Puch MAXI (1981), MAXI LUXE (1981), NEWPORT II (1981), SPORT MK II (1981), MAGNUM II (1981) Service 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

LUBRICATION

AND

MAINTENANCE

Changing

Gearbox

oil

1)

Warm

up

the

engine. Stop engine.

2)

Remove

oil

drain

plug

(2)

and filler

plug

(1).

3)

Drain

Oil.

4)

Replace drain

plug.

5)

1

speed

automatic:

Fill

with

fresh automatic transmission fluid

-

TYPE

F only

(oil

capacity

5.74

or

(170

cc)

to

bottom

of

oil fill

hole.

2

speed

automatic:

Fill

with

fresh automatic

transmission

fluid - TYPE

F

only

(oil capacity

9.5

oz

(280

cc)

to

bottom

of

oil

level

plug.

6)

Replace

oil

fill

plug.

Cleaning

and

oiling

the

chains

a

Engine

should

not

be

running.

Both

engine drive

ond

pedal

choins should

be

kept clean.

Every

few

hundred miles wipe

chains

thoroughly with o c!oth,

and using a small

brush,

lubricate with chain oil lubricant.

Always

keep

chains properly adjusted. The proper

slack

of

the

drive chain

schoufd

be

"4

in.

(2

cm).

To

adjust the

chains,

loosen

the

axle nuts

and

tighten or loosen the rear adjuster

nuts.

Once

choins

are

properly adjusted,tighten the

axle

nuts.

Make

sure

that

wheels

are

always

aligned.

Kickstand

lubrication

Remove

the

stand spring.

Remove

threa

hexagon

bolts.

Remove

stand.

Grease

both

halves

of

the

stand

pivot with

a

good

automotive lithium base grease.

Adjusting

Screws

and

Pirot

Bolts

Lubricate adjusting screws, tensioning screws and

pivot

bolts

on

control levers with

o

few

drops

of

oil.

MAINTENANCE

Please

contact

an

authorized

PUCH

Dealer

for

work

you

do

not wish to

carry

out

The

agent will

be

plea;ed

to

advise

and

help.

Checking

spark

plugs

Unscrew

spark

plug,

Insert

spark

plug into

suppressor

on

spark

plug

wire and touch spark plug electrode to

a

ground,

such

as

the cylinder head.

A

strong

spark

must

be

visible

between

the

spark

plug electrodes when operating

the

star-

ter.

Oily plugs or dirty

electrodes

do

not

spark

and

must

be

cleaned first with

o

piece

of

wood or a steel

wire

brush.

The

electrode

gap

should

be

from

-016

-

.MO

in.

(0,40to0,50

rnm).

if

larger. adjust

by

bending the ground electrode. When

replacing the spark plug

ensure

thread

matches properly

and

the

plug

can

be

screwed

in

easily.

Never

apply force.

Screw

in

plug

by

hand

for

2

to 3 turns

before

using

the

spark

plug spanner. Torque

to

14.5

ftllb

(20

Nrn).

11

-SPEED

AUTOMATIC

2-SPEED

AUTOMATIC

Drive

Chain

1977mopeds.com

1.800.965.1977

LUBRICATION

AND

MAINTENANCE

MAINTENANCE

Decarbonizing

the

engine

Carbon

deposits

on

the

cylinder

head,

piston

crown

and in

the

exhaust

ports

are normal

with

all

two-stroke engines and

can

eventually

lead

to

trouble if

not

removed

in

time. Combustion

deposits

from

oil

as

well

as

from

fuel

must

therefore

be

removed

regularly.

Cylinder

head

end

piston

crown

Carbon

deposits

on

the

cylinder

head

and

piston crown

should

be

removed

only

with

a

soft,

blunt

edged

instrument

to

avoid

damage

to

the

light

alloy

casting.

Scratching

should

be

avoided

since

every

new

scratch

will

collect

more

carbon

in

future

use.

Only

scaly

deposits

need

be

removed

from the piston crown, There

is

no

need

to

disturb

the

piston if it

is

covered only

by

Q

uniform

layer

of

oil

carbon.

Before

refitting

the

cylinder head,

thoroughly

remove

all

carbon

deposits

and

scmpings

from

the

cylinder

wall with

a

non

fraying

soft

cloth

and

smear

the

sur-

face

lightly

with

motor

oil.

Turn over

the

engine

a

few

times

tamoke

sure

it

cranks

easily.

Clean

the

mu-

ting

sudaces

with

a

dean

rag.

Replace

the

cylinder

head

and

tighten

the

four

cylinder

head

nuts.

Be

sure to tighten two

cylinder

head

nuts diagonally ocross

from

each

other

before

tightening

the

other

two

nuts

(7

ftJEbll0

Nm).

Exhaust

port

In

order

to

clean

the

exhaust

port,

remove

the

exhaust

pipe.

Crank

ttte

engine

over (with

the

spark

plug

removed

to

re-

duce

compression) until

the

piston

reaches

its

lowest point.

Remove

the

oil

carbon

from

the

exhaust

port,

Take

care

not

to

damage

the

pjston

or

cylinder

surface.

When

cleaning

the

exhaust

port.

it is

aEso

a

good idea

to

clean

the

muffier.

Cleaning

the

muffler

Unscrew

and

pull

off

the

exhaust

endpiece.

Remove

oil-

carbon

deposits from

the

inside

of the

muffler

using

a

scraper.

Also

carefully remove

the

oil deposits

from

the

exhaust

baffle

and

the

exhaust endpiece.

Replace

the

gasket

if

necessary.

NOTE:

For further break-down

of

exhaust

system

refer

to

diogram.

MAXI,

MAXl

LUX€

NEWPORT

II,

MAXl

SPORT

MK

ll

Q\

MAGNUM

ll

MAGNUM

MKII

1977mopeds.com

1.800.965.1977

LUBRICATION

AND

MAINTENANCE

Cleaning

the

air

cleaner

-

Magnum

Series

Remove

the left

hand

chain

guard,

Remove

clamp

nut

(1).

Loosen

clamp screw

(2)

and remove air cleaner

assembly

from the carburetor.

Remove

front

part

of

the

air cleaner

using

a

drift

and

carefully

push

out

filter

screen.

Wash

filter

screen

in

solvent

and

allow

it

to dry

thoroughly

before

replacing.

Reassemble

damper

pipe,

filter

screen,

and air

cleaner

assembly.

Cleaning

the

air

cleaner

-

MAXl

Series

The

air filter on

the

MAXl

is

a

non-serviceable

sealed

unit.

Cleaning

the

fuel

value

and line

Empty

fuel tank.

Pull

the

fuel line from

the

fuel

valve

and

blow

air

thrtl

line

until clear. Unscrew

the

fuel

valve.

Clean

the

valve

and strainer

by

washing

with solvent.

Cleaning

the

carburetor

Maintenance operations on

the

carburetor

are

outlined:

under

"CARBURETOR"

page

57.

Cleaning

the

main

jet,

needle

jet

and

float

chamber

1)

Close

the

fuel

valve.

2)

Remove

the

left

hand

chain

guard.

-

L70f~r~~mer

*

3)

Remove

the

air

cleaner.

4)

Loosen

carburetor

clornping

screw,

see

page

10

(1).

,iL'-

,%

_31fer

screen

5)

Pull

the

fuel

pipe

from

the

carburetor.

<>,.

aemper

PIP

6)

Turn

the

carburetor with its

float

chamber

line (bottom)

$<hcL

&a.

towards

the

clutch side

and

pull

off.

<Atr~knet

7)

Loosen

screws

and

pull

out

the

top parts,

see

page

10

(2)

with

throttle

slide

and

pull

off.

_I

8)

Screw

off

the

float chamber.

9)

Unscrew

the

main

jet

from the needle jet

and

clean

by

blowing through

or

by

using a stiff bristle.

Never

use

o

piece

of

wire. Also unscrew needle

jet

and

cleon.

10)

Clean

the

float

chamber

with gasoline.

11)

Wash

carburetor

body

and

blow

through.

Make

sure

that

the

bores

are

not

clogged with dirt.

12)

When

refitting

the

jets, tighten them properly.

1977mopeds.com

1.800.965.1977

LUBRlCATlON

AND

MAINTENANCE

CARBURETOR

ADJUSTMENT

Minor carburetor adjustment

may

be

required

to

campen-

sate

for

differences

in

fuel, temperature, altitude

and

loud.

IDLE

ADJUSTMENT

Start

engine

and

run

at moderate

speed

until

operating

temperature

is

reached. Adjust idle speed

by

turning

idle

adjustment

screw

(3)

in

or

out

until

engine runs

smoothly.

THROTTLE

CABLE

ADJUSTMENT

Check

for proper throttle

cable

slack

(.ON

in./l,O

mm).

In-

sufficient cable slock will

hold

the throttle partially

open

and

the

idle adjusting screw wilt

not

function.

If

necessary,

loosen

the

cable locknut

(4)

and

turn thehthrottle cable

adjuster

(5)

to

the

right

to

increase cable

slack.

Retighten the

cable

locknut.

Exploded

view

of

the

carburetor

Intake

manifold

Carburetor

body

Throttle slide

stop

screw

(Idle

screw)

Needle

jet

Main

jet

Float needle
Float

Float

bawl

Hose

swivel

connector

Throttle

slide

Jet-need

le

Choke

slide

Choke

lever

Top

cover

Slide spring

1977mopeds.com

1.800.965.1977

LUBRICATION

AND

MAINTENANCE

CHECKING

THE

IGNITION

SYSTEM

Ignition

timing

The

engine

will

reach

maximum

output

only

if

the

is

correctly

adjusted.

See

Ignition Timing

poge

110.

ignition

Breaker

point

gap

Check

the

point

gap

every

3600

miles

(5800

km).

Remove

the

magneto cover located

on

the

left

side

of

the engine.

Rotate

the

flywheel until the

breaker

points

ore

fully

open

and

visable

through

one

of

the

flywheel windows. Breaker

points

that

are

burnt

should

be

replaced.

Measure breaker points

gap

with

a

feeler

gouge

(.014

-

.018

in.10.35

-

0.45

rnm

for

1

speed,

,016

-

,020

in.10.40

-

0.50

mm

for

2

speed).

To

odjuste the

breaker

points

gap.

loosen

the

set

screw slightly, insert a screwdriver blade into

the

slot

on

the

breaker

plate

and turn

the

screwdriver slightly

until

the

correct

gap

is

obtained. Tighten

the

set

screw

and

check

that

the

gap

has

not altered.

-

rSEST1NO

SCREW

2-speed

Adjusting

the

starting

lever

After

the

first

300

miles

(480

krn)

and

then

every

3600

miles

(5800

km)

check

adjustment

of

the

starting lever.

The

free

play

at

the

startinq

lever (measured

at

the

end

of

the

lever) should

be

'1.1

in.

(2

cm).

Correct

play

is

achieved

by

loosing

the

lock-

nut

(1)

and

turning the adjuster until the correct lever

travel

is

obtained

Tighten

the

locknut.

1977mopeds.com

1.800.965.1977

LUBRlCATlON

AND

MAINTENANCE

Checking

the

brakes

Front

brake

The

correct

adjusted

travel

(measured

at

the

end

of

the

handbrake

lever]

is

''4

in.

(2

cm),

fo

adjust,

loosen

the

locknut

(1)

end

turn the adjuster until

brake

lever

travel

is

'/4in.

(2

cm),

tighten

the

locknut.

Rear

Brake

The

correct travel (measured

at

the

end

oft

the

handbrake

lever)

is

'14

in,

(2

cm).

To

adjust,

loosen

the locknut

(1)

and

turn

the

adjuster

until brake lever

travel

is

'14

in.

(2

cm).

Tighten

the

locknut.

Brake

linings

Pry

plastic inspection

pjugs

from

wheel hub.

Disconnect

brake

cable

from

brake

lever.

Insert a feeler

gauge

between

brake

drum

and

brake lining.

Gap

should

not

exceed

.04J

in.

(1,2

cm)

ot

either inspection

hole.

If

gap

exceed

this

meosure-

ment,

refer

to

section

"BRAKES"

on

brake replacement.

not

operate

your

unit.

FRONT

WHEEL

REMOVAL

Unscrew

speedometer

cable

from

hub.

Loosen

locknut

on

broke

cable

and

remove

brake

cable

from

hub.

Remove

the

axle

nuts.

Remove

wheel

from

fork.

To

replace

wheel

reverse the above procedure.

Torque

axle

nuts

to

20

fttlb

(27

Nm).

Be

certain

ta

readjust

the

brake

before

riding.

1977mopeds.com

1.800.965.1977

LUBRICATION AND

MAINTENANCE

REAR

WHEEL

REMOVAL

Loosen

the

two

chain

adjusters

(1).

Loosen

both

axle nuts

(2).

Loosen

the

brake

cable locknut

(4)

and remove brake

cable

from

brake

arm

(3).

Remove

the

chain

adjusters.

Push

wheel

forward.

Remove

the

two

chains

from

their

sprockets.

Tilt

machine

to

the

left

and

remove

the wheel.

To

replace wheel

reverse

the

above

procedure (see

page

97).

Be

certain

to

readjust

the

brake

before

riding.

.

REPLACING

HEADLIGHT

Remove

headlight rim

retaining

screw(s)

and

remove

reflector.

Turn

bulb

to

the left and remove

(see

"Technical

Data"

sheet

for

size

of

bulb).

REPLACING

REAR

LIGHT

BULB

AND

STOP

LIGHT

BULB

Remove

the

two screws

that

hold

the

lense.

Remove

bulb

ond

replace

(see

the

"Technical

Data"

section

for

size

of

bulb).

Stap

light

bulb

(top)

and

rear

light bulb

(bottom).

-13-

1977mopeds.com

1.800.965.1977

LUBRICATION

AND

MAINTENANCE

-

P

ft

Bead

~th

Spoons

TIRE

REMOVAL

1.

Letairoutofthetire

by

removing

thevalvecore.

Push valve

stem

thru

hole

in

rim.

2.

Separate

the

tire bead

from

the

sides

of

the

rim by

pressing with

the

thumbs.

Work

your

way

around

the

tire

on

both sides

to

be

sure

that

the

beod of

the

tire

is

not

sticking

to

the rim.

3.

Use

tire tools or

spoons

with rounded

ends

to lift

the

bead

on

one

side

of

the

tire off

the

rim.

Be

careful

not

to

pinch

the

inner

tube

between

the

tire tools

and

the

tire beud

or

the rim.

4.

Pull

the

inner

tube out from

between

the tire

and

rim.

5

Lift

the

bead

of

the

tire

up

over

the side

of

the rim

and

pull

off

tire.

TIRE

INSTALLATION

1.

Check

the

rim

strip to

be

sure

it

is

covering

a!l

spoke

ends.

2.

Wet

tire

bead

with

soapy

water.

Roll

the

tire

beud,

on

one

side

of

the tire, onto

the

rim. Put

the

tube

into

the

tire and inflate

it

only enough to

hold

the

tube

during

'C*

assern

bfy.

3.

Make

certain

that

valve

stem

is

protruding squarely

though

the

rim.

At this

point

it

may

be desirable to

let

some

air

out

of

the inner rube

to

make

the

next

step

easier.

Replace

Tlre

Onto

Rum

4.

Starting in the

area

of

the

valve

stem,

press

the

other

tire

beod

onto

the rim using

both

hands.

Work

your

way

to

the

opposite

side

of

the

wheel.

Be

careful

to

not

pinch

the

tube between the

tire

bead

and the rim.

If

the

last

few

inches

of

the

bead

cannot

be

pressed

onto

the

rim

by

hand,

a

rubber

hammer

may

be

used

to

get

the tire

over

the

rim.

Be

careful

to

not pinch

the

inner

tube.

Use

only

a

hand

pump

or

foot

pump

to

inflate

tires.

Because

of

the

small

vo-

a

lume

capacity

of

tires,

service

station

air

hoses

inflate

tires

very

rapidly.

They

are

also

usually

capable

of

pressure

be-

Make

certain

Valve

yond

that

which

the

tire

can

hold.

5.

Inflate

the

tire

to

about

half

the

recommended

pressure

and

check

to

see

that

the

tire

bead

is

seated

properly

on

the rim.

If

it

isn't.

use

thumb pressure

to

seat

bead.

6.

Inflate

the

tire

to

full pressure.

1977mopeds.com

1.800.965.1977

EXPLODED

ENGINE

VIEW

*

1977mopeds.com

1.800.965.1977

EXPLODED

ENGINE

VIEW

1977mopeds.com

1.800.965.1977

EXPLODED

ENGINE

VIEW

1977mopeds.com

1.800.965.1977

EXPLODED

ENGINE

VIEW

1977mopeds.com

1.800.965.1977

COMPLETE

SPECIAL

TOOL

LISTING

USAGEJKIT

CONTENTS

24

-

-

905.6.41.101.2

pp

906.6

21.001.0

P06.6.22.002.0

Spring

Pliers

PUCH low Scale

Ohmmeter

PUCH

Ignition

Jester

~o~o~[O~O~O~O~[O-

-

~0~0

-

00~~00~~0000

1010

Seperate

Order

Only

0

0

1977mopeds.com

1.800.965.1977

SPECIAL

TOOLS

1977mopeds.com

1.800.965.1977

SPECIAL

TOOLS

1977mopeds.com

1.800.965.1977

TORQUE

SPECIFICATION

F

The

torque

reading in foot

pounds

is

the

torque

required

to

bring

any

given

belt

to

its maximum

safe
stress point.
Tension is

the

pressure

in

pounds

per

square

inch

(P.S.f.)

that

the bolt

material

can

stand

before

stretching

occurs.

Tightening torque to

be

within a tolerance

of

10":~.

Engine

torque

specification

.......

Spork

plug

Cylinder

head

nuts

....

......

Flywheel nut

....

Crankcase

screws.

Clutch

cover

screws

. , .

.

Engine

mounting

bolts

...

Clutch

retaining

nut,

2

speed

.

Roller

retaining,

I,

h.

thread,

2

Clutch

retaining

nut,

I

speed

Kickstand

bearing

bolts

. .

Manifold

mounting boltsJnuts

Frame

torque

specification

.

.

-

...

=.

.

...

..~

.

.

-

...

speed

.

-.

.

...

...

Front/rear

axle

nuts

............

.

,

. .

, ,

. .

20ft/lb

(27Nm)

Rear

shock

top

..............

...

27ftllb

(23

Nm)

........

Rear

shock

bottom

.........

9

fttlb

(12

Nm)

Rear

fork

bearing

....................

. .

29

Wlb

(40

Nm)

.....

Handlebar bolts

..........

10-32ft/lb

(15-16

Nm)

Crank

wedge

nuts

..........

. . .

5ft/lb

(

7

Nm)

............... Fender

bracket

hardware

.

4ftlIb

( 6 Nm)

Steering

head

nut

..........

30

ft/ib

(41

Nm)

Fork

tube

clamp bolts

(MAGNUM MK

11)

;

. .

.......

40

ftilb

(54

Nm)

Fork br~dge plug

screws

(MAGNUM

MK

Ill

............

20

fv'lb

(27

Nm)

Fork

bridge bolts

..........

............

11

fulb

(15

Nm)

NOTE:

Nrn

stands

for

Newtan-meter

which

is

on

European standard

measure.

Its

conversion factor

to

receive

ft/lb

(foot-pounds)

is

0,735.

1977mopeds.com

1.800.965.1977

REMOVE

ENGINE

ENGINE

REMOVAL

Place

the

moped

on

a

bench.

Secure

in

position

on

bench

with

tie-down

straps.

Remove

left

and

right

hand

chain guards.

Loosen

clamp

screw

on

air

filter

assembly

and

remove.

1977mopeds.com

1.800.965.1977

REMOVE

ENGINE

r

Turn

fuel

tap

to

"Off

position.

Disconnect

fuel

supply

hose.

Loosen

carburetor

clamp

screw

and

twist

carburetor

to

the

left

and

remove

from

intake

manifold.

Disconnect drive

chain

by

removing

the

master

chain

link.

1977mopeds.com

1.800.965.1977

REMOVE

ENGINE

rlC

Disconnect

electrical

wiring

at

the

junction

block.

DISCONNECT

STARTER

CABLE:

1

-speed

automatic

Loosen

starter

cable

adjustment, twist

clutch

lever

and

dis-

connect

cable

from

lever.

2-speed

automatic

Loosen

clamp

screw

on

starter

lever

on

the

left

side

of

handlebar.

Pull

up

protective

plastic

cap

from

the

adjusting

sleeve.

Unscrew

starter

cable

nut

from

adjusting

sleeve.

Do

not

loosen

adjusting

sleeve

nor

the

starter

cable

adjusting

nut.

Remove suppressor

plug

from

spark

plug.

On

3-speed

models

remove

ignition

coil

from engine.

1977mopeds.com

1.800.965.1977

REMOVE

ENGINE

Drain

transmission

oil.

If

workbench,

part

no

49-34-001,

is

not

being

used

place

the

rear

wheel

in

a

support

stand.

MAGNUM

MK

If:

Remove

oil

supply

line

from

oil

pump

and

block-off

line

to

avoid

oil

drainage

from

oil

tank.

Remove

the

three

(3)

engine

mounting

bolts

and

withdraw

engine

from

frame.

1977mopeds.com

1.800.965.1977

DISMANTLE

ENGINE

=

I

SPEED

Place

engine

in

engine

holder

(905.6.36.108.0)

which

is

mounted

in

a

vise.

Remove

intake

manifold.

Disconnect

the

kick-stand

spring.

1977mopeds.com

1.800.965.1977

DISMANTLE

ENGINE

-

1

SPEED

r

Unscrew

the

kickstand

bearing

bolts,

bearing

cup

and

kick-

stand.

Remove

generator

cover.

Lock

flywheel

with

locking

tool

905.0.16.101.2

and

unscrew

flywheel

nut.

1977mopeds.com

1.800.965.1977

DISMANTLE

ENGINE

=

1

SPEED

Break

taper

between

flywheel

and

crankshaft

with

special

puller

050.7012.

Remove

flywheel

and

woodruff

key

from

crankshaft.

Unscrew

the

stator

plate

screws,

remove

the

stator

plate

assembly

and

pull

out

the

generator

wiring

including

the

rubber

grommet.

After

removing

the

cylinder

head

nuts

lift

off

the

cylinder

head

and

cylinder

head

gasket.

1977mopeds.com

1.800.965.1977

DISMANTLE ENGINE

=

I

SPEED

Remove

cylinder

and

base

gasket.

Remove

wrist

pin

retaining

rings.

Push

out

the

wrist

pin

and

remove

piston.

1977mopeds.com

1.800.965.1977

DISMANTLE ENGINE

=

I

SPEED

Remove

clutch

cover

screws

and

clutch

cover.

Mount

engine

in

engine

stand

so

that

the

lower

crankcase

holf

is

facing

upward.

Remove

all

crankcase

screws.

Slightly

tap

the upper crankcase

half

with

a

rubber

hammer

to

break sealant

between

the

two

housing

halves

and

remove

top

holf.

1977mopeds.com

1.800.965.1977