STIH)

STIHL GS 461 2012-06

 Contents

1. Introduction and 6. Ignition system 38 8.4 Rubber buffers /

safety precautions 2 support 60
6.1 Ignition timing 38 8.4.1 Water hose 60
1.1 Introduction 2 6.2 Ignition module 38 8.4.2 Shut-off cock 61
1.2 Safety precautions 3 6.3 Testing the ignition 8.4.3 Support 61
module 40
6.3.1 Testing the ignition
2. Specifications 4 module with engine 9. Actuating levers 63
analyzer MDG 1 40
2.1 Engine 4 6.4 Spark plug boot / 9.1 Master Control lever 63
2.2 Fuel system 4 ignition lead 41 9.1.1 Removal and
2.3 Ignition system 4 6.5 Flywheel 42 installation 63
2.4 Tightening torques 5 6.6 Wiring harness 43 9.2 Throttle trigger /
6.6.1 Testing 43 trigger interlock 64
6.6.2 Ground wire 43 9.3 Throttle rod 65
3. Troubleshooting 7 6.6.3 Wiring harness
Removal and
3.1 Clutch 7 installation 43 10. Fuel system 67
3.2 Chain Drive, Chain 6.6.4 Contact spring 46
Tensioner 8 6.7 Troubleshooting, 10.1 Air filter 67
3.3 Water system 9 ignition system 48 10.2 Filter base 67
3.4 Starter 10 10.3 Carburetor 67
3.5 Ignition system 11 10.3.1 Leakage test 69
3.6 Carburetor 12 7. Starter 51 10.4 Repairing
3.7 Engine 15 the carburetor 69
7.1 General 51 10.4.1 Metering diaphragm 69
7.2 Starter 10.4.2 Inlet needle 70
4. Clutch 16 Removal and 10.4.3 Pump diaphragm 71
installation 51 10.4.4 Adjusting screws 72
4.1 Clutch drum 16 7.3 Pawls 51 10.5 Carburetor adjustment 74
4.2 Clutch 16 7.4 Rope rotor 52 10.5.1 Basic setting 74
4.3 Pin / hand guard 18 7.5 Starter rope / starter 10.5.2 Adjustment 74
4.4 Chain tensioner 19 grip 52 10.5.3 Standard setting 75
4.5 Cut-off chain 20 7.6 Tensioning the 10.6 Intake elbow 76
4.6 Bar mounting studs 21 rewind spring 53 10.6.1 Impulse hose 77
4.7 Collar nuts for chain 7.7 Replacing the 10.7 Tank vent 78
sprocket cover 21 rewind spring 53 10.7.1 Testing 78
10.7.2 Removal and
installation 78
5. Engine 22 8. Antivibration 10.8 Fuel intake 79
elements 55 10.8.1 Pickup body 79
5.1 Muffler 22 10.8.2 Fuel hose 79
5.2 Leak testing 23 8.1 Ring buffer fuel tank / 10.8.3 Tank housing 80
5.2.1 Preparations 23 clutch side 55
5.2.2 Testing with 8.1.1 Ring buffer fuel tank /
negative pressure 24 ignition side 55 11. Special tools 83
5.2.3 Pressure test 25 8.1.2 Ring buffer guard /
5.3 Oil seal on clutch side 56
ignition side 25 8.1.3 Ring buffer guard / 12. Service accessories 85
5.3.1 Oil seals on ignition side 57
RA_761_00_01_01

clutch side 26 8.1.4 Stop buffer on clutch

5.4 Shroud 27 side 58
5.5 Cylinder 28 8.1.5 Stop buffer on ignition
5.6 Crankshaft 30 side 58
5.6.1 Ball bearing / 8.2 Handlebar 58
crankcase 34 8.3 Guard 59
5.7 Piston 35
5.8 Piston rings 37
5.9 Decompression valve 37 q
© ANDREAS STIHL AG & Co. KG, 2012

GS 461 1
1. Introduction and safety precautions
1.1 Introduction
This Service Manual contains
detailed descriptions of all the
typical repair and servicing
procedures for this power tool.
Refer to the illustrated spare parts
lists during all repair work. These
lists show the installation position
and order in which the individual
parts and modules should be
assembled.
Refer to the latest edition of the
relevant spare parts list to check the
part numbers of any spare parts
required.
A fault on the machine may be due
to several causes. To help locate
the fault, consult the chapter on
"Troubleshooting" and the
"STIHL Service Training System"
for all functional groups.
Refer to the "Technical Information"
bulletins for engineering changes
which have been introduced since
publication of this Service Manual.
The "Technical information
bulletins" also supplement the spare
parts list and Service Manual until
an updated edition is issued.
The special tools mentioned in the
descriptions are listed in the chapter
"Special Servicing Tools" of this
manual. The tools can be identified
according to part number in the
"Special Tools Manual". The manual
lists all tools supplied by STIHL.
Symbols are included in the text and
pictures for greater clarity.
The meanings are as follows:
2 GS 461
In the text:
1
: = Action to be taken 3
as shown in the illustration
above the text
2
– = Action to be taken
but not shown in the illustration
219RA000 TG
above the text
In the illustrations:
– Remove support 5910 850 1650
A Item pointer (short)
: Secure the support (1)
aDirection of movement (long
5910 851 1601 B to the
arrow)
assembly stand with two
screws (2) and washers.
b 4.2 = Reference to another
chapter, in this case to
Chapter 4.2 The screws must not protrude, as
they may damage the housings
Service Manuals and "Technical when clamping the machine,
information bulletins" are intended depending on the model.
exclusively for the use of properly
equipped repair shops. They must
not be passed on to third parties. Preparing to make repairs
In order to be able to clamp the
machine for the repair work on the
1 assembly stand, the chain sprocket
cover, cut-off chain and guide bar
must be removed.
x
xx
xx
x
xx
xx
xx
2411RA001 TG
In order to be able to fit the machine
on the assembly stand, the support
2411RA000 TG
5910 850 1651 mounting kit must
be used. The new support (1) can
be identified with the aid of the
marking "5910 851 1601 B" printed
on the housing. The machine is guided with the
collar screws through the lower
holes of the clamping rail and
fastened using nuts M 8 (arrows).
Always use original STIHL 1.2 Safety precautions
replacement parts.
They can be identified by the STIHL
Specific national safety regulations
part number,
and the safety instructions in the
the logo STIH)
instruction manual must be
and the
observed if the machine has to be
STIHL parts symbol (
started up during maintenance or
The symbol may appear alone on
repair work.
small parts.
Fuel is highly inflammable and can
also be explosive under certain
Storage or disposal of fuel
conditions.
Collect fuel in a clean container and
Do not bring any fire, flame, spark or
dispose of it in accordance with
other source of heat near the fuel.
environmental regulations.
All work with fuel must be performed
outdoors only. Spilled fuel must be
wiped away immediately.
Routing the leads
Test for leakage after all work on the
In principle, press all electrical leads
fuel system and engine.
into the guides using the wiring tool
5910 890 4000.
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.
Suitable gloves must be worn
without fail if parts are heated for
assembly/disassembly purposes.
The chapter "Tightening Torques"
lists all components of this machine
that must be tightened with the
specified tightening torques or
coated with thread-locking
adhesive. These specifications
must be observed throughout the
Service Manual when tightening
screws and nuts as well as other
fasteners.
Fuel system – barbed connectors
Pull or push the fuel hoses, by hand
whenever possible, in the direction
of the connector in order to ensure
leakproofness of the fuel system.
Avoid damaging the barbed
connectors
– sharp-edged pliers, screwdrivers,
etc., may not be used.
Also, do not cut open fuel hoses
with a knife or similar aids.
Do not reuse fuel hoses after
disassembly, but instead always
replace them with new hoses
– fuel hoses can be overstretched
when being detached.

Improper handling may result in
burns and other serious injuries.
Always replace damaged parts.
Check dismantled parts for wear
and damage before installation,
replace if necessary.
Mount new fuel hoses dry or using
STIHL press fluid
– apply press fluid to the ends of the
hose and the connectors, b 12.
Other press fluids are not permitted
and may lead to fuel hose damage.

Only use the machine with the

starter and shroud mounted –
otherwise the rotating flywheel
poses a risk of injury and there is a
risk of engine damage due to
overheating.

GS 461 3
2. Specifications

2.1 Engine

GS 461

Displacement: 76.5 cm3

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
Crankcase leakage test
at gauge pressure: 0.5 bar
under vacuum: 0.5 bar

2.2 Fuel system

Carburetor leakage test at
gauge pressure: 0.8 bar
Operation of tank vent at
gauge pressure: 0.5 bar
Fuel: as specified in instruction
manual

2.3 Ignition system

Air gap between ignition
module and fanwheel: 0.20 (+ 0.1/- 0.25) mm
Spark plug (suppressed): BOSCH WSR 6 F
NGK BPMR 7 A
Electrode gap: 0.5 mm

4 GS 461
2.4 Tightening torques

P and DG screws are fitted in plastic and light alloy metal parts. These screws form a permanent thread when
they are installed for the first time. The material is permanently deformed. Screws can be removed and installed
as often as necessary without impairing the strength of the screwed assembly, provided that the specified
tightening torque is observed.
For this reason it is essential to use a torque wrench.

When inserting DG and P screws into an existing screw thread:

Insert the DG or P screw in the hole and turn counterclockwise until it gently drops into the hole in axial direction
and engages the existing threads. Tighten the screw clockwise to the specified torque.

This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.

For the microencapsulated screw, before renewed assembly, clean both threads (insert tap in the internal thread
by hand and then blow out the threaded hole, brush off the exterior thread), coat the cleaned screw with
medium-strength Loctite 242 or 243.

Screwdriver speed with: P and DG screws max. 500 rpm.

Do not use an impact wrench to release or tighten screw connections.

Screws with and without locking serration must not be confused.

Fastener Thread size For component Tightening Comment

torques
Nm

Screw M 4x12 Cover for chain tensioner / crankcase 3.0

Stud M8 Stud / crankcase for bar 23.0 2)
M 10x1 Decompression valve 14.0
Screw D 4x12 Spring housing / fan housing 3.0
Collar nut M5 Filter cover / slotted nut 1.0
Collar nut M5 Flange / filter base / carburetor 3.5
Screw M 4x10 Flange / crankcase 2.5 5)
Screw M 4x12 Crank drive flange / crankcase 3.5 4), 6)
Screw P 6x21.5 Handlebar at top / tank housing 8.0 3)
Screw P 6x32.5 Handlebar at bottom / tank housing 8.0 3)
Screw P 4x19 Handle molding 1.6
Screw D 4x16 Hand guard clutch side 4.0 4), 6)
Screw M 5x35x22 Hand guard ignition side 7.0 4), 6)
Screw M 5x23 Shroud / crankcase 6.0
Nut M5 Shroud / cylinder 3.5
Screw M 5x25 Crankcase drive side / fan side 10.0 4), 6)
Screw M 5x20 Fan housing 7.0 4)
Carrier M 12x1 L Carrier 50.0
Screw M 4x16 Ring buffer / crankcase 4.5 5)
Screw P 6x19 Ring buffer / tank housing rear 5.5

GS 461 5
Fastener Thread size For component Tightening Comment
torque
Nm

Screw P 6x32.5 Ring buffer / tank housing rear ignition side top 5.5
Screw P 6x19 Ring buffer / tank housing front 5.5
Screw M 6x30 Muffler / crankcase 15 4), 6), 8)
Screw M 5x16 Muffler / cylinder 11.5 1), 4), 6)
Screw M 5x6 Muffler top 6.5 1), 4), 5)
Nut M 8x1 Flywheel / crankshaft 33.0 7)
Screw M 4x8 Side plate / crankcase 3.0 4), 6)
Screw M 3x20 Clamp / manifold 0.5
Screw P 4x14 Water attachment / handle housing 2.0
M 14x1.25 Spark plug 25.0
Screw M 5x20 Ignition module / crankcase 7.0 5)
Screw M 6x30 Cylinder / crankcase 15.0 4), 6)

Remarks:

1) Loctite 242 or 243 medium strength

2) Loctite 270 high strength
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

6 GS 461
3. Troubleshooting

3.1 Clutch

Problem Cause Remedy

Cut-off chain becomes stuck under Clutch shoes badly worn Replace clutch
full load

Clutch drum badly worn Replace clutch drum

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

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 7
3.2 Chain Drive, Chain Tensioner

Problem Cause Remedy

Chain sprocket wears rapidly Cut-off chain not properly tensioned Tension cut-off chain properly

Insufficient cooling of cut-off chain Check water cooling

Insufficient water volume Check water pressure

Cut-off chain becomes stuck under Clutch shoes badly worn Replace clutch
full load

Clutch drum badly worn Replace clutch drum

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

8 GS 461
3.3 Water system

Problem Cause Remedy

No water supply Shut-off cock, connectors of hose Clean shut-off cock and connectors
connections or opening of water of hose connections, replace if
outlet very dirty / clogged necessary

Too little water Water hose kinked or damaged – Check hose clips, water hose and
also check water supply hose seals, replace if necessary

Connectors of hose connection Check and clean connectors,

very dirty replace if necessary

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 9
3.4 Starter
Problem Cause
Starter rope broken Rope pulled out too vigorously as
far as stop or over edge, i.e. not
vertically
Normal wear
Starter rope does not rewind Heavy fouling or rust on rewind
spring
Spring insufficiently tensioned
Rewind spring broken
Starter rope cannot be pulled out Rewind spring overtensioned
far enough
Starter rope can be pulled out Guide peg on pawls or pawls
almost without themselves are worn
resistance (crankshaft does not
turn)
Spring clip fatigued
Spring clip improperly installed
Starter rope is difficult to pull or Starter mechanism is very dirty
rewinds very slowly
At very low outside temperatures:
Lubricant oil on the rewind spring
becomes viscous (spring winding
stick together) or moisture has
penetrated the rewind spring
(spring windings are frozen)
10
Remedy
Replace starter rope
Replace starter rope
Clean or replace rewind spring
Check rewind spring and increase
tension
Replace rewind spring
Check rewind spring and reduce
tension
Replace pawls
Replace spring clip
Install spring clip properly
Thoroughly clean complete starter
mechanism
Coat rewind spring with a little
standard solvent-based degreasant
(containing no chlorinated or
halogenated hydrocarbons), then
pull rope carefully several times
until normal action is restored
GS 461
3.5 Ignition system

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.

Problem Cause Remedy

Engine runs roughly, misfires, Spark plug boot is loose Press spark plug boot firmly onto
temporary loss of power spark plug and fit new torsion
spring and spark plug boot if
necessary

Spark plug sooted, smeared with oil Clean spark plug, replace if
necessary
In the event of repeated sooting,
check air filter

Ignition lead loose in ignition Replace ignition lead

module

Fuel / oil mixture Use a fuel mixture with the correct

– contains too much oil mixing ratio

Incorrect air gap between ignition Set the correct air gap
module and flywheel

Flywheel is cracked Install new flywheel

or has other damage or pole shoes
have turned blue

Incorrect ignition timing, flywheel Replace flywheel or woodruff key

out of adjustment
– woodruff key has sheared off or
groove in flywheel is worn

Weak magnetization in flywheel Install new flywheel

Irregular spark Check operation of switch shaft /

contact spring and ignition module
Damaged insulation on ignition lead
or interruption in ignition lead or
short circuit wire, check ignition
lead / 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 11
3.6 Carburetor

Problem Cause Remedy

Carburetor floods; engine stalls Inlet needle not sealing Remove and clean inlet needle or
– Foreign matter in valve seat or clean carburetor
cone

Inlet needle worn Replace inlet needle

Inlet control lever sticking on Check inlet control lever, replace if

spindle necessary

Helical spring not located on nipple Remove the inlet control lever and
of inlet control lever refit it correctly

Perforated disc on diaphragm is Fit new metering diaphragm

deformed and presses constantly
against the inlet control lever

Metering diaphragm is deformed Fit new metering diaphragm

Poor acceleration Low speed adjusting screw "too Check basic carburetor setting,
lean" correct if necessary

High speed adjusting screw "too Check basic carburetor setting,

lean" correct if necessary

Inlet needle sticking to valve seat 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

12 GS 461
Problem Cause Remedy

Engine will not idle, idle speed too Throttle shutter opened too wide by Set idle speed screw LA correctly
high idle speed screw LA

Oil seals / crankcase leaking Seal or replace oil seals /

crankcase

Throttle shutter does not close Replace carburetor

Engine stops when idling Idle jet bores Clean the carburetor
or ports blocked

Low speed adjusting screw "too Correct setting of low speed

rich" or adjusting screw L
"too lean"

Idle speed screw LA Set idle speed screw LA correctly

setting incorrect – throttle shutter
completely closed

Tank vent faulty Replace tank vent

Leak in fuel line between pickup Seal connections or replace fuel

body and carburetor line

Cut-off chain rotates at idle speed 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 13
Problem Cause Remedy

Engine speed drops quickly under Air filter dirty or wet Clean or dry air filter, replace if
load – low power necessary

Throttle shutter not opened fully Check throttle cable and rod

Tank vent faulty Replace tank vent

Fuel pickup body dirty Replace pickup body

Fuel strainer dirty Clean fuel strainer in carburetor,

replace if necessary

Leak in fuel line between pickup Seal connections or replace fuel

body and carburetor line

High speed adjusting screw H "too Check basic carburetor setting,

rich" correct if necessary

Main jet bores or ports blocked Clean the carburetor

Pump diaphragm damaged or Fit new pump diaphragm

fatigued

Incorrect ignition timing, flywheel Replace flywheel or woodruff key

out of adjustment
– 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

14 GS 461
3.7 Engine

Always check and, if necessary,

repair the following parts before
looking for faults on the engine:

- Air filter
- Fuel supply
- Carburetor
- Ignition system

Problem Cause Remedy

Engine does not start easily, stalls Oil seals in crankcase damaged Replace oil seals
at idle speed but operates normally
at full throttle

Crankcase leaking or Seal / replace crankcase

damaged (cracks)

Engine does not deliver full power Piston rings worn or broken Replace piston rings
or runs erratically

Muffler / spark arresting screen Clean muffler (inlet and outlet

carbonized openings), replace spark arresting
screen, replace muffler if necessary

Air filter dirty or wet Clean or dry air filter, replace if

necessary

Fuel line kinked or cracked Fit new lines and ensure they are
installed without kinking

Decompression valve not closed Close decompression valve, check

and replace if necessary

Engine is overheated 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 15
4. Clutch

4.1 Clutch drum – Coat the needle cage and

crankshaft stub with STIHL
grease, b 12

3443RA004 TG
1 2411RA002 TG

: Insert locking strip (1)

100% 0000 893 5903 into the cylinder

5902RA018 TG
: Remove cap (1) with the wide side in front and
80% ! align so that the words "OBEN-
TOP" are visible
– Examine the clutch drum (1) for
1 signs of wear
3
The remaining thickness must be 1
measured if there are distinct signs
of wear on the inside diameter of the
clutch drum (1). The clutch drum
must be replaced if the remaining
2411RA162 TG

thickness is less than approx. 80 %

of the original thickness.

3443RA493 TG
2

: Push out circlip (1) and remove Installation

washer (2) – always use new
circlip
: Remove the clutch drum (3)
1 until the groove completely
: Locking strip (1) 0000 893 5903
– Install the clutch drum
must rest against the cylinder
wall (arrow)
– Coat cap with STIHL press fluid, – Position as shown
b 12
– Remove rim sprocket and clutch
– Fit rim sprocket and press on cap drum
enclose the clutch drum

4.2 Clutch
3443RA047 TG

– Troubleshooting, b 3

– Remove filter cover

: Remove needle cage (1)
– Remove air baffle
– Clean needle cage and
crankshaft stub, b 12 – Take off the spark plug boot and
remove the spark plug

16 GS 461
 2

of
f
TOP TOP

off
1 1
1

5902RA012 TG
2411RA003 TG

: Unscrew the clutch (1) at Attach the springs to the side with
hexagon (arrow) the raised hexagon (arrow).
The clutch has a left-hand thread. – clamp assembled clutch on a
horizontal clutch shoe in the vise
Disassembly : Attach one end of the clutch
spring (1) to the clutch shoes
1 2
: Use the assembly hook (2)
5910 890 2800 to pull the other
of
2411RA005 TG
: Fit the clutch (1) on the
crankshaft stub so that the raised
hexagon (arrow) can be seen
: Screw on and tighten the
clutch (1) – left-handed thread
– Pull the locking strip out of the
cylinder
– Fit rim sprocket and clutch drum

end of the spring and hook it into

f
off

the clutch shoe

– Fit the spark plug and tighten it
down firmly
– Examine the clutch – all springs
must be hooked in properly
5902RA006 TG

– Refit the spark plug boot

off

– Insert air baffle

: Use hook (2) 5910 890 2800 to
remove the clutch springs (1) – Attach filter cover
TOP

If there are distinct signs of wear of

the clutch kit (set of 3), replace 1
clutch shoes.
2411RA004 TG

Assembly

3 1 The washer (1) must be in place

and the word "TOP" (arrow) must be
visible.
2
off

3443RA464 TG

: Fit holder (1) and slide clutch

shoes (2) over the legs (3)

GS 461 17
4.3 Pin / hand guard
1 1
The pin ensures that the hand guard
is securely mounted. If it is worn,
replace the pin.

– Remove starter, b 7.2

2411RA008 TG

2411RA010 TG
: Disassemble bolt (1) : Drive in pin (1) in accordance
with the following information

1 Installation

a
2411RA006 TG

: Pull out rubber buffer (1)

2411RA011 TG
2411RA009 TG

: Pin (1) a =
– Coat the knurled area of the new approx. 10.3...10.5 mm
1 pin with Loctite before fitting the
pin, b 12
2
2411RA007 TG

: The pin must be inserted in the 5 2

3 hole (arrow) so that the knurling
on the pin engages the knurled
: Unscrew the screw (1) profile

Turn the pin back and forth slightly 4

: Draw hand guard (2) with
insert (3) off the pivot pin until it fits.
2411RA012 TG

3
simultaneously
The pin must be driven in square. 1
– 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

18 GS 461
 – 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)

2411RA013 TG

2411RA017 TG
– Reassemble remaining parts in
1 reverse order

: Slide on the washer (1) : Hook assembly hook

4.4 Chain tensioner 5910 890 2800 onto tensioning
nut (arrow) and pull out the
complete chain tensioner
– Troubleshooting, b 3.2

– Remove sealing ring from shaft

– Remove outer side plate,
b 8.1.2
– Examine the chain tensioner,
3 replace if necessary

1 1
2411RA014 TG

Installation
2

: Slide hand guard (1) with 3

insert (2) across the machine as
far as it will go on the pivot pin
2411RA016 TG

(arrow)
2
: Screw in the screw (3) and
tighten

3443RA466 TG
: Turn the spur gear (1)
anticlockwise until the tensioner
slide (2) makes contact on the left
and the tensioning nut is visible
: Fit new sealing ring in the groove
(arrow) of the spur gear
: Unscrew the screw (3)

– Clean all disassembled parts,

b 12
2 1
– Grease screw threads, gear
2411RA015 TG

wheels and sealing ring with

STIHL grease, b 12

: Align rubber buffer (1) so that the – Before fitting the chain tensioner,
pegs face the machine and the assemble the individual parts and
raised part (2) faces upwards push limit stop into the mount

GS 461 19
 Installation

2 1 2 1 2 1 2
3
1

2411RA066 TG
2411RA018 TG

– If the cut-off chain cannot be
tensioned,
: Place guide bar (1) into the
second hole (arrow), then repeat
tensioning operation
– Reassemble remaining parts in
reverse order
: Clamp die (1) 5805 757 7106 in
vise and insert cut-off chain with
the tie straps to be unriveted
: Push insert (2) 5805 757 9500 as
far as it will go over the
segments (3) of the tie straps to
be unriveted and break away
segments (3)
2411RA073 TG
With the drive links (1) and (2),
always make sure that they
alternate – drive links that are the
same must not be installed one after
the other.
The lugs (arrows) of the drive
links (1) must face the same
direction.

4.5 Cut-off chain

1
The following damage to the cut-off 1 1
chain can be repaired. The following
assembly steps are the same for all
repairs.

– Drive link cracked

2411RA071 TG

– Rivet cracked

2411RA131 TG
2 2
– Segment broken off
2 3 2
: Insert cut-off chain into the die (1)
– Remove cut-off chain 5805 757 7106 so that the drive
: Twist lock links loose (1), twist
links (2) make contact on both
lock links rolled (2) and assemble
sides (arrows)
drive link (3) so that the "STIHL"
1 1 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" and "thrust screw A,
or NG 7 B")
– see Instruction Manual STIHL
NG 5 or NG 7
2411RA061 TG

– Adapt newly inserted chain link to

the dimensions of the others

If a drive link is cracked, both – Mount cut-off chain

neighboring tie straps (1) must
always be unriveted.

20 GS 461
4.6 Bar mounting studs – Reassemble remaining parts in – Pull out the collar nuts
reverse order
– Remove outer side plate, – Unscrew the assembly tool from
b 8.1.2 the collar nuts
4.7 Collar nuts for chain
– Unscrew studs out of the sprocket cover
crankcase using stud driver Installation
5910 893 0501 To replace the nuts, use special tool
stud 5910 893 9601.
1

1 1 2
2 1

2411RA022 TG
1
2411RA019 TG

2411RA020 TG
: Push in new collar nuts (1)
2
: When fitting, coat thread (1) of
the studs with Loctite, b 12 – Remove chain sprocket cover

: Screw in and tighten studs (1) : Screw the assembly tool (1) 1
with stud driver (2) 5910 893 9601 with the stud
5910 890 3000 marking "S" as far as it will go into
the collar nuts (2)

2411RA023 TG
– Hold the hexagon of the collar
nuts in place

: Screw the assembly tool (1)

5910 893 9601 with the stud
2411RA021 TG

marking "L" into the opposite side

– Flip over the chain sprocket cover
and clamp the assembly tool into
a vise by the hexagon
: Drill out the collar nuts with an 11
mm diameter drill bit – the base in
the chain sprocket cover must not
be drilled out
of the collar nuts as far as it will
go
Now the new collar nuts have been
flanged and secured in the chain
sprocket cover to prevent loss.
– Reassemble remaining parts in
reverse order

GS 461 21
5. Engine
5.1 Muffler
Check and if necessary repair the
fuel supply, carburetor, air filter and
ignition system before looking for
faults on the engine.
– Troubleshooting, b 3
To keep dirt particles from entering
the cylinder, move piston to top
dead center – the top dead center is
attained when the magnet poles of
the flywheel face upwards.
1 1
3
2 1
2411RA024 TG
: Remove screws (1) and (2)
: Take out and examine the
exhaust casing (3), replace if
necessary
1 any fouling on the cylinder and
2 2
2411RA025 TG
: Remove gasket (1) and unscrew
screws (2)
– always use a new gasket
– Remove and examine the
muffler, replace if necessary.
22
2 1
1
2411RA026 TG
2411RA028 TG
: Remove the muffler gasket (1) : Line up the cooling plate (1) with
and cooling plate (2) the pegs (arrows) on the cylinder
exhaust port and attach
– Installing and removing the spark
arresting screen, see Instruction
Manual
2
Installation
2411RA029 TG
: Line up the muffler gasket (1)
with the pegs (arrows) of the
2411RA027 TG
cooling plate (2) and attach
– Place the machine in an upright
position.
– Cover exhaust bore and remove
exhaust bore
: Examine and clean the mating
surfaces (arrows) on the exhaust
bore, cooling plate and muffler –
there must not be any gasket
residues or dirt particles in the
exhaust bore
Parts with damaged mating faces
must be replaced.
GS 461

2 2
2411RA030 TG
1 This makes adjustment of the
: Carefully fit the muffler (1)
: Coat the screws (2) with Loctite,
b 12
: Fit screws (2) and check that
cooling plate or gasket is
correctly positioned
: Insert and tighten the screws (2)
2 2
3 and screw it tight
2411RA031 TG
3 : Screw in spark plug (2) and
1 tighten it securely
– insert new gasket
: Coat the screws (3) with Loctite,
b 12
: Position exhaust casing (1),
screw in and tighten screws (2),
screws (3)
GS 461
5.2 Leak testing 5.2.1 Preparations
Defective oil seals and gaskets or – Remove filter cover and air baffle
cracks in housing are the usual
causes of leaks. Such faults allow – Remove shroud, b 5.4
supplementary air to enter the
engine and upset the fuel-air
mixture.
1
prescribed idle speed difficult, if not
impossible.
Moreover, the transition from idle 2
speed to part or full throttle is not
smooth.
2411RA032 TG
Oil seals tend to fail when subjected
to a vacuum, therefore always start
with the vacuum test and then – Take off the spark plug boot and
continue with the pressure test. remove the spark plug
The engine can be thoroughly
– Set the piston to the top
checked for leaks under vacuum
dead center (this can be checked
and at gauge pressure using the
through the spark plug hole)
pump 0000 850 1300.
– Remove the decompression
valve, b 5.9
: Fit the stopper (1) 1122 025 2200
– Remove exhaust casing and
loosen muffler screws, b 5.1
23
 5.2.2 Testing with negative
pressure
1
1
4 3

3443RA063 TG

3443RA065 TG
2 3
1

: Slide sealing plate (1) : Orient flange (1) 5910 850 4200
0000 855 8106 on the cylinder and push it onto the studs
exhaust port between the cooling – Screw (2) for impulse hose
plate and cylinder must be screwed in at the bottom
– Tighten screws lightly – Coat screw or inside of impulse
hose with STIHL press fluid,
The sealing plate must fill the full b 12
width between the screws.
: Slide on flange (1)
– Remove the carburetor, b 10.3 5910 850 4200 so that the
screw (2) engages in the impulse
hose (3)
2
1 constant, or does not decrease by
1 seconds, it may be assumed that
3443RA064 TG
2411RA034 TG
2
: Push the hose (1) of pump
0000 850 1300 onto the
connector (arrow)
: Slide ring (2) to the left
– Vacuum test
: Operate lever (3) until the
pressure gauge (4) indicates a
vacuum of 0.5 bar
If the vacuum reading remains
more than 0.3 bar within 20
the oil seals are in good condition.
If the vacuum in the crankcase is
reduced further,

the oil seals

1 must be replaced, b 5.3.
2411RA033 TG

: Washer (1) and sleeve (2) must 2 2 – After testing, slide the ring on the
be fitted pump back to the right to vent the
: Slide on sleeves (1) pump
5910 893 1701
– Continue with pressure test,
: Tightly screw on nuts (2) b 5.2.3

24 GS 461
5.2.3 Pressure test – Tighten screws of muffler and fit
exhaust casing, b 5.1 1
The same preparatory steps are
required as for the vacuum test, – Install the carburetor, b 10.3
b 5.2.2.
– Reassemble remaining parts in
reverse order

2411RA036 TG
3 2
5.3 Oil seal on ignition side

Avoid damage to the crankshaft

It is not necessary to disassemble
stub.
the complete engine in order to
replace the oil seals.
– Free the oil seal in its seat by
2411RA035 TG

tapping it with a suitable tube or a

– Remove starter, b 7.2
1 punch.

– Remove the flywheel, b 6.5

: Push the hose (1) of pump : Apply the puller (1)
0000 850 1300 onto the 5910 890 4400 with jaws (profile
connector (arrow) no. 3.1) 0000 893 3706

: Slide ring (1) to the right – Clamp the puller arms

– Pressure test
1 – Pull out the oil seal
: Operate the lever (2) until the
pressure gauge (3) indicates a
pressure of 0.5 bar. If this Installation
3443RA200 TG

pressure remains constant for at

least 20 seconds, the crankcase – Clean the mating surface, b 12
is airtight.
– 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.

To find the leak, coat the suspect

area with soapy water and
pressurize the crankcase. Bubbles
will appear if a leak exists.

– After testing, slide the ring on the

pump to the left to vent the pump
– disconnect the hose.

– Remove flange 5910 850 4200

– Loosen screws on muffler and

pull out sealing plate
0000 855 8106

GS 461 25
 Installation
1 1
– Clean the mating surface

– Coat the sealing lips of the new

oil seals with STIHL grease,
b 12
2411RA037 TG

2411RA039 TG
2

: Slide on oil seal (1) with the : Press out oil seal
sealing lip facing the crankcase
: Examine and clean flange (1),
: Use the press sleeve (2) replace if necessary
1115 893 4600 to install the oil
seal (1)

2411RA041 TG
The seating face must be flat and 2 1
free from burrs.
: Fit the assembly sleeve (1)
– Install woodruff key 1118 893 4602

– Crankshaft / flywheel connection – Slide the oil seal over the

must be degreased and oil-free, assembly sleeve with the sealing
2411RA040 TG

clean if necessary, b 12 lip facing the crankcase

1
– Reassemble remaining parts in : Remove the assembly sleeve (1)
reverse order Avoid damage to the crankshaft
stub.

5.3.1 Oil seals on clutch side – Free the oil seal in its seat by 2
tapping it with a suitable tube or a
punch.
– Remove clutch, b 4

: Apply the puller (1)

5910 890 4400 with jaws (profile
2 1 no. 3.1) 0000 893 3706
2411RA042 TG

– Clamp the puller arms 1

– Pull out the oil seal : Use the press sleeve (1)
1118 893 2401 to install the oil
seal (2)
2411RA038 TG

: Undo screws (1) and remove

flange (2)

– Remove gasket – always use a

new gasket

26 GS 461
 Installation
2
2
1

2411RA043 TG

2411RA045 TG
1 1

: Align new oil seal (1) in
accordance with the illustration
with the open side facing
upwards
: Press oil seal (1) by hand as far
as it will go into the mount on the
inside of the flange (2)
3443RA082 TG
1
: Fit the assembly sleeve (1)
1118 893 4602
: Pull out twist locks (1)
: Align holes of flange (2), slide
flange (2) over assembly : Fit shroud (2) so that the ignition
sleeve (1) and fit lead and insulating tube are
seated in the guide (arrow)
: Remove the assembly sleeve (1)

– Insert and tighten the screws

1
1
– Reassemble remaining parts in
reverse order

5.4 Shroud

3443RA083 TG
2
2411RA044 TG

– Remove the spark plug 2

: Screw in slotted nut (1) and

: Fit new gasket (1) so that the tab tighten
(arrow) engages in the recess
2 1
: Screw in twist locks (2) and
tighten

– Reassemble remaining parts in

reverse order
3443RA077 TG

: Unscrew twist locks (arrows) –

loss-proof screws

: Unscrew slotted nut (1) and

remove shroud (2)

GS 461 27
5.5 Cylinder

Before removing the cylinder,

decide whether or not the
crankshaft is to be removed.

With cylinder installed 2

The crankshaft must be prevented

3443RA085 TG

from twisting by blocking the piston
through the spark plug hole in order
to remove the flywheel and clutch.
: Unscrew pan head screws
With cylinder removed
The crankshaft is blocked by
placing the piston on the piston
support in order to remove the
flywheel and clutch.
– Remove shroud, b 5.4
3443RA089 TG
1
– Examine the intake elbow (1),
through the holes (arrows) replace if necessary. Engine
operation may be impaired even
by the slightest damage, b 3.7
: Undo screw (2) and remove
intake elbow (1)

– Clean the sealing faces, b 12

– Remove starter,
b 7.2
1 The mating surfaces must be in
perfect condition and without any
3443RA086 TG

– Remove filter base, b 10.2

damage whatsoever. Parts with
2 damaged mating faces must be
– Remove the carburetor, b 10.3 replaced.
: Carefully remove cylinder (1) by
– Remove the muffler, b 5.1 pressing the manifold flange (2) Always use a new cylinder gasket
out of the tank housing after removing the cylinder.
– Remove the decompression
valve, b 5.9

1
1
3443RA087 TG
3443RA084 TG

: Remove the cylinder gasket (1)

: Remove washer (1) and

sleeve (2)

Press out manifold flange in the

direction of the cylinder

28 GS 461
Installation

1
1 2
4

3443RA094 TG

2 3 3443RA092 TG
– Apply STIHL press fluid to the
inside of the intake elbow, b 12
: Push intake elbow (1) onto the
intake stub so that the tab (2) on
the right rests against the raised
part
: Push on hose clip (3) – the screw
head (4) must align with the
cooling fin (arrow)
: Tighten screw (4) as far as
possible
1
: Align piston support (1)
5910 893 5300 so that the
recesses (arrows) engage over
the flange, then push between
piston and crankcase
Avoid damage to the cylinder
gasket.
1 same time
3443RA095 TG
3443RA096 TG
: Orient cylinder (1) so that the
intake elbow (2) faces the tank
casing
When fitting the cylinder over the
piston, ensure that the clamping
strap securely encloses the piston
and that none of the piston rings
protrudes
– danger of breakage.
: Slide cylinder over piston; the
clamping strap is removed at the
– Remove clamping strap and
piston support

2
– Coat piston, piston rings and
inside of cylinder with oil, b 12

– Ensure that piston rings are

correctly positioned, b 5.8
3443RA093 TG

1 : Use the clamping strap (1)
: Align new cylinder gasket (1) so
that the embossing faces
upwards
: Guide new cylinder gasket (1)
over the piston so that the tab (2)
faces the guard
3443RA099 TG
0000 893 2600 to compress the
rings around the piston
: Fit screws (arrows) and secure
The clamping strap (1) must be cylinder with gasket.
fitted in such a way that the piston
rings do not protrude beyond the : Tighten the screws through the
piston sides. holes (arrows) crosswise

GS 461 29
 Always fit new ball bearings and oil
1 2 3 4 seals when removing the
crankshaft, b 5.6.1 and b 5.3.

3
1 Clutch side half of crankcase

3443RA098 TG

3443RA101 TG
1 2
2 2

: Place a piece of string (1) around : Orient the manifold flange (1), –
the manifold flange and guide the openings must rest against
through the opening on the tank the studs (2) 1

3443RA102 TG
housing
: Fit washer (3) and push
Ensure that the cylinder gasket is sleeve (4) into the opening of the
correctly positioned. intake elbow (1)
: Undo screws (1) and remove
: Push on cylinder (2) as far as it flange (2)
– Reassemble remaining parts in
will go and fit manifold flange (3) reverse order
onto tank housing

5.6 Crankshaft
1
– Empty the fuel tank, b 1.1

– Remove front handlebar, b 8.2

2411RA046 TG
– Remove the flywheel, b 6.5
2
3443RA100 TG

– Remove short circuit wire,

– Apply STIHL press fluid to the
outside of the manifold flange,
b 12
– Push tank housing towards the
cylinder and hold in place
b 6.6.3 The tools from the assembly tool kit
5910 007 2206 are used for
– Remove clutch, b 4.2 removal and installation.
: Unscrew the screws (arrows)
– Remove flange and replace oil
seal, b 5.3.1
– Remove chain tensioner, b 4.4

: Pull the manifold flange (1) – Remove guard, b 8.3

through the hole with the ends of
the string (2)
– Remove cylinder, b 5.5

– Remove the string

– Remove piston, b 5.7

– Remove tank housing,

b 10.8.3

30 GS 461

2 through the holes marked "28"
2411RA047 TG
1 20,2 32,8
: Unscrew spindle (1) until it no
longer rests on the crankshaft
stub
: Push assembly tool (2) from kit
5910 007 2222 onto the studs
(arrows), twist on and tighten the
nuts
: Turn spindle (1) clockwise until
the crankshaft stub has been
forced out of the ball bearing
– Replace ball bearings and oil
seals, b 5.6.1 and b 5.3
Ignition side half of crankcase
1
3443RA106 TG
: Remove the gasket (1)
GS 461
5,0 : Insert three M5 x 72 screws (3)
and screw them as far as
86
,5
possible into the crankcase half
¡
40,0
: Turn the spindle (1)
19,8
counterclockwise until the
40,6
crankshaft has been forced out of
3443RA107 TG
the ignition-side half of the
crankcase
Washer 5910 893 2101 without Crankshaft, con-rod and the needle
holes "28" can be reworked as bearing between them form a
illustrated with 5.5 mm holes. complete unit which must always be
replaced as such.
Dimensions are given in millimeters.
– Check the two halves of the
The drilled plate is shown from crankcase and the ball bearing,
above in the illustration. replace if necessary, b 5.6.1
– Before installation, clean the
crankshaft, b 12
3 2
Installation
3 Ignition side half of crankcase
3 1
Avoid damage to the crankshaft
2411RA048 TG
stub.
The tools from the assembly tool kit
5910 007 2201 are used for
removal and installation – use
washer 5910 893 2101.
: Unscrew the spindle (1) so that
the disk (2) rests against the half
of the crankcase.
– Left-hand thread
: 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
31

3443RA110 TG
– Heat the inner race of the ball
bearing to approx. 160 °C
(320 °F)
: Align the crankshaft with the
conical stub (arrow) facing the
ignition-side ball bearing and
push it as far as it will go.
The crankshaft must be fitted
rapidly, as the heat is transmitted to
the crankshaft stub and the inner
bearing race contracts.
1
3443RA111 TG
If the inner race cannot be heated,
the crankshaft can be drawn into the
crankcase with the assembly tool
5910 007 2201 – use washer
5910 893 2101.
: Screw the threaded sleeve (1)
5910 893 2420 onto the
completely screwed in spindle as
far as it will go
Coat the conical crankshaft stub
with oil.
32
– Align the crankshaft with the
conical stub facing the ignition-
side ball bearing and push it
home.
2
3443RA112 TG
1
: Fit the screw sleeve (2) over the
thread of the conical crankshaft
stub (1) and screw it on
2 3
2 – Coat the cylindrical crankshaft
2 1
2411RA049 TG
: By turning the spindle (1),
position washer 5910 893 2101
against the ignition-side half of
the crankcase and orient it so that
the edge number "28" is at the
bottom
: Insert M5x72 screws (2) through
the holes marked "28"
– anti-twist device
: Turn the spindle (1) clockwise
– Draw the ignition-side half of the
crankcase in as far as possible
The crankshaft also turns when it is
drawn in with the installing tool. For
this reason, ensure that the rod
eye (3) always faces upwards
towards the cylinder.
– Remove the assembly tool
1 2
3443RA116 TG
1
: Screw two screws (1) M5x72 into
the holes on the ignition side – for
guidance and to prevent twisting
: Fit new gasket (2) and secure it
at the guide sleeves
stub with oil
Clutch side half of crankcase
Avoid damage to the crankshaft
stub.
Examine and clean the mating
surfaces of the clutch-side half of
the crankcase (including the
cylinder sealing surface) – the
sealing face must not display any
signs of damage.
GS 461
 – Coat the cylindrical crankshaft
stub with oil 1

– Align the crankcase half with the

cylindrical crankshaft stub and
the two screws and position it
2

3443RA117 TG

2411RA050 TG
Ensure that the guide sleeves : Hold crankshaft (1) steady and
(arrows) align with the holes and screw threaded sleeve onto
that the housing gasket is not thread of crankshaft stub by
jammed or buckled. turning the spindle (2)

165RA133 TG
– Release crankshaft (1) and hold
1 assembly tool steady and
continue turning the spindle (2)
– By turning it, screw the spindle until the assembly tool rests
completely into the assembly tool against the crankcase half.

: Screw the threaded sleeve (1) – Screw nuts onto the studs and
5910 893 2409 onto the spindle tighten it by hand
3443RA118 TG

as far as it will go
– Left-hand thread : Turn spindle (2)
counterclockwise until the
crankcase half rests against the
– Heat the inner race of the ball guide sleeves
bearing to approx. 160 °C
(320 °F)

– Align the crankcase half with the

cylindrical crankshaft stub and
the two screws and position it
3443RA119 TG

: Push the crankcase home until it

makes contact

The crankcase must be fitted : Fit threaded sleeve on crankshaft

rapidly, as the heat is transmitted to stub (arrow) and push assembly
the crankshaft stub and the inner tool over the studs
bearing race contracts

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 33
 – Examine and install the piston, Examine both halves of the
b 5.7 crankcase for cracks and check all
mating surfaces for signs of
– Examine and install the cylinder, damage.
b 5.5
– Refer also to troubleshooting,
b 3.7
– Reassemble remaining parts in
3443RA117 TG reverse order
– Remove crankshaft, b 5.6

5.6.1 Ball bearing / crankcase

Ensure that the guide sleeves
(arrows) align with the holes and
that the housing gasket is not
jammed or buckled.
– Continue turning the spindle of
the assembly tool until the gap
between the halves of the
crankcase is closed
– Unscrew nuts.
Ignition-side half of the
crankcase
The two halves of the crankcase
can be replaced individually if they
are defective.
Examine and clean the mating
surfaces of the crankcase halves
(including the cylinder sealing
surface) – The mating surfaces
must be without any damage
whatsoever.

– Turn the spindle clockwise to
remove the assembly tool
– Remove the two M5x72 screws
which were fitted to prevent
twisting
2411RA046 TG
New crankcase halves are
delivered with the relevant
components pre-assembled
– see spare parts list.
Those parts which are not supplied
with the new crankcase must be
removed from the old crankcase
halves, examined and replaced if
necessary.
When fitting a new crankcase, the
machine's serial number must be
stamped on the crankcase with 2.5
mm figure stamps.
If the old crankcase is reused, the
3443RA122 TG
: Carefully drive the oil seal out
with a punch
: Examine and clean the
crankcase half, replace if
necessary
– Replace the ball bearings if the
crankcase half is in good
condition.
– Heat the area around the bearing
seat to
approx. 160 °C (320 °F)

oil seals and ball bearings must be

: Insert the screws (arrows) and
tighten them crosswise
– Install oil seals, b 5.3
replaced, all gasket residues The bearing drops out of its own
removed and the mating surfaces accord when this temperature is
cleaned thoroughly. The mating reached.
surfaces must be absolutely
flawless and clean to guarantee a
perfect seal.

– Fit flange with new oil seal,

b 5.3.1

34 GS 461
Installation – Replace the ball bearings if the – Remove flange, b 5.3.1
crankcase half is in good
condition. – Install crankshaft, b 5.6

– Heat the area around the bearing – Install oil seals,

seat to b 5.3
approx. 160 °C (320 °F)
– Fit flange with new oil seal,
The bearing drops out of its own b 5.3.1
accord when this temperature is

3443RA124 TG
reached.
– Reassemble remaining parts in
reverse order
– Heat the area around the bearing Installation
seat to
Because the clutch-side half of the 5.7 Piston
approx. 160 °C (320 °F)
crankcase does not have a fixed
bearing seat, the flange must be Before removing the cylinder,
– Position ball bearing so that the
fitted first – the flange acts as a stop decide whether the crankshaft is to
open side (balls visible) faces the
inside of the crankcase be removed, b 5.6
– Fit flange without installed oil
seal, b 5.3.1 – Remove cylinder, b 5.5
: Press the ball bearing home as
far as possible
The clutch-side snap ring does not
need to be removed.
The ball bearing must be fitted
rapidly, as it absorbs heat and
expands.

– Check that the ball bearing is

seated properly, if necessary, use
press arbor
3443RA127 TG

1120 893 7200 to press the ball

bearing fully home

3443RA128 TG
Clutch-side half of the crankcase – Heat the area around the bearing
seat to
approx. 160 °C (320 °F)
: Prise the hookless snap ring on
– Position ball bearing so that the the ignition side out at the recess
centering ring (arrow) points (arrow)
towards the flange

: Press ball bearing fully

home (flange)
3443RA125 TG

The ball bearing must be fitted

rapidly, as it absorbs heat and
The oil seal is seated in the ball expands.
bearing and does not need to be
removed separately. – Check that the ball bearing is
seated properly, if necessary, use
– Examine and clean the press arbor
crankcase half, replace if 1118 893 7200 carefully press in
necessary the ball bearing until it rests
against the flange

GS 461 35
 Installation

2
3443RA129 TG

3443RA136 TG
2

: Push the assembly drift (1)
1108 893 4700 through the
installed snap ring
: Push the piston pin (2) out of the
piston with the assembly drift (1)
1108 893 4700
If the piston pin is stuck, tap the end
of the drift gently with a hammer to
loosen it.
The piston must be held steady
during this process to ensure that
jolts are not transmitted to the
3443RA132 TG
The snap ring must be fitted so that
the gap in the ring (arrow) points
– Coat needle bearing with oil and upwards in axial direction of the
slide it into the rod eye piston.
: Line up the piston so that the
arrow (arrow) in the piston base
points towards the exhaust port
The assembly drift (1) can be
inserted through the fitted snap ring.
– Position the piston on the rod eye

3443RA137 TG
connecting rod. : Push the assembly drift (1)
1108 893 4700 with the stub end
– Remove the piston first through piston hole and rod
eye (needle cage) and secure the : Assembly tool
– Examine the piston rings, replace piston 5910 890 2212 with the taper
if necessary, b 5.8 sleeve (flat face facing upwards)
: Coat the piston pin (2) with oil on the piston boss, hold the
piston steady and press the tool
shank home until the snap ring
: Fit the piston pin (2) on the stub
slips into the groove
of the assembly drift (1) and slide
it into the piston
The tool must be precisely aligned
1 in axial direction of the piston pin.
– Use the assembly tool
5910 890 2212 to prepare the
snap ring for installation
3443RA130 TG

: Take out the needle bearing (1),

examine and clean it, replace if
necessary

36 GS 461
 5.9 Decompression valve

– Remove shroud, b 5.4

3443RA138 TG

3443RA140 TG
1
– Examine the piston rings, replace : Align the new piston rings so that
if necessary, b 5.8 the radii at the ends of the ring

2411RA052 TG
(arrows) face upwards
– Install the cylinder, b 5.5
– Carefully slide the piston rings
– Reassemble remaining parts in over the piston : Unscrew decompression
reverse order – danger of breakage valve (1)

: Position the piston rings so that

5.8 Piston rings the radiuses at the ring gaps
encircle the fixing pins in the
piston grooves
– Remove piston, b 5.7
Check the correct installed position
– Remove piston rings from piston of the piston rings again

– Install the piston, b 5.7

5902RA164 TG
– Reassemble remaining parts in
reverse order
: Examine the sealing cone
(arrow) on the decompression
valve for signs of damage
3443RA139 TG

– Use a new decompression valve

if the sealing cone on the
decompression valve does not
seal tightly or is damaged.
: Use a piece of old piston ring to
scrape the grooves clean
(arrows) – Fit the decompression valve by
hand and screw it in

– Screw the decompression valve

tight

– Reassemble remaining parts in

reverse order

GS 461 37
6. Ignition system

Exercise extreme caution while 6.2 Ignition module : Disconnect the ground wire (1)
carrying out maintenance and repair
work on the ignition system. The – Remove the ignition module.
high voltages which occur can
cause serious or fatal accidents. 1

Troubleshooting on the ignition 3

system should always start with the 2
spark plug, b 3.5
2
– Remove starter, b 7.2

3443RA180 TG
1

3443RA183 TG
The ignition module accommodates
all the components required to
control ignition timing. There are
two electrical connections on the : Unlock the plug (1) of the short
coil body: circuit wire and pull off

– High-voltage output (1) for the : Unhook short circuit wire (2) on
2411RA053 TG

ignition lead cable holder (3)

2 1
The electronic ignition system
basically consists of an ignition
module (1) and flywheel (2).
6.1 Ignition timing
Ignition timing is fixed and cannot
be adjusted during repair work.
Since there is no mechanical wear
in these systems, ignition timing
cannot get out of adjustment during
operation.
– Connector tag (2) for the short- : Slide grommet away from ignition
circuit wire module and unscrew ignition lead
Testing of the ignition module is A new ignition module is delivered
limited to a spark test. A new ignition with ignition lead, grommet and
module must be installed if no cable holder.
ignition spark is obtained (after
checking that the wiring and stop
switch are in good condition).
– Remove starter,
b 7.2
1
– Remove filter cover and pull off
spark plug boot, b 4.2
3443RA185 TG

– Inspect cable holder, replace if

necessary
1
: Drive cable holder (1) out with a
suitable punch
2411RA054 TG

– Reassemble parts in reverse

order
: Unscrew the screws (arrows)
– Examine spark plug boot and
ignition lead, replace if
necessary, b 6.4

38 GS 461
 : Position ground wire (3) and : Turn the flywheel until the raised
insert screw (4) part of the magnet poles (arrows)
– do not tighten is on the ignition module
– Setting gauge is pressed in
1 during the process
: Fit connector (5) of short-circuit
wire (6) with the crimped side
facing the ground wire : Press and hold the ignition
module (1) against the setting

3443RA186 TG
: Press short-circuit wire (6) into gauge
the cable holder (7) so that there
is no tensile load
– Before twisting in the ignition – Connector tab and blade
lead, fill the high-voltage output receptacle must run parallel to
with STIHL multi-purpose the edge of the ignition module

N
grease, b 12 1 2
Do not use either graphite grease or

S
silicone insulating paste.
1

2411RA059 TG
– Screw the ignition lead into the
ignition module – protective tube 3
and grommet must be pressed
onto ignition lead : Tighten screws (1) and pull out
1
setting gauge

2411RA057 TG
: Push on the grommet (1)
: Align cable lug (arrow) of the
Grommet (1) must be pushed on ground wire (2) so that the
fully to avoid faults on the ignition : Push back ignition module and distance to the blade receptacle
system caused by dirt or moisture. slide setting gauge (1) and housing wall is the same,
1111 890 6400 between the legs hold in place and tighten
of the ignition module and the screw (3)
magnetic pole of the flywheel
7 – Check correct functioning
– Turn the flywheel: it must not
2 touch the ignition module
6
3
5
4
N
2411RA056 TG

2
S

1
2411RA058 TG

The short circuit wire and ground

wire are run below the ignition lead 1
: Position ignition module (1) and Shown without setting gauge for a
insert screws (2) better view.
– do not tighten
: Push back ignition module (1)
and hold in place – flywheel must
turn freely

GS 461 39
 – Reassemble remaining parts in – Before starting the test, check
reverse order spark plug, replace if necessary –
use only spark plugs
3 recommended by STIHL
6.3 Testing the ignition
1 module

3443RA202 TG
2
The compensation for longitudinal
movement of the short-circuit
wire (1) is between the crankcase
Before starting the test, install a new
spark plug.
The engine may start and
accelerate during the test.
– Test the ignition module using

and the cable holder of the ignition
module
: Press short-circuit wire (1) into
the guide (2) – the protective
tube (3) must be flush with the fin
(arrow)
1 follow the steps of the diagnostic
2411RA051 TG
either the ZAT 4 ignition system
tester 5910 850 4503 or the
ZAT 3 ignition system tester
5910 850 4520.
If a spark is visible, the ignition
system is in order.
– If no spark is visible in the spark
window, check the ignition
system with the aid of the
troubleshooting chart, b 6.7
The ignition test refers only to a
spark test, not to the ignition timing.
3443RA205 TG
: Install engine analyzer MDG 1
between spark plug and spark
plug boot
– Ground clips must rest against
the hexagon of the spark plug
– To diagnose the GS 461, select
"Other STIHL products". Then
start the "Diagnosis" function and
software.
For an accurate result, crank the
engine quickly with the rewind

6.3.1 Testing the ignition starter.

module with engine
analyzer MDG 1 The engine may start and
: Position insulating tube (1) so accelerate during the test.
that it The STIHL MDG 1 is used to easily,
rests against the grommet reliably and quickly test the ignition
(arrow) module.

The following is tested during the

test run:

– Ignition voltage
– Spark
– Short circuit
1
– Remove filter cover and air baffle
– secure air filter with slotted nut
3443RA194 TG

Protective tube (1) with ignition lead

must be in the guide (arrow) when
the shroud is fitted.

– Fit the shroud, b 5.4

40 GS 461
6.4 Spark plug boot / ignition – Cut new ignition lead to the
lead specified length, see spare parts 1
list
– Remove the ignition module,
b 6.2
Installation

3443RA467 TG
2
: Ensure that the torsion spring
1 (arrow) is located in the recess

3443RA468 TG
: Slide the cover (1) over the spark
3443RA195 TG

plug boot
3
– Use a pointed tool to pierce the
– With an ignition module, use a other end of the ignition lead,
: Pull grommet (1) off high-voltage
pointed tool to pierce the center which is to be connected to the
output (arrow)
of the lead's insulation ignition module.
approx. 15 mm from the end of
: Unscrew ignition lead (2) from the ignition lead
the ignition module and pull – Before twisting in the ignition
grommet (1) off ignition lead lead, fill the coil tower with STIHL
: Pinch the hook of the torsion multi-purpose grease, b 12
spring into the center of the
: Remove the cover (3) from the ignition lead (arrow) where it has
spark plug boot Do not use either graphite grease or
been pierced
silicone insulating paste.

– Coat the inside of the spark plug

boot with
STIHL press fluid, b 12

: Push the ignition lead and torsion

spring into the spark plug boot
6161RA167 TG

: Use suitable pliers to pull the

torsion spring out of the spark
plug boot

– Unhook the torsion spring from

the ignition lead

– Pull the boot off the ignition lead

GS 461 41
 1 1
1

3443RA186 TG

3443RA197 TG

3443RA200 TG
2

– Push grommet (1) onto ignition : Screw puller (1) 1110 890 4500 : Check the woodruff key (1),
lead as far as it will go into the flywheel replace if necessary

– Screw the ignition lead into the
ignition module.
: Push on the grommet (1)
– Install the ignition module and
adjust the air gap between
ignition module and flywheel,
b 6.2
: Turn screw (2) clockwise until the
flywheel comes off the crankshaft
stub
– Unscrew puller (1)
1110 890 4500 from flywheel
: Make sure that the woodruff
key (1) is properly seated, align if
necessary
Connection between crankshaft and
flywheel must be degreased and oil-
free

– Reassemble remaining parts in

reverse order

6.5 Flywheel
3443RA198 TG

3443RA201 TG
– Remove shroud, b 5.4

– Remove starter, b 7.2

: Flywheel and magnet poles
(arrows) must not show any signs
– Block the piston with the locking of damage or blue discoloration,
strip, b 4.2 otherwise the flywheel must be
replaced
If the groove is worn (arrow),
replace the flywheel.
Ensure that the woodruff key
engages in the groove (arrow).

– Adjust the air gap between

ignition module and flywheel,
b 6.2
1
– Reassemble remaining parts in
reverse order
3443RA196 TG

: Unscrew the flywheel nut (1)

42 GS 461
6.6 Wiring harness The ground wire must also be 6.6.2 Ground wire
tested for contact and continuity.
Ground wire and short circuit wire Functioning of the short circuit wire
If the ground wire is damaged, the
are combined into one wiring may be impaired or made
wiring harness must also be
harness. impossible by a damaged ground
replaced.
wire.
– If no fault can be found, test the
6.6.1 Testing The ground wire is incorporated in
ignition system in accordance
the wiring harness of the short-
with flow chart, b 6.7
Check the short circuit wire if the circuit wire, if it is damaged, replace
spark plug and ignition lead with the whole wiring harness.
: Fit connector (3) of short-circuit
spark plug boot are in order. wire (1) with the crimped side – Perform contact and continuity
facing the ground wire test on ground wire,
– Remove starter, b 7.2
replace wiring harness if
: Press short-circuit wire (1) into necessary
the cable holder (2) so that there
2 is no tensile load
– Connector tab and blade 6.6.3 Wiring harness
receptacle must run parallel to Removal and installation
the edge of the ignition module
1
– Remove shroud, b 5.4
4
3 – Unplug the spark plug boot
3443RA206 TG

3 – Remove starter,
b 7.2
: Pull short-circuit wire (1) out of
the cable holder (2)
1 – Remove the ignition module,
b 6.2
3443RA202 TG

: Remove connector (3)

: Connect the ohmmeter to
ground (4) and the short circuit
wire (1)
– Set Master Control lever to "0"
The resistance measured must be
approx. 0 Ω. If it is much higher, the
2
1 2
The compensation for longitudinal
movement of the short-circuit
wire (1) is between the crankcase
and the cable holder of the ignition
module
: Press short-circuit wire (1) into 3443RA208 TG

reason is a break in the wire and the
wiring harness must be replaced,
b 6.6.
– Set Master Control lever to "F"
The resistance measured must be
infinitely high, otherwise replace the
wiring harness, b 6.6.
the guide (2) – the protective
tube (3) must be flush with the fin
(arrow)
: Press out grommet (1) in the
– Install starter, b 7.2 direction of the cylinder and pull
out wiring harness (2) in the
direction of the cylinder
: Pull grommet (1) off wiring
harness

– Remove tank housing, b 10.8.3

GS 461 43
 1 1

2411RA060 TG
3443RA210 TG

3443RA217 TG
1

: Pull fuel suction hose (1) out of
the guide (arrow) and set it aside
: Pull off blade receptacle (1) and
pull wiring harness out of the
guides (arrows)
– Check contact spring and switch
housing, replace if necessary,
b 6.6.4
– Use STIHL press fluid to simplify
assembly, b 12
: Press the bushing (1) into the
hole so that the wires run
horizontally in the bushing

– Examine wiring harness, replace

1 if necessary
3443RA211 TG

Installation 1
2
2
: Press out bushing (1) in the

3443RA218 TG
direction of the carburetor space
and pull out wiring harness (2) in
the direction of the carburetor
space The bushing (1) must enclose the
hole completely on the opposite
– Remove switch shaft, b 9.1.1 side.
3443RA216 TG

2 1 : Push wiring harness as far as it

will go into the protective tube (2)
: Push wiring harness (1) with towards the bushing
protective tube (2) in front
through the hole (arrow) towards
the cylinder

44 GS 461
 : Push grommet (1) onto wiring
harness (2)
1 3
4
– Install tank housing, b 10.8.3

2411RA062 TG

2411RA064 TG
2

: Press short-circuit wire (1) into Crimped side of the blade

the guides (arrows) receptacle (1) must face the switch
shaft bearing.

3443RA225 TG
: Push blade receptacle (1) of 1 2
ground wire (4) onto the contact
spring (2)
: Push fuel suction hose (1) into
2 the guide (arrow) and press
: Push in short-circuit wire (3) and between the wires and the
ground wire (4) between fin collar (2) of the intake elbow
(arrow) and housing wall mount – fuel suction hose is
– Short-circuit wire (3) must be secured
2411RA063 TG

routed below the ground wire (4)

– Install switch shaft, b 9.1.1

: Press ground wire (2) into the
guides (arrows)

Route wires parallel so that they do

not cross.

1
2411RA119 TG

: Check correct functioning

– The eyelet (1) of the short-
circuit wire must touch the
contact spring (arrow) in position
"0"
3443RA224 TG

1 2

GS 461 45

1 2
3443RA461 TG
Grommet (1) must be pushed on.
– Use STIHL press fluid to simplify
assembly, b 12
: Push wiring harness (2) through
the opening and press
grommet (1) completely into the
opening
: Pull wiring harness (2) further in
until the start of the protective
tube is at the fin (arrow)
– Install ignition module, b 6.2
– Reassemble remaining parts in
reverse order
6.6.4 Contact spring
– Remove throttle rod, b 9.3
– Remove switch shaft, b 9.1
– Remove ground wire
46
Installation
1
2
2411RA067 TG
2411RA069 TG
: At the recess (arrow), lift tab (1) 1
until the peg no longer engages
in the housing wall and pull out : Push contact spring (1) into the
switch housing (2) guide so that the connector
tab (2) faces upwards – contact
spring (1) must be behind the tab
(arrow)
2
2411RA068 TG
1
1
2411RA070 TG
: Lift contact spring (1) over the tab
(arrow) and pull out of guide
– Check contact spring and switch : Push switch housing (1) into the
housing, replace if necessary guide (arrows) until the peg of the
tab (2) engages in the hole of the
housing wall – switch housing is
secured
– Install switch shaft, b 9.1
GS 461
 3
4
1
1

2411RA064 TG

2411RA119 TG
2

Crimped side of the blade : Check correct functioning

receptacle (1) must face the switch – The eyelet (1) of the short-
shaft bearing. circuit wire must touch the
contact spring (arrow) in position
: Push blade receptacle (1) of "0"
ground wire (4) onto the contact
spring (2) – Reassemble remaining parts in
reverse order
: Push in short-circuit wire (3) and
ground wire (4) between fin
(arrow) and housing wall
– Short-circuit wire (3) must be
routed below the ground wire (4)

: Install switch shaft, b 9.1.1

1 2
2411RA072 TG

: 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 47
6.7 Troubleshooting, ignition system

Engine does not run

Master Control lever:

– in position "F"?

Check spark plug:

– Smeared with oil, black?
– Sooted?
– Electrode gap correct?
– Contacts shorted (threads)?
– Clean, adjust or replace spark plug,
b 6.3

Check spark plug boot:

– Firmly seated on spark plug (torsion
spring)?
– Torsion spring hook in center of ignition
lead?
– Spark plug boot damaged?
– 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

48 GS 461
 1

Powerful spark?
yes

no

Air gap:
– Check ignition module / flywheel,
– adjust if necessary, b 6.2

Check flywheel:
– Have pole shoes turned "blue"?
– Replace flywheel if necessary,
b 6.5

Check short circuit wire:

– Wire damaged?
– Plug connections firmly seated?
– Check continuity, replace wiring harness if
necessary, b 6.6.1

Check ignition lead:

– Severe chafing?
– Spark plug boot: Holes / cracks?
– Resistance of spark plug boot to ground:
Required 1.5...12 kΩ
– Ignition lead fully twisted into the ignition
module?
– 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

2 3

GS 461 49
 2 3

Switch shaft
Check correct operation:
– Short circuit wire chafed?
– Function between contact spring and eyelet
on the switch shaft:
– Position "F" = no connection
– Position "0" = connection
– Replace short circuit wire or contact spring
if necessary, b 6.6.3

Powerful spark?
yes

no

Replace ignition module.

b 6.2

Is engine
yes no
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

50 GS 461
7. Starter

7.1 General 7.2 Starter Installation

Removal and installation
If the action of the starter rope
becomes very stiff and the rope
rewinds very slowly or not
completely, it may be assumed that
1 1
the starter mechanism is in order
1
but plugged with dirt. At very low
outside temperatures, the
lubricating oil on the rewind spring

2411RA145 TG
may thicken and cause the spring

2411RA074 TG
windings to stick together. This has
a detrimental effect on the function
of the starter mechanism. : Push new pawls onto the shafts
(arrows) and coat pegs (1) with
To clean the rewind spring, it is : Remove screw (1) and screws
STIHL grease, b 12
sufficient to apply a few drops of a (arrows)
standard solvent-based degreasant
not containing any chlorinated or – Lift hand guard slightly and
halogenated hydrocarbons to the remove starter
rewind spring.
– Reassemble parts in reverse
Carefully pull out the starter rope order
several times and allow it to rewind
until its normal smooth action is 2 2
restored.
7.3 Pawls

Before installing, lubricate the
rewind spring and starter post with
STIHL special lubricant, b 12.
If clogged with dirt or pitch, the
entire starter mechanism, including
the rewind spring, must be removed
and disassembled. Take particular
care when removing the rewind
spring.
– Clean all components
2411RA146 TG
– Remove starter, b 7.2 1
– Relieve the tension of the rewind : Fit spring (1) so that the rings
spring, (arrows) run along the pawls and
b 7.4 enclose the pegs (2)
Check correct functioning
– Pull starter rope, the rope rotor
turns, and the pegs of the pawls
1 move in the direction of the
anchor loops – the pawls move
outward
2411RA085 TG

– Reassemble remaining parts in

reverse order

: Carefully ease the spring (1) off

the starter post

– Remove pawls

GS 461 51
7.4 Rope rotor
Relieve tension of rewind spring
The system will not be under
tension if the starter rope or rewind
spring is broken.
– Remove starter, b 7.2
– Pull the starter rope tensioned
with the starter grip out slightly
and hold the rope rotor tight
2 1
2411RA147 TG
: Unroll starter rope (2) from rope
rotor (1) – hold the rope rotor tight
: Pull out the twisted starter
rope (2) towards the starter grip
and straighten it out
: Keep the starter rope (2)
tensioned and carefully release
the rope rotor
– Remove pawls, b 7.3
52
2
1
2411RA148 TG
The rewind spring must be relieved.
: Remove washer (1) and carefully
remove rope rotor (2)
– Remove starter rope on the rope
rotor, remove any remaining
scraps of rope if necessary or
replace starter rope, b 7.5
1 pawls with STIHL grease, b 12
2
2411RA149 TG
: Examine the sealing ring (1) and
sealing lip of the spring
housing (2), replace if necessary
– Examine the return spring,
replace if necessary, b 7.7
Installation
– Coat the sealing ring, sealing lip
of spring housing and the whole
length of the starter post with
STIHL special lubricant, b 12
– Install starter rope in rope rotor,
b 7.5
2411RA150 TG
1
: Fit the rope rotor on the starter
post so that the inner loop of the
spring (arrow) enters the
recess (1) – the sealing lip of the
spring housing must enclose the
rope rotor hub
– Fit the washer
– Install pawls and spring,
b 7.3
– Tension the rewind spring, b 7.6
– Coat the shafts and pegs of the
– Reassemble remaining parts in
reverse order
7.5 Starter rope / starter grip
– Remove starter and segment,
b 7.2
– Relieve the tension of the rewind
spring, b 7.4
The rewind spring will not be under
tension if the starter rope is broken.
– Remove any remaining rope from
the rope rotor if necessary
The starter rope must not be
shortened.
GS 461
 Hold the tensioned rope rotor firmly,
1 as the rewind spring will be
damaged if it jumps back suddenly.
1
: Pull out the twisted starter
rope (1) towards the starter grip
and straighten it out

2411RA151 TG

2411RA152 TG
: Push starter rope (1) out a short : Then thread the starter rope (1)
distance, undo the knot and pull through the opening (arrow) and
out into the rope rotor
: Tie a simple knot in the end of the
starter rope (1) to secure it and
pull it into the rope rotor
2 – Tension the rewind spring, b 7.6
– Reassemble remaining parts in
reverse order
3443RA465 TG
: Keep the starter rope (1)
tensioned and carefully release
the rope rotor
The rewind spring must sit firmly in
the rope guide bushing.
If it tips: increase the spring tension
by another turn.
It must be possible to turn the rope
rotor another half-turn when the
starter rope has been drawn out
completely. Otherwise the spring
tension must be reduced
– danger of breakage.
Reduce spring tension

1 7.6 Tensioning the rewind Hold the rope rotor tightly and
spring remove one turn of the rope from
: Prise out nipple (1) and pull the rotor.
starter rope (2) out of the starter
– Remove starter, b 7.2 – Install starter, b 7.2
grip

– Check starter rope, replace if

necessary 7.7 Replacing the rewind
1 spring

Installation – Troubleshooting, b 3.4

– Remove starter and segment,

b 7.2
2411RA153 TG

1 – Relieve the rewind spring if

necessary and remove the rope
rotor, b 7.4
: Pull out part of the starter rope (1)

A worn rewind spring may still be

219RA419 TG

: Make a loop in the unwound

under tension while installed.
starter rope (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 53
 – Remove frame, keep if The rewind spring must sit
1 necessary completely in the mount or mount
for the loop, if necessary, press
The rewind spring must sit completely into the mounts.
2 completely in the mount or mount
3 – Coat the rewind spring with a few
4 for the loop, if necessary, press
1 completely into the mounts. drops of STIHL special lubricant,
b 12
2411RA154 TG

1 Reinstalling a rewind spring that

has popped out
1
: Unscrew screws (1) and carefully
If the rewind spring pops out during
remove spring housing (2) –
rewind spring can pop out
installation, fit it in the fan housing 2
as follows:
4 3
– Remove any fragments of the old 1
spring 1

2411RA155 TG
: Check sealing lip (4) and rubber 5
seal on the inside of the spring 1
housing (2), replace spring
housing if necessary : Coat the sealing ring (3), sealing
lip (4) of spring housing and the
whole length of the starter post
: Examine sealing ring (3), replace
3443RA176 TG

with STIHL special lubricant,

if necessary
b 12

: Position spring housing (2) so

Installing new rewind spring : Arrange the rewind spring (1) as that the protrusion (5) is over the
shown in the illustration mount for the loop

: Insert outer anchor loop in the
recess (arrow) of the fan housing
3443RA174 TG
: Insert and tighten the screws (1)
– Reassemble remaining parts in
reverse order

– Lubricate replacement spring 1

with frame with a few drops of
2411RA156 TG

STIHL special lubricant before

installing it, b 12

: Position replacement spring with

: Fit the rewind spring (1) in a
frame in the fan housing and
circular fashion, working in
press into in the mount (arrow) –
clockwise direction
the outer anchor loop must be
over the mount for the loop (1)
– Hold the inserted loops securely
to prevent them slipping out
again.

54 GS 461
8. Antivibration elements

The front handle / tank housing and Installation

engine housing are connected by
vibration-damping spring and stop
buffers.
2
Damaged ring buffers must be
replaced as a matter of principle. 2

3443RA266 TG
1
8.1 Ring buffer fuel tank / 1 4 3 4

2411RA075 TG
clutch side

: Push ignition lead (1) slightly to

– Remove chain sprocket cover the side
: Orient ring buffer (1)
– 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

1 : Press ring buffer (1) into the hole – Examine the ring buffer, replace if
until the groove (arrow) necessary
completely encloses the ridge (2)
3443RA262 TG

– Check sealing plug on the tank

– Insert and tighten the screw housing / check carburetor
space, replace if necessary
: Pry out plug (1) – Press plug into the ring buffer as
far as it will go
Installation
– Reassemble remaining parts in
2
reverse order

8.1.1 Ring buffer fuel tank / 1

1
ignition side
3443RA263 TG

– Remove shroud, b 5.4

3443RA269 TG
2 2
: Remove screw (1) and prise out
ring buffer (2) : Align ring buffer (1) with the
tapered side facing the
– Examine the ring buffer, replace if crankcase and fit
necessary
– Make sure that the ignition lead is
seated in the guide and does not
become jammed

: Insert and tighten the screws (2)

GS 461 55
 8.1.2 Ring buffer guard / clutch
side

1
1

3443RA331 TG
2

2411RA079 TG
2 1

– Use STIHL press fluid to simplify
assembly, b 12
: Push the ring (1) onto the
sleeve (2) as far as it will go
2411RA076 TG
: Remove rubber ring (1) from stop
dome of the tank housing and
push through the hole (arrow) of
: Unscrew screw (1) and remove the crankcase
side plate (2)
– Check rubber ring, replace if
necessary

Installation

2
3443RA332 TG

2411RA077 TG

1 1 1

2411RA079 TG
– Fit tank housing on ring buffer – : Pry out plug (1)
the holes must line up

: Push sleeve (1) with ring into the

ring buffer, screw in screw (2) – Use STIHL press fluid to simplify
and tighten assembly, b 12

– Reassemble remaining parts in : Push rubber ring (1) through the

reverse order
2 hole (arrow) of the crankcase and
press as far as it will go onto the
stop dome of the tank housing
2411RA078 TG

Rubber ring must not become

1 jammed between the ring buffer and
tank housing.
: Remove screw (1) and prise out
ring buffer (2)

– Examine the ring buffer, replace if

necessary

56 GS 461
 : Push rubber ring (1) through the
hole (arrow) of the crankcase and
press as far as it will go onto the
stop dome of the tank housing

Rubber ring must not become

1 jammed between the ring buffer and
tank housing.

2411RA081 TG

2411RA083 TG
2 1 2

– Use STIHL press fluid to simplify : Remove screw (1) and prise out
assembly, b 12 ring buffer (2)
2
: Press ring buffer into the hole – Examine the ring buffer, replace if
with the smaller diameter (1) necessary 1
pointing towards the housing until

2411RA086 TG
the groove (arrow) is completely
flush with the ridge (2)

– Insert and tighten the screw

– Use STIHL press fluid to simplify
assembly, b 12
– Press plug into the ring buffer as
far as it will go
: Press ring buffer into the hole
1
with the smaller diameter (1)
– Reassemble remaining parts in 2411RA084 TG
pointing towards the housing until
reverse order
the groove (arrow) is completely
flush with the ridge (2)

8.1.3 Ring buffer guard / : Remove rubber ring (1) from stop
– Insert and tighten the screw
ignition side dome of the tank housing and pull
through the hole (arrow) of the
crankcase
– Remove guard, b 8.3

– Check rubber ring, replace if

necessary

Installation
1 2411RA087 TG
2411RA082 TG

Rubber ring (1) must be fitted

1 between the tank housing and
crankcase.
: Pry out plug (1)
1
2411RA084 TG

– Reassemble remaining parts in

reverse order

– Use STIHL press fluid to simplify

assembly, b 12

GS 461 57
8.1.4 Stop buffer on clutch side – Reassemble remaining parts in The conical peg must enclose the
reverse order hole completely on the ignition side.
– Remove tank housing, b 10.8.3
– Reassemble remaining parts in
8.1.5 Stop buffer on ignition reverse order
side

8.2 Handlebar
– Remove the ignition module,
b 6.2

1 – Remove tank housing, b 10.8.3

3443RA346 TG

1
1

2411RA089 TG
: Press out stop buffer (1) from the
outside inwards 1 2

– Examine the stop buffer, replace

if necessary : Remove screws (1) on the
2411RA088 TG bottom of the tank housing and
remove the support (2)
Installation
: Push the stop buffer (1) out

– Examine the stop buffer, replace

if necessary 1

1 2
Installation

3443RA352 TG
3443RA347 TG

: Align stop buffer so that the : Undo screws (1) and remove
peg (1) faces the opening (arrow) handlebar (2)
of the tank housing
3443RA349 TG

– Use STIHL press fluid to simplify Installation

assembly, b 12
: Push stop buffer into the mount
and press the peg (1) into the
opening until it completely
encloses the opening (arrow)
1
– Coat screws for fastening the
handlebar with Loctite, b 12
– Use STIHL press fluid to simplify
assembly, b 12
: Align the stop buffer (1) with the
smaller conical pegs (arrow)
facing the crankcase and press
into the hole by turning slightly

58 GS 461
 – Check guard, replace if
necessary

2
Installation

– Use STIHL press fluid to simplify

1 the following assemblies, b 12

2411RA090 TG

3443RA354 TG
1 2

: Fit handlebar (1) on the bottom of : Position handlebar (1) on the

the tank housing into the handle side handle mount (arrow) 2
mount (arrow)
: Screw in screws (2)
1
– Tighten all 4 screws
1 2

2411RA096 TG
8.3 Guard

: First, press the bottom stud (1),

– Remove side plate, b 8.1.2 then the top stud (2) completely
into the mounts
2411RA091 TG

2 1
: Orient support (1) on the bottom 1 2
of the tank housing so that it
engages with the recess (arrow)
in the tab (2)
2411RA093 TG

2411RA095 TG
: Prise out plug (1) and pull out
1 tab (2) : Press in tab (1) between the
housing fins and press the
1 plug (2) on the ignition side into
the opening (arrow) so that the
2411RA092 TG

profiles engage with each other

1
– Reassemble remaining parts in
: Screw in screws (1) on the reverse order
bottom of the tank housing
2411RA094 TG

: Pull guard (1) out of the mounts

(arrows) and remove

GS 461 59
8.4 Rubber buffers / support 8.4.1 Water hose Installation

2411RA099 TG
2411RA097 TG

1
1

: Push out rubber buffer (1) to the : Guide water hose (1) through the
side opening in the support (2)

– Examine rubber buffer, replace if : Fit hose clip (3) and push water
necessary hose (1) as far as it will go onto
the connector (arrow)

Installation

– Use STIHL press fluid to simplify 1 2

the following assemblies, b 12

1
2411RA080 TG

2411RA100 TG
: Apply a screwdriver to the hose
clips (arrow) and turn slightly to : Fit hose clip (1) and push water
open the clip hose (2) as far as it will go onto
2411RA098 TG

1 the connector (arrow)

: Remove water hose (1) at both
connectors and remove hose
: Push rubber buffer (1) with the clips
rubber tab into the guide until the
lug (arrow) protrudes – lug stops
the rubber buffer from sliding out

60 GS 461
 1 1
1

2411RA102 TG

: Push hexagonal socket wrench
SW 4 into the connector (1) and
unscrew connector (1)
– Push in hexagonal socket
wrench along the whole length of
the connector
2411RA105 TG
: Fit connectors (1), screw in with
hexagonal socket wrench SW 4
and tighten
– Push in hexagonal socket
wrench along the whole length of
the connector

– Pull out shut-off cock – Fit water hose, b 8.4.1

8.4.3 Support
4 2 3 1
1 – Remove support from handlebar,
b 8.1.2
2411RA101 TG

2411RA103 TG

: Align hose clips (1) on both

connectors and press the tabs
(arrows) together until they
engage – make sure hose is not
twisted when secured
: Check shut-off cock (1), unscrew 1
hose connection (2) if necessary,
replace sealing ring (3) and O-

2411RA106 TG
ring (4)
8.4.2 Shut-off cock

– Remove water hose, b 8.4.1 Installation : Apply a screwdriver to the hose

clip (arrow) and turn slightly to
open the clip.
2
: Pull water hose (1) from
connector
1
2411RA104 TG

: Slide shut-off cock (1) into the

mount on the support (2)

GS 461 61
 Installation

3 1
3 1

2411RA110 TG
2

2411RA108 TG
1 : Screw in the screw (1) and
tighten
: Position support (1) with the
tab (2) on the base of the rear – Fit water hose, b 8.4.1
handle (3) and fit
– Fit support on handlebar,
b 8.1.2

2
2411RA107 TG

: Unscrew screw (1), lift 1

support (2) in the area of the
shut-off cock (3) and push out to
the rear

– Examine the support, replace if

necessary
– Reconfigure shut-off cock,
rubber buffer and water hose if
necessary
2411RA109 TG

: 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

62 GS 461
9. Actuating levers

9.1 Master Control lever

1
The positions of the Master Control
lever are described in the 2
1
Instruction Manual. 2

9.1.1 Removal and installation

2411RA113 TG

2411RA115 TG
– Remove filter base, b 10.2

– Remove throttle rod, b 9.3
: Lift eyelet (1) of the short-circuit
wire over the guide (2) and pull
out
– Check the switch shaft, replace if
necessary
: Guide short-circuit wire (1) so
that it lies snug around the switch
shaft (2) and press or hook into
guides (arrows) – short-circuit
wire (1) must be snug against the
switch shaft (2)

2 Installation
2 3
2411RA111 TG

1 3 1 2
3
: Set the switch shaft (1) to "0"

2411RA116 TG
: Prise out switch shaft (1) on the 1 4
2411RA114 TG

bearing (arrow) and carefully pull

off from switch housing (2)
– Short-circuit wire (3) is still fitted
to switch shaft (1) and must not
be damaged
: Push eyelet (1) onto the peg (2)
so that the crimped side (arrow)
faces in
: Place eyelet (1) in guide (3)
: Orient switch shaft (1) so that the
lever (2) faces the carburetor
: Lift contact spring (3) slightly and
push switch shaft (1) with the
bearing journal (4) into the hole
(arrow) of the switch housing

1
2411RA112 TG

: Pull short circuit wire (1) out of

the guides (arrows)

GS 461 63
 2 9.2 Throttle trigger / trigger 3 2
interlock

– Remove air filter, b 10.1

– Open the throttle wide and hold,

2411RA117 TG
then unhook throttle rod from

3443RA390 TG
1 throttle trigger
1

: Position screwdriver at the tab (1) : Drive pin (1) out with punch (2)
and press switch shaft (2) into the and remove throttle trigger (3)
guide (arrow) until it engages with torsion spring

– Examine trigger interlock, throttle

1 trigger and torsion spring,
1 replace if necessary

2411RA120 TG
2 2 Installation

: Unscrew screw (2) and remove 1

handle molding (1)
2411RA118 TG

– The trigger interlock (arrow)

may pop out.

: Short-circuit wire (1) and ground

wire (2) must be between the fin
(arrow) and housing wall, push in

3443RA392 TG
completely if necessary
– Short-circuit wire (1) must be 2
routed below the ground wire (2)
1 : Hook the torsion spring (1) into
the throttle trigger (2)
– Note the installed position
3443RA389 TG

(arrow)

1 : Pull trigger interlock (1) out of the

bearing points (arrows)
2411RA119 TG

: 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

64 GS 461

1 2
3443RA394 TG
3 replace if necessary
: Insert throttle trigger (1) in the
handle so that the holes on the
throttle trigger and handle line up
: Center throttle trigger (1) with
punch (2) and drive in pin (3) until
it is equidistant on both sides
3 2
1
3443RA398 TG
: Press end of the torsion
spring (1) toward the handle
: Position trigger interlock (2) so
that the limit stop (3) engages in
the throttle trigger
: Hook the torsion spring (1) onto
the trigger interlock
: Press the trigger interlock (2) into
the bearing points (arrows) until it
clicks into place
The trigger interlock may pop out.
GS 461
: Turn throttle rod (1)
counterclockwise and unhook
from throttle trigger (2) of the
carburetor
2 – Remove throttle trigger with
bushing and baffle
1
3443RA399 TG
– Examine the individual parts,
: Hook handle molding (1) with the
Hook tabs (2) into the openings Installation
(arrow) and fit in position
– Insert and tighten the screw 2 1
– Open the throttle wide and hold,
then hook throttle rod into throttle
trigger – throttle trigger must only
turn if the trigger interlock is
pressed
3443RA401 TG
– Check correct functioning
– Press throttle trigger down
completely, the lever on the : Guide throttle rod (1) with the
carburetor must be at full throttle square part (arrow) from the
and must not move any further in bottom through the bushing (2)
open direction
– Reassemble remaining parts in
reverse order 1
9.3 Throttle rod
– Remove filter base, b 10.2
3443RA402 TG
– Remove handle molding, b 9.2
– Open the throttle wide and hold,
: Press studs (1) into the hole of
then unhook throttle rod from
the baffle
throttle trigger
2
1
3443RA400 TG
65
 1
1

2
2411RA122 TG

2411RA122 TG
3

: Push baffle (1) with bushing (2)
and throttle rod (3) over the studs
and position
: Push the bushing (1) into the
mount (arrow) and position
– Open the throttle wide and hold,
then hook throttle rod into throttle
trigger – throttle trigger must only
turn if the trigger interlock is
pressed

– Check correct functioning

1 – Press throttle trigger down
completely, the lever on the
carburetor must be at full throttle
3443RA404 TG

and must not move any further in

open direction

: Hook throttle rod (1) clockwise – Reassemble remaining parts in

into the lever (arrow) of the reverse order
throttle shaft

66 GS 461
10. Fuel system

10.1 Air filter : Pull hose (4) off connector

(arrow) and remove filter base (5)
Dirty air filters reduce engine power, via the stud bolts
increase fuel consumption and
make starting more difficult. The air 2
filter and auxiliary filter should be Installation
checked when there is a noticeable 1
loss of engine power.

2411RA127 TG
– Refer also to Troubleshooting, 1 3 3
b 3.6, b 3.7
3 : Guide flange (1) over the stud
– Loosen slotted nut and remove bolts (arrows) and position so
filter cover 2 that the stud bolt (2) faces
upwards

2411RA125 TG
– Pull off air filter and auxiliary filter
: Tightly screw on nuts (3)
– Check the air filter and clean or
replace if necessary – see Sleeve (1) must be in place and – Reassemble remaining parts in
Instruction Manual bushing (2) must engage in reverse order
baffle (3).
– Check auxiliary filter, replace if
necessary – the auxiliary filter 10.3 Carburetor
cannot be cleaned
– Open filler cap and drain fuel tank
– Reassemble parts in reverse 2
order
– Collect fuel in a clean container,
3 3 b1

10.2 Filter base

– Remove filter base, b 10.2
2411RA126 TG

4
– Remove air filter, b 10.1 1 – Remove baffle with throttle rod,
b 9.3
Switch shaft (1) must be set to cold
start. The fuel hose may only be removed
when the tank filler cap is open.
: Guide filter base (2) over the stud
5 bolts (3), push hose (4)
2 completely onto the connector
1 (arrow) and fit filter base (2)
1
2411RA123 TG

4
3

: Unscrew nuts (1) and pull off

flange (2)

Switch shaft (3) must be set to cold

start.

GS 461 67
 1 1
2

2411RA128 TG

2411RA130 TG

2411RA132 TG
1 2

: 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
are released : Press bushing (1) into the holes
of the handle housing until the
rubber strips fully protrude on the
opposite side
2 1
– Install filter base, b 10.2

2411RA128 TG – Install air filter, b 10.1

– Check correct functioning

2411RA129 TG

1 2
– Reassemble remaining parts in
reverse order
Fuel hose must be located in the
: Push out bushing (1) and pull off mount (arrow).
carburetor (2)
: When fitting, make sure that the
– Examine the carburetor and connectors are pushed into the
repair or replace it if necessary fuel hose (1) and impulse
hose (2)
– Check sleeve, remove and
replace if necessary – Install throttle rod and check
operation, b 9.3

Installation

1
3443RA064 TG

Washer (1) and sleeve (2) must be

in place.

68 GS 461
10.3.1 Leakage test
The tank vent must also be checked
and replaced if problems develop
with the carburetor or fuel supply,
b 10.7
The carburetor can be tested for
If this pressure remains constant,
the carburetor is airtight. However, if 2 1
the pressure drops, this may have
the following three causes:
1. The inlet valve is not sealing
1 1
(foreign objects in the valve
seat,

3443RA298 TG
leaks with the pump sealing cone of the inlet needle
is damaged or
0000 850 1300.
inlet control lever is sticking),
1
– Remove the carburetor, b 10.3 remove to clean,
b 10.4.2 or b 10.7.1 : Unscrew the screws (1) and
remove the end cover (2)
2. Metering diaphragm or gasket is
damaged, replace if necessary, If the gasket and diaphragm are
1 3
b 10.4.1 or b 10.7.1 stuck to the carburetor, they must
be removed very carefully
3. Pump diaphragm or
gasket damaged,
replace if necessary, b 10.4.3
2 or 1 2
b 10.7.1
3443RA296 TG

– After completing the test, slide

ring (1) to the left and vent the
: Push the fuel line (1) system, then disconnect fuel line
1110 141 8600 onto the double from elbow connector of

219RA213 TG
carburetor
connector (2)
0000 855 9200 and then push
onto the fuel port (3) – Install filter base, b 10.2
: Carefully separate the metering
– Reassemble remaining parts in diaphragm (1) and gasket (2)
reverse order
2
The diaphragm material is
subjected to continuous alternating
10.4 Repairing the carburetor stresses and eventually shows
signs of fatigue. In other words, the
10.4.1 Metering diaphragm diaphragm distorts and swells and
must be replaced.
3443RA297 TG

– Troubleshooting, b 3.6 – Examine the metering diaphragm

1 for signs of damage and wear,
– Remove the carburetor, b 10.3 replace the gasket.
– Push pressure hose of the pump
0000 850 1300 onto the double – Check sleeve, remove and
connector replace if necessary

: 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 69
Installation
1 2 1

1 1
2 1
1

3443RA302 TG

3443RA304 TG
3443RA300 TG

Note the order in which the
gasket (1) and metering
diaphragm (2) are installed.
: Align the gasket (1) and metering
diaphragm (2) so that the pins
(arrows) engage in the holes
: Fit and tighten screws (1) : Pull the inlet control lever (1) with
spindle (2) out of the groove in
– Check that the metering the inlet needle
diaphragm and gasket are
correctly seated, then tighten the The spring under the inlet control
screws crosswise lever may pop out.
– Push sleeve onto the connector
2 1
– Reassemble remaining parts in
reverse order

10.4.2 Inlet needle

1

3443RA305 TG
2 – Remove the metering
2 diaphragm,
b 10.4.1
3443RA301 TG

: Pull out the inlet needle (2)

: Take out and examine the

: Align the end cover (1) so that the spring (1), replace if necessary
connector (arrow) points towards
the choke shutter 1

: Align the end cover (1) until the

holes engage in the pins (2)
3443RA303 TG

: Unscrew the screw (1)

165RA348 TG

: The sealing cone of the inlet

needle must be replaced if a
circular indentation (arrow) is
visible on its tip.

70 GS 461
Installation

10.4.3 Pump diaphragm

1 1
– Troubleshooting, b 3.6

– Remove the carburetor, b 10.3

2
2

3443RA306 TG

3443RA310 TG
1

: Fit the inlet needle (1) : Carefully separate pump

diaphragm (1) and gasket (2)
: Fit spring (2) in bore 2
The diaphragm material is

3443RA308 TG
subjected to continuous alternating
stresses and eventually shows
1 2 3 signs of fatigue. In other words, the
: Unscrew the screw (1) and diaphragm distorts and swells and
remove the end cover (2) must be replaced.

– Examine the pump diaphragm for

If the gasket and pump diaphragm
signs of damage and wear,
are stuck to the carburetor, they
replace the gasket.
must be removed very carefully.
3443RA307 TG

– Inspect the fuel strainer for

contamination and damage,
clean or replace it if necessary.
: First fit the spindle (2) of the inlet
control lever (3) at the conical
seat (arrow) of the spring, then
slide the clevis on the inlet control 1
lever into the groove on the inlet
needle (1)
3443RA309 TG

Ensure that the spring locates on

the nipple of the inlet control lever.

3443RA311 TG
– Press the inlet control lever down : Carefully remove pump
and secure it with the screw. diaphragm with gasket

– Check that the inlet control lever

moves easily : Pull the fuel strainer (1) out of the
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 71
Installation 10.4.4 Adjusting screws

1 2
1

3 H L

3443RA314 TG
2 1 LA
3
3443RA312 TG

3443RA316 TG
3
: Position the end cover (1) on the
carburetor housing from below so
: Fit new gasket (1) so that the that the gasket and pump There are three adjusting screws on
contours line up with the end diaphragm remain secured to the the carburetor:
cover (2) and engage in the end cover
– Adjusting screws (1) and (2) with
pegs (3) mounted limiter caps
: Orient end cover (1) so that the H = High speed adjusting
tabs (arrow) are in the opposite screw (1)
direction to the starter shaft lever L = Low speed adjusting
screw (2)
LA = Idle speed adjusting screw (3)
1
2 If the carburetor setting can no
2 longer be adjusted, this may also be
due to the adjusting screws.
3443RA313 TG

2 The high speed screw H and low

speed screw L have limiter caps
1 which must be removed before
3443RA315 TG

removing the adjusting screws.

: Place pump diaphragm (1) onto
the gasket so that the tab (arrow)
is on the same position as with
the gasket and engages in the
peg (2)
Gasket and pump diaphragm are
now secured.
Always use new limiter caps.
: Move the end cover (1) back and – Remove the carburetor, b 10.3
forth slightly until the pegs on the
end cover engage in the holes in – See also Troubleshooting on the
the carburetor housing
carburetor, b 3.6
– Check that the pump diaphragm
and gasket are correctly seated

: Screw in the screw (2) and

tighten

– Reassemble remaining parts in

reverse order

72 GS 461
Low speed adjusting screw
1 3443RA317 TG
: Screw puller (1) 5910 890 4500
about 5 turns into the limiter cap
– Left-hand thread
Do not turn puller (1) any further
– Low speed adjusting screw Lcan
be damaged.
H L
2
3443RA318 TG
: Turn limiter cap with the puller in
a clockwise direction until the
ridge (2) or screw slot aligns with
the groove (1)
The dot on the limiter cap must be
lined up with the mark (arrow).
– Pull out limiter cap
– Unscrew low speed screw L
GS 461
1
3443RA320 TG
: Examine the tip (arrow) for signs
of damage or wear. Fit a new low
speed adjusting screw L if
necessary.
: Examine O-ring (1), replace if
necessary
– Turn the low speed adjusting
screw L in as far as possible
– Continue with the high speed
adjusting screw H
High speed adjusting screw
3443RA321 TG
1 : Examine the tip (arrow) for signs
: Screw puller (1) 5910 890 4500
about 5 turns into the limiter cap
– Left-hand thread
Do not turn puller (1) any further
– High speed adjusting screw Hcan
be damaged.
H L
2
3443RA322 TG
1
: Check alignment of limiter cap,
turn with the puller in an
anticlockwise direction until the
ridge (2) or screw slot aligns with
the groove (1)
The dot on the limiter cap must be
lined up with the mark (arrow).
– Pull out limiter cap
– Unscrew high speed adjusting
screw H
1
3443RA324 TG
of damage or wear. Fit a new high
speed adjusting screw H if
necessary.
: Examine O-ring (1), replace if
necessary
: Turn the high speed adjusting
screw H in as far as possible
– Continue with "Fitting the limiter
cap"
73
Fitting the limiter caps
1
3443RA325 TG
: Press new limiter caps (1) onto
the hole in the adjusting screw
until they engage the first position
(arrow) – do not push them down
fully
If screwdriver
5910 890 2304 is not available, the
basic setting must be made without
fitting the limiter caps.
– Make the "basic setting",
b 10.5.1
10.5 Carburetor adjustment
10.5.1 Basic setting
Only necessary if the high speed
adjusting screw H or low speed
adjusting screw L has to be
replaced or for cleaning and setting
the carburetor.
The basic setting must always be
made after removing the limiter
caps.
– Install carburetor and air filter
– The adjusting screws must be
pre-set and the new limiter caps
must be fitted
– Check chain tension, adjust if
necessary
74
– Examine the spark arresting 10.5.2 Adjustment
screen (present only in some
countries); clean or replace it if – Push screwdriver
necessary, b 3.7 or b 5.1 5910 890 2304 through the
bushing and pre-fitted limiter
– Check the air filter and clean or caps of the high speed adjusting
replace if necessary, b 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
tolerance range of ± 200 rpm.
2411RA124 TG
To allow the engine to warm up,
1 there are the following options:
1. with cut-off chain and
Adjusting screws on disassembled
guide bar if
carburetor shown for a better view.
water supply possible
: Push screwdriver (1)
2. without cut-off chain and
5910 890 2304 through the pre-
guide bar if
fitted limiter caps of the high
water supply not possible
speed adjusting screw H and low
speed adjusting screw L
– Start engine and allow to warm
up for 1 minute with load change.
: Unscrew high speed adjusting
screwH counterclockwise
by 1 1/2 revolution out of its
seat
: Unscrew the low speed screw L
counterclockwise
by 1 revolution out of its seat
– Continue with "Adjustment",
b 10.5.2
GS 461
Setting idle speed
Set idle speed with fitted guide bar
and cut-off chain.
For the short time it takes to set the
idle speed, the machine can be
used without water supply. During
the time it takes to set the idle
speed, the guide bar and cut-off
chain must be sufficiently coated
with STIHL multispray
– The cut-off chain must not run dry,
repeat the STIHL multispray
process if necessary
1. Turn the
low speed adjusting screw L
left or right to set the highest
speed
If the highest set speed is between
2900 1/min and 3100 1/min,
continue with step 3.
If the highest set speed is outside
of the speed range of 2900 1/min
and 3100 1/min, continue with
step 2.
2. With the
idle speed screw LA
set the speed to 3000 rpm
and start again with
step 1
3. With the low speed adjusting
screw L
set the speed to 2500 rpm
4. Unscrew high speed adjustment
screwH
clockwise
by 1 1/2 revolution out of
its seat
– Continue with "Securing the
limiter caps"
GS 461
– Check the air filter and clean or
replace if necessary, b 10.1
Standard setting
– Switch off the engine
3443RA329 TG
– Carefully turn the high speed
adjusting screwH
counterclockwise as far as
: Insert a suitable punch through possible, max
the holes (arrow) of the bushing 3/4 turn
and press the limiter caps fully
home – Carefully turn the low speed
adjusting screwL clockwise as far
Now the basic setting of the high as possible, max
speed adjusting screw H and the 3/4 turn, then back by 1/4 turn
low speed adjusting screw L has
been established and secured. Check running behavior:
The engine must accelerate well
when the throttle is opened and idle
10.5.3 Standard setting smoothly.
Setting the idle speed
– Adjust to standard setting
– Let the engine warm up
1
Engine stops when idling
3443RA299 TG
1 – Turn the idle speed screw LA
clockwise until the cut-off chain
runs as well, then
The limiter caps (1) must not be turn back by 1 1/2 turn
removed when making the standard
setting.
To avoid problems, the following Cut-off chain runs when idling
steps must be performed for all
settings: – Turn the idle speed screw LA
anticlockwise until the cut-off
– Troubleshooting, b 3.6 chain stops, then
turn back by 1 1/2 turn
– Check chain tension, adjust if
necessary
– Examine the spark arresting
screen (if installed); clean or
replace it if necessary, b 3.7 or
b 5.1
75
Erratic idling behavior, poor
acceleration
(despite low speed screw = 1/4)
Idle setting is too lean.
– Let the engine warm up
– Turn the low speed adjusting
screw L counterclockwise until
the engine runs smoothly and
accelerates properly.
The setting of the idle speed
screw LA must usually also be
adjusted whenever the setting of the
low speed adjusting screw L has
been corrected.
Correcting the carburetor setting
for use at high altitudes
If the engine does not run
satisfactorily, a minor correction
may have to be made.
– Check the standard setting
– Let the engine warm up
– Turn the high speed adjusting
screw H slightly clockwise
(leaner), but no further than the
stop.
The screws should be adjusted as
little as possible. The slightest
adjustment produces a tangible
difference in engine behavior.
If you make the setting too lean it
will increase the risk of engine
damage through lack of lubrication
and overheating.
After descending from a high
altitude, set carburetor setting
back to "Standard setting".
76
10.6 Intake elbow
1
A damaged intake elbow may lead
to impaired engine performance,
b 3.7.
– Troubleshooting, b 3.6 or
b 3.7
3443RA430 TG
– Remove shroud, b 5.4
– Remove the carburetor, b 10.3 : Loosen screw (1) and push hose
clip over intake elbow towards
tank housing
– Unscrew screws of ring buffer
and loosen tank housing,
b 10.8.3
1
2
1
3443RA431 TG
3443RA084 TG
: Pull intake elbow (1) off the
intake fitting (arrow)
: Remove washer (1) and
sleeve (2) – Examine intake elbow and
replace if necessary. The
slightest damage may lead to
impaired engine performance,
1 b 3.7
The mating surfaces must be in
2 perfect condition and without any
damage whatsoever. Parts with
damaged mating faces must be
replaced.
3443RA429 TG
: Press the manifold flange (1) out
of the tank housing (2) by hand in
the direction of the cylinder
: 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
Installation – Examine the impulse hose and
1 2 3 4 replace it if necessary,
– Fit intake elbow to cylinder,
b 5.5

3443RA101 TG
2

: Orient the manifold flange (1), –

3443RA438 TG
the openings (arrows) must rest 1
against the studs (2)
3443RA434 TG

2 : Fit washer (3) and push
– Apply STIHL press fluid to the
outside of the manifold flange,
b 12
: To pull in the manifold flange (1),
place a string (2) that is
approx. 15 cm long around the
manifold flange and feed through
the hole in the tank housing
– Coat new impulse hose on the
sleeve (4) into the opening of the conical outside with STIHL press
manifold flange (1) fluid, b 12
– Install the carburetor, b 10.3 : Push impulse hose (1) through
the hole (arrow) and press in until
– Reassemble remaining parts in the rubber lip encloses the hole
reverse order completely
10.6.1 Impulse hose

A damaged impulse hose may lead

1 to impaired engine performance.

– Remove the carburetor, b 10.3

3443RA439 TG
– Remove tank housing, b 10.8.3
1
2
2411RA133 TG

: Align impulse hose (1) so that the

flange with the rounded side
(arrow) faces upward
– Press tank housing against the
manifold and hold in place – Install tank housing, to do so,
push impulse hose on the
: Pull the manifold flange (1) connector, b 10.8.3
1
3443RA437 TG

through the hole with the ends of

the string (2) – Install the carburetor, b 10.3

– Remove the string – Reassemble remaining parts in

: Press impulse hose (1) out of the
tank housing in the direction of reverse order
the cylinder

GS 461 77
10.7 Tank vent
10.7.1 Testing
If problems develop in the
carburetor or fuel supply, the tank
vent must always also be tested and
replaced if necessary. Correct
functioning is determined by testing
the fuel tank with negative pressure
or gauge pressure via the fuel
suction hose.
– Open filler cap and drain fuel
tank, b 1
– Close the filler cap
– Remove the carburetor, b 10.3
Testing with negative pressure
1 2 4 least 20 seconds, the tank and
2411RA134 TG
3 and push hose onto connector of
: Push the connector (1)
0000 855 9200 with hose (2) into
the fuel suction hose
: Slide ring (3) to the left and
connect the pump (4)
0000 850 1300 to the hose (2)
– Create vacuum in fuel tank
Pressure is equalized via the tank
vent. A negative pressure must not
build up inside the tank.
– Clean the area around the tank
vent
– Replace the tank vent or tank
housing if necessary, b 10.7 or
b 10.8.3
78
Testing with gauge pressure : Check hose (1), remove if
necessary from connector of filter
base and replace
2
: Push new hose (1) onto
connector of filter base
2411RA135 TG
1
1
: Slide ring (1) to the right and
connect the pump (2)
0000 850 1300 to the double
2411RA137 TG
connector (arrow) – create
excess pressure in fuel tank
– Actuate the pump until the : Pry out the tank vent (1) via the
pressure gauge shows a mounting rib (arrow) – always
pressure of 0.5 bar. If this use new tank vent
pressure remains constant for at
tank vent are airtight. If the
Installation
pressure drops, the leak must be
located and the faulty part
– 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
tank vent
10.7.2 Removal and installation
– Reassemble remaining parts in
– Remove the air filter cover, reverse order
b 10.1
1
2411RA136 TG
: Pull the hose (1) off the
connector (arrow) on the tank
vent
GS 461
10.8 Fuel intake : Pull off pickup body (1) and Installation
examine it, replace if necessary
10.8.1 Pickup body

– Reassemble parts in reverse

1
Very fine dirt particles in the fuel can order
clog the pores of the filter. This
reduces the intake diameter and
fuel can no longer be delivered in
sufficient quantities. 10.8.2 Fuel hose

3443RA449 TG
Always check the fuel tank and – Open the filler cap
pickup body first if problems
develop in the fuel supply. – Remove the carburetor, b 10.3
– Troubleshooting, b 3.6 or – Use STIHL press fluid to simplify
b 3.7 – Remove pickup body, b 10.8.1 assembly, b 12

Clean the fuel tank if necessary. – Push the fuel suction hose (1)
into the hole in the fuel tank
– Open the filler cap and drain the
tank. : Align fuel suction hose (1) so that
the straight side (arrow) of the
– Fill a little clean gasoline into the flange faces the housing wall,
tank, close the tank and shake it then press fully into the hole
thoroughly. 1

3443RA446 TG
Do not damage wires of wiring
– Reopen the tank and harness.
empty it

: Pull the fuel suction hose (1) from

– Ensure that the fuel is disposed
the guide (arrow)
of correctly and without harming
the environment, b 1

– Open the filler cap 1

3443RA225 TG
1 2

: Push fuel suction hose (1) into

3443RA447 TG

the guide (arrow) and press

1 between the wires and the
collar (2) of the intake elbow
2411RA138 TG

– Feed through lever tool below the mount – fuel suction hose is
wires secured

: Use hook 5910 893 8800 to pull : Pry out the fuel suction hose (1)
and pull out of the inside of the
the pickup body (1) out of the fuel
tank tank

– Examine the fuel suction hose,

Take care not to overextend the fuel
replace if necessary
hose.

GS 461 79
 1 2 1 2

3443RA064 TG
2411RA139 TG

3443RA208 TG
: Use hook 5910 893 8800 to pull : Remove washer (1) and : Press out grommet (1) in the
the fuel suction hose (1) out of sleeve (2) direction of the cylinder and pull
the fuel tank out wiring harness (2) in the
direction of the cylinder
Take care not to overextend the fuel
suction hose. 1

– Fit the pickup body, b 10.8.1

2 1
– Close the filler cap

– Reassemble remaining parts in

3443RA429 TG

reverse order

2411RA140 TG
10.8.3 Tank housing : Press the manifold flange (1) out
of the tank housing (2) by hand in
the direction of the cylinder : Pull out the tank housing (1) and
– Empty the fuel tank, b 1
examine it, replace if necessary

– Remove the carburetor, b 10.3

Those parts of the old tank housing
1 which are not supplied with the new
– Remove the ignition module, tank housing must be reused – see
b 6.2 spare parts list.

– Unscrew the ring buffer screws, – Reconfigure the front handle,

"Ring buffer fuel tank / clutch b 8.2
side", b 8.1,
3443RA453 TG

"Ring buffer fuel tank / ignition – Reconfigure the switch shaft,

side", b 8.1.1, b 9.1
"Ring buffer guard / ignition side",
b 8.1.3, "Ring buffer guard /
– Pull tank housing out by approx. – Reconfigure the front handle,
clutch side", b 8.1.2
30 mm b 6.6

: Disconnect the impulse hose (1) – Reconfigure the interlock lever

from the connector (arrow) and throttle trigger, b 9.2

80 GS 461
Installation : Align impulse hose (1) so that the
1 2 flange with the rounded side
(arrow) faces upward
1

1
2

3443RA461 TG
3443RA455 TG
Grommet (1) must be pushed on.
2

2411RA133 TG
: Push rubber ring (1) with inside – Use STIHL press fluid to simplify
diameter 12 mm and rubber assembly, b 12
ring (2) with inside
diameter 18 mm onto the stop : Push wiring harness (2) through – Push tank housing towards the
domes (arrows) the opening and press cylinder and hold in place
grommet (1) into the opening
until it encloses the opening on : Pull the manifold flange (1)
both sides through the hole with the ends of
1 the string (2)
: Pull wiring harness (2) in until the
start of the protective tube is at – Remove the string
the fin (arrow)
2411RA141 TG

1
2

: Push tank housing (1) with the

narrow part (2) first between the
crankcase halves as far as it will
go onto the intake elbow
3443RA434 TG

: To pull in the manifold flange (1),

place a string (2) that is approx.
15 cm long around the manifold
flange and feed through the hole
in the tank housing
3443RA439 TG

GS 461 81
 1 2 3 4

2
3443RA101 TG

2411RA144 TG
2

: Orient the manifold flange (1), – The rubber rings (1) and (2) must
the openings (arrows) must rest be between the tank housing and
against the studs (2) the crankcase.

: Fit washer (3) and push – Insert and tighten the screws of
sleeve (4) into the opening of the the ring buffers,
manifold flange (1) "Ring buffer fuel tank / clutch
side", b 8.1,
"Ring buffer fuel tank / ignition
side", b 8.1.1,
"Ring buffer guard / ignition side",
1 b 8.1.3, "Ring buffer guard /
clutch side", b 8.1.2

– Reassemble remaining parts in

reverse order
2411RA143 TG

: Press tank housing (1) in the

direction of the cylinder until the
holes line up with the ring buffers

82 GS 461
11. Special tools

New special tools

No. Designation Part No. Use Remarks

1 Set of tools 3/8" G
- Insert 3/8“
- Die
2 Service tool kit AS
3 Support mounting kit
4 Piston support
5 Installing tool
5805 007 1001 Unrivet and rivet cut-off chain
Bursting of segments
Unriveting of tie straps
5910 007 2222 Removal and installation of
crankshaft (clutch side)
5910 850 1651 Clamping machine to assembly stand
5910 893 5300 Positioning piston
5910 893 9601 Removing and installing collar nuts on
chain sprocket cover

Existing special tools

No. Designation Part No. Use Remarks

1 Carburetor and crankcase 0000 850 1300 Test crankcase and carburetor for
tester leaks
- Connector 0000 855 9200 Testing carburetor for leaks
- Hose for leakage test 1110 141 8600 Testing carburetor for leaks
- Plug for leakage testing 1122 025 2200 Testing decompression valve for leaks
2 Sealing plate 0000 855 8106 Checking crankcase does not leak
3 Installing tool 0000 890 2201 Installation of starter rope guide
bushing
4 Clamping strap 0000 893 2600 Tensioning the piston rings
5 Locking strip 0000 893 5903 Blocking the crankshaft
6 Bit T 27 x 125 0812 542 2104 Removing and installing spline socket
head screws with electric or pneumatic
screwdrivers; tightening down screws
with torque wrench
7 Assembly drift 1108 893 4700 Removing and installing piston pins
8 Puller 1110 890 4500 Removing the flywheel
9 Setting gauge 1111 890 6400 Setting the air gap between ignition
module and flywheel
10 Press sleeve 1115 893 4600 Pressing in oil seal
(Ignition side)
11 Assembly tube 1117 890 0900 Hooking in clutch spring
12 Press sleeve 1118 893 2401 Pressing in oil seal
(Clutch side)
13 Assembly sleeve 1118 893 4602 Protection of the oil seal
(Clutch side)
14 Press arbor 1118 893 7200 Pressing in ball bearing (clutch side)

GS 461 83
No. Designation Part No. Use Remarks

15 Press arbor 1120 893 7200 Pressing in ball bearing (ignition side)
16 Combination wrench 1129 890 3401 Spark plug 1)
17 Service tool ZS 5910 007 2201 Removal and installation of
including crankshaft (ignition side)
Washer 5910 893 2103
– Washer 5910 893 2101 Pulling together the crankcase
-Screw sleeve 5910 893 2420 Installing crankshaft
18 Engine analyzer 5910 840 0200 Running motor diagnosis
STIHL MDG 1
19 Test flange 5910 850 4200 Leakage test
- Sleeves 5910 893 1701 Spacer sleeves for test flange
20 ZAT 4 ignition tester 5910 850 4503 Testing ignition system
21 ZAT 3 ignition tester 5910 850 4520 Testing ignition system
22 Torque wrench 5910 890 0302 Screw connections (0.5 to 18 Nm)
23 Torque wrench 5910 890 0312 Screw connections (6 to 80 Nm)
24 Assembly tool 12 5910 890 2212 Fitting hookless snap rings in piston
25 Screwdriver 5910 890 2304 Setting carburetor with limiter caps
- Setting washer 5910 893 6600 Supplement to screwdriver
5910 890 2304
26 Bit T 27 x 150 5910 890 2400 IS-P screws (4 mm)
27 Assembly hook 5910 890 2800 Detaching tension springs from clutch
shoes
28 Stud puller M 8 5910 890 3000 Screwing in and tightening rail
mounting studs
29 Assembly stand 5910 890 3101 Holding machine for servicing / repairs
30 Wiring tool 5910 890 4000 Installing electrical leads
31 Puller 5910 890 4400 Removing oil seals
- Jaws (with profile no. 3.1) 0000 893 3706 Extracting oil seal(s)
32 Puller 5910 890 4500 Pulling out limiter caps
33 Screw sleeve 5910 893 2409 for assembly tool kit AS 5910 007 2222
– Pulling together the crankcase
34 Stud puller, M8 5910 893 0501 Removing rail mounting studs
35 Socket, 13 mm, long reach 5910 893 2804 Removing and installing
decompression valve
36 Assembly hook 5910 893 8800 Removing pickup body

Remarks:
1) Use only for releasing.

84 GS 461
12. Service accessories

No. Designation Part No. Use

1 Multispray (400 ml) 0730 411 7000 Lubricating, protects against corrosion

2 Grease (225 g tube) 0781 120 1111 Oil seals, sliding and bearing points

3 STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in fan
housing

4 STIHL press fluid OH 723 0781 957 9000 Rubber elements, antivibration elements

5 STIHL multi-purpose grease 0781 120 1109 High-voltage output on ignition module

6 Medium-strength thread-locking 0786 111 2101

adhesive (Loctite 242)

7 High-strength thread-locking 0786 111 2109

adhesive (Loctite 270)

8 Very high-strength thread-locking 0786 111 2117

adhesive (Loctite 648)

9 Standard solvent-based Cleaning mating surfaces and the carburetor,

degreasant not containing any cleaning the crankshaft stub and tapers in
chlorinated or halogenated flywheel
hydrocarbons

GS 461 85
englisch / english
0455 761 0123. VA0.E12. Printed in Germany