Dolmar 109 HappyStart User manual

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

2
Table of contents
Index Technical data Page 3
Special tools 4
01 Chain brake 5
02 Clutch, 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

- Bumper Depth Gauge Bumper Bumper
Drive Link Drive Link Drive Link
Type Spur (fixed) Rim (loose) Spur (fixed) Rim (loose)
Cutting length cm 38 33/38 38 45
Drive Link count 56 56/64 56 64
Sprocket Z 7877
Model 109 110i 115i
Displacement cm343 43 52 52
Bore mm 40 40 44 44
Stroke mm 34 34 34 34
Rating kW 2,0 2,3 2,4 2,7
Idling 1/min 2500 2500 2500 2500
Allowed max. engine speed
with bar and chain 1/min 12500 13200 12500 13000
(* with speed limitation)
Gap Flywheel / Coil mm 0,2-0,3 0,2-0,3 0,2-0,3 0,2-0,3
High tension wire length mm 180 180 180 180
Spark plug NGK BPMR-7A BPMR-7A BPMR-7A BPMR-7A
BOSCH 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 3/8 .325 3/8 3/8
mm (9,52) (8,2) (9,52) (9,52)
Drive link inch 0.58 0.58 0.58 0.58
mm (1,5) (1,5) (1,5) (1,5)
Filling Angle 35°30°35°25°
Side Angle 85°75°85°60°
Cutting Angle 60°60°60°60°
File Guide Angle 90°10°90°90°
Depth Gage Setting mm 0,65 0,65 0,65 0,65
File ø mm 5,5 4,5 5,5 5,5
Technical data
Kick back reduction
r.p.m.
H
Max.
LH
S
12
90°10°
r.p.m.
L
From 1/2 Cutter mm 4,8 4,0 4,8 4,8
3
DOLMAR GmbH
111/111i

Special tools
Puller for tension spring
of chain brake
950 237 000
Mounting tool for
clutch hub
944 500 690
Mounting tool for
clutch hub
944 500 680
Special socket wrench
for rubber buffer
944 500 621
Drift 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 GmbH

DOLMAR GmbH
34
5
5
76
5
4
2
1
9
10
6
8
11
12
13
14
16
12
11
01-04 Removing the hand guard
Remove the nut (11) and push the screw (12)
in direction of the cylinder. Unscrew screw
(13) on the starter side and remove the insert
(14).
01-02 Relieving the tension spring
To remove the brake band it is necessary to
remove the cover plate (3). For this purpose
unscrew screws (4) and remove retaining
rings (5). Relieve the tension spring (6) by
levering it off the housing peg (7).
01-02 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 tension spring in the brake gate
(9) and using the pulling hook (10) no.
950.237.000 pass the spring over the peg (7).
01-02 Releasing the chain brake
Insert the clutch drum (1) and by levering
down the brake gate, using a screwdriver (2),
release the chain brake.
01 Chain brake

DOLMAR GmbH
6
42
63
5
67
8
1
02-03 Checking the clutch drum /sprocket
of models 109 / 111
Worn sprockets or clutch drums (arrows)
must be replaced.
02-01 Removing the clutch drum
For the removal of the clutch/clutch drum it is
necessary to immobilize the cylinder unit.
For this purpose unscrew the silencer and
insert the piston stopper wedge (1) into the
exhaust duct of the cylinder.
02-01 Unscrewing the clutch
Use spanner (2), no. 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.
02-03 Checking the clutch drum /sprocket
Worn sprockets (arrows) or clutch drums must
be replaced.
Ring pinion system (8) is standard equipment
only for models 110/115. As replacement also
available for models 109/111.
02 Clutch drum

DOLMAR GmbH
7
4
57
6
8
10
11
121
3
9
10
8
12
03-02 Adjusting the oil pump delivery
Turn the screw:
clockwise for less chain oil
anti-clockwise for more chain oil.
03-02 Removing the oil pump
Unscrew screw (1) and remove the pump
housing (2) from the crankcase. Separate the
intake pipe from the angular nipple (3).
03-03 Checking the oil pump for wear
Unscrew the set screw (4) and check the
condition (5). Unscrew the guide bush (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 the stop (arrow).
03-05 Withdrawing the worm
To remove the worm (8), screw the tool (12)
onto the worm against the stop. Withdraw the
worm from the crankshaft by tightening the
screw.
Caution: Use the protective cap!
03 Oil pump

DOLMAR GmbH
12
3
6
5
7
8
10
11
12
8
5
04 Ignition system
04-01 Checking the spark plug
Unscrew the spark plug (1) and connect it to
the spark plug terminal (2). Hold the spark
plug against cylinder ground and withdraw the
starter rope (3). If no spark is generated,
repeat using new spark plug.
04-01 Checking the spark plug
Clean or renew contaminated or defective
spark plugs.
04-02 Replacing the spark plug terminal
Remove the hood (07-01) for removing the
spark plug terminal. Using a pair of pointed
pliers hold the spring (7) of the plug connector
and pass the rubber cap (5) towards 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, carburettor and bottom
part (07-06). Uns-
crew the nut (10) and withdraw the switch from
the short-circuiting cable.
04-03 Installing the short-circuiting switch
Push the short-circuiting cable (11) into the
switch and install the rubber cap (12) in place.
Install the switch in the crankcase ensuring
that the flat side faces upwards. Screw on nut
(10) with the toothed side facing the housing.

DOLMAR GmbH
9
1
3
2
4
3
5
4
S
N
2
9
8
7
10
04 Ignition system
04-04 Removing the ignition armature and
the flywheel
For the removal of the ignition armature
unscrew the cover (07-01) and the starting
assembly (1).
04-04 Removing ignition armature/flywheel
Withdraw short-circuiting cable (2) from the
armature and unscrew screws (3). When
replacing, remove ignition cable from the
ignition armature (4). Screw new ignition cable
forcefully into the ignition armature.
04-04 Installing the ignition armature
Install the ignition armature and secure 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
bottom part.
04-04 Withdrawing the flywheel
Unscrew nut (9). Screw the punch (10),
944 500 880, on the crankshaft and remove
the flywheel by striking a jarring blow.
04-04 Installing the flywheel
Ensure that the cone on the flywheel and on
the crankshaft is free from grease.
Tighten the nut using a torque of 25 Nm (refer
to table 995 709 180).

DOLMAR GmbH
1
2
34
7
8
3
4
6
5
9
11
10
10
05 Starter assembly
05-02 Removing the starter assembly
Relieve the return spring before removing the
starter assembly. For this purpose slightly
withdraw the starter rope (1), while holding the
rope drum (2). Remove the rope from the
drum and allow the drum to rewind slowly.
05-02 Removing the return spring
Remove retaining ring (3) and washer (4).
Separate handle (5) from rope (7), lift the rope
drum from housing (6). Return spring and cas-
sette (8) are secured to the ventilator housing
by means of three screws.
05-02 Attachment 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 the starter ratchets
Using a punch, remove the locating pin of the
starter ratchet from the flywheel.
05-03 Replacing the starter ratchets
Starter ratchet (9) with spring (10) and pin (11)
must be replaced as a complete assembly
only. Push the pin into the flywheel until it is
flush with the inner edge. Before installing the
pin, apply locking agent 980 009 000.

DOLMAR GmbH
11
2
4
3
2
15
5
7
8
9
6
11
12
10
13
14
06 Carburettor
06-01 Adjusting the carburettor
To perform the basic adjustment, carefully
screw in screws L and H against the stop.
Then back off:
idling jet (L) = 1 turn (max. +1/4)
compensation jet (H) =1 turn (max. -1/4)
.
06-01 Adjusting the carburettor
Adjustment of engine speed during idling is by
idling adjustment screw (S). When the engine
speed is excessive (moving chain) or too low
(engine stops) correct accordingly by means
of the idling adjustment screw.
06-03 Adjusting 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) from the connection nipple.
Unscrew the screws (2). Remove the choke
lever (3) and carburettor linkage (4) after
removal of the carburettor.
06-03 Carburettor (Walbro) control side
Remove cover (10) control diaphragm (11)
and seal (12). Unscrew the screw (13). The
control assembly (14) comprises the inlet
needle, rocker arm and shaft.

DOLMAR GmbH
7
8
9
6
12
12
9
11
10
66
S
7
8
06-04 Carburettor (Tillotson) pump side
Unscrew cover (6). Remove seal (7) and
diaphragm (8). Carefully remove the fuel filter
(9) for cleaning.
06-04 Carburettor (Walbro) pump side
Unscrew 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 removed.
06 Carburettor

DOLMAR GmbH
1
43
2
3
12
5
68
7
11 10
9
5
13
07 Cover system, air filter
07-01 Removing the air filter cover
For cleaning the air filter, remove cover (1).
For cleaning the auxiliary filter, remove cover
(4).
07-01 Removing the cover
In case of model 109 cover assembly (2) must
be removed to clean the air filter. 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 bottom are: - plug (9) for the winter heating
system - ventilation bore/seal (10) for the
carburettor control side.

DOLMAR GmbH
14
2
1
4
3
6
5
7
89
9
9
6
11
10
08-02 Replacing the vibration damper (KS)
Unscrew screws (5), (3) + (4). Always use
special tool, no. 944 500 621 when removing
or fitting vibration dampers (6).
08-02 Damping system design
Three identical vibration dampers (9) are
provided on the tank housing.
08-03 Damper system 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 located under-
neath.
Note: screw(8) is located under the auxiliary
filter.
08 Vibration damping system, handle

DOLMAR GmbH
27
1
3
4
2
5
5
8
9
10
12
11
6
15
09 Fuel tank
09-01 Removing and installing the fuel tank
For the removal of the fuel tank (1) it is
necessary to remove the vibration damper
(08-02). Separate the fuel pipe (2) from the
carburettor (06-02). Install seal (7) between
tank and bottom part.
09-02 Replacing the ventilation valve
Remove carburettor (06-02) and bottom (07-
06). Using a pair of pointed pliers, remove the
ventilation valve (3) from the tank. Seal (4) will
prevent contamination of the ventilation 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 lever and the
starting throttle locking system
For this purpose push out the cylindrical pins
(9) + (10). Remove the throttle lever and
torsion spring (11).
09-05 Removing the throttle lever and the
starting throttle locking system
Remove the half-throttle and compression
spring (12) from the housing.

DOLMAR GmbH
16
1
1
25
3
4
7
8
6
9
10
B
B12 11
10-01 Removing the cylinder
To remove the cylinder, unscrew the four
cylinder attachment screws (1) . Lift off the
cylinder from the housing and piston.
10-01 Replacing the piston rings
Spread the piston rings (3) at the ring cap (4)
and carefully remove the piston (5).
Note: When assembling, ensure that the arrow
points to the silencer.
10-01 Removing the cylinder
Remove the gudgeon pin retaining ring and
press out the gudgeon 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 on the top part.
10-01 Installing the cylinder
Place the fork (11), no. 944 600 001, on the
crankcase, align the piston rings (3) and
compress them using the tension band (12).
Pass the cylinder over the piston while sliding
the tension band downwards.
10 Cylinder and piston

DOLMAR GmbH
2
1
3S S
5
4a
5a
7
6
17
4
4
11 Crankcase, crankshaft
11-01 Replacing the radial sealing rings
Tightly screw tool (1), no. 944 500 900, into
the sealing ring (2) and withdraw it from the
crankcase by means of the spindle (3).
11-03 Dismantling the crankcase
For dismantling the crankcase and oil
reservoir remove the seven attachment
screws.
11-03 Removing 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 radial
sealing rings.
11-03 Assembling the crankcase halves
Start by inserting the crankshaft (6) into the
-KS- half. Place the seal (7) and press both
halves together.

DOLMAR GmbH
18
12 Checking operations
12-02 Checking the ignition system
Use tester no. 956.010.300 for checking the
ignition system / spark plug.
12-03 Checking the carburettor
For in-situ checking of the carburettor sepa-
rate the fuel pipe from the connection nipple.
Fit pressure tester no. 965.004.000 to the
connection 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, crankcase screws,
silencer screws, the flywheel nut and the
clutch hub, must be tightened using the
prescribed torque.

Assy. set Type 109/110i/111/111i/115i
Muffler
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