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Makita DCS3500, Repair Manual, Page: 28 / 32

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Makita DCS3500 Repair Manual Download Page 28

 

 

 

   

 

 

 

 

 

 

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Reparaturanleitung PS-4600 / PS-5000 

    

 

 

 

 

 

 

 

 

 

 

 

 

 

       28  

Repair manual DCS3500 / DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

13  TORQUES

 

Fastener

 

Part No.

 

Size 

Qty. 

Torque

 

Crankcase sides

     

Cylinder on crankcase 
Carburetor bottom on crankcase 
Muffler on cylinder 
Front shell to muffler 
Front shell to cylinder 
Carburetor / intake manifold in carburetor flange 
Intake manifold on carburetor bottom 
Intake manifold to hood 
Oil pump to crankcase 
Oil pump cover to crankcase 
Clutch to crankshaft 
Transmission cover chain tensioner to 
crankcase 
Mounting bolt in bar flange 
Mounting bolt in bar flange 
Sprocket guard mounting 
Chain brake cover 
Ignition mounting in crankcase 
Flywheel nut fastening 
Starter housing to crankcase 
Hood 
Handguard bearing to magneto side 
Grip/rear handle to tank 
Front handle on tank, side 
Front handle on tank, bottom 
Front handle side cover on tank 
Damping spring fastening on cylinder 
Damping spring / tank, mag. side rear 
Damping spring / tank, cyl. side front 
Damping spring cylinder / handle side cover 
Damping spring / crankcase, mag. side 
Damping spring / crankcase, cyl. side 
Damping spring / crankcase, cyl. side 
Spark plug 
Pawls to magnet wheel 
Mounting bolt TLC

 

908.405.205 
908.405.205 
908.005.165 
908.005.165 
908.005.165 
908.305.405 
908.004.405 
913.455.164 
913.455.164 
908.005.165 
908.005.165 

--- 

 

915.135.100 
195.232.010 
195.232.020 
923.208.004 
908.105.126 
908.805.205 
920.308.024 
908.005.165 
908.005.165 
908.005.165 
913.455.164 
913.455.164 
913.455.164 
913.455.164 
908.005.165 
913.455.164 
913.455.164 
913.455.164 
908.005.165 
908.005.165 
908.005.165 
965.603.021 
170.166.041 
195.232.040

 

M 5 x 20 Torx 

M 5 x 20 Torx with lock teeth 

M 5 x 16 Torx 
M 5 x 16 Torx 
M 5 x 16 Torx 

M 5 x 20 x 40 Torx 

M 4 x 40 Torx 

5,5 x 16 Torx 
5,5 x 16 Torx 

M 5 x 16 Torx 
M 5 x 16 Torx 

M 12 x 1 L with assembly wrench for centrifugal clutch 

 

BZ 3,5 x 9,5 

M 8 SK 6 / M8 

M 8 SK 6 / M8 x 1 

M 8, SW 13, 6KT-nut with flange 

M 5 x 12 Torx 
M 5 x 20 Torx 

M 8 x 1 / SW 13 

M 5 x 16 Torx 
M 5 x 16 Torx 
M 5 x 16 Torx 

5,5 x 16 Torx 
5,5 x 16 Torx 
5,5 x 16 Torx 
5,5 x 16 Torx 

M 5 x 16 Torx 

5,5 x 16 Torx 
5,5 x 16 Torx 
5,5 x 16 Torx 

M 5 x 16 Torx 
M 5 x 16 Torx 
M 5 x 16 Torx 

M 14 x 1,25 / SW 19 

-- 
-- 

 

6 x 
4 x 
2 x 
2 x 
2 x 
1 x 
2 x 
1 x 
1 x 
1 x 
1 x 
1 x 

 

1 x 
2 x 
1 x 
2 x 
2 x 
2 x 
1 x 
4 x 
3 x 
1 x 
1 x 
2 x 
2 x 
2 x 
1 x 
1 x 
1 x 
1 x 
1 x 
2 x 
2 x 
1 x 
2 x 
1 x 

10 +/-1 
12 +/-1 

5 +/-0,5 

8 +/-1 
8 +/-1 
8 +/-1 
3 +/-1 
3 +/-1 
5 +/-1 
5 +/-1 
5 +/-1 

35 +/-2,5 

 

1,5 +/-0,2 

15 +/-1 
15 +/-1 

1 +/-0,5 
5 +/-0,5 
5 +/-0,5 

25 +/-1 

5 +/-0,5 
5 +/-0,5 
5 +/-0,5 

3 +/-1 
5 +/-1 
5 +/-1 
3 +/-1 

5 +/-0,5 

5 +/-1 

5 +/-0,5 
5 +/-0,5 
5 +/-0,5 
5 +/-0,5 
5 +/-0,5 

15 +/-5 

8 +/-1 

10 +/-1 

Summary of Contents for DCS3500

Page 1: ...500M MEA4300G MEA4300L www dolmar de Repair Manual Caution Before doing any maintenance or service work the combination switch must be engaged in the service position in order to prevent unintended st...

Page 2: ...oting 4 00 Special tools 5 7 01 Sprocket guard Chain tensioning system 8 02 Clutch drum with chain sprocket 9 03 Chain brake Guide bar bolt 10 11 04 Clutch 12 13 05 Oil pump 14 06 Starter 15 07 Igniti...

Page 3: ...5 NGK BPMR 7A NGK CMR7A 5 Electrode gap mm 0 5 0 5 or spark plug Typ BOSCH WSR 6F CHAMPION RCJ 6Y BOSCH WSR 6F CHAMPION RCJ 6Y Fuel consumption at max load per ISO 7293 kg h 0 79 0 96 Specific consump...

Page 4: ...der or piston rings defective Spark plug does not seal Spring in starter broken broken parts inside the engine Engine speed gets stuck Multiple systems Engine speed about 4 500 6 000 rpm Carburetor to...

Page 5: ...862 T grip 100 mm 944 500 861 2 Mandrel Disassembly mandrel for tapping out the flywheel without damage to the crankshaft thread 944 500 880 3 Setting gauge Gauge for measuring the gap between flywhee...

Page 6: ...g and assembling the centrifugal clutch 944 500 590 8 Pressure gauge Pressure guage for checking the carburetor fuel valve 956 004 000 9 Tachometer Electronic tachometer for measuring the engine speed...

Page 7: ...epair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L 14 15 00 SPECIAL TOOLS 14 Sealing plate For sealing intake side 944 603 020 15 Sealing...

Page 8: ...ed Chain tensioner Carefully take the chain guide cover off the guide bar bolts Unscrew 4 screws and remove the spike bar and the cover Chain tensioner function An angled worm drive converts the turns...

Page 9: ...hain sprocket 2 for damage and wear Important customer information Before installing a new saw chain always check the condition of the chain sprocket A worn chain sprocket will damage a new saw chain...

Page 10: ...Pos 12 disengage the brake band spring 3 1 2 3 03 CHAIN BRAKE GUIDE BAR BOLT Removing the brake band CAUTION Wear protective gloves to prevent cuts Remove the sprocket guard bar and chain Remove the c...

Page 11: ...ing the guide bar bolt Screw two nuts onto the bar bolt and counterlock them Unscrew the bar bolt Assembly Apply Loctite 243 980 009 000 to the guide bar bolts and turn them all the way in 4 5 6 7 03...

Page 12: ...the clutch and use a socket wrench 5 to turn in the direction of the arrow left hand thread to loosen and remove the clutch Turn the clutch over and remove the disc The flyweights can now be pushed of...

Page 13: ...tarter in order to prevent damage to the starting ratchets 04 CLUTCH Inserting the flyweights Hook the springs as shown in the illustration Then press the flyweights onto the guide To do this first pu...

Page 14: ...ng screw in stop positions 2 or 3 not in one of the outer stops Removing the oil tank vent Note The ventilation valve must be pulled out It cannot be knocked into the tank 1 2 3 4 A 1 2 5 3 4 6 8 7 9...

Page 15: ...hile turning slightly counter clockwise Insert and tighten screw 5 Tension the return spring clockwise Turn the return spring about 6 turns with the aid of the cable which should be pressed into the g...

Page 16: ...nce two stroke oil Adjust spark gap Wash spark plug in acetone Do not sandblast If necessary replace spark plug Eliminate cause wrong carburetor setting too much oil in fuel frequent short operations...

Page 17: ...w the mandrel all the way down Leave about 2 mm between the mandrel and the flywheel Hold the machine in one hand or place on a soft surface and knock the flywheel loose with a tap on the mandrel CAUT...

Page 18: ...1 can now be taken up and off 2 3 4 5 6 7 8 1 12 11 10 9 13 14 15 16 07 IGNITION SYSTEM Pull short circuit wire 15 Unscrew 2 screws on ignition armature 14 Remove ignition armature and wire Installing...

Page 19: ...carburetor as possible in order to prevent the wire from touching the cylinder Note Do not twist the fuel line during assembly Note If replacing the foam 10 in the carburetor base make sure the posit...

Page 20: ...bent replace the diaphragm and gasket Check control diaphragm If control diaphragm is bent or torn or there is obvious wear at the button 8 If it does not return to its original position when pulled...

Page 21: ...orx screwdriver chap 00 pos 1 and remove cushion spring Spring 3 Remove starter housing see chap 06 and hood see chap 07 Loosen and remove screws with Torx screwdriver chap 00 pos 1 Pull out cushion s...

Page 22: ...h the lever onto the hinge iwth the slot The throttle lever must be turned by 180 to do this The throttle lever block 4 can easily be pushed through the diagonals on the seat The spring is engaged in...

Page 23: ...pull off the fuel nipple inside the tank Fuel lines 5 can be pulled off the fuel nipple Fuel line length Return L 118 mm dia 2 5 5 5 Supply L 93 mm dia 5 5 3 Carefully lever out fuel nipple 8 with a s...

Page 24: ...and unscrew the fastening bolt from the cylinder To seal off the intake side install the sealing plate 2 chap 00 pos 14 in the place of the carburetor Connect the over underpressure pump to the connec...

Page 25: ...e possible to fully identify the leak If pressure remains steady in the crankcase after shutting off the oil line hole for example with a rubber stopper see chap 05 it is an indication that there is a...

Page 26: ...assembly tool chap 00 pos 6 Remove spring ring 5 with needle nose pliers Assembling the cylinder and piston Use a new gasket Note The protuberance on the gasket must point towards the induction side B...

Page 27: ...case to 150 160 C using a hot air blower or in an oven Evenly apply Loctite 620 to the outer ring of the bearing on the crankshaft and insert into the heated housing without further pressure Note Befo...

Page 28: ...plug Pawls to magnet wheel Mounting bolt TLC 908 405 205 908 405 205 908 005 165 908 005 165 908 005 165 908 305 405 908 004 405 913 455 164 913 455 164 908 005 165 908 005 165 915 135 100 195 232 01...

Page 29: ...___ Reparaturanleitung PS 4600 PS 5000 29 Repair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L NOTES...

Page 30: ...___ Reparaturanleitung PS 4600 PS 5000 30 Repair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L NOTES...

Page 31: ...___ Reparaturanleitung PS 4600 PS 5000 31 Repair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L NOTES...

Page 32: ...ng PS 4600 PS 5000 32 Repair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L Makita Werkzeug GmbH Postfach 70 04 20 D 22004 Hamburg Germany F...

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