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v i t h 201 i l l u s t r a t i o n s
2nd
29 d r a w i n g s of s p e c i a l t o o l s
A l l r i g h t s reaerved
........................
Completing and Mounting the Clutch Cover 38
Mounting the Kick-starter Assembly
...................
.................................
Mounting the Clutch Actuation Mechanism
38
$0
40
Mounting the Clutch Cover
Rough Adjustment of the Clutch ............................
.................................... 40
Clutch Fine Adjustment
Drive for Speedometer .....................................
Oil Supply for the Lubrication of the Crankshaft Main
41
41
Bearings and Shaft Seal Rings
Lubri'cation of the Gearbox
.............................
................................ 41
42
Assembling Faults .........................................
Mounting the Engine in the Cycle Parts .................... 42
42
Cycle Parts ...............................................
...... 43
44
Mounting of the Rear-wheel Swing-fork .....................
Rear wlheel Springing and Rear Elastic Engine Mounting
Replacement of the Rubber Bearing .Rear-wheel Swing-fork .. 44
44
Demounting and Mounting the Swing Bearing Bolt ............
Mounting the Rear Swing-fork Including Engine Suspension .. 44
45
Rear Engine Suspension ....................................
Repair of the Suspension Units ............................ 45
46
Engine Suspension at Cylinder Head
Telescopic Fork
........................
........................................... 47
47
Steering Bearing .........................................
Criteria for Dismantling the Telescopic Fork .............. 48
49
Demounting and Mounting the Complete Telescopic Fork
Demounting and Mounting the Telescopic Fork Members
......
....... 49
50
Dismantling the Telescopic Fork Members Removed from
the Vehicle ...............................................
Mounting the Telescopic Fork Kembers Removed from the
50
Vehicle and Checking for Wear .............................
Funotional Test of Telescopic Form ........................ 52
Fuel Tank .................................................
Fuel Shut-off Cock ........................................
53
54
54
Rear-wheel Drive and Rear-wheel Hub
Dismantling the Rear-wheel Drive
........................
.......................... 55
56
Speedometer Drive .........................................
Changing the Wheel Bearings ............................... 56
Brakes ....................................................
Internal Shoe Brake .......................................
57
57
Disk Brake for the Front Wheel
Secondary Chain
............................
...........................................
57
a:
Exhaust System ............................................
Aligning the Wheels. Balancing the Front Wheel ............ 63
64
Cable Controls ............................................ 64
Electrical Equivment ......................................
Three-phase Dynamo ........................................
65
Mode of Operation .........................................
65
Technical Data ............................................
65
Technical Characteristic
Fault Diagnoses ...........................................
.......d.......................... sa
68
Behaviour of the Charging Control Light ................... 68
Measuring Instruments ..................................... 68
Measurements at the Vehicle ............................... 68
Use of an Oscillograph .................................... 68
Fault Localisation ........................................
Demounting from the Vehicle ...............................
71
Demounting the Three-phase Dynamo .........................
72
Demounting the Rectifier ..................................
72
Demounting the Three-phase Dynamo .........................
73
Stator with Retaining Cap .................................
73
Rectifier .................................................
73
Checking the Components ...................................
74
Checking the Rectifier ....................................
74
Testing the Stator .......................................
74
Testing the Rotor .........................................
75
Checking the Length of the Carbon Brush ...................
75
Aseembling Instruction ....................................
75
Important Information .....................................
75
75
Page
Regulator .................................................. 76
.................................................. 16
Mounting
Maintenance . .............................................. 76
)
................................................. 76
Adjuatrnent
.......... ......................... 76
r
....................................................
Damagesand their Causes
77
Battery
Ignition ..................................................
Ignition Coil ............................................... 77
77
Contact Breaker ............................................ 78
............................................ 7808
Ignition Timing
Sparking-plug ..............................................
Ignition Line Connector (Sparking-plug ConnecCor) ........... 80
Troubles in the Ignition System ............................ 8810
.............................
Headlamp ...................................................
Lighting and Signalling System
........... 81
Ignition-light Switch ......................................
Combined Stop-Tail-Number-plate Lighting Fitting
..........................
83
83
84
Stop-light Switch ..........................................
Switch Combination at Handle-Bars
Flashing-light Direction Indicator System
84
................... 85
Horn ................................?....................
............................................ 85
Circuit Diagram
Instruments and Tell-tale Lights ...........................
7 . Induction Byetern ........................................... 89
Description and Function of the System ..................... 89
Air Filter ................................................. 90
'(.l.
7.1.1.
7.1.2. Intake Silencer ............................................ 90
7.1.3. Connecting Piece at Carburetter ............................ 90
7.1.4. Carburetter ................................................ 90
7.1.4.1. Design and Function of the Carburetter ..................... 90
Fuel Level Basic Adjustnenf ................................
Fuel Level - Fine Adjustment ..........+ .................... 93
7.1.4.2. 92
7.1.4.3.
7.1.4.4. Idling Adjustment .......................................... 94
7.1.5. Intake Connection .......................................... 94
7.2. Fault Localisation ........................................ 94
Too Lean a Mixture .......................................... 94
Too Rich a Mixture ......................................... 95
7.2.1.
7.2.2.
S~ecialTools .............................................. 96
List of Special Tools ...................................... 96
8.
Drawings of Special Tools .................................. 98
8.1.
8.2.
9. Tightening Torques .Engine ................................. 120
10 . Tinhtenina Torques .Cycle Parts ........................... 120
Fig. 1. ET2 250 w i t h d i s k b r a k e
. 1.4, Gearbox
Clutch on t h e left-hand end of c r a n k s h a f t - in oil
b a t h ( 5 f r i c t i o n d i a k s w i t h cork p o r t i o n s )
G e a r - s h i f t eystem foot-opereted
Number o f speeds 5
Gear r a t i o s
l e t speed
2nd speed
3rd speed
4 t h apeed
5% speed
1.7.. . Weights
W.eight unladen ( w i t h f u e l and t o o l s ) 157 kg ( d e s i g n with drum brake, f r o n t )
153 kg ( d e s i g n with d i s k brake, f r o n t )
p e r m i s s i b l e t o t a l weight: 330 kg
1.8. Ca~a-cities
Gearbox 1,000 cmJ o f g e a r o i l SAE 80
Fuel t a n k 17 1 of f u e l - o i l mixture, i n c l u d i n g
1.5 1 o f r e s e r v e
O i l reservoir f o r o i l proportionating
system 1.3 1
Telescopic f o r k 230 cm3 of damping f l ~ i d ' ~ emember.
r
Pig. 5
~peed/gear diagram
ETZ 250 -Solo
Geschwindigkeit v in km/h =
epeed v in km/h
Pig. 5t%
Speed/geer d i a g r c l l ~
BTZ 250 -
aide-car dsefgn
Qeechwlndfgkeit v in km/h P
apeed v in km/h
2.1. Fuel v i e c o s i t y a t 50 'C 53 t o 6 8 c S t
(correeponds t o
According t o t h e d e s i g n o f t h e engine, a 8 06 roughly)
p e t r o l of an octane r a t i n g of a t l e a s t
88 ( i n t h e GDR a b b r e v i a t e d a s "VK 88") poar p o i n t maximum - 25 'C
should be used. f l a s h point 180
I n c o u n t r i e s o t h e r t h a n t h e GDR, t h e use
of a f u e l w i t h a s i m i l a r r a t i n g i s water content 0.1 %
recommended. En-co_uyt~ies-other-t_ha~4hg GDFJ,-egggg o_ii
2.2. Two-stroke Engine O i l f o r SAE 20-0: 40-0: gegr-o&l_SqE-80 wiih-simi-
Fuel-Oil lYlfxture
l a y ~ r g 1 p r 4 i e s - s h o g l 4 be-used,
Engine ofE i s added t o p e t r o l i n t h e
RATIO o f 1 : 50 2.4. L u b r i c a n t s f o r Cycle P a r t s
(e.g. 0.2 l i t r e s of engine o i l a r e The f o l l o w i n g l u b r i c a t i o n p o i n t s of t h e
added t o 10 l i t r e s of f u e l ) . c y c l e p e r t s must be l u b r i c a t e d w i t h
The mixing r a t i o of 1 : 50 a l s o a p p l i e s "Cenitol +k2" o r " C e r i t o l +k3" a n t i f r i c t i o n
t o t h e running-in period. b e a r i n g grease:
The two conrod b e a r i n g s , t h e c y l i n d e r
l i n e r and t h e 6306 c r a n k s h a f t main S t e e r i n g b e a r i n g , wheel b e a r i n g s , bearing
bearings a s well a s the piston a r e f o r r e a r wheel d r i v e , secondary c h a i n , brake
provided w i t h o i l by t h i e simple and cams and brake shoe b e a r i n g s , foot-operated
r e l i a b l e system o f pe*oil lubrication. brake s h a f t and speedometer d r i v e ( t h e two
Experiences g a t h e r e d i n t h e course o f l a t t e r i t e m s o n l y when being mounted o r
many y e a r s have shown t h a t i t i s a d v i s - repaired).
a b l i t o use
TWO-STROKE ENGINE OIL MZ 22 This a n t i f r i c t i o n b e a r i n g g r e a s e has a drop
i n t h e GDR. T h i s a d d f t i v e - t y p e o i l p o i n t o f about 130 t o 150 C , can be used
meeta t h e f o l l o w i n g requirements: f o r a temperature range from - 20 t o + 100
'C, and i s w a t e r - r e s i s t a n t a t + 50 OC.
v i s c o s i t y a t 50 'C 20 t o 25 c S t
pour point' maximum - 30 O C Ihr COUBTRIES OTHER THAN THE GDR, an a n t i -
f r i c t i o n b e a r i n g g r e a s e of s i m i l a r
It c o n t a i n s a d d i t i v e s which e f f e c t a c h a r a c t e r i s t i c s should be used.
high t e m p e r a t u r e and p r e s s u r e re-
s i s t a n c e . Limited tendency t o coking;
prevention of carbonaceous o i l depo-
2.5. Shock-absorber O i l -
T e l e s c o u i c Fcrk
s i t s o r d i s s o l v i n g them. Wear r e d u c i n g A s damping l i q u i d , a mixture o f
and c o r r o s i o n p r e v e n t i n g p r o p e r t i e s . 45 p a r t s of shock-absorber o i l and
Contains l e a d - s e p a r a t i n g a g e n t s pre- 1 p a r t o f molybdenum d i s u l p h i d e
v e n t i n g whisker formation i n spcrrk-
ing-plugs. should be used.
FOR MZ MOTOR-CYCLES I N OPERATION I B Shock-absorber o i l v i s c o s i t y :
COUBTRIES OTHER THAN THE GDR 8 t o 11 c S t a t 50 'C corresponde t o
i t i s a l s o a d v i s a b l e t o use only
tow-stroke engine o i l s which p o s s e s s 1.65 t o 1.92 'E a t 50 'C.
t h e s e p r o p e r t i e e (e.g. S h e l l 2 T,
C a s t r o l 2 T Aral 2 T, Mix01 "Sw,
2.6. Shock-absorber O i l - Susvension U n i t s
LT-2T, 8 t c . j . Shock-absorber o i l WITHOUT ADDITIVES of t h e
above v i s c o s i t y i e only used. The damping
2.3. O i l Capacity o f Gearbox v a l u e s of t h e Celeecopic f o r k and t h e s p r i n g -
loaded suspension u n i t s a r e based on t h i s
For gearbox and rimary d r i v e , an v i s c o s i t y . S p r i n g i n g and r o a d a b i l i t y w i l l
m o u n t o f 900 cm9 o f IGL 60. g e a r be impaired i f shock-absorber o i l s o f a
o i l i s r e q u i r e d . This i s an a d d i t i v e - d i f f e r e n t v i s c o s i t y w i l l be used.
t y p e g e a r o i l which i s u i t a b l e f o r t h e
l u b r i c a t i o n o f change-speed gearbox and 2.7. Lubricant f o r Contact Breaker
a x l e d r i v e s . It i s an a g e l n g - r e s i s t a n t
refined lubricating o i l with additives wUnterbr81ws p e c i a l o f 1 f o r c o n t a c t breaker,
f o r an i n c r e a s e o f t h e load-bearing v i s c o s i t y 700 t o 1,300 cSt a t 50 'C.
c a p a c i t y and a r e d u c t i o n o f wear.
It has f a v o u r a b l e low-temperature 2.8. h a k e Fluid
p r o p e r t i e s and meets t h e For t h e d i s k brake, t h e brake f l u i d known
f o l l o w i n g t e c h n i c a l requirements: $8 "Karipol grtinw o r - i n c o u n t r i e s o t h e r
than t h e GDR -
brake f l u i d SAE 70 R 3 o r
SAE J 1703 ( f o r d i s k brakes) have t o be
used.
The a b b r e v i a t i o n "'RfoF" used below means
width o v e r f l a t s of t h e t o o l ( s p a n n e r )
kequired.
3.1. Preliminarie~
It i s a d v i s a b l e , b e f o r e s t a r t i n g t h e d i s -
assembling o p e r a t i o n s , t o d i s c o n n e c t t h e
b a t t e r y and t o remove i t . During t h e
r e p a i r p e r i o d , i t can be s e r v i c e d . When
t h e motor-cycle i s k e p t i n t h e workshop,
t h e two f u s e s must be removed from t h e
f u s e s t r i p under t h e right-hand
panelling.
During t h e f o l l o w i n g work, t h e o i l i s
allowed t o d r a i n from t h e gearbox
(remove t h e o i l d r a i n p l u g (2) and
unscrew t h e lower f a s t e n i n g s c r e w ( 1 )
o f t h e c l u t c h cover). .
NOTE: The g e a r - s h i f t mechanism
d e t e n t screw (3) does n o t Fig. 7 . Right-hand s i d e o f motor-cycle
serve f o r draining o i l !
A f t e r having p u l l e d o f f t h e c a b l e s ( l ) ,
unscrew t h e b r u s h h o l d e r ( 2 ) . A f t e r
l o o s e n i n g t h e f a s l e n i n g screws (31, t h e
e t a t o r can be removed. Using a box
s p a n n e r (Wol 131, l o o s e n t h e f a s t e n i n g
screw o f t h e cam of t h e dynamo. Sense of
r o t a t i o n o f t h e spanner i s o p p o s i t e t o
t h e r u n n i n g d i r e c t i o n of t h e engine.
Then, t h e cam can be p u l l e d o f f when
s l i g h t l y s h a k i n g t h e f a s t e n i n g ecrew
(thread M 7 ) .
3.2. D i e m a n t l i n ~t h e Engine
3.2.1. Preliminaries
I t goes without s a y i n g t h a t t h e demounted
engine m u s t be cleaned e x t e r n a l l y b e f o r e
i t i s dismantled. N a t u r a l l y , a l l p a r t s m u s t
be k e p t i n such a way t h a t no p a r t w i l l be
l o s t o r damaged.
Before mounting t h e engine i n t h e engine
assembly d e v i c e , remove t h e f r o n t clamp-
i n g screw (WoF 13) and t h e f i t t i n g s l e e v e
under i t hy means of mandrel I f MW 3-4.
F i g . 16. p u l l i n g t h e d r i v e , g e a r
Move t h e l o c k - l e v e r ( 1 ) o u t o f t h e drum
cam ( 2 ) . unhook t e n s i o n s r i n g ( 3 ) and
remove i t from g u i d e b o l l P 4 ) . Remove w i r e
r e t a i n i n g r i n g ( 5 ) and s n a p r i n g ( 6 1 , cap
f o r d r i v e s h a f t ( 7 ) and o i l g u i d e p l a t e .
F i g . 18. D i s m a n t l i n g t h e c l u t c h
For d i s m a n t l i n g and a s s e m b l i n g t h e c l u t c h ,
the i n t e r n a l driver with drive gear ( 3 )
must be plugged on t h e assembly d e v i c e .
By t c r n i n g t h e l o c k n u t ( 4 ) c l o c k w i s e , t h e
c l u t c h f l a n g e i s r e l a x e d and t h e n u t s (WoF
TO) ( 5 ) can be l o o s e n e d and removed w i t h
l o c k p l a t e n . A f t e r removing t h e l o c k n u t ( 4 ) ,
t h e c l u t c h can be d i s m a n t l e d i n t o i t s i n d i -
v i d u a l p a r t s ( F i g . 21). Checking f o r wear
i s d e a l t w f t h i n S e c t i o n 3.4.1.
Seauence o f c l u t c h - a y g m b l & n g ( F i g s . 1 9 ,
Fig. 17. Removing g e a r - s h i f t det'ent and 19:,-2~,-2i)
circlips
Put i n t e r n a l d r i v e r with d r i v e g e a r (3)
3.2.4. Dismantling t h e Kick-starter on t h e a s s e m b l i n g d e v i c e ( F i g . 1 9 ) ;
Clamp t h e b e a r i n g c o l l a r o f t h e k i c k -
s t a r t e r s h a f t between c o p p e r jaws o r wood Place t h e pressure p l a t e with spacer b o l t
i n s e r t s i n a v i c e ( F i g . 8 4 ) . Do n o t damage ( 6 ) on t h e s u p p o r t i n screws o f t h e assemb-
t h e t h r e a d o f t h e s p l i n e d b o l t when d r i v - l i n g d e v i c e (Fig. 1 9 f ;
i n g o u t . To t h i s end, l o o s e n t h e n u t M6 P u t t h e g e a r r i n g ( 7 ) i n p l a c e ( F i g . 19) ;
(WOF1 0 ) o n l y s o f a r t h a t i t c a n be used
as " t h r e a d p r o t e c t i o n N . A f t e r removing A l t e r n a t e l y f i t i n t e r n a l segments ( 8 ) and
t h e splined bolt, the kick-starter spring e x t e r n a l segments ( 8 a ) ( t h e p a r c e l o f
r e l a x e s , t h e c l u t c h voer t u r n s t o t h e segments i s c e n t r e d by t h e i n t e r n a l
r i g h t . Now, t h e c o m p l e t e k i c k - s t a r t e r driver) ;
s h a f t c a n be drawn o u t o f t h e c l u t c h cover.
3.2.5. Dismantlina t h e Clutch
7
Mount t h e c l u t c h body ( ) , s c r e w i n t h e
hexagon-head s c r e w s (11 w i t h l o c k p l a t e s
( 1 0 ) and l o c k them ( F i g . l 9 a ) ;
A c t u a t i n g Mechanism
P l a c e t h e s p a c e r w a s h e r s 00-78.196 ( l 4 a )
By t u r n i n g c l o c k w i s e , remove t h e p r e s s u r e on t h e s p a c e r b o l t s ( F i g . 1 9 a ) ;
l e v e r i n t h e c l u t c h c o v e r from t h e worm
o f t h e b e a r i n g bush. P r e s s t h e b e a r i n g Put t h e compression s p r i n g s ( 1 2 ) on t h e
b u s h o u t o f t h e c l u t c h c o v e r (from t h e c l u t c h body (9);
inside to the outside). Mount t h e p r e s s u r e f l a n g e ( 1 3 ) and t e n s i o n
For t h e replacement o f t h e supporting i t w i t h t h e upper p a r t o f t h e c l u t c h assem-
b e a r i n g 6302 o f t h e c r a n k s h a f t , remove b l i n g d e v i c e . Adding t h e l o c k p l a t e s (10).
t h e c i r c l i p from t h e b e a r i n g bush and f a s t e n t h e p r e s s u r e f l a n e by means o f t h e
p r e s s out t h e bearing. n u t s ( 14) and l o c k them ?Fig. 20).
Fiq. 19. Aesernbling t h e c l u t c h -
1st ~ h a s e
Fig. 21
Zxploded v i e w
of c l u t c h
.2.7. D e m o u n t i n ~t h e C y l i n d e r Assemblg - Unscrew t h e s e a l i n g c a p ( l ) , remove i t
with packing and take Out t h e shims;
2 o o s e n t h e n u t s (WoF 13) c r o s s w i s e from t h e
c y l i n d e r s t u d s w i t h a s o c k e t wrench, p u l l
o f f t h e c y l i n d e r head and t h e n t h e c y l i n d e r .
- Remove c y l i n d r i c a l r o l l (2) f o r armature
d e t e n t and t h e w i r e c i r c l i p ( 3 ) ;
NOTE: When t h e e n g i n e i s n o t d i s m a n t l e d , - Press out the rubber stopper ( 4 ) ;
t h e opening of t h e c r a n k compart-
ment must be c l o s e d w i t h a c l e e n - Loosen t h e housing f a s t e n i n g s c r e w s (14
cleaning rag! screws) by means o f a s c r e w d r i v e r and
t a k e out o f housing;
P r e s s t h e gudgeon i n o u t b y mems o f t h e
p r e s s i n g d e v i c e ( I f 22-50.010 and draw t h e - Open t h e l o c k i n g h a n d l e of t h e e n g i n e
p i s t o n from t h e c o n n e c t i q g rod. assembling device.
MOTE: B e a t i n g o u t t h e gudgeon p i n i s d e t r i -
mental t o t h e c r a n k s h a f t and d e s t r o y s
t h e n e e d l e b e a r i n g on t h e p i n !
-
P r e s s t h e c o n t r o l arm ( l ! of t h e c o n t r o l
member ( 2 ) o n t o f t h e d r u m c m ( 3 ) in t h e
d i r e c t i o n of t h e arrow-head and p a l l
t h e c o n t r o l s h a f t with c o n t r o l member (4)
o a t o f t h e housing;
183TE: Do n o t damage t h e i n s u l a t i n g d i s k
( 5 ) of t h e drum cam!
Fig. 27, P r e s s i n g o u t t h e c r a n k s h a f t
- P r e s s o u t t h e c r a n k s h a f t by t u r n i n g t h e
p r e s s u r e s p i n d l e ( 6 ) of t h e c l u t o h
p u l l e r clockwise; support . t h e c r a n k s h a f t
w i t h your r i g h t hand from below and
r e t a l n i t s o t h a t i t cannot f a l l down
when it l e a v e s t h e b e a r i n g s e a t .
~i~h4-&a"d_h"+~g_h"Ifi Coked s p o t s i n t h e exhauet duct and t r a n s -
f e r p o r t s a r e cleaned i n t h e cylinder.The
Drive o u t t h e 6204 b e a r i n g from t h e gearbox combustion compartment i n t h e c y l i n d e r head
compartment t o t h e o u t s i d e . Remove t h e 6203 and t h e p i s t o n head must be cleaned w i t h
b e a r i n g w i t h p u l l i n g screw (1) and c a r t r i d g e s c r a p e r and w i r e brueh t o remove carbona-
(2). ceoue o i l d e p o s i t s . A f t e r c l e a n i n g , t h e s e
3.2.13. P u l l i n n t h e 6306 Bearings from two s u r f a c e s must be b r i g h t and without
t h e Crankshaft s c o r i n g . I n S e c t i o n 3.4.3.4., information
i s given about t h e c l e a n i n g of t h e p i a t o n
The c r a n k s h a f t main bearing8 6306 C 4 f a r e r i n g grooves.
preased o f f from t h e c r a n k s h a f t by t h e b a l l
b e a r i n g p u l l e r 22-50.431 (1). The two halves 3.4. Checking f o r Wear
of t h e t o o l a r e a p p l i e d between b e a r i n g and
crank d i s k of t h e c r a n k e h a f t , compreesed i n a 3.4.1. Clutch and Clutch O v e r a t i n q
v i c e and nre-tensioned w i t h 2 ecrewe Mec h a n i m
M 8 X 1 0 0 ~ ( 2 ) . B~ screwing i n two o t h e r acrews POINTS OF WEAR:
w i t h hardened p i n a t t h e s t a r t of t h e thread
( 3 ) , t h e b e a r i n g s a r e pressed a g a i n s t t h e - INTERh'AL SEGMENT WITH FRICTION LINING
crank d i e k s of t h e c r a n k s h a f t (Fig. 30). Wear i s increased w i t h i n c o r r e c t c l u t c h
adjustment (no c l u t c h l e v e r c l e a r a n c e o r
c l u t c h i s allowed t o s l i p e x c e s s i v e l y ) .
I n extreme c a e e s , t h e f r i c t i o n l i n i n g w i l l
burn away. When t h e c l u t c h can no l o n g e r
be r e a d j u s t e d and when i t s l i p s when t h e
engine i s a c c e l e r a t e d , new segments m u s t
be mounted.
J
Fig. 32. Clutch wear value
This holds when t h e dimension "X" i n Fig.32
f a l l s below 0.5 mm. New segnments have
a t h i c k n e s s of 3.0 mm + 0.1 mm.
Wear valne: -0.3 mm
Fig. 33. I n t e r n a l d r i v e r w i t h
drive gear
The c l u t c h t h r u s t bearing i s caulked
t h r e e times a t uniform s p a d n g s at:
t h e . o u t e r ring, seated i n the p r e s s u r e , Fig. 35. Clutch a c t u a t i n g mechanism
f l a n g e ( l ) . See t o i t t h a t t h e o u t e r
r i n g of t h e t h r u s t b e a r i n g does
not turn i n the pressure flange.
3.4.1.1. Primapr Drive 3.4.2. Gears. S h a f t s and S e l e c t o r Forks
Zf t h e r e i s e x c e s s i v e b a c k l a s h between The r e l i e f c u t s i n t h e claws a t t h e c o n t r o l
t h e d r i v e gear (28 teeth) riveted t o the
c l u t c h d r i v e r and t h e d r i v e g e a r (68
t e e t h ) t o t h e gearbox, n o i s e w i l l be
a r e a r r a n g e d a t an a n g l e o f 3 .
g e a r s (on b o t h s i d e s ) and t h e o c o u n t e r g e a r s
-
wear v a l u e
mTE: I t i s o f no u s e t o remove o n l y t h e THICKNESS OF T ~ EPISTON RINGS
p o i n t s o f s e i z u r e and t o l e a v e
t h e c a u s e o f jamming unchanged. a l l piston rings 2.00 -0.010
-0.022
wear v a l u e 1 .g0 mm (maximum)
Below a r e a few examples o f s u c h causes:
- Lack o f o i l (no f u e l - o i l m i x t u r e but
o n l y f u e l was f i l l e d up) ;
- I n s u f f i c i e n t f u e l s u p p l y and, hence,
s h o r t a g e o f o i l due t o i n s u f f i c i e n t
f u e l f e e d from f u e l t a n k t o c a r b u r e t t e r .
Vent h o l e s i n t a n k c o v e r clogged;
- F u e l f i l t e r cock clogged o r f a s t e n i n g
screws a t handle e x c e s s i v e l y t i hten-
ed ( t h e h a n d l e must move e a s i l y k ;
- B a s i c c a r b u r e t t e r t u n i n g changed;
- I g n i t i o n t i m i n g wrong; c o n s e q u e n t l y ,
overheating of t h e engine;
- Exhaust system changed, back p r e s s u r e
wrong ;
- A i r f i l t e r system d e f e c t i v e ;
- E n ~ i n edakes i n WOnQ a i r ( m i x t u r e
t o 6 l e a n i n t h e upper engine
speed r a n g e ) .
3.4.3.5. C y l i n d e r Head
V!hen t h e c y l i n d e r head has become l e a k y
- i n d i c a t e d by t h e o i l e d up u p p e r r i b s
of t h e c y l i n d e r -, t h e c y l i n d e r head
can be r e f i n i s h e d on a s u r f a c e p l a t e
by means o f f i n e emery c l o t h ( g r a i n
400) t o a l i m i t e d e x t e n t , p e r f o r m i n g Fig. 43. C r a n k s h a f t
motions i n a c i r c l e , u n l e s s t h e r e i s
a new c y l i n d e r head a v a i l a b l e . When d e f e c t s found c a n n o t be renoved by
r e f i n i s h i n g , a new o r a r e g e n e r a t e d
c r v l l c s h a f t must be mounted.
F i g . 42. C y l i n d e r head -
sealing
s u r f a c e and cumbustion chamber
Fig. 44. Measuring t h e amount t h e c r a n k s h a f t
i s o u t of t r u e r a d i a l l y
v!hen a c y l i n d e r head is l e a k y , an a d d i t i o n a l Then t h e amount t h e c r a n k s h a f t i s o u t o f
i n s e r t i o n of an aluminium shim i s wrong. t r u e r a d i a l l y i s measured a t t h e p o i n t s
T h i s w i l l n o t be a remedy, t h e compression i n d i c a t e d i n F i g . 44. For t h i s purpose, t h e
r a t i o w i i l be changed and a f u r t h e r power c r a n k s h a f t i s clamped between two f i x e d
r e d u c t i o r i w i l l be c-ausad. c e n t r e s o f a t e s t i n g equipment o r o f a
NOTICE Then demounting and mounting t h e lathe.
c y l i n d e r head, t a k e c a r e t h a t The p e r m i s s i b l e amount i s 0.03 mm. G r e a t e r
t h e f a s t e n i n g n u t s a r e loosened v a l u e s l e a d t o i g n i t i o n t r o u b l e s a t high
and t i g h t e n e d u n i f o r m l y and r o t a t i o n a l s p e e d s , v i b r a t i n g o f t h e engine
crosswie6. and l e a k y s h a f t s e a l r i n g s .
I f t h i s i s n e g l e c t e d , t h e c y l i n d e r head The r e s u l t i s a p o o r e n g i n e o u t p u t . A new
w i l l be subjected t o p e r t i c u l a r c r a n k s h a f t s h o u l d a l s o be t e s t e d because
i t may have been s u b j e c t t o t r a n s p o r t
s t r e ~ s e sa d become leaky. damage.
F u r t h e r checks i n t h e c a s e c o n c e r n t h e
b e a r i n g s e a t s and t h e grooves o f t h e snap
r i n g s ; t h e y m u s t be i n p r o p e r c o n d i t i o n .
B e a r i n g s e a t s a r e u s e l e s s when t h e bear-
i n g s can be pushed by hand i n t o t h e COLD
c a s e o r on t h e b e a r i n g s e a t of s h a f t s
( w i t h t h e b e a r i n g i n n e r r i n g i n a COLD
state).
A l l p a p e r packing8 a r e r e p l a c e d by new onee
i n any case.
The s h a f t s e a l r i n g s m u s t be checked f o r
f i s e u r e s i n t h e s e a l i n g l i p , t h e wear and
t e n s i o n of t h e l i p , f a r t h e r f o r t h e pre-
s e n c e o f t h e s p r i n g i n t h e grooved p r o v i d e d
f o r t h i s purpose and t h e q u a l i t y of t h e
c o n n e c t i o n o f t h e two s p r i n g ends. It i s
b e t t e r t o r e p l a c e a s h a f t s e a l r i n g pre-
matur,ely t h a n t o d i s m a n t l e t h e e n g i n e once
more a month l a t e r because o f t h i s r e l a t i v e -
Pig. 45. Neasuring t h e r a d i a l p l a y of l y cheap . p a r t .
t h e c o n n e c t i n g rod
Worn n e e d l e b e a r i n g s i n t h e b i g end and
s m a l l end o f t h e c o n n e c t i n g r o d a r e i n -
d i c a t e d by n o i s e under load. 3.4.5. R a d i a l Grooved B a l l B e a r i n g f o r
Measurement o f t h e big-end b o s s i s t a k e n Crankshaft and Gearbox
i n t h e manner shown i n Fig. 45. With t h e D e f e c t i v e c r a n k s h a f t main b e ~ r i n g sa r e
c r a n k s h a f t i n new c o n d i t i o n , t' h e r a d i a l i d e n t i f i e d by t h e c h a r a c t e r i s t i c engine
p l a y i s 0.020 t o 0.035 mm. n o i s e and by t h e i m p o s s i b i l i t y t o s e t t h e
If t h e v a l u e i s more t h a n 0.05 mm, t h e c o n t a c t b r e a k e r gap c o r r e c t l y .
c r a n k s h a f t i s WO&.
The c o n d i t i o n of t h e b e a r i n g t r a c k s and t h e
b a l l s can be found by i n s p e c t i o n a f t e r
p r e s s i n g t h e b e a r i n g s w i t h p l a s t i c cage
a p a r t . Worn b e a r i n g s a r e damaged by p i t t i n g .
F o r b e a r i n g s t h e r u l e a l s o holds t h a t a f t e r
a prolonged p e r i o d o f o p e r a t i o n o f t h e engine
a11 b e a r i n g s should be r e p l a c e d by new o n e s
(on t h e o c c a s i o n o f a g e n e r a l o v e r h a u l ) .
The f o l l o w i n g b e a r i n g s have t o be used:
For t h e c r a n k s h a f t , two 6306 C 4 f ( p l a s t i c
cage) a s main b e a r i n g s and one 6302 C 3 f
a s supporting bearing f o r t h e crankshaft i n
t h e b e a r i n g bush ( p l a s t i c cage) have t o
be used.
I n t h e gearbox, two 6203 J C 4 b e a r i n g s ,
one 6204 J C 4 b e a r i n g and
one' 6304 J C 4 b e z r i n g
a r e mounted.
Fig. 46. Checking t h e a x i a l p l a y o f t h e
big-end b o s s
The c o n d i t i o n of t h e b e a r i n g i n t h e small-
end b o s s , c a n o n l y be judged s u b j e c t i v e l y
by means o f t h e c o n v e n t i o n a l workshop
equipment. The gudgeon p i n must f i t with-
o u t any c l e a r a n c e i n t h e conrod, and i t '
muet be p o s s i b l e t o t u r n i t w i t h o u t jam-
ming w h i l e t h e r e s i s t a n c e o f f e r e d i s j u s t
f e l t . Gadgeon p i n s showing s i g n s of wear
o r a b l u e c o l o u r dae t o t a r n i s h i n g a r e
u s e l e s s and m u s t b e r e p l a c e d .
A x i a l p l a y of t h e big-end b o s s between
t h e c r a n k d i s k s i s 0.170 t o 0.563 mm.
Wear v a l u e : 1.0 m.
3.4.4. Case and Packinns
F i r s t and f o r e m o s t , t h e s e a l i n g s u r f a c e s
o f t h e c a s e m u s t be checked. I f t h e y a r e
damaged, t h e y can be r e f i n i s h e d i n c a s e s
n o t t o o s e v e r e i n t h e manner shown i n
Fig.42 f o r t h e c y l i n d e r head, u s i n g
a s u r f a c e p l a t e and f i n e emery c l o t h .
4. Assembling t h e Engine
======p=fP=SI=Il===II=L53==I==
Cylinder P i s t o n 69.6 .,
3.1. Preliminaries
It i s t a k e n f o r g r a n t e d that' a l l engine Marking Nominal s i z e 19ominalsize
p a r t s a r e p r o p e r l y cleaned D e f e c t i v e ( T o l e r a n c e group) i n mm i n mm
p a r t s were i d e n t i f i e d a n d r e j e c t e d . The
p a r t s t h a t a r e f u r t h e r u s a b l e were pre-
pared f o r r e - f i t t i n g . Before d e s c r i b i n g
t h e assembly of t h e engine, we below g i v e
some i n s t r u c t i o n s r e g a r d i n g t h e s e l e c t i o n
and mating of v a r i o u s u n i t a o f c o n s t r u c t i o n .
4. l . 7. S e l e c t i o n of P i s t o n and Cylinder T h i s Table g i v e s p i s t o n and c y l i n d e r
dimensions i n new c o n d i t i o n which were
The c y l i n d e r of t h e ETZ 250 d i f f e r s from procured by o u r Oepartment S p a r e P a r t s
t h e c y l i n d e r s used s o f a r . I n t h e c y l i n d e r , S a l e o r which were mounted i n o u r works.
f o u r t r a n s f e r p o r t s a r e a r r a n g e d . The
i n d u c t i o n duct'has a guide nose f o r t h e
p i s t o n r i n e. The p i s t o n can o n l y be u s
i n t h e 69.t design w i t h a c u r v e adbpted
t o t h e new c y l i n d e r .
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P i g . 51. T a b l e f o r b e a r i n g s e l e c t i o n
Kolbenbolzen = gudgeon p i n griin = green
(dimensions i n mm) Pleuelbohrung = conrod b o r e weil3 = white
Kennzeichnung = marking schwarz = black
T o l e r a n z i n um = t o l e r a n c e in um Radialspiel = radial play gelb = yellow
/ / b i s = up t o blau = blue
Nadel-AbmaB = dimensional d e v i a t i o n
braun = brown
of needle
4.1.4. B e a r i n ~ sand S e a l i n g Rings 4.1.5. Pre-assembly of t h e Gearbox
For t h e gearbox, bearings with p l a s t i c A l l d r i v e g e a m and n e e d l e s o f b e a r i n g s m u s t
cage a r e used. b e f i t t e d w i t h engine o i l .
2 X 6204 J C 4 , 4.1.5.1. C o m ~ l e t i n nt h e Drive S h a f t (AL
1 X 6203 J C 4 a n d
1 X 6304 J C 4 - S l i p on t h e d r i v e g e a r f o r t h e 4 t h speed
The c r a n k s h a f t main b e a r i n g s 6306 muat ( 1 ) ilp t o t h e f i r e d wheel ( 2 ) , mount ( 3 )
t h r u s t washer and c i r c l i p ( 4 ) ;
be used i n t h e s o r t e d group C 4 f and
t h e supporting bearing of t h e cranksheft NOTE: Pay p a r t i c u l a r a t t e n t i o n t o t h e p r o p e r
i n t h e b e a r i n g bush ( c l u t c h c o v e r ) i n t h e f i t of t h e c i r c l i p s i n t h e grooves.
s o r t e d group C 3 f . A s c l u t c h t h r u s t Checking by s t r i k i n g t h e s h a f t on
b e a r i n g , a grooved b a l l b e a r i n g 16 005 hardwood, keeping t h e d r i v e g e a r ( 1 )
is fitted. i n one hand.
The s h a f t s e a l r i n g s D 25 X 72 X 7 must - S l i p t h e c o n t r o l g e a r f o r 4 t h and 5 t h
o r i g i n a l shaf t s e a l r i n g s ) .
b e r e s i s t a n t t o f u e l and o i l ( o n l y use
The n e e d l e b e a r i n g f o r t h e c l u t c h d r i v e r
speeds ( 5 ) on t h e d i r v e s h a f t ; t a k e c a r e
t h e t t h e s i d e w i t h t h e 18 t e e t h p o i n t s t o
s h o u l d be s e l e c t e d a c c o r d i n g t o t h e t h e d r i v e g e a r f o r t h e 4 t h speed ( 1 ) ;
f o l l o w i n g Table when a new d r i v e r is
mounted.
- P l a c e a hardened and ground s p a c e r ( 6 )
a g a i n s t t h e c o l l a r ( s t a r t of t h e grooves).
Cluech d r i v e r Needle b e a r i n g Two of t h e s e s p a c e r e a r e r e q u i r e d on t h e
d r i v e s h a f t and two .on t h e o u t p u t a h a f t .
( marking) (mean deviation In mm) They a r e exchangeable.
yellow -1; -2; -3; -4 S l i p on t h e d r i v e g e a r f o r t h e 5 t h speed
( 7 ) and f i t t h e 24 n e e d l e 6 ( 8 ) (2.5 X
black -3; -4; -5; -6 11.81, t h e n mount t h e s p a c e r ( 6 ) and t h e
green -5; -6; -7; -8; -9 c i r c l i p (9) ( t a k e c a r e t h a t t h e c i r c l i p
i s w e l l s e a t e d i n t h e groove).
Fig. 52. Drive s h a f t ( A ) and o u t p u t s h a f t (B)
F i g . 54. Gearbox w i t h s e l e c t o r f o r k s
F i g . 55. Gearbox r e a d y f o r b e i n g mounted
P i g . 60. Mounting t h e c r a n k s h a f t
main b e a r i n g
4.2. NIounting t h e C r a n k s h a f t . t h e
Gearbox and t h e Foot-operated
Gear-shift Shaft
- Heat t h e i n n e r t r a c k r i n g of t h e 6306
b e a r i n g a l r e a d y i n t h e c a s i n g by means
of a h e a t i n g mandrel ( 1 i n F i g . 61) ;
- I n s e r t t h e l o n g c r a n k s h a f t end i n t o t h e
heated i n n e r t r a c k r i n g of t h e bearing
and, w i t h o u t h e s i t a t i o n , a l l o w i t t o s l i p
i n t o p l a c e up t o t h e s t o p ;
- I f , due t o h e s i t a t i n g i n f i t t i n g o r i n -
s u f f i c i e n t l y heated i n n e r t r a c k r i n g ,
t h e c r a n k s h a f t jams, t h e l a t t e r c a n be
p r o p e r l y f i t t e d by memo o f t h e p i p e ( 1 )
and t h e u p p e r p a r t o f t h e c l u t c h t e n s l o n - Fig. 63. Mounting t h e g e a r b o x
i n g d e v i c e . ( 2 ) 0 5 MW 150-2. (The p i p e
i s no s p e c l a l t o o l , s k e t c h f o r s e l f - - Take t h e preassembled g e a r b o x o u t o f t h e
c o n s t r u c t i o n i s i n c l u d e d i n t h e ~ p ~ e n d i x ) ; assembly c o n t a i n e ~and p u t i t i n t o . t h e
l e f t - h a n d c a s i n g h a l f up t o t h e s t o p .
The l o n g c o l l a r o f t h e drum cam and t h a t
of t h e guide b o l t f o r t h e s e l e c t o r f o r k s
must p r o j e c t from t h e c l u t c h s i d e when
~ r o p e r l ymounted ( g e a r - s h i f t p o s i t i o n
s o f no consequence) ;
- bHest the
earing,
i n n e r t r a c k r i n g of 6306 C 4 f
~ o u n tc a s l n g h a l f . When t h e
c a s i n g h a l f i s h e s t e d t o a b u t l00 Q C
and t h e i n n e r t r a c k r i n g of t b e 6306
b e a r i n g w e l l h e e t e d , t h e o ~ s f n ghalf
can be p r e s s e d , w i t h o u t t i l t i n g , on t o
t h e s e a l i n g s u r f a c a , When t h i s should
f a i l , use a p l a s t i c o r r u b b e r m a l l e t
and a p p l y e l i g h t blows t o remove a
t i l t e d position;
Fig. 67. Mounting t h e g e e - s h i f t detent
- P r e s s t h e s h a f t s e a l r i n g D 25 X 72 X 7 B e f o r e a s s e m b l i n g t h e c y l i n d e r check t h a t
(1) i n t h e c l u t c h s i d e by means of man- bore (B) is closed. I f t h i s i s n o t t h e
d r e l 29-50.409 ( p r i o r t o t h i s , o i l t h e c a s e , i n s e r t a b a l l 4.5 mm i n d i a m e t e r ,
sealing l i p ; i t points t o the clutch!); a p p l y s e a l i n g compound t o t h e t h r e a d e d
- Mount t h e w i r e c i r c l i p (2) t o l o c k t h e
s t u d and screw i t i n p l a c e .
shaft seal ring;
- Screw t h e g e a r - s h i f t d e t e n t s c r e w ( 3 ) i n
p l a c e t o g e t h e r w i t h packing r i n g , com-
p r e s s i o n s p r i n g and b a l l ;
- Put t h e $ e a r - s h i f t d e t e n t l e v e r (4) on
t h e p r o j e c t i n g g u i d e b o l t ( 5 ) , engage i t
w i t h t h e drum can! ( 6 ) and hook t h e t e n s i o n
s p r i n g ( 7 ) on t h e notched n a i l (8)
(Fig. 67);
- While t h e c a s i n g i s s t i l l h o t , use a
r u b b e r o r p l a s t i c m a l l e t t o a p p l y blows
on t h e b e a r i n g s t o r e l e a s e them.
NOTICE: Do n o t b e a t on c r a n k s h a f t ends
t h i s w i l l impair t h e t r u e
running o f ' t h e crankshaft
( 0 . 0 3 mm))
- Check t h e d r i v e s h a f t and o u t p u t s h a f t
f o r e a s e o f moving; t h e t*wo s h a f t s must
r u n f r e e l y o p p o s i t e t o eech o t h e r ;
- Put t h e foot-operated gear-shift l e v e r
on t h e g e a r - s h i f t s h a f t and s t i i f t Fig. 69.Engine r e a d y f o r mounting t h e
a l l gears. cylinder .,
4.4. mount in^ P i s t o n , C y l i n d e r and Check t h e c y l i n d e r s t u d s ( Z ) f o r t i g h t f i t
C y l i n d e r Head and a p p l y e n g i n e o i l t o t h e n e e d l e b e a r -
On s e l e c t i o n and mating of p i s t o n and i n g f o r t h e gudgeon p i n and i n s e r t i t i n t o
c y l i n d e r , i n f o r m a t i o n has a l r e e d y been t h e amall-end b o s s ( P ) .
g i v e n i n S e c t i o n 4.1.1. Close t h e c r a n k c a s e w i t h a c l e a n c l e a n i n g
T h i s S e c t i o n o n l y d e a l s w i t h t h e corr'ect r a g u n t i l t h e c y l i n d e r i s mounted i n o r d e r
mounting of p i s t o n and c y l i n d e r and t h e t h a t no f o r e i g n p a r t i c l e s ( l o c k r i n g f o r
a d j u s t m e n t o f t h e r a t i o of compression. gudgeon p i n ) c m g e t i n t o t h e crankcase'.
-
(68 teeth)
P a t t h e d r i v e g e a r on t h e d r i v e s h a f t ;
- Spacing p l a t e ( 1 ) 1.90 mm, 1.95 mm o r
2.00 mm i n t h i c k n e s s ;
t h e r e c e s s f o r engaging t h e l o c k i n g
p l a t e must be v i s i b l e ; - S e t of n e e d l e s ( 2 ) KK 22 X 26 X 26;
- - Clutch d r i v e r (3) ;
P i t t h e l o c k i n g p l a t e and, u s i n g
a n u t M 16 X 1.5, t i g h t e n up t o t h e - Thrust washer ( 4 ) 2.3 mm i n t h i c k n e s s ;
c o l l a r of t h e d r i v e s h a f t . For a r r e s t -
i n g t h e d r i v e g e a r , t h e holder-Up
- S p r i n g l o c k washer ( 5 ) .
22-50.413 o r t h e assembly b r i d g e Put t h e s e p a r t s in t h e above o r d e r on t h e
22-50.4 0 ( 1 ) and a s o c k e t wrench ( 2 ) end o f t h e c r a n k s h a f t ( c l u t c h s i d e ) ; t h e
(WoF 241 i s t o be used ( s e e Pig. 1 6 ) . s p a c i n g p l a t e and t h e t h r u s t washer must
Torque f o r t i g h t e n i n g : 80 t o 100 Nm be p l a c e d so t h a t t h e r e l i e v i n g o f t h e
( 8 t o 10 kpm). h o l e p o i n t s t o t h e c o l l a r o f t h e crank-
shaft.
NOTICE: An i n s u f f i c i e n t l y t i g h t e n e d NOTICE: The s e t of n e e d l e s ( 2 ) i s
d r i v e gear causes considerable a v a i l a b l e i n t o l e r a n c e groups
n o i s e when changing t h e load ( s e e S e c t i o n 4.1.4.)!
on t h e engine.
The p e r m i s s i b l e r a d i a l p l a y of t h e i n n e r
d r i v e r w i t h d r i v e g e a r ( 3 ) i s 0.004 t o
0.029 mm.
F o r f i t t i n g o b s e r v e a l l t h a t h a s been s a i d
w i t h r e s p e c t t o gud eon p i n n e e d l e b e a r i n g
( s e e S e c t i o n 4.1.3.7, and a p p l y e n g i n e
o i l t o t h e b e a r i n g when f i t t i n g .
4.5.3. Measuring and A d j u s t i n n t h e When, f o r c h e c k i n g , t h e c l u t c h i e p u t
End P l a y of t h e Clutch D r i v e r o n t h e c r a n k s h e f t end w i t h o u t s p r i n g
The g i v e n end p l a y i s determined by means O f lockwasher ( l ) and driver (2)*
- t h e measuring d e v i c e 0 5 - m 13-4. For t h i s t h e cone must f i t a l r e a d y i n s u c h a way
p u r p o s e , t h e measurin d e v i c e i s f i t t e d r i t h o ~ tthat the be by
s p r i n g l o c k washer ( 5 7 and t h r u s h washer ( 4 ) hand.
( P i g . 7 5 ) . When moving t h e i n n e r d r i v e r
a x i a l l y , t h e end p l a y i s i n d i c a t e d by t h e
dial.
The end p l a y o f t h e d r i v e g e a r w i t h i n n e r
d r i v e r i s 0.05 t o 0.'10 mm.
51
1
The b e a r i n g rubbere (12) and s p a c e r r i n g s
(13) of t h e r e a r engine suspension can only
be replaced w i t h t h e engine and t h e r e a r -
whe+I s a g - f o r k removed according t o t h e
previous Section.
Fig. 94. Engine shoes a x i a l
Y compressed
by p r e s s u r e r i n g (D and t i e
rod (2) with thread M6, rear-whee
The wear limit has been reached when t h e
engine shoes i n mounted c o n d i t i o r no l o n g e r
ahoy any pre-tension and can be moved by
swing-fork pushed i n p l a c e hand l a t e r a l l s t o and f r o .
- Pash t h e rear-wheel swing f o r k w i t h t h r u s
w a f b r s from t h e r e a r on t h e engine shoes
When r e p l a c i n t h e bearing rubbelg (12) and
up t o t h e s t o p a t t h e p r e s s a r e r i n g s . Re- a a c e r r i n g s 713) by new one8 check t h a t
move t h e p r e s s u r e r i n g s a d f u r t h e r push tEs b e a r i n g aleevee of t h e engine shoes
t h e swing-fork up t o t h e c e n t r e of t h e a r e f r e e from wear o r not. When i n t h e d r i l l
h o l e , a t t h e p o i n t where t h e s p a c e r r i n g
hole f o r the b e a r i n g b o l t ;
- Preee I n t h e a u x i l i a r y mandrel from t h e i s a p p l i e d , a shoulder qan be f e l t , then
t h e rsplacemsnt of t h e ~ n g i n eshoee i e
l e f t and c e n t r e t h e b e a r i n g with i t ;
- Screw t h e r i g h t f a s t e n i n g n u t a g t o t h e a d v i s a b l e Pn t h e i n t e r e s t of an adeqaate
e e r v i c e l i f e of t h e new rubber p a r t s and
end of t h r e a d on t h e ewing bearing b o l t .
- Gl'ease t h e ewing b e a r i n g b o l t and p r e s e s p e c e r ringa.
i t i n from t h e r i g h t t o t h e l e f t .
5.1.6. R e p a i r of t h e Susaeneion U n i t e
R e p a i r s a r e l i m i t e d t o t h e replacement o f
d e f e c t i v e p a r t s o f t h e spring-loaded eus-
p e n s i o n u n i t s and t h e l a b r i c a t i o n of t h e
1
ad u s t i n g s l e e v e s of t h e r e a r euspeneion
un ts.
The shock a b e o r b e r s must be r e p l a c e d
' c o m p l e t e l y and b r o u g h t t o a shop f o r
r e g e n e r a t i o n . S e l f - r e p a i r of shock absor-
bers i s not poesible. I n case of loes of
o i l t h e l a c k i n g amount can be r e p l e n i e h -
ed ( s p e c i a l wrench 05-W 82-4), i n most
c a s e s , however, t h e packing o f t h e p i s t o n
rod w i l l be d e f e c t i v e - t h e shock-absorber
must be r e g e n e r a t e d .
Shock-absorber marking
The marking i s arranged above t h e lower
f a s t e n i n g eye.
Meaning:
A 22 model
100 r a t e d s t r o k e i n mm
88 daqping f o r c e i n t h e
d i r e c t i o n o f p u l l i n kp
8 damping f o r c e i n t h e
d i r e c t i o n o f compression i n kp
M w i t h adjustment
97. Design o f t h e shock a b s o r b e r
1 . 50/l number of manufacturer
Supporting r i n g halves
From June 1978, t h e l e t t e r s OV o r MV a r e not applicable
o m i t t e d . "With a d j u s t m e n t H i s i n d i c a t e d Stop r u p b e r s
by 9 d n . Threaded p i e c e w i t h r a d i a l s e a l
Demounting t h e shock a b s o r b e r s r i n g AC 10 X 19 X 7
P i s t o n with non-return valve (top)
Clamp t h e lower eye o f t h e suspeneion u n i t and damping v a l v e (bottom)
i n a v i c e . P r e s s down t h e p r o t e c t i v e s l e e v e Bottom v a l v e w i t h s u p p o r t i n g r i n g
( 8 ) and t a k e o a t t h e two au p o r t i n Marking of t o l e r a n c e group
h a l v e s ( 1). W ,
t h e p a r t s P81 ( Protective sleeve
( 1 1 ) can be removed. Compression s p r i n g
P o s s i b l e shock-absorber d e f e c t s Piston tube
i d Adjusting sleeve
1. The shock a b s o r b e r i s i n e f f e c t i v e a l t h o u g h
no o i l l o s s i s v i s i b l e ( f o r e i g n p a r t i c l e s S p r i n g s f o r s u s p e n s i o n u n i t e
between t h e diaphragms o f t h e p i s t o n
valve). Description Unit S o l o w i t h Side-
2.Darnping commences not s o f t but j e r k i l y
t h e s u s p e n s i o n u n i t s a r e wstampingn
- car
e l e e v e i s i n s e r t e d between t h e s e b e a r i n g e
which a r e c o m p l e t e l y f r e e from maintenance.
,
No a d j u s t m e n t s have t o be made d u r i n g assem- 1
b l i n g a n d l a t e r on. l
l
- Fill t h e 6006 b a l l b e e r i n g s w i t h a n t i -
f r i c t i o n bearing grease;
l
l
- Prese t h e l o w e r b e a r i n g up t o t h e e t o p o n
t h e e x t e r n a l ring, u s e an i n t e r m e d i a t e I
ring 54 X 20 f o r t h i s ptmpoee;
- I n a e l t t h e s p a c e r sleeve;
l
- P r e s s t h e u p p e r b e a r i n g on t h e s p a c e r
a l e a r e u n t i l t h e inner r i n g c o n t a c t 8 t h e
latter.
O h r v e tbe follonin 1
Place a s p g e r r i n g d 54 r 40 m under t h e
lower b e a r i n g in o r d e r t h a t i t w i l l n o t be
P T B B M ~ o u t and p r e s s t h e upper b e e r i n g
over the spacer rfng 54 X X) i n p l a c e .
BOTICE: I n t h e l a t e r mounting o f t h e
u p p e r and lower clamping Lteada,
take care that the nut f o r the
c o n t r o l t u b e ( l ) , Fig. 100, i e
t i g h t e n e d w i t h a t o r q u e o f 150
Rm ( 1 5 kpm)!
Then, t h e s t e e r i n g assembly must be f r e e t o
be moved e a a i l y and f t muet n o t jam i n any
p o s i t i o n . I f t h i s , however, s h o u l d be t h e
c a s e , t h e a p a c e r s l e e v e between t h e i n n e r
t r a c k rings o f t h e b e a r i n g s m u s t be r e -
p l a c e d ( t h e s h o r t s p a c e r s l e e v e may l e a d
t o a deformation of t h e bearings).
The removal o f t h e s t e e r i n g b e a r i n g s from
t h e frame i s e f f e c t e d a c c o r d i n g t o t h e
F i g s . 101 t o 103 w i t h t h e h e l p o f t h e
Fig. 100. T e l e s c o p i c f o r k and s t e e r i n g e x t r a c t o n 22-51.006.
b e a r i n g ( s e c t i o n a l view) The removal and mounting o f t h e t e l e s c o p i c
f o r k r e q u i r e d f o r t h i s purpose i s ex-
Riqht-hand f o r k member: p l a i n e d i n S e c t i o n 5.3.2.
Spring f u l l y extended, design w i t h
-- - - ---- -- -
protective cap
Nut f o r c o n t r o l t u b e
Upper clamping head
Screw p l u g
S t e e r i n g b e a r i n g 6006
Lower clamping head
Compression s p r i n g ( s o l o s p r i n g
w i r e 4.0 mm i n d i a m e t e r
s i d e-car s p r i n g
w i r e 4.5 mm i n d i a m e t e r )
P r o t e c t i v e bellows
Piston r i n g a t supporting tube
Supporting tube
S l i d i n g tube
Guide t u b e
P r o t e c t i v e cap
R a d i a l s e a l r i n g 35 X 47 X 7
T h r u s t w a s h e r , t h i c k n e s s 2.0 mm and
locking ring
Valve p l a t e , t h r o t t l e and c i r c l i p
Plate f o r f i n a l stop
Compression s p r i n g f o r f i n a l s t o p
S e a l i n g washer Pig. 107. P r e s s t h e i n t e r n a l p a r t o f t h e
e x t r a c t o r i n t o t h e b a l l bearing
When t h e p e r m i s s i b l e wear l i m i t between
g u i d e tube and s l i d i n g tube has been
reached.
TEST METHOD:
The v e h i c l e i s on t h e prop s t a n d , t h e
t e l e s c o p i c f o r k i s f u l l y e x t r a c t e d . The
two s l i d i n g tubes a r e moved t o and f r o
a t t h e a x l e accomodation. The maximum
p l a y must n o t exceed 2.2 mm (new s t a t e
0.8 t o 1.2 mm). For t h i s measurement,
t h e tno f o r k members must n o t be d i s -
t o r t e d because otherwise t h e p l a y may
be reduced.
I n c a s e of doubt, t h e complete f o r k mem-
b e r s must be removed, t h e g u i d e t u b e s
clamped " i n e o f t p r o t e c t i v e jaws", and
t h e e x i s t i n g play a t t h e a x l e accomoda-
t i o n e measured by means of a d i a l gauge.
when t h e f o r k members l o s e o i l ( r a d i a l
s e a l r i n g s i n t h e s l i d i n g tube a r e l e a k y ) .
O i l l e v e l checking: s e e Fig. 114.
When t h e h y d r a u l i c o i l damping i s i n -
s u f f i c i e n t w i t h t h e f u l l amount of o i l
present.
Fig. 102. F i t t i n g t h e upper p a r t of t h e When t h e p r o t e c t i v e caps o r p r o t e c t i v e
extractor bellowe must be replaced by new ones.
5.3.3. Demountina and M o u n t i n ~t h e Com-
p l e t e Teleecopic Fork ( s e e Pig.100)
It i s p o e s i b l e t o demount t h e complete t e -
leecopic fork without loosening cable
connections. The following o r d e r i s a d v i s -
able :
Unhook t h e hand brake c a b l e c o n t r o l from
t h e handle-bars and l o o s e n t h e brake hose
from t h e brake saddle. Draw t h e hose o u t
o f t h e lower clamping head, c l o s e i t s
opening with a s u i t a b l e s t o p p e r and
f a s t e n i t t o t h e handle-bars.
Demount t h e cap f o r t h e c o n t r o l t u b e f a -
s t e n i n g n u t and s t e e r i n g damper.
Slacken back n u t f o r c o n t r o l tube and
ecrew p l u g s o f guide tubes by means of
s o c k e t wrench o r f l a t box spanner.
Demount t h e headlamps ( c o m p l e t e l y ) .
Remove t h e instrument pod, p l a c e t h e
handle-bars on t h e f u e l tank.
Demount f r o n t wheel, brake s a d d l e , and
front-wheel mudguard.
Completely demount t h e f l a s h i n g - l i g h t d i -
Fig. 103. P i t t i n g t h e screw, t i g h t e n i n g r e c t i o n i n d i c a t o r s , f r o n t , with t h e i r
holders.
i t a n d thus extracting the
b e a r i n g from t h e frame Unscrew t h e n u t s f o r c o n t r o l tube and
t h e screw plugs.
C a r e f u l l v d r i v e o u t t h e upper clamping
head upwards and t h e lower clamping head
w i t h f o r k members downwerd.
5.3.2. C r i t e r i a f o r Dismantling t h e NOTICE:
T e l e s c o p i c Fork The hanging-down instrument pod, f l a s h i n g -
Dismantling t h e t e l e s c o p i c f o r k members l i g h t d i r e c t i o n i n d i c a t o r s , headlamp and
becomes n e c e s s a r y : t h e handle-bars m u s t be so p r o t e c t e d t h a t
t h e y w i l l n o t be damaged and t h e c a b l e s not
1. When, due t o an a c c i d e n t , t h e guide pulled out!
t u b e s a r e d i s t o r t e d . The t e l e s c o p i c The complete t e l e s c o p i c f o r k is mounted i n
f o r k j a m s when i t i s c o n t r a c t e d . t h e i n v e r s e o r d e r . Pay p a r t i c u l e r a t t e n t i o n
NOTICE : t o t h e c o r r e c t i n s t a l l a t i o n of t h e c a b l e
harnesses. A f t e r connecting t h e brake hose,
The t e l e s c o p i c form jams when being t h e d i s k brake muet be bled.
c o n t r a c t e d even i f t h e f o r k members a r e APTER ASSEIYIBLING, THE SCREWED COLTECTIONS
~
ROTICE: - Remove t h e s c r e w p l u g s ( 1) ;
Apply d e c o r a t o r s s s i z e wCbemisol 1405" - Remove t h e f r o n t wheel;
t o t h e e x t e r n a l t h r e a d o f t h e screw p l u a
( K a n u f a c t u r e r : VFB Schuh-Chemie, E r i u r t k
.- Demount t h e front-wheel mudguard ;
-
compound) .
and f i t them (remove t h e o l d s e a l i n g
I n c o u n t r i e s o t h e r t h a n t h e GDR u s e -
Mark t h e g u i d e t u b e s d i r e c t l y below
t h e lower clamping head;
Loosen t h e clamping s c r e w s ( 2 ) ;
rubher solution.
Do n o t a l l o w s e a l i n g compound t o g e t i n t o - Draw t h e complete g u i d e t u b e s w i t h
t h e g u f d e t u b e e , remove s e a l i n g compound s l i d i n g t u b e s o u t downwards; u s e t h e
from t h e f a c e s of t h e ~ c i - e wplugs. f i t t i n g wrench 19 MW 22-1 ( 3 ) .
- Clamping s c r e w s ( 3 ) a t lower clamping Perform t h e mounting o p e r a t i o n s i n t h e
i n v e r s e order.
head 20 IJm ( 2 kpm) ;
T i g h t e n t h e ecrewe i n t h e manner d e s c r i b e d
- Nut f o r kockout wheel s p i n d l e ( 4 ) i n S e c t i o n 5.3.3.
80 Nm ( 8 kpm);
- Clamping s c r e w f o r kockout wheel s p i n d l e 5.3.5. D i e m a n t l i n ~t h e T e l e s c o p i c Fork
20 mm ( 2 kpm) .
(5) with t h e t e l e s c o p i c fork contracted Members Removed from t h e V s h i c r e
A f t e r having removed t h e p r o t e c t i v e cgps
o r p r o t e c t i v e b e l l o w a , c l e a n t h e f o r k mem-
5.3.4. Demountina and Mounting t h e b e r s e x t e r n a l l y , draw o u t t h e compression
T e l e s c o ~ i cF o r k Membera s p r i n g s (accomodated i n t h e g u i d e t u b e )
F o r demounting t h e i n d i v i d u a l f o r k membere, upwarde and d e c a n t t h e damping l i q u i d .
handle-bars, headlamp and i n s t r u m e n t pod DISMUITTLING I S N O 1 EFFECTED IN TfIE
need n o t be demotmted. The brake system o f FOLLOWING ORCER:
t h e d i s k b r a k e c a n b e c l o s e d . For remov-
i n g t h e r i g h t r h a n d f o r k member, however, - Ueing an L-handled s o c k e t wrench (WoF 101,
loosen t h e f a s t e n i n g n u t (1) f o r the
t h e brake s a d d l e m u s t b e demounted from t b s
e l i d i n g tsbe a n d fastened t o a s u i t a b l e support.ing t u b e and remove t h e n u t and t h e
p a r t a t t h e v e h i c l e u n t i l aesembly. Fig. c o r r u g a t e d n a a h e r ( 2 ) ( F i g . 107);
l 0 5 has been i n c l u d e d w i t h o u t t h e p a r t s
mentioned t o p r o v i d e a c l e a r survey.
To be observed s t r i c t l y - when clamping
t h e guide tubes ( A ) i n a v i c e , use s o f t
p r o t e c t i v e jaws and clamp i n t h e upper
t h i r d only.
The s l i d i n g tubes have t o be clamped a t
t h e a x l e accomodation o r t h e f a s t e n i n g hubs
f o r t h e mudgnard o r t h e brake s a d d l e .
- Remove the s e a l i n g washer ( 3 1 , t h e com-
p r e s s i o n s p r i n g ( 4 ) 19 mm i n d i a m e t e r ,
and t h e cup f o r t h e f i n a l s t o p ( 5 ) from
t h e s u p p o r t i n g tube ( 6 ) ;
- Push t h e supporting tube ( 6 ) i n t o t h e
guide tube ( A ) ;
- Remove t h e annular r i n g 32 X 1.6 ( P i g .
108) from t h e guide tube. The t h r o t t l e
arranged behind t h e annular r i n g ( 3 )
has a milled-out r e c e s s i n its e x t e r n a l
diameter i n o r d e r t h a t t h e a n n u l a r r i n g
can e a s i l y be pressed out by means of a
small screwdriver. Remove t h e t h r o t t l e
( 31, t h e valve p l e t e ( 4 ) and t h e com-
r e s s i o n s p r i n g - f o r t h e valve p l a t e ( 5 )
?see Fig. 109);
5.4. F u e l Tank
Because of t h e d a n g e r of e x p l o s i o n , re-
p a i r s o f f u e l t a n k s can o n l y be c a r r i e d
o u t when t h e r e l e v a n t s a f e t y r e g u l p t i o n s
a r e s t r i c t l y observed.
The FRONT a d REAR'of t h e f u e l t a n k
i s $ l a s t i c a l l y f a s t e n e d t o t h e frame
(FIR. 115).
As a consequence, t h e t r a n s m i s s i o n oP
v i b r a t i o r i p from t h e frame t o t h e f u e l Fig. 116. F u e l f i l t e r w c k . c sa.Ttied
t a n k is e f f e c t i v e l y a t t e n u a t e d . After
the' removal o f t h e f u e l tank, t h e r u b b e r
p a r t s c a n be s u b j e c t e d t o i n s p e c t i o n .
I n t h e cock, t h e f u e l f l o w s through two On t h e o c c a s i o n o f r e p a i r s i n t h e f u e l
s t r a i n e r s . The f i r s t one i s a c c e s s i b l e ( 1 ) cock, t h e f d e l hose l e a d i n g t o t h e carbn-
a f t e r unscrewing t h e f u e l shut-off cock r e t t e r should a l s o be checked.
from t h e f u e l t a n k ; t h e second One a f t e r ( 2 ) When t h i s hose has become b r i t t l e , l e e k s may
t h e l o o s e n i n g o f t h e f i l t e r bowl ( 3 ) . o c c u r i n t h e p o i n t s o f connection. The, t h e
It i s a d v i s a b l e t o c l e a n t h e s t r ~ i n e r s f i t t i n g o f a new f u e l hose having t h e d i -
a f t e r every 5,000 km o f road o p e r a t i o n mensions 5 X 8.2 mm i s r e o u i r e d .
o r once a y e a r c a r e f u l l y .
NOTICE!
Another c a u s e of t r o u b l e s i n t h e f u e l cock
may be t h e r u b h e r a c k i n g (4) under t h e On no account ehould h o l d i n g screwB ( 6 )
a c t u a t i n g l e v e r (5P whoae d r i l l - h o l e s may be t i g h t e n e d u n t i l t h e s p i n a p l a t e ( 7 )
be c l o s e d o r c l o g ed by s w e l l i n g o r by c o n t a c t s t h e c a s i n g (8). The a c t u a t i n g ( 5 )
f a s t e n i n g screws 7 6 ) which a r e t i g h t e n e d l e v e r m u s t be e a s i l y movable. When t h e f u e l
t o o much. cock should d r o p , t h e n t i g h t e n t h e h o l d i n g
screws ( 6 ) uniformly tkrough maximum one
A c t u a t i n g l e v e r and r u b b e r packing can be 5evolution.
removed a f t e r l o o s e n i n g t h e two r e t a i n i n g i h , r a t e of f l o w muRt be a t l e a n t 12 l i t r e s
s c r e w s a r r a n g e d on e i t h e r s i d e o f t h e p e r hour.
actuating lever.
Fig. 119. D r i v i n g o u t t h e f l a n g e d b o l t
R e p a i r o f t h e Brake & a t e r C y l i n d e r
Remove t h e hand brake l e v e r . Then use com-
p r e s s e d ' a i r , which must be admitted through
t h e hoee c o n n e c t i o n h o l e , t o p r e s s o u t t h e
i n t e r n a l p a r t s o f t h e brake m a s t e r c y l i n d e r .
With one o f your hands p r e v e n t t h e s e p a r t s
from b e i n g f l u n g away.
Scores i n t h e e l i d i n g surfaces of cylinder
and p'iston a r e s i g n s which c a l l f o r a r e -
placemert o f t h e complete brake m a s t e r cy-
l i n d e r . I f o n l y t h e p a c k i n g r i n g s a r k de-
f e c t i v e , t h e brake m a s t e r c y l i n d e r can be
assembled when u s i n g a new s e t o f packing
r i n g s . Absolute c l e a n l i n e s s i s n e c e s s a r y ,
Wetten a l l s l i d i n g s u r f a c e s and packings
w i t h brake f l u i d and demount t h e p a r t s accor-
d i n g t o Fig. 125. Push t h e r e t a i n i n g r i n g of
t h e end p a c k i n g r i n g by means o f a a l e e v e
( p i p e d i a m e t e r = 18 mm X 16 mm X 30 mm)
u n t i l i t engagea w i t h t h e groove provided
f o r t h i s purpoee.
F a s t e n t h e hand brake l e v e r i n s u c h a way
Arrangement o f t h e d i s k brake t h a t i t can be moved e a s i l y and f r e e from
any p l a y i n i t s h o l d e r . Adjust t h e p l a y
Brake master cylinder between p i s t o n and hand brake l e v e r t o
Brake hoee about 0.5 mm by means o f an a d j u s t i n g acrew.
Brake saddle
Brake diek
Fig. 125. Brake maeter c y l i n d e r
Cover
Vent r i n g
Hermetic bellows
Housing
Fastening c l i p
Spring
Brake p i s t o n
Sealing sleeve6
Washer
Packing
Clrclip
- Remove the
union n u t .
brake hose by loosening t h e
Fasten t h e hose t o t h e
Remove t h e cover
Drive out t h e two b o l t s by means of a
t e l e s c o p i c f o r k with b i n d i n g wire. mandrel from t h e s i d e of t h e small b o l t
diameter
NOTE: The hose opening m u s t n o t be deeper
than t h e l i q u i d l e v e l i n the re- Remove t h e brake shoes
s e r v o i r of t h e hand brake c y l i n d e r ! Dismantle t h e brake s a d d l e
- sDemount t h e brake s a d d l e from t h e
l i d i n g tube of the telescopic fork.
P r e s s o u t t h e brake p i s t o n by means o f
compressed a i r
Replacement of t h e brake s h o e s
Replace t h e b r a k e s h o e s i n t h e f o l l o w i n g
o r d e r of o p e r a t i o n s , when t h e y a r e worn
down t o t h e w,ear marking.
- Remove t h e f r o n t wheel
- Remove t h e b r a k e shoea i n t h e manner
d e s c r i b e d i n S e c t i o n =Repair o f t h e
Brake Saddle"
- Externally clean t h e brake s a d d l e
- P r e s s back t h e brake p i s t o n
- Mount t h e new brake shoea
- P i t t h e f r o n t wheel
NOTE: Do n o t a c t u a t e t h e b r a k e when Fig. 127. Brake shoe - wear marking
t h e brake s h o e s a r e removed!
V = wear groove
R e p l a c i n n t h e Brake Diek -
,Open t h e b l e e d e r v a l v e
The b r a k e d i s k must be r e p l a c e d when i t i s -Rafse t h e hose eo t h a t t h e f w e l i s
20 cm above t h e t o p edge o f t h e r e s e r v o i r
worn down t o l e e s t h a n 4.4 mm o r when i t
shows e c o r e e whoee bottom i s s u c h t h a t t h e and fill i n b r a k e f l u i d u n t i l t h e -ximum
l e v e l has been reached i n t h e r e e e x v o i r
a c t u a l t h i c k n e e s f a l l s below t h e above
minimum t h i c k n e e s . -Close t h e b l e e d e r v a l v e
NOTE: F o r r e a e o n s of s a f e t y , u s e new S e l f - ,p i t t h e h e r m e t i c b e l l o w s and screw t h e
l o c k i n g n u t s whenever mounting t h e cover i n place
brake diekf
B e f o r e mounting t h e wheel provided w i t h a
-Bleed t h e b r a k e .
new b r a k e d i s k , p r e s s back t h e b r a k e p i s t o n s bleed in^ t h e Brake
i n t o t h e brake saddle. The b r a k e i e b l e d a u t o m a t i c a l l y . T h i s p r o c e s s
l a s t s f o about an hour w i t h t h e r e e e r v o i r
Replacement o f t h e Brake F l u i d opened. $he l a s t r e m d n s o f a i r e s c a p e when
A f t e r about two y e a r s , t h e b r a k e f l u i d must s l i g h t l y t a p p i n g b r a k e s a d d l e and b r a k e hoee.
b e renewed. T h i s can be done w i t h t h e h e l p Then f i t t h e h e r m e t i c b e l l o w s and screw t h e
o f a f i l l i n g apparatus o r i n the following cover i n place.
way: More r a p i d b l e e d i n g i s e f f e c t e d i n t h e
- Put a s u i t a b l e hoee on t h e b l e e d e r v a l v e f o l l o w i n g way:
of t h e brake saddle -Close t h e r e s e r v o i r
- Open t h e b l e e d e r v a l v e . By pumping c o n t i - - P u t t h e f i l l i n g hose on t h e b l e e d e r v a l v e
nuouely w i t h t h e hand b r a k e l e v e r , eva- and f i l l i t up t o t h e h a l f o f t h e f u n n e l
c u a t e t h e b r a k e system t h r o u g h t h e hose - Raiee t h e hoee ( f u n n e l about 20 cm o v e r
into a euitable vessel t o p l e v e l marking o f t h e b r a k e m a s t e r
cylinder)
- F i l l i n brake f l u i d -Open t h e b l e e d e r v a l v e t h r o u g h h a l f a revo-
- Bleed t h e b r a k e system l u t i o n and, a t t h e same t i m e , p u l l t h e
hand b r a k e l e v e r up t o t h e s t o p . Close
fill in^ i n Brake F l u i d t h e v a l v e w i t h t h e hand b r a k e l e v e r p u l l e d
When a new b r a k e system has been newly i n -
-Repeat t h i s p r o c e e s u n t i l no a i r bubblee
w i l l emerge. The l i q u i d l e v e l m u s t n o t
s t a l l e d o r r e p a i r e d o r when t h e b r a k e f l u i d f a l l below t h e lower l e v e l marking.
must be renewed, t h e f i l l i n g o f new b r a k e
f l u i d c a n b e e f f e c t e d w i t h t h e h e l p of a
-F i n a l l y , f i l l t h e brake master c y l i n d e r
up t o t h e t o p marking. F i t t h e h e r m e t i c
f i l l i n g a p p a r a t u s o r i n t h e f o l l o w i n g way: b e l l o w s and s c r e w t h e c o v e r i n p l a c e .
- Remove t h e c o v e r and t h e h e r m e t i c bellowe
from t h e b r a k e m a s t e r c y l i n d e r
- P r o v i d e t h e hose ( 1 m i n l e n g t h ) w i t h a
f u n n e l and p u t t h e hose on t h e b l e e d e r
valve
F a u l t s i n t h e Brake System
Fault P o s s i b l e Cause Remedy
B r a k i n g e f f e c t i n s u f f i c i e n t brake disk dirty braking a t i n t e r v a l s u n t i l
brake d i s k is dry
brake l i n i n g
o i l e d up r e p l a c e brake s h o e s
piston eticks i n f r e e t h e p i s t o n and r e s t o r e i t
brake saddle t o proper operation o r replace
b r a k e s a d d l e , change b r a k e f l u i d
No c o u n t e r p r e e e u r e a t a i r i n b r a k e system b l e e d t h e b r a k e system
hand b r a k e l e v e r
b r a k e l i n e s and/or b r a k e s e a l t h e b r a k e l i n e s and t h e
c y l i n d e r leaky b r a k e c y l i n d e r o r r e p l a c e them
by new onee
amount o f b r a k e f l u i d t o p up b r a k e f l u i d
insufficient
compensating hole i n r e s e r - a d j u s t t h e play a t t h e
v o i r covered - brake f l u i d
c a n n o t be f e d a s r e q u i r e d
hand b r a k e l e v e r
--------------
Brake f a i l s t o s t o p b r a k e d i s k worn r e p l a c e t h e b r a k e d i s k by a
new one
underpressure i n r e s e r v o i r open t h e c o v e r , c l e a n t h e
vent hole
R e s i s t a n c e o f f e r e d by brake f l u i d c o n t a i n s r e p l a c e t h e brake f l u i d by
hand l e v e r diminishing formation of water vapour new one
when brake temperature bubbles
i s high
F i g . l 3 f . check in^ t h e c h a i n t e n s i o n
I 2 P
rig* 'J2* "lew O f exhauet si- The exhauet e i l e n c e r (Fig. 132) is welded and
lencer cannot be detached.
( 1 ) Exhaust p i p e (2) Weld The e x h a u e t p i p e i e f a e t e n e d t o t h e c y l i n d e r
1 3 ) Damping i n s e r t by means of a union nut which p r e s s e s t h e
( 4 ) Exhaust t a i l p i e c e tapered knurled c o l l a r a g a i n s t the c y l i n d e r
(wlthout packing). I n new c o n d i t i o n , t h e 5.12. Cable Controls
union n u t i s t i g h t e n e d w i t h a torque o f
1 Nm ( 1 5+3 kpm) . The c a b l e c o n t r o l e are 'expoeed t o e x t e r n a l
i n f l u e n c e s such aa r a i n , d i r t and l y e i n a
A f t e r having covered 500 km, t h e nut mnet high degree on t h e mo'tor-cycle. I n motor-
be re-tight,ened i n any cane w i t h t h e same parked c y c l e s which a r e o p e r a t e d d a i l y and f r e q u e n t l y
torque because, d u r i n g t h i e d i s t a n c e , t h e t h e c a bilne ct hoen topen, high f r i c t i o n occura i n
r o l e eo t h a t t h e a c t u a t i n g l e -
t a p e r of t h e exhauat p i p e w i l l a t t a i n vere can h a r d l y be p a l l e d .
proper c o n t a c t with t h e s n p p o r t i n g sur-
f a c e of t h e c y l i n d e r and t h e t h r u a t a r e a Ease of motion i s improved and t h e a e r v i c e
of t h e union nut. l i f e extended when t h e c a b l e c o n t r o l e a r e
Re-tightening i s e f f e c t e d by means of a s e a l e d a t t h e a c t a a t i n g l e v e r 8 and thoroughly
hook spanner, B 39-442, and an extension l u b r i c a t e d t o prevent t h e i n g r e s s o f water and
pipe put on. dirt.
A proper exhaust p i p e f a s t e n i n g l a r g e l y
depends on t h e t i g h t l y f i t t i n g of a l l The simpleet way of s e a l i n g i e t h e a p p l i c a t i o n
t h r e e euepeneion. p o i n t s ( c y l i n d e r , of w a t e r - r e p e l l e n t g r e a s e , e.g. C e r i t o l , t o
lower c o n n e c t i o n , - r e a r b r a c e ) . When one t h e p r o j e c t i n g wire end and t o t h e s l o t i n t h e
of t h e s e p o i n t s 4 s d e f e c t i v e , t h e s t r e e a a d j u s t i n g screw of t h e a c t u a t i n g l e v e r .
on t h e o t h e r two w i l l i n c r e a s e and they An a d d i t i o n a l p o s e i b i l i t y of extending t h e s e r -
w i l l work loose. v i c e l i f e of t h e c a b l e c p n t r o l s i s given by
The rubber bearings of t h e b r a c e must a t t a c h i n g a rubber p r o t e c t i v e bellow, p a r t No.
n o t be replaced by a r i g i d connection 05.44.050; t h e i n t e r i o r of t h e bellows is
because of t h e e l a s t i c engine snapension. f i l l e d w i t h a w a t e r - r e p e l l e n t greaee.
5.71. A l i m i n n t h e Wheels. Balancinq The cable c o n t r o l s a r e l u b r i c a t d by means of
t h e Front Wheel t h e device shown i n Fig. 134.
C o r r e c t l y aligned wheels a r e indispensable
f o r good roadholding.
Since t h e f r o n t t y r e i s n o t so wide ae
t h e r e a r t y r e , t h e f r o n t wheel muet be
s e t p a r a l l e l t o t h e measuring l a t h .
Teil B
(ffmgumrni>
6. 1. Three-phase Qynamo
6.1.1. Mode of Operation The a l t e r n a t i n g c u r r e n t d r a w n from t h e s t a t o r
i s converted i n t o d i r e c t c u r r e n t by an e f f i -
The t r a f f i c growing deneer and d e n s e r c i e n t three-phase b r i d g e r e c t i f i e r .
and t h e t r e n d toward i n c r e a s i n g t h e
s a f e t y on t h e road by t h e use o f halogen Due t o t h e u s e of modern s i l i c o n semi-conduc-
l i g h t , a d d i t i o n a l f o g lamps a n d r e a r t o r s , i t e n s u r e s maintenance-less o p e r a t i o n
f o g l i g h t s a l s o on motor-cycles l e a d and a l o n g s e r v i c e l i f e .
t o an i n c r e a s e of t h e demand f o r The b r i d g e r e c t i f i e r i s a s e p a r a t e component
e l e c t r i c a l energy. on which t h e e x c i t e r diode t r i o is a l s o
T h i s i n c r e a s e d demand cannot be met by mounted.
t h e d.c. dynamo w i t h r e a s o n a b l e c o s t s The s u p p l i e d v o l t a g e i s k e p t a t t h e d e s i r e d
and due t o i n c r e a s e d engine speeds. l e v e l by means of an e l e c t r o m e c h a n i c a l one-
Compared w i t h t h i s , t h e three-phase element r e g u l a t o r . A t t h e 'same t i m e , t h e
c u r r e n t dynamo of t h e same weight maximum c u r r e n t i s l i m i t e d by t h e r e g u l a t o r .
i s i n a p o s i t i o n t o produce a c o n s i d e r -
a b l y h i g h e r power. When o b s e r v i n g t h e r e g u l e t o r v o l t a g e and
t h e mounting c o n d i t i o n s r e q u i r e d i n t h e
Three-phase dynamos have no commutator, t e c h n i c a l documents, p r o t e c t i o n of t h e
t h e o u t p u t c u r r e n t is drawn from t h e three-phase dynam'b from d e s t r u c t i o n and a
s t a t o r winding without c o n t a c t . Only l o n g s e r v i c e l i f e of t h e e l e c t r i c a l equipment
a s m a l l e x c i t e r c u r r e n t , branched o f f a r e ensured.
v i a 3 e x c i t e r d i o d e s , is t r a n s m i t t e d
t o t h e r o t o r v i a 2 carbon b r u s h e s and
s l i p r i n g s s o t h a t o p e r a t i o n a t high
r o t a t i o n a l speeds i s possible.
.!OV
15V
1ov
5v
- -
5v
10v
5v
Fig. 146. Short-circuit of etator winding Hg. 147. Short-circuit of rotox winding
Pig. 148. Ground contact of seator winding Fig. 149. Interruption of etator winding
Par* I1
Charging c o n t r o l l i g h t charging c o n t r o l l i g h t defec- r e p l a c e e l e c t r i c bulb o r
-
f a i l s t o l i ~ h t igni- tive lighting f i t t i n g
-
tion
engine stopped
switched On cable 61 t o r e g u l a t o r i n t e r -
rupted r e p l a c e c a b l e by a new one
ground o f r e g u l a t o r and c a b l e
DF i n t e r r u p t e d r e p l a c e cable by a new one
r e c t i f i e r d e f e c t i v e (checking
acc. t o Section 6.1.10.1.) replece r e c t i f i e r
Part' I11
emits dimmed l i a h t -
Charging c o n t r o l l i g h t
i g n i t i o n s w i t c h switched
c o r r o s i o n I n holder of charging c l e a n o r r e p l a c e t h e holder
control lighting f i t t i n g
c a b l e DF from r e g u l a t o r t o r e p l a c e cable by a new one
on - engine stopped three-phaee dynamo I n t e r r u p t e d
r o t o r d e f e c t i v e (checking acc. r e p l a c e r o t o r
t o Section 6.1.70.3,)
.............................................
Part I V (loads mitched o f f )
Charging c o n t r o l l i g h t damaged cables and oonnectione r e p a i r o r r e p l a c e t h e
li h t s -i g n i t i o n switch
Z i i h e d on - engine
between 6 1 r e g u l . and 61 r e c t i - damaged p a r t s
f i e r , D+ r e g u l a t o r and D+ r e c t i -
rune f i e r , 51 r e g u l a t o r and b a t t e r y
The voltage meaeared between D+ r e p l a c e t h e r e g u l a t o r
r e g u l a t o r and ground i s g r e a t e r
than t h a t between 51 r e u l a t o r
and ground ( A U > 0;2 V?
r e g h l a t o r c o n t a c t s between DF
and 6 1 o f t h e r e g u l a t o r inslr- replace the regulator
l a t e d from each o t h e r
w i t h t h e b a t t e r y dieconnected
and t h e plugged connections
wfthdrawn, perform a t e s t bet-
weea DF and 61 a t t h e r e g u l a t o r
by meene of a r e s i s t a n c e
meaeuring bridge (R10.5 ohm)
rectifier d e f e c t i v e (check r e p l a c e the r e c t i f i e r
according t o S e c t i o n 6.1.10.1.)
c a b l e DF between r e g u l a t o r and renew t h e c a b l e o r t h e
three-phaee dynamo i n t e r r u p t e d connections involved
damaged carbon bruehee o r r e p l a c e t h e t3amaged p a r t s
oarbon brneh connectione by new onem
r o t o r d e f e c t i v e (check accord;
i n g t o Section 6.1.70.3.) replace the r o t o r
Cables U/VD between e t a t o r r e p l a c e t h e damaged p a r t s
and r e c t i f i e r and/or ground by new onee
c o n n e c t i o ~damaged
magnetic ehant of a t a t o r (check r e p l a c e t h e e t a t o r
according to S e c t i b n 6.1.10.2.)
ehorted t u r n s o f a t a t o r (check
acoording t o S e c t i o n
6.1.70.2.) replace the s t a t o r .
6.1.8. Demoant i n a from t h e V e h i c l e
6. t.8.1. demo ant in^ t h e T h r e e - ~ h a e
Dsnamo
NOTICE:
Before demounting, d i e c o n n e c t t h e b a t t e r y
from t h e e l e c t r b a l eystemi
A l l plugged c o n n e c t i o n s (U, V , 8 , DF, A f t e r l o o s e n i n g t h e t h r e e f a s t e n i n g ecrewa,
61, D-1 must be removed from t h e remove t h e e t a t o r w i t h r e t a i n i n g cap.
three-phase dynamo.
Fig. 754. P u l l i n g o f f t h e r o t o r
6.1.8.2. D e m o u n t i n ~t h e R e c t i f i e r
P i g . 155. I n t e r n a l e l e c t r i c a l equipment
(1) Regulator
( 2) C a p a c i t o r 2.5 p F , 50 V
(3) Ignition coil
(4) Line c o n n e c t o r s
(5) Rectifier
( 6) F a s t e n i n g screws
6.1.9. Demountinn t h e Three-phase
L?zBE!?
6 . 1 . 9 r l . S t a t o r w i t h R e t a i n i n g Cap
Carbon-brush h o l d e r ( g , Fig. 156)
Loosen t h e plugged connections o f t h e
carbon brush. Remove t h e f a s t e n i n g screws.
P u l l o f f t h e h o l d i n g clamp (10, F i g . 156).
Hold t h e carbon b r u s h e s (8, Fig. 156) d u r -
i q g t h i s o p e r a t i o n t o p r e v e n t them from
jumping o u t . Check carbon b r u s h e s .and
compression s p r i n g s f o r wear.
S t a t o r ( 6 , Fig. 156)
NOTICE: Remove t h e s o l d e r e d j o i n t of t h e s t a t o r
winding U/V/W.
Before demounting, d i s c o n n e c t t h e b a t t e r y Loosen t h e h o l d i n g a n g l e ( 5 , F i g . 156).
from t h e e l e c t r i c a l system! With t h i s , t h e s t a t o r a s complete comvonent
D+ and D- .
Remove t h e plugged c o n n e c t i o n s U/V/V, 61,
For t h e l a t e r assembling
o p e r e t i o n s , i t i s a d v i s a b l e t o mark t h e
can be removed from t h e r e t a i n i n g cap-
( 7 , ~ i g .156).
Rotor ( 4 , Fig. 156)
c a b l e s D+ and D- and 61 f o r i d e n t i f i c a t i o n
because exchanging by mistake of t h e s e The r o t o r i s n o t i n t e n d e d f o r r e p a i r s .
connections w i l l lead t o t h e d e s t r u c t i o n Replacement o f t h e s l i p r i n g body must
o f t h e d i o d e s of t h e r e c t i f i e r . t a k e p l a c e i n s p e c i a l r e g e n e r a t i n g work-
shops.
The c o n n e c t i o n s U/V/M between three-phase
dynamo and r e c t i f i e r may be exchanged,
damage w i l l n o t be caused.
A f t e r l o o s e n i n g t h e f a s r e n i n g screws (61,
t h e r e c t i f i e r can be removed.
F ~ E . 158. P r e s s i n n - I n mandrel
Round & e e l 22 TGL 1 1 163
St 50 K TGL 0-1652
A maximum p r e s s i n g f o r c e of 4,000 N
(400 kp) i s p e r m i s s i b l e f o r p r e s s i n g i n .
Care must be t a k e n t h a t t h e punch e x a c t l y
c o n t a c t s t h e d i o d e edge.
For t h e u s e of semiconductor d i o d e s , t h e
i n s t r u c t i o n s of the manufacturer m u s t be
observed.
--+-Q+- 72 Y max. 75 W
PIE. 159. P r i n c i p l e of d i o d e t e s t i n g
6.1.10.2. Testing the S t a t o r Stator
T e s t i n g t h e s t a t o r winding f o r s h o r t e d When mounting t h e s t a t o r i n t h e r e t e i n i n g
turns: cap t a k e c a r e t h a t t h e groove i n t h e
e t a t o r c o i n c i d e s with t h e groove i n t h e
A r e s i s t a n c e of abolrt 0.32 ohm should be retaining cap.
measured between t h e phasee (U/V/W, V/W).
Permissible torque f o r t i htening t h e
'hesting t h e s t a t o r f o r r o t o r f a s t e n i n g screw M 775.8 = 20 2 2 Sm
magnetic s h u n t : ( 2 2 0.2 kpm)
Bebveen t h e s t a t o r s h e e t pack and t h e Permissible torque f o r tightening the
winding ends of t h e e t a t o r , t h e l a t t e r s t a t o r f a s t e n i n g screw 5/5.8 = 4 + 0.5 Nm
i s t e e t e d f o r magnetic ehunt by connect- ( 0 . 4 2-0.05 kpm).
i n g a t e s t lamp and a p p l y i n g a t e s t It i s a d v i s a b l e t o mount t h e carbon-brush
v o l t a g e o f 2.4 V a.c. A l l c a b l e s U/V/W
must be disconnected from t h e s t a t o r . h o l d e r a f t e r moanting t h e r e t a i n i n g cap.
When t h e Tamp l i g h t s up, t h e s t a t o r
i s d e f e c t i v e a n d m u s t be replaced by
a new one. Before c o n n e c t i n g t h e b a t t e r y , check t h e
l i n e s . When t h e connections D+, D-, 61,
DF a r e exchanged by mistake, t h e r e i e t h e
6.1.10.3. T e s t i n g t h e Rotor r i s k o f d e s t r o y i n g t h e semiconductor e l e -
T e s t i n g t h e r o t o r winding: mente and a d d i t i o n a l components. Take c a r e
t h a t t h e p o l a r i t y o f the b a t t e r y ( n e g a t i v e
Measure t h e r e s i s t a n c e by meane Of a p o l e t o ground) i s c o r r e c t when connecting.
r e s i s t a n c e measuring bridge.
It should be about 4.2 + 0.3 ohm. Information f o r a d j u s t i n g t h e i g n i t i o n and
A f t e r removal from t h e v e h i c l e , t h e a p p l i c a t i o n of t h e l u b r i c a t i n g f e l t
measurement i s taken a t t h e s l i p r i n g s . pad i s g i v e n i n s p e c i a l documents f o r t h e
vehicle.
The t e s t t i p s a r e s l i g h t l y a p p l i e d t o
t h e s l i p r i n g s i n o r d e r t o avoid
damage t o t h e g r a p h i t e s l i p r i n g . 6.1.12. Important Information
When c h a r g i n g b a t t e r i e s w i t h mains-fed
6.1.10.4. Checking t h e L e n ~ t hof c h a r g i n g equipment, d i s c o n n e c t t h e b a t t e r y
t h e Carbon Brush from t h e e l e c t r i c a l syetem of t h e v e h i c l e .
Demoanting according t o S e c t i o n When performing welding o p e r a t i o n s i n t h e
6.1.9.1. vehicle, take care that + ( p o s i t i v e ) l i n e e
When t h e carbon-brush l e n g t h s f a l l s below of t h e e l e c t r i c a l system of t h e v e h i c l e
9 mm, a new carbon brush m u s t be do n o t g e t i n t o c o n t a c t w i t h t h e welding
fitted. e l e c t r o d e . The b a t t e r y must be disconnected.
When t h e engine i s running, c o n n e c t i o n s
between three-phase dynamo, r e c t i f i e r and
r e g u l a t o r m u s t n o t be i n t e r r u p t e d because
6.1.11. A s s e m b l i n ~I n s t r u c t i o n s t h i s w i l l lead t o damage t o t h e e l e c t r i c a l
system.
J o i n t s t o be s o l d e r e d m u s t be m a d e w i t h
a c i d - f r e e s o l d e r and p r o t e c t e d a g a i n s t For checking o p e r a t i o n s a t the three-phase
c o r r o e i o n by means of e l e c t r o - i n e u l a t i n g dynamo and r e c t i f i e r , t h e measuring
p r o t e c t i v e v a r n i s h ( c a n be s o l d e r e d ) . i n s t r u m e n t s must be connected w i t h s a f e
connections.
The p r o t e c t i o n should a l s o cover newly
s o l d e r e d e x c i t a t i o n diodes. This When o p e r a t i n g t h e three-phase dynamo with-
i s e f f e c t e d by d i p p i n t h e whole out b a t t e r y , a capacitor, F, 50 V,
r e c t i f i e r . The p l u g g e t connections must be connected between k5,61 d d- of t h e
m w t be covered and, a f t e r d i p p i n g , r e c t i f i e r ( i n t h e ETZ 250, i t i s p r e s e n t
remains of v a r n i s h must be removed c l o s e by t h e l i n e connector a t t h e i n t a k e
from them. s i l e n c e r a s standard equipment).
6.2. Regulator TO be s e t *
The three-phaee dynamo i s a temperature- - r e g u l a t e d v o l t a g e U3*
compensated, p o s i t i v e - r e g u l a t i n g r e g u l a t - Voltage which w i l l be r e g u l a t e d o v e r t h e
o r with break c h a r a c t e r i s t i c . This single- e n t i r e speed r a n g e when t h e dynamo i s
system r e g u l a t o r , 74 V, 15 R, o p e r a t e a loaded w i t h 3 A. The v o l t e g e must be with-
w i t h v o l t a g e r e g u l a t i o n and c u r r e n t ' regu-
lation.The c u r r e n t r e g u l a t i o n i e r a t e d f o r Ln t h e s p e c i f i e d t o l e r a n c e range. S h o r t
maximum c u r r e n t of 75 h. The r e g u l a t i n g v o l t a g e peaks beyond t h e t o l e r a n c e range
? s e r i e s ) r e s i s t o r ( c o n n e c t i o n s i d e ) and a t t h e b e g i n s i n g o f t h e l o w e r - p o s i t i o n and
a balancing reeist&7oe a r e incorporated u p p e r - p o s i t i o n r e g u l a t i o n should n o t be
Tn t h e r e g u l a t o r . confused w i t h wrong a d j u s t m e n t .
The r e g u l a t e d v o l t a g e may d i f f e r f o r about
6.2.1. Mounting -
+ 0.2 t o 0.1 V ( v o l t a g e jump) between
I n o r d e r t o eneure p r o p e r o p e r a t i o n o f t h e t h e end of t h e lower-poeition r e g u l a t i o n
r e g u l a t o r i t must be mounted s o t h a t i t and t h e b e g i n n i n g of t h e upper-position r e -
i s n o t exposed t o v i b r a t i o n e . gulation.
This has been r e a l i s e d i n t h e ETZ 250 The v o i t a g e jam should n o t be a d j u s t e d
f u l l y because t h e r e g u l a t o r cut-out t o o n e g a t i v e otEerwise t h e r e g u l a t o r
i s supended by means of a foamed-plastic armature w i l l c h a t t e r , i.e. c o n t i n u o u s l y
pocket and a r u b b e r s t o p p e r e l a s t i c a l l y . move between upper and lower p o s i t i o n .
When mounting, t a k e c a r e t o s e e t o it t h a t
t h e r e g u l a t o r cut-out i s p r o p e r l y inwerted - maximum load voltage U m
i n t h e h o l d e r provided f o r t h i s purpose. Voltage which i s r e g u l a t e d a t a speed of
more than 3,800 rpm when t h e dynamo i s
6.2.2. Maintenance loaded with 15 A,
Maintenance of t h e r e g u l a t o r i s g e n e r a l l y
r e s t r i c t e d t o keeping t h e connections - r e l e a s e c u r r e n t I AS
clean. When t h e headlamp l i g h t IB t o o dim, A t t h i s current, the current regulation
when t h e r e a r e s t a r t i n g d i f f i c u l t i e s and s t a r t 6 operating.
t h e l i k e , do n o t always blame t h e regu-
l a t o r f o r t h e f a u l t and on no account E l e c t r i c a l s e t t i n g values
make any u n a u t h o r i s e d i n t e r v e n t i o n s b u t
f i r s t check t h e l i n e s and t h e i r c o n n e c t o r s The f o l l o w i n g v a l u e s a p p l t o a r e g u l a t o r
f o r p r o p e r f i t and c o r r o s i o n . (emperature of 20 O C + 5
See t o i t t h a t t h e r e g u l a t o r i s not regula,ted v o l t a g e : 13.8 V to 14.6 V
touched by p a r t s such a s a s p a r e i n n e r
t u b e and t h e l i k e placed under t h e maximum load v o l t a g e : 13.0 V t o 13.5 V
d u a l sea:. release current: 11.5 A t o 14.0 A
6.2.3. Adjustment ROTICE:
Before t h e e l e c t r i c a l a d j u s t m e n t , a mecha- TO change t h e r e g u l a t e d v o l t a g e and t h e
n i c a l p r e - s e t t i n g o r a c o r r e c t i o n of t h e r e l e a s e c u r r e n t , o n l y c a r e f u l l y bend t h e
mechanical s e t t i n g must be e f f e c t e d i n any s p r i n g h o l d e r . Do not bend t h e c o n t a c t
c a s e . This f a c i l i t a t e s t h e e l e c t r i c a l ad- tongue
justment and e n s u r e s t h e observance of' t h e
r e q u i r e d v o l t s g e / c u r r e n t characteristic. 6.2.4. Dama~eeand t h e i r Causes
An e l e c t r i c a l adjustirient of t h e r e g u l a t o r The most e s s e n t i a l t h i n g s have a l r e a d y besn
I N THE VEHICLE i e a m a k e s h i f t and should s a i d i n S e c t i o n 6.1.
be evoided i n t h e i n t e r e s t o f an optimum I n a d d i t i o n , t h e f o l l o w i n g must be
performance o f t h e f u n c t i o n of t h e observed :
c u r r e n t s u p p l y system.
The improper f i t t i n g of t h e p r o t e c t i v e cap
For a d j u s t i n g t h e r e g u l a t o r c u t o u t , i t of the regulator cutout leads t o accidental
i s mounted on a t e a t a t a n d c o n t r o l l a b l e ground when t h e cap g e t s i n t o c o n t a c t w i t h
w i t h i n a speed r a n g e from 0 t o 7,000 rpm t h e c o r e o r w i t h t h e c o n t a c t a n g l e of t h e
t o g e t h e r w i t h a dynamo of t h e r e q u i r e d r e g u l a t o r c u t o u t . Before opening t h e regu-
type l a t e r , remove t h e f u s e s . The l u g 6 a t t h e
3 . s i d e of t h e cap m u s t b e c o r r e c t l y i n s e r t e d
I n o r d e r t o avoid e r r o r s i n t h e a d j u s t - i n t o t h e r e c e s s provided f o r t h i s purpose
ment, t h e v o l t a g e must always be s t a r t e d i n t h e regulrstor base. f h e w i r e bow must
from t h e speed "zero" of t h e dynamo. The t i g h t l y f i t on t h e cap.
v o l t a g e i s measured between t h e t e r m i n a l s
D+ and D- of t h e r e g u l a t o r . The measur-
i n g i n ~ t r u m e n tt o be used should be
o f q u a l i t y 1.5.
A f t e r about 2 t o 3 h o u r s , t h e p l a t e s and
a s p a r a t o r e have soaked and t h e e l e c t r o l y t e
l e v e l i s dropped.
Once more, e l e c t r o l y t e o f t h e same d e n s i t y
and t e m p e r a t u r e must be topped up t o t h e
upper edge o f t h e s e p a r a t o r . Subgequently,
t h e b a t t e r y i a charged w i t h d i r e c t c u r r e n t
o f 0.5 A.
During t h e c h a r g i n g , t h e h o l e s o f t h e
b a t t e r y must be open.
Charging must be continued u n t i l a l l c e l l e
v i v i d l y and uniformly evolve gas and t h e
l v o l t a g e r e a c h e e 2.5 t o 2.7 V p e r c e l l .
For 2 t o 3 measurements a t i n t e r v a l s o f
n e h o u r , t h e d e n s i t y of t h e e l e c t r o l y t e
F1.28 + 0.01 g/cm3) and t h e c e l l v o l t a g e
must remain c o n s t a n t . During c h a r g i n g , t h e
t e m p e r a t u r e o f t h e e l e c t r o l y t e must n o t
exceed 50 'C. A t t h e end of t h e c h a r g i n g
p r o c e s s , t h e l e v e l of t h e e l e c t r o l y t e
m u s t a g a i n be measured.
Mounting t h e b a t t e r g
Fig. 162. Mechanical r e g u l a t o r adjustment Before mounting t h e b a t t e r y i n t h e v e h i c l e ,
a a t l e a s t 0.3 mm t h e two b a t t e r y c a b l e s m u s t be connected
b 0.8 t o 1.1 mm t o t h e b a t t e r y ( r e d c a b l e to' t h e p o s i t i v e
c
d
0.5+0.1m
0.5 + 0.1 mm
pole - brown c a b l e t o t h e n e g a t i v e p o l e )
and p r e s e r v e d w i t h g r e a s e f o r b a t t e r y t e r -
e 1.4 €0 1.5 mm minals o r acid-free vaseline. A f t e r f i t t i n g
(l) c o n t a c t s of t h e v o l t a g e r e g u l a t o r t h e p r o t e c t i v e cap, t h e b a t t e r y can be mount-
(2) contacts of t h e current regulator ed and t h e two b a t t e r y c a b l e s can b e conn-
(current l i m i t i n g switch) e c t e d t o t h e f u s e box.
5.3. Batterg EIERE, AGAIm OBSERVE: connect
red oable t o red cable,
A f l a t lead b a t t e r y with a rated voltage brown c a b l e t o brow? c a b l e I
o f 12 V and a r a t e d c a p a c i t y o f 9 Ah
i s used. The vent hose m u s t b e i n s t a l l e d i n s u c h e
way t h a t a c i d which may emerge from i t
cannot g e t i n t o c o n t a c t w i t h v a r n i s h o r
metal p a r t s .
Maint-ensnce o f t h e b a t t e r x
The a v e r a g e s e r v i c e l i f e of t h e b a t t e r y i s
about 2 y e a r s . Due t o a good o r bad main-
t e n a n c e , t h i s perJod can be extended o r
s h o r t e n e d . The maintenance i s m a h l y l i m i t -
ed t o t h e t e r m i n a l s which have t o be k e p t
clean - t h e y m u s t be provided w i t h a t h i n
-
f i l m of g r e a s e f o r b a t t e r y t e r r o i n a l s and
t h e r e g u l a r control of the acid l e v e l ( i n
t h e c o l d s e a s o n e v e r 4 weeks, i n t h e warm
.
s e a s o n e v e r y 2 weekay When g r e a s i n g t h e
t e r m i n a l s , c a r e must be t a k e n t h a t no g r e a s e
gets into the cells.
When t h e a c i d l e v e l has dropped below t h e
r e q u i r e d h e i g h t , t o p up w i t h d i s t i l l e d
w a t e r only.
If a c i d i s s p i l l e d from t h e b a t t e r y , t h e
d e n s i t y of t h e amount t o be f i l l e d i n must
F i g . 163. B a t t e r y arrangement be s o s e l e c t e d t h a t t h e d e n s i t y of t h e
whole amount o f a c i g i n t h e b a t t e 2 y w i l l
1 Battery
Flasher unit be 1'.28 & 0.07 g/cm when t h e b a t t e r y i s
charged.
121
(5
Fuse box
Spare e l e c t r i c bulbs
Tool k i t
When n o t used o r when t h e d i s t a n c e covered
e v e r y day i s b e s s t h a n 50 km, t h e b a t t e r y
m u s t be charged e v e r y month w i t h 1 A.
When p u t t i n g i n t o o p e r a t i o n , accumulator
s u l p h u r i c a c i d (below c a l l e d e l e c t r o l y t e ) 5.4. Ignition
h a v i n g a d e n s i t y of 1.28 + 0.01 3fcm3 6.4.1. I w l i t i o n Coil
( i n t h e t r o p i c s 1.22 + 0.n1 g/cm ) measur-
ed a t 20 2 2 O C , is f r l l e d i n t o t h e The i g n i t i o n c o i l can be compared w i t h a
battery. t r a n s f o r m e r which c o n v e r t s a low v o l t a g e
A 1 1 c e l l s o f t h e b a t t e r y m u s t be f i l l e d i n t o a h i g h one. S i n c e , however,only an
up t o 5 mm on t o p of t h e s e p a r a t o r s o r a l t e r n a t i n g v o l t a g e can be transformed
up t o t h e given acid l e v e l mark, When w h i l e t h e e l e c t r i c a l system of t h e v e h i c l e
f i l l i n g , t h e t e m p e r a t u r e of t h e e l e c t r o - i s fed w i t h d i r e c t v o l t a g e , a c o n t i n u o u s
l y t e s h o u l d 25 O C n o t exceed. v o l t a g e change must be caused; t h i a i s
perfomned by t h e c o n t a c t b r e a k e r t o g e t h e r
with t h e capacitor.
The d e s i g n o f t h e c o n t a c t bpeaker i s shown
i n Fig. 165.
The a d j u s t i n g p l a t e ( 4 ) s e r v e s a s c a r r i e r
of late ( 3 ) and t h e f e l t pad (11) and a l s o
for- a d j u s t i n g the f i r i n g point.
To t h e p l a t e ( 3 ) w i t h t h e f i x e d c o n t a c t
( 2 b ) , t h e b e a r i n g b o l t (5) i s f a s t e n e d
on which t h e l e v e r (1) i s p i v o t e d .
The c o n t a c t ( 2 a ) r i v e t e d t o t h e r i g h t end
o f t h e l e v e r ( 1 ) Fa p r e s s e d on t h e f i x e d
c o n t a c t ( 2 b) by t h e r e t u r n s p r i n g (6)
which a l s o s e r v e s a s c u r r e n t conductor
and i s supported a t one s p r i n g end by t h e
c o n n e c t i n g screw. ( 7 ) . The c o n t a c t b r e a k e r
t h e a c c e n t r i c screw ?
p o i n t s gap can be ad usted p r e c i s e l y by
a f t e r loosening t h e
f a s t e n i n g s c r e w ( 8 ) . $he f e l t pad ( 1 1)
which i s s l i g h t l y soeked w i t h t h e s p e c i a l
011 WnterbrCilw should be approached t o
t h e cam j u s t f a r enough t h a t t h e l o b e i s
touched.
I f t h i s i s n o t observed and t h e f e l t i s
moved c l o s e r t o t h e cam, t h e o i l i s squeez-
ed o u t o f t h e f e l t and l u b r i c a t i o n o f t h e
cam i s n o t ensured. R e s u l t : The n o s e shows
g r e a t wear - t h e c o n t a c t b r e a k e r p o i n t s gap
and t h e s e t advanced i g n i t i o n w i l l change.
$he f e l t (10) s e r v e s f o r c o l l e c t i n g t h e
e x c e s s i v e o i l and must n o t be o i l e d i n
a d d i t i o n . A h e a v i l y contaminated f e l t
m u s t be r e p l a c e d .
Fig. 164, I g n i t i o n c o i l
6.4.3. Innit i o n Timing
The normal v o l t a g e of 12 V i s transformed
- ADJUSTING THl3 BREAKER POINTS GAP
t o t h e i g n i t i o n v o l t a g e of abolrt 12,000 V. B e f o r e a d j u s t i n g , i t i s n e c e s s a r y t o sub-
The trwo c o n n e c t i n g b o l t s of t h e i g n i t i o n j e c t t h e c o n t a c t b r e a k e r t o a check. For
c o i l a r e marked. t h i s p u r p o s e , t h e c o n t a c t s a r e removed
( s e e F i g . 165).
Terminal 1 i s connected w i t h t h e c o n t a c t The screw (7) i s unscrewed, t h e c o n t a c t
b r e a k e r and t e r m i n a l 15 w i t h t h e t e r m i n a l r a i l i s r e e s e d upward, t h e f a s t e n i n g
15/54 o f t h e i g n i t i o n l o c k . screw (87 removed and t h e b r e a k e r b a s e p l a t e
NOTICE: t a k e n o f f . When burns c a n be found on t h e
When t h e engine i s s t a t i o n a r y , t h e i g n i t i o n c o n t a c t s u r f a c e s , t h e y can be removed by
switched on and t h e c o n t a c t b r e a k e r c l o s e d , means of a f i n e emery f i l e . I n c a s e of
t h e i e p i t i o n c o i l w i l l be s u b j e c t t o a heavy b u r n i n g of t h e c o n t a c t s , t h e b r e a k e r
c u r r e n t which w i l l h e a t t h e i g n i t i o n c o i l b a s e p l a t e w i t h c o n t a c t b r e a k e r must be
i n a prolonged p e r i o d of time. A t t h e same replaced.
t i m e , t h e i n s u l a t i n g ' m a t e r i a l w i l l be When mounting t a k e c a r e t h a t t h e a d j u s t i n g
d e s t r o y e d . The i g n i t i o n c o i l w i l l break p l a t e ( 4 ) i s c l e a n and f r e e from o i l a s w e l l
down and, t h u s , become u s e l e s s . a s t h e complete b r e a k e r s e t . When t h i s i s
n e g l e c t e d , e r r a t i c i g n i t i o n and s t a r t i n g
6.4.2. Contact B r e a k e r d i f f i c u l t i e s w i l l occur. Old l u b r i c a n t r e -
mains must be removed from t h q b e a r i n g b o l t
( 5 ) and t h e b r e a k e r hammer m u s t be mounted
i n a s l i g h t l y o i l e d (breaker o i l ) condition.
The b r e a k e r p o i n t s must be s e t i n such a
m y t h a t t h e y a r e p a r a l l e l t o each o t h e r .
When a d j u s t i n g t h e b r e a k e r gap, t h e crank-
s h a f t i a t u r n e d u n t i l t h e n o s e of t h e
b r e a k e r l e v e r i s on t h e l o b e o f t h e came
The fasUening screw (8) i s loosened and,
by means o f t h e e c c e n t r i c screw (91, t h e
b r e a k e r p o i n t s gap La a d j u s t e d i n such e
m y t h a t t h e f e e l e r gauge can j u s t be drawn
through t h e contacts.
T i g h t e n t h e f a s t e n i n g screw (8) and once
more check t h e b r a k e r p o i n t s gap by means
o f t h e f e e I e r gauge.
The c o n t a c t b r e a k e r gap s e t muat remain
c o n s t a n t d u r i n g t h e whole opening a n g l e
w h i l e t h e c r a s h a f t i s t u r n e d , on no account
ehould t h e gap i n c r e a e e , o t h e r w i s e a cam
s t r o k e w i l l be involved which l e a d s t o
e r r a t i c i g n i t i o n a t higher r o t a t i o n a l
U speed's.
6.4.5. I m i t i o n L i n e Connector
(Sparking-plug connector)
The i g n i t i o n . l i n e c o n n e c t o r e s t a b l i s h e s
t h e c o n n e c t i o n between t h e s p a r k i n g - p l u g and
t h e i g n i t i o n c a b l e and t o s c r e e n t h e e l e c -
t r i c a l f i e l d of the sparking-plug t o the
outside.
I n o r d e r t o s c r e e n t h e s p a r k i n g - p l u g eo t h a t
i n t e r f e r e n c e i s completely suppressed, take
c a r e t h a t t h e sheet-metal s h e l l attached t o
t h e c o n n e c t o r i s p r o p e r l y s e a t e d on t h e
hexagon p a r t o f t h e s p a r k i n g - p l u g .
On no a c c o u n t should t h e s h e e t - m e t a l s h e l l
be removed b e c a u s e t h i s l e a d s t o i n t e r f e r e n -
c e s w i t h v.h.f. and t e l e v i s i o n r e c e p t i o n .
C a r e f u l l y h a n d l e n o t o n l y t h e p l u g but a l s o
t h e i g n i t i o n l i n e connector. Hair cracks i n
t h e i n s u l a t i n g body which l e a d t o t r a c k i n g
render i t useless. E r r a t i c i g n i t i o n occurs
when t h e p l u g c o n n e c t o r i s m o i s t , d i r t y
o r o i l e d up i n i t s i n t e r i o r .
.
The headlamp can be adjusted after loosening
the fastening nut ( 1 )
The passing beam of the headlamp is ad-
justed according to the acheme given
in Fig. 174.
6.5.7. Horn
The e l e c t r i c horn i s f a s t e n e d t o t h e frame
under t h e f c e l tank.
Before demounting t h e c y l i n d e r head o r t h e
c y l i n d e r , t h e s i g n a l horn must be unscrewed.
I f , upon a c t u a t i n g t h e push b u t t o n , t h e horn
f a i l s t o emit t h e r e q u i r e d volume of sound,
t h e n t h e l e a d s , t h e i r connections and t h e
push b u t t o n must be checked f o r d i r t y con-
t a c t s . I f such a r e p r e s e n t , t h e v o l t a g e
a p p l i e d w i l l be t o o low.
I f t h i e i s n o t t h e cause, t u r n t h e a d j u s t i n g
screw a t t h e horn s l i g h t l y t o t h e l e f t o r t o
t h e r i g h t u n t i l t h e sound has t h e d e s i r e d
loudness.
F i g . 196. C a r b u r e t t e r lower p a r t ( s e c t i o n a l
view) f u e l l e v e l
( 1 5 ) Vent t u b e f o r t h e f l o a t chamber
( 1 7 ) C l o s i n g p'late o f t h e f l o a t v a l v e
( 1 8 ) Needle j e t w i t h j e t c a r r i e r
( 1 9 ) Main j e t
( 21 ) Spring-loaded f l o a t n e e d l e
( 2 2 ) F l o a t v a l v e , complete
On t h e p i a c r y l p l ~ t eglued i n p l a c e , t h e
dimension o f 14 mm, s t a r t i n g from t h e
s e a l i n g surface, i s projected.
Fig. 195. F l o a t v ~ l v ef u l l y open,
measured w i t h o u t packing
(B) S t o p tongue
The f l o a t chamber p r e p e r e d i n t h i s way i s 7.2. Fault Localisation
a t t a c h e d w i t h PACKING t o t h e c a r b u r e t t e r t o 3.2.1, TOO Lean a Mixture
be measured. A n a c c u r a t e measurement depends The f a c t t h a t t h e f u e l - a i r m i x t u r e becomes
on t h e fact t h a t t h e flow r a t e of t h e f u e l
i s 12 1 p e r hour. The f u e l t a n k muet be a t t o o l e d n i s i d e n t i f i e d by t h e f o l l o w i n g
l e a s t half f u l l i n order t h a t the specified features:
p r e s s u r e on t h e f l o a t n e e d l e v a l v e 3 s g i v e n . 1 , Severe b u r n i n g o f t h e e l e c t r o d e s o f
P l u g t h e c a r b u r e t t e r , which i s cleaned and t h e sparking-plug;
checked f o r p r o p e r b a s i c a d j u s t m e n t , i n t o 2. Beads a p p e a r a t t h e s p a r k i n g - p l u g ;
t h e f u e l hose and open t h e f u e l cock. F u e l
w i l l be a d m i t t e d i n t o t h e f l o a t chamber 3. Within t h e r a n g e from h a l f t o f u l l
u n t i l t h e f l o a t l i f t e d by t h e r a i s i n g t h r o t t l e , t h e power d e l i v e r e d by t h e
f u e l l e v e l c l o s e s t h e f l o a t needle valve, e n g i n e i s t o o low;
t h u s , i n t e r r u p t i n g t h e f u e l f e e d , The 4. The e n g i n e t e n d s t o become s t u c k !
l e v e l now a c t u a l l y p r e s e n t i n t h e f l o a t
chamber i s compared w i t h t h e marking a t F a u l t s and d e f e c t s which c a u s e t h e m i x t u r e
the inspection g l a s s a n d , i f required, t o become t o o l e a n and t h e i r remedies:
c o r r e c t e d by r e a d j u s t i n g t h e tongue (A),
F i g . 194. 1. A i r f i l t e r f a i l s t o f i t p r o p e r l y i n
the c e n t r i n g c o l l a r of t h e intake
When t h e f l o a t n e e d l e v a l v e i s l e a k y , s i l e n c e r casing
t h i s i s i n d i c a t e d by t h e d r i p p i n g vent
( 1 5 ) , Fig. 196. I n t h i s c a s e , demount - Remove t h e a i r f i l t e r and f i t i t
t h e v a l v e and once more c a r e f u l l y c l e a n correctly i n the centring c o l l a r .
i t ; If i t t h e n i a s t i l l l e a k y , i t m u s t 2. A f t e r improper h a n d l i n g , t h e a i r f i l t e r
be r e p l a c e d by a new one. h a s been damaged.
The f u e l l e v e l is 14 + 1 mm measured from - R e p l ~ c et h e a i r f i l t e r by a new one.
t h e t o p edge o f t h e f l o a t chamber. 3. Packings between a i r f i l t e r c a s i n g and
i n t a k e e i l e n c e r o r between a i r f i l t e r
7.1.4.4. I d l i n ~Adjuetment c a s i n g and freme d e f e c t i v e .
NOTE: - Replace t h e packing5 o r r e - t i g h t e n t h e
screwed c o n n e c t i o n s .
1. The c e r b u r e t t e r should be a d j u s t e n d when
t h e e n g i n e s t i l l h a s operafing; tempem- 4. Packing between ~ i f ri l t e r c a s i n g end
ground .
t u r e . The v e h i c l e m u s t s t a n d on p l a n e cover missing o r defective.
- F i t a new p a c k i n g o r r e p l a c e t h e
2. The i d l i n g p o s i t i o n of t h e t h r o t t l e val- o l d one by R new one
ve s h o u l d n o t be s e t by means of t h e
a d j u s t i n g screw f o r -the t h r o t t l e c a b l e 5. Connection t o c a r b u r e t t e r i s d e f e c t i v e
c o n t r o l b u t by t h e s t o p s c r e w f o r t h e o r porous o r i t f a i l s t o f i t p r o p e r l y
t h r o t t l e valve. i n i n d r i l l - h o l e of the intake s i l e n -
The s t o p screw (14) f o r t h e t h r o t t l e v a l v e c a r casing.
i s a d j u s t e d i n s u c h a way t h a t t h e engine
r u n s p e r f e c t l y smooth. Then t h e slow runn-
- Replace t h e c o n n e c t i n g p i e c e by a new
one o r a l i g n i t .
i n g a i r s c r e w ( 1 1 ) i s f u l l y t u r n e d down
and s l a c k e n e d back t h r o u g h one r e v o l u t i o n . 6. I n t a k e socket porous.
Subsequently, the slow running a i r screw
i s screwed down and back f o r t r i a l t o
- Replace t h e i n t a k e s o c k e t by a new one
or - i f s t i l l p o s s i b l e - s e a l i t by
f i n d t h e maximum r o t a t i o n a l speed of t h e means of a r t i f i c i a l r e s i n .
engine. When i t has been found, t h e s t o p
screw f o r t h e t h r o t t l e v a l v e m u s t be s e t 7. I n s u l a t i n g f l a n g e broken o r p o r o u s ;
i n s u c h a way t h a t t h e e n ~ i n ea g a i n packings d e f e c t i v e .
r e a c h e s t h e i d l i n g speed ? s e e Fig. 192). - Replace t h e p a r t s i n q u e s t i o n by
T h i s p r o c e s s must be r e p e a t e d u n t i l t h e new ones.
e n n i n e epeed w i l l no l o n g e r change when
t h e slow r u n n i n g a i r screw i s a d j u s t e d . 8. Fuel f e e d i n s u f f i c i e n t due t o :
When, a t t h e b e g i n n i n g o f t h e a d j u s t i n g d i r t y f u e l cock,
o p e r a t i o n s , t h e speed does n o t change compressed r u b b e r s e a l r i n g ,
when t h e s l o w r u n n i n g a i r screw i a regu- hardened o r d e f e c t i v e f u e l l i n e ,
l a t e d , t h e n t h e i d l i n g j e t i s clogged.
clogged vent h o l e i n t a n k c o v e r .
If t h i s a d j u s t m e n t is performed c o r r e c t -
l y , t h e n t h e e n g i n e w i l l show a p e r f e c t - demount t h e f u e l cock and c l e a n i t s
t r a n s i t i o n from i d l i n g t o t h e p a r t i a l parts separately,
load range. - d e f e c t i v e and hardened f u e l l i n e s and
7.1.5. I n t a k e Connection and t h e damaged r u b b e r p a c k i n g m u s t
be r e p l a c e d by new o n e s ,
It i s t h e t a s k of t h e i n t a k e connection t o
f i x t h e p o s i t i o n o f t h e c a r b u r e t t e r and - t h e h o l e i n t h e t a n k c a p must be
cleaned by blowing compressed a i r
t o e s t a b l i s h t h e c o n n e c t i o n between c a r -
b u r e t t e r and i n l e t o r t of t h e c y l i n d e r . through it.
I t i s f s s t e n e d t o t i e c y l i n d e r by meane 9. The p a r t i a l - l o a d n e e d l e i s suspended
o f hexagon n u t s and s t u d b o l t a . t o o deep.
I n o r d e r t h a t t h e h e a t from t h e c y l i n d e r
is n o t transmitted t o t h e cfirburetter, - The p a r t i a l - l o a d n e e d l e m u s t be sus-
pended a t one o r more n o t c h e s h i g h e r
a p l a s t i c f l a n g e and two packtnge are
i n s e r t e d ( i n f r o n t o f and behind t h e u n t i l t h e normal m i x i n g r a t i o i s
p l a s t i c f l a n g e ) between t h e i n t a k e reached.
a o n n e c t i o n ~ n dt h e c y l i n d e r .
10. Central f l d a t i s d i s t o r t e d
i s i n s u f f i c i e n t l y opened
- f l o a t valve 3 * P a r t i a l - l o a d n e e d l e i s suspended
a t a n o t c h which i s a t t o o high a l e v e l
-
Adjust t h e c e n t r a l f l o a t . - Suspend t h e p a r t i a l - l o a d n e e d l e lower
f o r one o r more n o t c h e s u n t i l a
11. F l o a t n e e d l e jams normal r a t i o o f mixing has been
-P o l i s h t h e f l o a t n e e d l e and through reached.
b o r e s i n t h e v ~ l v ebody, 4. Needle j e t and p a r t i a l - l o a d n e e d l e
-Check t h e v e l v e f o r f o r e i g n p a r t i c l e s , m m (more than 20,000 km of road
operation)
-Replace t h e f l o a t n e e d l e and t h e
v a l v e s e a t f o r new p a r t a . - Replace t h e two p a r t s by new ones.
5. F l o a t v a l v e l e a k y
7.2.2. Too Rich a Mixture Cause: 1) v a l v e d i r t y ,
The f a c t t h a t t h e f u e l - a i r mixture becomes 2) f l o a t needle worn
t o o r i c h i s i d e n t i f i e d by t h e f o l l o w i n g - Clean -the f l o a t v a l v e ,
features:
1. S t a r t i n g the engine i s d i f f i c u l t ;
- it' a new f l o a t n e e d l e .
2. Engine power o u t p u t drops w i t h i n c r e a s -
Central f l o a t distorted
remains open t o o wide
- f l o a t valve
i n g t e m p e r a w r e of t h e e n g i n e ;
3. High f u e l consumption;
- Adjust t h e c e n t r a l f l o a t .
Main j e t t o o l a r g e
tt
4. I n c l i n a t i o n s i m u l a t e a "four-
- Use a n o t h e r main j e t w i t h t h e same
s t r o k e engine ;
dimension p r i n t e d on i t ( j e t s with
5. Sparking-plug w i t h t h e e p e c i f l e d t h e same nominal dimension d i f f e r
calorific v a l u e i s o i l e d up; bv t h e i r t o l e r a n c e s ) .
6. Formation of smoke i n t e n s e and v i s i b l e - I? t h i s f a l l s t o be a remedy, use
i n t h e s t a t e when t h e engine has t h e next smaller jet.
o p e r a t i n g temperature. 3. Packing i n s t e r t i n g p i s t o n damaged
- Replace t h e packing by a new one.
F a u l t s and d e f e c t s which cause t h e 9. S p r i n g f o r s t a r t i n g p i s t o n has an
m i x t u r e t o become t o o r i c h and i n s u f f i c i e n t pre-t ension
t h e i r remedies:
1. Dry a i r f i l t e r i s too o l d (more than
- Replace t h e s p r i n g by a new one.
10,000 km of road o p e r a t i o n ) 10. Sheath of t h e c a b l e c o n t r o l f o r t h e
- Replace t h e a i r f i l t e r by a new one.
s t a r t i n g d e v i c e has no c l e a r a n c e ;
consequently, t h e s t a r t i n g p i s t o n
2. Dry a i r f i l t e r has become wet cannot s e a l p r o p e r l y t h e s t a r t i n g
mixing t u b e
Cause: A i r f i l t e r c a s i n g n o t t i g h t
w a t e r has e n t e r e d
- - Adjust t h e c a b l e c o n t r o l s h e a t h
- Dry t h e a i r f i l t e r , r e p l a c e i t ,
so t h a t a c l e a r a n c e of 1 mm i s
given.
i f required.
Fig. 197. Range of S p e c i a l Tools f o r t h e ETZ 250
8.1. L i s t of S p e c i a l Tools
Spare Drawing
Reference
.
lio No.
1. E n ~ i n eAeeemblina Device
22-50.014
T e l l 8 m l t F e e t s i t z elngepaDt ='
Part 8 mounted with t i g h t f i t
Nominal dimension Allowance
Parts 4/5
Part 6
Part 7
Einzelheit X PaBmaD =
1 2 : 1 = Nominal d imene ion
D e t a i l X, s c a l e 2 : l
4. F i t t i n g d e v i c e f o r r u b b e r bear in^ i n s w i n p f o r k
22-51.445
- - -
St 38 b-2 070x20
c 45 $ 23 X 170 nickel-plated
S t 38 b-2 K 32 X 125 nickel-plated
- 103 -
5. Ex~andingmandrel f o r wheel bearinn ( H 8-820-3) 8.9-99.090
5oagh S i z e Remarks
7 St Zu -A 2 2 X 88 X 205
instrument f o r end lay o f c l u t c h driver (05-ML 13-41 89-99.117
1.
pipe 28 X 4 S t 35 hb 30 long
crankshaft end 05-43.058 t o be employed
S t 38 b-2
S t 38 b-2 l0 X
26
9 x40 1 welded part
S t 38 b-2) 0 45 X 45
c l i n d r i c a l pin
B
7 m6x80 1 welded
part TGL 0-7
c lindrlcal pin
g m 6 x 6 0 TGL 0-7
c l r c l i p 22 X. 2 TGL 0-9045'
hexagon-head ecrew
M8x50 TGL 0-933
hexagon nut M 8
Part 1
Part 2
e n t f e t t e t , phosphatiert=
degreased, phoephatieed
PaBmsd = nominal dimension AbmaB - allowance
Part 5
Hartltlten P brazing
vrwl
-.-. . - -.
: r 4
, \ , I , '
13. Anchor ~ u l l i n nscrew (02-MW 39-4) 89-99.026 ?
a l l e unbemaoten = f o r a l l r a d i i without
Radien R = 1 mm dimension R = 1 mm
. -- - -...
Part Quantity Deecription &t e r i a l Rough Size ~emarka
18. F i t t i n g t o o l f o r ~ a c k i nr i~n g ( 3 0 x 7 2 ~ 7 )29-50.406 (dynamo s i d e )
) welded part
1 3
3 1 pipe 28 X 6 St 35 hb 50 long TGL 1 4 100
) welded part
1 3
SchweiBnShte: welding seams Fraser 50 = m i l l i n g c u t t e r 50 i n d i a m e t e r
p l a n e n b i s Poe. 8/9 = t o be faced u n t i l i t e m s
Auflage h a t 8/9 make c o n t a c t
ohne schwelDnaht = without welding seem
kontrollbearbeitet = control finished
4 \ Bund entgraten
F o r t h i s t o o l a l s o u s e s p e c i a l p l i e r s 05-Msl 141-4
Swing-fork b e a r i n g b o l t
( s p r i n g s f u l l y extended)
Wiring diagram of t h e
e l e c t r i c a l aystem YIZ 6 V / 72 V