Author Topic: Dolmar Sachs 120si restoring - Picture story  (Read 776 times)

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Offline m_marc

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Dolmar Sachs 120si restoring - Picture story
« on: January 28, 2019, 09:24:10 am »
Hi guys,
I'm new of this forum, I'm Italian and I live in Nothern Itay near Switzerland.
I want to present you my recent project.

This autumn I decided to clean the toolshed at my granparents' house and in the middle of junk and sundries I found this:

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It's a 1989 Dolmar Sachs 120si in bad condition (subsequently become 6800, if I'm right).
I immediately decided that it could not stay in those conditions anymore and that I would have taken some time to fix it.

I did not have much time at home so far but now it's time to start, so I decide to start this post to tell you about the restoration live.

I want to start with some information that I collect: my grandad buy this chainsaw used from a friend in 1991 (the production year could be 1988-1989) and use it for several years.
Over the years it has stopped using it because of age, in favor of lighter chainsaw for the only small jobs he do in the woodshed.
It is in toolshed unused probably by 8-9 years.
I had not found the bar when I discovered the chainsaw but now I can tell you that a week later (when I had ended clearing up the closet) it had jumped out and it is in acceptable condition.

Now some technical data:

MANUFACTURED BY: DOLMAR Maschinen-Fabrik GmbH & Co. HAMBURG, GERMANY
SERIES OR ASSEMBLY NUMBER: 120
YEAR INTRODUCED: 1987
ENGINE DISPLACEMENT: 68 cc (4.1 cu. in.)
CYLINDER BORE: 49 mm (1.93 in.)
PISTON STROKE: 36 mm (1.42 in.)
CYLINDER TYPE: Aluminum with chrome plated bore
INTAKE METHOD: Piston ported
MANUFACTURER ADVERTISED H.P.: 4.8 DIN
WEIGHT: 7.3 kg (16.09 lbs.)
HANDLEBAR SYSTEM: Anti-vibration
CHAIN BRAKE: Yes
CLUTCH: Centrifugal
DRIVE TYPE: Direct
CONSTRUCTION: Die cast magnesium
MAGNETO TYPE: Electronic
CARBURETOR: Tillotson HS-236A
AIR FILTER SYSTEM: Nylon mesh element
STARTER TYPE: Dolmar automatic rewind
OIL PUMP: Automatic, gear driven, adjustable
MAXIMUM ENGINE RPM: 8,500 under load, 12,500 free speed
IDLE RPM: 2,400
IGNITION TIMING: fixed
FLYWHEEL/COIL AIR GAP: 0.15 mm (0.038 in.)
SPARK PLUG TYPE: Bosch WSR6F
SPARK PLUG GAP: 0.5 mm (0.020 in.)
CRANKSHAFT MAIN BEARINGS: Ball
FUEL TANK CAPACITY: 700 ml (23.6 fl. oz.)
FUEL OIL RATIO: 40:1
RECOMMENDED FUEL OCTANE: Regular grade
MIX OIL SPECIFICATION: Dolmar two-cycle chain saw mix oil
CHAIN PITCH: 3/8 in.
CHAIN TYPE: Chisel
SHORTEST GUIDE BAR SUPPLIED: 40cm
LONGEST GUIDE BAR SUPPLIED: 60cm

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Offline Cut4fun .

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #1 on: January 28, 2019, 02:11:55 pm »
Very cool saw. Jim here knows alot about them and I think Roger too. Maybe Bill also

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Offline 3000 FPS

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #2 on: January 28, 2019, 10:46:21 pm »
Those are great strong running saws.   Worth the time to restore.     Congratulations on your saw.   
PP 505, 475, 445.

Offline farmboy

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #3 on: January 28, 2019, 11:16:50 pm »
Agree w/Roger stout saw well worth restoring.  It will make you smile.
Shep

My IPL Illustrated Parts List is to large for me to download.

Offline Cut4fun .

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #4 on: January 29, 2019, 08:33:19 am »
Is this what you was wanting for IPL Shep?

Dolmar 116si 120si  siH IPL  http://download.dolmar.com/dipls/285.pdf
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Offline m_marc

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #5 on: January 29, 2019, 11:02:21 am »
Thank you all for the encouragement.
I'm sure it is a chainsaw that is worth bringing back into operation.

I had already found the same Part List at another link: http://www.barrettsmallengine.com/partslist/dolmarpartslist995700054.pdf

In these days the works begin, I'll try to keep you updated.
The first problem I have already seen (as you can see in the pics) it's that there isn't the hand guard anymore.
I hope that other parts of the lever and the brake are ok but I doubt it.

Offline farmboy

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #6 on: January 29, 2019, 11:20:13 pm »
Is this what you was wanting for IPL Shep?

Dolmar 116si 120si  siH IPL  http://download.dolmar.com/dipls/285.pdf
Yes.  Thanks.
Shep

Offline 660magnum

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #7 on: January 30, 2019, 12:44:37 am »
In your quest for the brake parts the 116Si is the exact same saw except for the piston and cylinder.

Many parts for the 6000/6800 are the same except the brakes are different. In fact the brake mechanism is about the only thing different between the two series.

I you put a Meteor piston in it, you will find that the skirt is short about .25 mm. However, mine seems to run fine with the free porting piston.

The regular 120 Dolmar is a different saw family.

I really like my 6800iH with a 24" bar.   W8YE
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That knowledge can live after us... and that "Pays It Forward".
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Offline m_marc

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #8 on: January 30, 2019, 01:12:00 pm »
Let's start!!

This morning I started to disassemble the chainsaw.
My doubts were concrete,  the hand gaurd there is not and unfortunately for me all the parts of the brake mechanism are missing, I have only the naked cover.
The engine has a good compression, the pull start works properly (I have to replace the cord) and there is a good spark.
Obviously I did not try to turn on the engine but this things that make me quiet confident.

Cleaning condition are awful, there is a solid mix of oil and sawdust encrusted in every hidden part.
Air filter is in pretty good condition, was well mounted, it is not damaged and it hasn't holes or ruptures, this is good for the health of the engine.
I separated engine from tank assemble and I have started to clean them, the rubber silent blocks are good.
Also the fly wheel is good and there is not vanes broken. Fuel hoses to the carburetor are old and stiff and brokes trying to bend it, tank was absolutely dry.
Cylinder and muffler are encrusted, muffler have some rusty points.

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From this view don't seem so bad

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From this it's worse

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Removing flywheel

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Tank collect years of sawdust and oil...

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For the first coarse cleaning I use kerosene. It melts sludge and oil very well but leave on the parts a greasy layer.
The second run of fine cleaning it's performed by Arexons Fulcron which is concentrated grease remover.

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This is the chain side cover and... I did not remove any other parts, every parts of the brake mechanism it's missing.
This afternoon I visited my trusted chainsaw shop for buy gaskets and carburetor's membranes; he still had in warehouse a complete kit for Tillotson HS-236 but I did not find a cylinder gasket (no problem, I'll make one with the old ones as a template and gasket's sheet).
For the brake assemble there aren't spare parts available and, as you rightly said, the actual 6800 differs precisely for the brake.
I talked also with the mechanic at the shop, who is old family friend (he has been working there for at least 30 years) and he told me that he will looking for. They have a warehouse of used items and parts, he is sure that there are something about Dolmar Sachs but he do not remember what. Finger crossed!!

In the next days I will continue the work.
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Offline Cut4fun .

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Re: Dolmar Sachs 120si restoring - Picture story
« Reply #9 on: January 30, 2019, 02:35:45 pm »
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