VEB BERLIN SR59 Operating Manual Download

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Lube chart

No.

Lube point

No. Of

Lubricant

Lube points

Front fork (under fender)

Grease

Brake lever, front

Grease

Speedometer

Grease

Spring retainer

Grease

Rocker bolt

Grease

Foot brake lever

Grease

Clutch spring

Grease

Rear wheel rocker arm

Grease

Foot brake cable

Motoroil

Chainlubrication

Motoroil

Gear box filling screw

Motoroil

Inspection screw for gear box

Motoroil

Kickstarter

Grease

Foot gear switch

Grease

Engine lubricant

Mixture

Fuel-Oil 5%

The Bowden cables do not carry lube points anymore, due to more advanced methods of production. They are
bathed in graphite before assembly. Just disassemble every 3000 miles and oil as described in section 4.23

Supercharger:

Both Ballbearings are factory assembled with hotgrease. This lasts for appx. 21000

miles.

Summary of Contents for BERLIN SR59

Page 1: ...Operating Manual for STADTROLLER BERLIN SR59 Edition 1960 VEB INDUSTRIEWERKE LUDWIGSFELDE ...

Page 2: ... US If you need parts you can contact us at 503 231 2768 or e mail us at sales scooterstation com This operating manual was was written by a collective of Authors of the VEB Industriewerke Ludwigsfelde Editorship conclusion 11 1 1959 All rights reserved Technical books press Leipzig GDR Type setting print Technical books print Naumburg Saale GDR KG 12 3 60 ...

Page 3: ...ingle ride but for the entire time in which you drive your motorscooter Please consider that the observance of our advice essentially contributes to the preservation of your property and thus to the peoples property If you don t find the information on the following pages sufficient or if you need additional advice you can always trustfully contact one of our authorized dealers They will always he...

Page 4: ...Mode of operation 18 2 12 Crankshaft 22 2 13 Crankcase 25 2 14 Cylinder and Cylinder head 27 2 15 Piston and piston rod 29 2 16 Fan 30 2 161 Verifying the fan drivebelt 30 2 162 Changing the drivebelt 31 2 17 Electrical System 32 2 171 alternator 32 2171 1 Verifying the Electrical system 34 2 171 2 Electrical tuneup every 6000 miles 35 2 127 Battery 37 2 172 1 Maintenance 38 2 172 2 Insufficient c...

Page 5: ...ear wheel suspension 65 2 34 Brakes 66 2 341 Brake maintenance 67 2 35 Axles and wheels 69 2 351 Flat tire 70 2 36 Tank 74 2 361 Cleansing the fuelfilter 75 2 37 Driver and buddyseat 76 2 38 Instrument panel and theft protection 77 2 39 Tools 78 3 Operating instructions 80 3 1 Location and purpose of control levers and knobs 80 3 101 Air lever Choke 81 3 102 Throttle 81 3 103 Ignition and lightswi...

Page 6: ... 241 What does the sparkplug s face tell us 102 4 25 Cleansing the exhaust pipe 103 4 3 Troubleshooting 104 4 31 Engine won t start 104 4 32 Red controllamp doesn t go out after start or lights up during ride 107 4 33 Fan controllamp doesn t go out after start or lights up during ride 107 4 34 Engine doesn t run smooth 107 4 35 Engine stalls abruptly 108 4 36 Excessive fuel consumption 108 4 37 He...

Page 7: ...5 6 Piston and cylinder installation of 115 5 7 Ignition timing adjustment of 117 5 8 Wheelbearing exchange of 118 6 Parts support and technical service 120 ...

Page 8: ...Illustration 1 Berlin SR59 as viewed from the left Illustration 2 Berlin SR59 as viewed from the right ...

Page 9: ... 1 1 Passage 24mm Main jet 90 Needle jet 67 Idle jet 40 Needle setting 3 slidegate valve cut out4mm Idle air screw 2 5 to 3 revolutions open Weight of float 10 6grams Airfilter Baffle wet air filter with intake silencer Ignition Battery Ignition Spark plug Isolator M 14 240 Length of thread 10mm Elektrodenabstand 0 6mm Unterbrecherkontaktabstand 0 4mm Vorzündung 4mm of OT 28 crankangle fixed setti...

Page 10: ...05 1 3 gear 1 285 1 4 gear 1 1 Ratio Engine Transmission 2 75 1 Transm Rear wheel 2 19 1 Gear ratio 1 Gear 18 4 1 2 Gear 10 8 1 3 Gear 7 73 1 4 Gear 6 02 1 Kickstart ratio 3 76 1 Power transmission Engine Transmission Sleeve chain 3 8 x 7 7 x 5Dmr 44 links Transm Rear wheel Chain x x 8 51 Dmr 94 rollers 1 03 Brakes Foot brake Drum brake Effective to Rear wheel Operates through Bowden cable Handbra...

Page 11: ... 110mm Rear wheel suspension Trapezoid swing torsion spring patented hydraulically absorbed Effect Proportional Displacement 70mm 1 06 Steering Lenkkopfwinkel 25º Vorderradnachlauf 75mm Lenkanschlag At Steering shaft Lenkwinkel 90º 1 07 Electrical System alternator Voltage regulating Type GMR 6 60 Manufacturer FEK Fahrzeugelektrik Karl Marx Stadt Performance 60W Propulsion Anchored directly on cra...

Page 12: ...imum width 650mm Maximum height 950mm Wheelbase 1430mm Ground clearance 110mm loaded Wading capability 240mm Turning circle 4 0 Meters Weight 140Kg 309lbs Dry curb weight 131Kg 289lbs Maximum weight 300Kg 662lbs Pressure on front axle unloaded 51Kg 112lbs loaded 100Kg 221lbs Pressure on rear axle unloaded 84Kg 185lbs loaded 200Kg 442lbs Avg Fuel consumption 2 8liters 100Km 85mpg Fuel consumption a...

Page 13: ...lling amounts Fuel tank 12 liters 3 2 US gallons Reserve in fuel tank 1 5 liters 1 6 US liquid quarts Transmission oil 0 4 0 45 liters 0 84 0 95 US liquid pints Radius with one tank filling appx 350Km 219miles ...

Page 14: ...x By now the oil has dropped out of the mix and attached itself to bearings and other parts within the engine Just before reaching BDC two openings called transfer ports are uncovered in the cylinder The scavenging phase has begun Meaning that the unburned mixture gasses are flowing out of the transfers and merging together to form a loop The gasses travel up the backside of the cylinder and loops...

Page 15: ...Image 4 Power curve chart ...

Page 16: ...esh charge of unburned mixture gasses is flowing through the intake into the crankcase The unburned mixture gasses are compressed and just before the piston reaches TDC the ignition system discharges a spark causing the gasses to ignite and start the process all over again Image 6 Motor viewed from left side ...

Page 17: ...The crank is installed into the crankcase by one ball bearing on the right and two ballbearings on the left The necessary pressuretightness of the crankendings at the bearings is achieved by spring pressured crank seals on each side Image 8 Crank with connecting rod and piston 2 13 Crankcase The enginecase is sliced vertically through the middle The front section contains the crankcase and the rea...

Page 18: ... well protected from dirt Image 10 Lightmetal lid right side 2 14 Cylinder and Cylinderhead The cylinder is made of special grey cast iron and is covered with large scaled cooling fins Together with the cylinderhead which is also equipped with cooling fins it is frimly screwed onto the crankcase using four long special screws At the foot of the cylinder a paper seal supplies the necessary sealing ...

Page 19: ...t the foot of the cylinder are corresponding with the adjacent ports in the crankcase When the cylinder is worn out it can be rebored and fitted with the next larger size of piston The measurements for reboring the cylinder are as follows 56 25 56 50 56 75 and 57mm Image 12 Cylinder and Exhaust connectors Image 13 Cylinder head A sparkplug that is necessary for the ignition of the gas air mix sits...

Page 20: ...4 drivebelt The drivebelt is hooked onto the left crank pivot secured by a beltdisc A supercharger alarm system consisting of a contact and an orange pilot lamp on the right hand side of the instrument panel supplies the appropriate control and security incase of possible blockage or snapping of the belt 2 161 Inspection of the blower beltdrive The belt for the flywheel should be loosly streched I...

Page 21: ...r cylinderscrew c Remove lower drivebelt disc right hand thread using a 19mm socket and remove disc Image 15 Belt drive d Unscrew the three screws of the guide rim and remove the guide rim On the extenstion of the guide rim you you have the flywheel and the drivebelt disc Now you can install the new drive belt A reserve belt is in the toolbox e Repeat steps a through d in reverse order ...

Page 22: ...rking light i Charging control lamp red on the lefthandside of the controlpanel j Neutral gear control lamp green on the lefthandside of the controlpanel k Control lamp for Supercharger orange on the righthandside of the controlpanel l Signal horn m Brake tail and licenseplate lamp n Wiring harness o Control lamp unused Can be used for Hi beam display for instance Image 16 Wiring diagram Suggestio...

Page 23: ...ires the battery is being charged by the alternator When the red control lamp is on it shows that the battery is currently feeding the electrical system The anchor that carries the commutator sits directly on the cone of the right crank pivot It gets screwed together with the circuit breaker cam using a long hexagonal nut The holding cap contains the pole housing with poles and field coils on the ...

Page 24: ...reaker points have burned spots they are to be smoothed out using a contact file More vigorous signs of conflagration on the points indicate a defecticve condensor The advice of a professional electric technician is now essential to have the defective part replaced 2 171 2 Electrical tuneup every 6000 miles The regular 6000mile inspection of the electrical system consists of a check up on proper p...

Page 25: ...unning it is being charged by the alternator The amount of charge adjusts itself depending on the battery s energy level Picture 19 Battery The Lead battery has a maximum capacity of 8Ah Ampere hours assumed that the battery is discharged at a rate of 20 hours with 5 of the nominal capacity equaling 0 4 A With the outside temperature falling the capacity of the battery secedes rapidly This is why ...

Page 26: ... dirty commutator carbons disaligned bad grounding of battery regulator or statorplate f Main cable between statorplate and regulator or ignition coil defective g Regulator or reverse current switch defective Since we have often had to discover that the battery was not installed correctly we have to point out explicitly that the stator and or the regulator will break if the wrong connector is atta...

Page 27: ...oltage regulator It is the regulators task to keep the voltage on a constant level regardless of the engine speed or the amount of operative consumers The voltage regulator also contains the reverse current switch Image 21 voltage regulator and ignition coil It switches the battery supply for the electric circuit off when the engine produces enough power to maintain all the consumers and back on w...

Page 28: ...s the cam s slideway slightly greased and thus reduces wear of the breaker lever to a bare minimum 2 18 Carburetor and filter Processing and conditioning the right mixture of fuel and air for combustion is maintained by the BVF Berliner Vergaser Fabrik engl Berlin Carburetor Plant 24 KN 1 1 Round slidegate valve carburetor The fuel level inside the floater housing is maintained on an optimal balan...

Page 29: ...gate notches in the needle jet additional influence can be taken towards the fuel air mix consistency within the scope of the jet needle until appx slidegate opening If the needle is placed higher the ratio will be richer and if the needle is placed lower the ratio will be leaner Incase of having to start a cold engine the carburetor has an air slidegate installed that can be operated by using the...

Page 30: ...er and should if possible not be removed because this might cause malfunctioning of the carburetor All parts are to be cleansed thoroughly with fuel and then checked for mechanical defects wear Wear and tear of things like loose parts of the carb worn out floater needle or jet needle defective floater damaged gaskets bent jet needle or a loose or inclined intake socket are responsible for poor fun...

Page 31: ...Illustration 25 Explosion diagram of carburetor ...

Page 32: ...ent screw 28 Floater housing cap 1x for stop pin 29 Dabber 8 Stop pin 30 Pressure spring for dabber 9 Slide gate 31 Lock washer 10 Needle 32 Cheese head screw for floater housing cap 11 Clamping yoke 33 Spring ring for cylinder screw 12 Pressure spring for slide gate 34 Lower gasket for floater housing 13 Guide jacket 35 Hollow screw 14 Pressure spring for choke 36 Locking screw 15 Air slide gate ...

Page 33: ... little motor oil Leave enough time to let excess oil drip off When done press the air filter back into it s seating and screw the lid back onto the intake silencer after also having cleansed it The intake silencer is made from aluminum pressure die cast To clean the intake silencer it must be removed from the rubber connection nozzle which itself is clamped onto the carburetor socket and can only...

Page 34: ...utch barrel on the other Chain transmission and clutch are operated in a constant oil bath because the clutch Image 26 Primary drive train compartment is connected to the lube chamber of the of the transmission Adjusting the primary chain is not necessary A designated pressure screw 3 which is secured by a counter nut 2 is used for adjusting the clutch actuation See image 27 Image 27 Clutch adjust...

Page 35: ...ide engine housing Before adjusting the counter nut has to be losened applying a 14mm wrench in a counterclockwise rotation Then the play can be adjusted using a screwdriver Clockwise rotation reduces the play counterclockwise expands Image 28 Clutch adjustment After adjusting the counter nut has to be tightened while the screwdriver holds the adjustment screw in place to avoid it from turning alo...

Page 36: ...o avoid oil leaks The switch for the neutral gear control lamp is installed on the wall of the gearbox housing next to the cogwheel In neutral the contact is closed so that the green control lamp on the instrument panel lights up Lubrication of the gear box and the primary drive train is maintained by first opening the transmission oil filling screw and then filling the gearbox with transmission o...

Page 37: ...only known chain tighteners that are attached to the rear fork 2 231 Chain maintenance The chain should be lubed once every 600 miles using viscous motor oil which can be applied through the little drilling in the rear end of the chain housing after the cap screw has been removed For this task the rear wheel should be rotated slowly However a thorough cleansing of the roller chain especially of th...

Page 38: ...end is facing running direction Image 32 Testing chain tension The correct slack span is to be checked regularly When measured in the middel of the chain it should sag by appx 20mm That means it should shuttle 10mm up and down If the slack span should have more or less play than recommended the chain the rubber housing and the attached sprockets and bearings will wear out early Also an unnecessary...

Page 39: ...hood mounts for fuel tank and rear hood The engine is installed in the bracket and secured with three threaded bolts nuts and locking plates keeping it in place 2 32 Front wheel balance beam fork An improved edition of the balance beam fork retains the front wheel and carries the suspension Street impacts are conveyed through the swinging arm the suspension pickups and the spiral springs which are...

Page 40: ... Loosen steering clamp and remove handlebar from steering column 4 Remove sleeve from steering column and unscrew counter nuts 5 Remove front fork including front fender from steering shaft 6 The fender can be removed by unscrewing the two fender screws on the sides of the fender 7 Push sleeves out of fork pipes 8 Unscrew both screws fom the fork bridge 9 After having removed the swinging arm bolt...

Page 41: ...eering columns 2 33 Rear wheel suspension The rear wheel suspension is realized by a torsion spring hydraulic shock and a trapezoid rocker The stability of the trapezoid rocker system is achieved by a stabilizer which is installed just behind the torsion spring and is screwable into the swinging arm The two pressure casted aluminum axle holders that are each connecting each sides upper and lower r...

Page 42: ...er swinging arms can be removed by removing the long hexagonal at the rubber bushing Image 37 Rear wheel rocker 5 Remove hydraulic shock 6 Losen stabilizer by removing hexagonal nuts 7 Remove lock rings from torsion spring 8 Using a hammer and a mandrel the torsion spring can now be hammered out of its sprocket seat Caution This task needs to be performed with great care to avoid damaging of the s...

Page 43: ...6 Brake cable nipple The front wheel can be adjusted at the cable jacket on the handlebar or at the hub The rear wheel brake is adjusted by turning a hexagonal nut that is sitting on the thread at the end of the brake cable The bearings for the brake key shafts are equipped with lubricating elements to ensure smooth running of the brakes by keeping the bearings constantly lubricated ...

Page 44: ... the wear of the brake shoes The rear brake is adjusted merely by clockwise rotation rotation at a time until snap of the adjustment nut To adjust the front brake first the hexagonal counter nut needs to be loosened counterclockwise Then the adjustment nut also needs to be turned counterclockwise Afterwards the counter nut needs to be tightened again The same procedure should now be done at the br...

Page 45: ...ree nuts have been taken out Afterwards the armature plate can be pulled out revealing the brake mechanism By removing the three countersinks the brake drum can be removed All inner parts are to be thoroughly cleansed the brake pads checked for wear and immaculate adhesive sealing as well as the right bevel on their ends All pivot points and spring loops are to be lubricated ever so slightly Simul...

Page 46: ... Remove wheel e The wheel will be ready for tire installation after having removed the five wheel nuts Image 42 Removing the front tire Removing the rear wheel a Remove hood Screw of knurled screw and the two nuts b loosen wheel nuts and rod axle c Tilt the scooter sideways and let it rest on the edge of the florboard d Unscrew rod axle e Remove bushing and unscrew wheel nuts f Remove rear wheel ...

Page 47: ...he two mounting levers towards both sides start lifting the rest of the tire over the rim Never apply brute force or use an oversize mounting lever without making sure that the opposite side of the tire is completely pushed into the drop base Otherwise the cable inside the tire might burst resulting in a broken tire 7 Remove tube Mounting a tire 1 Perform a thorough check of the tire to insure tha...

Page 48: ...ft and the right side of the valve whilst using your feet to press the other side of the tire into the rim s drop base Caution Do not damage tube with mounting lever 7 Inflate the tire a little and bounce the tire on the ground in a circular motion until the tire s checkmark has the same distance to the rim all around Wobbeling bad road holding and high wear and tear of the tire will occur if this...

Page 49: ...r filters dirt particles before they can get into the floater housing of the carburetor To avoid reduced flow rate the filter should be cleased regularly To cleanse the filter it needs to be removed from the fuel tap by unscrewing it After removing the screen from the filter housing both parts are washed out in benzine When reinstalling the filter into the fuel tap insure that the filter housing s...

Page 50: ...pened base frame The base frame is opened sideways to refuel the scooter The opened base frame also enables access to the tool kit which after being removed can be used to work on the spark plug that can be accessed easily by opneing the little round door in the hood A security lock prevents unauthorized access to the toolbox Caution Never clean seats with fuel bezine or thinner ...

Page 51: ... It could be connected to serve as a hi beam indicator for example The speedometer is mounted on the right hand side of the instrument panel ignition and lightswitch on the left The theft protection is mounted in the center of the instrument panel and equipped with a cover plate to protect it from water Operating the instrument panel 1 Open cover plate 2 Insert key also fits for opening base frame...

Page 52: ...the toolbox under the base frame of the seats This tool kit consists of the following Image 49 Tool kit 2 mounting levers 1 spark plug spanner 1 screwdriver 4 wrenches sizes 8 10mm 9 11mm 14 17mm and 19 22mm 1 pair of universal pliers 1 grease gun 1 sensing gauge 1 extension for socket wrench for tire exchange Also included in the toolkit is spare v belt for the supercharger 8x5x475 ...

Page 53: ... gear pilot light 2 Charging status light 3 Clutch lever 4 low beam switch and signal switch 5 Ignition and light switch 6 Theft protection 7 foot gear switch 8 Sidestand 9 Security lock 10 Kickstart 11 hood mount 12 foot brake lever 13 Supercharger pilot light 14 Throttle 15 Hand controlled brake 16 Choke lever 17 Blind pilot light ...

Page 54: ...evious use the choked needn t be closed pushed forward because it tends to stall the engine Applying the dabber also stalls an already warm engine Image 51 Handlebar with choke 3 102 Throttle The position of the carburetor s round slidegate and thus the engines rpm s are determined by the throttle control on the right hand side of the handle bar Image 52 Throttle setting B Adjusting screw for stop...

Page 55: ...pty or missing battery When switching on the ignition the red pilot light goes on except when in position 5 to acknowledge contact between the ignition coil and the battery When the engine is being accelerated the red pilot light must go out If the red pilot light does not go on when the ignition is switched on or if the pilot light does not go out when accelerating it means that the equipment is ...

Page 56: ...ch lever must always have a dead gear of 2 3mm Image 54 dipswitch and clutch lever By applying force to the lever with your hand the transition from dead gear to active gear can be felt Adjusting the dead gear is done by either a little little pressure screw that is located at the right hand side of the engine housing or the ring nut located at the clutch lever See section 2 211 The clutch lever m...

Page 57: ...art on the left hand side of the hood is provided for kickstarting the engine If the kickstart can t be kicked down because the mechanism is locked in sprocket on sprocket the scooter needs to first be pushed back and forth a little to switch it back into neutral gear ...

Page 58: ...d to move the gears up into 2nd 3rd and 4th gear and down to switch down again To switch from neutral into 1st gear the switch must also be pushed back To switch from Neutral to 1st gear push foot switch back 1st gear to 2nd gear push forward 2nd to 3rd gear push forward 3rd to 4th gear push forward 4th to 3rd gear push back 3rd to 2nd gear push back 2nd to 1st gear push back Neutral is found inbe...

Page 59: ...ot gear switch 2 Rear brake foot lever 3 109 Front brake lever The lever provided on the right hand side of the handle bar activates the front brake It should be used to support the rear brake when slowing down In conjunction with the rear brake the front brake is especially valuable on longer downhill rides due to the relocation of the center of gravity Using the front brake only occasionally bea...

Page 60: ...estand can be accessed easily CAUTION Before sitting on the scooter the sidestand has to be retracted Otherwise the floorboard may be damaged Image 58 Sidestand 3 111 Tip up hook A tip up hook can be found on the instrument panel s housing and used for convenience purposes like hanging up a purse or a brief case while on then road Pushing down the button opens the hook for use ...

Page 61: ...Driver buddyfront 22 0 psi rear 29 4 psi The pressures should not fall bellow the the suggested rates because it might lead to unsound tires 5 Check for function of front and rear lights as well as function of the pilot lights on thje instrument panel 6 Check braking action of front and rear wheel See section 2 34 3 22 Running in All movable parts of a new scooter must be run in Especially Power t...

Page 62: ...st fully and keep engine idleing Once the engine is running the red and orange pilot light should extinguish If they don t see sections 4 32 and 4 33 The green neutral light will first go out when a gear is engaged If these lights fail to light up with the ignition switched on the battery is most liekely empty With the battery removed from the scooter it can still be started by setting the ignitio...

Page 63: ...iving school it is advised to use the same gear uphill as you should going downhill This is extremely important with a two stroke engine because the engine is lubricated by the fuel When you are using the engine break high gear with closed throttle you are denying the engine it s lubricant and thus run into the risk of severely damaging your engine piston seizure or serious damage of the bearings ...

Page 64: ...y body with paint protection and coat blank parts with vaseline 7 Cover scooter with canvas to protect it against dust 4 Protection and maintenance work 4 1 General information The supplied maintenance booklet gives information on when the scooter should be inspected by an authorized dealer and what should be taken care of at which mileage The speed s mileage counter is used as reference Non obser...

Page 65: ...orks with an oil fuel ration of 5 This means that the engine is lubricated by the oil additive in the fuel Never fill scooter up with unmixed fuel Operating the engine without oil additive would destroy the crank big end bearings and the cylinder track because they would run dry To ensure proper lubrication of the engine at all times winter or summer therefore is 5 4 23 Lubricating the chassis Lub...

Page 66: ... Chainlubrication 1 Motoroil 11 Gear box filling screw 1 Motoroil 12 Inspection screw for gear box 1 Motoroil 13 Kickstarter 1 Grease 14 Foot gear switch 1 Grease 15 Engine lubricant Mixture Fuel Oil 5 The Bowden cables do not carry lube points anymore due to more advanced methods of production They are bathed in graphite before assembly Just disassemble every 3000 miles and oil as described in se...

Page 67: ......

Page 68: ... by using the supplied sensing gauge see image 61 or by simply stacking 3 postcards on top of eachother and using them to measure the distance The appearance of the spark plug s inner parts the so called face concludes the burn up of the engine and so gives the opportunity to detect disturbances in the engine s combustion processs timely and thus enables early troubleshooting See section 4 241 Whe...

Page 69: ...el residue within the engine compartment burned in piston rings or dirty ports and exhaust i Vehicle is being operated too slow If the right sparkplug s face is light colored white grey and the electrodes show signs of little pearl like objects the sparkplug was overheating The following problems might be responsible a Electrode distance too big b carburetor ratio is too lean c Mechanical defects ...

Page 70: ...on operation mode and used fuels need to be cleaned out after about 3000 miles If ignored the residues result in lacking performance and higher fuel consuption The exhaust of the SR59 Berlin is demountable After removing the nut which is connected to the end of the exhaust the end piece and the blind can easily be removed Image 62 Dismantled exhaust ...

Page 71: ...on is switched on but the red pilot light won t go on a Defective pilot light b Discharged or insufficiently charged battery c Bad contact within the ignition lock or the connecting cables d Broken wires Red pilot light is on but there is no spark Simple inspection remove the sparkplug connector from the cable and hold it three to four millimeters close to the cylinder When kickstarting a spark sh...

Page 72: ...h or bad ground b Loose contact at the cable connectors c Defective regulator d Defective alternator due to dirty commutator hanging brushes or short circuit within the coil 4 33 Supercharger pilot light doesn t go out or lights up while driving a Slipping v belt fails to drive supercharger fly wheel b Dodgy v belt see section 2 162 for details 4 34 Engine doesn t run smooth Four stroke motion Reg...

Page 73: ...et entirely due to broken clamping yoke h Wrong ignition timing i Old or defctive sparkplug wrong electrode distance k Breaker lever hangs or lifts off too far l Points burned m Piston rings burned into the grooves bad compression 4 35 Engine stalls abruptly a Empty gas tank Noticeble stuttering of the engine prior to stalling b Clogged tank fuel lines or dirty carburetor c Ignition cable loose or...

Page 74: ...t ignition timing and immaculate condition of the mechanical parts of the ignition e Correct handling of throttle gear switch and choke f Immaculate condition of all other parts of the scooter gear box brakes wheels tires and frame If the fuel consuption still seems to high it is strongly recommended to stop by an authorized workshop and have them perform a test drive with the scooter so that they...

Page 75: ...o and about five yards away from a white wall Image 63 Headlight bezel Image 64 Adjustment of headlight b Have one or two people sit on the scooter c Loosen bezel screws and adjust headlight where the boarderline between the bright bottom and dark upper area should be at least two inches under the center of the headlight d Tighten bezel screws ...

Page 76: ...oosen the three engine fixation screws that connect the engine to the frame 10 Loosen connectores of the triple cored cable at the alternator s cap Mark connector ends and bend open cable fastener under the engine open 11 Remove battery 12 Remove foot gear switch linkage from gear box lever 13 Pull engine out upwards first and then take it out of the frame sideways 14 Re install correspondingly in...

Page 77: ...r the piston pin out of the piston 5 5 Inspecting or exchanging piston rings 1 Remove cylinder as described in 5 3 2 If the piston pin is still stuck in the piston the necessary work can be done without removing the piston 3 Remove piston rings using a pair of piston ring pliers or three narrow pieces of tin to avoid breaking or overexpanding the rings Mark the rings in such a way that they can la...

Page 78: ... that the piston can rest 8 Lubricate bore not the piston Image 65 Piston arrow must point Image 66 Installing the piston forward during installation 9 Slide cylinder onto stud bolts 10 Press upper piston ring together firmly using your fingers so that the ring ends are adjacent to the locking pin Now slide cylinder over the piston and over the first piston ring 11 Press lower piston ring together...

Page 79: ...need to be loosened and the stator moved To the left if the test lamp light s up late and to the right if the lamp light s up early 7 Tighten stator plate screws again 8 To adjust the ignition timeng follow these instructions Loosen exhaust screw and remove exhaust pipe manifold Move the piston to TDC Mark the piston s position with a pencil and measure 4mm off TDC for the right ignition timing Yo...

Page 80: ...r SR 59 Berlin can only be obtained through authorized dealers or specialized retail stores This includes parts that are manufactured by IWL as well as third party parts excluding tires It is pointless to order directly from the manufacturer There are enough authorized dealers within the GDR German Democratic Republic that monitor our vehicles throughout their warranty period and are made availabl...

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VEB BERLIN SR59, Operating Manual

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