Dolmar PS-35 C Operating instructions

Repair Manual
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!
PS-35 C
PS-35 C TLC

2
Repair Manual PS-35
CONTENTS
Page
Technical data ...................................................................................................................................................................................... 3
00 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
06 Starter ................................................................................................................................................................................................. 14
07 Ignition system (trouble-shooting)....................................................................................................................................................... 15
07 Ignition system............................................................................................................................................................................ 16 – 17
08 Carburetor................................................................................................................................................................................... 18 – 20
09 Vibration damper ................................................................................................................................................................................ 21
10 Tank ............................................................................................................................................................................................ 22 – 23
11 Cylinder / Piston ................................................................................................................................................................................. 24
12 Cylinder / Piston / Crankcase ............................................................................................................................................................ 25
13 Torques .............................................................................................................................................................................................. 26
Notes ................................................................................................................................................................................................. 27

3
Repair Manual PS-35
TECHNICAL DATA
PS-35 C PS-35 C TLC
Stroke volume cm335
Bore mm 38
Stroke mm 30,6
Max. power at speed kW / 1/min 1,7 / 10.000
Max. torque at speed Nm / 1/min 2,0 / 7.000
Idling speed / max. engine speed with bar and chain 1/min 2.800 / 12.800
Clutch engagement speed 1/min 4.100
Sound pressure level at the workplace LpA eq per ISO 22868 1) 3) dB(A) 102,6 / KpA = 2,5
Sound power level LWA, Fl + Ra per ISO 22868 2) 3) dB(A) 109,8 / KWA = 2,5
Vibration acceleration ahv, eq per ISO 22867 1) 3)
- Tubular handle m/s24,9 / K = 2
- Rear handle m/s25,0 / K = 2
Carburetor Type membrane carburetor
Ignition system Type electronic
Spark plug Type NGK CMR6A
or spark plug Type -
Electrode gap mm 0,5
Fuel consumption at max. load per ISO 7293 kg/h 0,68
Specific consumption at max. load per ISO 7293 g/kWh 500
Fuel tank capacity l 0,40
Chain oil tank capacity l 0,29
Mixture ratio (fuel/two-stroke oil)
- when using DOLMAR oil 50 : 1 / 100: 1 (EXTRA)
- when using Aspen Alkalyt (two-stroke fuel) 50 : 1 (2%)
- when using other oils 50 : 1 (quality grade JASO FC or ISO EGD)
Chain brake engages manually or in case of kickback
Chain speed at max. power m/s 18,9
Sprocket pitch inch 3/8
Number of teeth Z6
Chain type see the spare-parts list
Pitch / gauge inch / (mm) 3/8 / 0,050 (1,3) / 3/8 / 0,043 (1,1)
Guide bar, length of a cut cm 30, 35, 40
Guide-bar type see the spare-parts list
Weight (fuel tank empty, without chain, guide bar and accessories) kg 4,4 4,5
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=).

4
Repair Manual PS-35
1 Torx screwdriver
Grip 944.500.860
T-grip 200 mm 944.500.862
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 flywheel and
armature 944.500.891
4 Torque wrench
3/8” Drive socket 944.500.864
Bit 152 mm 944.500.865
Bit 49 mm 944.500.866
Torque wrench 3/8” Drive 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
123
4567
00 SPECIAL TOOLS

5
Repair Manual PS-35
00 SPECIAL TOOLS
8 Needle-nose pliers
Various assembly/
disassembly tasks 944.603.400
9 Disassembly hook
Removal/installation
Brake band spring 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 944.603.140
13 Ignition tester
Checking the ignition 950.233.230
14 Mounting tool
Bearings on crankshaft 944.500.903
15 Radial ring puller
13 mm radial ring puller (944.500.871)
Spindle (950.203.020)
8910 11
12 13 14 15

6
Repair Manual PS-35
2
34
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM
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 2to forward or
backward motion of the tensioning pin 3.
If necessary, turn adjusting screw 2clockwise,
until the fastening screw 4is accessible.
Unscrew the fastening screw and pull the
chain tensioner up and out.
Assembly
Grease spindle and worm gear with multi-
purpose grease (944.360.000).
1

7
Repair Manual PS-35
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM
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 2up out of the sprocket guard.
Pull folding handle 1out of the sprocket guard.
Remove spring 3and locknut 4.
Chain tensioner
Unscrew bolt 5and 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 4with spring 3into the sprocket guard.
Press the carrier with folding handle 1into the
sprocket guard, making sure it engages with
locknut 4.
Insert plastic ring 2into the sprocket guard.
1
10
11
12
13
15
14
7
2
3
4
8
9
5 6
TLC

8
Repair Manual PS-35
02 CLUTCH DRUM AND CHAIN SPROCKET
Remove the sprocket guard, bar, and chain.
Release chain brake.
Remove the circlip 3with a blade screwdriver.
Remove washer 2.
Clutch drum with sprocket and needle
bearing
Check the chain sprocket 1for 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)!
3
2
1

9
Repair Manual PS-35
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 1and remove the cover 2.
Lift the brake band 3upward 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.
21 1 34
5
03 CHAIN BRAKE

10
Repair Manual PS-35
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 muffler. See Chap. 04.
Disengage the fan-side handguard arm
towards the muffler.
Pull the handguard off pin 9 using light back-
and-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.
03 CHAIN BRAKE
67 8910 10
ca. 4 mm

11
Repair Manual PS-35
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 muffler. To do this, unscrew the 3
screws 1and remove the upper muffler half 2.
Caution: If a catalytic converter is being
used, the muffler 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 muffler
assembly:
Insert wrench 4(Chap. 00, Pos. 7) into the
clutch and use a socket wrench 5to turn in
the direction of the arrow (left-hand thread) to
loosen and remove the clutch.
Remove the guide washer and spacer washer.
The flyweights can now be pushed off the
guide axially in one direction.
04 CLUTCH
12 3
4 5

12
Repair Manual PS-35
Inserting the flyweights
Hook the springs as shown in the illustration.
The press the flyweights onto the guide. To do
this, first push on one flyweight, then put on
the second flyweight.
Press the flyweights 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.
04 CLUTCH

13
Repair Manual PS-35
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 flow 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 2from the oil pump.
Unscrew screw 4and remove the oil pump.
The suction line 5remains 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 Aup against the
spring pressure and turn it until the pin 6goes
into the assembly slit 6. If necessary press the
supply piston 7in somewhat.
Note: When assembling put the adjusting
screw Acounterclockwise 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.
05 OIL PUMP
1
2
A4 3 1
2
3
5
A
7
6
8
9

14
Repair Manual PS-35
Disassembly
Unscrew three screws 1.
Remove fan housing 2.
Remove air guide 3from fan housing.
Detension the return spring.
Injury hazard! Unscrew screw 5 only after
detensioning the return spring!
Unscrew screw 5and remove cam 6and
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!
06 STARTER
12
5
6
7
3
10
8
9
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 8and 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 3in the fan housing and
make sure the three recesses 4engage.
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.

15
Repair Manual PS-35
07 IGNITION SYSTEM (TROUBLE-SHOOTING)
yes
Is the spark plug dry and properly installed?
Is the spark gap correct? (should be 0.5 mm)
Is the spark plug oily or does it have carbon deposits on it?
Is there damage to the insulation of the high-voltage cable or the ignition cable,
or to the wires themselves?
Is the gap between the flywheel and the ignition module outside of the 0.25-0.3 mm range?
Remove flywheel and check. Is the flywheel damaged?
Is the positioning key damaged?
Continue with troubleshooting in fuel system (tank, fuel hose, carburetor).
Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug?
Is there carbon black on the electrodes?
no
yes
no
yes
no
no
no
no
no
no
yes
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?
Replace ignition module. Has the defect been remedied?
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?
Is the gap uneven? Has the flywheel worn against the ignition module?
no
no
yes
yes
no

16
Repair Manual PS-35
Removing the flywheel
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 flywheel.
Hold the machine in one hand or place on a
soft surface, and knock the flywheel loose with
a tap on the mandrel.
CAUTION: The cone of the crankshaft must
always be degreased before assembly.
Torque nut 20 +5 Nm
07 IGNITION SYSTEM

17
Repair Manual PS-35
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 short-
circuit 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 flywheel so that the magnet is
against the armature (gap 0.25 – 0.3 mm).
Press the armature against the gauge towards
the flywheel 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.
Note: Check the starter pawls on the flywheel
for easy movement, and clean if necessary.
07 IGNITION SYSTEM
1
2 3 4

18
Repair Manual PS-35
ON
3
2
1
Removing the intake manifold and
carburetor
CAUTION: Completely empty the fuel tank
before disassembling the carburetor!
Remove cover.
Move combination switch 1to safety position.
Unscrew 2 screws 2.
Remove the air filter 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).
Removing the intermediate flange
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 flywheel so that the magnets are
NOT on the ignition armature.
Pull the cylinder, intermediate flange 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.
Before assembly, coat the cylinder path and
piston with oil.
Push assembly tool 6under 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 7stays in the
carburetor compartment.
08 CARBURETOR
ON
4
7
6
5

19
Repair Manual PS-35
08 CARBURETOR
Make sure that the intermediate flange 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 short-
circuit cable on top and then press the short-
circuit 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
flange for correct seating.
Note: Before inserting the carburetor, make
sure that the carburetor mounting flange is
positioned horizontally.
Insert the carburetor and pulse line, and
connect the fuel lines.
Install the intake manifold 3 (3 +/-0.5 Nm).
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.
Schematic diagram of the fuel lines
13
ON
10
4
8
9
11
7
12
Red fuel line

20
Repair Manual PS-35
08 CARBURETOR
6
5
7
4
8
3
2
1
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
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:
• Insufficient fuel
• Poor acceleration
• No maximum power
If the control lever is too high:
• Carburetor flooding
• Starting problems
• Poor idling
• Poor transition
Check the pump diaphragm:
• If pump diaphragm is dented, torn, or creased,
• If valve flaps 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 flexible,
replace the diaphragm and gasket.
Control lever
Correctly
Control lever
Too high
Control lever
Too low