STIHL MS 290/310/390 (2002) & 029/039 Chainsaw Manual Set (P/N 0458 209 3021)

The workshop manual takes a technician from fault diagnosis to bench repair. The companion publications give operators a maintenance schedule and help identify replacement parts by model, assembly, and part number.

Workshop coverage is specific to 029 and 039. For MS 290, MS 310, and MS 390, the included coverage is operation, routine maintenance, specifications, and parts identification. The workshop manual refers later engineering changes to separate STIHL Technical Information bulletins.

PDF Search, Navigation, and File Contents

Text search and bookmarks: All three PDFs have searchable text. The service and instruction manuals have embedded bookmarks. The parts list uses a linked table of contents and has no embedded bookmarks. The small legend on the automatic-choke schematic is easier to read when zoomed in.

The ZIP contains three printable PDFs with 160 pages total, including the title and contents pages within the files.

Chain Drive, Powerhead, and Fuel-System Service

The selected topics below show the range of the set. The manuals also cover chain-oil quantity adjustment and cold-weather operation.

• Clutch, chain drive, and brake: Clutch drum and sprocket service, clutch disassembly, chain-brake teardown and reassembly, front and side chain tensioners, and bar-mounting studs.

• Powerhead: Muffler and engine removal, crankcase pressure and vacuum testing, oil-seal replacement, and cylinder, piston, piston-ring, and crankshaft service.

• Ignition: Spark-plug diagnosis, ignition module and timing checks, flywheel and ignition-lead service, and checks for the ground wire, stop circuit, and contact spring.

• Rewind starter and controls: Rope rotor and pawl, starter rope and guide bushing, rewind spring replacement and tensioning, anti-vibration mounts, and Master Control components.

• Fuel and lubrication: Oil-pump service, fuel pickup and tank-vent work, diaphragm carburetor removal, leak testing, internal service, reassembly, adjustment, and a separate automatic-choke section.

• Operation and maintenance: Bar and chain installation, chain-brake checks, air-filter service, spark-plug inspection, starter-rope replacement, sprocket checks, chain sharpening, and a two-page maintenance chart.

• Workshop and parts references: Six troubleshooting sections, including an ignition flowchart, plus an automatic-choke fault chart, tightening torques, special-tool numbers, and illustrated parts tables.

STIHL wrote the workshop volume for its servicing dealers and staff. The instruction manual is for operators who need setup, operating, and routine maintenance guidance for the MS saws.

Leak Diagnosis and Repair Details

Crankcase sealing: The pressure and vacuum tests serve different purposes. The vacuum test can flag an oil seal that leaks even when the pressure test found no leak. The manual shows how to replace the seals without a full engine teardown and identifies the sealing surfaces, lip orientation, and clamping-ring position that matter during installation.

Pistons and fasteners: The low-compression version calls for the matching N-marked piston. For DG screws in polymer and light-alloy parts, the manual explains how engaging the existing formed thread avoids cutting a second thread and weakening the joint.

Ignition faults: The ignition chart helps trace a weak or absent spark through the terminal, stop circuit, air gap, flywheel, and ignition lead before replacing the module.

Carburetor Variants and Parts Selection

Automatic choke: The workshop volume explains how the control valve and bellows operate. Its schematic and fault chart guide diagnosis, and the repair section covers control-valve and bellows leak checks, filter service, lever-system repair, and throttle- and choke-shaft work. The main carburetor chapter identifies differences between Zama and Walbro components.

MS parts identification: The parts list includes 14 illustration pages, with separate cylinder plates and views of the engine housing, oil pump and clutch, chain brake and muffler, ignition, and rewind starter. It illustrates HD-19B and the U.S. applications HD-18B for MS 290 and HD-21B for MS 310 and MS 390. The reference numbers tie the drawings to the corresponding parts-table entries.

Special Tools and Service Safety

Holding and testing tools: The service manual identifies assembly stands 5910 850 3100 and 5910 890 3100, carburetor and crankcase tester 1106 850 2905, and vacuum pump 0000 850 3500. It also lists ignition setting gauge 1127 890 6400, piston snap-ring tool 5910 890 2210, and oil-seal press sleeve 1127 893 2400.

Chainsaw repair involves sharp cutters, fuel vapor, high ignition voltage, and spring-loaded brake and starter parts. Follow the factory safety information, use the specified holding and test equipment, and refer work beyond your tools or experience to a qualified STIHL technician.

Selected Pressure, Ignition, and Oil-Feed Specifications

For the 029 and 039, the crankcase pressure test specifies 0.4 bar (5.8 psi), held steady for at least 20 seconds. The ignition module procedure gives a flywheel-to-module air gap of 0.15–0.3 mm (0.006–0.012 in).

The 029/039 chain lubrication specifications list an adjustable oil feed of 6–15 cm³/min at 10,000 rpm.