Puch 1980 MAXI LUXE User manual

1977mopeds.com
1.800.965.1977

FOREWORD
This service manual far the full range of 198Qi81 models was issued to serve our workshops and their staff
as guide for expert repairs.
Since
the manual is intended as aid for the workshop, we renounced explanations which are self-evi-
dent to an expert.
Correct servicing requires the proper equipment including oll special workshop tools os detailed in our
list of special tools. The workshop manual is the base for appropriate and economical repairs however,
it
is of full value only combined with the "Service Bulletins" by which any alterations and improvements
ore publicized.
We sincerely hope that this manual will prove of invaluable assistance both for the workshop and cus-
tomer alike.
STEYR-DAIMPER-PUCH
OF AMERICA CORPORATION
GREENWICH, CONN. 06830
1977mopeds.com
1.800.965.1977

'80/'81 MODELS
THIS SERVICE MANUAL COVERS THE FULL RANGE
OF 1980/81 MODELS AS LISTED BELOW.
MAXI
MAXI LUXE
NEWPORT I1 SPORT MK El
MAGNUM I1
MAGNUM MK I1
1977mopeds.com
1.800.965.1977

CONTENTS
*
LUBRICATION AND MAINTENANCE ...................... 6
EXPLODED ENGINE VIEW . . a ..................... 15
SPECIALTOOLS ............................ 19
TORQUE SPECIFICATIONS .............. ......... 22
............................
REMOVEENGINE 23
DISMANTLE ENGINE - I SPEED .............. ...... 27
.............................
CRANKSHAFT 35
CRANKSHAFT-WRIST PIN ....... . . ............ .39
PISTON-CYLINDER .... ... ................ 41
CYLINDER ...... . . .................. 42
ASSEMBLE CRANKSHAFT . . ...................... 43
ASSEMBLE CLUTCH - 1 SPEED . . .................. 44
ASSEMBLE ENGINE - I SPEED . . .................. 47
INSTALL ENGINE - I SPEED .... ................... 52
CARBURETOR ....... ...... ............ 57
DISMANTLE ENGINE - 2 SPEED ...................... 59
...........
DISMANTLE OIL PUMP DRIVE ............ 65
.........
ASSEMBLE OIL PUMP DRIVE . . ....... 67
............
ASSEMBLE ENGINE - 2SPEED .... ..... &3
* INSTALL ENGINE - 2 SPEED ... ................... 80
ENGINE IDLE ........... ................. 83
OIL TANK. FUEL TANK ...... ................. 84
..... ..... .........
FRONT FORK-MAXI . . 85
...........
FRONTFORK-MAGNUMMKII .... ...... 90
SHOCK ABSORBERS - REAR SWING ARM .................. 95
REAR SWING ARM ........ .................. 96
......................
REAR WHEEL - BRAKES ... 97
.............................
BRAKES 98
.....................
BRAKES-HUBS ....... 99
.........
...................
HUBS 100
........
............
IDLER GEAR - DRIVE SPROCKET
101
...
SPOKINGWHEEL ...... . . ............. 102
..... ... ................
BALANCING 105
.........................
ELECTRICAL EQUIPMENT 106
............................
BREAKER POINTS 109
............................
IGNITIONTlMlNG 110
TIRE FITTING ............................ 112
...... ........
TROUBLE SHOOTING ........ 113
................
.....
WIRING DIAGRAM .... 176
......................
SPARK PLUG CONVERSlON TABLE 122
........................
METRIC CONVERSlON TABLE 723
......
ALPHABETICAL lNDEX
.........
* NOTES
1977mopeds.com
1.800.965.1977

LUBRICATION AND MAINTENANCE
ROUTINE MAINTENANCE SCHEDULE:
The required maintenance is clearly described in the following pages. and should be performed at the
mileage intervals shown in the following chart.
LUBRICATION & MAINTENANCE CHART
NOTE: Above time schedule applies to vehicles used on dry paved surfaces. If used in wet, muddy or
sandy areas, maintenance should be more frequent. Always check controls and lighting before
any trip.
OPERATIONS TO PERFORM
Tire weor and condition
Throttle
cable adjustment
Check tire pressure
Check Transmission ATF level
Clean and lubricate chain
Clean air filter
Change gearbox 011
Check spark plug
A
hook for this symbol to point out important safety
precautions. It means - Attention! Become alert!
Frequency in miles (km) I
First
300
(480)
x
x
x
x
x
x
x
Decarbonize engine
Clean Exhoust baffle
Retighten screws, nuts (inc. head nuts)
Clean
fuel valve and lines
Clean carburetor (filter screen, float chamber)
Idle speed adjustment
Check ignition timing
Adjust clutch
Check brakes (linings every 900)
Check/lubricate hub beartngs
Steering bearing adjust/lubricate
Check chain tensionJadjust
Lubricate front fork
Retighten upper fork bridge bolts
400
(950)
x
x
x
x
x
x
x
x
x
900
(1450)
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Every
(
x
x
x
x
x
x
x
x
x
--
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x x
x
x
x
1977mopeds.com
1.800.965.1977