Puch 1980 MAGNUM II Service Manual Download

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1977mopeds.com

1.800.965.1977

Summary of Contents for 1980 MAGNUM II

Page 1: ...1977mopeds com 1 800 965 1977 ...

Page 2: ...per equipment including oll special workshop tools os detailed in our list of special tools The workshop manual is the base for appropriate and economical repairs however it is of full value only combined with the Service Bulletins by which any alterations and improvements ore publicized We sincerely hope that this manual will prove of invaluable assistance both for the workshop and cus tomer alik...

Page 3: ... 80 81 MODELS THIS SERVICE MANUAL COVERS THE FULL RANGE OF 1980 81 MODELS AS LISTED BELOW MAXI MAXI LUXE NEWPORT I 1 SPORT MK E l MAGNUM I 1 MAGNUM MK I 1 1977mopeds com 1 800 965 1977 ...

Page 4: ...IL PUMP DRIVE 65 ASSEMBLE OIL PUMP DRIVE 67 ASSEMBLE ENGINE 2SPEED 3 INSTALL ENGINE 2 SPEED 80 ENGINE IDLE 83 OIL TANK FUEL TANK 84 FRONT FORK MAXI 85 FRONTFORK MAGNUMMKII 90 SHOCK ABSORBERS REAR SWING ARM 95 REAR SWING ARM 96 REAR WHEEL BRAKES 97 BRAKES 98 BRAKES HUBS 99 HUBS 100 IDLER GEAR DRIVE SPROCKET 101 SPOKINGWHEEL 102 BALANCING 105 ELECTRICAL EQUIPMENT 106 BREAKER POINTS 109 IGNITIONTlMlN...

Page 5: ...an air filter Change gearbox 011 Check spark plug A hook for this symbol to point out important safety precautions It means Attention Become alert Frequency in miles km I First 300 480 x x x x x x x Decarbonize engine Clean Exhoust baffle Retighten screws nuts inc head nuts Clean fuel valve and lines Clean carburetor filter screen float chamber Idle speed adjustment Check ignition timing Adjust cl...

Page 6: ...ve the stand spring Remove threa hexagon bolts Remove stand Grease both halves of the stand pivot with a good automotive lithium base grease Adjusting Screws and Pirot Bolts Lubricate adjusting screws tensioning screws and pivot bolts on control levers with o few drops of oil MAINTENANCE Please contact an authorized PUCH Dealer for work you do not wish to carry out The agent will be plea ed to adv...

Page 7: ... sur face lightly with motor oil Turn over the engine a few times tamoke sure it cranks easily Clean the mu ting sudaces with a dean rag Replace the cylinder head and tighten the four cylinder head nuts Be sure to tighten two cylinder head nuts diagonally ocross from each other before tightening the other two nuts 7 ftJEbll0 Nm Exhaust port In order to clean the exhaust port remove the exhaust pip...

Page 8: ...e operations on the carburetor are outlined under CARBURETOR page 57 Cleaning the main jet needle jet and float chamber 1 Close the fuel valve 2 Remove the left hand chain guard L 7 0 f r m e r 3 Remove the air cleaner 4 Loosen carburetor clornping screw see page 10 1 i L _ 3 1 f e r screen 5 Pull the fuel pipe from the carburetor aemper PIP 6 Turn the carburetor with its float chamber line bottom...

Page 9: ...k for proper throttle cable slack O N in l O mm In sufficient cable slock will hold the throttle partially open and the idle adjusting screw wilt not function If necessary loosen the cable locknut 4 and turn thehthrottle cable adjuster 5 to the right to increase cable slack Retighten the cable locknut Exploded view of the carburetor Intake manifold Carburetor body Throttle slide stop screw Idle sc...

Page 10: ... 45 rnm for 1 speed 016 020in 10 40 0 50 mm for 2 speed To odjuste the breaker points gap loosen the set screw slightly insert a screwdriver blade into the s l o t on the breaker plate and turn the screwdriver slightly until the correct gap is obtained Tighten the set screw and check that the gap has not altered rSEST1NO SCREW 2 speed Adjusting the starting lever After the first 300 miles 480 krn ...

Page 11: ...he locknut Brake linings Pry plastic inspection pjugs from wheel hub Disconnect brake cable from brake lever Insert a feeler gauge between brake drum and brake lining Gap should not exceed 04J in 1 2 cm ot either inspection hole If gap exceed this meosure ment refer to section BRAKES on brake replacement not operate your unit FRONT WHEEL REMOVAL Unscrew speedometer cable from hub Loosen locknut on...

Page 12: ...e wheel To replace wheel reverse the above procedure see page 97 Be certain to readjust the brake before riding REPLACING HEADLIGHT Remove headlight rim retaining screw s and remove reflector Turn bulb to the left and remove see Technical Data sheet forsize of bulb REPLACING REAR LIGHT BULB AND STOP LIGHT BULB Remove the two screws that hold the lense Remove bulb ond replace see the Technical Data...

Page 13: ... tube during C assernbfy 3 Make certain that valve stem is protruding squarely though the rim At this point it may be desirable to let some air out of the inner rube to make the next step easier Replace Tlre Onto Rum 4 Starting in the area of the valve stem press the other tire beod onto the rim using both hands Work your way to the opposite side of the wheel Be careful to not pinch the tube betwe...

Page 14: ...EXPLODED ENGINE VIEW 1977mopeds com 1 800 965 1977 ...

Page 15: ...EXPLODED ENGINE VIEW 1977mopeds com 1 800 965 1977 ...

Page 16: ...EXPLODED ENGINE VIEW 1977mopeds com 1 800 965 1977 ...

Page 17: ...EXPLODED ENGINE VIEW 1977mopeds com 1 800 965 1977 ...

Page 18: ...NG USAGEJKIT CONTENTS 24 905 6 41 101 2p p 906 6 21 001 0 P06 6 22 002 0 Spring Pliers PUCH l o w Scale Ohmmeter PUCH Ignition Jester o o O O O O O 0 0 0 0 0 0 0 0 0 0 1 0 1 0 Seperate Order Only 0 0 1977mopeds com 1 800 965 1977 ...

Page 19: ...SPECIAL TOOLS 1977mopeds com 1 800 965 1977 ...

Page 20: ...SPECIAL TOOLS 1977mopeds com 1 800 965 1977 ...

Page 21: ... h thread 2 Clutch retaining nut I speed Kickstand bearing bolts Manifold mounting boltsJnuts Frame torque specification speed Front rear axle nuts 20ft lb 27Nm Rear shock top 27ftllb 23Nm Rear shock bottom 9 fttlb 12Nm Rear fork bearing 29 Wlb 40 Nm Handlebar bolts 10 32ft lb 15 16 Nm Crank wedge nuts 5ft lb 7 Nm Fender bracket hardware 4ftlIb 6 Nm Steering head nut 30 ft ib 41 Nm Fork tube clamp...

Page 22: ... ENGINE REMOVAL Place the moped on a bench Secure in position on bench with tie down straps Remove left and right hand chain guards Loosen clamp screw on air filter assembly and remove 1977mopeds com 1 800 965 1977 ...

Page 23: ...ap to Off position Disconnect fuel supply hose Loosen carburetor clamp screw and twist carburetor to the left and remove from intake manifold Disconnect drive chain by removing the master chain link 1977mopeds com 1 800 965 1977 ...

Page 24: ...from lever 2 speed automatic Loosen clamp screw on starter lever on the left side of handlebar Pull up protective plastic cap from the adjusting sleeve Unscrew starter cable nut from adjusting sleeve Do not loosen adjusting sleeve nor the starter cable adjusting nut Remove suppressor plug from spark plug On 3 speed models remove ignition coil from engine 1977mopeds com 1 800 965 1977 ...

Page 25: ...01 is not being used place the rear wheel in a support stand MAGNUM MK If Remove oil supply line from oil pump and block off line to avoid oil drainage from oil tank Remove the three 3 engine mounting bolts and withdraw engine from frame 1977mopeds com 1 800 965 1977 ...

Page 26: ...DISMANTLE ENGINE I SPEED Place engine in engine holder 905 6 36 108 0 which is mounted in a vise Remove intake manifold Disconnect the kick stand spring 1977mopeds com 1 800 965 1977 ...

Page 27: ...TLE ENGINE 1 SPEED r Unscrew the kickstand bearing bolts bearing cup and kick stand Remove generator cover Lock flywheel with locking tool 905 0 16 101 2 and unscrew flywheel nut 1977mopeds com 1 800 965 1977 ...

Page 28: ...2 Remove flywheel and woodruff key from crankshaft Unscrew the stator plate screws remove the stator plate assembly and pull out the generator wiring including the rubber grommet After removing the cylinder head nuts lift off the cylinder head and cylinder head gasket 1977mopeds com 1 800 965 1977 ...

Page 29: ...DISMANTLE ENGINE I SPEED Remove cylinder and base gasket Remove wrist pin retaining rings Push out the wrist pin and remove piston 1977mopeds com 1 800 965 1977 ...

Page 30: ...er Mount engine in engine stand so that the lower crankcase holf is facing upward Remove all crankcase screws Slightly tap the upper crankcase half with a rubber hammer to break sealant between the two housing halves and remove top holf 1977mopeds com 1 800 965 1977 ...

Page 31: ...PEED Lift primary drive assembly from lower crankcase half Remove crankshaft with clutch assembly DISMANTLE CRANKSHAFT Remove large retaining ring from clutch drum and lift off pressure plate 1977mopeds com 1 800 965 1977 ...

Page 32: ...e to clamp only the clutch side crank web or damage to crankshaft is unavoidable Use special puller 905 6 34 109 0 to remove centrifugal clutch from crankshaft Remove clutch hub and woodruff key NOTE Clutch assembly may also be dismantled with engine mounted in moped Remove circlip shims clutch drum and bushing 1977mopeds com 1 800 965 1977 ...

Page 33: ...being removed or crankshah damage will occur Dismantle the primary drive as illustrated Remove circlip drive sprocket circlip seal locating ring bearing and inner circlip Remove all traces of sealing compound from crankcase fhor oughly clean all parts with degreosing solvent and visually inspect parts for wear and damage 1977mopeds com 1 800 965 1977 ...

Page 34: ...is being app lied for all crankshafts CONNECTING ROD ALIGNMENT Measuring and straightening can be accomplished if the crankshaft is dismantled or if still fitted to the engine after removing the cylinder and piston With a pair of steel blocks accurately ground to equal height measure the wrist pin with a feeler gouge as illustrated Straightening of the connecting rod can be carried out by means of...

Page 35: ...checked as well Three different faults may occur I Crank webs are out of true 2 Crank journal i s bent so that the webs are no longer para lel but oblique outward 3 Crank journal is bent so that the webs ore no longer paral lel but oblique inward 1977mopeds com 1 800 965 1977 ...

Page 36: ...ol indicators to zero Rotate crankshaft downwards one dial indicator will register plus the other minus Mark the position of the maximum reading an the crankshaft web Remove crankshaft from centering points Straighten crankshaft by hitting the maximum reading mark with a copper or plastic hammer Repeat testing with dial indfcator until the crankshaft is within the permissible tolerance which is 00...

Page 37: ...the readings taken show that the crank webs are bent inwards plus eading the crankshaft is straightened by inserting a tapered bar in the narrow marked position If the crank webs are bent outwards minus reading the crankshaft is straightened by hitting the flat side of the crank web Repeat the procedure until the out o f batance is within the permissible limit which is MX 8 0010 in 0 020 0 025 mm ...

Page 38: ...condition Before assembling an engine always check the small end bushing for wear If excessive wear is noticeable replace small end bushing SMALL END BUSHING fitting limits Wear limit 473 474 in 475 in 12 008 12 G20rnm 12 025mm For correct wrist pin assortment and sizes see assorting table on page 40 REPLACING SMALL END BUSHING fPni Use special tool 905 6 33 105 0to remove and replace bush Ing NOT...

Page 39: ...e to centralizing nut Adjust cutting edges of reamer to bushing size remove from guide sleeve and tighten adjustment nuts on reamer Apply ing oil to reamer insert cutting end of reamer into guide sleeve start reaming procedure until correct wrist pin bushing clearance is achieved Wrist pin and piston fit is matched together and coded as follows Wear limit yellow or blue dot inside wiston 475 in 2 ...

Page 40: ... 37 965mm 1 4943 in 1 4947 in Group 1 2 Cylinder Diameter 1 4961 in 7 4964 in 38 001 m m 38 038 rnm 1 4964in 1 4967in 38 008 mm 38 016 mm HI TORQUE CYLINDER SORTING TABLE Group 1 2 3 4 5 Cylinder diameter 1 4950 1A954 in 37 975 37 985 rnm 1 4954 1 4958 in 37 985 37 995 rnm f 4958 3 4962 in 37 995 38 005 rnm 1 4962 1 4966 in 38 005 38 015 mn 1 4966 14970 in 38 015 38 025 mrn Piston diameter 1 4938 ...

Page 41: ... 261 mm Measuring the cylinder The cylinder bore is measured with a bore gauge and a bore measuring adapter both items are commercially avoiloble Measuring procedure Adjust bore gouge by means of the stop measure to the no minol bore diameter The bore must be measured at six positions once parallel with and once diametrically opposed the wrist pin at the three positions indicated in fig The specif...

Page 42: ...eve 350 1 70 012 0to install flywheel side main bearing on crankshaft Lubricate oil seal and install crankshaft seal sealing lips facing outward on clutch side of crankshaft Again use installation sleeve 350 1 70 012 0to press clutch side main bearing on crankshaft with the locating ring groove facing the outside 1977mopeds com 1 800 965 1977 ...

Page 43: ... Centrifugal clutch must be replaced when linings are worn and limit pins on shoes prevent drum contact The clearance between pressure plate and face lining of centrifugal clutch should be between 012 Om in 0 30 030 mm The end float of the clutch drum must be between 04 008 in 0 10 0 20mm This clearance is achieved by variaus rile of upper and lower shims 1 and 2 The correct adjust rnent procedure...

Page 44: ... would give the required thickness of the lower shim EXAMPLE Primary gear circlip gap 047 in 1 20 mm Plus required gap 012in 0 30mm Lower shim required 059 in 1 50mrn NOTE tower shim 945 669 in 24117 mm is ovoible 0 s follows 043in 0 51 in 059 in 067 in 1 10mrn 1 30 rnrn 1 50 mrn 1 7 0m m Then lift clutch drum and measure the gclp between primary gear and circlip on crankshaft not circlip on beari...

Page 45: ...90 rnm NOTE Upper shim 866 591 in I 5 mm is as follows 043 in 051 in 059in 067 in 070in 073in 075in 077 in 079 in 083 in 087in 1 10 rnm 1 30 mm 1 50 m m 1 70 rnm 1 80 mrn 1 85 mrn 1 90mm 1 95mm 2 Wrnm 2 10mrn 2 20mm Once the required shims are established remove clutch as sembly and reassemble with shims Torque nut to X ft lb 27Nm NOTE Do not forget woodruff key Replace pressure plate and secure w...

Page 46: ...embly in housing half Reassemble primary drive lubricate seal and install with sealing lip facing outward Place assembly in crankctlse half f 1 NOTE Assure that locating rings on crankshaft clutch side main bearing and primary drive between bearing and seal have their gaps face straight up A Sparingly apply sealing compound non hardening to erank case joint fit crankcase half into place and torque...

Page 47: ...t a new cylinder base gasket into place lightly oil piston and cylinder wall and replace cylinder Be sure to align ring gap to their respective locating pins NOTE The exhaust port of the cylinder should face drain plug side of engine Place proper size cylinder head gasket where applicable into position Fit head and washers and torque cylinder head nuts to 7ft lb 10 Nm 1977mopeds com 1 800 965 1977...

Page 48: ...y free from domage Inspect contact breaker points for burning pitting or wear and replace if necessary Inspect coils and wires for cuts and loose connections Feed magneto wires through crankcase opening and replace rubber grommet Install generator stator plate assembly so that the locating screws are in the center of the locating holes NOTE Ensure no wires ore squeezed between stator plate assembl...

Page 49: ...e 905 0n16 101 2t o lock flywheel and torque nut to 25 ftJSb 35 Nm Before replacing gene rator cover set ignition timing see page 1 1 0 InstolI a new gasket and replace clutch cover Torque screws to 6 ftJlb 8 Nm Replace kickstand Torque bearing shell retaining bolts to 6 ftllb 8 Nm 1977mopeds com 1 800 965 1977 ...

Page 50: ...ASSEMBLE ENGINE 1 SPEED Fit kickstand return spring Fit new gasket and intake manifold 1977mopeds com 1 800 965 1977 ...

Page 51: ...INSTALL ENGINE 1 SPEED Place engine in frame and torque engine mounting bolts to 23 ftllb 32Nm Replace ignition coil Fit starter cable 1977mopeds com 1 800 965 1977 ...

Page 52: ...e clutch shaft 6 check housing and shaft for excessive wear Always replace On ring 7 and sea ring 4 Use reverse procedure on re assembling the shaft When fitting the starter lever ensure the lever is installed correctly Before the starter clutch engages fully the lever should form a right angle with the starter cable Reconnect electrical wires at junction block codes Match color 1977mopeds com 1 8...

Page 53: ...n is q in 2cm To adjust tension loosen axle nuts and tighten or loosen rear adjuster nuts Once the drive chain is properly adjusted tighten axle nuts Make sure i wheels ore in alignment for further information see page 93 Replace carburetor install fuel supply hose and fit air filter ossembly aDo not push intake hose too deeply into filter assembly as this could cause air flow restridion 1977moped...

Page 54: ... 4 fl oz 170 cc until fluid is level with filler hole aUse only Type F Transmission fluid Other types 04 fluid may dissolve clutch friction material Adjust starter cable with adjusting screw I Free play at the starter lever measured at the end of the L A lever should be 4 in 2cm 1977mopeds com 1 800 965 1977 ...

Page 55: ...t idle speed and throttle cable Start engine and run at moderate speed until operating temperature is reached Adjust idle speed between 800 1200 rpm Adjust throttle cable slack to 040 in I mm on adjusting screw 2 and tighten lock nut 1 4 1977mopeds com 1 800 965 1977 ...

Page 56: ... with compressed air Ensure that the seating of the inlet needle is correct CARBURMOR OPERATION TROUBLE SHOOTING TIPS The numbers quoted in the brackets on page 58 refer to the above illustration The carburetor O n your MOPED is o Bing variable venturi slide type carburetor The term variable ven uri comes from the fact that the slide varies the amount of the restriction of air through the throat o...

Page 57: ...t bowl 2 In order to start cr cold engine a very rich fuel air mixtures is required A rich mixture would be 1 part of fuel to 5 parts of air or 5 1 This can be accomplished by either increasing the amount of fuel or decreasing the amount of air In the Bing carburetor there is a choke plate ref no 25 which when pushed down cuts off most of the airflow through the throat of the carburetor and thus c...

Page 58: ...rter plate Drain transmission oil MOTE MAGNUM MU II disconnect oil supply line from oil pump and block off supply line to ovoid oil drainage from oil tank DISMANTLE ENGINE Follow the same dismantring procedures as outlined on pre vious pages Remove dutch cover gasket locating sleeves main shaft and clutch drum shims and roller retuiner thrust plate on main shaft Inspect bearings inside clutch cove...

Page 59: ...ft aLeft hand thread NOTE By loosening retainer nut and spinning first speed gear the nut and roller pack will remove as a unit Remove clutch drum Open lock washer place locking device 905 6 36 110 2 over centrifugal clutch and interlock with tool 905 6 36 109 2 and remove retainer nut 1977mopeds com 1 800 965 1977 ...

Page 60: ...DISMANTLE ENGINE 2SPEED Remove first speed centrifugal clutch Remove clutch spacer Lift off second speed centrifugal clutch 1977mopeds com 1 800 965 1977 ...

Page 61: ...DISMANTLE ENGINE 2SPEED Remove main shaft and second speed driving plate With special pliers 905 6 41 101 2 remove retainer spring 1977mopeds com 1 800 965 1977 ...

Page 62: ...embly table 905 0 31 101 2and unscrew all housing screws Separate housing halves Lift crankshaft from lower crankcase half Remove gasket and both housing dowels NOTE During engine overhaul it is important to replace all seals Press out drive shaft from left hand housing half and remove seal If bearing needs replacement remove circlip and bearing 1977mopeds com 1 800 965 1977 ...

Page 63: ...bushing is twisted and the oil supply holes are blocked or there are noticeable signs of abnormal wear remove the bushing and replace with MAXI Uptoserialno 5334443partno 321 1 12 617 3 From serial no 5334444 part no 321 2 12 617 3 MAGNUM Up to serial no 1602230 part no 321 1 12 617 3 From serial no 1602231 part no 321 2 12 617 3 After r rnovingthe left hand crankshaft oil seal drive out main bear...

Page 64: ...unit It is a factory metered unit to obtain the correct lubrication ratio for the engine It delivers 1 35 fl or 40 cc at I500 rpm per hour Testing oil pump delivery Fill gas tank with regular gasoline pre mix Remove oil pres sure hose from intake manifold place hose in a measuring container Run engine for 4 112 min at 3500 rpm Oil pump should deliver 0338fl oz 003 10 cc t 0 lO Repeat test at least...

Page 65: ...cages 905 6 34 113 0 a Do not lose drive gear locating pin I Remove crankshaft oil seal and drive shaft guide sleeve from housing half NOTE Always replace OM rings on guide sleeve to avoid leakage from crankcase Remove oil pump drive shaft and check fbr wear Do not lose thrust washers of lower end of drive shaft 1977mopeds com 1 800 965 1977 ...

Page 66: ...g pin are in line Place special plate 905 0 33 104 1between crank webs to I I avoid damage to crankshaft Use installation sleeve 350 1 70 012 0to install oil pump drive gear Oil pump drive shaft must be placed in crankcase before instolling the guide sleeve Before installing the drive shaft guide replace the t o 2 0 rings on guide sleeve For easier installotion lubricate both 0 rings 1977mopeds co...

Page 67: ...e half Crankshaft and drive shaft seals are pressed into position with the sealing lips facing inwards using tool no 905 6 33 112 1 A double lip seal is used in the left hand generator side crankcase half Lubricate seal lips before installation With using this special seal installer the correct installation position will be obtained 472 in 12 mm down from the upper edge not MAGNUM MK It O n MAGNUM...

Page 68: ...and the special plate 905 0 33 104 1 between the two crankshaft webs When press ing on the bearing race the bearing identification marks should be located outboard Crankshaft end float O W 006 in 0 05 0 15 mm Insert the crankshaft with bearing pressed into position in the right crankcase half and locate a new gasket in position I over the hollow dowels When installing the crankshaft use installati...

Page 69: ...e between the measuring sleeve and the ground bearing stop on the cronskhoft journal by using shims These shims are available in the thickness of 002 Om 008 012 in 0 05 0 10 0 20 0 30mm magneto side 004 008in 0 lO and 0 20rnrn clutch side Adjustment hint The specified end float of 002 006 in 0 05 004in 008in 0 15 mm is obtained when the crankshaft slightly touches the gauge with the gauge pressed ...

Page 70: ...ide and no 350 1 0 012 0 generator side place special plate no 905 0 33 104 1 between cronk webs to prevent damage to crankshaft Place protecting sleeve 905 6 31 208 1over crankshaft clutch side and install s h f tin right hand housing holf Fit both hollow dowels and place new gasket on housing F t 1 I I If bearing has been removed install bearing and circlip In stall seal and drive shaft in left ...

Page 71: ...ase halves to gether Do not force halves together Again rotate crankshaft to ensure correct installation Place engine into engine holder 905 6 36 103 Q Replace engaging plate into housing and screw the adjusting nut into the starter cable NOTE Starting clutch adjustment will be carried out later 1977mopeds com 1 800 965 1977 ...

Page 72: ...ASSEMBLE ENGINE 2 SPEED Install starter plate spring washer and circlip Install engaging plate return spring using tool no 905 6 41 101 2 Place thrust washer on crankshaft 1977mopeds com 1 800 965 1977 ...

Page 73: ...Install second geor driving plote and main shaft in housing Place thrust washer on main shaft assembling threads and second speed install screws geor damper use Loctite from inside facing outward 1977mopeds com 1 800 965 1977 ...

Page 74: ...ll second speed centrifugal clutch spring out cover plcte facing inward Replace spacer with the cone shaped side facing inward Install first speed centrifugal clutch spring cover plate fa cing outward 1977mopeds com 1 800 965 1977 ...

Page 75: ...clutch and second gear main shaft using special tools no 905 6 36 1 10 2 ond W5 6 36 109 2 Torque nut ta 22 29 ftllb 30 40 Nm and secure lock nut with the locking tab washer Remove clutch locking tool Lubricate bushing on end of crankshaft and install clutch drum 1977mopeds com 1 800 965 1977 ...

Page 76: ...1977mopeds com 1 800 965 1977 ...

Page 77: ...0is used to mec sure the end float between the first speed gear main shaft and the clutch cover Fit a new gasket to the cover place measuring device firmly on top of the gasket Sl dedown the measuring sleeve to contact the inner surface of the bearing Hold measuring device firmly against gasket and bearing and lock measuring sleeve In that position Now invert and place measuring tool over the mcin...

Page 78: ...asket End float is between 002 010 in OD5 0 25mm Bloce engine in special holder 905 6 36 108 0 When installing new bearings in clutch cover heat cover to appr 170 F 8V C and press bearings into place Fit new gasket instoll both hollow dowels and fit clutch cover Torque screws to 6 ft lb 8 Nm Install drive sprocket on main shaft and replace circlip Cont nue to assemble engine as outlined on previou...

Page 79: ...roperly placed with the closed end pointing in the direction of chain travel MAGNUM M K ll lnstall oil pressure line between manifold and oil pump Con nect oil supply line to oil pump If an air bubbIe is visible in the oil supply line between oil tank and and oil pump bleed by off squeezing the oil supply line Ensure bleeding procedure is earried out each time hose has been removed from oil tank o...

Page 80: ...d clearence of 008 012 in 0 20 0 30 mm3 between the starting clutch and the engaging plate No I identificies the starting cable with securing nut No 3 identfficies the sleeve Reconnect s t a e r cable 1 to adjustment nut 2 aDo not turn adjustment nut on engine only the secu ring nut on the starter cable r To replace starter cable remove clamp screw on starter lever and remove cable Free travel adj...

Page 81: ... installing air filter assembly clean metal filter element with gasoline or similar cleaning material blow completely dry with compressed air and spray filter element lightly with engine oil F 1 A FIT EXHAUST PIPE AND SILENCER Ensure t o use a new gasket between exhaust pipe and cylin 2 der 4 NOTE Do not make any alterations on the exhaust system h 3 or poor operating conditions may result 1977mop...

Page 82: ...ient cable slack will hold the throttle partially open and the idle adjusting screw will not function If necessary loosen the cable locknut 1 and turn the throttle cable adjuster 2 to the right to increase cable slack Retighten the coble lock nut IDLE ADJUSTMENT Start engine and run at moderate speed until operating tem perature is reached Adjust idle speed to 000 1200 rpm by turning idle adjustme...

Page 83: ...ting oil supply hose ensure there are no air bubbles visible in the oil supply hose Fuel tank MAGNUM To remove fuel tank remove the seat mounting nuts and lift seat of fmme The fuel tank is mounted on rubber pads in front and reor Turn fuel tap to Off position disconnect fuel cross over line and the line from the fuel tap Lift the tank to the rear and remove 1977mopeds com 1 800 965 1977 ...

Page 84: ... front wheel Remove front fender and heodlamp Remove the two 2 top bridge hexagonal bolts Pull both sliding tubes down and out of fork tubes Remove steering stem nut lift off top bridge and handlebar assembly and place over frame Remove lower steering stem nut and pull down bottom bridge assembly 1977mopeds com 1 800 965 1977 ...

Page 85: ...e bushing New Wear limit 1 06 in 0 1 04 in 26 95 mm 26 5 mm 3 Inspect all parts and replace if necessary Check springs for wear and replace ifweak SPRING DIMENSIONS Wire Diameter I18in 3 rnm Spring length New 7 24 in 184 mm Wear limit 690 in 175 mm 1977mopeds com 1 800 965 1977 ...

Page 86: ...ce locating tab on inside of bushing in position on lower sliding tube Insert spring in lower tube and rubber stop inside spring Place damper rubber over spring end and screw on top threaded coupling Knock out steering head bearing cups and install with spe cial tool 905 6 34 501 0 1977mopeds com 1 800 965 1977 ...

Page 87: ...idge NOTE Do not tighten lower nut front fork must turn easy but no play noticeable Replace top fork bridge torque steering head nut to 30ftllb 41 Nm Recheck steering head bearing for clearance Lubricate guide bushings ond insert in lower fork tubes 1977mopeds com 1 800 965 1977 ...

Page 88: ...der and front wheel Adjust headlamp Adjusting the headlamp Adjust the headlight with the machine running Correct od justment is to have the center spot of the beam 20 inches above the ground measured with the moped positioned 20 feet from the focus point 1977mopeds com 1 800 965 1977 ...

Page 89: ... tubes are worn or bent replace as a unit To replace spring or rubber stop inside spring unscrew spring from coupling Spring length New 7 68 in 195 mm Wear limit 7 28 in 185 mm Rubber stop length 4 72 in 120 mm Wire diameter 14 in 35 mrn ASSEMBLING Assemble the front fork in the reversed order t a dismantling Lubricate lower sliding tubes with grease prior assembling Torque upper bridge bolts to I...

Page 90: ...ving the two 2 upper tube clamp bolts arrow Remove the top fork bridge both heodlamp carriers and sealing bands Pull down both tube assemblies NOTE If tubes are very tight in lower fork bridge replace sealing plugs in inner tube assemblies and drive out tube assemblies using o rubber or plastic hammer NOTE Before proceeding further drain off oil from tubes 1977mopeds com 1 800 965 1977 ...

Page 91: ...to separate the upper and lower tube assemblies Inspect oil parts for wear and replace if required NOTE Alwoyr replace lower fiber washer 0 ring guide rino on wiston and seals in sliding tubes to ensure perfect I sealing bf hydraulic fork ASSEMBLING install seals in lower sliding tubes 1977mopeds com 1 800 965 1977 ...

Page 92: ... rod place a new fiber washer over rod end Place rubber bellows over tube assemblies and insert tubes in lower fork bridge NOTE Do not clamp tubes in lower bridge tilt top bridge is installed Place rubber sewling bonds p n 321 1 30 859 1 over upper tube breather holes NOTE There rubber sealing bonds prevent the drainage of oil from fork when moped is layed over on its side I Place both headlomp ca...

Page 93: ...y SAE 20 30motor oil Spring length New 16 69 in 424 mm Wear limit 16 29 in 414 mm Wire diameter 14 in 33 mm Replace both top sealing plugs with washers Ensure to replace both 0 rFngs for perfect sealing Torque both plugs and steering head nut to 20 ftllb 27Nm Retighten lower fork bridge clomp screws to 40 ftllb 154 Nm 1977mopeds com 1 800 965 1977 ...

Page 94: ...UM M K If This shock absorber is a true hydraulic unit but not service able if faulty replace as a unit REAR SWING ARM Remove engine accorcling to repair manual Remove rear axle nuts 1 2 1 loosen chain tensioners f rear broke cable adjustment 4 disconnect cable from backing plate and actating lever 3 remove rear wheel Remove lower shock absorber mounting hardware 1977mopeds com 1 800 965 1977 ...

Page 95: ...ifference is measured the swing arm bearing of the frome is distorted A distorted frame cannot be aligned but P must be replaced Further check swing arm rubber bush and both plastic bushes of pedal shaft FITTING THE SWING ARM Proceed in reversed order to dismantling NOTE To prevent excessive pre stressing excess wear of the rubber bearing the four 4 bearing cup bolts should only be torqued after m...

Page 96: ...k on top as it tends to distort the reading REAR WHEEL When refitting the chains take care that the tension is correct and the connecting links ore properly ploced with the closed I end pointing in the direction of chain travel r The designed slackness of the driving chain midway between I L the sprockets should be 3 4 2cm Bonded linings are used on all brake shoes fitted to our machines If lining...

Page 97: ... cam must be cleaned with gasoline or o simi ar degreasant MAG WHEELS Install return spring with a screw driver after brake shoes have been positioned on backing plate Remove the inspection plugs and insert a flat feeler gauge between the brake drum and the brake lining The gap should not exceed 047 in 1 2mm at either inspection hole If it does the brake linings must be replaced Disconnect cable b...

Page 98: ...are greased The original grease filling is sufficient for approximately 3600 miles 5800 krn use After this hubs must be dismantled cleaned and regressed Use lithium base grease 8 a 8 Ball bearings are not caged Do not lose any Wear limit 3 188 in 81 mrn MAC WHEEL FRONT Follow the same procedure as described with the spoke LE LEU hub Brake drum diameter New 3 149 in 80 mm 1977mopeds com 1 800 965 1...

Page 99: ...oceed with bearing rernoval installution as fellows a Remove rear wheel lift brake backing plate off hub and pull axle out towards brake drum b Push bearing spacer 2 to the side to partially clear inner bearing race inside the hub c Use punch to knock out one bearing at a time Bearing installation steps are a Press one beoring into hub insert spacer tube and press in other bearing b Insert axle fr...

Page 100: ...le com letehub to realace idler sprocket n i c r e w complete spreeket with speeiai tool 905 6 35 404 0 and replace if required DRIVE SPROCKET To replace drive sprocket remove mounting bolts and replace if required Torque nuts to 7 ft lb 10 Nm 1977mopeds com 1 800 965 1977 ...

Page 101: ...im Mark all spoke holes on the rim starting with no I next to the valve hole up to 36 in the right hand direction clockwise If Hub The brake drum facing downward mark the lower spoke holes brake drum side from T to 18 in the right hand direc tion clockwise See fig Mark the upper spoke holes opposite brake drum starting with A to R in the right hand direction clockwise See fig NOTE The upper holc m...

Page 102: ... side with the next spoke into hole number 3 from top down the next into hole 4 from the bottom up Continue this sequence till all spokes are installed on the T broke drum side With the brake drum side the hub still facing downward install the upper spokes in the spoke holes Starting on the hole marked A insert the first spoke from the top down see arrow The next spoke from the bottom up into hole...

Page 103: ... in rim hole 30 Spoke 0 in rim hole 3 Spoke 18 in rim hole 34 Spoke Q in rim hole 7 Spoke 1 in rim hole 12 Spoke B in rim hole 1 Spoke 3 in rim hole 16 Spoke D in rim hole 5 Spoke 5 in rim hole 20 Spoke F in rim hole 9 Spoke 7 in rim hole 24 Spoke H in rim hole 13 Spoke 9 in rim hole 28 P Spoke J in rim hole 17 Spoke 11 in rim hole 32 Spoke 1 in rim hole 2 3 Spoke 13 in rim hole 36 Spoke N in rim ...

Page 104: ... spoke u little provid ing the twist ir only slight Always rtort tensioning and loosening on the port having the biggest twist commencing alternatively to either side The fallowing spokes ore loosened or tightened to a lesser extent It i s usuatly not possible to true the rim welding The special key no 905 6 35 401 2 can be used for the trueing of wheels After trueing remove all spoke ends extendi...

Page 105: ...the flywheel turns a large number of reverses of magnetic flux is induced in the primary current ignition ormature When the breaker points are closed as in illustration one an induced current flows in the ignition armature of the magneto In illustration two the current in the ignition armature is at its greatest value 106 1977mopeds com 1 800 965 1977 ...

Page 106: ...r prevents the formation of a s p r k at the breaker contacts LIGHTING FUNCTION LIGHTING FUNCTION Tine magnetic flux generated by the flywheel also passes the lighting coil The flywheel and lighting coil together Form on alternating current generator i e with the fly wheel rotating and the circuit closed bulbs being switched on alternating current will flow thru the lighting coil windings The lamp...

Page 107: ...ied voltoge and copocity are used Breaker points gap Burned or worn breaker points must be replaced with new ones Turn flywheel until the fully opened breaker contacts are visible thru the recess in the flywheel Since breaker points wear after operation and the gap re duces the gap ef new points should be adjusted to at least 0 14 0 18 in 0 35mm 0 45mm for 1 speed and 0 16 0 20 in 0 40 0 50 mm for...

Page 108: ...ints Rotate flywheel until fully opened point gap is visible thru flywheel port Loosen fixing screw and adjust point gap to 014 018 in 0 35 0 45 rnm I speed engine f 016 020in 0 40 0 50 rnm 2 speed engine I eplicing the breaker points As already mentioned paints must be replaced if a They are burned or worn b Fiber block is worn or loose c Bearing bush i s worn or loose d Spring is loose e Fixed c...

Page 109: ...ator into plug hole C Connect one cable of Ohmmeter to the blue wire and the other to ground Turn flywheel to find TDC of piston travel ond zero gauge Turn flywheel opposite normal rotational direction opposite arrow on flywheel l speed 032 047in 0 80 1 20mm 2 speed 051 067 in 1 30 1 70mm A needle movement of the Ohmmeter should indicate the points are opening w thinthis tolerance If the tolerance...

Page 110: ...otor backward against engine direction and mark fly wheel in line with the timing mark on the housing This is ignition timing mark Re check ignition as described on pre vious page ADJUST lGNlTlON TIMING WITH UNMARKED FLYWHEEL without dial indicator Adjust breaker point gap to correct setting Find T D C of piston travel insert a drift into plug hole Make a pencil mark on the flywheel at the parting...

Page 111: ... aluminum rim from damage from the tire lever aA b q r ure a leather or rubber strip between lever and the rim fig A B and C TIRE MOUNTING lf Place lightly pumped up tube into tire and over the rim But for the final stages of tire mounting use o rubber hammer to get tire over the rim fig F 1977mopeds com 1 800 965 1977 ...

Page 112: ...strong blue spark i s evident proceed to STEP 4 Weak or no spark 6 replace the spark plug with a know good spark plug crank the engine if spork occurs attempt to start Weak or no spark c unscrew the plug protector from the hi tension wire hold the wire end appr I in 2 3 mrn from ground and crank the engine If spork occurs replace the spork p ug protector Weok or no spark d remove the blue black wi...

Page 113: ...shorts at attachment leads for internally shorted points replace shorted condenser 3 open points adjust to specifications 4 high point resistance replace points if blue and burned replace condenser 5 ignition armature resistance incorrect replace ormature After making any of the above repairs retime the engine and check for spark If spark occurs attempt to start the engine If spark does not occur ...

Page 114: ...coming out of the rnagnelo he magneto armature for the circuit is internaflv qrounded The correct bulb size is 6 Volt 5 Watt The taillight circuit is unique in that its on off function is not directly controlled by the Fighting switch It is controlled by the headlight armature being energrred ond in turn by induction energizing the tail lamp armature Bear in mind that because of the design o f the...

Page 115: ...he lighting circuit is maintained by having BOTH the leadlight and speedo meter bulbs operative in the circuit If either bulb fails it is certain that after a period of time the other will fail When replacing o headlight bulb be sure that the speedometer bulb i s operative Accessory directional signal con be tied to the head lamp circuit The easiest and neatest place to connect i s at the head lam...

Page 116: ...ide 4 Throttle stop adjust engine idle speed with throttle stop screw Ensure that preliminary ad justments such as timing throttie cable slack have been carried out Shortcomings of the following nature may be found on the one or two speed automatic ENGINE MAY BE DlFFlCULT T O CRANK 1 Starting clutch slips a adjust starter cable O n e speed automatic refer to page 55 Two speed automatic refer to pa...

Page 117: ...1977mopeds com 1 800 965 1977 ...

Page 118: ...1977mopeds com 1 800 965 1977 ...

Page 119: ...WlR1NG DIAGRAM 1977mopeds com 1 800 965 1977 ...

Page 120: ...WIRING DIAGRAM 1977mopeds com 1 800 965 1977 ...

Page 121: ... W 3 CS W 3 0 W 300 Mf 2 W 2 CO W 300 T 1 W 2 A W 300 T 2 W 2 C W 300 T 30 W 2 Q W 3 1 0 S l S W 2 A S W 3 1 O S 2 S W 2 C S W 340 S 1 S W 08 AS W 340 2 S W 08 CS W 370 S 1 S W 07 AS W 370 S 2 S W 07 CS W 4 0 0 S I S W 0 6 A S W 400 2 s w 06 Cs WA 95 T 40 H 10 B WA 95 TR 4 HR 10 A Y WA 95 TR 40 HR 10 B X Y W A 1 2 5 T 4 0 H 9 B WA 125 TR 4 HR 9 A Y WA 125 TR 30 HR 9 I 3 WA 125 TR 40 HR 9 B X W A 1...

Page 122: ...1977mopeds com 1 800 965 1977 ...

Page 123: ...LUME Cubic Centimeters cc 06102 Cub c lnches Cublc Inchzs cu In 1 16 39 Cubic Centim Llters I 61 02 Cubrc Inches Cubic Inches cu n 01639 Liters LIQUID CAPACITY LIQUID CAPACITY Liters I 2 113 Pints P nts pt 4732 L ters Liters I 1 057 Quarts Quarts qt 9463 Liters Liters 1 2642 Gallons Galtons gal 3 785 Liters Cubic Centimeters cc 0338 Flurd Ounces Flu d Ounces fl 02 29 58 Cubic Centlm U S Gallons 1 ...

Page 124: ...RBURETOR Disassembly Assembly idle adjustment Removal and installation CENTER STAND CHAINS CLUTCH 1 speed automatic Assembly Dismantling 2 speed automatic Assembly Dismantling Starter clutch Dismantling Assembly Adjust COIL RESISTANCES CONNECTING ROD CRANKCASE CRANKSHAFT CYLINDER CYLINDERH EAD CYLINDER HEAD GASKET SORTING DAMPER SPRING DOWLES CRANKCASE DRIVE CHAIN DRIVE PLATE DRIVE SHAFT DRIVE SPR...

Page 125: ...l inject components Dismantling Dismantling oil inject components lrrstajlation Piston ring Piston and wrist pin Primary drive F FORK FRONT Maxi 85 89 Magnum II 90 Magnum MK II 91 94 FWEL SYSTEM Carburetor see CARBURETOR Fuel tank 84 GUIDE BUSHING GUIDE RING HEADLIGHT 89 HEADSET 87 88 94 HUBS 99 100 IDLE ADJUSTMENT IDLE SPROCKET IGNITION COIL IGNITION FUNCTION IGNITION TIMING INTAKE HOSE INTAKE MA...

Page 126: ...f M A G Breaker point adjustment Breaker point inspection and cleaning Breaker point removal and installation Ignition timing Removal and installation MAINTENANCE also see tune up Brake adjustment Drive chain adjustment Front fork Spokes Wheels and tires METRIC CONVERSIONTABLE 1 OIL PUMP 65 67 OIL LINEBLEEDING 80 OIL SEALS 43 47 63 64 68 69 OILTANK 84 I PISTON RING 42 PISTON AND WR STPIN 30 39 40 ...

Page 127: ...IMING TIRE LEVER TIRE REPAIR TIRE AND TUBES TORQUESPECIFICATIONS TUNE UP Air filter Breaker point adjustment and ignition timing Carburetor TRANSMISSIONLUBRICATION WHEEL BALANCING 105 WHEEL BEARINGS 99 1 M WHEELS 97 99 102 104 WIRING DIAG A M S Maxi 118 Moxi tuxe Newport II Sport MK II 119 Magnum It 120 Magnum MU I1 121 1977mopeds com 1 800 965 1977 ...

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