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ASSEMBLY AND REPAIR

INSTRUCTIONS

FOR ENGINE

Removal from Frame

1.1 Remove the tank

1.2 Remove the exhaust

1.3 Remove the carburetor

1.4 Remove the cylinder head and top engine

brace

1.5 Remove the ignition wire

1.6 Remove the 10 mm x 1 engine mount bolts

front and rear

1.7 Disconnect the chain

1.8 Loosen the 8 mm bolt on bottom of engine

1.9 Remove the clutch cable

1.10 Remove the engine

22. Piston Disassembly

Disassembly of Engine

We suggest using the original MAl CO engine stand.

2.1

Drain gear oil - one (SW 17mm) drain plug

on lower left side.

2.2

Remove the cylinder by loosening the four

8 mm nuts (SW 13mm) at the base of the

cyl inder. The paper base gasket is removed

taking care not to tear it. Make sure no dirt

enters the crank case.

2.3

Remove the piston - the circlips on both

sides of the piston are removed with needle

nose pliers. An aluminium

pin is used to re-

move the piston pin by tapping the pin
lightly. Use caution not to apply any pres-

sure to the side of the connecting rod.

2.4

Lay engine on primary case side and remove

timing cover.

2.5

Remove stator by loosening and removing

23. Pulling Ignition Magnet

3 - 6 mm screws. Push rubber plug out with

screw driver.

2.6

Remove the 8 mm hex bolt from the center

of the rotor magnet and remove the nut

which keeps the magnet in position on the

crank shaft. A pin, available through your

dealer 60 mm long, is inserted in the middle

of the magnet and the 8 mm bolt is re-inser-

ted and tightened while crank shaft is held

stationary by a wooden fork arou nd the

connecting rod after piston pin is re-inserted,

widging against the wooden fork. The bolt

is tightened until the magnet pops off.

2.7

The engine is turned around with the prima-

ry case facing up. The kickstarter

lever is

removed and the 7 case screws. The cover

can then be lifted off.

2.8

Disassembly of the clutch is done with the

help of a two-prong puller. By compressing

the clutch on the clutch push pin with the

puller, the two keeper rings are removed

24. Clutch Disassembly

Maico 72-74.5 Radial Manaual

www.maicowerk.com

Courtesy of [email protected]

Содержание MC 250

Страница 1: ...AfAICO MC250 MC400 MC440 MC501 Instruction book Service manual From January 1974 Maico 72 74 5 Radial Manaual www maicowerk com Courtesy of vintagemaico gmail com...

Страница 2: ...27 Shimming the layshaft 18 28 Shimming the Crankshaft 18 CONTENTS I Preface Page 3 II Technical data Page 3 III Description of the machines Page 7 A Motor B Chassis IV Service instructions Page12 A...

Страница 3: ...dle Jet Low Speed Needle Position Idler Air Screw Ignition I PREFACE The Maico models MC 250 400 450 and 501 CCM are constructed and designed especially for compe tition and off road use They are suit...

Страница 4: ...Large volume foam air filter in fiberglass air cleaner box Spark Plug Type In Moist or Cold Conditions Timing Advance Points Gap at Top Dead Center Primary Drive Primary Drive Ratio Clutch Transmissi...

Страница 5: ...35 53 15 D 20 35 53 15 D 20 Maico 72 74 5 Radial Manaual www maicowerk com Courtesy of vintagemaico gmail com...

Страница 6: ...n bearing is 0 002 to 0 005 mm 4 Crankshaft Bearings Seals III DESCRIPTION OF THE MACHINES The Maico MC 250 400 440 and 501 ccm Motorcycles are very high performance competition motor cycles which are...

Страница 7: ...The MC 250 has a clutch which is used in conjunction with the double row prima ry chain It has six toothed outer clutch plates which are 99 mm in diameter and the final outer clutch plate which has a...

Страница 8: ...250 exhaust system and the 400 450 and 501 exhaust system 8 GEARBOX The gearbox is a dog shifting type 4 speed with 2 shift forks and a shifting cam It is available in two different ratios the wide r...

Страница 9: ...rbo All cables are coated with Teflon for minimum friction B CHASSIS 1 FRAME The double down tube frame is made of high quality chrome moly tubing The welds are par tially welded with the heli arc pri...

Страница 10: ...foot lever connected with a steel brake rod 14 Rear Wheel 8 FENDERS The front fender is rubber mounted on the lower triple clamp The rear fender is also rubber mounted under the seat and on the rear...

Страница 11: ...T be the proper heat rangel 16 Setting U Tuning Carburetor 15 Setting Ignition Timing with Dial Indicator IV SERVICE INSTRUCTIONS A PREPARATION FOR COMPETITION USE 1 TIMING Tools needed for setting th...

Страница 12: ...s The fork sealsshould be replaced if there is any leakage Petcocks In the two petcocks are screensto prevent dirt from entering the float bowl These screensmust be cleaned regularly Caution Only larg...

Страница 13: ...not rB lnstall it This will result in 1 3 me shock travel Next the air release valves located in the top oil filler caps should be checked by compressing forks and observing air pressure release The...

Страница 14: ...and then lubricating it 20 Chain Adjustment 21 Master link 3 The retainer nut and eye are replaced and re tightened The shock rod is pushed all the way to the bottom and rotated clockwise until it eng...

Страница 15: ...to apply any pres sure to the side of the connecting rod 2 4 Lay engine on primary case side and remove timing cover 2 5 Remove stator by loosening and removing 23 Pulling Ignition Magnet 3 6 mm scre...

Страница 16: ...half 3 4 The shift cam and pawl with springs are inserted with a screw driver The puller is then remo ved and the clutch plates and springs are lif ted out On the small clutch the clutch nut retainer...

Страница 17: ...box is filled with 1 liter gear oil oil filler screw SW 19 3 5 The final drive gear spacer ring and three needle bearings main shaft with sliders lay shaft with sliders and shift forks are re fitted T...

Страница 18: ...e assembly of the rear wheel is performed in reverse order C ASSEMBLY AND REPAIR INSTRUCTIONS FOR CHASSIS 1 Disassembly of Forks 1 1 Remove front wheel 1 2 Remove handlebars and bar clamps 1 3 Loosen...

Страница 19: ...SHOP BULLETINS AND RACING MODIFICATIONS SHOP BULLETINS AND RACING MODIFICATIONS Maico 72 74 5 Radial Manaual www maicowerk com Courtesy of vintagemaico gmail com...

Страница 20: ...Note USE a total of 18 20 clutch springs stacked as shown WORK SHOP BULLETIN NO 1 Subj 250 360 early 400cc clutch If slipping or incomplete clutch release occurs correct as follows 1 Steel clutch Mac...

Страница 21: ...W r I LET ra 113IJM mE lAMP Of l L li O Bl SLH 340 PillL S SHOP BULLETIN 3 t50LLf TIN Z50C L 0 OOlf l I T7LJ J5 Z3m 2 I If tfl STO __ 5 MM I I AIM 5TA6F I FOE MDlDCeLJ55 TPAIL CID Nt E X lIlOJT POET I...

Страница 22: ...two marks Mark this center position line over the gasket surface and con tinue the line 1 2 inch out over the outside of the case Next mark tne center line of the shift shaft pin hole No 1049 Draw th...

Страница 23: ...ility Increases speed horsepower This is not for motocross SHOP BULLETIN 11 T T pipe for 400cc may be made by cutting the center cylinderical section of the exhause pipe 2 75 inches Widen all ports to...

Страница 24: ...re than that ehims ehou1d be added to obtain the clearance SERVICE BULLETIN Inepection and AdJuetment of the 250 400 450 and 501 Tranemieeion Before taking the engine apart it ie recommended to clean...

Страница 25: ...ll depicts the related positions for the 250 1 00 and 1 50 3 Insert the thrust washer in the mainshaft either by inserting the clutch body or use some bushes to pull the mainshaft all the way towards...

Страница 26: ...nce should be present Service Bulletin No 1 February n 197 radial and also the U 501 The fig ff0 C depicts the related positions for th 250 360 OO d 501 sq are barrels The crank return spring in Fig 9...

Страница 27: ...Sl ION DATE g III Jan 19 4 DE5 GNfiD SEI AIM1 nl c 1 oJ 1 J ri fT I o 5HIM C I b __ M i J 1 I Is L __ f t l I l I l nd Q ea l I e f __ 3 a _ I i LAY SHAH FIGW E NO 1 j I e II T FOR tC 6NC CHECI N I I...

Страница 28: ...o t J j o c 0 C 2 III i t 4 r A J a u lei IJ U ILl I t U Q I o u cr u o l to t J j o c 0 C 2 III i t 4 r A J a u lei IJ U ILl I t U Q Maico 72 74 5 Radial Manaual www maicowerk com Courtesy of vintage...

Страница 29: ...lU CI I CD U l 0 a D 2 Q 2 z w 0 t el 0 I a 0 u I cn l a z t Ot 2 Ii ri t1 H lU CI I CD U l 0 a D 2 Q 2 z w 0 t el 0 I a 0 u I cn l a z Maico 72 74 5 Radial Manaual www maicowerk com Courtesy of vint...

Страница 30: ...SILVARAJ N Of 5IC N Nn 250 4 00 so SC fUARE BARREL 0 F o A FIGURE NO 4 o 00 new 501 RADIAL c _ E G E AR CfjANGINGCRMJK OATE 91M Jon19H DESIGNED SILVARAJ N Of 5IC N Nn 250 4 00 so SC fUARE BARREL 0 F o...

Страница 31: ...to use an old fork prevent dirt from damaging the new seal ShU dULLE11 4UOcc Cooper Motors aoes not recommend Increasing tne Vuce engine speed through changing the ports or changing the exhdUS system...

Страница 32: ...lL Jr HE EE E BO T Na T ITb l rT F NE D W8 J Qt r A7 E L_ _ _ _ _ L O L C M D D t U T D I WE LD 1 l B NU T OW r r TL Y O J Ef _ H E 0 If I I l L D LL lt_ lt O G H l E HO LE IN Tf Ir NU T W ITH A 3 10...

Страница 33: ...one needle jet too rich Carburet tor Jett in for sea level SHOP BULLETIN 2 400cc 400CC 400cc 400cc 501cc 250cc 250cc 250cc I 4 1 6DP 1 1 0 6DH 6fJ Needle Needle K otches from 2 2 2 2 2 2 5 3 lean oosi...

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