Dolmar 109 HappyStart Service Manual Download | Manualshive

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DOLMAR GmbH • Postfach 70 04 20 • D-2000 Hamburg 70 • Germany

Service Manual

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DOLMAR 109
DOLMAR 110i
DOLMAR 111
DOLMAR 111i
DOLMAR 115i

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Summary of Contents for 109 HappyStart

Page 1: ...DOLMAR GmbH Postfach 70 04 20 D 2000 Hamburg 70 Germany Service Manual 2 93 DOLMAR 109 DOLMAR 110i DOLMAR 111 DOLMAR 111i DOLMAR 115i ...

Page 2: ...utch clutch drum 6 03 Oil pump 7 04 Ignition system 8 05 Starter assembly 10 06 Carburettor intake system 11 07 Cover system air filter 13 08 Vibration dampers handle 14 09 Fuel tank 15 10 Cylinder and piston 16 11 Crankcase crankshaft 17 12 Checking operations 18 Torques 19 DOLMAR GmbH ...

Page 3: ...H WSR 6F WSR 6F WSR 6F WSR 6F CHAMPION Elektrode gap mm 0 5 0 5 0 5 0 5 Fuel tank capacity Ltr 0 56 0 56 0 56 0 56 Oil tank capacity Ltr 0 28 0 28 0 28 0 28 Carb adjustment L H 1 1 1 1 1 8 1 1 1 1 1 8 Starter rope ø length mm 3 5 980 3 5 980 3 5 980 3 5 980 Saw chain Model 093 084 093 099 Normal profil Low profil Normal profil Low profil Cutter type Semi chisel Chisel Semi chisel Chisel Gauge inch...

Page 4: ...ft for piston pin 944 603 260 Sealing plate for leakage test of crankcase 944 603 020 944 603 030 Mounting for roler bearing crankcase 950 500 050 Puller for drive worm of oil pump 957 433 000 Snap ring pincer for external snap rings of starting system 946 101 010 Radial ring extractor 944 500 900 Mounting sleeve for radial rings 944 500 550 Setting gauge for ignition armature 944 500 890 4 DOLMAR...

Page 5: ...02 Replacing the brake band A damaged or defective brake band 8 and a damaged or defective tension spring must be replaced without delay 6 Caution Safety components 01 04 Fitting the hand guard When fitting the hand guard ensure that the compression spring 16 is installed correctly 01 02 Pretensioning the tension spring and the brake gate Following the installation of the brake band engage the ten...

Page 6: ...944 500 680 for clutch 3 and use spanner 4 no 944 500 690 for clutch 5 Caution Left hand thread 02 01 Differing clutch designs Clutch 5 for models 109 110 111 Clutch 3 for model 115 Clutch springs may be replaced as a complete set 6 or individually 7 02 03 Mounting the clutch drum and clutch Prior to installation lightly grease the clutch drum bearing and tighten the clutch using a torque of 35 Nm...

Page 7: ...sh 6 and check the pump plunger 7 for damage Replace defective parts and clean the housing prior to assembling 03 04 Removing the intake pipe Unscrew the chain guide plate 9 and withdraw the intake pipe 10 from the oil reservoir 03 03 Cleaning the intake pipe Withdraw the oil filter 11 prior to cleaning the intake pipe 10 When installing the oil filter pass the spring over the intake pipe against ...

Page 8: ...ards the rear over the ignition cable 6 04 02 Installing the spark plug terminal First pass the rubber cap 5 over the ignition cable Then engage the spring 7 in the existing hole of the ignition cable In case of new ignition cables press in the tip of the spring refer to arrow 04 03 Replacing the short circuiting switch To remove the short circuiting switch 8 first remove the filter hood carburett...

Page 9: ...ure in place using screws 3 For setting the air gap fit gauge 5 no 944 500 890 between fly wheel and armature Turn the N S marking of the flywheel towards the ignition armature 04 04 Replacing the short circuiting cable For the removal of the short circuiting cable 2 it is necessary to remove carburettor 7 and bottom part 8 When installing the cable ensure that it is not caught when fitting the bo...

Page 10: ...ment of the starter rope in the rope drum In case of this rope drum a knot prevents the starter rope from being withdrawn 05 02 Pretensioning the return spring After fitting the starting assembly completely withdraw the starter rope and hold it in this position It must now be possible to turn the rope drum by another 1 2 turn Reduce the pretensioning force when this is not possible 05 03 Replacing...

Page 11: ... the control lever The control lever 5 must be aligned so that its surface is in parallel with the carburettor body refer to arrow 06 03 Carburettor Tillotson control side Remove cover 5 control diaphragm 6 and seal 7 Unscrew the screw 8 The control assembly 9 comprises the inlet needle rocker arm spring and shaft 06 02 Removing the carburettor Remove filter cover and hood Separate the fuel pipe 1...

Page 12: ...w cover 5 with idling adjustment screw S Remove seal 6 and diaphragm 7 Carefully remove the fuel filter 8 for cleaning 06 05 Removing the injection valve Unscrew attachment screw 9 and remove the valve assembly 10 from the carburettor body Use new valve if the needle tip 11 is worn 06 08 Removing the intermediate flange The intermediate flange 12 can be taken out after the carburettor has been rem...

Page 13: ...er For this purpose remove lever attachment screw 12 and the three cover attachment screws 3 07 03 Cleaning the air filter Remove auxiliary filter 5 and unscrew the main filter 6 07 03 Cleaning the air filter To clean the main filter separate the upper 7 and the lower part 8 07 06 Removing the bottom part Following the removal of the carburettor the bottom 11 can be removed Integrated into the bot...

Page 14: ...tem design The fourth vibration damper 6 with pot 10 and catching band 4 is located between the supporting web 11 and the crankcase 08 01 Removing and fitting the handle For the removal of the handle unscrew 1 2 x tank screws lateral 2 2 x tank screws bottom 3 1 x vibration damper 4 catching band 08 02 Replacing the vibration damper MS Remove screws 7 8 and using a Torx spanner unscrew the screws ...

Page 15: ...ntilation valve 09 03 Replacing the fuel pipe For the removal of the fuel pipe 2 withdraw the intake head 5 and withdraw the fuel pipe from the tank When installing the fuel pipe ensure that the sealing face 6 rests close against the tank 09 04 Replacing the intake head Separate the intake head 5 from the fuel pipe Note The felt 8 can be replaced as an individual part 09 05 Removing the throttle l...

Page 16: ...eon pin 6 Remove the piston from piston rod 7 with bearing 8 10 01 Different cylinder design Die cast cylinder 9 for models 109 111 and piston with one piston ring Henkel cylinder 10 for models110 115 and two piston rings 10 01 Cylinder and piston marking In case of Henkel duct cylinders piston and cylinder are precision machined to form a single assembly The identification A B or C can be found o...

Page 17: ...ving the crankcase After removing the attachment screws separate the crankcase using a plastic hammer 11 03 Crankcase is divided into a magnet side MS 4 including the oil reservoir 4a and tank closing mechanism 11 03 Crankcase is divided into a clutch side KS 5 including the oil reservoir and the intake pipe 5a Note Housings supplied as spare parts are already fitted with needle bearings and radia...

Page 18: ...ection nipple 12 05 Checking the crankcase with cylinder For pressure testing the crankcase blank off the exhaust duct using flange no 944 603 030 Screw flange no 944 603 020 to the inlet duct 12 03 Checking carburettor and crankcase Pressure testing of the carburettor or crankcase is to be performed at max 0 5 bar 12 04 Use a torque wrench for tightening screwed connections Cylinder base screw cr...

Page 19: ...uffler Crankcase Cylinder Ignition Coil Turbular handle Rubber buffer Intermediate flange Carburattor Clutch hub Flywheel Spark plug 8 5 0 5 10 0 1 0 10 0 1 0 6 0 1 0 2 7 0 3 2 0 0 2 5 0 0 5 35 0 0 5 25 0 5 0 25 0 5 0 19 DOLMAR GmbH Torques ...

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