Stihl 290, 310, 390 Chainsaw Service Manual (P/N 0458 209 3021)

• 160-page, three-PDF STIHL set — an 83-page 029 and 039 Service Manual, a 62-page 2002 English/USA instruction manual for MS 290, MS 310, and MS 390, and a 15-page U.S. illustrated parts list for series 1127.
• Clutch and chain-drive repair covers clutch drums and sprockets, clutch service, chain-brake disassembly and assembly, front and side chain tensioners, and bar-mounting studs.
• Engine work includes muffler and powerhead removal, crankcase pressure and vacuum testing, oil-seal replacement, and repair procedures for the cylinder, piston, rings, and crankshaft.
• Ignition, starter, and control systems address spark-plug diagnosis, ignition module and timing checks, flywheel and ignition-lead service, ground and stop circuits, the rope rotor and rewind spring, AV components, and Master Control parts.
• Fuel and lubrication coverage details oil-pump service, fuel pickup and tank-vent work, carburetor removal, leak testing, internal repair and adjustment, plus a separately documented automatic-choke system.
• Shop-reference content includes six main troubleshooting charts, ignition and automatic-choke fault diagrams, 14 exploded parts pages, tightening-torque data, special-tool numbers, model specifications, and a two-page maintenance chart.

Coverage and Document Identity

This package is not one 2002 service manual issued under all three MS model names. The workshop volume is a STIHL service publication copyrighted in 1992 and explicitly titled 029 and 039. The companion documents cover MS 290, MS 310, and MS 390 (1127). The instruction manual is copyright 2002 and carries the printed code 0458 209 3021; the U.S. parts list identifies all three MS models and their shared assemblies.

That distinction is important when selecting repair information. MS 310 is included in the operating, specification, and parts material, but the workshop volume has no separately named MS 310 repair chapter. Its procedures and technical data are organized around the 029 and 039 configurations, with their differences noted in the text.

Workshop Repair Depth

The service manual begins with fault tables for the clutch and chain drive, chain brake and tensioner, engine, ignition, rewind starter, chain lubrication, and fuel system. The repair chapters then move into bench work, including chain-brake teardown and reassembly, both chain-tensioner layouts, engine leakage testing, oil-seal replacement without complete engine disassembly, engine removal, and internal powerhead service. A useful variant note identifies low-compression machines by an “N” suffix and calls for the matching piston version.

Ignition coverage goes beyond a routine plug check. It provides a no-spark and intermittent-spark decision chart, plug-condition diagnosis, module service, ignition timing and air-gap setup, terminal and lead repair, flywheel removal, and checks for the short-circuit wire, ground wire, and contact spring. Starter repair covers the rope rotor, pawl, starter rope, rewind spring, spring tension, and rope-guide bushing.

The carburetor chapter covers removal, pressure leakage testing, internal service, reassembly, and adjustment of the all-position diaphragm carburetor. A separate automatic-choke section adds operating theory, fault isolation, control-valve and bellows leakage checks, filter service, lever-system repair, and throttle- and choke-shaft work. The parts list distinguishes HD-19B, HD-18B, and HD-21B carburetors, with the latter two identified for U.S. applications.

Exploded Views, Tools, and Specifications

The parts publication contains 14 exploded illustration pages. Examples include separate MS 290, MS 310, and MS 390 cylinder plates, Engine Housing, Oil Pump/Clutch, Chain Brake/Muffler, Ignition System, Fan Housing with Rewind Starter, and HD-series carburetor assemblies. These drawings add installed-position and part-number reference to the service procedures.

Named shop tools include assembly stand 5910 850 3100 / 5910 890 3100, carburetor and crankcase tester 1106 850 2905, vacuum pump 0000 850 3500, ignition setting gauge 1127 890 6400, piston snap-ring tool 5910 890 2210, and oil-seal press sleeve 1127 893 2400. The specification material covers model-specific engine dimensions and idle settings, fuel and oil capacities, cutting attachments, torque tables, leakage-test values, inspection data, and carburetor adjustments. The instruction manual contributes operating and maintenance coverage for bar and chain installation, chain-brake checks, air-filter service, spark-plug inspection, starter-rope replacement, sprocket checks, chain sharpening, and scheduled maintenance.

Two manual-specific repair cautions are especially useful. DG screws in polymer and light-alloy parts must re-enter the existing formed thread; poor alignment can cut another thread and weaken the joint. Oil-seal work also depends on protecting the crankshaft sealing surface and fitting the sealing lips and clamping rings in the stated orientation, or the engine may still leak after repair.

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.