1995–2004 Stihl 046 Chainsaw Service & Parts Manual Set

This manual set for the 1995–2004 Stihl 046 chainsaw combines the STIHL service manual, copyright 1995, with the July 2004 Spare Parts List for the 1128 series.

• Engine repair: Cylinder and piston replacement, piston rings, crankcase separation, crankshaft bearing replacement, and pressure and vacuum leakage tests.

• Chain drive and brake: Clutch drum and sprocket inspection, clutch removal, chain brake disassembly and function checks, and chain tensioner service.

• Fuel system: Air filter service, carburetor removal, leakage testing and adjustment, plus fuel hose, pickup body, tank vent and tank housing procedures.

• Ignition and heating: Ignition module, wiring harness and generator service, with troubleshooting charts and electrical test data for handle and carburetor heating.

• Starter and handles: Rewind spring replacement and tensioning, AV annular buffer replacement, and Master Control switch shaft, throttle trigger and interlock service.

• Chain lubrication: Pickup body, suction hose and tank vent valve service, plus disassembly and inspection of the automatic reciprocating oil pump.

• Parts identification: Exploded assembly views, replacement part numbers and variant listings, including HD-series carburetors and a rescue saw conversion kit for non-US markets.

The service manual was written for STIHL servicing dealers; its internal engine work and electrical tests call for workshop equipment and repair experience.

Engine, Crankcase and Exhaust Repair

The engine chapters cover crankshaft removal and installation with AS and ZS service tools. The crankshaft, connecting rod and needle bearing form a single replacement assembly.

Pressure and vacuum tests help trace air leaks that interfere with idle adjustment and acceleration. Oil seal replacement is also documented without complete crankcase disassembly, with separate press sleeves specified for the starter and clutch sides.

Muffler coverage distinguishes the Magnum spark arresting screen arrangement and explains catalytic converter inspection. Decompression valve removal and replacement are included.

Chain Brake, Starter and AV Handles

The chain brake section warns that incorrect anchor-pin removal can damage the crankcase bore and compromise brake spring seating. Chain tensioner illustrations identify the adjusting screw, spur gear and tensioner slide.

Clutch internal disassembly and starter rope-rotor procedures refer to the separate Standard Repairs, Troubleshooting handbook, which is not included. This set provides the model-specific clutch removal and rewind spring procedures.

The AV section treats damaged annular buffers as replacement sets. The service-tool inventory lists applications and part numbers, including AS tool 5910 007 2205 and ZS tool 5910 007 2220.

Fuel Supply and HD Carburetor Variants

Fuel-system instructions cover tank venting, impulse hose connections and tank housing removal. Carburetor coverage consists of removal, installation, leakage testing and adjustment; a complete internal carburetor overhaul procedure is not included.

The parts list distinguishes HD-14A for Europe, HD-16 for the USA and HD-24A for the Magnum BR. Separate exploded views cover the earlier HD-8A and HD-9A carburetors.

Ignition and Cold-Weather Heating

Ignition timing is fixed. The ignition chapter explains spark testing, wiring and stop-switch checks, and module replacement; detailed module testing requires specialized equipment.

For heated models, the handle-heating Troubleshooting Chart and Test Connections and Test Values table support fault isolation. Carburetor heating has its own diagnostic chart, heating element tests and thermostatic switch procedures.

The rear-handle section warns that creases or poor bonding can interrupt heat transfer and cause the heating element to overheat and fail.

Working on high-performance two-stroke equipment carries inherent risks. Follow the ignition-system precautions and consult a trained technician before unfamiliar teardown work.

Parts Drawings and Version Differences

The Oil Pump, Clutch and Wiring Harness illustrations pair numbered components with parts tables. Version keys and serial-number breaks help match older components to the appropriate configuration before parts are selected.

The 046/MS460 rescue saw conversion kit is listed for non-US markets. MS460 coverage is limited to that kit's parts listing.

Examples of Assembly Torque and Carburetor Settings

These are a few of the assembly and adjustment specifications in the service manual.

Cylinder-base screws are specified at 15.0 Nm (11.0 lbf.ft), with a diagonal tightening pattern. Spark-plug torque is 25 Nm (18.5 lbf.ft).

The carburetor's standard setting is one full turn open for both the high-speed (H) and low-speed (L) screws. The adjustment section also explains tachometer use and altitude corrections.

Searchable PDF and Publication Breakdown

Text search and section access: The PDF has searchable text. Bookmarks cover the service chapters and the start of the parts list. Small labels in the illustrated parts views remain readable when enlarged.

One printable, 114-page PDF contains both publications. The service manual is in English; the parts list presents German, English and French descriptions.

The service contents page, the parts list's combined cover/contents page, and its closing symbol key are already included in these page counts.