Stihl GS 461 Manual
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Stihl GS 461 Manual

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STIH)
STIHL GS 461
2012-06

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  • Page 1 STIH) STIHL GS 461 2012-06...

  • Page 2: Table Of Contents

    8.1.4 Stop buffer on clutch Shroud side Cylinder 8.1.5 Stop buffer on ignition Crankshaft side 5.6.1 Ball bearing / Handlebar crankcase Guard Piston Piston rings Decompression valve 37 © ANDREAS STIHL AG & Co. KG, 2012 GS 461...

  • Page 3: Introduction And Safety Precautions

    In order to be able to fit the machine "Special Tools Manual". The manual on the assembly stand, the support lists all tools supplied by STIHL. 5910 850 1651 mounting kit must be used. The new support (1) can Symbols are included in the text and be identified with the aid of the pictures for greater clarity.

  • Page 4: Safety Precautions

    Always use original STIHL Safety precautions The chapter "Tightening Torques" replacement parts. lists all components of this machine They can be identified by the STIHL that must be tightened with the Specific national safety regulations part number, specified tightening torques or...

  • Page 5: Specifications

    Specifications Engine GS 461 Displacement: 76.5 cm Cylinder bore: 52.0 mm Stroke: 36.0 mm Engine power according to ISO 7293: 4.3 kW (5.9 HP) at 9800 rpm Idle speed: 2500 rpm Clutch: Centrifugal clutch without linings Clutch engages at: 3500 rpm...

  • Page 6: Tightening Torques

    M 5x25 Crankcase drive side / fan side 10.0 4), 6) Screw M 5x20 Fan housing Carrier M 12x1 L Carrier 50.0 Screw M 4x16 Ring buffer / crankcase Screw P 6x19 Ring buffer / tank housing rear GS 461...
  • Page 7 3) Loctite 649 very high strength 4) Screws with locking serration 5) Microencapsulated screws 6) Screws with easy-slide coating 7) Connection between crankshaft and flywheel must be degreased and oil-free 8) Coat screws and threaded hole with medium-strength Loctite 242 or 243 GS 461...

  • Page 8: Troubleshooting

    Tension springs of the clutch shoes Replace clutch springs are broken Loud noises Tension springs stretched Replace all clutch springs Needle cage damaged Replace needle cage Clutch shoe retainer broken Replace retainer or clutch Clutch shoes and carrier worn Replace clutch GS 461...

  • Page 9: Chain Drive, Chain

    Cut-off chain runs when idling Idle speed too high Readjust idle speed screw LA Tension springs of the clutch shoes Replace clutch springs or replace are stretched clutch Tension springs of the clutch shoes Replace clutch springs are broken GS 461...

  • Page 10: Water System

    Leaks in the water system O-ring on water attachment Replace O-ring, replace whole damaged water attachment if necessary Hose clips open or damaged or Close hose clips, replace if hose damaged necessary, replace damaged hose GS 461...

  • Page 11: Starter

    Lubricant oil on the rewind spring standard solvent-based degreasant becomes viscous (spring winding (containing no chlorinated or stick together) or moisture has halogenated hydrocarbons), then penetrated the rewind spring pull rope carefully several times (spring windings are frozen) until normal action is restored GS 461...

  • Page 12: Ignition System

    / ignition module and replace if necessary. Check operation of spark plug Clean spark plug, replace if necessary If the engine runs roughly, this may also be due to problems in the carburetor or engine. GS 461...

  • Page 13: Carburetor

    Remove inlet needle, clean and refit Metering diaphragm or gasket is Replace metering diaphragm and damaged gasket Tank vent faulty Replace tank vent Leak in fuel line between pickup Seal connections or replace fuel body and carburetor line GS 461...
  • Page 14 Idle speed too high Readjust with idle speed screw LA (counterclockwise) Tension springs of clutch shoes Replace tension springs or replace stretched or fatigued clutch Anchor loops of the tension springs Replace tension springs for the clutch shoes are broken GS 461...
  • Page 15 – woodruff key has sheared off or groove in flywheel is worn Engine runs extremely rich, lacks Choke shutter does not open fully Examine the carburetor and starter power and has very low final speed shaft and repair or replace if necessary GS 461...

  • Page 16: Engine

    Insufficient cylinder cooling. Air Thoroughly clean all cooling air inlets in fan housing blocked or openings and the cylinder fins cooling fins on cylinder very dirty Air intake in fan housing is fouled Clean air intake on fan housing GS 461...

  • Page 17: Clutch

    – Install the clutch drum must rest against the cylinder wall (arrow) : Remove the clutch drum (3) – Coat cap with STIHL press fluid, – Position as shown b 12 – Remove rim sprocket and clutch – Fit rim sprocket and press on cap...
  • Page 18 (set of 3), replace clutch shoes. Assembly The washer (1) must be in place and the word "TOP" (arrow) must be visible. : Fit holder (1) and slide clutch shoes (2) over the legs (3) GS 461...

  • Page 19: Pin / Hand Guard

    – Pull insert out of hand guard : Orient insert (1) so that the tab (2) is at the top – Remove washer : Slide insert (1) into recess in hand guard (3) until the holes (4) and (5) are lined up GS 461...

  • Page 20: Chain Tensioner

    – Use STIHL press fluid to simplify assembly, b 12 : Press rubber buffer (1) into the mount so that the raised part (2) rests against the hand guard (arrow) – Reassemble remaining parts in reverse order : Slide on the washer (1)

  • Page 21: Cut-Off Chain

    (3) so that the "STIHL" embossing is visible, then rivet – Unrivet tie straps with with STIHL NG 5 or NG 7 (roll in STIHL NG 4 or NG 7 – see just like saw chain with "spinner Instruction Manual STIHL NG 4 insert A"...

  • Page 22: Bar Mounting Studs

    : Drill out the collar nuts with an 11 – Reassemble remaining parts in mm diameter drill bit – the base in reverse order the chain sprocket cover must not be drilled out GS 461...

  • Page 23: Engine

    : Remove gasket (1) and unscrew screws (2) – always use a new gasket Parts with damaged mating faces must be replaced. – Remove and examine the muffler, replace if necessary. GS 461...

  • Page 24: Leak Testing

    – insert new gasket – Remove exhaust casing and loosen muffler screws, b 5.1 : Coat the screws (3) with Loctite, b 12 : Position exhaust casing (1), screw in and tighten screws (2), screws (3) GS 461...

  • Page 25: Testing With

    0000 850 1300 onto the – Tighten screws lightly – Coat screw or inside of impulse connector (arrow) hose with STIHL press fluid, b 12 The sealing plate must fill the full : Slide ring (2) to the left width between the screws.

  • Page 26: Pressure Test

    – Coat the sealing lips of the new : Push woodruff key (1) out of the – If the pressure drops, the leak oil seal with STIHL grease, b 12 groove must be located and the faulty part replaced.

  • Page 27: Oil Seals On Clutch Side

    Installation – Clean the mating surface – Coat the sealing lips of the new oil seals with STIHL grease, b 12 : Slide on oil seal (1) with the : Press out oil seal sealing lip facing the crankcase : Examine and clean flange (1),...

  • Page 28: Shroud

    (arrow) engages in the recess : Screw in twist locks (2) and tighten – Reassemble remaining parts in reverse order : Unscrew twist locks (arrows) – loss-proof screws : Unscrew slotted nut (1) and remove shroud (2) GS 461...

  • Page 29: Cylinder

    – Remove the decompression valve, b 5.9 : Remove the cylinder gasket (1) : Remove washer (1) and sleeve (2) Press out manifold flange in the direction of the cylinder GS 461...
  • Page 30 : Align piston support (1) : Orient cylinder (1) so that the 5910 893 5300 so that the intake elbow (2) faces the tank – Apply STIHL press fluid to the recesses (arrows) engage over casing inside of the intake elbow, b 12...

  • Page 31: Crankshaft

    6.6.3 The tools from the assembly tool kit 5910 007 2206 are used for removal and installation. – Apply STIHL press fluid to the – Remove clutch, b 4.2 outside of the manifold flange, : Unscrew the screws (arrows) b 12 –...

  • Page 32: Crankcase

    – Left-hand thread : Remove the gasket (1) : Align the assembly tool with the washer (2) 5910 893 2101 against the ignition-side half of the housing so that the edge number "28" (arrow) is at the bottom GS 461...
  • Page 33 5910 893 2420 onto the : Turn the spindle (1) clockwise completely screwed in spindle as far as it will go – Draw the ignition-side half of the crankcase in as far as possible Coat the conical crankshaft stub with oil. GS 461...
  • Page 34 If it is not possible to heat the inner race, the crankcase half is drawn in with the assembly tool from kit 5910 007 2206. GS 461...
  • Page 35 The mating reached. : Insert the screws (arrows) and surfaces must be absolutely tighten them crosswise flawless and clean to guarantee a perfect seal. – Install oil seals, b 5.3 – Fit flange with new oil seal, b 5.3.1 GS 461...

  • Page 36: Piston

    – Check that the ball bearing is removed separately. seated properly, if necessary, use press arbor – Examine and clean the 1118 893 7200 carefully press in crankcase half, replace if the ball bearing until it rests necessary against the flange GS 461...
  • Page 37 The tool must be precisely aligned in axial direction of the piston pin. – Use the assembly tool 5910 890 2212 to prepare the snap ring for installation : Take out the needle bearing (1), examine and clean it, replace if necessary GS 461...

  • Page 38: Piston Rings

    : Use a piece of old piston ring to scrape the grooves clean – Fit the decompression valve by (arrows) hand and screw it in – Screw the decompression valve tight – Reassemble remaining parts in reverse order GS 461...

  • Page 39: Ignition System

    – Inspect cable holder, replace if necessary : Drive cable holder (1) out with a suitable punch – Reassemble parts in reverse order : Unscrew the screws (arrows) – Examine spark plug boot and ignition lead, replace if necessary, b 6.4 GS 461...
  • Page 40 – Before twisting in the ignition receptacle must run parallel to lead, fill the high-voltage output the edge of the ignition module with STIHL multi-purpose grease, b 12 Do not use either graphite grease or silicone insulating paste. – Screw the ignition lead into the ignition module –...

  • Page 41: Testing The Ignition

    – If no spark is visible in the spark window, check the ignition – To diagnose the GS 461, select system with the aid of the "Other STIHL products". Then troubleshooting chart, b 6.7 start the "Diagnosis"...

  • Page 42: Spark Plug Boot

    : Unscrew ignition lead (2) from the ignition lead – Before twisting in the ignition the ignition module and pull lead, fill the coil tower with STIHL grommet (1) off ignition lead : Pinch the hook of the torsion multi-purpose grease, b 12...

  • Page 43: Flywheel

    Ensure that the woodruff key replaced engages in the groove (arrow). – Adjust the air gap between ignition module and flywheel, b 6.2 – Reassemble remaining parts in reverse order : Unscrew the flywheel nut (1) GS 461...

  • Page 44: Wiring Harness

    (2) in the direction of the cylinder The resistance measured must be infinitely high, otherwise replace the wiring harness, b 6.6. : Pull grommet (1) off wiring harness – Remove tank housing, b 10.8.3 GS 461...
  • Page 45 : Pull fuel suction hose (1) out of : Pull off blade receptacle (1) and – Use STIHL press fluid to simplify the guide (arrow) and set it aside pull wiring harness out of the assembly, b 12 guides (arrows) : Press the bushing (1) into the –...
  • Page 46 : Press ground wire (2) into the guides (arrows) Route wires parallel so that they do not cross. : Check correct functioning – The eyelet (1) of the short- circuit wire must touch the contact spring (arrow) in position "0" GS 461...

  • Page 47: Contact Spring

    Grommet (1) must be pushed on. : At the recess (arrow), lift tab (1) until the peg no longer engages – Use STIHL press fluid to simplify in the housing wall and pull out : Push contact spring (1) into the...
  • Page 48 : Install switch shaft, b 9.1.1 : Short-circuit wire (1) and ground wire (2) must be between the fin (arrow) and housing wall, push in completely if necessary – Short-circuit wire (1) must be routed below the ground wire (2) GS 461...

  • Page 49: Ignition System

    – Replace spark plug boot and/or torsion spring if necessary, b 6.4 Check ignition: with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap TI 32.94), alternatively check with MDG 1 b 6.3, b 6.3.1 GS 461...
  • Page 50 – Check resistance of spark plug lead to ground, (spark plug boot and ignition module have been removed) Value: Required < 10 Ω, Replace spark plug boot and / or ignition lead or ignition module if necessary, b 6.4 GS 461...
  • Page 51 Replace ignition module. b 6.2 Is engine running? Engine runs smoothly, – Look for fault in fuel or carburetor troubleshooting procedure completed system – Check engine for leaks – Check position of flywheel on crankshaft, b 5.2, b 6.5 GS 461...

  • Page 52: Starter

    Before installing, lubricate the – Remove starter, b 7.2 rewind spring and starter post with STIHL special lubricant, b 12. – Relieve the tension of the rewind : Fit spring (1) so that the rings If clogged with dirt or pitch, the...

  • Page 53: Rope Rotor

    – Tension the rewind spring, b 7.6 – Coat the shafts and pegs of the : Unroll starter rope (2) from rope pawls with STIHL grease, b 12 rotor (1) – hold the rope rotor tight – Reassemble remaining parts in...

  • Page 54: Tensioning The

    (1) and use it to turn the rope rotor six full revolutions in the direction of the arrow : Thread the new starter rope into the starter grip from above, then press nipple (1) into the starter grip until it engages GS 461...
  • Page 55 The rewind spring must sit completely in the mount or mount – Coat the rewind spring with a few for the loop, if necessary, press drops of STIHL special lubricant, completely into the mounts. b 12 Reinstalling a rewind spring that...

  • Page 56: Antivibration Elements

    – smaller diameter points toward : Unscrew screw (2) and remove the crankcase the sleeve (3) and hose – Use STIHL press fluid to simplify : Unscrew screws (4) and remove assembly, b 12 ring buffer : Press ring buffer (1) into the hole –...
  • Page 57 8.1.2 Ring buffer guard / clutch side – Use STIHL press fluid to simplify : Remove rubber ring (1) from stop assembly, b 12 dome of the tank housing and push through the hole (arrow) of the crankcase : Push the ring (1) onto the...

  • Page 58: Ignition Side

    Rubber ring must not become jammed between the ring buffer and tank housing. – Use STIHL press fluid to simplify : Remove screw (1) and prise out assembly, b 12 ring buffer (2) : Press ring buffer into the hole –...

  • Page 59: Stop Buffer On Clutch Side

    (2) peg (1) faces the opening (arrow) of the tank housing Installation – Use STIHL press fluid to simplify assembly, b 12 – Coat screws for fastening the handlebar with Loctite, b 12 : Push stop buffer into the mount –...

  • Page 60: Guard

    – Check guard, replace if necessary Installation – Use STIHL press fluid to simplify the following assemblies, b 12 : Fit handlebar (1) on the bottom of : Position handlebar (1) on the the tank housing into the handle side handle mount (arrow)

  • Page 61: Rubber Buffers / Support

    (1) as far as it will go onto necessary the connector (arrow) Installation – Use STIHL press fluid to simplify the following assemblies, b 12 : Apply a screwdriver to the hose : Fit hose clip (1) and push water...

  • Page 62: Shut-Off Cock

    – Remove water hose, b 8.4.1 : Apply a screwdriver to the hose clip (arrow) and turn slightly to open the clip. : Pull water hose (1) from connector : Slide shut-off cock (1) into the mount on the support (2) GS 461...
  • Page 63 – Reconfigure shut-off cock, rubber buffer and water hose if necessary : Push support (1) as far as it will go towards the guard, then press in the direction of the clutch side until the lugs engage GS 461...

  • Page 64: Actuating Levers

    : Lift contact spring (3) slightly and faces in push switch shaft (1) with the bearing journal (4) into the hole (arrow) of the switch housing : Place eyelet (1) in guide (3) : Pull short circuit wire (1) out of the guides (arrows) GS 461...

  • Page 65: Throttle Trigger

    : Pull trigger interlock (1) out of the bearing points (arrows) : Check correct functioning – The eyelet (1) of the short- circuit wire must touch the contact spring (arrow) in position "0" – Reassemble remaining parts in reverse order GS 461...

  • Page 66: Throttle Rod

    : Press studs (1) into the hole of : Press the trigger interlock (2) into then unhook throttle rod from the baffle the bearing points (arrows) until it throttle trigger clicks into place The trigger interlock may pop out. GS 461...
  • Page 67 – Reassemble remaining parts in : Hook throttle rod (1) clockwise reverse order into the lever (arrow) of the throttle shaft GS 461...

  • Page 68: Fuel System

    : Guide filter base (2) over the stud bolts (3), push hose (4) completely onto the connector (arrow) and fit filter base (2) : Unscrew nuts (1) and pull off flange (2) Switch shaft (3) must be set to cold start. GS 461...
  • Page 69 : Push fuel hose (1) and impulse : Press carburetor (1) over the – Use STIHL press fluid to simplify hose (2) back slightly studs (arrows) – sleeve (2) must assembly, b 12 – Fuel hose and impulse hose be in place...

  • Page 70: Leakage Test

    – Check sleeve, remove and 0000 850 1300 onto the double replace if necessary connector : Push ring (1) to the right and pump air into the carburetor until the pressure gauge (2) shows a pressure of approx. 0.8 bar (80 kPa) GS 461...

  • Page 71: Inlet Needle

    : Align the end cover (1) until the holes engage in the pins (2) : Unscrew the screw (1) : The sealing cone of the inlet needle must be replaced if a circular indentation (arrow) is visible on its tip. GS 461...

  • Page 72: Pump Diaphragm

    – Check that the inlet control lever : Pull the fuel strainer (1) out of the moves easily carburetor body with a needle and clean or replace it – Install the metering diaphragm, b 10.4.1 – Reassemble parts in reverse order GS 461...

  • Page 73: Adjusting Screws

    Gasket and pump diaphragm are the carburetor housing carburetor, b 3.6 now secured. – Check that the pump diaphragm and gasket are correctly seated : Screw in the screw (2) and tighten – Reassemble remaining parts in reverse order GS 461...
  • Page 74 – Unscrew low speed screw L necessary Do not turn puller (1) any further – High speed adjusting screw Hcan be damaged. : Turn the high speed adjusting screw H in as far as possible – Continue with "Fitting the limiter cap" GS 461...

  • Page 75: Carburetor Adjustment

    10.1 screw H and low speed adjusting screw L Set speed with speed tester or engine analyzer STIHL MDG 1 (select from software "Other STIHL products" / "Tachometer"). Set the specified speeds within the : Press new limiter caps (1) onto tolerance range of ±...

  • Page 76: Standard Setting

    : Insert a suitable punch through – The cut-off chain must not run dry, 3/4 turn the holes (arrow) of the bushing repeat the STIHL multispray and press the limiter caps fully process if necessary home – Carefully turn the low speed adjusting screwL clockwise as far 1.

  • Page 77: Intake Elbow

    "Standard setting". : Pull tank housing (2) out slightly – when pulling out the tank housing, make sure that the wiring harness is not exposed to tensile loads GS 461...

  • Page 78: Impulse Hose

    : Fit washer (3) and push – Coat new impulse hose on the sleeve (4) into the opening of the conical outside with STIHL press – Apply STIHL press fluid to the manifold flange (1) fluid, b 12 outside of the manifold flange, b 12 –...

  • Page 79: Tank Vent

    – Wet O-ring of new tank vent with replaced. STIHL press fluid, b 12 – Reassemble parts in reverse – Press new tank vent in by hand order until you hear it click into place...

  • Page 80: Fuel Intake

    – Open the filler cap pickup body first if problems develop in the fuel supply. – Remove the carburetor, b 10.3 – Use STIHL press fluid to simplify – Troubleshooting, b 3.6 or – Remove pickup body, b 10.8.1 assembly, b 12 b 3.7...

  • Page 81: Tank Housing

    – Reconfigure the front handle, – Pull tank housing out by approx. clutch side", b 8.1.2 b 6.6 30 mm – Reconfigure the interlock lever : Disconnect the impulse hose (1) and throttle trigger, b 9.2 from the connector (arrow) GS 461...
  • Page 82 (arrow) faces upward Grommet (1) must be pushed on. : Push rubber ring (1) with inside – Use STIHL press fluid to simplify diameter 12 mm and rubber assembly, b 12 ring (2) with inside...
  • Page 83 "Ring buffer guard / ignition side", b 8.1.3, "Ring buffer guard / clutch side", b 8.1.2 – Reassemble remaining parts in reverse order : Press tank housing (1) in the direction of the cylinder until the holes line up with the ring buffers GS 461...

  • Page 84: Special Tools

    Hooking in clutch spring Press sleeve 1118 893 2401 Pressing in oil seal (Clutch side) Assembly sleeve 1118 893 4602 Protection of the oil seal (Clutch side) Press arbor 1118 893 7200 Pressing in ball bearing (clutch side) GS 461...
  • Page 85 Pulling together the crankcase -Screw sleeve 5910 893 2420 Installing crankshaft Engine analyzer 5910 840 0200 Running motor diagnosis STIHL MDG 1 Test flange 5910 850 4200 Leakage test - Sleeves 5910 893 1701 Spacer sleeves for test flange ZAT 4 ignition tester...

  • Page 86: Service Accessories

    Oil seals, sliding and bearing points STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in fan housing STIHL press fluid OH 723 0781 957 9000 Rubber elements, antivibration elements STIHL multi-purpose grease 0781 120 1109...
  • Page 87 englisch / english 0455 761 0123. VA0.E12. Printed in Germany...

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