MZ TS 150 - User Manual

REPAIR MANUAL
for the
MZ MOTOR-CYCLES
TS 125
and TS 150
with 174 illustrations
and
23 drawings of special tools
4th Edition
VEB MOTORRADWERK ZSCHOPAU
Betrieb des IFA-Kornbinats Zweiradfahrzeuge

Summary

Technical Data

Engine

Detailed specifications of the engine, including performance and dimensions.

Carburetter

Specifications for carburetter components and settings.

Electrical Equipment

Specifications for the motorcycle's electrical systems.

Dimensions and Masses

Key dimensions and weight specifications for the motorcycle.

Ignition

Specifications and details for the ignition system.

Fuel, Lubricants and Fluids

Fuel

Recommendations and specifications for fuel.

Engine Oil

Details on engine oil type, mixing ratio, and properties.

Disassembly of the Engine

Dismantling the clutch driver

Procedure for removing the clutch driver.

Removing the primary drive

Steps to remove the primary drive components.

Dismounting the clutch

Guide to dismounting the clutch assembly.

Driving out the gudgeon pin

Method for removing the gudgeon pin.

Removing the gearbox sprocket

Procedure for removing the gearbox sprocket.

Dismantling the gear shift mechanism

Instructions for dismantling the gear shift mechanism.

Pulling off the armature

Steps for removing the dynamo armature.

Pushing out the crankshaft

Method for pushing out the crankshaft.

Dismantling the ball bearing

Procedure for removing ball bearings.

Mounting the gearbox bearings

Instructions for mounting gearbox bearings.

Checking the crankshaft for true running

Method for checking crankshaft true running.

Inserting the crankshaft bearing at the left-hand side

Procedure for inserting crankshaft bearings.

Checking the connecting-rod bearing

Method for checking the connecting-rod bearing.

Replacing the small-end bush

Steps for replacing the small-end bush.

Mounting the crankshaft

Procedure for mounting the crankshaft.

Setting the gear-shift detent axle

Procedure for setting the gear-shift detent axle.

Inserting the gear-shift pawl

Steps for inserting the gear-shift pawl.

Causes of faults in the gear-shift set

Common faults affecting the gear-shift set.

Mounting the gear-shift set

Instructions for mounting the gear-shift set.

Mounting the right-hand casing half

Procedure for mounting the right-hand casing half.

Tightening the casing screws

Steps for correctly tightening casing screws.

Inserting the right-hand crankshaft bearing

Method for inserting the right crankshaft bearing.

Aligning the cover plate

Procedure for aligning the cover plate.

Aligning the gearbox

Method for aligning the gearbox.

Adjusting the neutral control switch

Neutral control switch

Gear-shifting test

Mounting the kick-starter assembly

Checking the primary drive

Fastening the driver

Fastening the clutch compression springs

Mounting the clutch cover

Assembling the Engine

Timing diagram

Checking the ring grooves

Determining the timing

Checking the piston ring gap

Inserting the gudgeon pin

Mounting the cylinder

Fastening the cylinder head

Electrical Equipment

Wiring diagram without flashing-light direction indicators (TS 125 and 150)

Ignition coil

Sparking plug

Battery

Regulator cutout

Wiring diagram with flashing-light direction indicators (TS 125 and 150)

Dynamo, 2-pole

Dynamo

Detailed information and checks for the dynamo.

Servicing the Carbon Brushes

Servicing the Commutator

Fault Indication by the Charging Control Light

Adjustable Resistor

Putting the Battery into Operation

Ignition System

Ignition Timing

Procedure for setting ignition timing.

Contact breaker

Ignition timing with ignition setting gauge

Ignition Timing by Means of a Graduated Dial

Setting the Firing Point

Sparking-plug

Plug Cable Connector

Troubles

Lists common ignition system troubles and their causes.

Ignition-light Switch

Headlamp

Focusing the Headlamp

Tail Lamp and Stop-light Switch

Re-adjusting the stop light switch

Flashing-light Direction Indicator System

Speedometer

Induction System

Causes of faults

Carburetter BVF 22 N 1-3 and 24 N 1-1

Detailed description of BVF carburetters.

General

Mixing Ratio of Rich Air-fuel Mixture

Mixing Ration of Lean Air-fuel Mixture

Description of the BVF Carburetters 22 N 1-3 and 24 N 1-1

Trouble Shooting and Tuning

Guide to troubleshooting and tuning the carburetter.

Cycle Parts

Exhaust System

Steering

Details and maintenance of the steering system.

ES 125;1 and 150;1

Front Fork and Steering Bearing

Replacement of the Swing-arm Bearing Pin

TS 125 and TS 150

Steering Bearing

Telescopic Fork (see Fig. 136)

Detailed instructions for the telescopic fork.

Repairing the telescopic units of the fork

Assembling and removing the guide tubes with the help of the combined assembling spanner

Fitting the seal ring

Fuel Tank

Information on the fuel tank and its mounting.

Fuel Shut-off Cock

Brakes

Information on the brake system.

Checking and Changing the Secondary Chain

Adjusting the Clutch

Procedure for adjusting the clutch.

Removing and Dismantling the Rear Wheel Drive

Speedometer Drive

Replacement of the Wheel Bearings

Inspections Required in the Case of Poor Road-holding

Repairing the Spring-loaded Suspension Units

Instructions for repairing suspension units.

Shock-absorber Marking

Removal of the Shock-absorbers

Common Faults in Shock-absorbers

Filling the Shock-absorbers with Fluid

Cable Controls

MZ TS 150 Specifications

General

Front Suspension	Telescopic fork
Fuel System	Carburetor
Frame Type	Tubular steel
Rear Suspension	Dual shock absorbers
Rear Brake	Drum