Puch 1980-1981 Puch User manual

PUCH
'80/ '81
Maxi, MaxiLuxe,NewportII,SportMKII
MagnumII,MagnumMKII
MOPEDMAINTENANCE
MANUAL
Includes
•TechnicalData
•Description
• Maintenanceandservice
•TroubleShooting
Steyr- Daimler- Puch
PUCHSERVICE - AUSTRIA 907.2.71.894.50580

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FOREWORD
Thisservicemanualforthefullrangeof1980/81modelswasissuedtoserveourworkshopsandtheirstaff
asguideforexpertrepairs.
Sincethemanualisintendedasaidfortheworkshop,werenouncedexplanationswhichareself-evi-
denttoanexpert.
Correctservicingrequirestheproperequipmentincludingallspecialworkshoptoolsasdetailedinour
listofspecialtools.Theworkshopmanualisthebaseforappropriateandeconomicalrepairshowever,
itisoffullvalueonlycombinedwiththe"ServiceBulletins"bywhichanyalterationsandimprovements
arepublicized.
Wesincerelyhopethatthismanualwillproveofinvaluableassistancebothfortheworkshopandcus-
tomeralike.
STEYR-DAIMLER-PUCH
OFAMERICACORPORATION
GREENWICH,CONN.06830
-1-

'80/'81MODELS
THISSERVICEMANUALCOVERSTHEFULLRANGE
OF1980/81MODELSASLISTEDBELOW.
MAXI MAXI LUXE
,3
NEWPORTII SPORTMKII
MAGNUMII MAGNUMMKII
i?
-3-

CONTENTS
LUBRICATIONANDMAINTENANCE6
EXPLODEDENGINEVIEW15
SPECIALTOOLS19
TORQUESPECIFICATIONS22
REMOVEENGINE23
DISMANTLEENGINE- I SPEED27
CRANKSHAFT35
CRANKSHAFT-WRISTPIN39
PISTON-CYLINDER.41
CYLINDER42
ASSEMBLECRANKSHAFT43
ASSEMBLECLUTCH- 1SPEED44
ASSEMBLEENGINE- 1 SPEED47
INSTALLENGINE- 1 SPEED52
CARBURETOR57
DISMANTLEENGINE- 2 SPEED59
DISMANTLEOILPUMPDRIVE65
ASSEMBLEOILPUMPDRIVE67
ASSEMBLEENGINE-2SPEED68
INSTALLENGINE- 2 SPEED80
ENGINE IDLE 83
OILTANK,FUELTANK. 84
FRONT FORK-MAXI 85
FRONTFORK-MAGNUM MK II90
SHOCKABSORBERS- REARSWINGARM95
REARSWINGARM96
REARWHEEL- BRAKES97
BRAKES98
BRAKES-HUBS99
HUBS100
IDLER GEAR- DRIVESPROCKET101
SPOKINGWHEEL102
BALANCING105
ELECTRICALEQUIPMENT106
BREAKERPOINTS109
IGNITIONTIMING110
TIREFITTING112
TROUBLESHOOTING 113
WIRINGDIAGRAM116
SPARKPLUGCONVERSIONTABLE122
METRICCONVERSIONTABLE123
ALPHABETICAL INDEX 124
NOTES' 129
-5-

LUBRICATIONANDMAINTENANCE
ROUTINEMAINTENANCESCHEDULE:
Therequiredmaintenanceisclearlydescribedinthefollowing pages, andshouldbeperformedatthe
mileageintervalsshowninthefollowingchart.
LUBRICATION& MAINTENANCECHART
OPERATIONSTOPERFORM
Tirewearandcondition
Throttlecableadjustment
Checktirepressure
CheckTransmissionATFlevel
Cleanandlubricatechain
Cleanairfilter
Changegearboxoil
Checksparkplug
Decarbonizeengine
CleanExhaustbaffle
Retightenscrews,nuts(inc.headnuts)
Cleanfuelvalveandlines
Cleancarburetor(filter screen, floatchamber)
Idlespeedadjustment
Checkignitiontiming
Adjustclutch
Checkbrakes(liningsevery900)
Check/lubricatehubbearings
Steeringbearingadjust/lubricate
Checkchaintension/adjust
Lubricatefrontfork
Retightenupperforkbridgebolts
Frequencyin
First
300
(480)
X
X
X
X
X
X
X
X
X
X
X
X
X
miles(krr
.)
Every
600
(960)
X
X
X
900
(1450)
X
X
X
X
X
X
X
X
1800
(2900)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
3600
(5800)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
7200
(11600)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOTE: Abovetimescheduleappliestovehiclesusedondrypavedsurfaces.Ifusedinwet.muddyor
sandyareas,maintenanceshouldbemorefrequent.Alwayscheckcontrolsandlightingbefore
anytrip.
A
Lookforthissymboltopointoutimportantsafety
precautions, itmeans- Attention!Becomealert!
-6-

LUBRICATIONANDMAINTENANCE
LUBRICATION
ChangingGearboxoil
1)Warmuptheengine.Stopengine.
2) Remove oildrainplug(2)andfillerplug(1).
3)DrainOil.
4)Replacedrain plug.
5)1 speedautomatic:
Fillwithfreshautomatictransmissionfluid- TYPEF only
(oilcapacity5.74oz(170cc)tobottomofoilfillhole.
2speedautomatic:
Fillwithfreshautomatictransmissionfluid- TYPEF only
(oilcapacity9.5oz(280cc)tobottomofoillevel plug.
6)Replaceoilfill plug.
Cleaningandoilingthechains
Am Engineshouldnotberunning.
Bothenginedriveandpedalchainsshouldbekeptclean.
Everyfewhundredmileswipechainsthoroughlywitha cloth,
andusinga smallbrush,lubricatewithchainoillubricant.
Alwayskeepchainsproperlyadjusted.Theproperslackof
thedrivechainschouldbe *f* in.(2cm).Toadjustthechains,
loosentheaxlenutsandtightenorloosentherearadjuster
nuts. Oncechainsareproperly adjusted, tightentheaxlenuts.
Makesurethatwheelsare alwaysaligned.
Kickstand lubrication
Removethestandspring.Removethreehexagonbolts.
Removestand.Greasebothhalvesofthestandpivotwitha
goodautomotivelithiumbasegrease.
AdjustingScrewsandPivotBolts
Lubricateadjustingscrews,tensioningscrewsandpivotbolts
oncontrolleverswitha fewdropsofoil.
^1 <$
J5g_
IHL/*J^SJ
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1wmtttiM -"* fi
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1-SPEED AUTOMATIC
A
* '
2-SPEED AUTOMATIC
DriveChain
MAINTENANCE
PleasecontactanauthorizedPUCHDealerforworkyou
donotwishtocarryoutyourself.Theagentwillbepleased
toadviseandhelp.
Checkingsparkplugs
Unscrewspark plug. Insertsparkplugintosuppressoron
sparkplugwireandtouchsparkplugelectrodetoa ground,
suchasthecylinderhead.A strongsparkmustbevisible
betweenthesparkplugelectrodeswhenoperatingthestar-
ter.Oilyplugsordirtyelectrodesdonotsparkandmustbe
cleanedfirstwitha pieceofwoodora steelwirebrush.The
electrodegapshouldbefrom.016- .020in.(0,40to0,50mm),
iflarger,adjustbybendingthegroundelectrode.When
replacingthesparkplugensurethreadmatchesproperly
andtheplugcanbescrewedineasily.Neverapplyforce.
Screwinplugbyhandfor2 to3 turnsbeforeusingthespark
plugspanner.Torqueto14.5 ft/lb (20 Nm).
-7-

LUBRICATIONANDMAINTENANCE
MAINTENANCE
Decarbonizingtheengine
Carbondepositsonthecylinderhead,pistoncrownandintheexhaustportsarenormalwithall
two-strokeenginesandcaneventuallyleadtotroubleifnotremovedintime.Combustiondeposits
fromoilaswellasfromfuelmustthereforeberemovedregularly.
Cylinderheadandpistoncrown
Carbondepositsonthecylinderheadandpistoncrownshouldberemovedonlywitha soft,bluntedged
instrumenttoavoiddamagetothelightalloycasting.Scratchingshouldbeavoidedsinceeverynew
scratchwillcollectmorecarboninfutureuse.
Onlyscalydepositsneedberemovedfromthepistoncrown.Thereisnoneedtodisturbthepistonifit
iscoveredonlybya uniformlayerofoilcarbon.Beforerefittingthecylinder head, thoroughlyremoveall
carbondepositsandscrapingsfromthecylinderwallwitha nonfrayingsoftclothandsmearthesur-
facelightlywithmotoroil.Turnovertheenginea fewtimes tomake sureitcrankseasily.Cleanthema-
tingsurfaceswitha cleanrag.Replacethecylinderheadandtightenthefourcylinderheadnuts.Be
suretotightentwocylinderheadnutsdiagonallyacrossfromeachotherbeforetighteningtheothertwo
nuts(7 ft/lb/10 Nm).
Exhaustport
Inordertocleantheexhaust port, removetheexhaustpipe.
Cranktheengineover(withthesparkplugremovedtore-
ducecompression)untilthepistonreachesitslowestpoint.
Removetheoilcarbonfromtheexhaustport.Takecarenot
todamagethepistonorcylindersurface.Whencleaning
theexhaustport,itisalsoa goodideatocleanthemuffler.
Cleaningthemuffler
Unscrewandpullofftheexhaustendpiece.Removeoil-
carbondepositsfromtheinsideofthemufflerusinga
scraper.Alsocarefullyremovetheoildepositsfromthe
exhaustbaffleandtheexhaustendpiece.Replacethegasket
ifnecessary.
NOTE: Forfurtherbreak-downofexhaustsystemreferto
diagram.
MAXI. MAXI LUXE
NEWPORTII.MAXISPORTMKII
II
MAGNUMII
MAGNUM MKII
©•
^
^
-8-

LUBRICATIONANDMAINTENANCE
Cleaningtheaircleaner— MagnumSeries
Removethelefthandchainguard.Removeclampnut (1).
Loosenclampscrew(2)andremoveaircleanerassembly
fromthecarburetor.Removefrontpartoftheaircleaner
usinga driftandcarefullypushoutfilterscreen.Washfilter
screeninsolventandallowittodrythoroughlybefore
replacing. Reassembledamperpipe,filterscreen,andair
cleanerassembly.
Cleaningtheaircleaner— MAXI Series
TheairfilterontheMAXIisa non-serviceable sealedunit.
Cleaningthefuelvalveandline
Emptyfueltank. Pull the fuel linefromthefuelvalveand
blowairthrulineuntilclear.Unscrewthefuelvalve.Clean
thevalveandstrainerbywashingwithsolvent.
Cleaningthecarburetor
Maintenanceoperationsonthecarburetorareoutlined:
under"CARBURETOR"page57.
Cleaningthemainjet,needlejetandfloatchamber
1)Closethefuelvalve.
2)Removethelefthandchainguard.
3)Removetheaircleaner.
4)Loosencarburetorclampingscrew,seepage10(1).
5)Pullthefuelpipefromthecarburetor.
6)Turnthecarburetorwithitsfloatchamberline(bottom)
towardstheclutchsideandpulloff.
7)Loosenscrewsandpulloutthetopparts,seepage10
(2)withthrottleslideandpulloff.
8)Screwoffthefloatchamber.
9)Unscrewthemainjetfromtheneedlejetandclean
byblowingthroughorbyusinga stiffbristle.Never
usea pieceofwire.Alsounscrewneedlejetandclean.
10)Cleanthefloatchamberwithgasoline.
11)Washcarburetorbodyandblowthrough.Makesure
thattheboresarenotcloggedwithdirt.
12)Whenrefittingthejets,tightenthemproperly.
«M
/[6331]
4
••>
(j
FrontotAir Cleaner
FilterScreen
VWtf*. Damp* Pipe
^-Qr^
Rear ofAir Cleaner
-9-

LUBRICATIONANDMAINTENANCE
CARBURETORADJUSTMENT
Minorcarburetoradjustmentmayberequiredtocompen-
satefordifferencesin fuel, temperature,altitudeand load.
IDLEADJUSTMENT
Startengineandrunatmoderatespeeduntiloperating
temperatureisreached.Adjustidlespeedbyturningidle
adjustmentscrew(3)inoroutuntilenginerunssmoothly.
THROTTLECABLEADJUSTMENT
Checkforproperthro'ttlecableslack(.040in./1,0mm).In-
sufficientcableslackwillholdthethrottlepartiallyopenand
theidleadjustingscrewwillnotfunction.Ifnecessary,loosen
thecablelocknut(4)andturn the-throttle cableadjuster(5)
totherighttoincreasecableslack.Retightenthecable
locknut.
w
o-
Explodedviewofthecarburetor
1Intakemanifold
2Carburetorbody
3Throttleslidestopscrew(Idlescrew)
4Needlejet
5Mainjet
6Floatneedle
7Float
8Floatbowl
9Hoseswivelconnector
10Throttleslide
11Jet-needle
12Chokeslide
13Chokelever
14Topcover v
15Slidespring
-10-

LUBRICATIONANDMAINTENANCE
CHECKINGTHEIGNITIONSYSTEM
Ignitiontiming
Theenginev/illreachmaximumoutputonlyiftheignition
iscorrectlyadjusted.SeeIgnitionTimingpage110.
Breakerpointgap
Checkthepointgapevery3600miles(5800km).Removethe
magnetocoverlocatedontheleftsideoftheengine.Rotate
theflywheeluntilthebreakerpointsarefullyopenandvisable
throughoneoftheflywheelwindows.Breakerpointsthatare
burntshouldbereplaced.
Measurebreakerpointsgapwitha feelergauge(.014—
.018in./0.35- 0.45mmfor1 speed,.016- .020in./0.40-
0.50mmfor2 speed).Toadjustethebreakerpointsgap,
loosenthesetscrewslightly,inserta screwdriverbladeinto
theslotonthebreakerplateandturnthescrewdriverslightly
untilthecorrectgapisobtained.Tightenthesetscrewand
checkthatthegaphasnotaltered.
SLOT
SETTING SCRE\\
POINT QAP
2-speed
Adjustingthestartinglever
Afterthefirst300miles(480km)andthenevery3600miles
(5800km)checkadjustmentofthestartinglever.Thefreeplay
atthestartinglever(measuredattheendofthelever)should
be
3/<
in.(2cm).Correctplayisachievedbyloosingthelock-
nut(1)andturningtheadjusteruntilthecorrectlevertravel
isobtained.Tightenthelocknut.
1-speed
%in.(2cm)
-11-

LUBRICATIONANDMAINTENANCE
V4ifU2cm)
%in.(2cm
B
Checkingthebrakes
Frontbrake
Thecorrectadjustedtravel(measuredattheendofthe
handbrakelever)is "« in.(2cm).To adjust, loosenthe
locknut(1)andturntheadjusteruntilbrakelevertravelis
'^in. (2cm).Tightenthelocknut.
RearBrake
Thecorrecttravel(measuredattheendoftthehandbrake
lever)is V* in.(2cm).To adjust, loosenthelocknut(I)and
turntheadjusteruntilbrakelevertravelis
s/<
in.(2cm).
Tightenthelocknut.
Brakelinings
Pryplasticinspectionplugsfromwheelhub.Disconnect
brakecablefrombrakelever.Inserta feelergaugebetween
brakedrumandbrakelining.Gapshouldnotexceed.047in.
(1,2cm)ateitherinspectionhole. If gapexceedthismeasure-
ment, refertosection "BRAKES" onbrakereplacement.
Donotoperateyourunit.
FRONTWHEELREMOVAL
Unscrewspeedometercablefromhub.Loosenlocknuton
brakecableandremovebrakecablefromhub.Removethe
axlenuts.Removewheelfromfork.
Toreplacewheelreversetheaboveprocedure.Torqueaxle
nutsto20ft/lb(27 Nm). Becertaintoreadjustthebrake
beforeriding.

LUBRICATIONANDMAINTENANCE
REARWHEELREMOVAL
Loosenthetwochainadjusters(1).Loosenbothaxlenuts
(2). Loosenthebrakecablelocknut(4)andremovebrake
cablefrombrakearm(3).Removethechainadjusters.Push
wheelforward.Removethetwochainsfromtheirsprockets.
Tiltmachinetotheleftandremovethewheel.
Toreplacewheelreversetheaboveprocedure(seepage97).
Becertaintoreadjustthebrakebeforeriding.
REPLACINGHEADLIGHT
Removeheadlightrimretainingscrew(s)andremovereflector.
Turnbulbtotheleftandremove(see"TechnicalData"sheet
forsizeofbulb).
.-"^St
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REPLACINGREARLIGHTBULBANDSTOPLIGHTBULB
Removethetwoscrewsthatholdthe lense. Removebulb
andreplace(seethe"TechnicalData"sectionforsizeof
bulb).
Stoplightbulb(top)andrearlightbulb(bottom).
-13-

LUBRICATIONANDMAINTENANCE
Presswith
Thumbsto
separate
tire Bead.
LiftBead
ith Spoons
SpokeEnds
Replace Tire Onto
Rim
TIREREMOVAL
1. Letairoutofthetirebyremovingthevalvecore.
Pushvalvestemthruholeinrim.
2. Separatethetirebeadfromthesidesoftherimby
pressingwiththethumbs.Workyourwayaroundthe
tireonbothsidestobesurethatthebeadofthetireis
notstickingtotherim.
3.Usetiretoolsorspoonswithroundedendstoliftthe
beadononesideofthetireofftherim.Becarefulnot
topinchtheinnertubebetweenthetiretoolsandthe
tirebeadortherim.
4. Pulltheinnertubeoutfrombetweenthetireandrim.
5.Liftthebeadofthetireupoverthesideoftherimand
pullofftire.
TIREINSTALLATION
1. Checktherimstriptobesureitiscovering al
ends.
spoke
MakecertainValve
Stem is Straight
2. Wettirebeadwithsoapywater.Rollthetirebead,on
onesideofthetire,ontotherim.Putthetubeintothe
tireandinflateitonlyenoughtoholdthetubeduring
assembly.
3.Makecertainthatvalvestemisprotrudingsquarely
thoughtherim.Atthispointitmaybedesirabletolet
someairoutoftheinnertubetomakethenextstep
easier.
4. Startingintheareaofthevalvestem,presstheother
tirebeadontotherimusingbothhands.Workyour
waytotheoppositesideofthewheel.Becarefultonot
pinch* thetubebetweenthetirebeadandtherim.If
thelastfewinchesofthebeadcannotbepressedonto
therimbyhand,a rubberhammermaybeusedtoget
thetireovertherim.Becarefultonotpinchtheinner
tube.
Useonlya handpumporfootpump
toinflatetires.Becauseofthesmallvo-
lumecapacityoftires,servicestation
airhosesinflatetiresveryrapidly.They
arealsousuallycapableofpressurebe-
yondthatwhichthetirecanhold.
A
5.Inflatethetiretoabouthalftherecommendedpressure
andchecktoseethatthetirebeadisseatedproperly
ontherim.Ifit isn't, usethumbpressuretoseatbead.
6.Inflatethetiretofullpressure.
-14-

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1-Speed ToolKit
905 6.90.902.9
2-Speed ToolKit
Small
905.6.40.002.0
LargeToolKit
9056.400040
siooiivioads

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