MZ TS 125 Operating instructions

REPAIR MANUAL
for the
MZ MOTOR-CYCLES
TS 125
and TS150
with 174 illustrations
and
23 drawings of special tools
4th Edition
VEB MOTORRADWERK ZSCHOPAU
Betrieb des IFA-Kornbinats Zweiradfahrzeuge

l
I
The motor-cycles of types TS 125, TS 130, ES 12511 and ES 15011 are product8 from VEB Motorradwerk Zldropau
S
This Repair Manual was written by a team of engineers in the employ of VEB Motorradwerk Zschopau
VEB Motorradwerk Zsdropau reserve the right to modily or deviate from published specifications tor technical or
technological reasons at any time without notice.
All rights reserved
VEB
FACHBUCHVERLAG LEIPZIG
Dead line: June P, 1983
Photomeohanfcal print: Salzland-Druckeref StaOfurt
SG 157A30/84
RH TS 1251150 und ES 12511 U. 15011. englisch. g;. Aufl.

Preface
111the high latitudes of Finland, in the parhing heat of Africa, under the mort
different operating conditions
MZ motor-cycles run to the retidaction of their
owners.
To ensure that the vehicles, remain in perfect working order and reliable .in
service after a long period of operation, involving a certain amount of wear.
we issue this Repair Manual to give the necessary instructions to our
MZ work-
shops
at home and abroad.
Repair
WOI'~~ is a matter of confidence in several respects:
reliability and workmanship of the mechanic; the safety of the driver
depends on them.
finding the actual cause of the trouble; this ensures that no material
is wasted and labour costs are restricted to a minimum.
from this. three advantages result: no retouching work, short times of
inoperatiun and low repair costs.
A good worksmanship in repairs largely depends on the use of the special tools
and means recom~~~endedby
MZ. Authorised MZ Service-shops may obtain them
from the
R1Z Spare Sales Department, whereas amateur constructors only have
the possibil~tyof making them themselves. But to do it yourself you shbuld use
the sketches given in the Append~x.
U'e should like to underline that especially customers of "self-service work-
shops" and amateur constructors bear this in mind to avoid considerable addi-
tional expenditure of labour and material.
We hope this book of reference offers the required information to the staff of
the workshops conlracted for servicing our products at home and abroad and to
le friends of
MZ motor-cycles throughout the world, and wewish good success.
VEB MOTORRADWERK ZSCHOPAU
~etrieb,des IFA-Kombinats Zweiradfahrzeuge
Service Dept.

Table of Contents
Tedmiecrl Data .................................... 8
Engine .........
Carburetter .......
Electrical Equipment ...
Transmission .......
Power Train .......
Cycle Parti .......
Dimensions and Masses ...
Capacities ..... : ..
Characteristics and Diagrams
...............................
Fuel. Lubricmts and Fluids 12
........................................
Fuel 12
......................................
Engineoil 12
Gear011 ...................................... 12
...............................
Lubricants for Cycle Parts 13
Shock-absorber Fluid
................................. 13
...............................
Contact Breaker Lubrication 13
Dissossembly of the Engine ............................... 13
4 . Assembling the Engine .................................. 16
. S .. Electrical E~ulpment ................................. 30
Dynamo
Checking
Checking
...............
the Armature for Accidental Earth .
the Armature for Shorted Turns . .
Checking the Field Coil for Accidental Earth .
Checking the Field Coil for Shorted Turns . .
Servicing the Carbon Brushes .......
Servicing the Commutator ........
Fault Indication by the Charging Control Light
Adjustable Resistor
...........
Polarity Reversal in the Dynamo ......
Regulator Cut-out ............
.............. Adjustment
Mounting and Servicing
..........
Faults and Their Causes .........
................ Battery
..... Putting the Battery into Operation
Servicing the Battery ..........
Ignition System ............
.............. Ignition Coil
............. Ignition Timing
Ignition Timing by Means of a Graduated Dial
.
Setting the Firing Point .........
Sparking-plug .............
Plug Cable Connector ..........
...............
Troubles
Electric Horn
.............
Ignition-light Switch ...........
Headlamp ...............

.................................
5.7.1. Focusing the Headlamp 41
?
.............................
5.8. Tail Lamp and Stop-light Swit&
42 v
5.9. Flashing-light Direction Indicator System ................... : ...... 43 :
....................................
5.10. Speedometer 44 v.
...................................
6 . Induction System 44 l
l
..........................
8.1.
Carburetter BVF 22 N 1-3 and 24 N 1-1
45
.......................................
6.1.1. General 45
6.1.2.
Description of the BVF Carburetters 22 N 1-3 and 24 N 1-1 ...................
45
.
8.1.3. Trouble Shooting and Tuning .............................. 47
7 . Cycle Parts ..................................... 60
Exhaust System ................................... 50
Steering
...................................... 51:
ES
12511 and 15011 ................................... 51
................................
Removing the Handlebars 51
.............................
Front Fork and Steering Bearing 51
Replacement of the Swing-arm Bearing Pin
.........................
51:
TS
125 and TS 15C ...................................
52
Steering Bearing
................................... 52
Telescopic Fork (see Fig . 136) .............................. S!
FuelTank ...................................... 571
l
Fuel Shut-off Cock .................................. 58
Brakes 58
1
.......................................
Replacement of the Foot-rest Tubes ............................
591
Checking and Changing the Secondary Chain ........................ 59
Adjusting the Clutch
................................... 60
Removing and Dismantling the Rear Wheel Drive ...................... 61
!
Speedometer Drive .................................. 62 . 1
Replacement of the Wheel Bearings ............................
62
Inspections Required in the Case of Poor Road-holding .................... 62
1
Repairing the Spring-loaded Suspension Units ........................
63
Shock-absorber Marking ................................ 63
Removal of the Shock-absorbers ............................. 64
Common Faults in Shock-absorbers ............................ 64
Filling the Shock-absorbers with Fluid ........................... 64
Mating Shock-absorbers ................................ 64
I
Cable Controls ..................................... 64:
9 . us( of special Tools ................................... 65
8.1. Engine ....................................... 65
9.2. Cycle Parts ..................................... 65
9.3. Electrical Equipment ................................. 85
10 . Sketches for Making Special Tools ............................ 66
Supplement: Repair Instructions for the Engines 12513 . 15013 and the Telescopic Fork with Aluminium Slide Tube

Fig. 1. TS 125 and 150
Fig. 2. ES 12511 and 150/1

Fig. 3. Sectional view of engine

1. Technical Data
1.1. Engine TS 125and ES 12511 TS 150and ES 15011
-- -
Type MM 12512 MM 15012
Strokelbore 58/52 mm 58/56 mm
Swept volume 123cm:' 143 cm'
Maximum output 7.35 kW (10hp) 8.45 kW (11.5 hp)
(at 6000 to 6300 rpm) (11 SAE hp) (12.5 SAE hp)
Maximum torque 12.3Nm (1.25 kp-m) 14.7 Nm (1.4 kpm)
(at 5000 to 5500 rpm)
, Type of carburetter 22 N 1-3 24N1-1
Number of cylinders 1 1
Piston mass, complete with two rings, gudgeon pin and
locks 160
+ 5 g 200 f 5g
Compression volume with the sparking-plug inserted
. 14.0 cm3 16.5cm"
Cycle two-stroke reverse scavenging
Cooling system air stream produced in driving
Connecting-rod bearing bottom, cage-type needle bearing
K 25 X 31 X 17 L
top, bronze bushing
Crankshaft main bearing 3 ball bearings 6303 c 3 f (silent, 17
X 47 X 14 mm)
lubrication by gear lubricant
Cylinder light-alloy, liner of special grey cast-iron onto which
the light metal is cast
Timing in crank degrees
inlet 150"
transfer 115"
outlet 165"
1.2. Carburetter
Transfer port
Main jet
Needle jet
Partial-load needle No.
Needle position, from top
Starter jet
Slow-running jet
Slow-running air screw
Throttle opening
Air filter
Float valve seat
1.3. Electrical Equipment
Ignition
Ignition timing
Contact breaker points gap
Sparking-plug
Electrode gap
Dynamo
Charging control light (red)
Regulator
Battery
Ignition coil
Headlamp (asymmetrical)
Tail lamp
combined with stop light
(3rd for running-in) (4th forrunning-in)
70 75
35 40
opened by
2 to 3 turns opened by 2 to 3 turns
3 mm 3 mm
dry air filter (paper cartridge)
15(1.5mm)
. 15(1.5 mm)
battery ignition
3.0-0.5
mm before T.D.C., fixed setting
0.3 to 0.4 mm
M 141260
0.6 mm
direct current 6
V, 60 W, short-time operation 90 W
in speedometer
RSC 6016, under left-hand panelling
6
V, 12 Ah (flat lead storage battery)
6
V, under left-hand panelling
ESTypes fixed
- lamp opening 136 mm
TSTypes movable
- lamp opening 170mm
ESTypes lamp opening 95 mm
TS Types
lamp opening 100 mm
contact in rear brake
i

Flashing-light direction indicators ES
TSTypes
Flasher unit
Horn
By-pass light signal
Bulbs (data in parantheses apply to TSSpes)
bilux (twin-filament)
parking light
stop light
tail light
flashing-light indicator
charging control light
idling indication
speedometer illumination
1.4. Transmission
Clutch
Gear-shift system
Number of speeds
Gear ratios
1st speed
2nd speed
3rd speed
4th speed
Bearing on clutch shaft
Bearing on layshaft
Rearing on shaft gear
Idling indicating light
1.5. Power Train
Transnlission
enginelgearbox
by sleeve-type chain
or double sleeve-type chain
(from 4th quarter of 1973)
Transmission
gearboxhear wheel
by roller chain
1.6. Cycle Parts
Frame
Steeringangle
Caster
Suspension system
front
TS 125and ES 12511 TS 150 and ES 15011
I
2-light system at the handle bar ends
4-light system
in headlamp shell
under fuel tank
actuated by push-button
arranged below dimmer switch
6 V, 45/40 W
passing beam asymmetric
6 V, 4 W, BA 9 s cap
6V, l8W, S 8.5 cap
(6 V, 21 W,
BA 15s cap)
6 V, 5 W, S 8 cap (BA 15S)
6V, 18W, S8.5cap
(6 V, 21 W, BA 15s cap)
6 V, 1.2 W
6V, 1.2 W
6V,1.2 W
multiple disk clutch in oil bath
foot-operated, left-hand side
4
3.05 : 1
1.805
: 1
1.285
: 1
1 :l
6202 (15
X 35 X 11mm)
6201 (12
X 32 X 10mm)
6004 (20
X 42 X 12 mm)
electric control bulb (green) in speedometer
2.31
: 1 37;16 teeth
A 9.5 X 9.5 ('18" X 3/e") 48 links
2
X 9.525 X 4.77 (3/8" X 3/16")48 links
3.2
: 1 3.0
: 1
f 48: 15teeth
C 48: 16 teeth
12.7
X 6.4 X 8.51 ('l2" X l/,") 120rollers
continuous pressed-steel, seamed
TS 60"
ES 61"
TS 90 mm
ES 95 mm
C
TS telesco~icfork with hydraulic damping, total travel
of spring 185 mm

rear
Wheels
Rims, frontlrear
Tyres, frontlrear
Tyre inflation pressure when loaded with:.
75 kg front
rear
150 kg front
rear
Permissible total mass
front
rear
Drake actuation
Brake diameterlwidth of lining
front
rear'
1.7. Dimensions and Masses
Wheel base
Length
Height withlwithout mirror
(flat handlebars)
Height withlwithout mirror
(elevated handlebars)
Height with mirror
Width withlwithout mirror
(flat handlebars)
Width withlwithout mirror
(elevated handlebars)
Width with flashing-light indicators
Ground clearance, loaded, at prop stand
Weight unladen,ready for operation
with fuel andtools
TS
ES
Permissible total mass
1.8. Capacities
Gearbox
Fuel tank
including reserve
Telescopic fork
Suspensions units, rear
1.9. Characteristicsand Diagrams
The maximum speed,'depending on sitting position,
is
about
100 kmlh for
the TS 125and ES 12511
105kmlh for the TS 150 and ES 1M/1
The maximum speed will only be reached if the re-
TS 125 and ES 12511
TS 150 and ES 15011
longitudinal swing
spring-loaded suspension
units with hydraulic damp
ing, total travel of spring 150mm
spring-loaded suspension units with hydraulic damp
ing total travel of spring 105 mm, spring pre-load ad-
justable
wire spokes
1.60
X 18 1 1.85 B X 18
2.75-18
1 3.00-18
150kPa (1.5 kp/cm2)
270 kPa (2.7 kp/cm2)
mechanically, by means of cable controls for both
brakes
about 1150
mm
7301620 mm
about 750 mm
140mm
0.45 1of GL
60 gear oil for summer and winter
12.5 1of petrol41mixture
about 1.5
1
220 cm3 of shock-absorber oil for each unit
70
a3 of shodr-absorber oil for each unit
quired favourable conditions are given (rider stooping
so
as to be almost "lying", tightly fltting motoring suit,
plane road, no headwind).
The engine charaderi$tics, traffic fuel consumption,
and acceleration are shown
in the following diagrams
(Fig. 4 to 9).