter rope

becomes very stiff and the rope
rewinds very slowly or not
completely, it can be assumed that
the starter mechanism is in order
but plugged with dirt. At very low
outside temperatures the lubricating
oil on the rewind spring may thicken
4903RA121 TG
4903RA119 TG
and cause the spring windings to
stick together. This has a 1
detrimental effect on the function of
the starter mechanism. : Engage the segment (1) in the
slots (arrows) in the fan housing
In such a case it is sufficient to apply first and then swing it into
a few drops of a standard solvent- : Take out the screws (arrows). position.
based degreasant (containing no
chlorinated or halogenated – Lift the hand guard a little and – Push the segment (1) into the
hydrocarbons) to the rewind spring. remove the fan housing. lugs as far as stop.
Carefully pull out the starter rope
– Reassemble in the reverse – Reassemble in the reverse
several times and allow it to rewind
sequence. sequence.
until its normal smooth action is
restored.
Before installing, lubricate the 8.2.1 Segment 8.3 Pawls

rewind spring and starter post with
STIHL special lubricant, b 14. – Remove the fan housing, b 8.2
If clogged with dirt or pitch, the

entire starter mechanism, including 1
the rewind spring, must be removed
and disassembled. Take particular 1
care when removing the spring.
– Clean all components, b 14
4903RA122 TG
4903RA120 TG
: Pry the segment (1) off the lugs – Relieve tension of rewind spring,
(arrows) and lift it away. b 8.4
: Carefully ease the spring clip (1)

off the starter post.
MS 311, MS 391 51
– Take three full turns of the rope
off the rope rotor.
1 – Pull out the rope with the starter

grip and slowly release the rope
1 rotor.
4903RA123 TG – Remove the starter rope or
4903RA126 TG
remaining rope from the rotor,
b 8.5
: Remove the pawls (1). The spring clip's guide loops must – Remove the spring clip and
be in line with the pawls (arrows). pawls, b 8.3
Installing Check operation.
– Pull the starter rope, the rotor

turns and the pegs on the pawls
move in the direction of spring
1 1 loops – the pawls move 1
outwards. 2
4903RA128 TG
reverse sequence.
4903RA124 TG
8.4 Rope Rotor

: Remove the washer (1).
– Fit the new pawls in the bores
(arrows) and lubricate the Rewind spring must be relaxed.
pegs (1), b 14 1
: Carefully remove the rope rotor
2 (2).
– Coat bore in rope rotor with

STIHL special lubricant,
b 14
4903RA127 TG
1
Relieving tension of rewind
4903RA125 TG
spring
The system will not be under

: Position the spring clip (1) so that tension if either the starter rope or
its loops engage the pegs on the rewind spring is broken.
pawls. The rounded part of the
spring clip (short arrow) must – Remove the fan housing and the
engage the starter post’s groove. segment, b 8.2
: Push the straight part of the : Pull out the starter rope (1)
spring clip over the starter post about 5 cm and hold the rope
until it snaps into the groove. rotor (2) steady.
52 MS 311, MS 391
Installing 8.5 Starter Rope / Grip Installing
– Remove the fan housing and the

segment, b 8.2
– Relieve tension of rewind spring,

b 8.4
The system will not be under

tension if the starter rope is broken.
4903RA129 TG
165RA227 TG
1 – Remove remaining rope from the
rope rotor and starter grip.
: Fit the rope rotor on the starter : Tie one of the special knots
post so that the inner spring loop Do not shorten the starter rope. shown in the end of the rope.
(arrow) engages the recess (1).
The recess in the hub of the rope

rotor is the anchor point for the
1
spring.
– Fit the cover washer.
– Install the pawls and spring clip,

b 8.3
4903RA130 TG
4903RA131 TG
– Install the starter rope, b 8.5
– Tension the rewind spring, b 8.6 : Push the end of the starter rope : Thread the rope through the top
(1) out a little and undo the knot. of the starter grip.
– Lubricate pegs on pawls with
grease, b 14 – Pull the starter rope out of the
rope rotor and fan housing.
reverse sequence. – Pull the old rope out of the starter
grip.
4903RA132 TG
: Pull the rope into the starter grip

until the knot is properly seated in
the grip (small arrow).
MS 311, MS 391 53
– Tension the rewind spring, b 8.6
2
– Install the segment and fan
housing, b 8.2
1 – Reassemble all other parts in the

reverse sequence.
4903RA133 TG
4903RA137 TG
8.6 Tensioning the Rewind 1
Spring
: Thread the starter rope (1) – Hold the rope rotor (2) steady.
through the guide bushing
(arrow). 2 : Pull out the twisted rope (1) with
the starter grip and straighten it
out.
1
1
4903RA136 TG
1
4903RA134 TG
– Remove the fan housing and the

segment, b 8.2
4903RA138 TG
: Pull out a short length of starter
: Thread the starter rope (1)
rope (1).
through the side of the rope rotor.
– Hold the starter grip (1) firmly to
: Use the starter rope (1) to rotate
– Secure the rope (1) with a simple keep the rope tensioned.
the rope rotor (2) six turns
overhand knot.
clockwise.
: Let go of the rope rotor and
slowly release the starter rope so
The rewind spring is now tensioned.
that it can rewind properly.
Hold the rope rotor steady since it
1 will otherwise spin back and may
damage the rewind spring.
4903RA135 TG
: Pull the rope (1) back into the

rotor until the knot locates in the
recess (arrow).
54 MS 311, MS 391
8.7 Replacing the Rewind
Spring
The replacement spring, in a spring

housing, comes ready for 2
4903RA139 TG
4903RA140 TG
installation.
1
– Wear a face shield and work
gloves
The rewind spring is correctly to protect your eyes and hands – Lubricate the replacement spring
tensioned when the starter grip sits from injury. with frame with a few drops of
firmly in the rope guide bushing STIHL special lubricant before
(arrow) without drooping to one – Remove the fan housing and the installing, b 14
side. If this is not the case, tension segment, b 8.2
the spring by one additional turn. : Position the replacement spring
– Relieve tension of rewind spring if with frame in the fan housing
When the starter rope is fully – the anchor loop (2) must be
necessary and remove the rope
extended, it must still be possible to above the lug (1).
rotor, b 8.4
rotate the rope rotor another full turn
before maximum spring tension is
– Remove any remaining pieces of : Push the rewind spring with
reached. If this is not the case,
old spring. frame into its seat (arrow) in the
reduce spring tension since there is
fan housing.
otherwise a risk of breakage.
The frame slips off during this
If the rewind spring can no longer be
process.
To reduce spring tension: properly tensioned, install a new
Pull the rope out, hold the rope rotor spring.
steady and take off one turn of the The rewind spring may pop out and
rope. Even a worn rewind spring is still unwind.
pre-loaded in the installed condition.
– Install the fan housing, b 8.2 – Remove the frame.
– Place a blanket over the work
area and pull the rewind spring
out of the fan housing.
MS 311, MS 391 55
1
4903RA141 TG
4903RA143 TG
Make sure that the new rewind : Fit the rewind spring (1)
spring (1) is properly seated and the clockwise in the housing.
outer anchor loop is engaged on the
lug (arrow). If necessary, use – Hold the spring windings so that
suitable tools to push the rewind they cannot pop out.
spring fully into its seat in the fan
housing.
Make sure that the rewind spring (1)
is properly seated. If necessary, use
If the rewind spring has popped out,
suitable tools to push the rewind
refit it in the fan housing as follows:
spring fully into its seat in the fan
housing
– Secure the spring so that it

cannot pop out.
– Install the rope rotor, b 8.4

1
reverse sequence.
4903RA142 TG
– Arrange the spring (1) in its

original position.
: Fit the anchor loop in its

seat (arrow) in the fan housing.
56 MS 311, MS 391
9. Servicing the AV System
Vibration-damping springs and The peg's head (arrow) must locate – Reassemble all other parts in the
buffers are used for the connection properly on the buffer. reverse sequence.
between the handlebar, tank
housing and engine housing. – Reassemble all other parts in the
reverse sequence. 9.3 AV Spring on Fuel Tank
Damaged springs and buffers must
always be replaced. – Remove AV spring from
9.2 AV Spring on Oil Tank handlebar, b 9.4
9.1 Buffer on Oil Tank

The antivibration spring is at the – Remove the stop buffer, b 9.6
forward end of the oil tank and is
– Remove the handlebar, b 9.7 secured to the underside of the
machine.
– Remove the handlebar, b 9.7
4903RA144 TG
1
2
0001RA177 TG
2 : Take out the screw (1).
: Pull off the buffer (1). 0001RA179 TG

: Lower the tank housing (2).
1
Installing : Unscrew the AV spring (1).

1
– Unscrew the bearing plug (2).
2
0001RA051 TG
0001RA176 TG
: Pry out the AV spring (1).

1
0001RA206 TG
– Use STIHL press fluid to simplify

assembly, b 14 2
: Push the buffer (2) onto the : Screw home the bearing plug (1)
peg (1) on the handlebar as far as far as stop.
as stop.
: Screw the AV spring (2) into the
handlebar (arrow) as far as stop.
MS 311, MS 391 57
Installing
1
1 2
2
1
0001RA213 TG
4903RA145 TG
4903RA147 TG
: Unscrew the AV spring (1). : Fit and tighten down the screw
(1) firmly.
: Unscrew the bearing plug (2). – Push the complete AV spring (1)
– Reassemble all other parts in the into the handlebar.
reverse sequence.
Installing : Insert the screws (arrows) and
tighten them down firmly.
9.4 AV Spring on Front
1 Handle : Coat the screw (2) with
threadlocking adhesive, fit it and
The AV spring is located between tighten it down firmly, b 14
the handle frame and cylinder.
2 – Reassemble all other parts in the
– Remove the shroud, b 6.4 reverse sequence.
0001RA207 TG
1
: Screw home the bearing plug (2)
as far as stop.
2
: Screw the AV spring (1) into the
plug (arrow) on the tank housing
as far as stop.
4903RA146 TG
– Push the AV spring (1) into its

seat.
: Take out the screws (1 and
arrows).
: Remove the complete AV

spring (2).
58 MS 311, MS 391
9.5 Stop Buffer at Clutch : Push the stop buffer (1) into the : Push home the annular buffer (1)
Side bore and make sure it is properly so that its bore engages the peg
seated. (2) in the tank housing.
The stop buffers are located
between the tank housing and – Reassemble all other parts in the
engine housing. They are fitted at reverse sequence.
the ignition and clutch sides.
– Remove the tank housing, 9.6 Annular Buffer at Ignition

b 12.11.4 Side
– Remove the cover, b 5.2 1

– Remove the ignition module,
b 7.3
4903RA148 TG
: Annular buffer (1) must be
properly seated in the
recess (arrow).

1 reverse sequence.
4903RA150 TG
4903RA151 TG
1
9.7 Handlebar
: Ease the stop buffer (1) out of the
bore. : Pry out the annular buffer (1). – Remove the shroud, b 6.4
Installing – Remove AV spring from

Installing handlebar, b 9.4
2
1
1
1
4903RA149 TG
2
4903RA152 TG
4903RA153 TG
– Position the stop buffer (1)

with its short end facing the – Line up the annular buffer (1)
engine housing. with its tapered end facing the : Take out the screw (1) and
engine housing. remove the chain catcher (2).
assembly, b 14 – Use STIHL press fluid to simplify
assembly, b 14
MS 311, MS 391 59
2
1
1 1
0001RA228 TG
4903RA155 TG
0001RA222 TG
1
: Remove the screws (1) from the : Ease the handlebar (1) sideways : Push the AV spring (1) into its
underside of the machine. and take it out of the guide seat (2).
(arrow).
1
0001RA229 TG
0001RA222 TG
4903RA269 TG
: Ease the tank housing to one : Position the handlebar (1)

side and pry out the AV : Push the handlebar (1) out of the against the guide (arrow).
spring (1). lower guide.
– Remove the handlebar (1).
– Check the annular buffer and

replace it if necessary, b 9.1
1
Installing
4903RA155 TG
4903RA154 TG
: Ease the handlebar (1) sideways

: Take out the screws (arrows). and place it in the guide (arrow).
– Insert the screws and tighten

1 them down firmly.
0001RA233 TG

reverse sequence.
: Push the handlebar, buffer (1)
first, into the engine housing.
60 MS 311, MS 391
10. Control Levers
10.1 Master Control Lever

1
1
4903RA160 TG
4903RA159 TG
2
4903RA157 TG : Carefully push the switch shaft : Remove the handle molding (1).
(1) over the taper (arrow).
– Remove the filter base, b 12.3 The interlock lever (arrow) may
: Push the switch shaft (1) onto the pop out.
: Pry the switch shaft (1) out of its pin (2) until it snaps into position.
mount (arrow).
2 1
: Lift the switch shaft (1) a little and
pull it away. – Reassemble all other parts in the
reverse sequence.
Installing – Check operation.
0001RA276 TG
10.2 Throttle Trigger/Interlock
1 Lever
: Take the throttle rod (1) out of the
guide (arrow) and disconnect it
1 from the throttle trigger (2).
4903RA158 TG
: Push the switch shaft (1) onto the

0001RA274 TG
pin (2).
1
: Push the tabs (1) apart and 1

4903RA161 TG
through the tank housing.
: Ease the interlock lever (1) out of

its mounts (arrows).
– Disconnect the torsion spring and

remove the interlock lever.
MS 311, MS 391 61
1
1
0001RA278 TG 1
4903RA265 TG
4903RA162 TG
2
: Use a suitable drift (2) to drive out : Place the throttle trigger (1) in the : Push the interlock lever (1) into
the pin (1). handle and line up the holes in its pivot mounts (arrows) until it
the trigger and handle. snaps into position – check that
torsion spring is in position.
The interlock lever (1) may pop out.

2 1
1 3
2 1
0001RA279 TG
4903RA266 TG
4903RA267 TG
: Remove the throttle trigger (1)
with torsion spring (2). : Use a suitable drift (2) to center
the throttle trigger (1).
Installing : Drive home the pin (3) until it is : Attach the throttle rod (1) to the
recessed by same amount at trigger (2) and fit it in the
both sides. guide (arrow).
1
0001RA281 TG
2
4903RA163 TG
: Attach the torsion spring (1) to

the trigger (2) 1
– note the installed position
(arrow). : Attach the torsion spring (1) to
the interlock lever (arrow).
62 MS 311, MS 391
2 1
1
0001RA287 TG
4903RA166 TG
4903RA169 TG
1 2
: Engage tabs of handle : Move the switch shaft (1) in the : Position the choke rod (1) in the
molding (1) in the direction of the carburetor and guide (arrow).
openings (arrow). disconnect the choke rod (2).
– Rotate the switch shaft (2) and
– Push down the handle – Take the choke rod (2) out of the push the choke rod (1) fully into
molding (1) until it snaps into guide. the guide.
position.
– Check operation – rotate the
– Check operation. switch shaft. If necessary, push
home the choke rod until it is
– Reassemble all other parts in the properly seated.
reverse sequence.
10.2.1 Choke Rod 4903RA167 TG
– Remove the air filter, b 12.1

1
: Disconnect the choke rod (1)

2 from the choke shaft (arrow).
Installing
4903RA165 TG
2
1
: Carefully pry the choke rod (2)

1
out of its seat in the guide (arrow)
4901RA168 TG
and move the switch shaft (1) in

the direction of cold start at the
same time.
: Engage the choke rod (1) in the

bore (arrow) in the choke
shaft (2).
MS 311, MS 391 63
10.2.2 Throttle Rod
– Disconnect the throttle rod from

the trigger, b 10.2
1 1
– Remove the filter base, b 12.3
4903RA171 TG
4903RA173 TG
: Rotate the throttle rod (1) about : Pass the throttle rod (1) through
90° counterclockwise. Pass the the opening (arrow).
throttle rod (1) through the
1 2 opening (arrow) in the direction of : Rotate the bent end (1) clockwise
the tank housing and remove it. and push it under the throttle
0001RA303 TG
trigger.
Installing
: Pry the throttle rod (1) out of the
carburetor carrier (2).
1 1 2
0001RA310 TG
4903RA172 TG
: Push the throttle rod (1) into the

4903RA170 Tg
: Line up the throttle rod (1) (see guide (2) in the carburetor carrier
illustration). until it snaps into position.
: Push the throttle rod (1) between – Check operation – the throttle
: Pull the throttle rod in the the tank housing and air guide lever on the carburetor must
direction of the handle until its shroud and rotate it about 90° at move upwards when the throttle
bent end (1) is in front of the the same time. trigger is pulled.
opening (arrow).

sequence.
64 MS 311, MS 391
11. Chain Lubrication
11.1 Pickup Body 11.2 Oil Suction Hose
Impurities gradually clog the fine – Remove the clutch, b 4

pores of the filter with minute
particles of dirt. This prevents the oil – Remove the brake band, b 5.2
pump from supplying sufficient oil.
In the event of problems with the oil
– Open the oil tank cap and drain
supply system, first check the oil
4903RA176 TG
the oil tank b 1.
tank and the pickup body. Clean the
oil tank if necessary, b 1 1
– Remove the oil pump, b 11.3
– Troubleshooting, b 3.3 – Line up the oil suction hose (1)
– the tab (arrow) must locate
– Open the oil tank cap and drain against the housing.
the oil tank.
1
– Collect chain oil in a clean assembly, b 14
container, b 1
: Push home the oil suction hose
(1) until its groove is properly
4903RA174 TG
seated in the engine housing.
1
– Check position of pickup body. If
necessary, use hook
: Remove the oil suction hose (1). 5910 893 8800 to position it
properly.
– Fit the pickup body, b 11.1
2 – Install the oil pump, b 11.3
219RA457 TG
Installing – Reassemble all other parts in the

reverse sequence.
: Use hook (2) 5910 893 8800 to
remove the pickup body (1) from
the oil tank.
Do not overstretch the suction hose.
– Pull off the pickup body (1).

1
4903RA175 TG

sequence.
: Push the oil suction hose (1),

pickup body first, through the
housing bore (arrow).
MS 311, MS 391 65
11.3 Oil Pump Installing
– Remove the brake band, b 5.2

1
– Remove the clutch, b 4
4903RA180 TG
1
4903RA182 TG
: Pull off the oil suction hose (1). 2
: Fit the oil pump (1) over the

crankshaft stub (2).
1
4903RA178 TG
1
: Remove the washer (1). 4903RA181 TG
4903RA183 TG
1
: Push the connector (1) onto the
1 nipple (arrow).
2
4903RA179 TG
: Pull the worm (1) with drive

4903RA177 TG
spring (2) out of the oil pump.
: Pull the oil pump (1) off the

nipple (2) and then lift it off over
the crankshaft stub.
1
2
219RA470 TG
: The spring (1) and worm (2) form

a single unit and must be
replaced if damaged.
66 MS 311, MS 391
11.4 Valve Installing
1
A valve is installed in the tank wall to
keep internal tank pressure equal to
atmospheric pressure. The valve
must be replaced if it is faulty.
2
– Open the oil tank cap and drain
4903RA184 TG
the oil tank b 1.
2
4903RA186 TG
– Place the oil pump (1) in position.
: Fit and tighten down the screws Check correct installed position.
(2) firmly.
: Insert the valve in the housing
bore (arrow).
– Connect the oil suction hose to
the oil pump.
– Use a 6 mm drift to carefully
4903RA185 TG
drive in the new valve from
– Push the worm fully home.
outside – note installed depth.
: Use a 6 mm drift to carefully

drive the valve out of its seat in
the housing and into the oil tank.
1
4903RA270 TG
219RA479 TG
: Fit the cover washer (1) so that
: Installed depth of new valve:
the word TOP (arrow) faces
219RA476 TG
a = 1 mm +/- 0.1.
outwards.
1
– Check adjustment of oil pump
: Remove the old valve (1) from reverse sequence.
and readjust if necessary – see
instruction manual. the oil tank.

reverse sequence.
MS 311, MS 391 67
12. Fuel System
12.1 Air Filter 12.2 Baffle

2
Dirty air filters reduce engine power,
increase fuel consumption and
make starting more difficult. The air
filter should be checked when there
is a noticeable loss of engine power. 1
4903RA101 TG
– See also Troubleshooting,
b 3.6, b 3.7 1
4903RA205 TG
– Remove the shroud, b 6.4 : Pull the short circuit wire (1) out
of the guides (arrows).
– Pull the ring terminal off the pivot
1 : Unscrew the nuts (arrows). pin (2).
– Remove the baffle (1).
2 – Reassemble in the reverse

sequence.
4903RA204 TG
1
12.3 Filter Base
: Lift the retaining tab (1) a little
4903RA207 TG
2
and remove the air filter (2).
3
– Check the air filter and clean or – Remove the baffle, b 12.2
replace if necessary : Pull the filter base (1) out of
– see instruction manual. – Remove the choke rod, rubber buffer (3) first and then
b 10.2.1 rubber buffer (2).
sequence. – Disconnect the ground wire from : Remove the filter base (1).
the contact spring, b 7.7.4.
68 MS 311, MS 391
1 1
2
2
4903RA209 TG
4903RA211 TG
4903RA214 TG
: Pry out the rubber buffer (1). : Slide the filter base (1) over the – Install the short circuit wire,
studs. b 7.7.2
Installing – Reassemble all other parts in the

reverse sequence.
1
12.4 Air Guide Shroud
1 – Remove the filter base, b 12.3
4903RA212 TG
– Remove the throttle rod,
4903RA210 TG
b 10.2.2

: Push the filter base (1) fully into
– Use STIHL press fluid to simplify the rubber buffer (arrow).
assembly, b 14 – Remove the manifold, b 12.9
: Push the rubber buffer (1),

tapered end first, into the
bore (arrow) as far as stop – the 1
tapered end must slide fully home
and engage the bore. 1
4903RA213 TG
4903RA215 TG
: Push the filter base (1) fully into

the rubber buffer (arrow). : Pull the ignition lead (1) out of the
guides (arrows).
MS 311, MS 391 69
1
1
4903RA103 TG
4903RA218 TG
4903RA221 TG
: Pull the short circuit wire (1) out : Remove the air guide shroud (1) : Push the (1) fully into its
of the guides (arrows). upwards. seat (arrow) until it snaps into
position.
Installing
1
1
4903RA216 TG
4903RA222 TG
4903RA219 TG

: Make sure the protective tube (1)
: Position the fuel hose (1) in the covers the opening (arrow).
recess in the air guide
shroud (arrow).
1
1
4903RA217 TG
1
4903RA223 TG
4903RA220 TG
: Push the air guide shroud (1) in 2

the direction of the intake port
until it engages the edge (arrow). : Fit and tighten down the screws
(1) firmly.
: Line up the air guide shroud (1)
and hold the fuel hose (2) at the – Pay attention to mark when
same time. installing the short circuit wire,
b 7.7.2

reverse sequence.
70 MS 311, MS 391
12.5 Carburetor
– Remove the filter base, b 12.3 Installing
– Open the fuel tank cap and drain

2
the fuel tank. 1
– Collect the fuel in a clean
container, b 1
0001RA359 TG
Disconnect the fuel hose only when
4903RA225 TG
the tank cap is open.
1 : Shoulder (arrow) must fully

engage the intake manifold (1).
: Check that the sleeve (1) and
washer (2) are in place. – Use STIHL press fluid to simplify
assembly, b 14

0001RA461 TG
– Install the air filter, b 12.1
1 1
– Check operation.
: Push the fuel hose (1) back a little
– the fuel hose is disconnected.
4903RA226 TG
reverse sequence.
: Push the carburetor (1) into 12.5.1 Leakage Test

position.
1 In the case of problems with the
carburetor or fuel supply system,
also check and clean or replace the
tank vent, b 12.10
4903RA224 TG
The carburetor can be tested for

leaks with the pump
0000 850 1300.
: Remove the carburetor (1). – Remove the filter base, b 12.3

0001RA465 TG
– Install a new fuel hose,

b 12.11.2 1
: The fuel hose must be located in

its seat (arrow).
: When positioning the carburetor,

make sure the stub (1) is pushed
into the fuel hose.
MS 311, MS 391 71
12.6 Servicing the Carburetor
2 1 2
12.6.1 Metering Diaphragm
0001RA346 TG
165RA336 TG
1
1
: Push the fuel hose (1) – Push the pressure hose of pump
4903RA187 TG
1110 141 8600 onto the 0000 850 1300 onto the nipple.
nipple (2) 0000 855 9200.
: Push the ring (1) to the right and
pump air into the carburetor until
the pressure gauge (2) indicates – Troubleshooting, b 3.6
a pressure of about 0.8 bar
(80 kPa). – Remove the carburetor, b 12.5
If this pressure remains constant, : Take out the screws (arrows).

the carburetor is airtight. However, if
it drops, there are three possible – Remove the end cover (1).
causes:
0001RA342 TG
If the gasket and diaphragm are

1. The inlet needle is not sealing stuck to the carburetor, remove
(foreign matter in valve seat, them very carefully.
sealing cone of inlet needle is
: Push the fuel hose with nipple
damaged or inlet control lever is
onto the carburetor’s fuel
sticking). Remove to clean,
stub (arrow).
b 12.6.2 2 1
2. Metering diaphragm or gasket

damaged, replace if necessary,
b 12.6.1
3. Pump diaphragm or gasket

0001RA348 TG
damaged, replace if necessary,

b 12.6.3
– After completing the test, push : Carefully separate the metering

the ring (1) to the left to vent the diaphragm (1) and gasket (2).
system and then pull the fuel
hose off the carburetor. The diaphragm material is
subjected to continuous alternating
– Install the filter base, b 12.3 stresses and eventually shows
signs of fatigue. i.e. the diaphragm
– Reassemble all other parts in the distorts and swells and has to be
reverse sequence. replaced.
– Check the metering diaphragm

for signs of damage and wear.
Install a new gasket.
72 MS 311, MS 391
Installing 12.6.2 Inlet Needle
2 1
4903RA190 TG
4903RA188 TG
0001RA353 TG
: Fit the screws (arrows).
– Note installed positions of – Check position of metering – Remove the metering

metering diaphragm (2) and diaphragm and gasket, then diaphragm, b 12.6.1
gasket (1). tighten down the screws firmly in
a crosswise pattern. : Take out the screw (1).
: Fit the gasket (1) and metering
diaphragm (2) on the pegs The end cover must be in line with
(arrows). the edge of the carburetor body.
2 1
2
1
0001RA361 TG
1
4903RA189 TG
4903RA191 TG
: Pull the inlet control lever (1) with

spindle (2) out of the inlet
needle’s groove.
: Position the end cover (1) so that : Check operation – throttle shaft
the lever (arrow) points in the lever (1) must engage the air
direction of the choke shutter. valve lever (2). The small spring under the inlet
control lever may pop out.
– Move the end cover (1) a little – Reassemble all other parts in the
until the pegs engage the holes in reverse sequence.
the end cover.
2
0001RA362 TG
: Remove the inlet needle (1).
– Remove the spring (2).
MS 311, MS 391 73
12.6.3 Pump Diaphragm
1 2 3
1
0001RA364 TG
165RA348 TG
0001RA366 TG
: If there is an annular indentation : Position the inlet control lever (3)
(arrow) on the sealing cone of the with spindle (2) on the spring
inlet needle, fit a new inlet (arrow) first, then slide the inlet – Troubleshooting, b 3.6
needle. control lever’s clevis into the
groove in the inlet needle (1). – Remove the carburetor, b 12.5
Installing Make sure the spring locates on the : Take out the screw (1).
control lever’s nipple.
– Remove the end cover (2).
– Press the inlet control lever down
and secure it with the screw.
If the gasket and pump diaphragm
1 – Check that the inlet control lever
are stuck to the carburetor, remove
them very carefully.
moves freely.
2
– Install the metering diaphragm,
0001RA363 TG
b 12.6.1
: Fit the inlet needle (1).
: Fit the spring (2) in the bore.
0001RA367 TG
: Carefully remove the pump

diaphragm with gasket.
74 MS 311, MS 391
Installing
2
1 1 2
1
0001RA372 TG
4903RA262 TG
0001RA370 TG
2
: Carefully separate the pump : Position the end cover (1) so that
diaphragm (2) and gasket (1). the lever (arrow) points in the
: Fit the new gasket (1) so that the direction of the adjusting screws.
The diaphragm material is contours (arrows) match and it is
subjected to continuous alternating held in position by the pegs (2). : Fit the end cover (1) from below
stresses and eventually shows so that the pump diaphragm and
signs of fatigue. i.e. the diaphragm gasket are still held in position.
distorts and swells and has to be
replaced.
– Check the pump diaphragm for 1 2

signs of damage and wear. Install
a new gasket. 2
– Check fuel strainer for 0001RA371 TG

1
contamination and damage. 2
Clean or replace if necessary.
0001RA373 TG
: Fit the pump diaphragm on the
gasket (1) so that the contours
1 (arrows) match and it is held in – Move the end cover (1) a little
position by the pegs (2). until its pegs engage the holes in
the carburetor body.
– Check that the pump diaphragm

and gasket are properly seated.
0001RA369 TG
: Fit and tighten down the screw

(2) firmly.
: Use a needle to remove the fuel

strainer (1) from the carburetor
reverse sequence.
body. Clean or replace the fuel
strainer.

sequence.
MS 311, MS 391 75
12.6.4 Air Valve 12.6.5 Levers on Throttle Shaft
Air valve shaft stiff or air valve – Remove the carburetor, b 12.5
1 3
cannot be closed or opened
properly: – Carburetor troubleshooting,
2 b 3.6
The air valve matches the end
cover. If it is damaged, the complete 4
4903RA192 TG
end cover must be replaced. 5
– Carburetor troubleshooting,
b 3.6 Lever (1) must butt against lever (2)
and engage lever (3). 4 3
Position of throttle shutter/air
valve Lever (5) must engage lever (2) for
cold and warm starts 1
4903RA194 TG
The correct position of the air valve – the choke lever (5) returns to the
can be checked visually as follows. idle position when the throttle is
opened. 2
– Throttle shutter in idle position
– air valve fully closed. – Screw (4) must be tightened : Take out the screw (1).
down firmly.
– Throttle shutter in idle position / – Relieve tension of the torsion
full throttle position – air valve spring (2) and remove the lever
closed / wide open. (3).
– Throttle shutter in full throttle – Pull off the torsion spring (2) and
position – air valve wide open. lever (4).
– Throttle shutter in cold start

position l Installing
– air valve fully closed.
4903RA193 TG
– Throttle shutter in warm start

1
position n
– air valve open about 5° The torsion springs (arrows) must
be preloaded and attached to the
The air valve must move freely in levers.
both directions (open and closed)
and always return to the idle
4903RA195 TG
position.
The air valve is fully closed in the

idle position. : Push the lever (1) onto the
throttle shaft as shown (arrow).
76 MS 311, MS 391
12.6.6 Adjusting Screws
1
1
2
2
4903RA196 TG
4903RA199 TG
3
0001RA382 TG
3
: Fit the torsion spring (1) so that : Hold lever (1) and lever (2)
its leg locates against the lever together against the stop (arrow).
(arrow).
Grommet has been removed for the
: Tighten down the screw (3) sake of clarity.
firmly.
There are three adjusting screws on
the carburetor:
H = high speed screw (1)
L = low speed screw (2)
LA = idle speed screw (3)
If the carburetor cannot be adjusted

properly, the problem may be the
4903RA197 TG
adjusting screws.
1 2 4903RA200 TG
The high speed screw H has a
limiter cap, which has to be
: Attach the torsion spring to the removed before the screw is
lever (arrow).
removed.
– Check operation.
: Fit the lever (1) and tighten the – Remove the carburetor, b 12.5
screw (2) moderately – Reassemble all other parts in the
– the lever must still turn freely. reverse sequence. – See also carburetor
troubleshooting, b 3.6
1
4903RA198 TG
0001RA383 TG
: Hold the lever (2) steady.

: Pull off the grommet (1).
: Rotate the lever (1) clockwise
until it butts against the stop on
lever (2) and engages the end of
the throttle shaft.
MS 311, MS 391 77
Low speed screw High speed screw
The high speed screw( H) has a

limiter cap, which has to be
removed before the screw is
removed.
0001RA388 TG
1
1 1
0001RA384 TG
: Pull out the limiter cap (1).

– Take out the high speed screw
: Take out the low speed screw (H).
L (1).
0001RA386 TG
1 2
: Screw the puller (1)
5910 890 4500 counterclockwise
into the limiter cap – left-hand
thread.
165RA371 TG
0001RA467 TG
3
: Inspect the tip (arrow) for
– Inspect the sealing ring (1), damage or wear and replace the
washer (2) and spring and screw (H) if necessary.
replace if necessary.
2 – Screw down the high speed
0001RA387 TG
: Inspect the tip (arrow) for screw (H) as far as stop.

damage or wear and replace the
1
low speed screw (L) if necessary.
– Continue with pre-installing
: Rotate the limiter cap until the lug limiter cap.
– Screw down the low speed screw
(2) is in line with the slot (1).
(L) as far as stop.
– Continue with the high speed

screw (H).
78 MS 311, MS 391
Pre-installing limiter cap 12.7 Carburetor Adjustment
12.7.1 Basic Setting 2
The basic setting is necessary only 1

if the high speed screw (H) or low
speed screw (L) has to be replaced
1 or after cleaning and adjusting the
0001RA391 TG
carburetor from scratch.
It is necessary to carry out the basic

165RA372 TG
setting after removing the limiter
cap. For the sake of clarity the adjusting
screw is shown on the exposed
Always install a new limiter cap. The carburetor, air filter and carburetor.
grommet are installed, the adjusting
: Push the new limiter cap (1) on to screws fitted and the new limiter cap : Starting with the high speed
the high speed screw (H) as far pre-installed. screw H (1) against its seat,
as the detent (arrow) open it one full turn counter-
– do not push fully home. – Check chain tension and adjust if clockwise
necessary. – this is the basic setting.
The basic setting is performed
through the pre-installed limiter cap – Inspect the spark arresting : Starting with the low speed screw
with screwdriver 5910 890 2304. screen (if fitted) and clean or L (2) against its seat,
replace if necessary, b 3.7 or open it one full turn counter-
– Reassemble in the reverse b 6.1 clockwise
sequence. – this is the basic setting.
– Check the air filter and clean or
– Carry out the basic setting, replace if necessary, b 12.1 – Warm up the engine.
b 12.7.1
Setting disk 5910 893 6600 may be
fitted on the screwdriver
5910 890 2304 to simplify
adjustments.
MS 311, MS 391 79
12.7.2 Standard Setting
1
2
0
4
14
6
12
8
4903RA201 TG
4903RA202 TG
10
4903RA203 TG
: To adjust the high speed screw : Push a suitable drift through the
(H), insert the screwdriver (1) opening (arrow) and push home
5910 890 2304 through the the limiter cap until it is flush with
The limiter cap must not be
opening (arrow) and push the the carburetor body.
removed for the standard setting.
pre-installed limiter cap into the
high speed screw (H). This completes the basic setting of Always perform the following steps
the high speed screw (H) and the before carrying out any
Adjust idle speed with a tachometer. low speed screw (L) and the high adjustments:
Adjust specified engine speeds speed screw (H) is locked.
within a tolerance of ± 200 rpm. – Troubleshooting, b 3.6
1. Adjust engine speed idle speed – Check chain tension and adjust if
screw (LA) to 3,300 rpm.
necessary.
2. Turn the low speed screw (L)

– Inspect the spark arresting
clockwise or counterclockwise
screen (if fitted) and clean or
to obtain the maximum engine replace if necessary, b 3.7 or
speed. b 6.1
If this speed is higher than

– Check the air filter and clean or
3,700 rpm, abort the procedure and
start again with step 1.
3. Use the idle speed screw (LA)

to set the engine speed again to
3,300 rpm.
4. Set the engine speed to

2,800 rpm with the low speed
screw ( L).
5. Set engine's maximum speed to

13,000 rpm with the high speed
screw (H).
80 MS 311, MS 391
Standard Setting Erratic idling behavior, poor 12.8 Carburetor Carrier
acceleration
– Shut off the engine. (although standard setting is
correct) 2
– Turn the high speed screw (H)
slowly counterclockwise as far as Idle setting too lean.
stop, but not more than a 3/4 turn. 1
– Warm up the engine.
– Turn the low speed screw (L)
slowly clockwise as far as stop, – Turn the low speed screw (L)
4903RA230 TG
then turn it back 1 full turn. counterclockwise until the engine
runs and accelerates smoothly.
Adjusting engine idle speed It is usually necessary to change the

setting of the idle speed screw (L) – Remove the carburetor, b 12.5
– Carry out standard setting. after every correction to the low
speed screw (L). : Take out the sleeve (2) and
washer (1).
– Warm up the engine.
Adjustment for operation at high
altitude
Engine stops while idling
A minor correction may be
– Turn the idle speed screw (LA) necessary if engine power is not 1
clockwise until the chain begins satisfactory when operating at high
to run, then turn it back 1/2 a turn. altitude. 2
1
– Check standard setting.
4903RA231 TG
Saw chain runs while engine is
idling – Warm up the engine.
– Turn the idle speed screw (LA)

– Turn the high speed screw (H) – Disconnect fuel suction hose
counterclockwise until the chain
clockwise (leaner) – no further from the carburetor carrier.
stops running, then turn it back
than stop.
1/2 a turn.
: Push the manifold flanges (1) out
Turn the adjusting screws only very of the carburetor carrier (2) in the
slightly. Even minor adjustments direction of the cylinder.
can noticeably affect engine running
behavior.
– Remove the carburetor
If the setting is made too lean there carrier (2).
is a risk of engine damage as a
result of lack of lubrication and
overheating.
MS 311, MS 391 81
Installing 12.9 Intake Manifold
A damaged intake manifold can

result in engine running problems.
1 – Troubleshooting, b 3.6 or
1
b 3.7
0001RA399 TG
1 – Remove the shroud, b 6.4
4903RA232 TG

: Fit the fuel hose (1) in the
guide (arrow).
– Remove the carburetor carrier,
: To pull the manifold flanges
b 12.8
through the openings in the
carburetor carrier, wind pieces of
string (1) (about 15 cm long) 2
around the backs of the flanges
and pass the ends of the strings
through the openings.
1 1 1
2
1 1
4903RA234 TG
4903RA235 TG
: Take out the sleeve (2) and
ring (1).
4903RA233 TG
When reassembling, check that all

: Remove the intake manifold (2).
wires are properly seated in their
guides.
– Inspect the intake manifold (2)
: Pull the ends of the strings with – Reassemble all other parts in the and replace it if necessary – even
the manifold flanges through the reverse sequence. very minor damage can result in
intake opening. engine running problems, b 3.7
– Pull the manifold flanges into the

openings in the carburetor carrier
with the string.
– Remove the string.
82 MS 311, MS 391
12.10 Tank Vent Vacuum test
12.10.1 Testing
2
If problems occur on the carburetor
or the fuel supply system, also
check and clean the tank vent and
replace it if necessary. Check
0001RA404 TG
function by performing pressure and
vacuum tests on the tank via the fuel
0001RA407 TG
hose.
: Inspect and clean the sealing – Open the fuel tank cap and drain 1
faces (arrows), b 14 the fuel tank, b 1.
: Push the ring (1) to the left and
The sealing faces must be in perfect – Close the tank cap. connect the pump (2)
condition. Always replace 0000 850 1300 to the
components with damaged sealing nipple (arrow)
– Remove the carburetor, b 12.5 – subject the fuel tank to a
faces.
vacuum.
Installing Equalization of pressure takes

place via the tank vent. There must
be no buildup of vacuum in the fuel
tank.
1 1
– Clean the area around the tank
2 1 0001RA406 TG
vent.
1 1 – Always install a new fuel hose.

4903RA236 TG
– If necessary, install a new tank

: Push the nipple (1) vent or fuel tank, b 12.10 or
0000 855 9200 into the fuel hose b 12.11.4
: Position the manifold (2) on the (arrow).
cylinder.
: Fit and tighten down the

screws (1) firmly.
– Install the carburetor carrier,

b 12.8

reverse sequence.
MS 311, MS 391 83
Pressure test – Coat sealing ring of new tank
vent with STIHL press fluid,
b 14
2 1
– Push home the tank vent by hand
2 until it snaps into position.
4903RA060 TG
reverse sequence.
0001RA408 TG
1 : Take out the screw (1). 12.11 Fuel Intake

12.11.1 Pickup Body
: Push the ring (1) to the right and : Lower the tank housing (2).
connect the pump (2)
0000 850 1300 to the Any impurities mixed with the fuel
nipple (arrow) are retained by the pickup body
– pressurize the fuel tank. 1 (filter). The fine pores of the filter
eventually become clogged with
– Operate the pump until the minute particles of dirt. This restricts
pressure gauge indicates a the passage of fuel and results in
pressure of 0.5 bar. If this fuel starvation.
pressure remains constant for at
least 20 seconds, the fuel tank, In the event of problems with the
fuel supply system, always check
4903RA108 TG
including the tank vent, is airtight.

If the pressure drops, the leak the fuel tank and the pickup body
must be located and the faulty first.
part replaced.
: Slide the wooden assembly – Troubleshooting, b 3.6 or
block (1) between the engine b 3.7
– Always install a new fuel hose.
housing and tank housing.
Clean the fuel tank if necessary,
sequence. – Open the tank cap and drain the
1 fuel tank.
12.10.2 Removing and Installing – Pour a small amount of clean

gasoline into the fuel tank. Close
the tank and shake the saw
vigorously.
4903RA244 TG
– Open the tank again and drain it.

1
– Dispose of fuel properly in
: Pry the tank vent (1) out of its accordance with environmental
requirements, b 1
4903RA243 TG
seat using the rib (arrow) for

leverage.
Always install a new tank vent.

: Take out the screws (arrows) and
pry the AV spring (1) out of the
handlebar.
84 MS 311, MS 391
1
1
2
1
0001RA410 TG
4903RA060 TG
4903RA164 TG
– Open the tank cap. – Remove the shroud, b 6.4 : Pull out the fuel hose (1) with
connector.
: Use hook 5910 893 8800 to – Remove the air guide shroud,
remove the pickup body (1) from b 12.4
the fuel tank.
Do not overstretch the fuel hose.
: Lower the tank housing (2).
: Pull off the pickup body (1).
1
sequence. 1
4903RA000 TG
12.11.2 Fuel Hose
: Remove the fuel hose (1).
4903RA108 TG
1 : Slide the wooden assembly

block (1) between the engine
housing and tank housing. 1
4903RA243 TG
0001RA412 TG
2
: Take out the screws (arrows) and
pry the AV spring (1) out of the : Pull the fuel hose (2) off the
handlebar. connector (1).
MS 311, MS 391 85
Installing 12.11.3 Fuel Suction Hose
1
2
4903RA246 TG
1
0001RA417 TG
4903RA242 TG
1 : Line up the fuel suction hose (1)
and push it into the housing bore
: Push the fuel hose (1) onto the as far as stop – the flange must
– Remove the pickup body,
connector (2) as far as stop. engage the guide (arrow).
b 12.11.1
Note position of the hose – Remove the tank housing, – Use STIHL press fluid to simplify
– the flats (arrows) must be in assembly, b 14
b 12.11.4
alignment.
– Install the tank housing,
: Pull the fuel suction hose (1) out
b 12.11.4
of the fuel tank.
1
Installing
1
4903RA240 TG
0001RA419 TG
: Push the fuel hose (1) through
4903RA245 TG
the opening (arrow) in the engine

housing.
: Use hook 5910 893 8800 to
remove the fuel suction hose (1)
from the fuel tank.
: Push the fuel hose (1) through
the bore (arrow) in the fuel tank.
Do not overstretch the fuel suction
hose.
1 – Fit the pickup body, b 12.11.1
– Close the tank cap.

4903RA241 TG
: Push the fuel hose (1) with

connector into the fuel suction
hose (2).

reverse sequence.
86 MS 311, MS 391
12.11.4 Tank Housing Installing
– Drain the fuel tank, b 1 1

– Remove the handlebar, b 9.7 1
– Remove the stop buffer, b 9.5
4903RA247 TG
– Remove the control levers, b 10
4903RA249 TG
: Pull out the connector (1) with 2
fuel hose.
: Slide the tank housing (1),
1 narrow part (2) first, into the
engine housing.
1
2
4903RA060 TG
4903RA248 TG
– Lower the tank housing (2).
4903RA250 TG
: Pull out the tank housing (1).
Only transfer those parts from the

old tank housing that are not – Push the connector (1) with fuel
included with the replacement hose into the fuel suction hose.
– see parts list.
reverse sequence.
MS 311, MS 391 87
13. Special Servicing Tools
New Special Tools
No. Description Part No. Application Rem.
1 Test flange 1140 890 1200 Leakage Test
Existing Special Tools
1 Pump 0000 850 1300 Testing engine and carburetor for leaks
- Sealing plate 0000 855 8107 Testing carburetor for leaks
- Nipple 0000 855 9200 Testing carburetor for leaks
- Hose for leakage test 1110 141 8600 Testing carburetor for leaks
- Plug for leakage test 1122 025 2200 Leakage testing decompression valve
2 Installing tool 0000 890 2201 Installing rope guide bushing
3 Locking strip 0000 893 5903 Blocking the crankshaft
4 Pliers DIN 5254-A 19 0811 611 8380 Removing and installing external
circlips
5 Screwdriver bit, T 27 x 125 0812 542 2104 Removing and installing spline socket
screws with electric or pneumatic
screwdrivers; tightening down screws
with torque wrench
6 Wooden assembly block 1108 893 4800 Installing tank vent
7 Setting gauge 1111 890 6400 Adjusting air gap between the ignition
module and flywheel
8 Assembly drift 1108 893 4700 Removing and installing piston pin
9 Assembly tube 1117 890 0900 Attaching springs
10 Installing sleeve 1118 893 4602 Protecting the oil seal
11 Installing sleeve 1122 893 2405 Installing oil seal
12 Installing sleeve 1122 893 4600 Protecting the oil seal
(clutch side)
13 Combination wrench 1129 890 3401 Spark plug 1)
14 Puller 1135 890 4500 Removing flywheel
15 Ignition system tester, ZAT 4 5910 850 4503 Testing ignition system
16 Ignition system tester, ZAT 3 5910 850 4520 Testing ignition system
17 Torque wrench 5910 890 0302 0.5 to 18 Nm
18 Torque wrench 5910 890 0312 6 to 80 Nm
19 Installing tool 12 5910 890 2212 Installing hookless snap rings in piston
88 MS 311, MS 391
20 Screwdriver 5910 890 2304 Adjusting carburetor

- Setting disk 5910 893 6600 Add-on for screwdriver (adjusting
carburetor)
21 Screwdriver bit, T 27 x 150 5910 890 2400 IS-P screws (4 mm)
22 Hook 5910 890 2800 Detaching springs on clutch shoes
23 Assembly stand 5910 890 3101 Holding machines for repairs
24 Puller 5910 890 4400 Removing oil seals
- Jaws (No. 3.1) 0000 893 3706 Removing oil seal(s)
25 Puller 5910 890 4500 Removing limiter caps
26 Stud puller M8 5910 893 0501 Removing bar mounting studs
27 Socket, 13 mm, long 5910 893 2804 Removing and installing
decompression valve
28 Hook 5910 893 8800 Removing pickup body
Remarks:
1) Use for releasing only.
MS 311, MS 391 89
14. Servicing Aids
No. Description Part No. Application
1 Lubricating grease (225 g tube) 0781 120 1111 Oil seals, sliding and bearing points
2 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in fan
housing
3 STIHL press fluid OH 723 0781 957 9000 Rubber components, AV elements
4 STIHL multipurpose grease 0781 120 1109
5 Dirko HT red sealant 0783 830 2000 Engine housing
6 Medium-strength threadlocking 0786 111 2101

adhesive (Loctite 242 or 243)
7 High-strength threadlocking 0786 111 2117

adhesive (Loctite 648)
8 Standard commercial solvent- Cleaning sealing faces and carburetor,

based degreasant containing no crankshaft stubs and flywheel taper
chlorinated or halogenated
hydrocarbons
90 MS 311, MS 391
MS 311, MS 391 91
92 MS 311, MS 391
englisch / english
0455 542 0123. M2,2. K09. FST. Printed in Germany

MS311, MS391 SM

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STIHL MS 311, 391 2009-06

1. Introduction and 6. Engine 27 9. Servicing the

3. Troubleshooting 8 7. Ignition System 39 10. Control Levers 61

3.1 Clutch 8 7.1 Ignition Timing 39 10.1 Master Control Lever 61

5.1 Checking Operation 20 8. Rewind Starter 51

12. Fuel System 68

12.1 Air Filter 68

13. Special Servicing

14. Servicing Aids 90

1.1 Introduction The special tools mentioned in the

Service manuals and all technical

Remove the chain sprocket cover, Improper handling may result in

Displacement: 59 cm3 64.1 cm3

2.2 Fuel System

Carburetor leakage test at 0.8 bar

2.3 Ignition System

Air gap between ignition

2.4 Chain Lubrication

Speed-controlled oil pump with reciprocating piston and

Oil delivery rate: 11.5 (+2.5) cm3/min

Oil delivery rate: 6.0 (+/-2.0)...17.5 (+3.0 / -4.5)

Fastener Thread size For component Torque Remarks

Screw P 4x14 Chain tensioner cover/engine housing 1.5

1) Loctite 242 or 243, medium strength

Use the following procedure when refitting a DG or P screw in an existing thread:

Coat micro-encapsulated screws with medium-strength threadlocking adhesive before re-installing.

Do not mix up screws with and without binding heads.

Condition Cause Remedy

Clutch drum badly worn Install new clutch drum

Clutch springs stretched or fatigued Replace the clutch springs or install

Clutch spring hooks broken Replace the clutch springs or install

Needle cage damaged Fit new needle cage

Clutch shoe retainer broken Install new retainer or clutch

Clutch shoes and carrier worn Install new clutch

Condition Cause Remedy

Wrong chain pitch Fit chain of correct pitch

Insufficient chain lubrication Check chain lubrication

Chain sprocket worn Fit new chain sprocket

Clutch drum badly worn Install new clutch drum

Brake band blocked Check freedom of movement and

Clutch springs stretched or fatigued Replace the clutch springs or install

Clutch spring hooks broken Replace the clutch springs

Brake band stretched or worn Fit new brake band

Clutch drum worn Install new clutch drum

In the event of trouble with the

Condition Cause Remedy

Valve in oil tank blocked Clean or replace valve

Teeth on worm worn Install new worm

Worm drive spring broken Install new worm

Oil pump damaged or worn Install new oil pump

Oil pump damaged or worn Install new oil pump

Oil intake hose connection Install new oil intake hose

Worm drive spring not engaged in Engage drive spring in notch in

Condition Cause Remedy

Normal wear Fit new starter rope

Insufficient spring tension Check rewind spring and increase

Rewind spring broken Fit new rewind spring