Repair Manual

PS-35 C

PS-35 C TLC

Caution:

Before doing any maintenance or service work, the combination switch must be in STOP position, in order to prevent unintended starting by the easy start system!

CONTENTS

Page

09

10

11

12

13

06

07

07

08

00

Technical data ...................................................................................................................................................................................... 3

Special tools .................................................................................................................................................................................... 4 - 5

01 Sprocket guard / Chain tensioning system .......................................................................................................................................... 6

02 Clutch drum with chain sprocket .......................................................................................................................................................... 8

03 Chain brake .................................................................................................................................................................................. 9 - 10

04 Clutch ........................................................................................................................................................................................... 11 - 12

05 Oil pump ............................................................................................................................................................................................. 13

Starter ................................................................................................................................................................................................. 14

Ignition system (trouble-shooting) ....................................................................................................................................................... 15

Ignition system ............................................................................................................................................................................ 16 – 17

Carburetor ................................................................................................................................................................................... 18 – 20

Vibration damper ................................................................................................................................................................................ 21

Tank ............................................................................................................................................................................................ 22 – 23

Cylinder / Piston ................................................................................................................................................................................. 24

Cylinder / Piston / Crankcase ............................................................................................................................................................ 25

Torques .............................................................................................................................................................................................. 26

Notes ................................................................................................................................................................................................. 27

Repair Manual PS-35 2

TECHNICAL DATA

Stroke volume

Bore

Stroke

Max. power at speed

Max. torque at speed

Idling speed / max. engine speed with bar and chain

Clutch engagement speed

Sound pressure level at the workplace L pA eq

Sound power level L

WA, Fl + Ra

per ISO 22868 1) 3)

per ISO 22868 2) 3)

Vibration acceleration a hv, eq

- Tubular handle

per ISO 22867 1) 3)

- Rear handle

Carburetor

Ignition system

Spark plug or spark plug

Electrode gap

Fuel consumption at max. load per ISO 7293

Specifi c consumption at max. load per ISO 7293

Fuel tank capacity

Chain oil tank capacity

Mixture ratio (fuel/two-stroke oil)

- when using DOLMAR oil

- when using Aspen Alkalyt (two-stroke fuel)

- when using other oils

Chain brake

Chain speed at max. power

Sprocket pitch

Number of teeth

Chain type

Pitch / gauge

Guide bar, length of a cut

Guide-bar type

Weight (fuel tank empty, without chain, guide bar and accessories)

1) Figures derived in equal part from idling, full-load and racing speed.

2) Figures derived in equal part from full-load and racing speed.

3) Uncertainty (K=).

Repair Manual PS-35 cm 3 mm mm kW / 1/min

Nm / 1/min

1/min

1/min dB(A) dB(A) m/s 2

Type m/s 2

Type

Type

Type mm l l kg/h g/kWh m/s inch

Z inch / (mm) cm kg

PS-35 C

35

38

30,6

1,7 / 10.000

2,0 / 7.000

2.800 / 12.800

4.100

102,6 / K pA

= 2,5

109,8 / K

WA

= 2,5

PS-35 C TLC

4,9 / K = 2

5,0 / K = 2 membrane carburetor electronic

NGK CMR6A

-

0,5

0,68

500

0,40

0,29

50 : 1 / 100: 1 (EXTRA)

50 : 1 (2%)

50 : 1 (quality grade JASO FC or ISO EGD) engages manually or in case of kickback

18,9

3/8

6 see the spare-parts list

3/8 / 0,050 (1,3) / 3/8 / 0,043 (1,1)

30, 35, 40 see the spare-parts list

4,4 4,5

3

00 SPECIAL TOOLS

Repair Manual PS-35

4

1 2

5 6

3

7

1 Torx screwdriver

Grip

T-grip 200 mm

T-grip 100 mm

944.500.860

944.500.862

944.500.861

2

Mandrel

Disassembly mandrel for tapping out the fl ywheel without damage to the crankshaft thread 944.500.880

3 Setting gauge

Gauge for measuring the gap between fl ywheel and armature 944.500.891

4 Torque wrench

3/8” Drive socket

Bit 152 mm

Bit 49 mm

Torque wrench 3/8” Drive

944.500.864

944.500.865

944.500.866

950.230.000

5 Piston stop wedge

Wedge for blocking the engine through the exhaust port 944.602.000

6 Assembly and disassembly wrench

Wrench for disassembling and assembling the centrifugal

clutch 944.500.695

7 Tachometer

Electronic tachometer for measuring the engine speed of

2- and 4-stroke engines 950.233.220

4

00 SPECIAL TOOLS

8

Repair Manual PS-35

12

9

13

10

14

11

15

8 Needle-nose pliers

Various assembly/ disassembly tasks

9 Disassembly hook

Removal/installation

Brake band spring

944.603.400

950.237.000

10 Over/underpressure pump

For checking sealing of

radial rings and gaskets 957.004.001

11 Sealing plate

For sealing intake side 944.603.040

12 Sealing plate

For sealing exhaust side

13 Ignition tester

Checking the ignition

14 Mounting tool

Bearings on crankshaft

15 Radial ring puller

13 mm radial ring puller

Spindle

944.603.140

950.233.230

944.500.903

(944.500.871)

(950.203.020)

5

01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM

2

1

Remove the sprocket guard, bar, and chain.

Chain tensioner

Carefully pull the chain guide plate off the front bar pin 1 .

Chain tensioner function

An angled worm drive converts the turns of the adjustment screw 2 to forward or backward motion of the tensioning pin 3.

4 3

If necessary, turn adjusting screw 2 clockwise, until the fastening screw 4 is accessible.

Unscrew the fastening screw and pull the chain tensioner up and out.

Assembly

Grease spindle and worm gear with multipurpose grease (944.360.000).

Repair Manual PS-35 6

01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM

5 6

7

10

8

9

14

TLC

15

13

12

11

4

3

2

Disassembly

Folding handle

Remove the sprocket guard, guide bar and chain.

Fold up folding handle 1.

Using a small screwdriver, carefully pry the plastic ring 2 up out of the sprocket guard.

Pull folding handle 1 out of the sprocket guard.

Remove spring 3 and locknut 4.

Chain tensioner

Unscrew bolt 5 and remove chain guide plate 6.

Unscrew bolt 7.

Remove cover 8, locking bolt 10 and clamping nut 9.

Unscrew bolt 11 and remove it and washer 12.

Remove tensioning handle 13 and driver 14.

Note: Do not misplace spring with ball 15.

Assembly in reverse order.

Installing the folding handle

Insert locknut 4 with spring 3 into the sprocket guard.

Press the carrier with folding handle 1 into the sprocket guard, making sure it engages with locknut 4.

Insert plastic ring 2 into the sprocket guard.

1

Repair Manual PS-35 7

02 CLUTCH DRUM AND CHAIN SPROCKET

Remove the sprocket guard, bar, and chain.

Release chain brake.

Remove the circlip 3 with a blade screwdriver.

Remove washer 2.

3

2

1

Clutch drum with sprocket and needle bearing

Check the chain sprocket 1 for damage and wear.

Check the clutch drum needle bearing for wear and damage.

Note: If using a new clutch drum, lubricate the needle bearing.

Check the inside of the clutch drum for damage and wear.

Replace the clutch drum if damaged or worn.

Note: Always use a new circlip 3

(927.306.000)!

Repair Manual PS-35 8

03 CHAIN BRAKE

1 2 1

3

4

5

Removing the brake band

CAUTION: Wear protective gloves to prevent cuts!

Remove the sprocket guard, bar, and chain.

Remove the clutch drum, see Chapter 02.

Push the hand guard forward to engage the chain brake. This tensions the brake band spring.

Unscrew screws 1 and remove the cover 2.

Lift the brake band 3 upward and turn it out of the disengagement mechanism 4.

Secure the chain saw from slipping (vise).

Using the disassembly hook (Chap. 00, Pos.

9), disengage the brake band spring 5.

Repair Manual PS-35 9

03 CHAIN BRAKE

10 9 7 8 6

Removing the hand guard and disengagement mechanism

Remove the starter. See Chap. 06.

Unscrew the handguard screw on the fan side.

Remove the circlip 6.

Lift the spacer plate 7 over the pin 8, push it back a little, and remove it from pin 9.

Remove the bushing from pin 8 and 9.

Pull the disengagement mechanism off the shafts in parallel.

Remove the muffl er. See Chap. 04.

Disengage the fan-side handguard arm towards the muffl er.

Pull the handguard off pin 9 using light backand-forth motions.

Note: When reassembling, always use a new circlip 6 (927.304.000)!

Install the handguard in the reverse order.

Make sure that the handguard guide 10 is not unhooked. If necessary, push it back into position with a screwdriver (about 4 mm from pin 9). The handguard can only be assembled when the rest piece is in this position.

Assemble the disengagement mechanism, brake band, and brake band spring in the reverse order.

10 ca. 4 mm

Repair Manual PS-35 10

04 CLUTCH

2 1

3

Disassembly

CAUTION: To prevent cuts, wear protective gloves!

Remove the sprocket guard, bar and chain.

Pull the handguard towards the front handle to release the chain brake if necessary.

Remove the clutch drum, see Chapter 02.

Remove the muffl er. To do this, unscrew the 3 screws 1 and remove the upper muffl er half 2.

Caution: If a catalytic converter is being used, the muffl er will be very hot after operation!

Move piston to bottom dead centre (visible through the exhaust opening).

Press the piston stop wedge 3 (cap. 00, pos.

5) into the exhaust opening.

Position of gasket and cooling plate for muffl er assembly:

4 5

Insert wrench 4 (Chap. 00, Pos. 7) into 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.

Remove the guide washer and spacer washer.

The fl yweights can now be pushed off the guide axially in one direction.

Repair Manual PS-35 11

04 CLUTCH

Inserting the fl yweights

Hook the springs as shown in the illustration.

The press the fl yweights onto the guide. To do this, fi rst push on one fl yweight, then put on the second fl yweight.

Press the fl yweights all the way onto the guide.

CAUTION: Note the position of the springs.

Do not replace springs individually! If a spring breaks or is fatigued, all two springs must be replaced.

The illustration shows the inside of the clutch.

Installing the clutch

Install the clutch with the arrow marking point outside.

Torque: 35 ± 2.5 Nm

CAUTION: Before installing the clutch, disassemble the starter (see chap. 06), in order to prevent damage to the starting catches.

Repair Manual PS-35 12

05 OIL PUMP

1

A

4 3 2

General

The oil pump is driven by the drive worm gear

1 on the crankshaft.

This gear engages the oil pump piston 3.

Consequently, the oil pump operates only when the engine is on.

The oil fl ow rate can be adjusted with adjusting screw A:

• Turn right for more oil

• Turn left for less oil

Disassembly

Remove the clutch drum and clutch, see chapter

04. Remove brake band, see chapter 03.

Move the drive worm gear 1 gently back and forth and work it off the shaft.

Pull the oil pressure line 2 from the oil pump.

Unscrew screw 4 and remove the oil pump.

Repair Manual PS-35

7

1

A

5

3

6

8

9

2

The suction line 5 remains in the crankcase.

It extends into the oil tank. To remove it, carefully pull on the connection to the oil pump.

Removing the oil pump

Push the adjusting screw A up against the spring pressure and turn it until the pin 6 goes into the assembly slit 6. If necessary press the supply piston 7 in somewhat.

Note: When assembling put the adjusting screw A counterclockwise to stop.

Removing the oil tank vent

Note: The ventilation valve 8 must be punched into the tank.

Press in a new valve about 2 mm deep under the housing surface.

Make sure that the ventilation channel 9 is free of deposits. Clean if necessary.

13

06 STARTER

1 2

Disassembly

Unscrew three screws 1.

Remove fan housing 2.

Remove air guide 3 from fan housing.

Detension the return spring.

Injury hazard! Unscrew screw 5 only after detensioning the return spring!

Unscrew screw 5 and remove cam 6 and spring 7.

Pull off the cable drum 8.

Carefully turn the fan housing over and pull the return spring cassette 9 out of the fan housing.

Caution! The return spring can jump out of the plastic cassette! Always wear protective goggles and gloves!

Repair Manual PS-35

8

9

5

6

7

3

10

4

If the spring pops out, put it back into the plastic housing as shown in the schematic.

Assembly

Note: If installing a new return spring cassette, grease it on the spring side.

Carefully insert new return spring cassette 9.

Lightly grease the surface of the spring and spring cassette with multipurpose grease

(944.360.000).

Thread in a new starter cable (dia 3.5 mm /

1/8“, length 900 mm / 35.4“) as shown in the illustration, tie a knot in both ends, and tighten both knots.

Put on the cable drum 8 and turn it slightly until the return spring engages.

Insert spring 7 in the cam 6 and place them together in the cable drum 8 while turning gently counter-clockwise until they engage.

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 gap in the cable drum.

Place the air guide 3 in the fan housing and make sure the three recesses 4 engage.

Pull the opening 10 on the fan housing over the pin on the hood.

Position the fan housing correctly on the saw, press against it slightly, and pull the starter handle until the starter catches.

Tighten screws 1.

14

07 IGNITION SYSTEM (TROUBLE-SHOOTING)

Is the spark plug dry and properly installed?

yes

Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug?

Is there carbon black on the electrodes?

no

Is the spark gap correct? (should be 0.5 mm) yes

Is the spark plug oily or does it have carbon deposits on it?

no

Install ignition testing lamp.

Or unscrew the plug and use insulated pliers to hold it against the cylinder with the spark plug can firmly on.

Caution: Do not hold the spark plug directly against the hole. Detonation hazard!

Pull the starting cable smartly. Is there an ignition spark?

yes

Is there damage to the insulation of the high-voltage cable or the ignition cable, or to the wires themselves?

no

Is the gap between the flywheel and the ignition module outside of the 0.25-0.3 mm range?

Is the gap uneven? Has the flywheel worn against the ignition module?

no

Remove flywheel and check. Is the flywheel damaged?

Is the positioning key damaged?

no

Continue with troubleshooting in fuel system (tank, fuel hose, carburetor).

no yes no yes no no no yes no yes

Dry spark plug connector and fasten firmly to spark plug.

Replace spark plug. Use ONLY a spark plug approved by DOLMAR.

See operating manual! Otherwise the ignition module might be damaged.

Eliminate the causes for carbon deposits on electrodes (bad two-stroke oil, wrong mix, defective air filter, check carburetor adjustment).

Use DOLMAR high-performance 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.

Replace spark plug and check ignition module for corrosion, if necessary replace.

Has the defect been remedied?

Check radial play of drive shaft, and repair if needed.

Replace ignition module if traces of overheating become visible.

Adjust gap between flywheel and ignition module correctly.

Replace flywheel. Before installation wipe cone seat at drive shaft and flywheel with acetone or alcohol to remove any grease.

Tighten fastening nut to the correct torque! Has the defect been remedied?

no

Replace ignition module. Has the defect been remedied?

Repair Manual PS-35 15

07 IGNITION SYSTEM

Removing the fl ywheel

Remove starter see chap. 06.

Block the piston, see chap. 04.

Loosen the nut in the direction of the arrow and remove it along with the washer.

Screw the disassembly mandrel (chapter 00 pos. 2) onto the threaded end of the shaft.

Do not screw the mandrel all the way down.

Leave about 2 mm between the mandrel and the fl ywheel.

Hold the machine in one hand or place on a soft surface, and knock the fl ywheel loose with a tap on the mandrel.

CAUTION: The cone of the crankshaft must always be degreased before assembly.

Torque nut 20 +5 Nm

Repair Manual PS-35 16

07 IGNITION SYSTEM

2 3

1

4

Note: Check the starter pawls on the fl ywheel for easy movement, and clean if necessary.

Removing the ignition armature

Remove cover.

Remove the starter. See Chap. 06.

Pull off short-circuit cable 2.

Unscrew 2 screws on ignition armature 3.

Note: Be aware of the 2 plastic washers between the cylinder and the ignition armature.

Remove ignition armature and high-voltage cable.

Installing the ignition armature

NOTE: The high-voltage cable is moulded onto the ignition system and cannot be replaced separately.

Insert plastic pieces into the bolt holes on the cylinder.

Insert the ignition armature, install the shortcircuit cable 1 under the top screw, and screw in the screws until just before they stop.

Insert the setting gauge 4 (Kapitel 00 Pos.

3) between the ignition armature and the fylwheel.

Position the fl ywheel so that the magnet is against the armature (gap 0.25 – 0.3 mm).

Press the armature against the gauge towards the fl ywheel and tighten the armature screws

(5 +/-0.5 Nm). Then check the gap again to make sure it is correct.

Connect short-circuit cable 2.

Repair Manual PS-35 17

08 CARBURETOR

3

ON

2

1

Removing the intake manifold and carburetor

CAUTION: Completely empty the fuel tank before disassembling the carburetor!

Remove cover.

Move combination switch 1 to safety position.

Unscrew 2 screws 2.

Remove the air fi lter and intake manifold 3.

Pull the fuel lines and pulse line from the carburetor.

CAUTION: There is fuel in the line. Catch escaping fuel with a cloth.

Remove the carburetor and throttle linkage.

Note: When reassembling, engage the linkage in the marked hole (arrow).

ON

4

Removing the intermediate fl ange

Disengage the combination switch 1.

Remove the front handle to simplify pulling off the cylinder.

Unscrew the spark plug.

Completely unscrew cylinder head bolts.

Turn the fl ywheel so that the magnets are

NOT on the ignition armature.

Pull the cylinder, intermediate fl ange and ignition armature up and off.

Assembly

Note: Carefully remove old cylinder base

gasket fragments! When assembling, install a new cylinder base gasket. The gasket tab must point towards the outlet side.

5

6

7

Before assembly, coat the cylinder path and piston with oil.

Push assembly tool 6 under the piston.

Position the opening on the piston ring to the piston ring lock.

Press the piston ring together using piston ring clamp 5.

Carefully push the cylinder onto the piston.

Let the piston ring clamp slide down with it.

Remove the assembly tool and piston ring clamp and push the cylinder all the way down.

Make sure that red fuel line 7 stays in the carburetor compartment.

Repair Manual PS-35 18

08 CARBURETOR

10

ON

9

8

4

11

7

12

Make sure that the intermediate fl ange goes into its space on the cylinder side.

When lowering the cylinder make sure that the pulse line 11 and the red fuel line 7 enter the carburetor area.

Before completely lowering the cylinder make sure that the short-circuit cable is led into the openings 10.

Make sure that the return line (right primer connection) is behind the guide 12.

Install the combination switch 1 with the shortcircuit cable on top and then press the shortcircuit cable 9 under the holder 8.

Install the contact spring with short-circuit cable.

Tighten the cylinder head bolts by hand evenly alternating crosswise and then tighten to the right torque (10 +/- 0.5 Nm), likewise alternating crosswise.

Screw in screws 4.

Check the cylinder side annular spring on the fl ange for correct seating.

Note: Before inserting the carburetor, make sure that the carburetor mounting fl ange is positioned horizontally.

Insert the carburetor and pulse line, and connect the fuel lines.

Install the intake manifold 3 (3 +/-0.5 Nm).

Schematic diagram of the fuel lines

Red fuel line

13

Note: When installing the tank suction line, make sure that the nose on the connection nipple 13 is pushed into the position on the connection as shown.

Repair Manual PS-35 19

08 CARBURETOR

Base Setting

L= 1 1/2

H= 2 1/4

NOTE: Adjust the carburetor only using a tachometer.

Pressure test

Connect the pressure gauge

(chapter 00 item 10) to the carburetor fuel connection 1.

Set up a pressure of max. 0.5 bar.

If the pressure drops, check the following components:

• Inlet needle, if necessary replace control set

• Inlet needle seat for dirt / foreign objects, if necessary clean

• Replace gasket 6 and diaphragm 5 on the pump side

Control lever

Control lever

Correctly

Control lever

Too high

Control lever

Too low

Repair Manual PS-35

7

2

3

4

8

6

5

1

General check

• Screen 7 for contamination

• Pulse hole for contamination

Check control parts

(control lever/inlet needle):

Check the tip of the inlet needle for wear.

Check control lever for correct installation, see illustration to the left, check for wear.

If the control lever is too low:

• Insuffi cient fuel

• Poor acceleration

• No maximum power

If the control lever is too high:

• Carburetor fl ooding

• Starting problems

• Poor idling

• Poor transition

Check the pump diaphragm:

• If pump diaphragm is dented, torn, or creased,

• If valve fl aps are bent, replace the diaphragm and gasket

Check control diaphragm:

• If the control diaphragm is bent, hardened or torn, or if there is visible wear on the button 8.

• If the diaphragm is not fl exible, replace the diaphragm and gasket.

20

09 VIBRATION DAMPER

Repair Manual PS-35

3

2

1

4

Disassembly

Springs 1 and 2

Remove the sprocket guard.

Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1).

Pull out damping spring.

Spring 3

Remove starter housing (see chap. 06).

Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1).

Pull out damping spring.

Spring 4

Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1).

Remove damping spring.

Remove spring bush.

Note: During assembly, insert spring retainer between the cushion spring and the cylinder.

Screw the metric-thread screw into the cylinder.

21

10 TANK

1

Grip mechanism

Unscrew screw 1 and pull the lower grip half slightly up and to the rear in the area of the screw hole.

Note: When disassembling the throttle lever, the following must be performed:

• Remove cover.

• Unscrew all middle screws of the damping springs (Chapter 09).

• Remove tubular handle.

The throttle lever has a slot 2 at the hinge.

Pull the tank and engine unit slightly apart

(being careful of the fuel lines), swing the throttle lever up, and remove it.

Repair Manual PS-35

4

3

3

2

In assembly, fi rst place the throttle lever spring

3 on the throttle lever, then push the lever onto the hinge with the slot. The throttle lever must be turned by 180° to do this.

The catch lever 4 can easily be pushed through the chamfer on the seat.

The spring 3 is engaged in the throttle lever as shown.

22

10 TANK

Removal

Unscrew all middle screws of the damping springs (Chapter 09). Also remove the damping spring 2.

Remove front handle.

Using needle-nose pliers, carefully pull the fuel lines from the fuel nipple 8.

Note: When assembling the fuel lines, follow the schematic diagram in Chapter 08.

5

Pressure test

Attach the over/underpressure pump (chap.

00 pos. 10) to one of the two fuel connections

5. Seal off the second connection.

Set up a pressure of max. 0.3 bar.

If the pressure drops off, check the following:

• Air valve

• Both fuel lines

• Fuel nipple

• Tank cap O-ring

• Check tank for holes

Note: Detergent can be used to localise leaks.

8

Vacuum testing ventilation valve 6

Attach the over/underpressure pump as described.

When the pump is operated the underpressure must quickly dissipate.

If underpressure builds, replace the ventilation valve.

Pull out the ventilation valve 6 with a small screwdriver or wire. Before inserting a new valve, wet it with fuel.

Parts

To remove the suction head 7 pull it through the tank opening with a hooked wire.

Note: Do not use pliers,as this may damage the line. Do not pull on the suction head or fuel line, as this can pull off the fuel nipple inside the tank.

Turn the fuel nipple 8 slightly counterclockwise out of the retainer and then carefully lift it out with a sharp fl at point screwdriver.

Note: Do not lever against the line connections, as this can break them off.

Repair Manual PS-35

6

7

23

11 CYLINDER / PISTON

M4 x 25

Vacuum testing

If correct carburetor setting is not possible, it will be necessary to test a leakage of the engine.

Remove hood.

Remove the muffl er. See Chap. 04.

Remove carburetor (see chap. 08).

6

1

2

3

4

To seal the outlet side, screw on the sealing plate 4 (Chap. 00 Pos.12) and muffl er gasket

3.

To seal off the intake side, install the sealing plate 2 (chap. 00 pos. 11) in the place of the carburetor.

Connect the over/underpressure pump to the connection on the sealing plate 1.

Seal off the pulse line 6 and bring the cylinder to top dead center.

Set up an underpressure of max. 0.3 bar.

If the underpressure changes within 20 seconds, it may have the following causes:

• Radial ring leaking

• Crankcase gasket leaking

• Crack in crankcase

• Crack in cylinder

• Spark plug leaking

• Rubber intake on cylinder leaking

• Defective pulse line

Note: The engine must be removed in order to localize leaks.

Remove clutch. See Chap. 04.

Remove oil pump (see Chap. 05).

Remove fl ywheel. See Chap. 07.

Remove cylinder (see Chap. 08).

Remove crankcase (4 bolts on underside) and remove it from the engine mount.

Note: Install cylinder on crankcase again (see

Chap. 08).

Always perform sealing tests with underpressure!

If a leak is diagnosed, it can be found using overpressure and detergent or similar liquid.

Repair Manual PS-35 24

12 CYLINDER / PISTON / CRANKCASE

8

7

Remove and reinstall the circlip 7 with needlenose pliers.

Install the piston with the arrow marking 8 on the outlet side of the crankshaft (piston ring lock on the inlet side).

Before assembly, wet the cylinder path, piston and needle bearing with oil!

Crankcase

Use a new crankcase gasket, cylinder base gasket and radial seal rings.

Remove the radial seal rings with the puller

(Chap. 00 Item 15).

Fill new radial seal rings 5 with grease and place in housing.

Crankcase

Crankcase CS 1 and MS 2 are replaceable as separate parts, and are bolted with 3 bolts 3

(10 +/-0.5 Nm).

Insert crankcase gasket 4 dry.

The crankcase is bolted to the engine mount with 4 bolts 6 (10 +/-0.5 Nm).

5

3

Ball bearing

Heat both crankcase sides CS and MS to 150-

160°C.

Wet deep-groove ball bearing evenly with

Loctite 601 and insert in hot housing without using pressure.

Grease crankshaft 5 with two-stroke oil.

2

6

Repair Manual PS-35

4

1

5

25

13 TORQUES

Screw crank case MS with CS crank case MS with CS on engine housing crank case MS with CS on cylinder intermediate fl ange on engine housing base cpl. to cylinder muffl er cover cpl. to base cpl.

muffl er cover cpl. to cylinder carburetor to fl ange ring oil pump to crank case CS clutch cpl. on crank shaft transmission cover to engine housing assembly of sprocket guard brake cover to engine housing ignition coil cpl. to cylinder fl ywheel fastening by nut starter cpl. to engine housing hood grip shell at tank fastening of tubular handle at side of tank fastening of tubular handle on bottom of tank fastening of damping spring to cylinder damping spring - tank magnet side back damping spring - tank clutch side front damping spring - tank clutch side back damping spring - engine housing magnet side damping spring - engine housing clutch side spike bar fastening to engine housing spark plug contact spring to intermediate fl ange hand guard to engine housing damping spring - tubular handle

Repair Manual PS-35

Part No.

908.405.255

913.350.404

908.405.205

913.455.164

908.005.165

908.005.165

908.505.555

908.004.406

908.005.165

125.180.200

165.888.120

185.232.020

165.888.120

908.805.205

165.888.140

913.455.164

908.605.205

913.455.164

913.455.164

913.455.164

908.005.165

913.455.164

913.455.164

913.455.164

913.455.164

913.455.164

913.455.164

965.603.030

165.888.120

913.447.134

913.455.164

Size

Torx M5x25

Torx 5x40

Torx M5x20

Torx 5,5x16

Torx M5x16

Torx M5x16

Torx M5x55

Torx M4x40

Torx M5x16

M10 x 1 L

3x10 cross recess

SW 13 / M 8 hexagon nut with shoulder

3x10 cross recess

Torx M5x20 with clamp washer

SW 13 / M8x1

Torx 5,5x16

Torx M5x20

Torx 5,5x16

Torx 5,5x16

Torx 5,5x16

Torx M5x16

Torx 5,5x16

Torx 5,5x16

Torx 5,5x16

Torx 5,5 x16

Torx 5,5 x16

Torx 5,5 x16

SW16

3x10 cross recess

Torx 4,7 x13

Torx 5,5 x16

Qty.

1

1

1

1

2

2

1

3

1

1

2

2

1

1

1

2

1

2

4

2

2

2

3

4

2

1

1

2

1

1

1

Torque [Nm]

1 +/-0,2

5 +/-0,5

20 +5,0

4 +/-0,5

3 +/-0,5

3 +/-0,5

4 +/-0,5

4 +/-0,5

4 +/-0,5

4 +/-0,5

4 +/-0,5

4 +/-0,5

10 +/-0,5

10 +/-0,5

10 +/-0,5

4 +/-0,5

8 +1/-0,5

8 +1/-0,5

8 +1/-0,5

3 +/-0,5

5 +/-0,5

35 +/-2,5

1 +/-0,2

1,5 +/-0,5

4 +/-0,5

4 +/-0,5

4 +/-0,5

12 +/-2

1,5 +/-0,2

3 +/-0,2

4 +/- 0,5

26

NOTES

Repair Manual PS-35 27

DOLMAR GmbH • Postfach 70 04 20 • D-22004 Hamburg • Germany