Service Manual
Contents
1. PS 340 341 PS 400 401 8 0 1 0 DOLMAR Wd Crankcase 10 0 1 0 Cylinder 6 0 0 5 Ignition coil 3 0 1 0 Turbular handle 3 0 0 5 Rubber buffer 2 5 0 5 Intermediate flange 6 0 0 5 Carburator 2 5 0 2 Clutch bub 29 0 2 9 Flywheel 20 3 2 Spark plug 15 0 1 0 DOLMAR GmbH nderungen vorbehalten DOLM AR Postfach 70 04 20 D 22004 Hamburg EE 0 A htto www dolmar com Form 995 721 020 1 94 GB2. 7 Pass the connecting rod 6 over the rollers 11 03 Assembling the crankshaft and crankcase Install the crankshaft 19 in the crankcase 9 Fit the mounting bush 17 no 944 500 540 to the crankshaft and mount the crankcase 8 11 03 Assembling the cylinder and piston Place the fork 21 on the crankcase and mount the piston Align the piston ring 5 and compress it using the tension band 18 Pass the cylinder 20 over the piston while pushing the tension band downwards m DOLMAR Vdd 12 Checking operations 12 01 Tightening torque 12 02 Checking the ignition system Use the torque wrench part no 950 232 000 Use the tester part no 956 010 300 for for tightening the screws flywheel and the checking the ignition system and the spark clutch plug 12 03 Checking the carburettor 12 03 Checking the carburettor continued Separate the fuel line 1 from the connecting Subject the carburettor to a pressure test nipple 2 of the carburettor and connect the using a max pressure of 0 5 bar pressure tester 3 part no 956 004 000 12 05 Checking the crankcase 12 05 Checking the crankcase For pressure testing the crankcase block the Subject the crankcase to a pressure test using exhaust duct with plate 944 603 010 Screw a max pressure of 0 5 bar the plate 944 603 020 with the connection nipple for the pressure tester to the inter mediate flange Block the impuls line 4 16 Muffler
3. Ignition system 04 01 Removing the spark plug Pull off the spark plug cap 1 and remove the spark plug using wrench no 941 716 131 i d 04 01 Checking the spark plug Connect the spark plug 2 with the cap 1 and connect to cylinder Smartly withdraw the starter rope 3 Caution The short circuit switch 4 must be in position l horizontal 04 01 Checking the spark plug If no spark can be produced try again using a new spark plug Clean or renew contaminated or defective spark plugs 04 04 Removing the ignition armature Disconnect the short circuit cable 7 from the ignition armature 8 Remove the screws 9 04 04 Gaining access to the ignition armature Before removing the ignition armature it is necessary to remove the handle 5 and the fan housing 6 04 04 Removing the ignition armature Hold the ignition cable 10 and unscrew the ignition armature 04 Ignition system 04 04 Mounting the ignition armature When mounting the ignition armature the air gap 11 between the flywheel and the ignition armature must be set to 0 2 mm using gauge 944 500 890 04 04 Replacing the ignition cable and the short circuitcable Prior to the replacement of these cables it is necessary to remove the flywheel 13 starter system 14 carburettor 15 and the bottom 16 04 05 Mounting the flywheel Clean the crankshaft and the flywheel cone 18 before m
4. Service Manual 1 94 PS 340 341 PS 400 401 DOLMAR VM DOLMAR Vdd Index Index Technical data page Special tools 01 Chain brake 02 Clutch clutch drum 03 Oil pump 04 Ignition system 05 Starting system 06 Carburettor intake system 07 Deko Valve 08 Vibration damping system 09 Fuel tank 10 Cylinder piston 11 Crankcase crankshaft 12 Checking operations Torques 10 11 12 13 13 14 14 16 17 DOLMAR Vdd Technical data Boe mm Rating ee ree Allowed max engine speed oe with bar and chain 1 min ee 11500 12000 Gap _Fiywheel Coll mm amp 02 02 BPMR 6F RDJ 7Y 0 5 tanken te EI a 0 4 Oil tank capacity ac 3 900 es ee a Saw chain Terms Pitch sga 02 092 CRER Gauge inch 3 5 952 3 8 mm ror 9 52 Drive Link inch SS 0 50 mm 1 3 1 3 Filing Angle GER Sideplate Angle i Cutting Angle NEEN File Guide u eee e JORO Depth Gauge Depth Gauge Bumper Tie Strap Bumper Tie Strap Cutting length cm G 35 40 35 40 Drive Link Count oT 52 56 N a nea Kick back Reduction DOLMAR VAL Special tools Puller for oil seals Mounting sleeve Setting gauge for for radial rings ignition armature 944 500 870 944 500 540 944 500 890 Sealing plate for leakage Drift for piston pin Mounting tools for test of crankcase clutch hub 944 603 020 944 603 030 944 603 250 944 500 690 Dis and mounti
5. k Sg P AA u 08 02 Vibration damper CS 08 02 Vibration damper MS Two of the total four vibration dampers 1 2 The other two vibration dampers 3 4 are are arranged at the crankcase clutch side arranged at the crankcase magnet side MS CS 08 02 Replacing the vibration dampers 09 01 Fuel tank For replacing the vibration dampers and for Arranged in the fuel tank are the ventilation removing the fuel tank unscrew all four valve 6 and the intake line 5 incorporating screws and withdraw the bushes 1 2 3 the fuel filter 09 02 Replacing the ventilation valve 09 05 Checking the fuel filter For cleaning and replacing the ventilation Remove the screw plug and pull out the filter valve 6 remove the valve from its seat in the 8 from the fuel tank For cleaning and fuel tank 7 replacing withdraw the filter from the intake line DOLMAR Vdd 10 Cylinder piston 11 Crankcase 10 01 Removing the cylinder Remove the four attachment screws 1 of the cylinder 2 Withdraw the cylinder from the crankcase and piston 10 01 Removing the piston Press out the gudgeon pin 4 in the direction of the arrow Separate the piston 5 from the piston rod with the permanently fixed needle bearing 6 for the gudgeon pin up z a _ P Fi e Ze D D wl L Le 3 de 11 03 Unscrewing the crankcase screws The two crankcase halves KS MS are screwed together by means of
6. le rocker arm spring and shaft 06 03 Aligning the rocker arm Following installation the rocker arm 13 must be aligned parallel with the carburettor bottom Gauge 956 008 000 06 04 Pump side of carburettor Unscrew the cover 14 and remove the joint 15 and the pump diaphragm 16 Carefully remove the fuel filter 17 from the carburettor body for cleaning DOLMAR Vdd 06 Carburettor intake system N 06 08 Removing the bottom The bottom together with the intermediate flange is attached by means of two screws to the cylinder and by means of one screw 1 to the housing 06 08 Removing the choke lever Withdraw the choke lever 2 from its guide in the bottom 06 08 Removing the short circuit switch Slightly lift the short circuit switch 3 and remove it from the bottom Withdraw the cable 4 from the switch housing 06 08 Removing the intermediate flange Following the removal of the bottom the intermediate flange 6 together with the joints 7 and 8 can be removed 12 06 08 Bottom with installation parts Choke lever 2 short circuit switch 3 and joint 5 07 01 Checking the Decompression valve Remove top cover cylinder air filter Unscrew the deco valve Clean or renew in the case of contermination or wear Tighten the deco valve using a torque of 8 Nm DOLMAR Vdd 08 Vibration damping system 09 Fuel tank ol oy S Le Bes zs e s Er BW A er CES b
7. ng tools for Jarring blow punch drive worm of oil pump 950 500 020 944 500 880 DOLMAR Vdd 01 Chain brake 02 Clutch clutch drum 01 02 Replacing the brake band 01 02 Replacing the brake band Remove the sprocket guard from the engine Lift brake band out of the sprocket guard 2 unit Release the chain brake by pushing the and of the hook 3 When fitting a brake band lever in direction of the arrow ensure that the guide piece 4 is installed Unsrew the five srews and remove the correctly in the slot of the sprocket guard protection plate 1 02 01 Removing the clutch and clutch drum 02 01 Unscrewing the clutch Block the cylinder unit before removing the To unscrew the clutch use spanner 8 no clutch drum or clutch For this purpose 944 500 690 unscrew the muffler 5 and pass the piston Caution Left hand thread stopp wedge 6 944 602 001 into the exhaust If required the clutch springs 7 have to be duct of the cylinder replaced as a complete set 02 03 Checking the clutch drum sprocket 02 04 Mounting the clutch drum Clean or renew in the case of contamination or Lightly grease the needle bearing 9 prior to wear installation Tighten the clutch using a torque of 25 Nm DOLMAR Vdd 03 Oil pump 03 01 Adjusting the oil pump delivery Adjustment is by turning the screw clockwise less chain oil anti clockwise more chain oll 03 02 Dismantling the oil pump Slightly raise the cla
8. ounting the flywheel Ensure that the key 19 is seated correctly DOLMAR Vdd 04 04 Adjusting the air gap Insert the adjustment gauge 12 and turn the marking N S of the flywheel towards the ignition armature Push the ignition armature tightly against the flywheel and uniformly tighten the screws 9 using a torque of 3 Nm SS 04 05 Withdrawing the magnet wheel Immobilise the cylinder unit using the piston stopping wedge Screw off the nut 17 Screw on punch 944 500 880 Strike a jarring blow to separate the flywheel from the crankshaft 04 05 Tightening the flywheel Tighten the flywheel using a torque of 20 Nm DOLMAR Width 05 Starting system Relieve the return spring before removing the starting system For this purpose reel off the starting rope 1 from the rope drum 2 in the direction of the arrow 05 02 Coiling the return spring by hand Engage the eye of the spring over the pin 8 of the rope drum Coil the spring 7 in an anti clockwise direction Grease the spring prior to installation using grease no 944 360 000 i i T j S 2 E 05 02 Coiling the starter rope Coil the starter rope 1 as far as possible on the drum Hold the rope tight and together with the drum turn 2 3 turns in the direction of the arrow to pretension the return spring 10 05 02 Removing the starting system Remove the brake spring 3 and the retaining ring 4 Carefull
9. six screws S ETA am e Z 4 10 01 Removing the retaining rings Using a pair of pointed pliers remove the two retaining rings 3 from the piston Note Do not displace the connecting rod 6 after the removal of the cylinder as otherwise the loose rollers 7 of the connecting rod bearing would fall out 11 02 Replacing the radial rings Pass the device 10 part no 944 500 870 over the crankshaft and screw it tightly into the rubber lip of the radial ring Hold the device and withdraw the radial ring by screwing in the screw 11 11 03 Dismantling the crankcase After the removal of the screws the two halves of the crankcase 8 9 can be separated by lightly tapping with a plastic hammer 11 Crankcase Crankshaft WW 11 03 Removing the needle bearing Prior to the removal of the needle bearing 12 remove the retaining ring 13 using a Suitable pair of pliers Note Crankcases supplied as spare parts are already fitted with bearings radial rings 11 03 Aligning the suction line and seal for the crankcase Prior to assembling the crankcase halves place the gasket 14 over the locating pins 15 15 Install the chain oil suction line 16 11 03 Assembling the crankcase halves Install and tighten the screws using a torque of 10 Nm DOLMAR Vdd 11 03 Mounting the connecting rod bearing rollers Apply grease to the crankpin of the crankshaft 19 and install the 12 rollers
10. ws from the chain guide plate 1 and remove the guide plate and the chain tensioner 2 03 02 Removing the oil pump Pull out the oil pump from the crank case and from the suction line 3 03 03 Inspecting the oil pump Remove the retaining ring and the washer 4 Remove the set screw 5 Remove the oil pump plunger 6 together with the compression spring from the housing 7 6 03 02 Mounting the oil pump When mounting the oil pump the pin 12 must be inserted into the hole 13 03 03 Assembling the oil pump Prior to reassembling the oil pump liberally grease the oil pump plunger 6 and the housing 7 with silicon compound no 980 007 100 DOLMAR Vdd 03 Oil pump 03 04 Checking the intake line and the filter 03 04 Greasing the suction line Withdraw the intake line 3 from the Prior to the installation of the suction line crankcase Remove the filter 8 from the grease the line in way of the sealing face 9 intake line for cleaning at the crankcase using silicone grease 03 05 Removing the drive worm 03 05 Mounting the drive worm Screw the extractor device 950 500 011 in Screw the worm fully into the device place for the removal of the drive worm 10 Caution Left hand thread Manually remove the worm from the crankshaft using device 950 500 011 03 05 Fitting the drive worm Pass the device over the crankshaft until the edge arrow butts against the crankcase DOLMAR Vdd 04
11. y take out the rope drum 5 and remove the disk 6 05 02 Mounting the rope drum Pass the rope drum over the guide pin on the crankcase housing and fit the retaining ring 4 to prevent the drum from falling out Apply silicone paste to the starter ratchet 9 prior to installation UDAT fai 05 02 Checking the return spring To check the pretensioning of the spring withdraw the rope completely and hold it in the extended position It must now be possible to turn the rope drum by at least another half turn Reduce the preload tension if this is not possible 06 Carburettor intake system x ae g f 06 01 Adjusting the carburettor For basic adjustment screw in both screws L and H against the stop Then back off the idling jet 1 by 1 1 1 4 turns and the high speed jet 2 by 1 3 4 turn DOLMAR Vdd 06 01 Idling adjustment When during idling the engine speed is too high moving chain or too low engine stalls correct the setting of the idling screw S speed accordingly 06 02 Removing the carburettor Unscrew the nuts Disengage the throttle linkage 4 at the lever of the throttle valve shaft Remove the choke lever 5 Separate the fuel line 6 and the impulse lead 7 from the carburettor 06 03 Control side of carburettor Unscrew the cover 8 and remove the control diaphragm 9 and the gasket 10 Remove screw 11 The control set 12 comprises the inlet need
Download Pdf Manuals
Related Search