Repair Manual

PS-6100
PS-6100 H

Caution:
Before doing any maintenance or service work, the combination switch must be in STOP position (ignition current
interrupted), in order to prevent unintended starting by the easy start system!

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 INHALT

TECHNICAL DATA ...................................................................................... 3 Removing the ignition armature ............................................................. 18

Installing the ignition armature ............................................................... 18
00 SPECIAL TOOLS ......................................................................................... 4 Combination switch ................................................................................ 18
01 CHAIN TENSIONING SYSTEM ................................................................... 6 08 CARBURETOR .......................................................................................... 19
Chain tensioner / Function / Assembly ..................................................... 6 Removing the carburetor ........................................................................ 19
Assembly ................................................................................................ 19
02 CLUTCH DRUM / CHAIN SPROCKET ....................................................... 7
Removing the carburetor base ............................................................... 20
Sprocket and clutch drum with needle bearing ........................................ 7
Assembly ................................................................................................ 20
03 CHAIN BRAKE / GUIDE BAR BOLT .......................................................... 8 Removing the manifold ange ................................................................ 20
Removing the brake band ........................................................................ 8 Intake diaphragm .................................................................................... 20
Remove the handguard and disengagement mechanism ........................ 8 Base setting ............................................................................................ 21
Replacing the guide bar bolt ..................................................................... 9 Pressure test .......................................................................................... 21
Check control parts ................................................................................ 21
04 CLUTCH ..................................................................................................... 10
Disassembly ........................................................................................... 10 09 VIBRATION DAMPER ............................................................................... 22
Inserting the yweights ............................................................................11 Disassembly / Assembly ......................................................................... 22
Installing the clutch ..................................................................................11
10 TANK .......................................................................................................... 23
05 OIL PUMP .................................................................................................. 12 Grip mechanism ..................................................................................... 23
General ................................................................................................... 12 Removing the tank ................................................................................. 24
Disassembly ........................................................................................... 12 Pressure test .......................................................................................... 24
Removing the oil pump ........................................................................... 12 Vacuum testing ventilation valve ............................................................ 24
Removing the oil tank vent ..................................................................... 12 Parts ....................................................................................................... 24

06 STARTER ................................................................................................... 13 11 CYLINDER / PISTON ................................................................................. 25

Disassembly ........................................................................................... 13 Drive, pressure test ................................................................................. 25
Assembly ................................................................................................ 13 Drive, vacuum test .................................................................................. 25
Cylinder and piston disassembly ............................................................ 26
07 IGNITION SYSTEM .................................................................................... 14 Assembling the cylinder and piston ........................................................ 26
Trouble-shooting .................................................................................... 14
Spark plug .............................................................................................. 15 12 CRANKCASE ............................................................................................ 27
Checking the ignition spark .................................................................... 16 Disassembly / Assembly ......................................................................... 22
Checking the ignition .............................................................................. 16
13 TORQUES .................................................................................................. 28
Replacing the plug connector ................................................................. 16
Removing the ywheel ........................................................................... 17 NOTES ....................................................................................................... 29
Starting ratchets ..................................................................................... 17

Repair Manual PS-6100 / PS-6100 H 2

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 TECHNICAL DATA

PS-6100 PS-6100 H
Stroke volume cm3 61
Bore mm 47
Stroke mm 35
Max. power at rated speed kW / 1/min 3.4 / 10,000
Max. torque at speed Nm / 1/min 3.7 / 7,000
Idling speed / max. engine speed with bar and chain 1/min 2,700 / 13,800
Clutch engagement speed 1/min 5,100
Sound pressure level at the workplace LpA, eq per ISO 22868 1) 3) dB(A) 105 / KpA = 2.5
Sound power level LWA, Fl + Ra per ISO 22868 2) 3) dB(A) 117 / KWA = 2.5
Vibration acceleration ahv, eq per ISO 22867 1) 3)
- Tubular handle m/s2 5.0 / K = 2
- Rear handle m/s2 4.0 / K = 2
Carburetor Type Diaphragm carburetor
Ignition system Type electronic
Spark plug Type NGK BPMR 7A
or spark plug Type -
Electrode gap mm 0.5
Fuel consumption at max. load per ISO 7293 kg/h 1.5
Specic consumption at max. load per ISO 7293 g/kWh 430
Fuel tank capacity l 0.8
Chain oil tank capacity l 0.48
Mixture ratio (fuel/two-stroke oil)
- when using DOLMAR oil 50 : 1 / 100: 1 (EXTRA)
- when using Aspen Alkylat (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. engine speed) m/s .325=25.6 3/8=29.6
Sprocket pitch inch .325 oder 3/8
Number of teeth Z 7
Chain type see the Extract from the spare-parts list
Pitch / gauge inch / (mm) .325 / 0.058 (1.5 mm) oder 3/8 / 0.058 (1.5 mm)
Guide bar, length of a cut cm 38 / 45 / 53
Guide-bar type see the Extract from the spare-parts list
Weight (fuel tank empty, without chain, guide bar and accessories) kg 6.0 6.1
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-6100 / PS-6100 H 3

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 00 SPECIAL TOOLS

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
ywheel without damage to the crankshaft
thread 944.500.880

3 Setting gauge
Gauge for measuring the gap
between ywheel 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 944.500.590

7 Tachometer
Electronic tachometer for measuring
the engine speed of
2- and 4-stroke engines 950.233.220

Repair Manual PS-6100 / PS-6100 H 4

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 01 CHAIN TENSIONING SYSTEM

3 2

Remove the sprocket guard, bar, and chain. If necessary, turn adjusting screw 1 clockwise, Assembly
until the fastening screw 3 is accessible.
CAUTION: Do not work on the chain brake NOTE: The worm gear is available only as a set.
unless the spring is detensioned! Unscrew the fastening screw and pull the Grease spindle and worm gear with multi-
chain tensioner up and out. purpose grease (944.360.000).
Chain tensioner Lock the cover bolts with Loctite 601.
Unscrew 4 screws, and remove the cover.

Chain tensioner function

An angled worm drive converts the turns
of the adjustment screw 1 to forward or
backward motion of the tensioning pin 2.

Repair Manual PS-6100 / PS-6100 H 6

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 02 CLUTCH DRUM / CHAIN SPROCKET

Check the inside and outside of the clutch

drum 3 for damage and wear.
Replace the clutch drum if annealing.
Note: Make sure to assemble with thrust
washer 1!
4 Note: Always use a new circlip 5
(927.408.000)!
5 1 When assembling the clutch drum, make
2 sure that the lug of the oil pump drive 2 is
not positioned on the oil pump drive. When
3 inserting, turn the clutch drum slightly.

Remove the sprocket guard, bar, and chain. Sprocket and clutch drum with needle
Release the chain brake. bearing

Remove the circlip 5 with the universal Check the chain sprocket 4 for damage and
wrench. wear.

Remove cup washer. Important customer information:

Before installing a new saw chain, always
check the condition of the chain sprocket. A
worn chain sprocket will damage a new saw
chain, and must be replaced.
Check the clutch drum needle bearing for
wear and damage.
Assembly the bearing with multi-purpose high-
performance grease (944.360.000).

Repair Manual PS-6100 / PS-6100 H 7

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 03 CHAIN BRAKE / GUIDE BAR BOLT

1 2
3
5

Removing the brake band Secure the chain saw from slipping (vise). Remove the handguard and
CAUTION: To prevent cuts, wear protective Using the disassembly hook (chap. 00, Pos. disengagement mechanism
gloves and disassembly the spike bar (2 8), disengage the brake band spring 3. Unscrew bolt 4 and pull out the sleeve 5.
screws)!
Remove the sprocket guard, bar, and chain.
Pull the handguard towards the tubular handle
to release the chain brake.
Remove the clutch drum, see chapter 02.
Push the hand guard forward to engage the
chain brake. This releases the brake band
spring.
Remove the cover plate, see chapter 01.
Fold the brake band 1 upward and turn it out
of the disengagement mechanism 2.

Repair Manual PS-6100 / PS-6100 H 8

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 03 CHAIN BRAKE / GUIDE BAR BOLT

7
6

ca. 5 mm

Remove the circlip 6. Note: Make sure that the handguard guide Replacing the guide bar bolt
Pull the disengagement mechanism up in 7 is not unhooked. If necessary, push it back Screw two nuts onto the bar bolt and
parallel with the axes. into position with a screwdriver (about 5 mm counterlock them.
from the axle support). The handguard can
Pull off the handguard with gentle back-and- only be assembled when the rest piece is in Unscrew the bar bolt.
forth motion. this position. Assembly: Apply Loctite 243 (980.009.000) to
Note: When reassembling always use a new Assemble the handguard and disengagement the guide bar bolts and turn them all the way
circlip 6 (927.304.000)! mechanism, brake band and brake band in.
spring in reverse order.

Repair Manual PS-6100 / PS-6100 H 9

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 04 CLUTCH

3
2

4 5

Disassembly Move piston to bottom dead centre (visible Insert wrench 4 (chap. 00, Pos. 6) into the
CAUTION: To prevent cuts, wear protective through the exhaust opening). clutch and use a socket wrench 5 to turn in
gloves and disassembly the spike bar (2 Press the piston stop wedge 3 (cap. 00, pos. the direction of the arrow (left-hand thread) to
screws)! 5) into the exhaust opening. loosen and remove the clutch.

Remove the sprocket guard, bar and chain. Remove the guide washer (inside of the
Position of gasket and cooling plate for mufer clutch).
Pull the handguard towards the front handle to
assembly: The yweights can now be pushed off the
release the chain brake if necessary.
guide axially in one direction.
Remove the clutch drum, see chapter 02.
Remove the mufer. To do this, unscrew the 3
screws 1 and remove the mufer 2.

Caution: If a catalytic converter is being

used, the mufer will be very hot after
operation!

Repair Manual PS-6100 / PS-6100 H 10

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 04 CLUTCH

Inserting the yweights Press the disc onto the clutch. It must be at Installing the clutch
Hook the springs as shown in the illustration. and be engaged.
Install the clutch with the arrow marking point
Then press the yweights onto the guide. To up.
do this, rst push on two yweights half-way, Mounting torque: 35 +/-2.5 Nm
then put on the third yweight by setting it on
its edge. CAUTION: Before installing the clutch,
disassemble the starter (chap. 06) in order
Press the yweights all the way onto the to prevent damage to the starting catches.
guide.
CAUTION: Note the position of the springs.
Do not replace springs individually! If
a spring breaks or is fatigued, all three
springs must be replaced. The springs
must not touch the cover.
The illustration shows the inside of the clutch.

Repair Manual PS-6100 / PS-6100 H 11

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 05 OIL PUMP

1
6

2 9

1 10

A 3
A 4 3 2 5

General The suction line 6 remains in the crankcase.

The oil pump is driven by the clutch drum. It extends into the oil tank. To remove it,
Lugs on the clutch drum transfer the power to carefully pull on the connection to the oil
the drive arms of the oil pump drive 1. pump.
The drive worm of the oil pump drive engages Removing the oil pump
in the teeth of the oil pump 3. Push the adjusting screw A up against the
This means that oil is pumped only when the
8 spring pressure and turn it until the pin 7 goes
chain is running. into the assembly slit 7. If necessary press the
The oil ow rate can be adjusted with supply piston 8 in somewhat.
adjusting screw A:
Note: When assembling put the adjusting
•• Turn right for more oil screw A counterclockwise to stop.
•• Turn left for less oil A 7
Removing the oil tank vent
Disassembly
Pull the oil pressure line 2 from the oil pump. Note: The ventilation valve 9 must be
Remove the clutch drum and clutch, see
punched into the tank.
chapter 04. Remove brake band, see chapter Unsrew screw 4 and remove the oil pump.
03. Remove spacer ring 5 from the crankshaft. Press in a new valve about 2 mm deep under
Turn the oil pump drive 1 counter-clockwise the housing surface.
Note: Make sure to install in the right position.
and pull it off the shaft. Make sure that the ventilation channel 10 is
See illustration.
free of deposits. Clean if necessary.

Repair Manual PS-6100 / PS-6100 H 12

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 06 STARTER

CAREFUL! Injury hazard! The return spring

11 can pop out! Always wear eye protection and
protective gloves!
10
If the spring pops out, put it back into the plastic
9 housing as shown in the schematic.
3
Assembly
8 Note: If installing a new return spring cassette,
2 grease it on the spring side.
Carefully insert a new return spring cassette 6
and press down until it engages. Lightly grease
7
the surface of the spring and spring cassette
1 with multipurpose grease (944.360.000).
Insert spring 8 in the cable drum 7 and thread in
6
Disassembly a new cable (dia. 3.8 mm, 1 m long) as shown.
Tie knots in both ends and tighten. Press the
Disengage the hood clip 3 with the combina- 4
knot on the cable drum into the space provided.
tion tool.
Unscrew four screws 1 and remove the fan 5 Guide the hole 11 in the driver over the end of
the spring, press down the driver and turn it
housing 2.
slightly counter-clockwise until it is ush on the
Remove the air guide 5 from the fan housing. cable drum 7.
CAREFUL! Injury hazard! Do not unscrew Put the drum 7 on its spindle and turn it slightly
screw 10 if the return spring is under ten- until the return spring engages.
sion.
Insert screw 10 and tighten.
Unscrew screw 10 and remove the driver 9
Tension the return spring clockwise. Turn the
with spring 8 and the cable drum 7. return spring about 6 turns with the aid of the
Separate the driver 9 and cable drum 7. cable, which should be pressed into the gap in
Lightly tap the fan housing on a wooden sur- the cable drum.
face with the entire surface of the hollow side, Place the air guide 5 in the fan housing and
and hold it down. Now lift the fan housing make sure the ve recesses 4 engage.
carefully and in small steps. This will allow Position the fan housing correctly on the saw,
the return spring pack 6, which should now press against it slightly, and pull the starter
have fallen out, to relax in a controlled man- handle until the starter catches.
ner if the return spring has popped out of the Tighten screws 1.
plastic pack.
Repair Manual PS-6100 / PS-6100 H 13

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 07 IGNITION SYSTEM (TROUBLE-SHOOTING)

no
Is the spark plug dry and properly installed? Dry spark plug cap and fasten firmly to spark plug.
If needed, replace the cap or cap spring.
yes

Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? Replace spark plug. Use ONLY a spark plug approved by DOLMAR.
Is there carbon on the electrodes? yes See operating manual! Otherwise the ignition module might be damaged.
Eliminate the causes for carbon deposits on electrodes (bad two-stroke oil, wrong mix,
no defective air filter, check carburetor adjustment).
Use DOLMAR EXTRA two-stroke oil.
Is the spark gap correct? (should be 0.5 mm) no
yes Adjust spark gap.
Is the spark plug oily or does it have carbon deposits on it?
yes
no Wash spark plug in acetone. Do not sandblast!
If necessary, replace spark plug.
Install ignition testing lamp. Eliminate cause: wrong carburetor setting, too much oil in fuel,
frequent short operations.
Alternatively, using insulated pliers, hold the unscrewed spark plug
against the cylinder.
Caution: Do not hold the spark plug directly against the hole. Detonation hazard! no
Replace spark plug and check ignition module for corrosion, if necessary replace.
Has the defect been remedied?
Pull the starting cable smartly. Is there an ignition spark?
no
yes Replace high-voltage cable and/or ignition cable. Has the defect been remedied?
yes
Is there damage to the insulation of the high-voltage cable or the ignition cable,
or to the wires themselves?
no
no Check radial play of drive shaft, and repair if needed.
yes Replace ignition module if traces of overheating become visible.
Is the gap between the flywheel and the ignition module outside of the 0.25-0.3 mm range? Adjust gap between flywheel and ignition module correctly.
Is the gap uneven? Has the flywheel worn against the ignition module?
no
no
Remove flywheel and check. Is the flywheel damaged? Replace flywheel or key. Before installation wipe cone seat at drive shaft
yes and flywheel with acetone or alcohol to remove any grease.
Is the positioning key damaged?
Tighten fastening nut to the correct torque! Has the defect been remedied?
no
Continue with troubleshooting in fuel system (tank, fuel hose, carburetor). no
no
Replace ignition module. Has the defect been remedied?

Repair Manual PS-6100 / PS-6100 H 14

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 07 IGNITION SYSTEM

3 1 2
CAUTION:
Do not touch the spark plug or plug cap if
the engine is running (high voltage).
Normal
Switch off the engine before starting any
maintenance work. Proper spark plug,
A hot engine can cause burns. Wear good combustion
protective gloves!
The spark plug (NGK BPMR 7A, parts no. 965
603 021) must be replaced in case of damage
to the insulator, electrode erosion (burn) or if
the electrodes are very dirty or oily. Deposits
Pull the plug cap 3 off the spark plug. Use only Poor-quality oil,
the combination wrench supplied with the saw material wear
Spark plug
to remove the spark plug.
Disengage the hood clips 1 with the combina-
tion tool and remove the hood 2. The electrode gap must be 0.5 mm.

Overheating
Wrong thermal value

Carbon deposits
Wrong spark plug
Wrong thermal value

Repair Manual PS-6100 / PS-6100 H 15

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 07 IGNITION SYSTEM

Checking the ignition spark Replacing the plug connector

See Instruction Manual. Hold the plug connector spring using pointed
pliers and push the rubber cap backwards
Checking the ignition over the ignition cable.
NOTE: Test the ignition only in the manner
NOTE: Lightly grease the ignition cable for
described here. Testing the ignition when
easier assembly and disassembly of the spark
uninstalled can destroy the ignition
plug cap.
armature.
Remove the hood. Check the rubber cap and ignition cable for
damage, and replace if necessary. The spring
Pull off the spark plug cap and connect the
must not be bent. During assembly, push the
ignition tester 1 as shown in the illustration.
hook of the spring into the middle of the cable
Start the engine, let it warm up and then check from above.
the ignition over the entire speed range.
Pull the rubber cap over the spring. Check for
NOTE: When it reaches the cut-off speed the proper seating of the spring in the cap.
ignition will cut off. Incorrect positioning of the spring can cause
For ignition cut-offs, see IGNITION SYSTEM weak ignition sparking or complete non-
(TROUBLE-SHOOTING). functioning.

Repair Manual PS-6100 / PS-6100 H 16

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 07 IGNITION SYSTEM

Removing the ywheel Screw the disassembly mandrel (chap. 00, Starting ratchets
Pos. 2) onto the threaded end of the shaft.
Remove the starting system, see chapter 06. Check the starter pawls on the ywheel for
Block the piston, see chapter 04. Do not screw the mandrel all the way down. easy movement, and clean if necessary.
Leave about 2 mm between the mandrel and Install spring as illustrated.
Loosen the nut in the direction of the arrow
the ywheel.
and remove it along with the washer. Screw tightening torque: 8 +/-1.0 Nm.
Hold the machine in one hand and knock the
ywheel loose with a tap on the mandrel.
CAUTION: The cone of the crankshaft must
always be degreased before assembly.
Nut tightening torque: 28 +/-2.0 Nm

Repair Manual PS-6100 / PS-6100 H 17

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 07 IGNITION SYSTEM

Press the armature against the gauge towards

2 the ywheel and tighten the armature screws
6
(5 +/-0.5 Nm). Then check the gap again to
make sure it is correct.

5 Combination switch
1
8

3
4 7

Removing the ignition armature Secure the high-voltage cable under the cable
Remove the cover. clamp with bolt 4.
Remove the starter. See Chap. 06. Carefully push cable lug 2 through the rubber
Remove the ywheel. See Chap. 07. grommet on the carburettor oor.
10 9
Unscrew 2 bolts on ignition armature 1. Note: Make sure not to press the rubber
Pull off cable lug 2 . grommet into the carburettor when doing this.
Remove the cover and air lter. Pull off cable
Unscrew bolt 3 and remove with cooling air If the grommet gets pushed out, it can be
lug 2.
guide. reinserted from the cylinder side.
Unscrew 4 anged nuts 8 (A/F 7).
Unscrew bolt 4 and remove with cable clamp. Route the high-voltage cable as shown,
Unscrew bolts 7.
Remove ignition armature with high-voltage engage the cooling air guide tab 5 and secure
cable, carefully pulling cable lug 2 through the it with bolt 3. Carefully remove the air lter base from the
rubber grommet on the carburettor oor. rubber buffers 9 and disengage the choke
Install the ywheel.
linkage (arrow).
Installing the ignition armature Insert the setting gauge 6 (chap. 00, Pos. 3)
The combination switch 10 with ground wire
between the ignition armature and the fylwheel.
NOTE: The high-voltage cable is moulded and contact spring can now be removed from
onto the ignition system and cannot be Position the ywheel so that the magnet is the air lter base.
replaced separately. against the armature (gap 0.25 –– 0.3 mm).
Note: If the gasket on the carburetor or air ap
Insert the ignition armature and screw in the is damaged, it must be replaced.
screws until just before they stop.
Assemble in reverse order.

Repair Manual PS-6100 / PS-6100 H 18

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 08 CARBURETOR

3 2 5
2
4 4
1
1

6 7

Removing the carburetor Assembly Before installing the air lter base, see Chap.
Place the insert 5 in the intake manifold if 07 under Combination switch, and engage
CAUTION: Completely empty the fuel tank
necessary. the choke linkage 7 in the choke valve
before disassembling the carburetor!
actuator on the carburetor.
Engage the air ap linkage 6, see illustration.
Remove the cover and air lter. Remove
the air lter base, see Chap. 07 under Note: Engage the air ap linkage 6 on the
Combination switch. carburetor in the throttle ap actuator on the
carburetor side.
Remove the pulse line 1, fuel line (red) 2 and
primer suction line 4 from the carburetor. Push the carburetor and air ap onto the
stationary bolts.
CAUTION: There is fuel in the line. Catch
escaping fuel with a cloth. Connect the primer suction line 4 to the
carburetor.
Disengage the throttle cable 3.
Connect the pulse line1 and fuel line (red) 2,
Pull the carburetor and air ap off the and then connect the throttle cable 3.
stationary bolts and then disengage the air Position the carburetor and air ap with the
ap linkage 6 from the carburetor. red side on the outside.

Repair Manual PS-6100 / PS-6100 H 19

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 08 CARBURETOR

2 13
16 17
12
5
10
11

9 1
12

11
8 14 15

Removing the carburetor base Removing the manifold ange Intake diaphragm (reed valve)
Remove the insert 5 from the intake manifold Unscrew 4 bolts 13 and remove the manifold If the intake diaphragm 16 is damaged or
if necessary. ange. protruding away from the air hose ange, it
Detach the Bowden cable 11. must be replaced.
Remove the carburetor ange 10 from the 1 Pulse line Note: Turn the side with TOP on it to the
intake manifolds.
2 Fuel line (red) outside when assembling.
Remove the primer return line 12 from the
primer. Tighten screw 17 to 3 +/-0.5 Nm.
4 Primer suction line (top primer
Unscrew 3 bolts 8. connection) Note: After pushing the carburetor manifold
Lift the carburetor base slightly and pull the 14 through the ange, put in the insert 15.
rubber grommet 9 with the short-circuit cable 12 Primer return line (bottom primer
Tighten bolts 13 to 5 +/- 0.5 Nm.
down and off. connection)
Carefully remove the carburetor base while
letting the Bowden cable 11 and lines slide out Note: Check all lines for cracks and damage.
of the base. Any damaged lines must be replaced.
Assembly
Assemble in reverse order.
Route the lines as shown.
Tighten bolts 8 to 5 +/-0.5 Nm.

Repair Manual PS-6100 / PS-6100 H 20

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 08 CARBURETOR

Base Setting Pressure test

H= 2 1/2
Connect the pressure gauge (956.004.001) to the
L= 1 1/2 carburetor fuel connection 23.
Set up a pressure of max. 0.5 bar.
If the pressure drops off, check the inlet needle 24
for damage or foreign objects. If necessary, replace
control parts.
If the inlet needle is OK, replace the gasket 20 and
diaphragm 21.
19
If the pump diaphragm 18 is obviously dented, it needs
18
to be replaced along with the gasket 19.
22
Check:
23
•• Screen 22 for contamination
•• Pulse hole for contamination
T
Check control parts
L (control lever/inlet needle):
H Check the tip of the inlet needle for wear.
Check control lever for correct installation, see
24 illustration to the bottom.

Control lever If the control lever is too low:

•• Insufcient fuel
20 •• Poor acceleration
•• No max. speed
21
If the control lever is too high:
•• Carburetor ooding
•• Warm starting problems
Control lever Control lever Control lever •• Poor idling
Too high Too low Correctly installed

Repair Manual PS-6100 / PS-6100 H 21

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 09 VIBRATION DAMPER

Disassembly Damper spring A

CAUTION: To prevent cuts, wear protective Remove the cover for easier disassembly.
gloves and disassembly the spike bar (2 Unscrew bolt 1 from damper spring A.
screws)!
Damper spring B and C
Note: For removal and installation, guide the Remove the sprocket guard, bar, and chain.
Torx screwdriver through damper springs.
Remove starter housing (see chap. 06).
Unscrew bolts 2 from damper springs A, B
and C.
NOTE: The engine unit is connected to
the tank unit by fuel lines and the throttle
cable. The two units cannot be separated!
Carefully lift the engine unit on the clutch side
A over damper springs B and C (spread the
engine unit slightly apart from the tank).

1 Unscrew the damper springs.

Damper spring D
D Note: Damper spring D cannot be removed
2 B until damper springs A, B and C have been
removed.
Carefully lift the engine unit on the fan side
over damper spring D and spread the engine
unit slightly apart from the tank. Unscrew the
C
damper springs.
Assemble in reverse order.
Make sure the fuel lines remain connected
to the tank.

Repair Manual PS-6100 / PS-6100 H 22

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 10 TANK

Grip mechanism
The throttle trigger is linked to the carburetor by
a Bowden cable.
4
3 NOTE: Do not lubricate the Bowden cable!
The grip shell is attached to the tank with a Torx
screw 3.
Disengage the throttle lock 1 and spring 2.
Check for ease of motion and functioning of the
2 safety throttle lock spring 2.
To replace the throttle trigger and throttle lockon
lever drive out the cylinder pins 5 (3.3 x 28.4
mm) with a mandrel (ø 2 mm).

Repair Manual PS-6100 / PS-6100 H 23

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 10 TANK

Removing the tank fuel line (red) to the fuel nipple 7. Vacuum testing ventilation valve 9
NOTE: Make sure the fuel tank is empty Pressure test Attach the over/underpressure pump as
before removing it. Attach the over/underpressure pump (chap. described.
Remove the ywheel. See Chap. 09. 00 pos. 11) to one of the two fuel connection. When the pump is operated the underpressure
(6 or 7). Seal off the second connection. must quickly dissipate.
Detach the throttle cable from the carburetor,
see Chap. 08. Set up a pressure of max. 0.3 bar. If underpressure builds, replace the ventilation
If the pressure drops off, check the following: valve.
Detach the Bowden cable from the carburetor
ange, see Chap. 08. •• Air valve Pull out the ventilation valve 9 with a small
•• Fuel line screwdriver or wire. Before inserting a new
Spread the engine unit and the tank unit apart
•• Tank cap O-ring valve, wet it with fuel.
a little and use needle-nose pliers to carefully
pull the fuel lines off the fuel nipple. •• Check tank for holes
Parts
Separate the tank and the engine unit. Note: Detergent can be used to localise leaks.
To remove the suction head 8 pull it through
Note: When attaching the lines, connect the 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, because they can otherwise be drawn
7 into the inside of the tank.

6 Turn the fuel nipple slightly counter-clockwise

out of the retainer and then carefully lift it out
with a sharp at point screwdriver.
Note: Do not lever against the line
connections, as this can break them off.

9
8

Repair Manual PS-6100 / PS-6100 H 24

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 11 CYLINDER / PISTON

an indication that there is a defect in the

2 crankcase gasket to the oil tank.
Drive, vacuum test
Since the radial gasket ring can also fail
1 at negative pressure, a vacuum must be
established in the crankcase to test the radial
ring.
Seal off the intake and exhaust sides as
described above.
Connect the over/underpressure pump to the
connection on the sealing plate 2.
Move the piston to top dead centre.
Pull the pulse line from the cylinder connection
Drive, pressure test Move the piston to top dead centre. and seal the connection.
If it is not possible to adjust the carburetor Pull the pulse line from the cylinder connection Set up a negative pressure of max. 0.5 bar.
properly, it will be necessary to check the and seal the connection.
If the pressure does not rise to more than
sealing of the Drive. Set up a pressure of max. 0.5 bar. 0.3 bar within 20 seconds, the radial gasket
To seal the exhaust side, install sealing plate If the pressure drops within 20 seconds, it can is OK. Otherwise the radial gaskets must be
1 (944.603.108) in the place of the mufer have one of these causes: replaced.
(rubber coating towards the cylinder). •• Radial ring leaking Remove the ywheel and clutch, see
To do this it will be necessary to remove the •• Cylinder base gasket leaking IGNITION SYSTEM and CLUTCH / CLUTCH
mufer, see chap. 04. •• Crankcase gasket leaking DRUM.
•• Crack in crankcase On the clutch side, pull the circlip from the
To seal the intake side, install sealing plate 2
(944.603.200) in the place of the carburetor •• Crack in cylinder shaft.
unit. •• Spark plug leaking Guide the 15 mm radial gasket puller
To do this it will be necessary to remove the NOTE: Detergent can be used to localise (944.500.895) over the shaft and turn it rmly
carburetor unit, see chap. 07 and 08. leaks. If there is a leak into the oil tank, it into the radial gasket. When the spindle is
will not be possible to fully identify the leak. screwed in, it will press against the shaft and
Connect the over/underpressure pump pull the radial gasket out.
If pressure remains steady in the crankcase
to the connection on the sealing plate 2
after shutting off the oil line hole, for example Caution: Under no circumstances hammer
(944.603.200)
with a rubber stopper (see chap. 05), it is in the puller.

Repair Manual PS-6100 / PS-6100 H 25

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 11 CYLINDER / PISTON

Cylinder and piston disassembly

Remove the mufer, see chap. 04.
Remove the starting system, see chap. 06.
4 Remove the carburetor unit, see chapter 08.
Unscrew the cylinder bolts and pull the cylinder up and
off.
5 Remove and reinstall the circlip 5 with needle-nose
pliers.
6
Assembling the cylinder and piston
Carefully remove any gasket residues!
Use a new cylinder base gasket 2!
1 Before assembly, lightly oil the cylinder race,
piston and needle bearing 6!
2
Install the piston with the arrow marking 4 on the outlet
3 side of the camshaft (piston ring lock on the inlet side).
Move piston to bottom dead centre.
Position the opening on the piston ring towards the
piston ring lock.
Use the piston ring tensioner 1 to press the piston ring
together.
Push the cylinder onto the piston. Let the piston ring
tensioner slide down with it.
Remove the piston ring tensioner and press the
cylinder all the way down on the pins 3.
Hand-tighten the screws lightly crosswise, and then
tighten to the correct torque (12 +1.0 Nm), again
crosswise.

Repair Manual PS-6100 / PS-6100 H 26

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 12 CRANKCASE

The complete crankcase is divided into: Disassembly

•• CS crankcase clutch side To disassemble, unscrew the 6 bolts. Using a rubber
•• MS crankcase magneto side hammer, carefully drive the crankshaft out of the
Two pins ensure tting. crankcase MS.
Remove spacer ring 2 from the crankshaft. Using a
rubber hammer, carefully drive the crankshaft out of
the crankcase CS.
To remove and install the bearings, heat the crankcase
CS and MS to 160-180°C.

Assembling
1 NOTE: Before installation, apply ““Loctite 620”” to the
outer ring of the bearing.
Place the bearings in the hot crankcase.
When driving the crankshaft into the crankcase MS or
CS, support the crankshaft side between the webs.
When installing the second crankcase half, the
crankshaft webs must be supported against each
other.
NOTE: Make sure to remove the support after
assembly.
Before assembly, carefully clean all sealing surfaces
and remove any remnants of the old gasket. When
assembling, install a new gasket.
Hand-tighten the screws lightly crosswise, and then
MS tighten to the correct torque (12 +1.0 Nm), again
crosswise.
KS
CS 2 After bolting the crankcase sides together, cut off the
ash 1.

Repair Manual PS-6100 / PS-6100 H 27

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 13 TORQUES

Screw Part No. Size Qty. Torque [Nm]

crank case MS with CS 908.405.255 Torx 6 10 +/-1
cylinder on crank case 908.005.255 Torx 4 12 +/-1
reed valve to air hose 908.004.085 Torx 1 3 +/-0,5
air hose to cylinder 908.405.145 Torx 4 5 +/-0,5
carburetor base on crank case 908.005.165 Torx 4 5 +/-0,5
mufer to cylinder 908.005.205 Torx 2 8 +/-1
mufer to cylinder, upper screw 908.305.405 Torx 1 8 +/-1
contact spring to intake manifold 915.135.100 cross recess 1 1,5 +/-0,2
air lter base to intake manifold 175.131.300 A/F 7 4 3 +/-0,5
oil pump to crank case 908.005.165 Torx 1 5 +/-0,5
clutch on crankshaft --- M12 x 1 L 1 35 +/-2,5
chain tensioner gear cover to crankcase 908.705.125 Torx 1 5 +/-0,5
bar bolt to bar ange 195.232.010 M8 SK6/M8 (Lock with Loctite 243) 2 15 +/-1
assembly of sprocket guard 923.208.004 A/F 13 2 1 +/-0,5
brake cover 908.105.124 Torx 4 5 +/-0,5
ignition coil cpl. crank case 908.805.205 Torx 2 5 +/-0,5
ywheel fastening by nut 920.308.024 A/F 13 1 28 +/-2,0
starter cpl. to crank case 908.005.205 Torx 3 5 +/-0,5
handguard mounting to starter housing 908.005.205 Torx 1 5 +/-0,5
grip half / rear handguard to tank 913.455.164 Torx 1 5 +/-0,5
fastening of tubular handle at side of tank 913.455.204 Torx 1 5 +/-0,5
fastening of tubular handle on bottom of tank 913.455.204 Torx 2 5 +/-0,5
side support cover to tank 913.455.204 Torx 1 5 +/-0,5
side support cover to damping spring 908.006.145 Torx 1 5 +/-0,5
damping spring - tank magnet side back 181.114.300 Torx 1 5 +/-0,5
damping spring - tank clutch side front 181.114.300 Torx 1 5 +/-0,5
damping spring - tank clutch side back 130.114.400 Torx 1 5 +/-0,5
damping spring - cylinder 181.114.400 Torx 1 5 +/-0,5
crank case MS/damping 908.006.145 Torx 1 5 +/-0,5
crank case CS/damping 908.006.145 Torx 2 5 +/-0,5
spike bar to crank case 908.005.165 Torx 2 5+/-0,5
spark plug 965.603.021 A/F 19 1 15 +/-5
starting ratchets to ywheel 170.166.041 Torx 2 8 +/-1
ignition cable holder 908.005.095 Torx 1 5 +/-0,5
evacuation tube 908.005.095 Torx 1 5 +/-0,5
air lter --- M4 1 3+/-0,5

Repair Manual PS-6100 / PS-6100 H 28

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 NOTES

Repair Manual PS-6100 / PS-6100 H 29

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

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