VEB BERLIN SR59 Operating Manual
Operating Manual for
STADTROLLER
BERLIN
SR59
VEB INDUSTRIEWERKE LUDWIGSFELDE
Edition 1960
The Stadtroller „SR 59-Berlin“ is a Product of VEB Industriewerke Ludwigsfelde.
Scooterstation offers full parts support for the SR59 Berlin scooter within the US. If you need parts
you can contact us at: (503)-231-2768 or e-mail us at sales@scooterstation.com
This operating manual was was written by a collective of Authors of the VEB Industriewerke
Ludwigsfelde.
All rights reserved – Technical books press Leipzig GDR – Type setting & print: Technical books
print Naumburg (Saale) GDR.
Editorship conclusion: 11/1/1959
KG 12/3/60
A lot of unnecessary frustration
will be avoided if you don´t put this operating manual aside carelessly, but instead briefly familiarize
yourself with the directions and suggestions this manual provides. All sections of this manual have
been compiled by skilled personell and serve the purpose of imparting knowledge about this vehicle
to you without which the operation of a modern motorvehicle would just be impossible. We want to
give you the maintenance and care advice necessary for you to be able to enjoy your vehicle,
instead of having to spend your valuable free time at an authorized dealers shop, that you should
better use for your own recreation.
It´s a simple fact that any new motorvehicle should be treated with a lot of care and attention. This
is why you will save lots of money, frustration and potential anger if you apply the knowledge
gained from this operating manual. Not only should you consider the given advice for a single ride,
but for the entire time in which you drive your motorscooter.
Please consider that the observance of our advice essentially contributes to the preservation of
your property and thus to the peoples property.
If you don´t find the information on the following pages sufficient or if you need additional advice,
you can always trustfully contact one of our authorized dealers. They will always help and advise
you, because our authorized dealers ought to avoid repairs before they happen by making qualified
suggestions and giving helpful advice.
VEB Industriewerke Ludwigsfelde
This manual was translated into english by Stephan Henkel and is property of Scooterstation Inc.,
OR. U.S.A. Copying or reproduction of this manual is prohibited without the written consent of
Scooterstation Inc.,USA. © 2002 Scooterstation. All rights reserved.
LEGAL DISCLAIMER:
This manual is to serve the purpose of reference only. Scooterstation is not responsible for any
malfunction or damage of your scooter resulting in the use of this manual. Scooterstation is not
responsible for any possible personal injuries or death that may result in the use of this manual.
Table of contents
1. Technical data ..................................................................................................... 11
1.01 Engine......................................................................................................... 11
1.02 Transmission and drivetrain........................................................................ 12
1.03 Brakes......................................................................................................... 13
1.04 Wheels........................................................................................................ 14
1.05 Suspension.................................................................................................. 14
1.06 Steering....................................................................................................... 15
1.07 Electrical system......................................................................................... 15
1.08 Frame.......................................................................................................... 15
1.09 Body............................................................................................................ 16
1.10 Equipment
1.11 Dimensions & weight.................................................................................... 16
1.12 amounts of fillings........................................................................................ 17
2. Description.............................................................................................................. 18
2.1 Engine........................................................................................................... 18
2.11 Mode of operation.............................................................................. 18
2.12 Crankshaft......................................................................................... 22
2.13 Crankcase......................................................................................... 25
2.14 Cylinder and Cylinder head................................................................ 27
2.15 Piston and piston rod......................................................................... 29
2.16 Fan.................................................................................................... 30
2.17 Electrical System.............................................................................. 32
............................................................................................ 16
2.161 Verifying the fan-drivebelt..................................................... 30
2.162 Changing the drivebelt.......................................................... 31
2.171 alternator............................................................................. 32
2171.1 Verifying the Electrical system............................... 34
2.171.2 Electrical tuneup (every 6000 miles)...................... 35
2.127 Battery.................................................................................. 37
2.172.1 Maintenance.......................................................... 38
2.172.2 Insufficient charging of Battery............................... 39
2.173 Lights and signals................................................................. 39
2.173.1 Failure of signal horn
2.174 Regulator.............................................................................. 41
2.175 Ignition.................................................................................. 41
2.18 Carburetor and airfilter...................................................................... 43
2.181 Maintenance of carburetor.................................................... 45
2.182 Cleansing the airfilter............................................................ 50
2.2 Power Train................................................................................................. 52
2.21 Primary Transmission and clutch...................................................... 52
2.211 Adjusting the clutch.............................................................. 53
2.22 Gearbox............................................................................................ 55
2.23 Rear powertransmission.................................................................... 56
2.231 Chain maintenance.............................................................. 57
2.3 Chassis....................................................................................................... 60
2.31 Frame............................................................................................... 60
2.32 Front wheel balance beam fork......................................................... 61
2.321 Disassembling the balance beam fork.................................. 62
2.322 Adjusting the steering column bearings................................ 63
2.33 Rear wheel suspension..................................................................... 64
2.331 Disassembling the rear wheel suspension............................ 65
2.34 Brakes.............................................................................................. 66
2.341 Brake maintenance............................................................. 67
2.35 Axles and wheels............................................................................. 69
2.351 Flat tire............................................................................... 70
2.36 Tank................................................................................................ 74
2.361 Cleansing the fuelfilter
.................................................... 75
2.37 Driver- and buddyseat...................................................................... 76
2.38 Instrument panel and theft protection............................................... 77
2.39 Tools................................................................................................ 78
3. Operating instructions............................................................................................ 80
3.1 Location and purpose of control levers and knobs....................................... 80
3.101 Air lever (Choke).............................................................................. 81
3.102 Throttle............................................................................................. 81
3.103 Ignition and lightswitch...................................................................... 82
3.104 Dipswitch.......................................................................................... 84
3.105 Clutch............................................................................................... 85
3.106 Kickstarter........................................................................................ 86
3.107 Foot gear switch............................................................................... 86
3.108 Rear brake foot lever........................................................................ 88
3.109 Front brake lever.............................................................................. 89
3.110 Sidestand......................................................................................... 89
3.111 Tip up hook...................................................................................... 90
3.2 Correct operation........................................................................................ 90
3.21 Before your first ride......................................................................... 90
3.22 Running in........................................................................................ 92
3.23 Starting up........................................................................................ 93
3.24 Start and shifting gears................................................................ 94
3.25 Shifting down gears on a slope......................................................... 94
3.26 Slowing down / using your brakes..................................................... 96
3.27 Stopping........................................................................................... 96
3.28 Mothballing the bike for storage........................................................ 96
4. Checkup- and maintenance work........................................................................... 98
4.1 General Information.................................................................................... 98
4.2 What do do ?.............................................................................................. 98
4.21 Daily................................................................................................. 98
4.211 Before leaving the driveway................................................ 98
4.212 During stays in transit.......................................................... 99
4.213 After returning..................................................................... 99
4.22 Lubricating the engine...................................................................... 99
4.23 Lubricating the chassis..................................................................... 100
4.24 maintenance of sparkplug................................................................ 100
4.241 What does the sparkplug´s face tell us ?............................. 102
4.25 Cleansing the exhaust pipe.............................................................. 103
4.3 Troubleshooting.......................................................................................... 104
4.31 Engine won´t start............................................................................. 104
4.32 Red controllamp doesn´t go out after start or lights up during ride..... 107
4.33 Fan controllamp doesn´t go out after start or lights up during ride..... 107
4.34 Engine doesn´t run smooth................................................................ 107
4.35 Engine stalls abruptly......................................................................... 108
4.36 Excessive fuel consumption............................................................... 108
4.37 Headlight doesn´t work...................................................................... 109
4.38 Adjusting the Headlight..................................................................... 110
5. Repair instructions....................................................................................... 112
5.1 Engine, removal and installation of.............................................................. 112
5.2 Cylinderhead, removal of
....................................................................... 113
5.3 Cylinder, removal of
5.4 Piston, removal of....................................................................................... 113
5.5 Pistonring, inspection of and exchange....................................................... 114
.............................................................................. 113
5.6 Piston and cylinder, installation of............................................................... 115
5.7 Ignition timing, adjustment of...................................................................... 117
5.8 Wheelbearing, exchange of......................................................................... 118
6. Parts support and technical service.............................................................. 120
Illustration 1: Berlin SR59 as viewed from the left
Illustration 2: Berlin SR59 as viewed from the right
1 Technical data
1.01 Engine
Mode of operation Two-stroke
Process Loop scavenging
Piston stroke 58mm
Cylinder bore 56mm
No. Of cylinders and
Orientation 1 cylinder, standing, leaning 15º forward
Piston displacement 143ccm
Compression ratio 7.75:1:8.1
Room for compression 20,4ccm
Continous output at 4000rpm 6.5hp
Maximum output at 5100rpm 7.5hp
Max. torque at 3500rpm 1.15kgm
Coolant Forced air (axial load supercharger)
Lubrication 4%
Carburetor
Design Round slidegate valve carburetor
Type 24 KN 1-1
Passage 24mm
Main jet 90
Needle jet 67
Idle jet 40
Needle setting 3
slidegate valve-cut out4mm
Idle air screw 2,5 to 3 revolutions, open
Weight of float 10,6grams
Airfilter Baffle wet air filter with intake silencer
Ignition Battery Ignition
Spark plug Isolator M 14-240
Length of thread 10mm
Elektrodenabstand 0,6mm
Unterbrecherkontaktabstand 0,4mm
Vorzündung 4mm of OT (28% crankangle), fixed setting
Piston
Material Si 20
Piston rings 2 Compression rings
Oversizes for cylinder-diameter 56.25; 56.50; 56.75; 57.00mm
Crankshaft bearings
Amount 3
Type Ball bearings
Connecting rod bearings Doublerowed roller bearings, cageless, with friction disc
Dimension of rolls 5x5 in compliance to DIN 5402
1.02 Transmission and power transmission
Clutch Multiple disc clutch in oilbath, adjustable at motor
and handlebar
Coating Frictionlambals „Original Cosid“
Number of compression
springs 6
Transmission Docked to engine, hand controlled
Number of gears 4
Idle motion display electronic pilot lamp on lefthandside of controlpanel
Gearshift by footswitch and circuit breaker
Gears
1. gear 3.05 :1
2. gear 1.805 :1
3. gear 1.285 :1
4. gear 1 :1
Ratio
Engine/Transmission 2.75 :1
Transm./Rear wheel 2.19 :1
Gear ratio
1. Gear 18.4 :1
2. Gear 10.8 :1
3. Gear 7.73 :1
4. Gear 6.02 :1
Kickstart ratio 3.76 :1
Power transmission
Engine/Transmission Sleeve chain 3/8“ x 7.7 x 5Dmr.
44 links
Transm./Rear wheel Chain ½“ x ¼ “
x 8.51 Dmr. 94 rollers
1.03 Brakes
Foot brake Drum brake
Effective to Rear wheel
Operates through Bowden cable
Handbrake Drum brake
Effective to Front wheel
Operates through Bowden cable, adjustable at
hub and handle bar
Diameter of brake drums
rear/front 150mm
Brake lining
width 24mm
Material „Original Cosid“, glued on
1.04 Wheels
Type Full disc wheels, light alloy
Axles
Front wheel Normal axle
Rear wheel Knockout spindle
Rims Drop base rims 2.50 C x 12
Tires
Dimensions 3.50-12
Type Block profile
Air Pressure
Front 1.2atü (17.64psi) single driver
Rear 1.5atü (22.05psi) single driver
Front 1.4atü (20.58psi) with buddy
Rear 2.0atü (29.40psi) with buddy
1.05 Suspension
Front wheel suspension Balance beam fork, Pressure spring with friction damping
Effect Proportional
Displacement 110mm
Rear wheel suspension Trapezoid swing, torsion spring (patented), hydraulically
absorbed
Effect Proportional
Displacement 70mm
1.06 Steering
Lenkkopfwinkel 25º
Vorderradnachlauf 75mm
Lenkanschlag At Steering shaft
Lenkwinkel 90º
1.07 Electrical System
alternator Voltage regulating
Type GMR 6/60
Manufacturer FEK (Fahrzeugelektrik Karl-Marx-Stadt)
Performance 60W
Propulsion Anchored directly on crankshaft tap
Controller RSC 60/6 on Blowercasing
Charging control lamp on the lefthandside of the controlpanel
Fuse 15A
Ignition coil TJ 6/1 at crankshaft tap
Battery
Voltage 6V
Capacity 8Ah
Negative pole to ground
Headlight 130mm face
Main light 35/35W Bilux
1.08 Frame
Type Central frame
Seams Electrical and autogenic welding seams
Stand Sidestand on left side of floorboard
1.09 Body
Front Fender, Legshield, headlight with casing,
instrument panel
Floor and Rear Floorboard made from GA1-alloy, Rear hood
with removable toolbox and tippable seats, that
can be locked
Number of seats 2
1.10 Equipment
Speedometer Installed on instrumentpanel with nightlight
Propulsion through the front wheel
Tools Under the seats in the rear hood
1.11 Measurements and weights
Maximum length 2080mm
Maximum width 650mm
Maximum height 950mm
Wheelbase 1430mm
Ground clearance 110mm (loaded)
Wading capability 240mm
Turning circle 4.0 Meters
Weight 140Kg (309lbs.)
Dry curb weight 131Kg (289lbs.)
Maximum weight 300Kg (662lbs.)
Pressure on front axle
unloaded 51Kg (112lbs.)
loaded 100Kg (221lbs)
Pressure on rear axle
unloaded 84Kg (185lbs.)
loaded 200Kg (442lbs.)
Avg. Fuel consumption 2.8liters/100Km (85mpg)
Fuel consumption at speeds
of 40Km/h (25mph) 2.1l/100Km (112mpg)
of 50Km/h (31mph) 2.4l/100Km (99mpg)
of 60Km/h (37.5mph) 2.9l/100Km (82mpg)
Top speed 82Km/h (51mph)
Continous top speed 75Km/h (47mph)
climbing ability (single driver) 1
st
gear 33% (30º) at 15Km/h (9.5mph)
nd
2
gear 18% (16º) at 30Km/h (19mph)
rd
3
gear 12% (11º) at 50Km/h (31mph)
th
4
gear 5% (4.5º) at 60Km/h (37.5mph)
1.12 Filling amounts
Fuel tank 12 liters ( 3.2 US gallons)
Reserve in fuel tank 1.5 liters (1.6 US liquid quarts
Transmission oil 0.4 – 0.45 liters (0.84-0.95 US liquid pints)
Radius with one tank filling appx. 350Km (219miles)
)
2 Description
2.1 Engine
2.11 Mode of operation
The aircooled supercharged single cylinder two-stroke engine of the SR59 Cityscooter operates as
a loop-scavenging-triple-port-Engine. This engine is an advanced version of the reliable and
successful 125cc two-stroke motor of the MZ-125-2 Motorbike. The following section describes the
mode of operation of the RM150 engine:
As the piston moves upward (from bottom dead center (BDC) to top dead center(TDC)), a vacuum
is created beneath the piston in the enclosed volume of the crankcase. The piston uncovers a little
air inlet just before reaching the top dead center. This little air inlet is the end of the intake port,
through which fresh air enters the crank case due to the vacuum created before. Because this very
same air had to pass through the carburetor prior to entering the crank case, it is mixed with just the
right amount of fuel and oil (the oil being necessary for the lubrication of the engine) When the
piston is on a downward move after passing TDC it relocks the intake port and thus compresses the
air/fuel mix. By now, the oil has dropped out of the mix and attached itself to bearings and other
parts within the engine. Just before reaching BDC two openings called transfer ports are uncovered
in the cylind
The scavenging phase has begun. Meaning that the unburned mixture gasses are flowing out of the
transfers and merging together to form a loop. The gasses travel up the backside of the cylinder
and loops around in the cylinder head to scavenge out the burnt mixture gasses from the previous
power stroke. It is critical that the burnt gasses are scavenged from the combustion chamber, to
make room for as much unburned gasses as possible. Now the loop of unburned mixture gasses
have traveled into the exhaust pipe's header section. Most of the gasses aren't lost because a
compression pressure wave has reflected from the baffle cone of the exhaust pipe, to pack the
unburned gasses back into the cylinder before the piston closes off the exhaust port. Now the
crankshaft has rotated past bottom dead center (BDC 180 degrees) and the piston is on the
upstroke. The compression wave reflected from the exhaust pipe is packing the unburned gasses
er.
back in through the exhaust port as the piston closes off the port to start the compression phase.
Image 3. Explosion drawing of engine
Image 4. Power curve chart
Image 5. Gas consumption curve
In the crankcase the pressure is below atmospheric producing a vacuum and a fresh charge of
unburned mixture gasses is flowing through the intake into the crankcase. The unburned mixture
gasses are compressed and just before the piston reaches TDC, the ignition system discharges a
spark causing the gasses to ignite and start the process all over again.
Image 6. Motor viewed from left side
Image 7. Motor viewed from right side
2.12 Crankshaft
The crank is made from several metal parts, that were manufactured hydraullically under several
tons of pressure. These parts consist of the two strokediscs, the two crank pivots and the
strokepivot on which the connecting rod is installed on a doublerowed rollerbearing. A polished
seperator disc seperates the two rows of rollers and thus keeps an ideal tracking and also insures
sufficient lubrication even at high revolutions. At the top end of the connecting rod there is a
bronze bushing into which the piston bolt is installed.
The crank is installed into the crankcase by one ball bearing on the right and two ballbearings on
the left. The necessary pressuretightness of the crankendings at the bearings is achieved by spring
pressured crank seals on each side.
Image 8. Crank with connecting rod and
piston
2.13 Crankcase
The enginecase is sliced vertically through the middle. The front section contains the crankcase
and the rear section the transmissioncase.The crankcase picks up the crank and carries the
cylinder. The two halfes of the engine case are held together by screws . The seperation surfaces
of both halfes of the engine case should have minor amounts of a fluid sealer applied to them prior
to closing the enginecase. Two lightmetal cast lids close the exposed areas around the sides of the
enginecase.
Image 9. Crankcase section
(1)Ratchet
(2)Bushing for countershaft
The main transmission of power including the clutch can be found in the left area while the
alternator and the clutch access are installed in right side, well protected from dirt.
Image 10. Lightmetal lid, right side
2.14
Cylinder and Cylinderhead
The cylinder is made of special grey cast iron and is covered with large scaled cooling fins.
Together with the cylinderhead which is also equipped with cooling fins, it is frimly screwed onto the
crankcase using four long special screws. At the foot of the cylinder a paper seal supplies the
necessary sealing.
Image 11. Cylinder
Where the cylinder and the crankcaes meet, the crankcase is also equipped with some cooling
fins, to harmonize the optical impression of the engine.
Precisely carved, you will find the previously decribed (sect. 2.11, mode of operation) transfer ports
in the cylinder. The two port openings located on the sides at the foot of the cylinder are
corresponding with the adjacent ports in the crankcase. When the cylinder is worn out, it can be
rebored and fitted with the next larger size of piston. The measurements for reboring the cylinder
are as follows: 56,25; 56,50; 56,75 and 57mm.
Image 12. Cylinder and Exhaust connectors Image 13. Cylinder head
A sparkplug that is necessary for the ignition of the gas/air mix, sits in the center of the cylinder
head. The cooling fins are oriented in direction of the supercharger blower.
2.15 Piston and piston bolt
The purpose of the silicon bearing cast lightmetall alloy piston is to pick up the pressure from the
burnig fuel. The oscillation of the piston caused by the work cycles is transformed into the
necessary rotational movement by the crank. The sealing of the piston toward the cylinder walls is
achieved by the presence of two 2,5mm wide piston rings which are secured against rotating by
safety lock pins, to protect them from getting into the transfer ports, which could otherwise do harm
to the engine. The piston is connected to the crank by a specially hardened lapped piston bolt that
is secured against shifting by circlips.
Image 14. Orientation of aggregate, right side
2.16 Fan
An axial load supercharger forces fresh cool air onto the cooling fins of the cylinder to cool the
warm air that is being produced by the cycle process of the running engine. The axial load
supercharger is made from two components: a light metal fan casing and an air guiding cover that
directs the air.
The flywheel is driven by a 8x5x474 drivebelt. The drivebelt is hooked onto the left crank pivot
secured by a beltdisc. A supercharger alarm system consisting of a contact and an orange pilot
lamp on the right hand side of the instrument panel, supplies the appropriate control and security
incase of possible blockage or snapping of the belt.
2.161 Inspection of the blower beltdrive
The belt for the flywheel should be loosly streched. It should also easily put the flywheel into
motion. If fitted too loose, it will lead to the belt „throbbing“, bearing the danger that the belt will
make contact to the housing and thus be subjected to premature wear. Also when the belt is
installed too tight, it will show signs of premature wear, because the tension that occurs during
operation adds to the initial tension of the belt. This leads to excessive friction on the belt´s profile,
which will cause the belt to eventually snap.
It is hard to give an exact value for the tension necessary for the belt but it´s safe to say, that when
you can push the installed drivebelt in by about 1/3 of an inch, that the tension set is just about right
to achieve the longest endurance of your belt. By using distancing strips between the blowercase
and the clutch lid the right tension of the belt can be set.
2.162 Changing the drivebelt
a) Removal of engine housing
b) Removal of alloy lid on the left half of the enginecase underneath the blower by unscrewing
the two upper and loosening the lower cylinderscrew.
c) Remove lower drivebelt disc (right-hand-thread) using a 19mm socket and remove disc.
Image 15. Belt drive
d) Unscrew the three screws of the guide rim and remove the guide rim. On the extenstion of the
guide rim you you have the flywheel and the drivebelt disc. Now you can install the new drive belt.
(A reserve belt is in the toolbox).
e) Repeat steps a) through d) in reverse order.
2.17 Electrical System
The electrical system consists of the following:
a) alternator 6V, 60W
b) Led-battery 6V, 8Ah (K20)
c) Ignition coil
d) Cntroller switch
e) Ignition and lightswitch
f) Circuit breaker and condenser (mounted on the holding cap of the alternator)
g) Sparkplug (in Cylinder head)
h) Headlight (Hi beam, low beam and parking light)
i) Charging control lamp (red, on the lefthandside of the controlpanel)
j) Neutral gear control lamp (green, on the lefthandside of the controlpanel)
k) Control lamp for Supercharger (orange, on the righthandside of the controlpanel)
l) Signal horn
m) Brake-, tail- and licenseplate lamp
n) Wiring harness
o) Control lamp (unused. Can be used for Hi-beam display for instance)
Image 16. Wiring diagram
Suggestion: A more detailed and colored version of the wiring diagram can be downloaded from
our website at
www.scooterstation.com
2.171 alternator
The genereator generates the electricity necessary for ignition, lights and signal horn. Also the
alternator charges the battery through a controller switch.
Image 17. alternator
The battery functions as a direct current shunt link alternator. The alternator is made from two main
parts. The anchor and the holding cap.
The controller switch is installed on the blowerhousing and keeps the alternators voltage steady,
regardless of the number of revolutions the engine is doing or how many of the lights are currently
turned on.
Also the controller switch automatically switches the battery off, when reaching a high enough
number of revolutions as well as switching battery support on when the revolutions fall under a
certain amount. When the red controll lamp on the controlpanel expires, the battery is being
charged by the alternator. When the red control lamp is on, it shows that the battery is currently
feeding the electrical system.
The anchor that carries the commutator, sits directly on the cone of the right crank pivot. It gets
screwed together with the circuit breaker cam using a long hexagonal nut. The holding cap contains
the pole housing with poles and field coils on the inside. The front face carries the circuit breaker
and the condenser as well as the brushes that are forced onto the commutator by springs and
supply the current. A three wired cable connects the alternator with the regulator-aggregate and the
circuit breaker with the ignition coil. The aeration of the of the alternator housing, wich is enclosed
by a housing lid, is achieved by a sufficiently large breakout in the partition wall of the housing. The
housing lid itself carries a little detachable plate, which if taken off the housing lid, enables easy
monitoring of brushes, condenser and commutator.
2.171.1 Monitoring the electrical system
During regular operation the electrical system doesn´t need any extra attention. However it is
necessary to have the electrical system inspected and serviced by special personnell (IKA dealers
workshop) every 6.000 miles. Merely the breaker points should be inspected for abrasion every
1.000 miles.
When the cam is in it´s highest position, the contact gap should be 0,4mm. Less or more gap will
result in bad starting behaviour, unsteady running, less performance and higher gas consumption of
the engine. Adjustment of the points is done with detached circuit breaker cover (see image 18) and
loosened clamping screw ( C ), by pivoting the smaller statorplate around the bolt (D). The pan
head screws (A and B) are not to be loosened during this procedure.
The clamping screws ( C ) and (B) are to be tightened again after adjustment. If the breaker points
have burned spots, they are to be smoothed out using a contact file. More vigorous signs of
conflagration on the points indicate a defecticve condensor. The advice of a professional electric
technician is now essential to have the defective part replaced.
2.171.2
Electrical tuneup (every 6000 miles)
The regular 6000mile inspection of the electrical system consists of a check up on proper
positioning and insulation of the wiring and faultless seating of all clamping screws and
connectors. All contacts are checked for cleanness and are polished if needed. (This covers ignition
coil contacts, ground contact of the battery, regulator contacts, alternator contacts, tail- and
stoplight connecting contacts in the front of the rear housing and on the frame).
Image 18, Statorplate
The condition of the commutator and the carbon as well as the tension of the carbon springs will be
inspected. The positive (+) carbon´s wear is heavier compared to the negative carbon (-). The
lowest height of the carbon may not exceed 11mm. After reaching this height, the carbon should be
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