Chainsaw Repair
Husqvarna - Stihl - Poulan - Jonsered - Dolmar chainsaws and more => Dolmar Makita => Topic started by: KilliansRedLeo on May 29, 2014, 08:50:04 pm
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I need to remove the clutch, flywheel and split the cases on a Dolmar 7900. I am wondering if there are factory tools for these things and what the part numbers for the tools might be.
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The Dolmar 372 clutch tool works on the 7900.
There's been a great deal of this work done without factory tools but just common general purpose ones.
There's no internal threads on the exterior of the flywheel to use a special tool like on a Stihl.
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German Handbook says roughly:
Removing the flywheel by using the bolt part 944.500.880 in order to apply jarring blows on the shaft end of the crankshaft without damaging the thread.
There is no puller as for older models. Hope this helps... :P
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I use a punch on the end of the crank. Have someone hold the saw. Whack the crank with punch. Saw goes down. Flywheel stays up. Flywheel is off. I'll talk to my Amish dolmar dealer this weekend about a clutch tool.
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What saw is this TJ?
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What saw is this TJ?
Dolmar 7900
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OK. I think he uses a husky case splitter but I'll ask this weekend. I guess he says what saw in his first post lol.
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I checked, it appears that the Husqvarna 372 clutch tool will work on the clutch.
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The 372 clutch tool works on my 7900 like it was made for it. A burp from the air wrench and the clutch spider is off.
I re-did the oil pump on my 7900 last August. While I was at it, I used a new worm and the newer style clutch bearing. My older 7900 is a 2006 model. Apparently, they changed the bearing in 2009.
The old clutch bearing is a 10 X 14 X 12
The new bearing is a 10 X 16 X 12 and has more rollers
Each bearing requires the appropriate clutch drum.
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Also in 2009 there was a new chain catcher used that is rounded on the chain side.
There was also a cup added to the upper AV on the top handle to cylinder as a travel limiter.
If the rubber tail (166 chip guide, part # 038 213 190) is not on the back of the chain cover, chips will eventually erode the front corner of the gas tank.
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I used the Husky case splitter on 7900.
Shep
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Thanks guys for all your help. The saw came from Vermont from a guy I used to work with. He done blew it up! However later I will put up another thread with pictures of the piston and cylinder. Both the piston and cylinder are scored, the piston top however is full of BB sized pits. Saw obviously ingested something. It also appears that someone has been in it before because of a layer of silicone on the case joint under the muffler.
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I'm sure it will be in good shape when you get done with it.
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husky splitter works on these and i think same for clutch. only special tool that is nice to have is the sleeve to install the seal and the driver for the seal. there is a lip on the crank that makes installing the seal impossible without rolling the lip. tape, plastic bottle, film negative or similar takes the place of the sleeve and measure the seal depth before disassembly makes the driver not needed.
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Nate, if you have that tool and the sleeve in stock add them to my order.
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Not only does the HVA case splitter work, so does the flywheel side crank installation tool work to get the flywheel off without damage to the crank threads and the 288 seal sleeve will also work on the step in the clutch side seal installation as Nate mentioned!
Should have all the parts from Nate in a few days to begin reassembly.
Also found the reason the saw blew up. Looks like an air leak on the clutch side that caused the ring to stick in the piston groove just to the right of the exhaust port, then the ring caught in the ports on the flywheel side and broke parts out both above and below the ring groove. Unbelievably the ring remained in one piece!
I will put up some pics tomorrow, right now it is beer-thirty!
Thanks for everyone's help!
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I assume you don't need the seal tools now. make sure on reassembly to "glue" the bearings in the case. heard of it but haven't seen it personally. the bearings will spin in the case.
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I assume you don't need the seal tools now. make sure on reassembly to "glue" the bearings in the case. heard of it but haven't seen it personally. the bearings will spin in the case.
Gluing the bearings in is typical of all the newer Solo collaboration Dolmar chainsaws from this century.
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The WM I have specifies LocTite 601 for the bearing glue . In researching 601 I find that there is an improved 'oil tolerant' formula LocTite 603. Both of the products are expensive 30$ for a small amount. Anyone tried the 603 product or have another recommendation?
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Those Service Manuals were written back in the early part of the century.
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Well the WM I have is for the latest saw 7910 and it still specifies 'LocTite 601' to glue in the clutch side bearing. I was wondering if anyone had used the LocTite 603 product for this application.
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Sorry I am late with pictures of the damage. The cylinder scoring cleaned up well but under closer inspectionI found some damage to the left side rear transfer port. The first four pictures are of all sides of the piston. next is a pair of close-ups that show the damage to the piston itself and the last picture it the damage to the transfer port.
Even though the cylinder ceaned up I don't believe I would trust the cylinder.
Any thoughts?
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I'd just deburr those spots and run it. :)
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I would use it.... But that's just me. As long as there isn't any edges for the ring to snag on.
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Got nothing to lose, I will give it a try just to see but it is a customer saw and I don't want it coming back!
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Give your customer the option. Cylinder or anything we have doubts about I give them the options and let them choose. As much as we all would like to repair a Saw to like new condition money sometimes limits our ability to do that. Just did a suzuki rm125 That had a similar damage to port edges and we let him choose. Ended up just cleaning cylinder and installing a new piston.
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Nate, an RM-125? Nice little bike, what year was it?
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01 I think. It was one of those deals that one of our regular customers took us too literal when we say we will work on anything! Another friend/customer was in the shop picking up his water pumps and saw the 125 and his face lit up...asked if we worked on stuff like that...couple hours later he comes back with a Kawasaki 1100 stx jet ski!!!!! needs rebuilt. he was quoted couple grand for just a topend rebuild. Off subject but anyone know where to get wiseco piston kits? bought the one for the rm125 off ebay.
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Nate, http://www.wiseco.com/Catalogs/PersonalWatercraft.aspx (http://www.wiseco.com/Catalogs/PersonalWatercraft.aspx)
Here is what Weisco offers for the Kaw STX
http://www.wiseco.com/ProductSearch.aspx (http://www.wiseco.com/ProductSearch.aspx)
It will help if you know what year it is and if is the 'DI' model.