Stihl MS 460 Service Manual
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Stihl MS 460 Service Manual

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STIH)
STIHL MS 460
2004-11

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  • Page 1 STIH) STIHL MS 460 2004-11...
  • Page 2 Installing 11.3.1 Removing and 5.4.2 Removing Stop Switch Installing 5.4.3 Installing Wiring Harness 11.3.2 Servicing Chain Tensioner 7.5.1 Testing Wiring Bar Mounting Studs Harness Ignition System Troubleshooting © ANDREAS STIHL AG & Co. KG, 2004 MS 460, MS 460 C...
  • Page 3 14.3 Heating Element in Carburetor with Rear Handle Limiter Caps) 14.4 Heating Element in 12.5 Tank Vent Front Handle 12.6 Pickup Body 14.5 Generator 12.7 Fuel Hose 12.8 Tank Housing Special Servicing Tools Servicing Aids MS 460, MS 460 C...
  • Page 4 "Special Servicing Tools" of this procedures for this power tool. manual. Use the part numbers to identify the tools in the "STIHL You should make use of the Special Tools" manual which lists all illustrated parts lists while carrying the special servicing tools currently out repair work.
  • Page 5 Warning! Do not bring any fire, flame, spark or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. MS 460, MS 460 C...
  • Page 6 0.15 – 0.3 mm Spark plug (suppressed): Bosch WSR 6F NGK BPMR 7 A Electrode gap: 0.5 mm Chain Lubrication Fully automatic, speed-controlled oil pump with rotary piston Oil delivery rate: 8 – 18 cm at 10,000 rpm MS 460, MS 460 C...
  • Page 7 Crankshaft (flywheel) 33.0 Remarks: 1) Secure screw with Loctite 649 2) Secure screw with Loctite 243 3) Only machines with wrap-around handle 6) Only machines with spark arresting screen 7) Only machines with handle heating MS 460, MS 460 C...
  • Page 8 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 speed setting for polymer: – P screws: max. 500 rpm MS 460, MS 460 C...
  • Page 9 Chain sprocket worn Install new chain sprocket Chain does not stop immediately Brake spring stretched or broken Fit new brake spring when brake is activated Brake band stretched / worn / Fit new brake band broken MS 460, MS 460 C...
  • Page 10 Coat rewind spring with a standard becomes viscous at very low solvent-based degreasant outside temperatures (spring (containing no chlorinated or windings stick together) halogenated hydrocarbons). Then pull rope carefully several times until normal action is restored MS 460, MS 460 C...
  • Page 11 Bore in pump housing worn Fit new oil pump Oil pump delivers insufficient oil Control screw and/or control edge Replace control screw and/or oil on pump piston worn pump Bore in pump housing worn Fit new oil pump MS 460, MS 460 C...
  • Page 12 Check operation of Master Control lever and ignition module Ignition timing wrong, flywheel out Install new flywheel of adjustment, key in flywheel has sheared off Weak magnetization in flywheel – Install new flywheel pole shoes have turned blue MS 460, MS 460 C...
  • Page 13 (relative to correct installed edge of housing position) Inlet needle sticking to valve seat Remove inlet needle, clean and refit Diaphragm gasket leaking Fit a new diaphragm gasket Metering diaphragm damaged or Fit a new metering diaphragm shrunk MS 460, MS 460 C...
  • Page 14 Main jet bores or ports blocked Clean the bores and ports Setting of high speed screw (H) Rotate high speed screw (H) too rich clockwise (leaner), no further than stop Throttle shutter not opened fully Check linkage MS 460, MS 460 C...
  • Page 15 Decompression valve sticking Replace the decompression valve 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 MS 460, MS 460 C...
  • Page 16 5.4.2 : Pull off the clutch drum (1) with needle cage (2). – Inspect the needle cage for damage. : Disengage the chain brake by pulling the hand guard towards the front handle. MS 460, MS 460 C...
  • Page 17 (see arrow).t : Loosen the twist lock (1) and lift off the carburetor box cover (2) upwards. : Remove the air baffle (1). – Pull off the spark plug boot and unscrew the spark plug. MS 460, MS 460 C...
  • Page 18 : Fit the clutch shoes over the crankshaft. shoes. arms (1) of the clutch carrier so that the series number (2) is on Note that clutch has a left-hand the same side as the longer thread. hexagon (3). MS 460, MS 460 C...
  • Page 19 The braking time is in order if clutch shoes. deceleration of the saw chain is imperceptible to the eye. : Fit the clutch and tighten it down firmly, b 3.5 – Remove locking strip from the cylinder. MS 460, MS 460 C...
  • Page 20 : Take out the screw (arrow). Install a new brake band if there are noticeable signs of wear (large areas on inside diameter and/or parts of outside diameter) and its remaining thickness is less than 0.6 mm. MS 460, MS 460 C...
  • Page 21 – Clean the entire housing recess for the chain brake. – If the groove in the anchor pin for the brake spring is worn, install a new pin. – Remove the cylinder, b 6.5.1 : Remove the E-clip (arrow). MS 460, MS 460 C...
  • Page 22 : Check that cam lever is properly the hand guard. positioned on face (arrow) of hand guard bearing boss. The short arm (arrow) of the bell crank must point to the top of the hand guard. MS 460, MS 460 C...
  • Page 23 – Place cover in position. crank (arrow). : Insert screws (arrows) and – Position the brake band behind tighten down firmly, b 3.5 the lugs on the crankcase. : Install clutch drum/chain sprocket, b 5.1 MS 460, MS 460 C...
  • Page 24 : Remove the cover plate. : Inspect the teeth on the spur gear and adjusting screw (1), replace both parts if necessary. To do this, pull off the thrust pad (2) and unscrew the tensioner slide (3). MS 460, MS 460 C...
  • Page 25 – Remove the top casing. fitting the spur gear. Install all other parts in the reverse sequence. : Take out the screws (arrows). – Remove the bottom casing. – Remove the gasket and heat shield. MS 460, MS 460 C...
  • Page 26 (if fitted). If necessary, bend back screen (arrow). replace if necessary, b 6.7.2 the retaining tabs (2) and pull out the screen (not on MS 460 – Clean the spark arresting screen Magnum). or fit a new one if necessary.
  • Page 27 : Fit M5x30 screw (1) with sleeve. and the vacuum pump. : Fit spark plug (2) and tighten it down, b 3.5 – Remove muffler top casing, b 6.1 : Back off the screws (arrows) half way. MS 460, MS 460 C...
  • Page 28 : Pump air into the crankcase with washer (2) are in place. rubber bulb until the gauge (arrow) indicates a pressure of 0.5 bar. If this pressure remains constant for at least 20 seconds, the crankcase is airtight. MS 460, MS 460 C...
  • Page 29 0000 850 3501 to b 6.8 nipple (arrow) of the test flange. : Close the vent screw (1) on the pump. : Operate lever (2) until pressure gauge (3) indicates a vacuum of 0.5 bar. MS 460, MS 460 C...
  • Page 30 : On machines with heated : Use pliers 0811 611 8380 to handles, take out the screws remove the retaining ring (arrow). (arrows). – Put the generator to one side. MS 460, MS 460 C...
  • Page 31 – Install the oil pump, b 11.3.1 : Slip the installing sleeve (1) – If a decompression valve is fitted, 1118 893 4602 onto the check that the cover (arrow) is crankshaft stub. properly seated. MS 460, MS 460 C...
  • Page 32 : Take the sleeve (1) out of the : Carefully separate the cylinder manifold. gasket from the cylinder base. : Remove the washer (2) from the – Pull the cylinder off the piston. studs. MS 460, MS 460 C...
  • Page 33 – Remove the piston from the connecting rod and take the needle cage out of the small end. – Inspect the piston rings and replace if necessary, b 6.6 MS 460, MS 460 C...
  • Page 34 : Remove the sleeve from : Stand the installing tool, sleeve installing tool 5910 890 2212. downward, on a flat surface (wooden board) and press vertically downwards until the sleeve butts against the tool's shoulder. MS 460, MS 460 C...
  • Page 35 (1) on manifold. The screw head must the wooden assembly block (2) point to the right. 1108 893 4800. – Tighten down the clamp so that it closes against the spacer sleeve. MS 460, MS 460 C...
  • Page 36 Install all other parts in the reverse sequence. : Press the manifold down. : Fit sleeve (1) in manifold. : Fit the washer (2) on the studs. Install all other parts in the reverse sequence. MS 460, MS 460 C...
  • Page 37 : Take out the screws (arrows). – Remove the piston, b 6.5.2 grooves so that the radii at the ends of the rings face upward. – Remove the oil pump. – Install the piston, b 6.5.2 MS 460, MS 460 C...
  • Page 38 : At the chain tensioner side of the : Remove the gasket from the crankcase, use a 5 mm drift (2) to crankcase. drive the dowel pin out of the two halves of the crankcase. MS 460, MS 460 C...
  • Page 39 : Turn spindle (1) counter- : Use press arbor (1) clockwise until the crankshaft. is 1120 893 7200 to press the ball pushed out of the ball bearing. bearing out of the crankcase, from the outside inwards. MS 460, MS 460 C...
  • Page 40 : Push the annular buffer (arrow) : Place the ball bearing, open side out of the clutch side of the facing up, on the inside of the crankcase. crankcase and push it home by hand as far as stop. MS 460, MS 460 C...
  • Page 41 : Push the annular buffer home so press arbor (1) 1118 893 7200 to that its annular groove (1) press home the ball bearing as engages the housing rib (2). far as stop. MS 460, MS 460 C...
  • Page 42 : Screw spindle of service tool ZS : Screw threaded sleeve (1) to (2) 5910 007 2200 fully home thread (2) of crankshaft stub. and then screw the threaded sleeve (1) 5910 893 2420 onto the spindle. MS 460, MS 460 C...
  • Page 43 5910 893 2409 of service tool AS wise until the crankshaft locates 5910 890 2205 onto the spindle against the ball bearing. : Fit crankshaft stub in the ball as far as stop (left-hand thread). bearing. – Unscrew the hex nut. MS 460, MS 460 C...
  • Page 44 3.5 end of the crankshaft. crankshaft stub. Trim away any excess gasket If the retaining ring is fatigued, fit a material in the area of the cylinder new one. mounting face. MS 460, MS 460 C...
  • Page 45 – Fit the shroud, b 6.4 – Install chain tensioner, b 5.5 Install all other parts in the reverse sequence. The electronic (breakerless) ignition system basically consists of an ignition module (1) and flywheel (2). MS 460, MS 460 C...
  • Page 46 : Pull the short circuit wire (1) off the connector tag on the ignition module and out of the wire retainer (2). : Take out the screws (arrows). – Remove the ignition module. MS 460, MS 460 C...
  • Page 47 : Remove the wire retainer. – If necessary, install ignition lead, b 7.2, before fitting wire retainer. – Coat threads of screws with Loctite 242, b 16, before installing. Secure ground wire under ignition module’s right-hand mounting screw. MS 460, MS 460 C...
  • Page 48 (min. 1,000 rpm) spark plug. and check spark in the tester’s window (2). : Use adjusting knob (3) to set spark gap to about 2 mm. Warning! The engine may start and accelerate during the test. MS 460, MS 460 C...
  • Page 49 : Pull the cover off the spark plug : Pull the lead back into the spark boot. plug boot so that the leg spring locates properly inside it. – Push the cover over the spark plug boot. MS 460, MS 460 C...
  • Page 50 : Unscrew the flywheel nut (arrow). – Install the ignition module, b 7.1.2 : Screw puller (1) 1110 890 4500 into the flywheel. : Screw home the thrust bolt until the flywheel is released. MS 460, MS 460 C...
  • Page 51 : Pull the wires sideways out of the housing sideways and lift it away. tank housing. – When installing, push home the – Remove the carburetor, b switch actuator until it snaps into 12.2.1 position. MS 460, MS 460 C...
  • Page 52 – Check air gap between flywheel retainers. and ignition module, b 7.3.2 – Fit the grommets properly in the openings in the tank housing. It neither of these checks reveals a fault, install a new ignition module, b 7.1.2 MS 460, MS 460 C...
  • Page 53 – Leg spring hook in center of ignition lead? – Boot damaged? If necessary, install new spark plug boot and/or leg spring Test ignition system with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap – see TI 32.94) MS 460, MS 460 C...
  • Page 54 – Spark plug boot: Holes/cracks? – Resistance: spark plug boot to ground: spec. 1.5 – 12kW – Check resistance of ignition lead: spec. < 10 W, If necessary, install new spark plug boot and/or ignition lead MS 460, MS 460 C...
  • Page 55 Engine runs Check # / $ function Look for fault in fuel system on Master Control lever or carburetor, or separate check engine for leaks, stop switch check position of flywheel on crankshaft MS 460, MS 460 C...
  • Page 56 – Pull the pawls (1 + 2) out of the STIHL special lubricant, b 16. rope rotor. – Lubricate pegs of new pawls with grease, b 16. Install in the reverse sequence. MS 460, MS 460 C...
  • Page 57 : Use a screwdriver or pliers to : Thread the new starter rope carefully remove the spring (1) through the top of the starter grip. from the starter post. : Remove the rope rotor, b 8.4 MS 460, MS 460 C...
  • Page 58 – Install the rope rotor, b 8.4 : Press knot into recess (arrow). : Grip the rope next to the rotor and use it to turn the rope rotor six – Tension the rewind spring, times clockwise. b 8.5.1 MS 460, MS 460 C...
  • Page 59 – Fit the starter rope, b 8.5 Installing the rope guide bushing – Install all other parts in the – Place the new bushing in its seat reverse sequence. in the fan housing/starter cover. MS 460, MS 460 C...
  • Page 60 – Take the rewind spring out of the fan housing. – Remove any remaining pieces of spring from the fan housing. : Position the anchor loop about 25 mm from the edge of the spring housing. MS 460, MS 460 C...
  • Page 61 : Remove the annular buffer (4). Remove the tank housing for access to the other rubber buffers, b 12.8 : Push the stop buffer into the guide so that the groove (1) engages the housing rib (2). MS 460, MS 460 C...
  • Page 62 : Disconnect short circuit wire (1) : Slide the switch housing into its and ground wire (2) from the guide before fitting the switch contact springs. shaft in its pivot mount. Install all other parts in the reverse sequence. MS 460, MS 460 C...
  • Page 63 : Pull the throttle rod out of the The torsion spring must be fitted : Fit the handle molding, making throttle trigger. under the interlock lever and locate sure it engages behind the lugs in the notch (arrow). as shown. MS 460, MS 460 C...
  • Page 64 : Use hook (1) 5910 893 8800 to : Pull the suction hose with pickup pull the pickup body out of the oil body out of the crankcase. tank. Do not stretch the oil hose during this operation. MS 460, MS 460 C...
  • Page 65 : Use a 7 mm drift to carefully press home the new valve from outside until it is about 1 mm below the housing face (’a’ in illustration). Reassemble all other parts in the reverse sequence. MS 460, MS 460 C...
  • Page 66 Install in the reverse sequence. Always install new O-rings. – Lubricate the pump piston and worm with grease before installing, b 16. : Take out the screws (arrows). – Pull the oil pump out of its seat. MS 460, MS 460 C...
  • Page 67 If filter mesh is damaged, install a new filter base. Install in the reverse sequence. : Pull off the air baffle (1) to the : Pull off the baffle in the direction rear. of the arrow. MS 460, MS 460 C...
  • Page 68 : Disconnect the throttle rod from : Pull off the carburetor. : Fit the grommet so that the the throttle shaft. rubber tabs (1) locate between Reassemble in the reverse the housing rib (2). sequence. MS 460, MS 460 C...
  • Page 69 Reassemble all other parts in the reverse sequence. : Push the fuel line with nipple onto : Carefully separate the diaphragm the carburetor’s elbow connector. and gasket. – Inspect diaphragm for damage and wear and replace if necessary. MS 460, MS 460 C...
  • Page 70 : If there is an annular indentation that the perforated plate (1) faces on the sealing cone of the inlet the inlet control lever (2). needle, fit a new inlet needle. Install all other parts in the reverse sequence. MS 460, MS 460 C...
  • Page 71 : Place the gasket (1) on the end and gasket. cover (2). – Inspect diaphragm for damage : Wet the pump diaphragm (3) with and wear, fit a new gasket. fuel and place it on the gasket. MS 460, MS 460 C...
  • Page 72 (if fitted). If the setting is too lean there is a risk of engine damage due to – Check chain tension. insufficient lubrication and overheating. – Warm up the engine. – Adjust idle speed. MS 460, MS 460 C...
  • Page 73 : Turn the limiter caps (arrows) 4. Set the engine speed to counterclockwise as far as stop 2,500 rpm with the low speed so that the lugs can be seen in screw (L). the carburetor openings. MS 460, MS 460 C...
  • Page 74 Fine tuning – Check the air filter and clean or replace as necessary. – Check and clean or replace spark arresting screen (if fitted). – Check chain tension. – Warm up the engine. MS 460, MS 460 C...
  • Page 75 – Open the tank again and drain it. Dispose of fuel properly in accordance with environmental requirements. : Pull the pickup body off the suction hose. – Fit a new pickup body. Install in the reverse sequence. MS 460, MS 460 C...
  • Page 76 : Take the sleeve (1) out of the fuel tank. manifold, and pull the washer (2) off the studs. : Remove the mounting screws from the side of the front handle. Heat the screwed joints. Do not overheat polymer. MS 460, MS 460 C...
  • Page 77 – Remove the chain catcher, : Pull the impulse hose off the and ground wire (2) from the b 5.2 nipple. contact springs. : Take the plugs (arrows) out of the annular buffers at the clutch side. MS 460, MS 460 C...
  • Page 78 – Pass the ends of the string through the intake opening. : Press the manifold down. : Fit an M6x10 screw with washer in the thread insert. – Screw the thread insert into the tank housing. MS 460, MS 460 C...
  • Page 79 – Tighten down the screws firmly, seated in the tank housing. b 3.5 Install all other parts in the reverse sequence. : Fit the sleeve (1) in the manifold. : Push the washer (2) over the studs. MS 460, MS 460 C...
  • Page 80 If the reading obtained is outside this tolerance, test each component separately. : Clip one test lead to the metal of the heating element, and the other test lead to the wire that goes to the thermostatic switch. MS 460, MS 460 C...
  • Page 81 + 13 °C (55 °F) switch and + 6 °C (43 °F)? Does thermostatic switch Replace thermostatic open between + 6 °C (43 °F) switch and + 13 °C (55 °F)? Carburetor heating system in order MS 460, MS 460 C...
  • Page 82 – Remove the interlock lever, b 10.2 : Push back the insulating tube (arrow) on the pin and socket connector of the wire between the generator and rear handle heating element. MS 460, MS 460 C...
  • Page 83 – After completing the test, reconnect the wires and push the insulating tube over the pin and socket connector. – Install the interlock lever and handle molding, b 10.2 MS 460, MS 460 C...
  • Page 84 Resistance of rear handle heating element about 1 W ? Check generator Install new Resistance between engine ground and generator generator red connection = about. 0.6 W ? yellow connection = about 0.8 W ? MS 460, MS 460 C...
  • Page 85 Install new Check heater switch heater switch Closed: about 0 W ? Open: Circuit interrupted (On machines with carburetor heating refit connector pin of wire from heating element in the round plug) System in order MS 460, MS 460 C...
  • Page 86 Break in wire, Install new front heating element handle damaged Short circuit – Repair damaged insulation insulation Generator W Connector Ground 0.6...1.0 Generator OK on wire Disconnect the wire MS 460, MS 460 C...
  • Page 87 Lead 2 Spec. Actual Cause Remedy Generator WVH Connector Ground 0.6...1.0 Generator OK on gen’s red wire Generator WVH Break in wire, Install new and W generator damaged generator Short circuit – Repair damaged insulation insulation MS 460, MS 460 C...
  • Page 88 : Unscrew the nut (arrow) from the – Removing the backing from the switch. new heating element. – Remove the washer. : Place heating element (1) in handle housing (2) and press firmly and uniformly into position, from the center outwards. MS 460, MS 460 C...
  • Page 89 Run the saw at maximum revs for no more than 30 seconds with the heating switched on. : Pull the wires out of the rubber grommet. – Pull the connecting wire out of the heater switch, b 14.2 MS 460, MS 460 C...
  • Page 90 : Inspect the magnet ring (arrow) in the flywheel for cracks or other damage. If damage is found, replace the flywheel. Reassemble in the reverse sequence. : Take out the screws (arrows). – Remove the generator. MS 460, MS 460 C...
  • Page 91 Removing crankshaft (clutch side) Screw sleeve 5910 893 2420 Installing crankshaft Service tool ZS (set) 5910 007 2220 Removing crankshaft (starter side) Screw sleeve 5910 893 2409 Pulling crankcase halves together Puller 5910 890 4500 Removing limiter cap MS 460, MS 460 C...
  • Page 92 (clutch side) Press arbor 1120 893 7200 Removing and installing ball bearing (flywheel side) Circlip pliers DIN 5254-A 19 0811 611 8380 Removing and installing external retaining rings Remarks: 1) Use for releasing P screws only. MS 460, MS 460 C...
  • Page 93 STIHL multipurpose grease 0781 120 1109 High voltage output on ignition module Medium-strength threadlocking 0786 111 1101 adhesive (Loctite 242) High-strength threadlocking 0786 111 1109 adhesive (Loctite 270) High-strength threadlocking 0786 110 0126 adhesive (Loctite 649) MS 460, MS 460 C...
  • Page 94 englisch / english 0455 176 0123. M7. L4. Fi. Printed in Germany...

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