a) 0) ==) 1 MO! |ServiceManual steyr Daimler Puch of America Corporation Greenwich-Conn.06830FOREWORD This service manual for the full ronge of 1980/81 models was issued to serve our workshops and their staff a5 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 all special workshop tools as 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 core publicized. We sincerely hope that this manual will prove of invaluable assistance both for the workshop and cus- tomer alike. STEYR-DAIMLER-PUCH ‘OF AMERICA CORPORATION GREENWICH, CONN, 06830’80/'°81 MODELS THIS SERVICE MANUAL COVERS THE FULL RANGE (OF 1980/81 MODELS AS LISTED BELOW. MAXI MAXI LUXE aeCONTENTS LUBRICATION AND MAINTENANCE .. 6 EXPLODED ENGINE VIEW. : . Le . 15 SPECIAL TOOLS é : 10 TORQUE SPECIFICATIONS aa . oe : 2 REMOVE ENGINE... : 3 . 8 DISMANTLE ENGINE ~ | SPEED 27 CRANKSHAFT 35 CRANKSHAFT-WRIST PIN 9 PISTON-CYLINDER a CYLINDER 42 ASSEMBLE CRANKSHAFT 43 ASSEMBLE CLUTCH ~ 1 SPEED . 44 ASSEMBLE ENGINE ~ 1 SPEED . a7 INSTALL ENGINE ~ 1 SPEED 52 CARBURETOR 7 DISMANTLE ENGINE — 2 SPEED 9 DISMANTLE OIL PUMP DRIVE 65 ASSEMBLE OIL PUMP DRIVE or ASSEMBLE ENGINE — 2 SPEED 6 INSTALL ENGINE — 2 SPEED 80 ENGINE IDLE 83 OIL TANK, FUEL TANK s as 84 FRONT FORK-MAXI 85 FRONT FORK-MAGNUM MK II 90. SHOCK ABSORBERS - REAR SWING ARM 95 REAR SWING ARM 96 REAR WHEEL - BRAKES ” BRAKES 98. BRAKES-HUBS . 99, HUBS : 100 IDLER GEAR - DRIVE SPROCKET 101 SPOKING WHEEL 102 BALANCING ‘ 105, ELECTRICAL EQUIPMENT 106 BREAKER POINTS : 109 IGNITION TIMING . = 110 TIRE FITTING “ 112 TROUBLE SHOOTING = 113 WIRING DIAGRAM : 116 SPARK PLUG CONVERSION TABLE 7 ¢ 122 METRIC CONVERSION TABLE : 123 ALPHABETICAL INDEX 124 NOTES 129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 Frequency in miles (km) Every 900 [1800 (960) | (1450) | (2900) OPERATIONS TO PERFORM Tire wear and condition Throttle cable adjustment Check tire pressure Check Tronsmission ATF level Clean and lubricate chain Cleon air filter Change gearbox oil Check spark plug Decarbonize engine Clean Exhaust baffle Retighten screws, nuts (ine. heed nuts) Clean fuel valve and lines Clean carburetor (liter screen, float chomber) Idle speed adjustment Check ignition timing Adjust cl Check brakes (linings every 900) Check/lubricate hub becrings Steering bearing adjust/lubricate Check chain tension/adiust Lubricate front fork Retighten upper fork bridge bolts 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, Look for this symbol to point out important safety precautions. It means - Attention! Become alert! -6-LUBRICATION AND MAINTENANCE LUBRICATION ‘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 cutomatic: Fill with fresh automatic transmission fluid - TYPE F only (il capacity 5.74 oz (170 ec) to bottom of oil fill hole 2 speed automatic: ZOO ey Fill with fresh automatic transmission fluid - TYPE F only = ; = (oil capacity 9.5 oz (280 cc) to bottom of oil level plug. 1-SPEED AUTOMATIC 6) Replace oil fil plug. Cleaning and oiling the chains AX Engine should not be running. Both engine drive and pedal chains should be kept clean. Every few hundred miles wipe chains thoroughly with a cloth, ond using a small brush, lubricote with chain oil lubricant. ‘Always keep cheins properly adjusted. The proper slack of the drive ehain schould be " in. (2 em). To adjust the chains, loosen the axle nuts and tighten or loosen the rear adjuster 2-SPEED AUTOMATIC nuts.Once chains are properly adjusted, tighten the axle nuts. Moke sure that wheels are always aligned. Kickstand lubrication Remove the stand spring. Remove thre hexagon bolts. Remove stand. Grease both halves of the stand pivot with o Drive Chain good automotive lithium base grease. Adjusting Screws and Pivot Bolts Lubricote adjusting screws, tensioning screws and pivot bolts on control levers with a few drops of oil MAINTENANCE Please contact an authorized PUCH Dealer for work you do not wish to carry out yourself. The agent will be pleased to advise and help, Checking spark plugs Unserew 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 a piece of wood or @ steel wire brush, The electrode gap should be from 016 — .020 in. (0,40t00,50 mm), if larger, adjust by bending the ground electrode. When replacing the spark plug ensure thread matches properly nd 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 f/lb (20 Nm).LUBRICATION AND MAINTENANCE MAINTENANCE Decarbonizing the engine Carbon deposits on the cylinder head, piston crown and in the exhoust ports are normal with ll two-stroke engines and con 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 and 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 a uniform layer of oil carbon. Before refitting the cylinder head, thoroughly remove all carbon deposits and scrapings 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 tomake sure it cranks easily. Clean the ma- ting surfaces with a cleon rag. Replace the cylinder head and tighten the four cylinder head nuts. Be sure to tighten two cylinder head nuts diagonally across from each other before tightening the other two nuts (7 f/lb/10 Nm). Exhoust port In order to cleen the exhaust port, remove the exhaust pipe. Cronk the engine over (with the spork 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 piston or cylinder surface. When cleaning the exhoust port, itis also @ good idea to clean the muffler. Cleaning the muffler Unserew and pull off the exhaust endpiece. Remove oil- carbon deposits from the inside of the muffler using a Scraper. Also corefully remove the oil deposite from the \ exhaust baffle and the exhaust endpiece. Reploce the gasket — cm) iPnecessary. j ~ NOTE: For further break-down of exhaust system refer to io) fagram = MAXI, MAXI LUXE MAGNUM II NEWPORT II, MAXI SPORT MK II Ys MAGNUM MKuI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 port of the air clecner using ¢ drift and ccrefully push out filter screen. Wash filter screen in solvent and allow it to dry thoroughly before replacing. Reossemble damper pipe, filter screen, ond air cleaner assembly. Cleaning the air cleaner — MAXI Series The air filter on the MAXI is @ non-serviceable sealed unit. Cleaning the fuel valve ond line Empty fuel tank. Pull the fuel line from the fuel valve and blow air thru line until clecr. Unscrew the fuel valve, Clean the valve and strainer by woshing with solvent. Cleaning the carburetor Mointenance 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 choin guard oe Fegmnrcmaner 3) Remove the air cleaner. 5 4) Loosen corburetor clamping screw, see page 10 (1). NCS, sees 5) Pull the fuel pipe from the carburetor. SR samen 6) Turn the corburetor with its float chamber line (bottom) towards the clutch side ond pull off 7) Loosen screws ond pull out the top parts, see page 10, 2) with throttle slide and pull off NA 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 a piece of wire. Also. unscrew noodle jet and clean 10) Clean the floct chamber with gasoline. 11) Wash carburetor bedy and blow through, Moke sure that the bores are not clogged with dirt. 12) When refitting the jets, tighten them properly.LUBRICATION AND MAINTENANCE CARBURETOR ADJUSTMENT Minor carburetor adjustment may be required to compen- sate for differences In fuel, temperature, altitude and load, IDLE ADJUSTMENT Start engine and run ot moderate speed until operating temperature is reached, Adjust idle speed by turing idle adjustment screw (3) in or out until engine runs smoothly. THROTTLE CABLE ADJUSTMENT Check for proper throttle cable slack (,040 in./1,0 mm). In- sufficient cable slock will hold the throttle partially open and the idle adjusting screw will not function. If necessary, loosen the cable locknut (4) and turn the throttle cable adjuster (5) to the right to inerease cable slack. Retighien the cable locknut. \) Exploded view of the carburetor 1 Intake manifold 2 Carburetor body 3. Throttle slide stop screw (Idle screw) 4 Needle jet 5 Main jet 6 Float needle 7 Float 8 Float bow! 9 Hose swivel connector 10 Throttle slide 11 Jet-needle 12 Choke slide 13. Choke lever _ 9 Top cover 15 Slide spring =10-LUBRICATION AND MAINTENANCE CHECKING THE IGNITION SYSTEM Ignit timing The engine will reach maximum output only if the ignition is correctly adjusted. See Ignition Timing page 110, 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 brecker points are fully open and visable through one of the flywheel windows. Breaker points that are burnt should be replaced, Measure breaker points gap with o feeler gauge (014 - 018 in./0.35 — 0.45 mm for 1 speed, 016 — .020 inJ0.40 ~ 0.50 mm for 2 speed). To adjuste the breaker points gap. loosen the set screw slightly, insert o screwdriver blade into the slot on the breaker plate and turn the screwdriver slightly until the correct gop is obtained, Tighten the set screw and check that the gap has not cltered. 1-018 2-speed Adjusting the starting lever ‘After the first 300 miles (480 km) and then every 3600 miles {5800 km) check adjustment of the starting lever. The free ploy at the starting lever (measured at the end of the lever) should be "in, (2 em). Correct play is achieved by loosing the lock- nut (1) and turning the adjuster until the correct lever travel is obtained. Tighten the locknut. 1-speed -n-LUBRICATION AND MAINTENANCE ‘Checking the brakes Front brake The correct adjusted travel (meosured at the end of the handbrake lever) is * in. (2 cm). To adjust, loosen the locknut (1) and turn the adjuster until brake lever travel is *hin. 2 em), Tighten the locknut. Rear Brake The correct trovel (measured ot the end oft the handbrake lever) is * in, (cm). To adjust, loosen the locknut (I) and turn the adjuster until brake lever travel is“ in. (2 cm). Tighten the locknut. 6 Brake linings Pry plastic inspection plugs from wheel hub, Disconnect broke cable from broke lever. Insert a feeler gouge between broke drum and brake lining. Gap should not exceed .047 in, (1.2m) at either inspection hole, If gop exceed this measure- ment, refer to section “BRAKES” on brake replacement. Addo not operate your unit. FRONT WHEEL REMOVAL Unscrew speedometer coble from hub. Loosen locknut on brake cable and remove brake cable from hub. Remove the exle nuts, Remove wheel from fork To replace wheel reverse the above procedure. Torque oxle nuts to 20 ftilb (27 Nm). Be certain to readjust the brake before riding. =12-LUBRICATION AND MAINTENANCE REAR WHEEL REMOVAL Loosen the two chain adjusters (1). Loosen both oxle nuts ). 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 serew(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 end replace (see the “Technical Dota” section forse of Stop light bulb (top) and rear light bulb (bottom). -13-LUBRICATION AND MAINTENANCE ‘umbs 2 —— —_S Lit Boxe nth Spoons Spoke Ends Replay Tee Onto Stems Siraight TIRE REMOVAL 1. Let air out of the tire by removing the valve core. 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 bead of the tire is not sticking to the rim, 2. Use tire tools or spoons with rounded ends to lift the bead on one side of the tire off the rim, Be coreful not to pinch the inner tube between the tire tools and the tire bead 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 all spoke ends. 2 Wet tire bead with soapy water, Roll the tire bead, 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 assembly. 3, Make certain that valve stem is protruding squarely though the rim. At this point it may be desirable to let some cir out of the inner tube to make the next step 4. Starting in the area of the valve stem, pross the other tire bead 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- lume capacity of tires, service station air hoses inflate tires very rapidly. They are also usually capable of pressure be- yond that which the tire can hold. 5, Inflate the tire to about half the recommended pressure tnd check to see that the tire bead is seated properly fon the rim. If it isnt, use thumb pressure to seat beac. 6. Inflate the tire to full pressure auEXPLODED ENGINE VIEW SNIONS OLLWWOLNW G3adS 3X1 IXVW ~15-EXPLODED ENGINE VIEW SNIONS OLLVWOLNW G33ds 2 IMIN LHOdS IXVIN-IlLYOd MAN Q aeEXPLODED ENGINE VIEW © MAGNUMII 2 SPEED AUTOMATIC ENGINE aEXPLODED ENGINE VIEW \ af \ a Vie J ® ane 2 SPEED AUTOMATIC OIL INJECT a6 MAGNUM MK II 1 WW OS & Be “ és ~18-SPECIAL TOOLS Tg TG we DOOD OOOO SERA =e ais afofojofolo[ofo|ofolOIo! 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Secure in position on bench with tie-down straps. Remove left and right hand chain guards. Loosen clamp screw on air filter ossembly and remove. =23-REMOVE ENGINE ¢ Turn fuel tap to "Off" position. Disconnect fuel supply hose. Loosen corburetor clamp screw and twist carburetor to the left and remove from intake manifold Remove both exhaust nuts on cylinder and the mounting bolt on the muffler housing, Remove exhaust system. Disconnect drive chain by removing the master chain link. -24—REMOVE ENGINE Disconnect electricel wiring ot 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 handleber. Pull up protective plastic cop from the adjusting sleeve. Unscrew storter cable nut from adjusting sleeve. Do not loosen edjusting sleeve nor the starter cable adjusting nut. Remove suppressor plug from spark plug, On ‘-speed models remove ignition coil from engine,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 MKII: Remove cil 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. =26~DISMANTLE ENGINE - 1 SPEED ” Place engine in engine holder (905.6.36.108.0) which is mounted in a vise Remove intoke manifold Disconnect the kick-stond spring. -27-DISMANTLE ENGINE - 1 SPEED Unscrew the kickstand bearing bolts, bearing cup and kick- stand, Remove generator cover. Lock flywheel with locking toot 905.0.16,101.2 and unscrew flywheel nut. =28-DISMANTLE ENGINE - 1 SPEED Break toper between flywheel and crankshaft with special puller 050.7012. Remove flywheel and woodruff key from crankshaft. Unscrew the stator plate screws, remove the stotor 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,DISMANTLE ENGINE - 1 SPEED 3 3 3 & g 5 Remove wrist pin retaining rings. and remove piston Push out the wrist pinDISMANTLE ENGINE - 1 SPEED Remove clutch cover screws and clutch cover. Mount engine in engine stand so that the lower crankcase half is facing upward. Remove all crankcase screws. Slightly tap the upper crankcase half with a rubber hommer to break seclant between the two housing halves and remove top half -31-DISMANTLE ENGINE - 1 SPEED Lift primary drive assembly from lower eronkcase halt Remove crankshaft with clutch assembly. DISMANTLE CRANKSHAFT Remove large retaining ring from clutch drum and lift off pressure plate, ~32-DISMANTLE ENGINE - 1 SPEED Place crankshaft between soft jaws in a vise, clomping the clutch side web only and remove clutch retainer nut, Ensure to clamp only the clutch side crank web, o damage to crankshait is unavoidable. Use specie! puller 905.6.34.109.0 to remove centrifugal clutch from crankshaft. Remove clutch hub and woodruff key. NOTE: Clutch assembly may also be dismantled with engine eg mounted in moped. . Remove circlip, shims, clutch drum and bushing,DISMANTLE ENGINE - 1 SPEED , ay Remove main bearings with puller 905.0.34.101.0 and cages 905.6.34.111.0. BA Slane sanisote web ony onside of which bearing is being removed, or crankshaft damage will occur. Dismantle the primary drive as illustrated, Remove circlip ¢ drive sprocket, circlip, seal locating ring, beoring ond inner circlip. NOTE: Do not press gear off shaft. Remove all traces of sealing compound from crankcase. Thor- ‘oughly clean all parts with degreasing solvent and visually inspect parts for wear and damage. ~34—CRANKSHAFT CHECKING CRANKSHAFT BY SIGHT Whenever dismentling or fitting a new crankshaft check beoring seoting and seal running areas. Other repoir works to the cronkshah are outlined in the following steps in this menucl NOTE: The same testing and repoir method is being opp- lied for all erankshatts. - CONNECTING ROD ALIGNMENT f Measuring ond straightening can be accomplished it the crankshaft is dismantled or, if still fitted to the engine, after removing the cylinder ond piston. With a pair of steel blocks eccurately ground to equel height, measure the wrist pin with « feeler gauge as illustrated. Straightening of the connecting rod can be carried out by means of two (2) home made forks as illustrated.CRANKSHAFT , When completely dismontling the engine the crankshatt should be checked as well Three different faults may occur: 1. Crank webs are out of true 2. Crank journal is bent so that the webs are no longer paral- lel but oblique (outward). 3. Crank journal is bent so that the webs are no longer paral- lel but oblique (inward). ste -36-CRANKSHAFT > CRANKSHAFT-TESTING, BALANCING AND CENTERING 1. Crank webs ore out of true: With the big-end pointing upwards, clamp crenkshoft between two center points, Place two dial indicators on the erenkshoft journals close to the crank webs and set the dial indicators to zero. Rotate crankshaft downwards, one dial indicator will register plus, the other minus, Mork the position of the maximum reading on the crankshaft web e Remove crankshaft from centering points. Straighten crankshaft by hitting the maximum reading mark with @ copper or plastic hammer. Repeat testing with diol-indicator until the crankshaft is the permissible tolerance, which is 0008 ~ 0010 in (0,020 - 0,025 mm), SisCRANKSHAFT tv 2. Cronk webs are not parallel Set dial indicators to zero when the big end journal is parallel to the crank journals, Rotate crankshaft with big end journal upwards. Readings taken are either both plus or both minus. If the readings taken show that the crank webs are bent inwards (plus reading) the crankshaft is straightened by inserting @ tapered bar in the narrow (marked) position If the crank webs are bent outwards (minus reading) the crankshaft, is straightened by hitting the flat side of the cronk web . Repeat the procedure until the out of balance is within the permissible limit, which is .0008 - .0010 in, (0,020 - 0,025 mm)CRANKSHAFT - WRIST PIN BIG-END BEARING CLEARANCE If overheating, jamming or wear is apparent, crank- shaft assembly must be replaced. It is very difficult to measure the correct clearance and can only be carried out by the manufacturer. However, a very simple method is by firmly grasping the connecting rod to check for big end bearing wear. If rod is free but no play is noticeable, big end bearing is in good condition. Before assembling on engine, always check the small end bushing for woar. If excessive wear is noticeable replace small end bushing, SMALL END BUSHING: Fitting limits Weer limit 473 ~ .474 in. 475 in. 12,008 — 12,020 mm — 12,025 mm For correct wrist pin assortment ond sizes see ossorting table ‘on page 40, REPLACING SMALL END BUSHING Use special too! 905.6.33.108.0 to remove and replace bush- ing. NOTE: Lubrication hole in bushing being installed ond con- necting rod small-end must be in line. If replacement bushing has no hole, one must be drilled after bushing is in position. -39-CRANKSHAFT - WRIST PIN For centralizing and reaming use special too! 905.6.17.101.0 To enable accurate reaming place centralizing nut (1) over little end, insert guide sleeve (2) in centralizing nut. Insert tapered end of the reamer shoft (3) in guide sleeve and centralize tool over bushing. Tighten guide sleeve to centralizing nut Adjust cutting edges of reamer to bushing size, remove from guide sleeve and tighten adjustment nuts on reamer. Apply- ing oil to reomer, insert cutting end of reamer into guide sleeve, start reaming procedure until correct wrist pin bushing cleorance is achieved, Wrist pin and piston fit is matched together and coded as follows: Weer limit yellow or blue dot inside piston 475 in. 2 or 3 dots on end of wrist pin 12,025 mm SORTING TABLE Wrist pin boss yellow A727 - 4726 in. blue | 12.006 - 12.003 mm -40-PISTON - CYLINDER Piston-cylinder Piston and cylinder are metched together and marked on the piston crown and on the joint surface of the cylinder top. ALU-Cylinder and piston: 1,2,34 oF 5 on piston crown 1123.4, or 5 on cylinder head joint surface Hi-Torque-Cylinder and piston: 11,22 or 33 on piston crown 11.22 or 33 on cylinder head joint surface MAGNUM-Cylinder and piston: 1 or 2 on piston crown 1 or 2 on cylinder heod joint surface. MAGNUM SORTING TABLE Cylinder Diameter Piston Diameter 1.4961 in. - 37,965 mm - 37,975 38,001_mm 1,4947 in. - 1.4951 1.4964 in. - 1,4967 in. 38,008_mm - 38,016 mm NOTE: The O’size pistons are available for the Hi-Torque and MAGNUM.Cylinders only. The boring has to be done locally ALU-CYLINDER SORTING TABLE Piston dicmeter 1.4938 - 1.4942 in, (37.945 - 37.955 mm) Cylinder diameter 1.4950 - 1.4954 in. (37.975 - 37.985 mm) 1.4954 - 1.4958 in. (37.985 - 37.995 mm) | 1.4942 - 1.4946 in. (37.955 - 37.965 mm) 1.4958 - 1.4962 in. (37.995 - 38,005 mm) | 1.4946 - 1.8950 in, (37.965 - 37.975 mm) 1.4962 - 1.4966 in. (38.005 - 38.015 mm) _| 1.4950 - 1.4954 in. (37.975 - 37.985 mm) 1.4966 - 1.4970 in. (38.015 - 38.025 mm) | 1.4954 - 1.4958 in. (37.985 - 37.995 mm) HI-TORQUE-CYLINDER SORTING TABLE 1 7.4960 - 1.4963 in, (38,000 - 38,005 mm) |1,4944 - 1.4946 in. (37,956 — 37.965 mm)] 7.4963 ~ 1.4965 in, (38,005 - 38,010 mm) | 1.4946 - 1.4949 in, (37.965 - 37.970 mm)| 7.4965 — 1.4968 in. (38,010 - 38,015 mm) [1.4949 - 1.4951 in, (37,970 - 37.978 mm) [Group Cylinder diameter 4 Piston diometer mn) hlaCYLINDER Piston/eylinder clearance limit ing gap ALU-Cyl: Min, 0008 in. (0,020 mm) 006 - .012 in. Max. .0016 in. (0,040 mm) 0,15 - 0,30 mm Hi-Tor.-Cyl.: Min. .0014 in. (0,037 mm) (for all models) Max. .0020 in. (0,052 mm) MAGNUM.-Cyl.: Min, .0014 in. (0.036 mm) Max. .0020 in. (0,052 mm) NOTE: When boring o cylinder for O/size piston, note piston sort type number, and refer to respective sorting table and edd .25 mm to cylinder sorting (diameter) size, EXAMPLE: O/size piston sorting group 22, cylinder diameter required 1.7462 - 1.7464 inches (38,256 - 38,261 mm). Measuring the cylinder The cylinder bore is measured with a bore gauge and a bore: measuring adapter (both items are commercially available). Measuring procedure t Adjust bore gauge by means of the stop measure to the no- minal bore diameter The bore must be measured at six positions, once parallel with and once diametrically opposed the wrist pin at the three positions indicated in fig, The specified temperature of 68"F (20°C) is important if reliable results cre to be obtcined, The lowest positon of the pointer indicates the bore diometer. Maximum permissible ovality of cylinders: ALU-Cylinder .0904 in. (0,01. mm) Hl-Torque-Cyl. 0012 in. (0,03 mm) MAGNUM.-Cyi, 0012 jin. (0,03 mm) =42—ASSEMBLE CRANKSHAFT - 1 SPEED ‘ASSEMBLING CRANKSHAFT Use special tool 905.0.33.104.1 between the two (2) crankshaft webs ond special installation sleeve 350.1,70.0120 to install flywheel side main bearing on crankshaft. Lubricete oil seal and install crankshaft seal, sealing lips facing outward, on clutch side of erankshaft Again use installation sleeve 350.1.70.012.0 to press clutch side main bearing on crankshaft, with the locating ring groove facing the outside, =43—ASSEMBLE CLUTCH - 1 SPEED AUTOMATIC (ONE SPEED) The automatic consists of o centrifugal clutch and a one (1) speed gear train Starting engine: engaging the pressure plate with the centri- fugal clutch (face lining) will give o solid drive between erankshaft and clutch drum. Centrifugal clutch storts to open at appr. 1200 - 1500 rpm. Fully engaged at appr. 2600 - 3000 rpm and is disengaging between 1400 - 1150 rpm. Centrifugal clutch must be replaced when linings are worn ‘and limit pins (on shoes) prevent drum contact, The clearance between pressure plate and face lining of centrifugal clutch should be between .012~020 in, (0,30— 0,50 mm). The end-float of the clutch drum must be between .004 -.008 in. (0.10 — 0,20 mm). This clearance is achieved by various size of upper and lower shims (1 and 2). The correct adjust tment procedure is outlined in the following steps. ¥4 01-02 DH 03-05: 004 - 008 in 012 - .020in Install clutch drum, woodruff key and centrifugal clutch with- ‘out upper and lower shims (arrows) on crankshaft, torque nut to 20 ft/lb (27 Nm). —44—ASSEMBLE CLUTCH - 1SPEED First establish the thickness of the lower shim. Press clutch drum down and measure moximum gap between primary gear and circlip on crankshaft with a feeler gauge To this measurement odd the required clearance of .012— 020 in, (0,30-0,50 mm) between pressure plote ond face 2 ling, this would give the required thickness of the lower shim. (0 'a0.'0 s0\"nm) EXAMPLE: Primary gear‘cirelip gap O47 in, (1,20 mm) Plus required cop (012 in. (0,30 mm) lower shim required (059 in. (1,50 mm) NOTE: Lower shim .945/.669 in. (24/17 mm) is ovaible as follows: 043 in, 051 in 059 in, 067 in. 110mm = 1,30mm —1,50mm 1,70 mm Then lift clutch drum and measure the gap between primary gecr ond circlip on crankshaft (not circlip on bearing). Clutch drum must be shimmed to cllow 604 ~ ,008 in. (0,10 ~ 0,20 mm) end-float. —45—ASSEMBLE CLUTCH - 1SPEED (004—008 in, (0.10-0.20 mm) From this measurement deduct lower shim chosen and end: float, This will give required thickness of upper shim. EXAMPLE: Primary gear/circlip gap Less lower shim chosen Less required end-float Upper shim required 142 in. (3,60 mm) (059 in. (1,50 mm) (008 in. (0,20 mm) 075 in. (1.90 mm) NOTE: Upper shim 866/.591 in, (22/15 mm) is as follows. 043 in. 051 in, .059in. .067 in. .O70in. .073in. O75 in. O77 in. .079in. .083 in. 087 in, 4.10 mm 1.20 mm 1,50 mm 7,70 mm 1,80 mm 1,85 mm 1190 mm 1,95 mm 2,00 mm 2,10 mm 2,20 mm Once the required shims are established, remove clutch as- sembly and reassemble with shims. Torque nut to 20ft/Ib (7 Nm), NOTE: Do not forget woodruff key. . Replace pressure plate and secure with large retaining ring. ¢ Minimum starter clutch lining (face lining) is 040 in. (1,0 mm). ~46—ASSEMBLE ENGINE - 1 SPEED ASSEMBLING ENGINE: Lubricate magneto side oil seal and install with sealing lip facing inwards, Ensure sufficient gap between magneto side bearing and oil seal appr. .040 in. (1 mm) to allow oil flow to bearing, Install crankshaft and clutch assembly in housing halt, Reassemble primary drive, lubricate seal and install with seeling lip facing outward. Place assembly in crankcase half. NOTE: Assure that locating rings (on crankshaft clutch side main bearing and primary drive, between bearing and sec!) have their gaps face straight up. Sparingly apply sealing compound (non-hardening) to crank- case joint, fit crankcase half into place and torque crankcase screws to 6 fllb (8 Nm). _47-ASSEMBLE ENGINE - 1 SPEED Place engine in upright position, oi small end bushing and install piston, Ensure the orrow on the piston crown and ring locating pins ore facing the exhaust (drain plug) side. Fit a new cylinder base gasket into place, lightly oil piston nd cylinder wall and replace cylinder. Be sure to align ring gap to the pins. pective locating NOTE: The exhaust port of the cylinder should face drain plug side of engine, Place proper size cylinder head gasket, where applicable, into position. Fit head and washers and torque cylinder head ruts to 7A/Ib (10 Nm).