NSU Supermax User manual

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RMAX
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Downloaded From NSUsupermax.com

SUPE'RMAX
with suspension units
All righis reserved by NSU.
Reproduction
or Ironslation of this Instruction Book
-either in excerpt or in tolo - is not permitted Issue
of May 1961
without the written approval of Messrs.
NSU MOTORENWERKE AKTIENGESELLSCHAFT. NECKARSULM
N)U MOTORENWERKE AKTIENGESELLSCHAFT NECKARSULM
Downloaded From NSUsupermax.com

','
wifh all the interesting details of'yournew,'ma,chirie, ·but·· ;,
especially \with all the. hi'nts and advices we 'offer you" J
for
the correct 'servicing of your machine., , ' '
, F,urthermore,.:ve
w~~ldask, you, a~cor9ing' to ,the, di'r~l=- .. ,
tions, given, in ,the' attached Service and Inspection Card,
tota~e yo~r machin'~ to an' N'SU. Gealer's,workshop in .,
. order to have the ,various ,jobs, sugge~ted by the. works;
carried out by eXl"erts, Only NSl) Dealers have, besides
original NSU spares, time-saving special";to~)s c;md ,main~ '."
·tenence 'manuals at thei.r disponal,. as~ weI!, as' expert
mechanics ,specially NSU-tr~lined. We' would, therefor~
,"1
, suggest 'that" you take your machine, in case of repair,
work, to'o,
~Iways-to your NSU:Dealer,
I ", • ~ - , " , •
",1
Any. 'guara'ntee'".eldims fhat, might a;ise to ,be reported
to'your Dea,ledor'his~ examination,. who' then fibs to bring
1
the ea-se to the G'~n~ral Agent's atte~Jion,'AII guara~tee
I
, claims submitted' direct to' ,the General Agent can ,only ..
1
. be finalized on havi'ng the Dealer's" report, '
R;pai~ iobs at -the"'General Agent'~ can' only. b,e :carried ':.
'througth on appointment m~de beforehand "thrpug!l y;'ur
Dealer.;'"
.,
Finally,..we would ask you to.al.ways adh~re' to our,well,',
,meant advice, and 'wish yo~ .,:
"
Many Miles of Trouble-free Riding'dn NSl:J! ,
NSU MOTORENWERKE AKTIE'NGESEl:LSCHAFT
NECKARSULM
2 .,
~ , ."
,"
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Depr NS!J Friend', ," '. I
. We would ask you to, study this,hlstruc-
t,ion
'book carefully, and thus acquaint, YOljfself not o~ly",
, C· Od'-I '1' E ~ T "s ,,
\ A'
":I/l!roduction
,,
Tec~nical pata ,
. Des'cription .
-"
Operating' Instru~tions
Care and Lubrication
Maintenance ." _ . .
Peri~dical Lubrication and Inspection, .
. , Recommended Lubri~~nt~. , .. , ,
-Laying:
the Machine- up for thE! Winter .
'I" - ~r'acin~'. Troubles,
Air-filter , " . ,
'-, " Brakes - Adiu~ting fr'ont 'brake
. ~ , ... '
Bra~es ~ Adju,sting ~e,ar brake' ,"
Brakes - Bearings for rear-chain sprocket arid
." driving wheel with cush-drive
B'r~kes ~ Spindle for f?ot,brake p;dal .
,', .. Car!Ju,rettor " ': ' .' " ,,~.,'
G:.arburettor ,- Operat,i?n; .'
.', Carblirettor - .. Tickler Knob,
~ha'in -"Chain: Tension' "
Chain -Lubrication
'Chassis'.
'Cha'ssis ~,.Fr.ame:' .. '
_ r o·
\,
Chassis _I ~'ivoted Saddle
,fOp ;.
2
,8'
,'11-:-20 '
:21~28
,29-42
,4~64
"
.66-67
68
69
10
. " 13/31
" 43
44/45
41
3~
54,
13
25
'46
30/36,
'17118
17
, 19
3
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Clutch . . . . . . .
Clutch - lubricating Operating
Clutch -
Adjusting . . . .
Rod 37
53
15
Electrical System -Adjusting Headlamp
Electrical System -Batery . . . . .
Electrical System -
Charging the battery
Electrical System -
Dipper Switch . .
Electrical System -Electric Horn
.
.
.
62
15/59
23/59
14/28
15
Electrical System -Faults in the Lighting Circuit. . 71
Electrical System - Fuse. . . 14
Electrical System - Headlamp 60
Electrical System -
Harn Button 14/28
Electrical System -Ignition Faults 57/59
Electrical System -Ignition
and lighting Generator 14
Electrical System -Ignition
Key. . . . .. . 25
Electrical System -
light Switch . . . . .. 14/28
Electrical
System - lubricating Pad on Contact
Breaker . . . . . . ·42
Electrical System -Positions
of light Switch ·
28
Electrical System -
Sparking Plug . . 14/58
Electrical System -Tail
light.
15/60
Electrical System -Timing
the Ignition · 58
Electrical System -
Stop. light
15/60
Electrical System - Wiring Diagram
61
Engine. . . . . . . . .
11
Engine -Adjusting Valve Clearance
23/64
Engine -
Crankshaft Assembly . . . 11
Engine -
Characteristics. . . 7
Engine -
lubrication . . . . 12/21/31/33
Engine - lubricating Starter Spindle
34
Engine -
Starting
25
Engine -Valve Gear. . . . . . 11
Front Forks . . . . . . . . 19
Front Forks - Thiefproof lock.
18
Fuel Tank. .. . . . . . . . 20
Fuel
Tank -Check.ing Fuel Supply
23
Fuel Tank -Fuel Tap Positions.
24
Fuel Tank - Standard Fuel Consumption.
56
Gearbox . . . . . . . . . . .
16
Gearbox - Gearchange Mechanism.
53
Handlebars . . . . . 18
Handlebars -Checking Play in Steering-head
Bearings
65
Handlebars -Lubricating
Control Cables . . 35
Handlebars -Lubricating
Controls. . . . . 34/42
Handlebars -Lubricating
Steering-head Bearings
42
Power Transmission -
Engine-Gearbox
16
Power Transmission - Gearbox-Rear Wheel
17
Rear Forks . . . . . . . 19
Running - Changing Down.
27
Running - Changing up. . 27
5
4
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__
..
,, ., ;
....
,,
~. -"'~ ..
Running - ,Engaging Neutral Gear,
, 25 , , ;
Th~ Ch~r:a'cteris,ics of the MAX Engine
'Running -Prep'aring for a Trip' "
'~3
H.""
Runn~ng -: Running-i'n Period
21/22
20 ~-....--';--,.-:-r---"'::,--:-,--..".---::-.,.---,
Runnin,g - Starting off ','
, 27
.. 1
19 ~~r--+~-+-+-t--'--j--+--+---:-I
" Running -
Stopping
27
Running - Ihe End of the Journey,
" 28,
Sidecar" " _ 51/52 ;
Speedometer 20 '
Speedomet~r - Greasing the D~ive ,
~7
'Yyres -Checking Tyre Press~res
-23
"", ". . ,'
=:; 12, ,'. ~
Tyres -:- Fitting Tyres
50
~ " '/1 1---'--1--, +'I/~'+-+-t--;..jf--:'"--+--j---:-l
Tyres -Tyre
Pump ,
'20.
I , 0
10iJ-...-'-I---.lL---+--+---f--+'--+-+---l
. I
Wheels , , , _ ,
20
/
. .. , --
9'~-++-+-,.I---+-+-.c..-I---+-+---l
'~
Wheels -, Greasing Front and ~~ar Wheel Bearings,
40
81--.+-=--l--J.----jI---+--t--+--l-:--;
Wheels ~ Removing Fro'nt Wheel
47
.,
·71---+--!--+--I----+-+-+-:----1r---:1
\'
, -
Wheels -RelTloving Rear Wheel,
. 49,
6'·l--L~-l..-_l--L.:.-....L~~~-:--:::.l:-:~ •
3500 4000,4500 5000, S50~ 6000 6500 7001) 7501)
Engine Speed ~"r.p: '!':: ;
" I,
-\ ".-
- .:.,.
18
"
11
7
16
15
,~
14
:t:
:13
.S
/,
' .. ",
" i
2,0 I--+..L.-+-..,.+---+,,~ ~-+.-._;;::-'-, 1--+---1
;,
~....- ...... ~
~ ~ 1.9 I-,-...::...j---+--+ ."'.",.~~+-+-~p",r.-___t
~ e: 1---1---+~q'-+-+-+--'-+--t---t
'~,5: 1.,8 V
'1.7 ''1./ "
/5 '.,
, ',3500 4000 4~00 5000 5500 50006500
7000 '7500
.. . "- . . fngine
Speed ':: p. m;'
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TECHNICAL
ENGINE - CLUTCH- GEARBOX
Cycle
4 stroke
Stroke
66 mm
.
Bore. .
69 mm
No. of cyl'inders 1
Capacity . . . . 247 cc.
Compression ratio.
704 :1
Output. . 18 h. p.
Engine speed
. . . . 7 000 J. p. m.
Valves . . . . . . Valves are suspended in
light alloy cylinder head and operated
by eccentric-driven overhead camshaft
Lubricotion
By gear pump
Ignition. . . . Coil ignition
Ignition timing advance.
Automatic
Carburettor Two-slide carburettor
Air fi Iter . . . Wet air filter on frame
Clutch . . . . •
Multi-plate dry,
clutch with rubber shock absorbers
Clutch control Manual
Gear box 4 speed gearbox in unit
with
engine
Type of engagement. Do!=) Clutches
Gear reduction for primary drive
2.583: 1
Gearbox ratIos Solo
o"erotion
Sid"T ".m';,"
Bottom
gear.
3.15 : 1
2nd
gear 2.025,1
. 3rd gear ....
1.406 , 1
Top
gear'. . . . . 1
,1
Reduction
ratio for final drive 2.625: 1 3.0 ; 1
Overall ratios
Bottom gear. 21.36 : 1
24.41 : 1
. 2nd gear . . 13.73 , 1 15,7
,1
3rd
gear . . 9.53 ; 1 10.89: 1
Top
gear. . 6.78 ,1 7.75: 1
P~imory .drive between engine and gear box Helical
gears
Final drive betwe'en gear box and rear wheel Enclosed cha
in
Maximum speed approx. 72 m. p. h.
Peak speed approx. 78 m. p. h. one person I •• nlng forward
DATA
FRAME -WHEELS -BRAKES -EQUIPMENT
Central pressed steel frame
Front fork/rear fork
Swinging spring forks
Shock absorber, front
Hydraulic
Shock absorber, rear.
Hydraulic
Stand
Frame ..
Centre stand
Tank capacity
3 Imp. galls. (14 Ltr.)
(0.33 Imp.
galls, reserve)
Length
approx.
79" (2010 mm)
Width approx.
26
3
//' (680 mm)
Height approx.
373 //' (960 mm)
Interchangeable
Tyres 3.25 -19
Front brake
Wheels.
Internal expanding brake
Internal expanding brake
Brake operation
Front brakes by hand
Rear brake by foot
Weight ..
384 Ibs. (174 kg)
Admissible total weight.
715 Ibs. (325 kg)
Rear brake
Equipment
Electrical equipment .
Generator set with outo-
matic advance and re-
tard, electric horn, bat-
tery in locked box
Speedometer.
in head lamp
Accessories
Tools, tyre pump
Available against extra charge
Sidecar attachment
on request:
Pivot-action pilli0n seat
with folding foot rests
Design and equipment subject to change without notice
8 9
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i'f
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Eccentric on intermediate'sh~ft
,~ocker "'rry> ,
I
I·
Exho·us.t .. cams , Eccentric
rod
Balance weight
Eccentric on camshaft
:: I
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I:
','
Oil pump driving gear
Oil pump ,
Gear 0.." crankshaft
\
Intermed,iate gear
, Clutch
_ .. ' -
10
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D.ESCRIPTION
The Engi!1e
The NSU Mal' engine
is an a.ir-cooled, four-stroke engine built in unit with the
gea~ b0x'" -
The' Cranksh~ft
runs in roller bearings, The driving pinion for the oil
pump
and for the intermediate gear is fitted on the
left-hand end of the crankshaft, while the generator is '
fitted' on the right-hand end. The connecting-rod big-end
bea,r-ings
·isa roller· bearing. The light:alloy piston is pro-
vided _
Y".ith. tWQ compression rin--9s and one oil scraper
ring.
Valve Geqr
The valves are of the overhead type driven from the
overhead camshaft by means of two rocker arms. The
valve springs
are of hairpin form" -
in co~trast 'to pre:vious
l
designs· in whi~h the'drive to the
overhead camshaft is by means oJ a shaft, gears, or a
chain;
the 'drive of the Max consists of .a pair of eccen-
.'lric shafts,
each carrying two eccentrics at 900 to each
,other,' and. two' connecting rods. The lower eccentric'
shaft is bolted to, the intermediate gear, 'and the upper
.to th:~' camshaft. The two connecting. roS:ls which trans-
mit synchronously
the rotary motion to' the camshaft
are 'carried on the eccentrics in bronze' beari.ngs, In order
that the expansion of the cyliilder barrel dnd head on
I heating. up may not affect the eccentric drive adversely,'
the camshaft housing is free to swing, and is held on
the left-hand side by the stationary distance rod which
is secured to t~e, crankcase ot the centre qf the lower
eccentric·shaft.
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Lubrication of the Engine
is by means of the dry-sump system.
In this system the double gear pump comprises a scaven-
ging and a pressure pump. The scavenging pump has a
higher capacity than the pressure pump so that the oil
returning from
the points of lubrication cannot accumulate
at the pump, but is returned to the oil tank. The oil passes
through a filter on its way from the tank to the pressure
pump, where it recommences its cycle.
The oil
for lubricating the crankshaft is forced by the
pump through passqges drilled in the left-hand crank-
shaft, the left-hand flywheel, and the crank pin, to the
big-end bearing.
The cylinder walls and the gearbox are lubricated by
oil
thrown off from the crankshaft assembly.
For lubricating the valve mechanism passages are pro-
vided in the crankcase, cylinder, and cylinder head which
lead the oil directly to the individual lubrication points.
The dipstick in the oil tank is provided with two notches
the cap of the oil tank.
-The return flow
of the oil can be observed by removing
which
indicate the maximum and minimum oil levels.
Breathing
The pressure built up in the crankcase when the 'piston
descends is relieved through passages drilled in the right-
hand crankshaft and in the crankcase leading to the rear
of the engine.
The Carburettor
is a Bing two-slide ca~burettor.
The control cables that operate the carburettor are ad-
justed .at the twist grip and the air control lever on the
right hand side of the handlebars.
The wet air filter is so arranged that the air IS drawn
in from the frame and enters the filter 10 a steady
stream i there is practically no suction noise.
I
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1-
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Electrical System ,
The generator with aut?matic advance and retard, which
IS of Bosch manufacture, runs at crankshaft speed and
has an output of 60 ~atts at 6 volts, ",
.'
Th~ sparki~g plug used
h~adlamp IS fitted with a
dipped beam,s.! par,kin~
(! 5 amp.s), for all CIrCUitS
light sWItch.
is a Bosch W 190 M 11 S. The
. i
twin filament for the main ,and'
lamp, a warning lamp, 9 fuse'
other than the' ignition, and a'
\ -, .
The dipper sJlllitch and the push button for the electric
horn
are on the left hand side of the handle~ars.
14
1'::--
.J
-'The tail la~p on the, rear rpud~ua'rd i.s a combined rear
. Ii'ght .a[ld reflector 'rVhic~ also serves to illuminate the
. number plpte. It also' indiJdes a stop' .Iight 'which lights
up'
when the foot brakl? is applied .
h ...
."' , .;
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the. battery is rpounted in :C.- special lock-up container,
'on the left 'of the rear mudguard. This cohtainer 15
rubber-mounted to' protect the battery from vibralio'n"
The electric horn is fitted on a, sprung mounting on the
-fronl of the"fr~me u()d~r. the tank,
Transmission
The .:n!JIt;plate c1~tchwhich is mounted on the leff :hand
side of .the eng ire ·.is a dry clutch containing' three steel
and four fric,tion' plates and is operated by the dutch
lever 'on the left handlebar, through p.n -adjusIGble· cable
'. and a clutch -operatin!;! lever with a square threod:
15
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The Four-Speed Gear Box
is built in unit with the engine. The gear p'lnlons are in
constant mesh, and are engaged by dogs. The foot-
change lever and the folding kick-starter are on the
left-hand side of the machine.
The
Gearbox is lubricated
by oil thrown off from crankshaft.
Primary and Final Drives
Engine - Gear box
Helical gears .running in an oil bath transmit the power
from the engine to the clutch through an intermediate
pinion and a rubber shock absorber.
'Primary and final D~jves
, Gearbox - Rear wheel '
The final dri:e' is by meall's of a .rolle~ chain which runs
in 'a dust-pr90f casing, and ,the tension of ,which can be
adjusted by a pair of cams 0n the ends of the rear
. forks. A rubber shock absorber is also incorporated in
this drive:
. ... ; ..... ,
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I'
I Chassis
the pressed~steel Fr~me
h'as the engine mounted 01) its rear section. In addition
the top of the Gylin'der head is connected to the frame .
. A
central stand with c'urved feet serves to su'pport the
,machine.
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