1997-2012 STIHL TS 460 Super Cut Saw Service Manual
Repair guide for all TS 460 configurations. Explains assembly, disassembly, and troubleshooting. PN 42210213000.
Stihl Models Covered & Key Technical Specifications
Models: STIHL TS 460
Sub-models / Variants: 4221, USA, AUS
Model Years: 1997–2012
Technical Data:
- Engine displacement: 72.4 cc
- Engine type: Single-cylinder two-stroke
- Power output: 3.0 kW (4.75 bhp)
- Bore: 48.0 mm
- Stroke: 40.0 mm
- Max permissible speed: 9,600 r.p.m.
- Idle speed: 2,500 r.p.m.
- Fuel tank capacity: 0.95 l
- Spark plug gap: 0.5 mm
- Spark plug thread: M14x1.25
- Ignition timing: 2.8–3.2 mm B.T.D.C. at 8,000 r.p.m.
Stihl Manual Features & Content Preview
STIHL TS 460 Technical Service Documentation (1997–2012)
- Official 360-page OEM publication covering the 4221-series build
- Comprehensive reference for shop maintenance and diagnostic repair work
- Features 47 exploded-view diagrams and a dedicated torque table with 28 fastener specifications
- Delivered as an instant download directly to your device the moment payment clears
- Fully indexed, searchable PDF covering every chapter and appendix
Component and Assembly Overview
This technical documentation provides essential data on the engine, fuel system, and cutting wheel drive assembly. It serves as a detailed reference for the components of the two-stroke engine. Sections outline the mechanical makeup of the cylinder, piston, crankshaft, and oil seals. You will also find comprehensive maintenance data for the diaphragm-type carburetor, detailing the precise adjustment values for both high and low-speed screws.
Workshop professionals require accurate specifications to ensure reliable operation. The torque table lists critical values, including 10 Nm for cylinder and crankcase spline screws. Fuel mixture ratios are clearly documented at 1:50 with STIHL two-stroke oil, or 1:25 for other brands.
When conducting crankcase leakage testing, the manual establishes a 0.5 bar pressure standard for system validation. The ignition system utilizes an electronic breakerless magneto, with timing fixed at 2.8–3.2 mm B.T.D.C. at 8,000 r.p.m. Intake air management is also covered in depth, highlighting the combination felt prefilter and paper cartridge system.
Servicing heavy-duty cut-off saws carries inherent risks. Always follow standard shop safety protocols, wear appropriate personal protective equipment, and verify the equipment is fully depressurized and disconnected before beginning any repair assessment.
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