Stihl MS 500i Air Filter Problem Fixed

The OEM washer that meets the air filter appears to be inadequate allowing dust to get inside the filter. This video suggests three possible solutions to correct this issue.
You can buy 2-packs of the washers I used here:
Update: I’m out of 2-packs. I found this link to another seller if you’re looking for the washers. Good luck!
www.ebay.com/i...

[@jeffreyrudolph5061]

Found the same , went w/ 2 OEM but I like your solution. Vibration & relaxation are the main culprit on the fines . Awesome saw !

[@lumberjaxe8910]

Thanks for going to the effort to try to rectify this. Though you put a washer under the foam gromet, now you have hightened the position of the air cleaner in which will cause dust to be sucked in, during high durations of vibration. There also is a video on YT that a Fella uses a pool noodle cut and he attaches it to the inside housing of the cover. This also is not a solution because the housing is naturaly shaped in a curvature fashion and equal down pressure on the air cleaner is not applied around the circumference of the base of the air cleaner ( rubber seal) and again is applying uneven pressure and cause's warpage to the air cleaner. Best method i come up with is punch a hole in 3mm rubber mat, the same circumference as the inside pressing plastic plate that pushes the top of the air cleaner and slip this over the rotating worm gear thread that fixes to the intreverted thread, then cut around the punch mark about 12mm, put saw cover back on then enough downward pressure is applied to the air cleaner.

[@em4703]

I think the double OEM washer is the best and simplest solution. It has enough give and also pushback to avoid all the issues that an o-rings could create. Thats what I used from day 1 together with silicone grease on the rubber seal at the bottom of the air filter. Works perfectly and never saw a speck of dust in the intake hundreds of tanks later.

[@lumberjaxe8910]

@@em4703 Yes I agree with the grease around the air filter seal is good insurance. These are great saws and are built for hard work. have run about 500 litres through my saw now, cutting firewood six hrs a day and the rubber gromet is doing the Job.. Mechanics are telling me these saws are coming in dusted. Unless owners take the responsibility of being on to this fault, is going to be an expensive loss.

[@stihl9968]

Excellent fix, did the same thing except I used the 1/8" thick neoprene washer, will watch and check it again very soon since I have two big trees to cut up and looks like some dead to remove.

[@robertodebeers2551]

Thank you. I'm going to try this right now. My new 500i filter isn't doing all it should. Cheers.

[@jimmydickson8854]

You shouldn’t need to do this stihl needs to rectify this recalls

[@christopherkeane3142]

Thanks for this video. I'm going to try the two OEM washer solution because I can't find the NBR washers anywhere in Europe.

[@MattEttinger]

I couldn’t find the same ones I bought but I did find these. They appear to be the same thing and you can buy a 4-pack. Good luck! www.ebay.com/itm/Oil-Resistant-Neoprene-Rubber-Washers-3-4-OD-X-1-4-ID-X-1-16-Thickness-/293159614674?_trksid=p2349624.m46890.l49286

[@em4703]

Im using double washers. Works perfectly

[@glennllewellyn7369]

Get 2 or three foam circle washers, clean them and glue them together.

[@cory1369]

My decompression will not work right.I don’t like the way throws chips while you’re cutting because the side covers to shallow short

[@pagey007]

500i does not like a long bar with an 8 tooth for that reason .. recycles back onto the top of the rails and binds chain ..Same goes for the husky 572xp

[@bkb5668]

I have a west coast cover on mine it is the 500i-R version with larger spikes and the clutch cover is larger it also has a roller chain catch and wrap handle bar. Run what ever bar you would like up to 32" bar chain sprocket combo. You just have to set them up right. I run mine with 25" and 28" bars 3/8 full skip. Light bars are the best for this combo 28" and up. P.S. I would pull a 36" in a pinch and not sweat it to bad!!!! Lol

[@smigletat9634]

@@pagey007 So inadvertently enough are you referring to if you ran a smaller sprocket that it would delete this problem?

[@pagey007]

@@smigletat9634 Yes it helps , And the 500 i does not run an 8 tooth so well imho as power is very "peaky" , and with a 7 tooth its easier to keep it "on the pipe" so to speak .. I run an 8 tooth on the 572 with the rubber flap in the side cover removed shortened ,, See vid .. kzbin.info/www/bejne/Z6GwqGehhcqqjM0

[@KEN-Woodworking]

Nice 👌🏻

[@valqueenofValhalla]

You should also consider opening the veins on the side of the case so more air flows to the filter if you look the slits are blocked we all know more air = cooler running equipment

[@trevorwatson2591]

I had the same thought process; however, I presume the German engineers were intentional with their air flow design. I am reluctant to alter the design which might introduce an unforseen problem. Admittedly I am ignorant and timid due to creating an unforseen problem...

[@pagey007]

Might have been my video.. I fixed mine the same way.. High density foam washer sorted mine..

[@moms762]

I think I already saw one guy that modified his and put what appeared to be a motorcycle Air filter on his and had it clamped on with a hose clamp.

[@xring100]

Thanks for the video can you post a link to where you found the 25 pack i checked you ebay link they were all gone

[@MattEttinger]

I couldn’t find the same ones I bought but I did find these. They appear to be the same thing and you can buy a 4-pack. Good luck! www.ebay.com/itm/Oil-Resistant-Neoprene-Rubber-Washers-3-4-OD-X-1-4-ID-X-1-16-Thickness-/293159614674?_trksid=p2349624.m46890.l49286

[@xring100]

@@MattEttinger thanks appreciate it

[@stevessaws3612]

Nice. I put an o-ring on top of my filter.

[@guly]

Exactly where does that hold on to tho? On top of filter, im not following? Just loosely in the center circle of the topside?

[@stevec8861]

Thanks for showing that. Sad you have to jury-rig the most costly per cc saw on market to keep fines out of motor. Enough for me to try a Husky new autotune rather than Stihl's new fuel injection when I need a new pro saw. No excuse for Stihl marketing crap like that, especially when they took so long to bring the 500i to North American market. Just no excuse.

[@pagey007]

I own both.. 572 with free flow muffler hauls.. Will have a video up soon.. 🙂

[@samturner4850]

I cut 200 or so full cords with a 500i since getting mine late January. Lots of fines getting in, but it still runs strong. I’d say it’s a problem, but most users won’t run it enough to see the consequences.

[@stevec8861]

@@samturner4850 I've seen nonsense like this with some no-name cheap saws, but the 500i is most expensive per cc saw on market! Moreover, Stihl was very slow to launch this in North American, so they had plenty of time to work such bugs out but failed to do so. Sorry, just no excuse for Stihl not fixing this during R&D phase.

[@FredFlintstone21]

Maybe stihl isn't rectifying this because they believe the small particles getting in are of no consequence

[@em4703]

Why stress over it? Put another OEM washer over the existing one. Solved. But yes I agree they should just offer the normal washers with double thickness instead of having us use 2. Or at least come with 2 from the factory for people that wont bother doing this themselves.

[@Johnrider1234]

We cut 500 facecord every year

[@moms762]

Looks to me like you might be able to do away with their system and the way it holds the plastic and filter down and modify it to take a stud, or bolt and o-ring or something.

[@billhackley3540]

a little to clean to take serious

[@Johnrider1234]

We have 13 stihl.