STIHL TS 460 1

Service ManualCutquik TS 460

This Service Manual contains a Refer to the "Technical Information The STIHL Special Tools manualdetailed description of all repair Bulletins" for engineering changes lists all special servicing toolswork for the Cutquik TS 460. which have been introduced since currently available from STIHL.

publication of this service manual.You should make use of the Technical information is Always use original STIHLillustrated parts lists while carrying considered to be a supplement to replacement parts.out repair work. They show the the parts list until publication of a Original STIHL parts can be identi-installed position and the new edition. fied by the STIHL part numberassembly sequence of the the STIHl logoassemblies. Microfilmed parts lists Service manuals and technical and the STIHL parts symbol ((((are always more up to date than information bulletins describingprinted lists! engineering changes are intended The symbol may appear alone on

exclusively for the use of STIHL small parts.A fault on the machine may have servicing dealers and staff andseveral causes. Consult the must not be passed on to third"troubleshooting charts" when parties.tracing faults.

STIHlSTIHlSTIHlSTIHlAndreas StihlD-71336 Waiblingen

STIHL TS 460 2

CONTENTS

1. Specifications 3

1.1 Engine 31.2 Fuel System 41.3 Ignition System 41.4 Cutting Wheel 51.5 Special Accessories 51.5.1 For User 51.5.2 For Service 51.6 Tightening Torques 6

2. TroubeshootingCharts 7

2.1 Clutch,Bearing with Guard 7

2.2 Engine 72.3 Ignition System 82.4 Rewind Starter 92.5 Fuel System 10

3. Cutting Wheel DriveAssembly 12

3.1 Bearing with Guard 123.2 Testing of Radial and

Axial Truth of Running 163.3 V-Belt 183.4 V-belt Pulley/

Clutch Drum 183.5 Clamp 19

4. Clutch 20

4.1 Disassembly 204.2 Assembly and

Installation 21

5. Engine 22

5.1 Removing and RefittingExhaust Muffler 22

5.2 Cylinder and Piston 225.2.1 Removal 225.2.2 Installation 24

5.3 Piston Rings 275.4 Crankcase 275.4.1 Removing theCrankshaft 275.4.2 Installing the Crankshaft 295.5 Leakage Testing the

Crankcase 305.5.1 Preparations 315.5.2 Pressure Test 325.5.3 Vacuum Test 335.6 Replacing the Oil Seals 345.7 Removing and

Installing the Engine 355.8 Engine Housing 38

6. Ignition System 42

6.1 Repairing ComponentParts 42

6.1.1 Spark Plug 426.1.2 Ignition Module 446.1.2.1 Ignition Timing 446.1.2.2 Removing and Installing 446.1.3 Ignition Lead/Spark Plug

Terminal 456.1.4 Short Circuit Wire/

Ground Wire 476.1.5 Flywheel 48

7. Rewind Starter 50

7.1 Routine Maintenance 507.2 Rope Rotor 507.3 Replacing the Starter

Rope 517.4 Replacing the Rewind

Spring 527.5 Tensioning the Rewind

Spring 537.6 Pawl 537.7 Starter Cup 547.8 Replacing the Rope

Guide Bush 54

8. AV Handle System 55

8.1 Repair 55

9. Throttle Control 56

9.1 Throttle Trigger,Throttle Trigger Interlock 56

9.2 Slide Control 579.3 Contact Springs 579.4 Throttle Cable 579.5 Handle 589.6 Handle Tube Bracket 589.7 Handle Grip 59

10. Fuel System 61

10.1 Air Filter 6110.2 Construction

and Function of theCarburetor withCompensator 62

10.3 Removing and Installingthe Carburetor 63

10.4 Leakage Testing theCarburetor 65

10.5 Servicing theCarburetor 65

10.6 Carburetor Adjustment 7110.7 Pickup Body 7210.8 Fuel Tank 7310.9 Expansion Tank 7510.10 Tank Vent 7510.11 Manifold 77

11. Special ServicingTools and Aids 78

11.1 Special Servicing Tools 7811.2 Servicing Aids 80

STIHL TS 460 3

1. Specifications

1.1 Engine STIHL single-cylinder two-stroke enginewith special impregnated cylinder bore

Displacement: 72.4 cm³Bore: 48.0 mmStroke: 40.0 mmPower output: 3.5 kW (4.75 bhp)Max. permissible speed 9.600 r.p.m.Idle speed: 2,500 r.p.m.Bearings: Crankshaft supported in heavy-duty

deep groove ball bearings,needle cages on small andbig ends

Connecting rod length: 70 mmRewind starter: Single pawl system with

automatic rope rewindmechanism

Reserve pull on rope rotor: min. 1/2 turn of rope rotorStarter rope: 4.5 mm dia., 1000 mm longClutch: Centrifugal clutch without liningsDiameter: 80 mmClutch engages at: 3,200 r.p.m.Crankcase leakage test

at gauge pressure: pü = 0.5 barunder vacuum: pu = 0.5 barSilencing: Intake air silencer and

exhaust muffler

STIHL TS 460 4

1.2 Fuel System Carburetor: All position diaphragmcarburetor with integralfuel pump

Standard settingHigh speed adjusting screw H: Back off 1 turnLow speed adjusting screw L: Back off 1 turn

(starting with the screwstight against theirseats)

Carburetor leakage test atgauge pressure: pü = 0.8 barFuel tank capacity: 0.95 I (950 cm 3)Fuel mixture: Regular brand-name gasoline

(leaded or unleaded) and STIHLtwo-stroke engine oil

Octane number: min. 90 RONMix ratio: 1:50

with STIHL two-stroke engine oil 50:11:25with other brand-nametwo-stroke engine oils

Air filter: Felt prefilter, large main filter(paper filter cartrigde)and auxiliary filter

1.3 Ignition System Type: Electronic magnetoignition (breakerless)

Air gap: 0.2-0.5 mmIgnition timing: 2.8-3.2 mm B.T.D.C.

at 8,000 r.p.m.Spark plug (suppressed): Bosch WSR 6 F or

NGK BPMR 7 AElectrode gap: 0,5 mmSpark plug thread: M14x1.25Length of thread: 9.5 mmHeat range: 200

STIHL TS 460 5

1.4 Cutting Tools

Cutting wheel for stone 300x3.5x20 mm diaCutting wheel for steel 300x3.5x20 mm diaCutting wheel for stone 300x6.0x20 mm diaCutting wheel for asphalt 300x3.5x20 mm diaCutting wheel for stone 350x4.0x20 mm diaCutting wheel for steel 350x4.0x20 mm diaDiamond cutting wheel for stone 300x2.6x20 mm diaDiamond cutting wheel for asphalt 300x3.2x20 mm diaCutting depth approx. 100 mm (for 300 mm dia)

approx. 115 mm (for 350 mm dia)

1.5 Special Accessories

1.5.1 For UserSTIHL-Cutquik cartCutting depth limiterWet cutting attachmentWater attachment

1.5.2 For ServiceElectrician's repair kit

STIHL TS 460 6

1.6 Tightening Torques

Fastener Thread For component Torque Remarkssize Nm Nm

Spline screw IS-M5x58x22 Cylinder/crankcase 10.0Spline screw IS-M5x35x22 Crankcase/engine housing 10.0Spline screw IS-M5x20 Spacer flange 7.0

Clutch 50.0Spline screw IS-M5x20 Cast arm/engine housing 7.0Hexagon nut M10X1 Starter cup 40.0Collar nut M8x1 Flywheel 25.0Spline screw IS-M5x14 Filter base/engine housing 7.0Spline screw IS-M5x58x35 Connector/carburetor/flange 5.0Spline screw IS-M5x14 Housing cover/engine housing 7.0 1)Spline screw IS-M5x20 Ignition module 8.0 1)Spline screw IS-M5x20 Fan cover 6.0Spline screw IS-M5x14 Muffler/cylinder 10.0Spline screw IS-M5x35 Muffler/engine housing 10.0 1)Spline screw IS-M4x6 Deflector baffle/muffler 3.0Spline screw IS-M5x14 Clamp 4.0Spline screw IS-M4x6 Short circuit wire/ground 3.0Spline screw IS-DG5x24 Handle molding/handle 3.0Spline screw IS-M5x14 Annular buffer/engine housing 7.0Spline screw IS-DG5x24 AV-molding/handle 3.0Spline screw IS-M5x14 Annular buffer/handle tube bracket 7.0Spline screw IS-M5x14 Support/handle tube bracket 7.0Spline screw IS-M5x14 Handle tube/handle tube bracket 7.0Spline screw IS-DG5x24 Handle tube/handle 6.0Spline screw IS-M5x20 Shroud/engine housing 6.0Spline screw IS-M5x20 Carburetor box cover 6.0Spline screw IS-M5x20 Starter cover 6.0

M14x1.25 Spark plug 27.5

1) Washer must be fitted under screw head.

STIHL TS 460 7

2. TROUBLESHOOTINGCHARTS

2.1 Clutch,Bearing with Guard

Condition Cause Remedy

Insufficient frictional contact -clutch slips

Clutch springs stretched or fatigued,spring hooks broken

Fit new springs

Cutting wheel rotateswhile engine is idling

Engine idle speed too high Correct at idle speed adjustingscrew

Clutch springs stretched or fatigued,spring hooks broken

Fit new springs

Cutting wheel does notrotate at full throttle

Small V-belt not tensioned Tension small V-belt

Clamp damaged Replace clamp

Small V-belt torn Replace small V-belt

2.2 Engine

Always check and, if necessary, repair the following parts before looking for faults on the engine:- Air filter, fuel system, carburetor, ignition system

Condition Cause Remedy

Engine does not start easily, stallsat idle speed, but operates normallyat full throttle

Oil seals in crankcase damaged Replace oils seals

Gaskets on spacer flange leaking Fit new gaskets

Cylinder base gasket leaking Replace gasket

Crankcase damaged (cracks) Replace crankcase

Engine does not deliver full poweror runs erratically

Secondary air seepage throughfaulty gasket on spacer flange

Replace gaskets

Piston rings worn or broken Fit new piston rings

Muffler carbonized Clean the muffler (inlet andexhaust), fit new spark arrestingscreen

Engine overheating Insufficient cylinder Thoroughly clean cylindercooling due to dirty cooling finscooling fins

STIHL TS 460 8

2.3 Ignition System

Warning: Exercise extreme caution while carrying out maintenance and repair work on the ignition system,The high voltages which occur can cause serious or fatal accidents!

Ignition system in order.Look for fault in fuel system andcarburetor.

yes

Replace ignition module. Does enginenow run after positive spark test?

Fit new flywheel.Is spark test positive?

Use ohmmeter to check ignition leadfor break. If break is detected, fit newignition lead. Does spark test nowproduce sparkover?

Does flywheel appear tobe in good condition?

Fit new spark plug.Is air gap correct?

Adjust air gap (0.2-0.5 mm).Is spark test positive?

Insert screwdriver in place of spark plug in spark plugterminal and hold about 4 mm away fromground. Sparkover?

Replace faulty ignition lead of shortcircuit wire. Repair contact spring.

Faulty insulation on ignitionlead or short circuit wire?

Clean spark plug and reset electrode gap.Does spark test produce powerful spark?

Press terminal firmly onto sparkplug and fit spring if necessary.

Spark plug terminal firmly seated on spark plug?

Remove spark plug.Is it in good condition?

no

no

nono

no

yes

no

no yes

yes no

no

no

no

yes

yes

STIHL TS 460 9

2.4 Rewind Starter

Condition Cause Remedy

Starter rope broken Rope pulled out too vigorously asfar as stop or over edge - i.e. notvertically

Fit new starter rope

Normal wear Fit new starter rope

Rewind spring broken Spring overtensioned – no reservewhen rope is fully extended

Fit new rewind spring

Very dirty or corroded Fit new rewind spring

Starter rope can be pulled outalmost without resistance(crankshaft does not turn)

Guide peg on pawl or pawl is worn Fit new pawl

Spring clip fatigued or broken Fit new spring clip

Starter cup worn or damaged Fit new starter cup

Starter rope is difficult to pull andrewinds very slowly

Starter mechanism is very dirty(dusty conditions)

Thoroughly clean completestarter mechanism

Lubricating oil on rewind springbecomes viscous at very lowoutside temperatures (springwindings stick together)

Apply a few drops of kerosine(paraffin) to spring, then pullrope carefully several timesuntil normal action is restored

STIHL TS 460 10

2.5 Fuel System

Condition Cause Remedy

Carburetor floods; Inlet needle not sealing. Remove and clean or replaceengine stalls Foreign matter in valve seat

or cone damagedinlet needle, clean fuel tank, pickupbody and fuel line if necessary

Inlet control lever sticking on Free off inlet control leverspindle

Helical spring not located on Remove inlet controlnipple of inlet control lever lever and refit correctly

Perforated disc on diaphragm is Fit new metering diaphragmdeformed and presses constantlyagainst inlet control lever

Inlet control lever too high Set inlet control lever flush with(relative to design position) bottom of metering chamber

Poor acceleration Idle jet "too lean" Back off low speed adjustingscrew slightly (see CarburetorAdjustment)

Main jet "too lean" Back off high speed adjustingscrew slightly (see CarburetorAdjustment)

Inlet control lever too low Set inlet control lever flush with(relative to design position) bottom of metering chamber

Inlet needle sticking to valve seat Remove inlet needle,clean and refit

Compensator hose to Clear compensator hosemanifold is blocked using air pressure; replace

manifold if necessary

Diaphragm gasket leaking Fit new diaphragm gasketMetering diaphragm damaged Fit new metering diphragmor shrunk

STIHL TS 460 11

Condition Cause Remedy

Engine will not idle, Throttle shutter opened too Reset idle speed adjusting screwidle speed too high wide by idle speed adjusting screw correctly

Engine stalls at idle speed Idle jet bores Clean jet bores and ports withor ports blocked compressed air

Idle jet "too rich" Screw down low speedadjusting screw slightly(see Carburetor Adjustment)

Setting of idle speed adjusting Set idle speed adjusting screwscrew incorrect - throttle shutter correctlycompletely closed

Small plastic plate in valve jet Clean or renew valve jetdoes not close

Engine speed drops quickly Air filter plugged Clean air filterunder load - low power

Tank vent faulty Clean or replace tankvent if necessary

Leak in fuel line between tank Seal or renew connectionsand fuel pump and fuel line

Compensator hose to Seal connections ormanifold leaks replace manifold

Pump diphragm damaged Fit new Pump diphragmor fatigued

Main jet bores or Clean bores and portsports blocked

Fuel pickup body dirty Fit new pickup body

Fuel strainers dirty Clean fuel strainers

See also 2.2

STIHL TS 460 12

3. CUTTING WHEELDRIVE ASSEMBLY

3.1 Bearing with Guard

Top: Top:Relieve tension of V-belt Top: Removing the axial clamp ring

Removing the bearing 1 = Thrust washerBottom:1 = Guard Bottom: Bottom:2 = Mounting screws Pliers 0881 611 8200 Unscrewing the nut

- Check axial and radial truth of - Lift the bearing with guard out of - Lock the V-belt pulley. Unscrew- running; see 3.2. - the V-belt. - the nut and draw the V-belt pulley

- off the shaft.- Relieve tension of V-belt by - Draw the axial clamping ring off- turning hexagon nut of clamp - the shaft. Important! The nut has a- counterclockwise until arrow left-hand thread.- points left (at the "0"). - Remove the thrust washer.

- Unscrew the mounting screws on- the bearing and remove the guard.

STIHL TS 460 13

Top: Top:1 = Woodruff key Top: 1 = Rubber washer2 = Washer Flat head screws 2 = Disk

Bottom: Bottom: Bottom:Removing the shaft Removing the flange Removing the bearing

- Remove the woodruff key from - Unscrew both flat head screws - Remove the disk and rubber- the groove in the shaft. - and remove them together with - washer from the flange and

- the spring washers. - guard.- Remove the washer from the- shaft. Note: Note the number of spring - Remove the bearing from the

washers. - guard.- Draw the shaft out of the deep- groove ball bearings. - Remove the flange from the

- guard.

STIHL TS 460 14

Top:1 = Countersunk screw Top:

Top: 2 = Limit stop Removing aRemoving the rubber ring 3 = Spline screw circlip

4 = Rubber vibration bufferBottom: Bottom:1 = Rubber washer Bottom: Pressing out the deep groove ball2 = Disk Pliers 0811 641 8380 bearings with drift pin 4119 893 7200

- Remove the rubber ring from the - Unscrew the countersunk screw - Remove the circlips from the- bearing. - and remove the limit stop. - grooves before removing the

- deep groove ball bearings.- Remove the rubber washer and - Unscrew the spline screw in- disk from the bearing. - order to replace the rubber - Force both deep groove ball

- vibration buffer. - bearings and the ring out of the- bearing with the drift pin.

Note: The limit stop and rubbervibration buffer only feature inmachines for the USA.

STIHL TS 460 15

Top:Flange Top: Top:mounting screws 1 = Deep groove ball bearing Correctly positioned spring washers

2 = RingBottom: Bottom:Fitting the circlip Bottom: Longer collar on thewith pliers 0811 641 8380 Pressing in the deep groove ball bearings V-belt pulley

- Unscrew the flange mounting - Slide the first deep groove ball - Slide the same number of spring- screws and remove the flage - bearing onto the shaft, then the - washers onto the flat head- from the guard. - ring and the second deepgroove - screws as were removed during

- ball bearing. - disassembly, as shown in theThe parts are assembled in - drawing.reverse order. - Position the deep groove ball

- bearings and press them in with - Slip the V-belt pulley onto theNote: Particular care must be - the shaft until they contact the - shaft with the longer chamferedtaken when carrying out the - circlip. - edge first and tighten the nut withfollowing work. - a torque of 37.5 Nm.

- Draw the shaft out of the deep- Place the circlip in one of the - groove ball bearings.- bearing grooves.

- Place the second circlip in the- bearing groove.

STIHL TS 460 16

approx. 130 mm over one fullrevolution of the wheel. Refer tothe table "Test procedure".

- Remove the test equipment aftercompleting the measurement.

3.2 Checking the Axial andRadial Truth of Running

Top:Fitting the test wheel1 = Arresting grooves

1 =Test wheel 5910 851 6100 2 = Arresting lugs2 = Gauge holder

5910 850 6000 Bottom:Tightening the V-belt 3 = Dial gauge 0000 890 9100 Test equipment in position

- Place V-belt in V-belt of bearing, Since changes in the shaftposition guard and loosely screw diameter (due to scoring etc.) canin mounting screws. affect the radial truth of running of

the cutting wheel, it is normally- Turn hexagon of tensioning sufficient to inspect the shaftdevice clockwise until spring around the cutting wheel mount.force is eliminated.

The axial truth of running, on the- Tighten all three mounting other hand, depends on the statescrews starting with rear screw. of various components and must

therefore be determined bymeasurement.

- Fit the test wheel and thenposition the thrust washer so thatthe arresting lugs engage in thearresting grooves in the shaft.

- Tighten the screw.

- Secure the gauge holder with dialgauge to the guard cover so thatthe axial truth of running can bedetermined for a diameter of

STIHL TS 460 17

Test procedure Actual condition Possible causes Remedy

Radial truth of running:Visual inspection Wear marks or scoring Mounting screw loose, Replace theof the spindle (shaft) around the cutting wheel use of wrong cutting spindle (shaft)

mount wheels (diameter ofmount Ø > 20 mmor > 22 mm)

Axial truth of running:Check the axial truth of Axial eccentricity Nonerunning with the STIHL ≤ 0,15 mmtest wheel or diamondcutting wheel (over a > 0,15 mmdiameter of 130 mm) Damaged or uneven contact Dirt; thrust washers or Replace the

surfaces of the thrust washers cutting wheel fitted incorrectly; thrust washers(especially the inner thrust application of force whenwasher); contact surfaces not cutting or during transportplane; genuine STIHL partshave not been used

Spindle (shaft) Incorrect handling, Replace thedamaged use of force spindle (shaft)

Distinct radial play in the Deep groove ball bearings Replace thebearing seat --> spindle damaged by exposure to dirt spindles andbearing defective and/or bearing seat worn deep groove

down at the spindle ball bearings

STIHL TS 460 18

3.3 V-belt 3.4 V-belt Pulley/Clutch Drum

Top:Removing the cover

Bottom:Removing the V-belt

Top:Assembly pin 1119 893 7200

Bottom:Forcing out the needle sleeve

- Remove the V-belt, see 3.3.

- Remove the starter cup, see 7.7.

- Draw the V-belt pulley off thecrankshaft stub.

- Check the clutch drum: it must notshow any major signs of wear orscoring. Replace the V-belt pulley ifnecessary.

- Remove the bearing with guard,see 3.1.

- Remove the starter cover, see7.2.

- Remove the cover.

- Remove the V-belt from theV-belt pulley.

The parts are assembled inreverse order.

- Check the needle sleeve andforce it off the V-belt pulleyfrom the clutch side using anassembly pin if necessary.

Top:Removing the V-belt pulley

Bottom:Friction surface of the clutch drum

STIHL TS 460 19

3.5 Clamp

Top:1 = Wheel2 = Bushing

Bottom:Properly positioned needle sleeve

Bottom:Mounting screwsof clamp

Top:Removing the throttle trigger interlock

Below:Attaching the tension rod

Top:Relieving tension of the clamp

- Remove bushing and wheel fromcrankshaft stub.

The parts are assembled inreverse order.

Note: Insert assembly pins onthicker, beaded side of needlesleeve and press in from side onwhich the clutch drum is locateduntil they are flush with the inneredge of the V-belt pulley.

- Remove the V-belt, see 3.3.

-Turn hexagon nut on clampcounterclockwise until innerspring is completely slack.

- Take out clamp mountingscrews, remove clamp.

- Remove throttle trigger interlockfrom recess in housing.

The parts are assembled inreverse order.

Note: Insert hooks of tension rod inhole and put both parts together.Tighten mounting screws to 4.0 Nm.

STIHL TS 460 20

4. CLUTCH

4.1 Removing and Disassembly

Top:Socket 5910 893 5616

Bottom:Clutch

Top:Removing the cover washer

Bottom:Assembly pin 5910 890

Top:Removing a clutch spring

Bottom:Component parts of clutch

Troubleshooting charts, see 2.1.

- Remove the V-belt, see 3.4.

- Unscrew clutch fromcrankshaft stub using socket.

Caution! Clutch has aleft-hand thread.

- Remove cover washerfrom crankshaft stub.

- Use assembly hook to removeall the clutch springs.

- Pull the clutch shoes offthe carrier.

- Pull the retainers off theclutch shoes.

- Clean all parts and stub ofcrankshaft in white spirit.Replace any damaged orworn parts.

STIHL TS 460 21

4.2 Assembly and Installation

- Slide cover washer ontocrankshaft stub with convex sidefacing outward.

- Screw clutch onto crankshaftand torque down to 40 Nm.

- Fit V-belt pulley, see 3.4.

- Fit the retainers onto theclutch shoes.

- Fit the clutch shoes over thearms of the clutch carrier so thatthe series number, e.g. 1122a,is on the same side as thecarrier’s hexagon.

- Clamp the clutch, e. g. one of theshoes, in a vise.

- Attach one end of each springto the clutch shoes by hand.

- Use the other assembly hook toattach the other ends of thesprings and press them firmlyinto the clutch shoes with onefinger.

Top:Fitting retainer onclutch shoe

Bottom:Pushing clutch shoeonto carrier

Top:Clutch clamped in a vise

Bottom:Attaching clutch springs Tightening the clutch

STIHL TS 460 22

5. ENGINE

5.1 Removing and RefittingExhaust Muffler

5.2 Cylinder and Piston

5.2.1 Removal

Troubleshooting chart, see 2.2

- Take out the cover platemounting screws and removethe cover plate.

- Remove the spark arrestingscreen.

- Clean the spark arresting screen,fit a new one necessary.

- Remove the mountingscrews from the muffler andlift the muffler away.

- Remove the asket.

Note: Install new gasket so that itsbead points toward the lowermuffler. Fit lock washers underlower screws and tighten screwson muffler and deflector baffle to10.0 Nm and 2.5 Nm respectively.

Top:Deflector bafflemounting screws

Bottom:Spark arresting screen

Top:Muffler mounting screws

Bottom:Removing gasket1 = Bead

Always check and, if necessary,repair the fuel system, carburetor,air filter and ignition system beforelooking for faults on the engine.

Troubleshooting chart, see 2.2.

- Remove the muffler, see 5.1.

- Remove the carburetor, see 10.3.

- Unscrew the spark plug.

- Remove cylinder base screws oncylinder base through holes incylinder.

- Pull the cylinder off the piston.

Throughholes to cylinderbase screws

STIHL TS 460 23

Top:Removing snap ring

Bottom:Assembly drift 1108 893 4700

Top:Pushing out piston pin

Bottom:Piston rings

- Take out the spacer flangemounting screws. Removethe spacer flange andgasket from the cylinder.

- Inspect the cylinder and replaceit if necessary.

Note: If a new cylinder has to beinstalled, always fit the matchingpiston. Replacement cylindersare only supplied complete withpiston for this reason.

- Remove the cylinder gasket.

Important: Before removing thepiston, decide whether or notthe crankshaft has to beremoved as well. To remove thestarter cup, the clutch and theflywheel, see 7.7, 4.1 and 6.1.5,block the crankshaft by slidingthe wooden assembly blockbetween the piston andcrankcase.

- Use a scriber or similar tool toease the hookless snap ringsout of the grooves in the pistonbosses.

- Now use the assembly drift topush the piston pin out of thepiston. If the piston is stuck,tap the end of the drift lightlywith a hammer if necessary.Important: Hold the pistonsteady during this process toensure that no jolts aretransmitted to the connectingrod. Remove piston and takethe needle cage out of theconnecting rod.

- Inspect piston rings andreplace if necessary, see 5.3.

Top:1 = Mounting screws2 = Gasket3 = Spacer flange

BottomRemoving the cylinder gasket

STIHL TS 460 24

5.2.2 Installation

Use the installing tool asfolllows:

- Remove the sleeve from thetool.

- Attach the snap ring to themagnet so that the snapring gap is on the flat sideof the tool's shank.

- Thoroughly clean the gasketseating surface on thecylinder. Lubricate theneedle cage with oil and fit itin the small end.

- Mount spacer flange withnew gasket on cylinder,insert screws and tighten to10 Nm.

Top:Needle cage in connecting rod

Bottom:1 = Arrow on

piston head2 = Fan cover Installing piston pin

Top:1 = Installing tool 5910 890 22122 = Sleeve

Bottom:1 = Snap ring (hookless)2 = Magnet

- Heat the piston on anelectric heating plate toapprox. 60 °C and slip itover the connecting rod sothat the arrow on thepiston head points to theleft (looking at fan cover).

- Push the assembly drift,small diameter first, throughthe piston and small end(needle cage) and line up thepiston.

- Fit the piston pin on theassembly drift and slide it intothe piston (the pinslides home easily if thepiston is hot).

- Fit the wire snap rings.

Note: Use installig tools to fit thesnap rings.

STIHL TS 460 25

Top:1 = Flat face on tool's shank2 = Pin

BottomPressing in the installing tool until thesleeve butts against the tool's shoulder

Slipping sleeve on to otherend of the shank

Top: Insertingsnap ring inpiston boss

Bottom:Fitting cylinder gasket1 = Slot

- Remove the sleeve and slip itonto the other end of theshank.

Note: Inner pin must again pointtoward flat face of tool's shank.

- Apply installing tool to thepiston boss (flat face on shankmust point toward pistonhead), hold the piston steady,center the tool shank exactlyand press home until the snapring slips into the groove.

Note: Fit the snap ring so that itsgap is on the pistons vertical axis(it must point either up or down).

- Repeat the above procedure to fitthe other snap ring.

- Fit new cylinder gasket tocrankcase so that slot in gasketis positioned over slot incrankcase.

- Push the large slotteddiameter of the sleeve over themagnet and snap ring. Positionthe sleeve so that the inner pinpoints toward flat face of tool'sshank.

- Stand the installing tool,sleeve downward, on a flatsurface (wooden board)and press verticallydownwards until the sleevebutts against the tool'sshoulder.

STIHL TS 460 26

Top:Wooden assembly block 1108 893 4800

Bottom:Correct position of piston ring

Top:Clamping strap 0000 893 2600

Bottom:Compressing pistonrings with clamping strap

Fitting aligned cylinder overthe piston

- Lubricate piston and pistonrings with oil.

- Position the woodenassembly block betweenthe piston and crankcase.

- Rest the piston on thewooden assembly block.

- Position the piston rings sothat the radii at the ring gapmeet at the fixing pin in thepiston groove when the ringsare compressed.

- Use the clamping strap tocompress piston rings aroundthe piston and check thatpiston rings are correctlypositioned.

- Lubricate inside of cylinderwith oil and line it up so that itis positioned as it will be inthe installed position (see ill.).It is important to observe thispoint as the piston rings mightotherwise break.

- Slide the cylinder over thepiston - the clamping strap ispushed downward as thepiston rings slip into thecylinder.

STIHL TS 460 27

5.4 Crankcase5.3 Piston Rings

Top:Ring grooves in piston

Bottom: Mounting thepiston rings

Top:Socket 0812 542 2104

Bottom:Tightening the cylinder base screws

Top:Flywheel

Bottom:Piston fitted on wooden assembly block

- Remove the clamping strapand wooden assembly block.Carefully line up the cylinderand the cylinder gasket. Fitcylinder base screws andtighten them alternately to10Nm in a diagonal pattern.

The parts are assembledin reverse order.

- Remove piston, see 5.2.1.

- Remove piston rings from piston.

- Scrape off carbon buildup ingrooves using an old pieceof piston ring.

- Fit new piston rings in ringgrooves so that the chamferson the ends face the pistonhead.

- Mount piston, see 5.2.2.

- Remove clutch, see 4.1.

- Remove cylinder, see 5.2.1.

- Remove expansion tank, see10.9.

- Remove flywheel from crankshaftstub, see 6.1.5.

- Remove piston, see 5.2.1.

5.4.1 Crankshaft Removal

STIHL TS 460 28

Top:Crankcase mountingscrews

Bottom:Removing the crankcase

Top:Removing the bottom of the crankcase

Below:Removing the crankshaft

Top:1 = Oil seal2 = Ball bearing3 = Circlip

Bottom:1 = Crankshaft2 = Connecting rod

- Remove the crankcasemounting screws.

- Remove the crankcase fromthe engine housing.

- Remove bottom ofcrankcase.

- Remove crankshaft fromcrankcase.

- Remove oil seals, circlip, andball bearings from crankshaft.

- The crankshaft, connectingrod and needle bearing forman inseperable unit. Thismeans that the crankshaftmust always be replaced as acomplete unit in the event ofany damage to any one ofthese parts. When fitting areplacement crankshaftalways install new oil sealsand ball bearings.

- Inspect both halves of thecrankcase for cracks andreplace if necessary.

STIHL TS 460 29

5.4.2 Installing the Crankshaft

Ball Bearing

Top:Installing the crankshaft1 = Annular groove2 = Long peg

Bottom:Inserting the circlip using pliers0811 641 8380

Top:Oil seal (clutch side)

Bottom:Oil seal (ignition side)

If the old crankcase and bottom ofthe crankcase are to be reused,remove gasket residue and cleansealing surfaces with standardcommercial grease solventwithout chlorinated orhalogenated hydrocarbons, see11.2. Sealing surfaces must beabsolutely clean to ensure aperfect seal.

- Warm new ball bearing to atemperature of approx. 50 °Cand press in as far as stop oncrankshaft stub.

- Position crankshaft so thatlong pin lies on side withsurrounding groove.

- Fit circlip into groove ofcrankcase.

- Fill space between sealinglip and dust lip withlubricating grease, see 11.2.

- Apply a thin coating of sealantto the outer circumference ofthe oil seal, see 11.2.

- Slide the oil seal onto thecrankshaft stub so that theopen side faces the ballbearing.

- Press the oil seals into thecrankcase until they areflush with the outer edge.

STIHL TS 460 30

5.5 Leakage Testingthe Crankcase

Top:Carburetor and crankcase tester1106 850 2905

Bottom:Vacuum pump 0000 850 3500Groove in bottom of crankcase

- Apply a thin bead of sealantto groove in bottom ofcrankcase, see 11.2.

Note: Please follow themanufacturer's instructions forusing the sealant.

- Fit and press on the bottomof the crankcase.

- Wait approximately oneminute, then turn overcrankshaft several times.

Installation continues in reverseorder of removal.

Note: Tighten crankcase mountingscrews to 10 Nm.

Defective oil seals and gaskets orcracks in the castings are theusual causes of leaks. Suchfaults allow supplementary air toenter the engine and thus upsetthe fuel-air mixture.

This makes adjustment of theprescribed idle speed difficult,if not impossible.

Moreover, the transition fromidle speed to part or full throttleis not smooth.

The crankcase can be checkedthoroughly for leaks with thecarburetor and crankcasetester and the vacuum pump.

STIHL TS 460 31

5.5.1 Preparations

Top:1 = Test flange 1119 850 42012 = Bushings 0000 963 200083 = Screws 9043 319 8100

Bottom:Test flange fitted

- Remove the carburetor,see 10.3.

- Remove the deflector bafflefrom the muffler, then removethe spark arresting screen,see 5.1.

- Remove the outermounting screws from themuffler.

- Back off the muffler'sinner mounting screws half-way.

- Slide the sealing platebetween the muffler and thecylinder exhaust port andretighten the inner mountingscrews moderately.

Note: The sealing plate mustcompletely fill the spacebetwen the two mountingscrews.

- Set the piston to top deadcenter (T.D.C.).

- Attach the test flangewith bushings and screwsto the spacer flange forleakage testing.

Important! A new carburetorgasket must be installedbetween the test flange and thespacer flange.

Top:Sealing plate 0000 855 8106

Bottom:Sealing plate fitted

Top:Outer mounting screws of exhaustmuffler

Bottom:Inner mounting screws of exhaust muffler

STIHL TS 460 32

5.5.2 Pressure Test

- Connect tester's pressurehose to nipple on test flange.

- Close the vent screw onthe rubber bulb.

- Use rubber bulb to pump airinto the crankcase until thegauge indicates a pressure of0.5 bar. If this pressureremains constant for at least20 seconds, the crankcase isairtight.

However, if the indicated pressuredrops, the leak must be locatedand the faulty part replaced.

Note: To find a leak, coat thesuspect area with oil andpressurize the crankcase again.Bubbles will appear if a leak exists.

- Carry out the vacuum test,see 5.5.3.

- After finishing the test, openthe vent screw anddisconnect the hose.

- Remove the test flange andrefit the carburetor, see 10.3.

- Loosen mounting screwson exhaust muffler andpull out sealing plate.

- Insert outer mounting screwsand lock washers and tightenall mounting screws to 10.0 Nm.

Top:Tester's pressure hose fittedon test flange nipple

Bottom:Closing the vent screw Pressure testing the crankcase

STIHL TS 460 33

5.5.3 Vacuum Test

1 = Lever2 = Vent screw

Testing crankcase for leaks with vacuumpump

Oil seals tend to fail whensubjected to a vacuum, i.e. thesealing lip lifts away from thecrankshaft during the piston'sinduction stroke because there isno internal counterpressure.

An additional test can be carriedout with the vacuum pump todetect this kind of fault. Thepreparations for this test are thesame as for the pressure test, see5.5.1.

- Connect the vacuum pump'ssuction hose to test flangenipple.

- Close the pump pistonsvent screw.

- Pull out the pump pistonseveral times until the gaugeindicates a vacuum of 0.5 bar.

Note: If the pressure remainsconstant or rises to no more than0.5 bar, within 20 seconds, it canbe assumed that the oil seals arein good condition.

However, if the pressure continuesto rise (reduced vacuum in thecrankcase), the oil seals must bereplaced, even if no leaks weredetected in the pressure test.

- Upon completion of test,open vent screw again andremove hose.

- Remove test flange andreinstall carburetor, see 10.3.

- Loosen mounting screwson exhaust muffler andpull out sealing plate.

- Insert outer mounting screwswith lock washers andtighten all mounting screwsto 10.0 Nm.

STIHL TS 460 34

5.6 Replacing theOil Seals

1 = Assembly sleeve 1122 893 46002 = Press sleeve 1127 893 2400

Top:Assembly bushing on thecrankshaft stub

Bottom:Pressing in the oil sealwith press sleeve

Note: When using the puller, makesure that it does not damage thecrankshaft surface, especially in thearea of the oil seal.

- Clean sealing surfaceswith standard commercial,solvent-based degreasantcontaining no chlorinatedor halogenatedhydrocarbons, see 11.2.

- Fill space between sealinglip and dust lip withlubricating grease, see 11.2.

- Apply a thin coating of sealantto the outer circumference ofthe oil seal, see 11.2.

- Slide the assembly bushingonto the crankshaft stub.

- Slide oil seal overassembly bushing with openside facing crankcase andpress it in with press sleeve.

- Wait approx. one minute, thenturn over crankshaft severaltimes.

- Remove assembly bushings.

- Install clutch, see 4.2.

Top:Puller 0000 890 4400 with jaws0000 893 3711 (with profile 6)

Bottom:Pulling out oil seal

It is not necessary to disassemblethe complete engine if only the oilseals have to be replaced.

Clutch side:

- Remove the clutch, see 4.1.

- Apply the puller and pull out theoil seal.

STIHL TS 460 35

5.7 Engine Removal andInstallation

Top:Jaws 0000 893 3706(with profile 3.1 and 4)

Bottom:Removing the oil seal

Pressing in the oil sealwith press sleeve

Shroud mounting screws (the twoscrews on the right side are hidden)1 = Spark plug terminal

Note: When using the puller, makesure that it does not damage thecrankshaft surface, especially in thearea of the oil seal.

- Clean sealing surface withstandard commercialsolvent-based degreasantcontaining no chlorinated orhalogenated hydrocarbons,see 11.2.

- Fill space between sealinglip and dust lip withlubricating grease, see 11.2.

- Apply a thin coating of sealantto outer circumference of oilseal, see 11.2

- Slide oil seal over crankshaftstub with open side facingcrankcase and press it in withthe press sleeve.

- Wait approximately oneminute, then turn overcrankshaft several times.

- Install flywheel, see 6.1.5.

The engine can be removed fromthe engine housing without havingto remove the carburetor andmuffler.

- Remove V-belt, see 3.3.

- Unplug spark plug terminal fromspark plug.

- Remove hood mounting screws.Remove hood, press spark plugterminal out of the hood opening.

Ignition side:

- Remove flywheel, see 6.1.5.

- Install jaws with profile 3.1 atthe pulley.

- Attach the pulley and pull outthe oil seal.

STIHL TS 460 36

Top:Carburetor box covermounting screws

Bottom:Withdrawing the grommet

Top:1 = Nipple of throttle cable2 = Slotted pin

Bottom:Throttle cablemounting screw

Top:Manifold clamp

Bottom:Choke shutter

- Remove carburetor box covermounting screws, removecarburetor box cover.

- Withdraw grommet frommounting in engine housing.

- Disconnect nipple of throttlecable from slotted pin onthrottle lever.

- Remove throttle cablemounting screw and pressthrottle cable out of themachine sideways.

- Loosen screw of manifoldclamp and pull manifold off ofconnector.

- Remove choke shutter fromits mounting in engine housing.

STIHL TS 460 37

Top:Compensator hose

Bottom:Outer muffler mountingscrews

Top:Flywheel

Bottom:Connecting piecemounting screws

Top:Crankcase mountingscrews

Bottom:Fuel hose

- Pull compensator hose offof angle connector.

- Remove outer muffler mountingscrews.

- Remove flywheel, see 6.1.5.

- Remove clutch, see 4.1.

- Unscrew connecting piecemounting screws, removeconnecting piece.

- Remove expansion tank,see 10.9.

- Remove crankcase mountingscrews.

- Lift engine slightly and pull fuelhose off of angle connector.

STIHL TS 460 38

5.8 Engine Housing

Removing the engine

Top:1 = Peg2 = Choke lever

Bottom:Removing the spark plugterminal

Top:1 = Short circuit wire2 = Mounting screws3 = Wire holder

Bottom:Removing the ignition module1 = Mount for ignition lead

- Lift engine out of enginehousing.

The parts are assembled inreverse order.

Note: Tighten crankcase mountingscrews to 10 Nm.

Tighten mounting screws forconnecting piece to 10 Nm.

Tighten outer mounting screws ofmuffler to 10 Nm

Fit choke shutter so that pinengages choke lever.

Pull spark plug terminal out ofshroud opening before mountingshroud.

- Remove engine, see 5.7.

- Disconnect short circuit wire fromconnector on ignition module andwithdraw from wire holder.

- Remove ignition modulemounting screws. Removeignition module, disconnectignition lead from mounting.

STIHL TS 460 39

Top:Pressing out the grommet

Bottom:Main filter

Top:Removing the auxiliary filter1 = O-ring

Bottom:Filter base mountingscrews

Top:Removing the manifold

Bottom:1 = Mounting screw2 = Ground wire3 = Point of separation of short circuit wire

- Remove handle tube bracket,see 9.6.

- Press grommet for short circuitwire out of engine housing andpull out short circuit wire.

- Remove filter cover.

- Remove main filter and prefilterfrom filter base.

- Remove auxiliary filter fromfitting.

- Remove O-ring from locatingpin.

- Remove filter base mountingscrews, remove filter base.

- Remove manifold from enginehousing.

- Unscrew mounting screw ofground wire.

- Pull short circuit wire apart atpoint of separation.

STIHL TS 460 40

Top:Plug

Bottom:Annular buffermounting screw

Top:AV-molding mounting screws

Bottom:AV-molding removal

Top:Annular buffer

Bottom:Removing the connecting piece

- Remove plug from annularbuffer.

- Unscrew annular buffermounting screw and removetogether with thrust plate.

- Unscrew AV-moldingmounting screws.

- Remove AV-molding andhandle grip.

- Remove plugs from annularbuffers.

- Remove annular buffers frommountings in engine housing.

- Pull connecting piece out ofengine housing.

STIHL TS 460 41

Top:Filler cap

Bottom:Fuel hose

Top:Pressing out the grommet

Bottom:Washer

Inserting the annular buffer1 = Middle groove2 = Housing rib

- Unscrew filler cap and pullring out of filler opening.

- Pry fuel hose off of nippleand pull fuel tank out ofengine housing.

- Press grommet out of enginehousing and pull out shortcircuit lead.

- Remove washer fromengine housing.

The parts are assembled inreverse order.

Note: When using a new enginehousing, stamp the machinenumber on the number plate of theengine housing using 2.5 mm highfigure stamps.

Glue the new surface to theengine housing.

Press in the annular buffer untilthe center nut engages thehousing rib.

Press plugs into annular buffers.Tighten connecting piecemounting screws to 10 Nm.

Run short circuit lead correctlybetween fuel tank and expansiontank, see 6.1.4.

Caution: Do not insert connectingpiece until tank has been mounted.

Tighten mounting screws ofannular buffer on handle grip andAV-molding to 8.0 Nm and 3.0 Nmrespectively.

STIHL TS 460 42

6. IGNITION SYSTEM

Warning: Exercise extremecaution when carrying outmaintenance and repair work onthe ignition sysytem. The highvoltages which ocur can causeserious or even fatal accidents!

6.1 Repairing ComponentParts

6.1.1 Spark Plug

1 = Flywheel2 = Ignition module

Top:Checking the electrode gap withfeeler gauge

Bottom:Resetting electrode gap with Boschspark plug gauge

Troubleshooting on the ignitionsystem should always begin at thespark plug.

In the event of starting difficulties,low engine power, misfiring, etc.,unscrew the spark plug and checkthat it is the approved type. Onlythe spark plugs listed in thespecifications may be used. Othermakes of spark plugs areunsuitable because they havelong-reach electrodes.

Sooted or carbonized spark plug:

- Use brass wire brush to cleanthe spark plug and then blow itclear with compressed air.

Note: Never use a steel wirebrush for this job.

Spark plug with smeared oil:

- Wash the insulator nose witha grease solvent and blow itclear with compressed air.

Electrode gap:

Electrode gap becomes wider as aresult of normal erosion.

The electronic (breakerless)ignition system basically consistsof an ignition module and flywheeland is easily accessible.

- Check the electrode gap atregular intervals with a feelergauge. It should be 0.5 mm.

- Bend the ground electrode asnecessary.

Important: Always fit a new sparkplug if the electrodes are badlyeroded.

STIHL TS 460 43

Condition of insulator nose Meaning

Normal: Grayish yellow to brown, dry Engine in order; correct spark plug(heat range as specified)

Sooted: Velvet-like, dull black coating ofsoot

Mixture too rich, lack of air (dirty airfilter, choke shutter partly closed),electrode gap too wide, wrong sparkplug (heat range too high)

Smeared with oil: Coating of damp oil carbon andsoot

Too much oil in fuel mix

Overheated: Welding beads on insulator nose,pitted electrodes

Mixture too lean, spark plug loose,wrong spark plug (heat range toolow)

Checking the spark plug:

Accurate checking of the sparkplug is only possible with a specialspark plug tester.

A provisional check can be carriedout by fitting a clean spark plug inthe spark plug terminal andholding it against ground. Thereshould be a powerful sparkover atthe electrodes when you crank theengine with the starter rope.

Checking the spark plug:

Accurate checking of the sparkplug is only possible with a specialspark plug tester.

A provisional check can be carriedout by fitting a clean spark plug inthe spark plug terminal andholding it against ground. Thereshould be a powerful sparkover atthe electrodes when you crank theengine with the starter rope.

Warning: Do not touch any liveparts - contact with high voltagecan cause serious or fatalaccidents.

Note: It is recommended that anew spark plug be fitted in allcases of doubt.

If there is no sparkover eventhough the spark plug is in goodcondition, first check theconnections.

Note: Chafed insulation on theignition lead or short circuit wirewill cause a short circuit to ground.In this case the engine will eithernot start or only run erratically.

Installing the spark plugs:

- Clean the spark plug seatand inspect the sealing ring tomake sure it is in goodcondition.

Fit the spark plug and tighten it to27.5 Nm.

The appearance of the spark plugs insulator nose gives valuable information with regard to the effects ofvarious operating conditions:

STIHL TS 460 44

6.1.2.1 Ignition Timing6.1.2 Ignition Module 6.1.2.2 Removing and Installing

1 = High voltage output2 = Connector tag

Ignition timing on the electronic(breakerless) magneto ignitionsystem is fixed at 3.0 mm B.T.D.C.at 8,000 r.p.m. and is notadjustable. However, in view of thepermissible tolerances in theelectronic circuit, it may varybetween 2.8 and 3.2 mm B.T.D.C.at 8,000 r.p.m.

Since there is no mechanical wearin these systems, ignition timingcannot get out of adjustment.

However, an internal fault in thecircuit can alter the switching pointin such a way that a spark test willstill show the system to be in orderalthough timing is outside thepermissible tolerance. This willimpair engine starting and runningbehavior.

Top:1 = Short circuit wire1 = Wire retainer

Bottom:Ignition module mounting screws

The ignition module accomodatesall the components required tocontrol ignition timing. There aretwo electrical connections on thecoil body:

1. the high voltage output2. the connector tag for the short

circuit wire

Accurate testing of the ignitionmodule is only possible withsophisticated test equipment. Forthis reason it is only necessary tocarry out a spark test in theworkshop. A new ignition modulemust be installed if no ignitionspark is obtained (after checkingthat wiring and stop switch are ingood condition).

- Remove the fan cover, see 6.1.5.

- Pull the short circuit wire off theignition module and out of theretainer.

- Remove the ignition modulemounting screws.

STIHL TS 460 45

6.1.3 Ignition Lead/Spark Plug Terminal

Top: Removing the unscrewed ignitionlead from the high voltage outlet

Bottom:Removing the wire holder

Adjusting gauge 1111 890 6400 positionedbetween the flywheel and the ignitionmodule

Top:Removal of the ignition lead

Bottom:1 = Insulating tube2 = Grommet

Note: Before screwing in theignition lead, fill the high voltageoutput with STIHL MultipurposeGrease, see 11.2.

Caution: Do not use graphite(Molykote) grease or siliconinsulating paste.

- Slide grommet over the highvoltage output.

- Fit ignition module and slightlytighten screws.

Important: There must be awasher under the head of eachscrew.

- Slide adjusting gauge betweenlegs of ignition module andmagnet poles of flywheel.

- Press ignition module againstadjusting gauge, tightenmounting screws to 8.0 Nm.

Further assembly is carried out inreverse order.

- Remove grommet fromhigh voltage output.

- Unscrew ignition lead fromcontact pin; to this end, turnignition module and pullignition lead out of highvoltage output.

- If necessary, press out thepegs of the wire holder andremove the wire holder.

- Remove shroud, see 6.1.5.

- Remove ignition module,see 6.1.2.2.

- Pull ignition lead out ofmounting in engine housing.

- Remove grommet andinsulating tube from ignitionlead.

STIHL TS 460 46

Top:Removing the dust seal

Bottom:Removing the torsion spring from thespark plug terminal

Top:Attaching the torsion spring

Bottom:Proper positioning of the torsionspring in the seat of the spark plugterminal

Piercing center of ignitionlead

- Pinch the hook of the torsionspring into the center of thelead, i.e. about 10 mm fromthe end of the lead.

- Pull the lead back into theterminal so that the torsionspring locates properly inside it.

- Fit the dust seal on the sparkplug terminal.

- Slide insulating tube andgrommet (thin end first) ontoignition lead.

Note: Use a pointed tool to piercethe center of the other end of theignition lead which screws onto themodule.

- Mount ignition module, see6.1.2.2.

- Remove shroud, see 6.1.5.

- Pull the dust seal off the sparkplug terminal and slip it downand off the ignition lead.

- Use a suitable pair of pliersto grip the torsion spring andpull it out of the spark plugterminal.

- Unhook the torsion springfrom the ignition lead andslip the spark plug terminaloff the lead.

- Cut new ignition lead tolength (see parts list or cutto same length as old lead).

- Coat end of the ignitionlead (about 20 mm) withoil.

- Fit spark plug terminal overthe ignition lead.

- Use suitable pliers to grip theend of the ignition lead insidethe spark plug terminal and pullit out.

STIHL TS 460 47

6.1.4 Short Circuit Wire /Ground Wire

Top:Separating point of short circuit wire

Bottom:Grommet

Top:Ground wireMounting screw

Bottom:Properly positioned short circuit wireand ground wire

- Remove fan housing, see 6.1.5.

- Remove expansion tank,see 10.9.

- Remove short circuit wirefrom connection on ignitionmodule and pull wire out ofwire holder.

- Press grommet out of enginehousing and pull out shortcircuit wire.

- Pull short circuit wire apart atseparation point in carburetorbox.

- Pull grommet out of enginehousing and remove shortcircuit wire.

- Unscrew ground wire mountingscrew in carburetor chamber.

- Remove fuel tank, see 10.8.

- Remove contact springs, see 9.3.

- Remove short circuit wire andground wire from handle grip.

The parts are assembled in reverseorder.

Note: Position both wires in the handlegrip correctly.

Top:1 = Short circuit wire2 = Wire holder

Bottom:Grommet

STIHL TS 460 48

Top:Short circuit wire and groundwire in the slot of the connectingpiece

Bottom:1 = Peg2 = Grommet3 = Locating Slot

6.1.5 Flywheel

Top:Shroud mounting screws(the screws on the right are hidden)1 = Spark plug terminal

Bottom:Locking strip 4221 893 5900

Top:Locking strip in the cylinder

Bottom:Fan cover mounting screws

Fit short circuit wire and groundwire in the slot in theconnecting piece.

Fit short circuit wire in the areaof the expansion tank into thelocating slot.

Press grommet into mountingand lay short circuit wire behindpin.

Removing the flywheel:

- Remove spark plug terminalfrom spark plug.

- Remove shroud mountingscrews. Remove shroud,pressing the spark plugterminal out of the opening inthe shroud.

- Remove spark plugs andreplace with locking strip incylinder to block crankshaft.

- Take out the fan cover mountingscrews and remove the fancover.

STIHL TS 460 49

Top:Puller 1116 893 0800

Bottom:Puller fitted in position

1 = Flywheel2 = Magnet poles

- Inspect the condition of theflywheel. If you find anydamage (e.g. cracks, brokenfan blades), fit a new flywheel.

Installing the flywheel:

Important: Clean the stub of thecrankshaft and the flywheel hubbore with a standard commercialsolvent-based degreasantcontaining no chlorinated orhalogenated hydrocarbons, see11.2.

- Fit the flywheel.

- Fit the mounting screw andtighten it down to 25 Nm.

Further assembly is carried out inthe reverse order.

Note: Tighten down the fan covermounting screw to 6.0 Nm.

- Rotate the flywheel so thatthe magnet poles areopposite the ignition module.

- Unscrew the flywheelmounting nut from thecrankshaft.

- Remove the flywheel fromthe crankshaft.

Note: If the flywheel cannot beremoved by hand, screw the pulleronto the crankshaft stub, tap theend of the puller lightly with ahammer to release the flywheel.Unscrew the puller.

Top: Flywheelmounting nut

Bottom:Removing the flywheel

STIHL TS 460 50

7. REWIND STARTER

7.1 RoutineMaintenance

7.2 Rope Rotor

Top. Removing spring clip

Bottom:Removing the rope rotor fromthe starter post

If the action of the starter ropebecomes very stiff and the roperewinds very slowly or notcompletely, it can be assumed thatthe starter mechanism is in orderbut plugged with dirt. At very lowoutside temperatures thelubricating oil on the rewind springmay thicken and cause the springwindings to stick together. Thishas a detrimental effect on thefunction of the starter mechanism.In such a case it is sufficient toapply a few drops of paraffin(kerosine) to the rewind spring.

Then carefully pull out the starterrope several times and allow it torewind until its normal smoothaction is restored.

If clogged with dirt or pitch, theentire starter mechanism,including the rewind spring, mustbe removed and disassembled.Take special care when removingthe spring.

Wash all parts in paraffin or whitespirit.

Lubricate the rewind spring andstarter post with STIHL speciallubricant, see 11.2, beforeinstalling.

Removing rope rotor

Troubleshooting chart - see 2.4.

- Unscrew the starter covermounting screws andremove the starter cover.

Relieving tension of rewindspring:

- Pull out the starter rope to alength of approx. 10 cm andhold the rope rotor steady.

- Use a screwdriver to catch therope between the rope guidebush and the rope rotor andpull it out.

- While still holding the roperotor steady, take all turns offthe rope rotor.

- Pull out the rope with thestarter grip and then let go ofthe rope rotor.

Note: The rope rotor will spin backand relieve the tension of therewind spring. The rewind springwill not be under tension if thestarter rope is broken.

- Use a screwdriver or suitablepliers to carefully remove thespring clip from the starter post.

- Take the washer and roperotor with pawl off the starterpost.

- Take the starter rope off therope rotor.

- Replace the worn or brokenstarter rope - see 7.3.

Starter cover mounting screws

STIHL TS 460 51

7. 3 Replacing theStarter Rope

Installing spring clip

Top:Threading the starter rope into the startercover (Elastostart)

Bottom:Threading the starter rope through therope rotor

Installing rope rotor

- Coat the bore in the rope rotorwith STIHL special lubricant -see 11.2. Fit the rotor on thestarter post so that the innerspring loop slides into the lugon the rotor.

Note: Check that the spring loophas engaged by turning the roperotor slightly counterclockwise andletting it go - it must spin back.

- Fit the washer and installthe spring clip in the starterpost groove.

Note: Make sure the spring clipengages the pawl guide peg andpoints it in the counterclockwisedirection.

- The spring clip must betreated very carefully. If it isbent or twisted duringdisassembly or assembly,the rewind starter mightmalfunction.

- Tension the rewind spring -see 7.5.

- Remove rope rotor, see 7.2.

- Remove remaining rope fromrope rotor and pull off thestarter grip.

- Thread new starter ropethrough starter grip from belowand fasten with special knots.

- Thread the other end of therope from the outside throughthe rope guide bush in thestarter cover.

- Thread end of rope into holeon side of rope rotor, insertin inner hole from below, pullthrough to top, and fastenusing a simple knot.

Top:Threading ropethrough the starter grip1 = Special knot

Bottom:Special knots used

STIHL TS 460 52

7.4 Replacing theRewind Spring

Starter rope fastened tothe rope rotor with knots

Top:Position of anchor loopa = 20 mm

Bottom:Fitting rewind spring with aid of woodenassembly block 1108 893 4800

- Withdraw the rope until the knotengages in the chamber in therope rotor provided for thispurpose.

- Mount rope rotor, see 7.2.

- Remove the rope rotor, see 7.2.Take out the spring housing.Use pliers to remove anyremaining pieces of the springfrom the starter cover.

- The rewind spring is suppliedready for installation with thespring housing. It should belubricated with a few drops ofSTIHL special lubricantbefore installation, see 11.2.

- Position the rewind spring withspring housing (bottom platemust face up) in the fanhousing. Engage the anchorloop over the lug in the startercover.

Important: If the rewind springpops out and uncoils duringinstallation, it must be refitted inthe spring housing as follows:

- Position anchor loop about20 mm from the edge of thespring housing.

- Refit the rewind spring in thespring housing in theclockwise direction, startingcoutside and working inwards.

Note: The wooden assembly blockcan be placed over the springhousing to simplify refitting.

- Install the rope rotor - see 7.2.

Rewind spring in position

STIHL TS 460 53

7.5 Tensioning theRewind Spring

- Grip the rope between the roperotor and fan housing, pull it outand make a loop.

- Grip the rope close to the rotorand use it to turn the rope rotorsix full turns in counterclockwisedirection.

- Hold the rope rotor steady.

- Pull out the rope with the startergrip and straighten it out.

- Hold the starter grip firmlyto keep the rope tensioned.

- Let go of the rope rotor andslowly release the starter grip.

Note: The rewind spring iscorrectly tensioned when thestarter grip sits firmly in the ropeguide bush without drooping toone side. If this is not the case,tension the spring by oneadditional turn.

When the starter rope is fullyextended, it must still be possibleto rotate at least another half turnbefore maximum spring tension isreached. If this is not the case, pullthe rope out, hold the rope rotorsteady and take off one turn of therope.

Do not overtension the rewindspring as this will cause it tobreak.

- Refit the starter cover.

- Remove the starter cover.

- Remove the spring clip, see 7.2.

Note: Do not pull the rope rotor offthe starter post.

- Pull the pawl out of the rope rotor.

- Coat peg of new pawl withgraphite grease, see 11.2, andfit it in position.

- Check that washer is fittedon starter post.

- Install the spring clip in thestarter post groove.

Note: Make sure the spring clipengages the pawl guide peg andpoints it in the anticlockwisedirection.

The spring clip must be treatedvery carefully. If it is bent ortwisted during disassembly orassembly, the rewind starter mightmalfunction.

- Refit the starter cover.

Grip on starter cover

7.6 Pawl

Top:Tensioning rewind spring

Bottom:Straightening twisted rope

1 = Spring clip2 = Pawl3 = Washer

STIHL TS 460 54

7.7 Starter Cup 7.8 Replacing the StarterRope Guide Bush

Top:Starter cup mounting nut

Bottom:Starter cup removal

TopRope guide bush

Bottom:Installing tool 0000 890 2201

Flaring the newrope guide bush

- Remove starter cover, see 7.2.

- Use locking strip to blockpistons, see 6.1.5.

- Remove mounting nut ofstarter cup.

- Remove starter cup.

The parts are assembled inreverse order.

Note: Tighten nut to 40 Nm.

The wear on the guide bush isaccelerated by the starter ropebeing pulled sideways. The wall ofthe guide bush eventually wearsthrough and becomes loose.

- Remove the starter cover.

- Remove the rope rotor, see7.2. Remove rope from roperotor and pull it out of the ropeguide bush.

- Use a suitable tool to pry theold bush out of the startercover.

Installing the new rope bush:

- Place the new bush in its seatin the starter cover.

- Insert the screw spindle ofthe installing tool through thebush from inside the housing.

- Fit the thrust sleeve and thehexagon nut.

- Tighten down the hexagonnut until the bush is firmlyseated.

Note: The installing tool flares thelower end of the rope bush.

- Thread the starter rope backonto the rope rotor andreattach, see 7.3.

- Refit the rope rotor - see 7.2.

- Fit the starter cover.

STIHL TS 460 55

8 AV HANDLE SYSTEM

8. 1 Repair

Top:Prying out the annular buffer(starter side)

Bottom:Fitting annular buffer1 = Annular groove

Top:Prying out the annular buffer(ignition side)

Bottom:Inserting the annular buffer1 = Annular groove

Top:Prying out the rear annular buffer

Bottom:Inserting the rear annular buffer1 = Central groove2 = Housing rib

The engine housing, handle andhandle tube are connected byvibration damping rubber buffers.Damaged rubber buffers (annularbuffers) must always be replacedin sets.

- Unscrew the annular buffermounting screw - see 9.6 and9.7.

- Pry the annular buffers out oftheir seats at the starter side.

- Press new annular buffer intothe handle grip or support untilthe annular groove engagesthe rib.

- Pry out annular buffer at theignition side.

- Press new annular buffer intosupport until annular grooveengages rib.

- Remove AV-molding, see 9.7.

- Pry stoppers out of rearannular buffers and annularbuffers out of mountings inengine housing.

- Press in new annular buffersuntil middle groove engageshousing rib.

Further assembly is carried outin reverse order.

STIHL TS 460 56

9. Throttle Control

9.1 Throttle Trigger,Throttle Trigger Interlock

Top:Mounting screws of handle molding

Bottom:Torsion spring

Top:Removing the throttle interlock

Bottom:Removing the throttle trigger

Detaching throttle cable fromthrottle trigger

- Detach nipple of throttle cablefrom throttle trigger.

The parts are assembled inreverse order.

Note: Tighten mounting screws ofhandle molding to 3.0 Nm.

- Unscrew mounting screws ofhandle molding, removehandle molding.

- Disconnect torsion springfrom throttle trigger andthrottle interlock and removefrom pin.

- Remove throttle interlock frompin.

- Remove throttle trigger frompin.

STIHL TS 460 57

9.2 Slide Control 9.3 Contact Springs 9.4 Throttle Cable

- Remove throttle trigger, see 9.1.

- Remove slide control andtorsion spring from handlegrip.

- Insert longer, angled end oftorsion spring in slot in slidecontrol.

- Mount slide control and presstorsion spring into mount inhandle grip.

- Mount throttle trigger, see 9.1.

- Remove slide control, see 9.2.

- Unscrew contact springmounting screws, removecontact springs.

- Insert contact springs.

- Screw in screws with shortcircuit and ground wires andtighten to 2.0 Nm

- Remove carburetor box cover,see 10.3.

- Disconnect nipple of throttlecable from slotted pin onthrottle lever.

- Remove mounting screwof throttle cable.

Top:Withdrawing the slide control

Bottom:Properly positioned torsion spring

Top: Contact springmounting screws

Bottom:Properly positioned contact springs

Top:1 = Nipple of throttle cable2 = Slotted pin

Bottom:Throttle cablemounting screw

STIHL TS 460 58

9.6 Handle Tube Bracket9.5 Handle Bar

Throttle Cable in handle grip

- Remove throttle trigger, see 9.1.

- Remove throttle cable frommount in handle grip.

The parts are assembled inreverse order.

- Unscrew handle bar mountingscrews from handle grip andhandle tube bracket.

- Unscrew handle bar mountingscrews from handle tube bracket,remove handle bar.

- Mount handle bar, screw inscrews and tighten to 8.0 Nm.

- Remove handle bar, see 9.5

- Unscrew support mountingscrews, remove support.

- Pry stopper out of annularbuffer.

Top:Handle bar mounting screws(right)

BottomHandle bar mounting screws(left)

Top:Support mountingscrews

Bottom:Prying out the stopper

STIHL TS 460 59

9.7 Handle Bar

Top: Removing themounting screw

Bottom:Annular buffer

Top:1 =Annular groove2 = Annular rib

Bottom:1 = Pressure plate2 = Mounting screw

Top:1 = Short circuit wire2 = Ground wire3 = Throttle cable

Bottom:AV-moldingmounting screws

- Unscrew mounting screwof annular buffer.

- Remove handle tube bracket.

Note: Follow the same procedurein removing the handle tubebracket on the other side.

- Press annular buffer out ofhandle tube bracket.

The parts are assembled inreverse order.

Note: Press in annular buffersuntil annular groove engagesannular rib on handle tube bracket.

Insert pressure plates in annularbuffer. Screw in screw and tightento 8.0 Nm.

- Remove contact springs, see 9.3.

- Pull short circuit and groundwires and throttle cable out ofhandle grip.

- Unscrew mounting screws forAV-molding, remove AV-molding.

STIHL TS 460 60

Top: Annular buffermounting screw

Bottom:Annular buffer

Top:1 =Annular groove2 = Annular rib

Bottom:1 = Pressure plate2 = Mounting screw

- Remove rubber vibration bufferfrom handle grip or AV-molding.

- Remove handle bar, see 9.5.

- Pry stopper out of annular buffer.

- Unscrew annular buffermounting screw.

- Remove handle grip

- Press annular buffer out ofhandle grip.

The parts are assembled inreverse order.

Note: Press annular buffer in untilannular groove engages annularrib on handle grip.

Insert pressure plates in annularbuffers, screw in screws andtighten to 8.0 Nm

Tighten AV-molding mountingscrews to 3.0 Nm.

Top:Rubber vibration buffer at AV-molding

Bottom:Prying out the stopper

STIHL TS 460 61

10. Fuel System

10.1 Air Filter

Choke trigger

Top:Hexagon cap nut

Bottom:Removing the prefilter

Top:Main filter

BottomRemoving the auxiliary filter1 = O-ring

Dirty filters cause decreasedengine performance, increase fuelconsumption, and make startingmore difficult.

The air filter must be cleanedwhenever engine performancebegins to suffer.

- Before removing filter, closechoke shutter to prevent dirtand grime from enteringcarburetor, to this end, presschoke trigger forward.

- Loosen hexagon cap nut offilter cover and remove filtercover.

- Remove coarse dirt from areasurrounding filter and inside offilter cover.

- Detach prefilter from mainfilter.

- Dry wet prefilter, then firmlyknock out or blow out dirt andgrime.

Note: If dirt and grime cannot beeliminated in this way, then a newprefilter must be used.

- Remove main filter from filterbase.

Note: Dirty main filters should bereplaced, in which case theauxiliary filter should be replacedat the same time.

- Remove auxiliary filter fromthe mount, tap gently torelease dirt and grime, andwash in clean, nonflammablecleaning solution (e.g., warm,soapy water).

Note: Replace auxiliary filters withdamaged flock immediately.

- Inspect O-ring on locator pin,replace if necessary.

The parts are assembled inreverse order.

STIHL TS 460 62

10.2 Structure andFunction of theCarburetor with

Carburetor without compensator Carburetor with compensator

The carburetor with compensatormaintains a constant fuel ratioduring carburation regardless ofhow dirty the air filter is. Thepressure on the clean side of theair filter and at the meteringdiaphragm is constant.

The manifold for the air filter isequipped with a hose. When fittedto the connectors on the cover onthe regulator side, it forms theconnection between the meteringdiaphragm chamber and the cleanside of the air filter.

When the air filter is dirty, thequantity of air is reduced. This,however, causes a drop inpressure not only in the venturi ofthe carburetor, but at the outsideof the metering diaphragm as well.The metering diaphragm movesupward, the inlet needle closespartially, thus reducing the flow offuel.

The combustion mix can no longerbecome too rich; it is no longernecessary to readjust the highspeed adjusting screw as the filterbecomes dirtier. Performance isreduced, however, due to reducedvolume of air. Optimumperformance can only be regainedby cleaning the air filter.

STIHL TS 460 63

10.3 Removing and Installingthe carburetor

Carburetor box coverfastening screws

Top:Removing the grommet

Bottom:1 = Nipple of throttle cable2 = Slotted pin

Top:Throttle cablemounting screw

Bottom:Clamp on manifold

The all-position diphragmcarburetor consists of a fuelpump and the actual carburetor.Although the fuel pump shares acommon housing with thecarburetor, it operates as acompletely separate andindependent unit.

Troubleshooting chart - see 2.5.

- Unscrew carburetor boxmounting screws, removecarburetor box cover.

- Remove grommet from mountin engine housing.

- Detach nipple of throttle cablefrom slotted pin at throttlelever.

- Unscrew throttle cablemounting screw and pressthrottle cable to the side out ofthe machine.

- Loosen screws on manifoldclamp and remove manifoldfrom connector.

STIHL TS 460 64

Top:Choke knob

Bottom:Unscrewing the carburetor mountingscrews1 = Mounting screws2 = Opening in connecting piece

Top:Removing the connector

Bottom:1 = Fuel hose2 = Compensator hose

Top:Gaskets

Bottom:1 = Pin2 = Choke lever

- Remove choke knob frommount in engine housing.

- Remove carburetor mountingscrews through openings inhandle grip and connectingpiece.

- Lift the carburetor andconnector slightly and removethe connector and mountingscrews from the carburetor.

- Disconnect fuel hose andcompensator hose from angleconnectors.

The parts are assembled inreverse order.

Note: Slide new gaskets overmounting screws on both sides ofcarburetor.

Tighten mounting screws to5.0 Nm.

Fit choke shutter so that pinengages choke lever.

STIHL TS 460 65

10.4 Leakage Testing theCarburetor

10.5 Servicing theCarburetor

The carburetor can be testedfor leaks with the carburetorand crankcase tester.

- Remove the carburetor, see10.3

- Push the fuel line onto thecarburetor's elbow connector.

- Push the nipple into thetester's pressure hose.

- Close the vent screw on therubber bulb and pump air intothe carburetor until the pressuregauge shows a reading ofapprox. 0.8 bar.

If this pressure remains constant,the carburetor is airtight. However,if it drops, there are two possiblecauses:

1. The inlet needle is not sealing(foreign matter in valve seat orsealing cone of inlet needle isdamaged or inlet control leversticking).

2. The metering diaphragm isdamaged.

In either case the carburetor mustbe removed and serviced.

It is advisable to check theservicability of the fuel pumpwhenever the carburetor isremoved for repair.

- Remove the carburetor - see10.3.

- Unscrew the fuel pump endcover and remove the gasketand pump diaphragm.

Pressure testing carburetorwith carburetor/crankcase tester1106 850 2905

Top:Nipple 0000 855 9200fitted in fuel line 1110 141 8600

Bottom:Fuel hose fitted on carburetor'selbow connector

Top:Fastening screws on fuelpump end cover

Bottom:Fuel pump end cover with gasket

STIHL TS 460 66

Pump diaphragmon carburetor body

Top:Fuel strainer in carburetor body

Bottom:Mounting screws of meteringchamber end cover

Top:Metering diaphragm withgasket on carburetor

Bottom:Separating gasket and diaphragm

Note: The diaphragm and gasketoften stick to the cover orcarburetor body. If this is thecase, take particular care whenseparating them.

- If the fuel strainer in thepump side of the carburetorbody is dirty, use a scriber toremove it and then clean it.

Important: If the fuel strainer isdamaged, fit a new one.

In such a case the fuel pickupbody should also be inspectedand replaced if necessary - see10.7.

- To disassemble the carburetor,take out the screws of themetering chamber end coverand lift away the cover.

- Remove the meteringdiaphragm and gasket fromthe carburetor body or thecover.

- Carefully separate thediaphragm and gasket.

Note: The diaphragms are themost delicate parts of thecarburetor. They are subjected tocontinuous alternating stressesand the material eventually showssigns of fatigue, i.e. thediaphragms distort and swell.Check and replace if necessary.

STIHL TS 460 67

Top:Damaged inlet needle

Bottom: 1 = Full throttlefixed jet 2 = Part throttlefixed jet

Top:Pressing out valve jet

Bottom:Sealing plug

- The inlet needle valve islocated in a recess in themetering diaphragm chamber.Remove the oval headcountersunk screw.

- Remove the inlet control leverwith spindle, helical springand inlet needle.

Note: If there is an annularindentation on the sealing cone ofthe inlet needle, it will benecessary to replace the inletneedle because it will no longerseal properly. This is indicated byconstant flooding of the carburetoreven though the needle is clean.

- Remove full throttle fixed jetfrom metering chamber.

Note: The part throttle fixed jetcannot be removed, but ratheronly blown through.

- Use a 5 mm dia drift to pressthe valve jet out of its seat andwash it in white spirit.

- Remove the sealing plugfrom the metering chamber.

Caution: The sealing plug isdestroyed during removal. Itshould, therfore, only be removedif a replacement is available.

Top:Oval head countersunk screwon control lever spindle

Bottom:1 = Oval head countersunk screw2 = Inlet control lever3 = Spindle4 = Helical spring5 = Inlet needle

STIHL TS 460 68

1 = Identification on valve jet2 = Idle jet portProper positioning of inletcontrol lever Carburetor adjusting screws

Top:Locating pegs on housing

Bottom:Locating pegs on fuelpump end cover

- Remove the carburetoradjusting screws.

- Wash the carburetor body andall servicable parts in freshwhite spirit and blow clear withcompressed air, paying specialattention to the bores andports.

- Fit valve jet in preciselyvertical position in hole andturn so that identificationfaces idle jet port. Press invalve jet until it is flush withunderside of meteringchamber.

- Screw in full throttle fixed jet.

- Fit the inlet needle and thehelical spring in their respectivebores. Insert spindle in the inletcontrol lever, engage clevis inannular groove on head of theinlet needle and tighten downthe oval head countersunkscrew. Make sure that thehelical spring locates on thecontrol levers nipple.

Important: The top of the inletcover lever must be level with thebottom of the metering chamber. Ifnecessary, use suitable pliers tocarefully bend the lever.

- Check easy action of the inletcontrol lever.

- Fix newly installed seal plugwith Loctite, see 11.2. (Fill gapbetween housing and seal plugwith Loctite.)

- Refit the carburetor adjustingscrews. - Fit gasket, metering diaphragm,

and end cover, whereby themetering diaphragm and thegasket are fixed by theintegrally cast pegs on thecarburetor body.

- Insert the fuel strainer at thepump side. Fit the pumpdiaphragm, gasket and endcover and tighten downsecurely. The pump diaphragmand gasket are held in positionby the integrally cast pegs onthe end cover.

STIHL TS 460 69

Top:Throttle shutter fasteningscrew

Bottom:1 = Washer2 = Circlip

Top:Removing the throttle shaft

Bottom:1 = Lever on the throttle shaft2 = Slotted pin3 = Circlip

Top:1 = Bushing2 = Torsion spring

Bottom:Properly positioned torsion spring

Removing the throttle shaft:

- Unscrew the throttle shutterfastening screw.

- Use suitable pliers to pullthe throttle shutter out ofthe carburetor.

- Press circlip off of throttleshaft and remove washer.

- Carefully pull throttle shaft outof carburetor.

- Remove torsion spring andbushings.

- Press circlip off of slotted pin,remove slotted pin fromthrottle shaft lever.

- Slide bushings and torsionsprings onto throttle lever.

Note: Slide bushings on so that ineach case the end with the smallerdiameter faces the torsion spring.

- After sliding in the throttle shaft,make sure that the torsionsprings are positioned properly.

STIHL TS 460 70

Top:Mounting the throttle shutter1 = Round notch2 = Notches

Bottom:Choke shutter mounting screws

Top:1 = Circlip2 = Ring

Bottom:Removing the choke shaft

Top:1 = Gasket2 = Torsion spring

Bottom:Choke lever mounting bolt

- Mount throttle shutter withround notch toward control-side end cover and othernotches facing inward.

- Screw in mounting screwusing Loctite, see 11.2., andtighten.

Removing the choke shaft

- Unscrew choke shuttermounting screws, removechoke shutter.

- Press circlip off of chokeshaft.

- Remove ring and gasket.

- Remove choke shaft fromcarburetor.

- Remove torsion spring andgasket.

- Unscrew choke lever mountingscrew, remove choke lever.

STIHL TS 460 7110.6 Carburetor Adjustment

Top:Properly positioned torsion spring

Bottom:1 = Ring2 = Gasket

The ignition system is equippedwith an electronic maximumengine speed limiter. Unlikemachines equipped with ordinaryignition systems, the maximumengine speed cannot be made toexceed a predeterminedmaximum r. p.m. by adjusting thecarburetor.

Likewise, the machine cannot beadjusted by hand for "maximumperformance". Extremely leancarburetor settings yield neitherhigher rpms nor increasedpower, but instead increase therisk of engine damage.

The carburetor has a standardsetting when it leaves the factory.

This is the optimum setting of thehigh speed adjusting screw for thebarometric pressure and climaticconditions at the factory (300mabove sea level). It ensuresmaximum engine performance,fuel efficiency and the highestpossible reliability.

Standard setting

If the carburetor has to be adjustedfrom scratch, first carry out thestandard setting to obtain astarting point for the fine tuning.

- Slide ring on with open sidefacing gasket.

- Press circlip into groove ofchoke shaft.

- Fit choke shutter with roundnotch facing pump-side endcover and other notchesfacing outward.

- Screw in mounting screwusing Loctite, see 11.2.,and tighten.

- Fit new gasket in chokelever.

- Following insertion of chokeshaft, make sure that torsionsprings are positionedproperly.

- Slide new gasket over chokeshaft.

Fitting the choke shutter1 = Round notch2 = Notches

STIHL TS 460 72

10.7 Fuel Pickup Body

Turn the high speed adjustingscrew (H) and low speed adjustingscrew (L) clockwise for leanermixture at high altitudes orcounterclockwise for richer mixtureat sea level. Turn screws veryslowly and carefully - even slightadjustments produce a noticablechange in engine running behavior.

Adjusting engine idle speed

Cutting wheel rotates whileengine is idling

Turn the idle speed adjustingscrew (LA) counterclockwise untilthe cutting wheel stops rotating.

Engine stops while idling

Turn the idle speed adjustingscrew (LA) clockwise until theengine runs smoothly.

Erratic idling behavior, pooracceleration

Idle setting too lean. Turn the lowspeed adjusting screw (L)counterclockwise until the engineruns and accelerates smoothly.

Exhaust smokes at idle speed

Idle setting too rich. Turn the lowspeed adjusting screw (L)clockwise until the engine speeddrops - and then turn it backstepwise until the engineaccelerates smoothly when thethrottle is opened.

Fuel filler cap

- Carefully screw in bothadjusting screws clockwiseuntil they are hard againsttheir seats.

Now make the followingadjustments:

H = High speed adjusting screwbacked off 1 full turn

L = Low speed adjusting screwbacked off 1 full turn

When used at high altidudes(mountains) or near sea level, aminor correction may benecessary.

- Check the air filter and clean itif necessary.

- Adjust idle speed correctly(cutting wheel must not rotate).

- Start the engine.

- Warm up the machine.

The diaphragm pump draws fuelout of the tank and into thecarburetor via the fuel hose. Anyimpurities mixed with the fuel areretained by the pickup body (filter).The fine pores of the filtereventually become clogged withminute particles of dirt. Thisrestricts the passage of fuel andresults in fuel starvation.

Important: In the event of troublewith the fuel supply system,always check the fuel tank andpickup body first. Clean the fueltank if necessary.

Cleaning the fuel tank:

- Unscrew the filler cap anddrain the tank.

- Pour a small amount of cleangasoline into the tank.

- Close the tank and shake theCutquik vigorously.

- Open the tank again and drainit.

Adjusting screws on carburetor1 = High speed adjusting screw2 = Low speed adjusting screw3 = Idle speed adjusting screw

STIHL TS 460 73

10.8 Fuel Tank

Top:Removing pickup body with assemblyhook 5910 893 8800

Bottom:Pulling pickup body off hose

Top:Fuel Hose

Bottom:Housing covermounting screws

Top:Removing the fuel tank

Bottom:Removing the rubber ring

Removing and refitting pickupbody:

- Use the special assemblyhook to pull the pickup bodyout through the filler neck.

Note: During removal, make surethat the fuel hose is not subjectedto too much stretching.

- Remove pickup body fromfuel hose and replace pickupbody.

The parts are assembled inreverse order.

- Remove carburetor box cover,see 10.2.

- Remove fuel hose fromconnector on fuel tank.

- Unscrew filler cap and pullring out of fuel tank filleropening.

- Unscrew housing covermounting screws, removehousing cover.

- Remove fuel tank from enginehousing.

- Remove rubber ring fromthreaded connector of fueltank.

STIHL TS 460 74

Top:Removing the tank vent grommet

Bottom:Removing the elbow

Top:1 = Pickup body2 = Hose3 = Elbow

Bottom:Grommet

Top:Properly positioned elbowa = 65°

Below:Washers

- Remove grommet for theconnectors of the elbow.

- Remove elbow from grommetand remove, together withhose and pickup body, fromfuel tank.

- If necessary, remove hosewith pickup body from elbow.

- Remove grommet from fueltank.

- Remove washers from fueltank.

The parts are assembled inreverse order.

Note: Position elbow as shown indiagram.

Inspect washers on housing cover,if necessary, glue new ones to theplaces provided.

Tighten housing cover mountingscrews to 6.0 Nm.

STIHL TS 460 75

10.9 Expansion Tank 10.10 Tank Vent

Top:Vent hose

Bottom:Removing the expansion tank

Top:Removing the tank vent

Bottom:Grommet

1 = Tank vent2 = Vent hose

Correct operation of the carburetoris only possible if atmosphericpressure and internal fuel tankpressure are equal at all times.This is ensured by the tank vent.

Important: In the event of troublewith the carburetor or the fuelsupply system, always check andclean the tank vent.

Note: Equalization of pressure inboth directions takes place viavalve in tank vent.

- Remove tank vent fromexpansion tank, see 10.9.

- Remove vent hose from tankvent.

- Remove carburetor box cover,see 10.3.

- Disconnect vent hose fromconnector on connecting piece.

- Remove housing cover, see10.8.

- Remove expansion tank fromengine housing.

- Remove tank vent fromexpansion tank.

- Remove grommet fromopening.

The parts are assembled inreverse order.

Note: Inspect and, if necessary,glue down new washer betweenexpansion tank and enginehousing.

STIHL TS 460 76

Top:Cap

Bottom:Removing the valve

Top:Removing connectingpiece

Bottom:Vent insert

Top:Mounted vent inserta = approx. 6 mm

Bottom:Mounted vent hosea = approx. 140 mm

- Press cap off of tank vent.

- Remove valve from tank vent.

- Detach throttle cable fromcarburetor, see 9.4, and layaside.

- Remove AV-molding, see 9.7.

- Remove short circuit wire andground wire from slot inconnecting piece and lay aside.

- Push handle grip somewhat tothe side and pull out connectingpiece.

- Unscrew vent insert fromconnecting piece.

- Wash all parts in clean whitespirit and blow throughthoroughly with pressurized air.

The parts are assembled inreverse order.

Note: Screw in vent insert to adepth of approx. 6 mm.

Pull vent hose into tank until itextends approx. 140 mm out ofhole on the side.

Caution: Press connecting piecein carefully, so that connector doesnot break off in grommet duringassembly.

STIHL TS 460 77

10.11 Manifold

Top:Hose

Bottom:Pressing out the manifold Removing the manifold

- Remove manifold from enginehousing.

The parts are assembled inreverse order.

Note: Tighten filter base mountingscrews to 6.0 Nm.

- Remove fan housing, see6.1.5.

- Remove air filter, see10.1.

- Remove filter base mountingscrews, remove filter base.

- Loosen screw on clamp,remove manifold fromconnector and remove clamp.

- Disconnect hose fromconnector on carburetor endcover.

- Press manifold collar out ofengine housing.

Top:Filter base mountingscrews

Bottom:Clamp

STIHL TS 460 78

No. Part Name Part No. Application

1 Locking strip 4221 893 5900 Blocking crankshaft2 Press sleeve 1127 893 2400 Fitting oils seal3 Assembly sleeve 1122 893 4600 Protecting oil seal at clutch side4 Puller 0000 890 4400 Removing oil seals5 - Jaws (No. 3.1 + 4) 0000 893 37066 - Jaws (No. 6) 0000 893 37117 Puller 1116 893 0800 Removing flywheel8 Crimping tool 5910 890 8210 Attaching connectors to electrical

wires9 Assembly drift 1108 893 4700 Fitting piston pin10 Clamping strap 0000 893 2600 Compressing piston rings11 Wooden assembly block 1108 893 4800 Fitting piston12 Carburetor and crankcase tester 1106 850 2905 Testing carburetor and crankcase

for leaks13 - Nipple 0000 855 920014 - Fuel line 1110 141 860015 Vaccum tester 0000 850 3501 Testing crankcase for leaks16 Sealing plate 0000 855 8106 Sealing exhaust port for leakage

test17 Test flange 1119 850 4200 For leakage test18 - Bushings 0000 963 100819 - Screws 9043 319 810020 Setting gauge 1111 890 6400 Setting air gap between ignition

module and flywheel21 Socket, 13 mm 5910 893 5608 Nut for flywheel22 Socket, 17 mm 5910 893 5610 Nut for starter cup23 Socket, 21 mm long 5910 893 5616 Removing and installing clutch24 Torque wrench 5910 890 0301

5910 890 0302Screwed joints (0.5 to 18 Nm) 1)

25 Torque wrench 5910 890 03115910 890 0312

Screwed joints (6 to 80 Nm) 1)

26 Screwdriver bit I-5x120x6.3 0812 542 2104 For spline screws27 Assembly hook 5910 893 8800 screws Removing pickup bodies28 Installing tool 5910 890 2212 Fitting hookless snap rigs in

piston29 Assembly hook 5910 890 2800 Detaching springs from the clutch

shoes30 Installing tool 0000 890 2201 Flaring rope guide bush

11. Special Servicing Tools and Aids

11.1 Special Servicing Tools

1) This version is equipped with an opto-acoustical signal device.

STIHL TS 460 79

No. Part Name Part No. Application

31 T-handle screwdriverQI-5x150

5910 890 2400 For all IS screws

32 Pliers A 10 0811 611 8200 Outer circlip on the pressure plate33 Pliers C 19 0811 641 8380 Inner circlip on the spindle bearing

and on the crankshaft34 Test wheel 5910 851 6100 Testing axial truth of running of

the cutting wheel mount35 Gauge holder 5910 850 6000 Testing axial truth of running36 Dial gauge 0000 890 9100 Testing axial truth of running37 Press arbor 1119 893 7200 Installation and removal of the

needle sleeves in the V-belt pulley38 Press arbor 4119 893 7200 Removal of the deep groove ball

bearings in the spindle bearing

STIHL TS 460 80

No. Part Name Part No. Application

1 Lubricating grease 0781 120 1111 Oil seals, needle sleeve in theV-belt pulley

2 High-strength threadlocking(Loctite 270)

0786 111 1109 Throttle shutter fastening screw,sealing plug

3 Standard commercial, solvent-based degreasant containing nochlorinated or halogenatedhydrocarbons

Cleaningcrankshaft stub

4 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewindspring in rope rotor

5 Ignition lead HTR (10m) 0000 930 2251

6 Electrician's repair kit 0000 007 1013

7 Dirko sealant, 100g (3 1/2 oz) 0783 830 2120 Crankcase sealing faces, oil seals

8 Graphite grease Peg on starter pawl

9 STIHL multipurpose grease 0781 120 1109 High voltage connection on ignitionmodule

11.2 Servicing Aids