Stihl MS 460 Service Manual

1MS 460, MS 460 C
q
© ANDREAS STIHL AG & Co. KG, 2004
Contents
1. Introduction 3
2. Safety Precautions 4
3. Specifications 5
3.1 Tightening Torques 6
4. Troubleshooting
Chart 8
4.1 Clutch, Chain Drive,
Chain Brake,
Chain Tensioner 8
4.2 Rewind Starter 9
4.3 Chain Lubrication 10
4.4 Ignition System 11
4.5 Carburetor 12
4.6 Engine 14
5. Clutch, Chain Drive,
Chain Brake and
Chain Tensioner 15
5.1 Clutch Drum/Chain
Sprocket 15
5.2 Replacing the
Chain Catcher 16
5.3 Clutch 16
5.4 Chain Brake 18
5.4.1 Checking Operation 18
5.4.2 Removing 19
5.4.3 Installing 21
5.5 Chain Tensioner 23
5.6 Bar Mounting Studs 24
6. Engine 24
6.1 Muffler/Spark
Arresting Screen 24
6.2 Leakage Test 26
6.2.1 Preparations 26
6.2.2 Pressure Test 27
6.2.3 Vacuum Test 28
6.3 Oil Seals 29
6.4 Removing the Shroud 30
6.5 Cylinder and Piston 31
6.5.1 Removing 31
6.5.2 Installing 32
6.6 Piston Rings 36
6.7 Crankcase 36
6.7.1 Removing the
Crankshaft 36
6.7.2 Installing the
Crankshaft 39
6.8 Decompression Valve 44
7. Ignition System 44
7.1 Ignition Module 45
7.1.1 Ignition Timing 45
7.1.2 Removing and
Installing 45
7.1.3 Testing
the Ignition Module 47
7.2 Spark Plug Boot/
Ignition Lead 48
7.3 Flywheel 49
7.3.1 Removing 49
7.3.2 Installing 50
7.4 Stop Switch 50
7.5 Wiring Harness 50
7.5.1 Testing Wiring
Harness 51
7.6 Ignition System
Troubleshooting 52
8. Rewind Starter 55
8.1 General 55
8.2 Removing and
Installing 55
8.3 Pawls 55
8.4 Rope Rotor 56
8.5 Starter Rope 56
8.5.1 Tensioning 57
8.6 Starter Rope Guide
Bushing 58
8.7 Replacing Rewind
Spring 59
9. AV Handle System 60
10. Master Control/
Handle System 61
10.1 Switch Shaft 61
10.2 Throttle Trigger/
Interlock Lever 62
11. Chain Lubrication 63
11.1 Pickup Body/Suction
Hose 63
11.2 Valve 64
11.2.1 Cleaning 64
11.2.2 Replacing 64
11.3 Oil Pump 65
11.3.1 Removing and
Installing 65
11.3.2 Servicing 65

Stihl MS 460 Specifications

General

Chain Pitch	3/8"
Engine Power	4.4 kW (6.0 bhp)
Displacement	76.5 cc
Weight	6.6 kg
Guide Bar Length	40-63 cm (16-25 inches)