Stihl MS 461 Manual
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Stihl MS 461 Manual

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STIH)
STIHL MS 461
2013-10

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  • Page 1 STIH) STIHL MS 461 2013-10...

  • Page 2: Table Of Contents

    Shroud Fuel Tank / 12.6.3 Standard Setting Cylinder Ignition Side 12.7 Intake Manifold Crankshaft 9.1.2 Annular Buffer on 6.6.1 Bearings / Crankcase 37 Spiked Bumper / Clutch Side © ANDREAS STIHL AG & Co. KG, 2013 MS 461, MS 461-R...
  • Page 3 Heater Switch 13.5 Heating Element in Rear Handle 13.6 Heating Element in Handlebar 13.7 Generator 13.8 Wiring Harness 13.8.1 Handle Heating and Generator Troubleshooting Chart 13.8.2 Test Connections and Test Values Special Servicing Tools Servicing Aids MS 461, MS 461-R...

  • Page 4: Introduction And Safety Precautions

    The meanings are as follows: 5910 850 1650 to the assembly stand with two screws (1) and washers. The above operation is not necessary with the new assembly stand 5910 890 3101 since the mounting plate is already fitted. MS 461, MS 461-R...

  • Page 5: Safety Precautions

    Safety Precautions Remove the spiked bumper replacement parts. to reduce the risk of injury from They can be identified by the STIHL contact with the sharp tips. If the machine is started up in the part number, course of repairs or maintenance...

  • Page 6: Specifications

    Specifications Motor MS 461, MS 461-R Displacement: 76.5 cm Bore: 52.0 mm Stroke: 36.0 mm Engine power to ISO 7293: 4.4 kW (6.0 HP) at 9,800 rpm Max. speed (with cutting attachment): 13,500 rpm Idle speed: 2,500 rpm Clutch: Centrifugal, without linings...

  • Page 7: Tightening Torquese

    Handle Molding Screw M 5x35x22 Hand guard, left 4), 6) Screw M 5x23 Shroud / crankcase Shroud / cylinder Locknut Chain catcher / spiked bumper Screw M 5x20 Chain catcher / spiked bumper / crankcase, bottom MS 461, MS 461-R...
  • Page 8 2) Loctite 270, high strength 3) Loctite 649, high strength 4) Screws with binding head 5) Micro-encapsulated screws 6) Waxed screws 7) Degrease crankshaft/flywheel and mount oil-free VW) Carburetor and handle heating system R) Rescue saw MS 461, MS 461-R...

  • Page 9: Troubleshooting

    Replace the clutch springs Loud noises Clutch springs stretched Replace all clutch springs Needle cage damaged Fit new needle cage Clutch shoe retainer broken Install new retainer or clutch Clutch shoes and carrier worn Install new clutch MS 461, MS 461-R...

  • Page 10: Chain Drive, Chain

    Saw chain does not stop Chain brake spring Fit new brake spring immediately when brake is stretched / broken activated Brake band Fit new brake band stretched / worn / broken Clutch drum worn Install new clutch drum MS 461, MS 461-R...

  • Page 11: Chain Lubrication

    Oil pump delivery rate set too low Adjust oil pump (only on machines with adjustable oil pump) Worm driver is loose Install new worm Sealing ring between oil pump and Replace the sealing ring crankcase damaged MS 461, MS 461-R...

  • Page 12: Rewind Starter

    (spring windings degreasant (containing no stick together) or moisture has got chlorinated or halogenated onto the rewind spring (spring hydrocarbons), then pull rope windings frozen together) carefully several times until normal action is restored MS 461, MS 461-R...

  • Page 13: Ignition System

    Check ignition lead/ignition module and replace as necessary. Check operation of spark plug. Clean the spark plug or replace if necessary. The carburetor or engine may also be the cause of poor engine running behavior MS 461, MS 461-R...

  • Page 14: Carburetor

    Metering diaphragm or gasket Fit a new metering diaphragm and damaged gasket Tank vent faulty Fit new tank vent Leak in fuel hose between pickup Seal connections or install new fuel body and carburetor hose MS 461, MS 461-R...
  • Page 15 Saw chain runs while engine is Engine idle speed too high Readjust with idle speed screw idling LA (counterclockwise) Clutch springs stretched or fatigued Replace the clutch springs or install new clutch Clutch spring hooks broken Replace the clutch springs MS 461, MS 461-R...
  • Page 16 – key has sheared off or slot in flywheel is worn Engine running extremely rich, has Choke shutter does not open fully Check carburetor and choke shaft, no power and a very low maximum service or replace if necessary speed MS 461, MS 461-R...

  • Page 17: Engine

    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 Air inlet in fan housing dirty Clean air inlet on fan housing MS 461, MS 461-R...

  • Page 18: Clutch Drum

    80% of the original thickness, install – Remove the rim sprocket and a new clutch drum. clutch drum. – Install the clutch drum. : Fit the retainers (1) and push the clutch shoes (2) over the arms (3) of the carrier. MS 461, MS 461-R...
  • Page 19 – Fit the boot on the spark plug. – Fit the air baffle. – Fit the filter cover. The washer (1) must be in place and the word "TOP" (arrow) must face outwards. MS 461, MS 461-R...

  • Page 20: Chain Brake

    : Remove covers (2) and (3). of a second). If the chain brake does not operate properly, refer to troubleshooting, : Turn the brake band (1) to one b 3.2. side and disconnect it from the brake lever (2). MS 461, MS 461-R...

  • Page 21: Brake Lever

    – Remove the rewind starter, b 8.2 : Place the covers (1) and (2) in position. : Position the brake band (1) in the : Insert and tighten down the guide (arrow). screws (3) firmly. MS 461, MS 461-R...
  • Page 22 The turns of the brake spring must be tightly against one another in the relaxed condition. If this is not the case, replace the brake spring. : Position the protective tube so that it leaves the first turn (arrow) free. MS 461, MS 461-R...

  • Page 23: Cam Lever

    (4). The cam lever is not yet under – Check the cam lever, spring and tension – the spring may become cam running face on the hand detached. guard, and replace as necessary. MS 461, MS 461-R...

  • Page 24: Chain Tensioner

    Pin (4) b = about 4.6 - 4.8 mm Pin (5) c = about 5.1 - 5.3 mm – Lubricate the brake lever and cam lever with STIHL grease, b 15 – Reassemble all other parts in the reverse sequence.

  • Page 25: Bar Mounting Studs

    : Fit the O-ring in the spur gear recess (arrow). – Clean all disassembled parts, b 15 – Lubricate the threads, gears and O-ring with STIHL grease, b 15 – Reassemble in the reverse : Before installing, coat the sequence. threads (1) of the collar studs...

  • Page 26: Engine

    – make sure – Remove and inspect the muffler there is no gasket residue or dirt and replace it if necessary. particles in the exhaust port. Always replace components with damaged sealing faces. MS 461, MS 461-R...

  • Page 27: Leakage Test

    : Coat screws (2) with it down firmly. threadlocking adhesive, b 15 – Remove the top casing and : Check the position of the heat loosen the muffler screws, b 6.1 shield and gasket and fit the screws (2). MS 461, MS 461-R...

  • Page 28: Vacuum Test

    (arrow). – Tighten the screws moderately. – Coat screw or inside of impulse : Push ring (2) to the left hose with STIHL press fluid, The sealing plate must completely – vacuum test. b 15 fill the space between the two screws.

  • Page 29: Pressure Test

    – Clean the sealing face, b 15 is airtight. – Lubricate sealing lips of new oil – If the pressure drops, the leak seal with STIHL grease, b 15 must be located and the faulty part replaced. To find the leak, coat the suspect area with oil and pressurize the crankcase again.
  • Page 30 – Clean the sealing face. – Lubricate sealing lips of new oil Clutch Side seal with STIHL grease, b 15 – Remove the clutch, b 4 – Remove the oil pump, b 11.3 : Fit the installing sleeve (1) 1118 893 4602.

  • Page 31: Shroud

    : Carefully lift the cylinder (1) away, pushing the manifold – Remove the carburetor, b 12.4 flange (2) out of the tank housing at the same time. – Remove the muffler, b 6.1 – Remove the decompression valve, b 6.9 MS 461, MS 461-R...
  • Page 32 5910 893 5300 so that the – Coat the inside of the manifold recesses (arrows) engage the with STIHL press fluid, b 15 flange and then push it between the piston and crankcase. : Push the manifold (1) onto the...
  • Page 33 – Remove the clamping strap and piston support. – Coat the outside of the manifold flange with STIHL press fluid, b 15 – Push tank housing towards : Insert the screws (arrows) to hold cylinder and hold it in that the cylinder and gasket in position.

  • Page 34: Crankshaft

    6.6.1 and b 6.3. Clutch side of crankcase : Remove the gasket (1). : The tensioner slide (1) must butt against the thrust pad (arrow). : Remove the circlip (1). MS 461, MS 461-R...
  • Page 35 5910 893 2101. at the ignition side and push it home. : Unscrew the spindle (1) until the drilled plate (2) butts against the crankcase – left-hand thread. – Heat the inner bearing race to about 160°C (320°F). MS 461, MS 461-R...
  • Page 36 Therefore, make sure Make sure the sleeves (arrows) the small end (3) of the connecting engage the holes and the gasket is rod always points upward to the not pinched or twisted. cylinder. – Remove the installing tool. MS 461, MS 461-R...
  • Page 37 – Unscrew the spindle clockwise and take away the service tool. – Take out the M5x72 screws. : Hold the crankshaft (1) steady and rotate the spindle (2) to screw the threaded sleeve onto the crankshaft stub. MS 461, MS 461-R...

  • Page 38: Bearings / Crankcase

    – Heat area of bearing seat to about 160°C (320°F). – Position the ball bearing so that its open side (balls visible) faces the inside of the crankcase. : Push the ball bearing home as far as stop. MS 461, MS 461-R...

  • Page 39: Piston

    : Use the assembly drift (1) – Install the crankshaft, b 6.6 1108 893 4700 to push the piston pin (2) out of the piston. – Install the oil seals, b 6.3 – Reassemble all other parts in the reverse sequence. MS 461, MS 461-R...

  • Page 40: Piston Rings

    : Fit the piston pin (2) on the assembly drift (1) and slide it into the piston. : Use a piece of old piston ring to scrape the grooves (arrows) – Prepare snap ring for installation clean. with installing tool 5910 890 2212. MS 461, MS 461-R...

  • Page 41: Decompression Valve

    – Fit the decompression valve and screw it home by hand. – Tighten down the decompression valve firmly. – Reassemble all other parts in the reverse sequence. MS 461, MS 461-R...

  • Page 42: Ignition System

    : Use a suitable punch to drive out the retainer (1). – Reassemble in the reverse sequence. : Take out the screws (arrows). – Check the spark plug boot and ignition lead, and replace if necessary, b 7.4 MS 461, MS 461-R...
  • Page 43 The setting gauge is not shown in position and fit the screws (2). the illustration. – do not tighten down yet. : Push the ignition module (1) back and hold it there – the flywheel must turn freely. MS 461, MS 461-R...

  • Page 44: Testing The Ignition Module

    The engine may start and accelerate during the test. – To test the ignition module, use either the ZAT 4 ignition system tester 5910 850 4503 or the ZAT 3 ignition system tester 5910 850 4520. MS 461, MS 461-R...

  • Page 45: Spark Plug Boot

    15 mm from the end of the lead. – To run diagnosis on MS 461, select "Other STIHL Products". Then start the diagnosis function : Pinch the hook of the leg spring...

  • Page 46: Flywheel

    If damage is found, replace the flywheel. Before installing the ignition lead, pack the high voltage output with STIHL multipurpose grease b 15. : Unscrew the flywheel nut (1). Do not use either graphite grease or silicone insulating paste.

  • Page 47: Wiring Harness

    7.7 – Check ground wire for contact and continuity, : Fit short circuit wire terminal (3) replace wiring harness if with its crimped side facing the necessary. ground wire. MS 461, MS 461-R...

  • Page 48: Wiring Harness Removing And

    (2) out in direction : Pull the wires out of the guides of cylinder. (arrows). – Use STIHL press fluid to make : Pull the grommet (1) off the installation easier, b 15 wiring harness. : Fit the grommet (1) into the bore –...
  • Page 49 (arrow) and housing wall – the ground wire must be under the short circuit wire. : Push the ground wire (2) into the guides (arrows). Position the wires next to one another without crossing over. MS 461, MS 461-R...

  • Page 50: Wiring Harness Removing And Installing On Models With Heating System

    Make sure the grommet (1) is in : Pull the connectors and wires out place. of the guides (arrows). – Use STIHL press fluid to make installation easier, b 15 : Press grommet (1) out in direction of carburetor box and...
  • Page 51 – Leave the heater switch with wire and protective tube (4). to one side. – Use STIHL press fluid to make : Pull the wires out of the guides installation easier, b 15 : Pull the wires out of the guide (arrows).
  • Page 52 : Push the wires into the guide (arrow) – the thin wire must be under the thick wire. : Push the thin black wire (1) into the guide (arrow). Crimped sides of connectors must point towards switch shaft mount (arrow). MS 461, MS 461-R...
  • Page 53 : Push the red generator wire (1) wiring harness (2). place. and connector (2) into the guide (arrows). – Use STIHL press fluid to make – Install the tank housing, installation easier, b 15 b 12.9.3 : Push the wiring harness (2)

  • Page 54: Contact Spring

    (arrows) in position "0". – Install switch housing and switch shaft, b 10.1 : Push the contact spring (1) for the ground wire and contact spring for short circuit wire (2) into guides of switch housing (3). MS 461, MS 461-R...

  • Page 55: Ignition System

    – If necessary, install new spark plug boot and/ or leg spring, b 7.4 Test ignition system: with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap see TI 32.94), or test with MDG 1 b 7.3, b 7.3.1 MS 461, MS 461-R...
  • Page 56 – Ignition lead screwed fully into ignition module? – 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 or module, b 7.4 MS 461, MS 461-R...
  • Page 57 7.2 Machine 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 6.2, b 7.5 MS 461, MS 461-R...

  • Page 58: Rewind Starter

    : Fit the new pawls in the bores (arrows) and lubricate the : Take out the screw (1) and In such a case it is sufficient to apply pegs (1) with STIHL grease, screws (arrows). a few drops of a standard solvent- b 15...

  • Page 59: Rope Rotor

    Installing : While still holding the rope – Lubricate full length of starter rotor (1) steady, unwind the post with STIHL special lubricant, starter rope (2). b 15 : Pull out the twisted rope (2) in – Install starter rope in rope rotor, direction of starter grip and b 8.5...

  • Page 60: The Rewind Spring

    – Install the rewind starter, b 8.2 Spring – Remove the rewind starter, b 8.2 : Thread the new starter rope through the top of the starter grip, press the nipple (1) into the grip until it snaps into place. MS 461, MS 461-R...

  • Page 61: The Rewind Spring

    Installing new rewind spring : Fit the anchor loop in its seat (arrow) in the fan housing. – Lubricate the rewind spring with a few drops of STIHL special lubricant, b 15 – Reassemble all other parts in the reverse sequence.

  • Page 62: Av Elements

    – small diameter facing the : Take out the screw (2) and crankcase. remove the sleeve (3) with hose. – Use STIHL press fluid to make : Take out the screws (4) and installation easier, b 15 remove the annular buffer.
  • Page 63 9.1.2 Annular Buffer on Spiked Bumper / Clutch Side – Use STIHL press fluid to make : Pull the rubber ring (1) off the installation easier, b 15 tank housing stub and push it out through the crankcase bore (arrow).

  • Page 64: Annular Buffer On Oil Tank / Ignition Side

    Installing – Use STIHL press fluid to make : Take out the screw (1) and pry installation easier, b 15 out the annular buffer (2). – Use STIHL press fluid to make installation easier, b 15 : Push the annular buffer, small –...

  • Page 65: Stop Buffer At Clutch Side

    (1) faces the opening – Insert screw and tighten it down (arrow) in the tank housing. firmly. – Use STIHL press fluid to make – Use STIHL press fluid to make – Push the plug into the annular installation easier, b 15 installation easier, b 15 buffer.

  • Page 66: Wrap Around Handlebar On Rescue Saw

    : Position the handlebar (1) in its remove the handlebar (2). seat (arrows) on the side of the machine. – Use STIHL press fluid to make installation easier, b 15 Installing : Fit the screws (2) : Push retainer (1) into place so –...

  • Page 67: Handlebar With Heating

    : Pull the thick black wire (2) in – Pull the grommet off the wire. direction of handlebar heating element and out of grommet (3) and protective tube (4). – Take out all 4 handlebar mounting screws, b 9.2 MS 461, MS 461-R...
  • Page 68 : Thread the wiring harness (1) through the bore (arrow) in direction of carburetor box until the protective tube (2) projects 5- 8 mm into the carburetor box. : Push the wire fully into the guide (arrow). MS 461, MS 461-R...
  • Page 69 (2) and tighten it down firmly. : Fit the grommet (1) on the wire, push the connector sleeve (2) into the heater switch (3) as far as stop. – Push the grommet onto the heater switch. MS 461, MS 461-R...

  • Page 70: Control Levers

    : Push the switch shaft (1), pivot pin first, into the mount (arrow) and place it in position. : Rotate the switch shaft (1) until the seat of the switch slide (2) faces away from the switch housing. MS 461, MS 461-R...

  • Page 71: Lockout Lever

    (arrow) until it snaps into – Remove the air filter, b 12.1 trigger and torsion spring, position. replace as necessary. – Open throttle wide and hold trigger in that position, then disconnect throttle rod from trigger. MS 461, MS 461-R...

  • Page 72: Throttle Trigger

    : Push lockout lever (2) into the mounts (arrows) until it snaps into – Open throttle wide and hold place. trigger in that position, then disconnect throttle rod from The lockout lever may pop out. trigger. MS 461, MS 461-R...

  • Page 73: Throttle Rod On Models With Heating

    (1) locates against the grommet (2). – Reassemble all other parts in the reverse sequence. : Push the grommet (1) into its seat (arrow) and locate it in position. : Push knob (1) into hole in baffle. MS 461, MS 461-R...

  • Page 74: Chain Lubrication

    – Remove the washer. – Pull off the pickup body (1), check it and replace if necessary. – Reassemble in the reverse sequence. : Push the oil suction hose (1), pickup body first, through the housing bore (arrow). MS 461, MS 461-R...

  • Page 75: Adjusting Uprated Oil Pumps

    See owner's manual for most – Coat stub and sealing ring with suitable settings for different uses. STIHL press fluid, b 15 : Take out the screws (1). : Pull off the oil pump (2), check and replace if necessary.

  • Page 76: Valve

    1 mm +/- 0.1 (a). Reassemble all other parts in the reverse sequence. – Use a 5 mm drift to carefully drive the valve out of the crankcase from inside the oil tank. MS 461, MS 461-R...

  • Page 77: Fuel System

    – Reassemble all other parts in the Switch shaft (3) must be in cold start off the baffle (1). reverse sequence. position. – Check the baffle and replace if : Remove the filter base (4) from necessary. the studs. MS 461, MS 461-R...

  • Page 78: Carburetor

    – Check the carburetor and service : Remove the heating element (1) the fuel hose (1) and impulse or replace it if necessary. and put it to one side hose (2). – Check the sleeve, remove and replace it if necessary. MS 461, MS 461-R...
  • Page 79 : Fit the baffle plate (1) over the studs so that the lettering (arrow) : Fit the new gasket (1). faces outwards. – Use STIHL press fluid to make installation easier, b 15 : Push the knob of grommet (2) fully into the bore (3).

  • Page 80: Leakage Test

    – Push the pressure hose of pump 0000 850 1300 onto the nipple. : Push the ring (1) to the right and pump air into the carburetor until the pressure gauge (2) indicates a pressure of about 0.8 bar (80 kPa). MS 461, MS 461-R...

  • Page 81: Inlet Needle

    : Line up the end cover (1) so that the holes engage the pegs (2). : Take out the screw (1). : If there is an annular indentation (arrow) on the sealing cone of the inlet needle, fit a new inlet needle. MS 461, MS 461-R...

  • Page 82: Pump Diaphragm

    – Check that the inlet control lever moves freely. : Use a needle to remove the fuel strainer (1) from the carburetor – Install the metering diaphragm, body. Clean or replace the fuel b 12.5.1 strainer. – Reassemble in the reverse sequence. MS 461, MS 461-R...

  • Page 83: Adjusting Screws

    – Remove the carburetor, b 12.4 : Insert and tighten down the – See also carburetor screw (2) firmly. troubleshooting, b 3.6 – Reassemble all other parts in the reverse sequence. MS 461, MS 461-R...
  • Page 84 – Screw down the low speed – Take out the high speed Version without limiter caps screw (L) as far as stop. screw (H). – Remove the low speed screw (L) – Continue with the high speed with spring. screw (H). MS 461, MS 461-R...

  • Page 85: Adjusting The Carburetor

    (H) if – Go to "Setting", b 12.6.2 necessary. : Inspect the O-ring (1) and replace if necessary. : Screw down the high speed screw (H) as far as stop. MS 461, MS 461-R...

  • Page 86: Setting

    All versions 5. Remove tachometer after obtaining engine speed of Adjust engine speeds with 13,000 rpm. tachometer or STIHL MDG 1 engine Turn high speed screw (H) analyzer (select "Other STIHL another 1/8 turn clockwise Products" / "Tachometer"). Adjust (leaner), a maximum engine...

  • Page 87: Standard Setting

    – Turn the low speed screw (L) Readjust carburetor to "Standard slowly clockwise as far as stop, Setting" after returning from high but not more than altitude. a 3/4 turn, then turn it back a 1/4 turn. MS 461, MS 461-R...

  • Page 88: Intake Manifold

    : Loosen the screw (1) and push – Coat the outside of the manifold – Remove the carburetor, b 12.4 the hose clamp over the manifold flange with STIHL press fluid, in the direction of the tank b 15 – Take out the annular buffer housing.

  • Page 89: Impulse Hose

    : Position the manifold flange (1) – – Coat tapered outside of new – Open the fuel tank cap and drain its flats (arrows) must locate impulse hose with STIHL press the fuel tank, b 1. against the studs (2). fluid, b 15 –...

  • Page 90: Removing And Installing

    – always install a new tank vent. Installing – Coat sealing ring of new tank vent with STIHL press fluid, b 15 – Push home the tank vent by hand until it snaps into position. – Reassemble all other parts in the reverse sequence.

  • Page 91: Fuel Hose

    12.9.1 from the fuel tank. Do not overstretch the fuel suction hose. – Use STIHL press fluid to make installation easier, b 15 – Fit the pickup body, b 12.9.1 – Push the fuel suction hose (1) – Close the tank cap.

  • Page 92: Tank Housing

    Only transfer those parts from the old tank housing that are not included with the replacement – see : Push the manifold flange (1) out parts list. of the tank housing (2) in the direction of the cylinder. MS 461, MS 461-R...
  • Page 93 : Position the impulse hose (1) so place. that the rounded side (arrow) of the flange faces up. – Use STIHL press fluid to make installation easier, b 15 : Push the tank housing (1) in direction of cylinder until the...

  • Page 94: Heating System

    : Pull the insulating tubes (1) with – If these readings are not connectors out of the guides. obtained, install a new heating – Remove the baffle, b 12.2 element. – Set the ohmmeter to measuring range "Ω". MS 461, MS 461-R...

  • Page 95: Thermostatic Switch

    The thermostatic switch and the connectors. heating element form a single unit. If the switch is faulty, the heating element must be replaced. Removal and installation are described in the chapter on "Heating Element", b 13.1.2 – Check operation MS 461, MS 461-R...

  • Page 96: Carburetor Heating System Troubleshooting Chart

    Circuit diagram of handle and carburetor heating system G = Generator 1 = Rear handle 2 = Handlebar 3 = Heater switch 4 = Thermostatic switch 5 = Heating element (carburetor) 6 = yellow wire 7 = red wire MS 461, MS 461-R...

  • Page 97: Handle Heating System

    If the system is in order, the out of the guides (arrows). ohmmeter will indicate a value of about 10 Ω in measuring range "Ω". If no reading is obtained, there is a break in the circuit. MS 461, MS 461-R...
  • Page 98 (3) as far – Test ground wire contact ring and as stop. ground for break. – Install the carburetor, b 12.4 : Push the grommet onto the – Reassemble all other parts in the heater switch. reverse sequence. MS 461, MS 461-R...

  • Page 99: Heating Element In Rear Handle

    2 Ω in measuring position. transferred to the handle and range "Ω". cause the new heating element to overheat. If the reading is outside this range, install a new heating element. MS 461, MS 461-R...

  • Page 100: Heating Element In Handlebar

    – Reassemble all other parts in the reverse sequence. : Push insulating tube (1) of thick wire in direction of wiring harness and separate the pin and socket connector. – Set the heater switch to F, b 9.2.2. MS 461, MS 461-R...

  • Page 101: Generator

    – Fit the screws and tighten them pin and socket connectors. down firmly. – Remove the insulating tubes. : Inspect the generator and poles (arrow) for cracks or other damage. If damage is found, replace the generator. MS 461, MS 461-R...

  • Page 102: Wiring Harness

    Harness, Removing and Installing on Models with Heating System", b 7.6.4 : Push the insulating tubes (1) onto the generator wire. : Connect the pins (2) and sockets (3) and center the insulating tubes (1) on the connectors. MS 461, MS 461-R...

  • Page 103: Handle Heating And Generator Troubleshooting Chart

    Install new rear handle heating element b 13.5 Resistance Install new rear handle heating element about 1.6 Ω? Check generator Resistance between engine ground Install new generator, and generator connection about 0.5 – 1 Ω? b 13.7 MS 461, MS 461-R...
  • Page 104 9.2.2 Check the heater switch Install new (contact sleeve against switch housing) heater switch, Closed: about 0Ω? b 13.4 Open: Circuit interrupted, b 13.4 Reconnect connector to thermostatic switch, b 13.1.3 System in order MS 461, MS 461-R...

  • Page 105: Test Connections And Test Values

    Break in wire, Install new heating element handlebar damaged Short circuit – Repair insulation, damaged replace handlebar insulation if necessary Pull out wire for this purpose MS 461, MS 461-R...
  • Page 106 Circuit diagram of handle and carburetor heating system G = Generator 1 = Rear handle 2 = Handlebar 3 = Heater switch 4 = Thermostatic switch 5 = Heating element (carburetor) 6 = yellow wire 7 = red wire MS 461, MS 461-R...

  • Page 107: Special Servicing Tools

    Service tool ZS (set) 5910 007 2201 Removing and installing including crankshaft (ignition side) drilled plate 5910 893 2103 - Drilled plate 5910 893 2101 Pulling two halves of crankcase together - Screw sleeve 5910 893 2420 Installing crankshaft MS 461, MS 461-R...
  • Page 108 Relieving tension of rewind spring Stud puller M8 5910 893 0501 Removing bar mounting studs Socket, 13 mm, long 5910 893 2804 Removing and installing decompression valve Hook 5910 893 8800 Removing pickup body Remarks: 1) Use for releasing only. MS 461, MS 461-R...

  • Page 109: Servicing Aids

    Oil seals, sliding and bearing points STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in fan housing STIHL press fluid OH 723 0781 957 9000 Rubber components, AV elements STIHL multipurpose grease 0781 120 1109...
  • Page 110 englisch / english 0455 773 0123. VA1.K13.

This manual is also suitable for:

Ms 461-r

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