1997–2012 STIHL TS 460 Super Cut Saw Service Manual (P/N 42210213000)

• 360-page PDF set: the TS 460 Service Manual occupies 82 PDF pages (cover, 80 numbered pages, and one blank); the TS 460 (4221) parts list 54 pages; the TS 510/760 (4205) parts list 72 pages and appears twice; the TS 700 catalog 42 pages; and the TS 800 catalog 38 pages.
• TS 460 cutting-wheel drive and clutch repair covers the bearing with guard, radial and axial runout testing, V-belt and pulley service, clamp work, and clutch disassembly, assembly, and installation.
• Engine repair procedures address the muffler, cylinder and piston, piston rings, crankshaft and crankcase, pressure and vacuum leakage testing, oil-seal replacement, and engine removal and installation.
• Fuel and ignition diagnosis includes the three-part air-filter system, compensating diaphragm carburetor, carburetor leak testing and service, fixed electronic ignition, module installation, flywheel work, and stop-circuit wiring.
• Starter, anti-vibration, and throttle sections cover the rope rotor, starter rope and rewind spring, AV buffers, throttle trigger and interlock, slide control, contact springs, throttle cable, and handle assemblies.
• Factory reference material includes system-specific troubleshooting charts, a component torque table, cutting-wheel specifications, special-tool part numbers, servicing aids, and illustrated parts breakdowns for the covered models and accessories.

This file is best understood as a factory service-and-parts set, not as a 360-page repair manual for one model. Detailed workshop procedures apply to the STIHL TS 460; the TS 510/760, TS 700, and TS 800 sections are parts catalogs only. STIHL states that the service material was intended for its servicing dealers and staff, making this set best suited to technicians who already have small two-stroke engine repair experience and access to the specified pullers, gauges, and test fixtures.

TS 460 Workshop Coverage

The TS 460 Service Manual is the 1997-12 issue. Its troubleshooting charts isolate faults in the clutch and bearing-with-guard assembly, engine, ignition system, rewind starter, and fuel system before the repair chapters move into component work. The cutting-wheel drive section covers bearing and guard service, spindle runout checks, V-belt replacement, pulley and clutch-drum work, and clamp service. Engine coverage extends through top-end repair, crankshaft removal and installation, crankcase sealing, pressure and vacuum leak tests, oil seals, and removal of the engine from the housing.

The manual does more than name the required equipment. It identifies tools by application and part number, including the crankshaft locking strip 4221 893 5900, carburetor/crankcase tester 1106 850 2905, ignition-module setting gauge 1111 890 6400, flywheel puller 1116 893 0800, and cutting-wheel test wheel 5910 851 6100. Related torque specifications, leakage-test data, runout limits, ignition settings, carburetor adjustment data, and servicing lubricants are organized with the procedures they support.

Fuel, Ignition, and Controls

Fuel-system chapters cover the prefilter, main filter, and auxiliary filter; carburetor-compensator operation; removal and leakage testing; diaphragm, inlet-needle, valve-jet, throttle-shaft, and choke-shaft service; final adjustment; pickup-body inspection; and tank-vent repair. Ignition coverage addresses the breakerless module, fixed non-adjustable timing, module air-gap setup, spark-plug diagnosis, ignition lead and terminal, short-circuit and ground wires, and flywheel removal and inspection.

The manual specifically warns that the cylinder must be aligned before it is fitted over the piston; incorrect alignment can break the piston rings. It also explains that an excessively lean carburetor setting will not produce additional speed or power and can damage the engine.

Named visual references include the Carburetor with Compensator functional schematic and exploded parts views for Engine Housing/Cylinder, Ignition System, Carburetor HS-276D, Support with Guard, and Belt Tensioner/Clutch.

Parts Catalog Coverage and Limits

The 07/2004 TS 460 parts list carries model code 4221 and distinguishes HS-276D and HS-275B carburetor configurations. It also marks a tank-vent production breakpoint at machine number 1 44 493 244 (47/1999) and covers water attachments, Cutquik cart hardware, guide-wheel kits, water tanks, guard assemblies, tools, and cutting wheels.

The additional parts material covers TS 510 and TS 760 (4205), plus TS 700/TS 700-Z and TS 800/TS 800-Z applicability in the later SCS 02-2009 3.27 catalogs. The 72-page TS 510/760 catalog is duplicated in the PDF, so the 360-page count does not represent 360 unique pages. These additional catalogs provide exploded views and part-number identification, but they do not add diagnostic or repair procedures for those models. The TS 460 manual also directs dealers to later Technical Information Bulletins for post-publication engineering changes; those bulletins are not included.

Ignition service involves potentially lethal high voltage, while the starter, clutch, fuel system, and cutting assembly introduce stored-energy, fire, and rotating-component hazards. Use the specified shop procedures, isolation practices, and personal protective equipment throughout diagnosis and repair.