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Puch 1980-1981 Puch User Manual

Puch 1980-1981 Puch
127 pages
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PUCH
'80 / '81
Maxi,
Maxi Luxe, Newport II, Sport MK II
Magnum II, Magnum MK II
MOPED MAINTENANCE
MANUAL
Includes
Technical Data
Description
Maintenance and service
Trouble Shooting
Steyr - Daimler -
Puch
PUCH SERVICE
-
AUSTRIA
907.2.71.894.5 0580
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Puch 1980-1981 Puch Specifications

General IconGeneral
BrandPuch
Model1980-1981 Puch
CategoryMotorcycle
LanguageEnglish

Summary

Foreword

Lubrication and Maintenance

Lubrication Procedures

Describes lubrication for gearbox, chains, and other components.

Engine Maintenance Tasks

Procedures for engine decarbonizing, exhaust port, and muffler cleaning.

Component Cleaning Procedures

Cleaning air filters, fuel valves, lines, and carburetors.

Ignition System Checks

Procedures for checking ignition timing and breaker points.

Brake System Checks

Procedures for checking front and rear brakes.

Wheel Removal

Steps to remove front and rear wheels.

Tire Service

Instructions for tire removal and installation.

Exploded Engine Views

Maxi Luxe 1-Speed Engine View

Visual breakdown of Maxi Luxe 1-speed automatic engine.

Newport II / Sport MK II 2-Speed Engine View

Visual breakdown of Newport II/Sport MK II 2-speed engine.

Magnum II 2-Speed Engine View

Visual breakdown of Magnum II 2-speed automatic engine.

Magnum MK II 2-Speed Oil Inject Engine View

Visual breakdown of Magnum MK II 2-speed oil inject engine.

Special Tools

Tool Usage Illustrations

Visual guide demonstrating the use of special tools.

Torque Specifications

Engine Torque Values

Specific torque settings for engine components.

Frame Torque Values

Specific torque settings for frame components.

Engine Removal

Engine Removal Procedures

Steps to remove the engine from the moped frame.

Dismantle Engine - 1 Speed

Engine Holder Setup

Securing the engine for disassembly using an engine holder.

Crankshaft Dismantling

Procedures for dismantling the engine crankshaft.

Crankshaft Service

Crankshaft Inspection and Alignment

Checking crankshaft condition and rod alignment.

Crankshaft Balancing and Centering

Methods for crankshaft testing and balancing.

Wrist Pin and Bushing Service

Procedures for wrist pin and small end bushing.

Piston and Cylinder Matching

Matching pistons to cylinders and sorting tables.

Cylinder Measurement

Cylinder bore measurement and clearance limits.

Clutch and Engine Assembly (1-Speed)

1-Speed Clutch Assembly

Procedures for assembling the 1-speed automatic clutch.

1-Speed Engine Assembly

Steps for assembling the 1-speed engine components.

Install Engine - 1 Speed

Engine Installation Procedures

Procedures for installing the 1-speed engine into the frame.

Carburetor Service

Carburetor Overview and Operation

General description and function of the carburetor.

Carburetor Cleaning and Adjustment

Detailed steps for cleaning and adjusting the carburetor.

Dismantle Engine - 2 Speed

Engine Removal (2-Speed)

Steps to remove the 2-speed engine from the frame.

2-Speed Engine Dismantling

Detailed steps to dismantle the 2-speed engine.

Oil Pump Drive Service

Oil Pump Drive Dismantling

Procedures for dismantling the oil pump drive.

Oil Pump Drive Assembly

Steps for assembling the oil pump drive.

Assemble Engine - 2 Speed

Engine Case Assembly

Procedures for assembling engine case halves and bearings.

Crankshaft Installation

Steps for installing the crankshaft into the engine case.

Install Engine - 2 Speed

Engine Installation Procedures

Steps for installing the 2-speed engine into the frame.

Engine Idle Adjustment

Transmission Filling

Procedure for filling the transmission with fluid.

Idle and Throttle Cable Adjustment

Adjusting engine idle speed and throttle cable slack.

Fuel and Oil Tank Service

Oil Tank Removal

Steps to remove the oil tank.

Fuel Tank Removal

Steps to remove the fuel tank.

Front Fork Service

Front Fork Dismantling (Maxi)

Steps to dismantle the front fork for Maxi models.

Front Fork Assembly (Maxi)

Steps to assemble the front fork for Maxi models.

Front Fork Service (Magnum)

Procedures for dismantling and assembling the Magnum front fork.

Rear Suspension and Swing Arm Service

Shock Absorber Information

Details on shock absorber serviceability.

Rear Swing Arm Service

Procedures for rear swing arm removal and fitting.

Wheel and Brake Service

Rear Wheel Alignment and Brakes

Rear wheel alignment and brake shoe information.

Hub Maintenance

Procedures for front and rear hub maintenance.

Wheel Spoking and Truing

Sprocket Service

Procedures for idler and drive sprocket replacement.

Wheel Spoking Procedures

Step-by-step guide for respoking wheels.

Wheel Truing and Balancing

Methods for wheel truing and balancing.

Electrical System

Ignition System Function

Components and function of the flywheel magneto and ignition.

Lighting System Function

How the lighting system operates.

Breaker Points Service

Adjusting and replacing breaker points.

Ignition Timing

Ignition Timing Adjustment

Steps to check and adjust ignition timing.

Tire Fitting

Tire Removal and Mounting

Procedures for changing motorcycle tires.

Troubleshooting

Engine Starting Problems

Troubleshooting steps for engine starting issues.

Performance and Operational Issues

Addressing poor performance and operational faults.

Lighting Circuit Troubleshooting

Diagnosing problems in lighting circuits.

Wiring Diagrams

Maxi / Maxi Luxe Wiring Diagram

Electrical wiring diagram for Maxi and Maxi Luxe.

Newport II / Sport MK II Wiring Diagram

Electrical wiring diagram for Newport II/Sport MK II.

Magnum II Wiring Diagram

Electrical wiring diagram for Magnum II.

Magnum MK II Wiring Diagram

Electrical wiring diagram for Magnum MK II.

Conversion Tables

Spark Plug Conversion Table

Cross-reference for spark plug compatibility.

Metric Conversion Tables

Tables for converting between metric and imperial units.

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