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Release the chain brake by levering down the brake gate using a screwdriver.
Remove the cover plate to remove the brake band and relieve the tension spring.
Replace a damaged or defective brake band or tension spring without delay. Caution: Safety components.
Remove the nut and push the screw in direction of the cylinder. Unscrew screw on starter side.
Ensure the compression spring is installed correctly when fitting the hand guard.
Immobilize the cylinder unit by unscrewing the silencer and inserting a piston stopper wedge.
Use specific spanners for clutch removal. Caution: Left-hand thread.
Note different clutch designs for models 109, 110, 111, and 115. Springs can be replaced individually or as a set.
Replace worn sprockets or clutch drums. Note different designs and parts availability for models.
Grease clutch drum bearing lightly before installation. Tighten clutch to 35 Nm.
Adjust oil pump delivery by turning the screw clockwise for less oil, anti-clockwise for more oil.
Unscrew the pump housing from the crankcase and separate the intake pipe.
Check set screw condition and pump plunger for damage. Replace defective parts.
Unscrew the chain guide plate and withdraw the intake pipe from the oil reservoir.
Withdraw the oil filter prior to cleaning the intake pipe. Pass spring over pipe when installing filter.
Screw tool onto worm and withdraw from crankshaft by tightening the screw.
Test spark plug by pulling rope and checking for spark. Clean or renew defective plugs.
Pass rubber cap over cable, engage spring in hole. Ensure correct installation for new cables.
Install switch ensuring flat side faces up. Push cable into switch and install rubber cap. Screw on nut.
Remove cover, starting assembly, and short-circuiting cable. Unscrew screws and ignition cable.
Install armature, secure with screws. Use gauge for air gap. Align N/S marking of flywheel.
Remove carburettor and bottom part to remove cable. Ensure cable is not caught when fitting bottom part.
Unscrew nut. Screw punch onto crankshaft and remove flywheel by striking a blow.
Ensure cone is grease-free. Tighten nut to 25 Nm.
Relieve return spring by withdrawing rope. Remove rope from drum and allow drum to rewind slowly.
Remove retaining ring and washer. Separate handle from rope, lift rope drum. Remove spring and cassette.
Completely withdraw rope, hold it. Turn rope drum 1/2 turn. Reduce pretensioning force if necessary.
Replace starter ratchet, spring, and pin as an assembly. Push pin into flywheel and apply locking agent.
Adjust L and H screws for basic settings. Use idling adjustment screw (S) for engine speed control.
Remove filter cover and hood. Separate fuel pipe, unscrew screws, remove choke lever and linkage.
Align control lever surface parallel with the carburettor body.
Remove cover, diaphragm, seal. Unscrew screw. Control assembly includes needle, rocker arm, shaft.
Unscrew cover, remove seal and diaphragm. Carefully remove fuel filter for cleaning.
Unscrew attachment screw and remove valve assembly from carburettor body. Use new valve if needle tip is worn.
The intermediate flange can be taken out after the carburettor has been removed.
Remove cover for cleaning the air filter or auxiliary filter.
Remove cover assembly, lever attachment screw, and cover attachment screws to clean air filter.
Remove auxiliary filter and unscrew main filter. Separate main filter parts for cleaning.
Remove the bottom part after the carburettor. Note integrated plug and ventilation bore/seal.
Unscrew tank screws, remove vibration damper and catching band for handle removal/fitting.
Unscrew screws. Use special tool for removing or fitting vibration dampers.
Remove screws, including those located underneath, using a Torx spanner.
Three identical vibration dampers are provided on the tank housing. Fourth damper is between supporting web and crankcase.
Remove vibration damper. Separate fuel pipe from carburettor. Install seal between tank and bottom part.
Remove carburettor and bottom part. Remove ventilation valve from tank. Seal prevents contamination.
Withdraw intake head and fuel pipe from tank. Ensure sealing face rests close against tank when installing.
Separate the intake head from the fuel pipe. The felt can be replaced as an individual part.
Push out cylindrical pins. Remove throttle lever, torsion spring, half-throttle, and compression spring.
Unscrew cylinder attachment screws. Lift off the cylinder from the housing and piston.
Spread piston rings at the ring cap and carefully remove the piston. Ensure arrow points to silencer when assembling.
Remove gudgeon pin retaining ring and press out gudgeon pin. Remove piston from piston rod with bearing.
Note die cast cylinder (9) for models 109/111 and Henkel cylinder (10) for models 110/115.
For Henkel cylinders, piston and cylinder are precision-machined. Identification A, B or C is on the top part.
Place fork on crankcase, align piston rings, compress with tension band. Pass cylinder over piston.
Screw tool into sealing ring and withdraw it from crankcase using spindle.
For dismantling crankcase and oil reservoir, remove the seven attachment screws.
After removing attachment screws, separate crankcase using a plastic hammer.
Crankcase is divided into magnet side (MS) and clutch side (KS), including oil reservoir and intake pipe.
Insert crankshaft into KS half. Place seal and press both halves together.
Use tester for checking the ignition system / spark plug.
For in-situ checking, separate fuel pipe. Fit pressure tester to connection nipple.
Pressure-testing of carburettor or crankcase is to be performed at max. 0.5 bar.
Tighten cylinder base screws, crankcase screws, silencer screws, flywheel nut, and clutch hub using prescribed torque.
For pressure-testing, blank off exhaust duct and screw flange to inlet duct.
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