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Puch Maxi 50 User Manual

Puch Maxi 50
151 pages
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Table of Contents

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Puch Maxi 50 Specifications

General IconGeneral
CoolingAir-cooled
Fuel SystemCarburetor
Final DriveChain
Front SuspensionTelescopic fork
Front BrakeDrum
Rear BrakeDrum
Engine TypeSingle-cylinder, two-stroke
TransmissionAutomatic
Top Speed45 km/h
Rear SuspensionSwingarm
BrakesDrum

Summary

Lubrication and Maintenance

Carburetor and Idle Adjustments

Details on adjusting the carburetor, idle speed, and throttle cable.

Ignition System Maintenance

Includes ignition timing, breaker points, and starting lever adjustments.

Brake and Wheel Maintenance

Covers checking brakes, brake linings, and front wheel removal.

Tire Fitting Procedures

Detailed steps for removing and fitting tires and tubes.

Torque Specifications

Engine Component Torque Settings

Specified torque values for various engine components.

Frame Component Torque Settings

Specified torque values for frame and related components.

Engine Removal Procedures

Initial Engine Removal Steps

Steps for removing the engine, including chain guards and air filter.

Fuel, Exhaust, and Drive Chain Disconnection

Procedures for disconnecting fuel, exhaust, and drive chain.

Electrical and Starter Cable Disconnection

Steps to disconnect electrical wiring and starter cable.

Dismantle Engine - 1 Speed

Initial Dismantling Steps

Mounting engine, removing intake manifold and kickstand spring.

Flywheel, Stator, and Cylinder Head Removal

Steps for removing kickstand bolts, generator cover, and flywheel.

Cylinder, Piston, and Wrist Pin Removal

Procedures for removing cylinder, base gasket, wrist pin, and piston.

Clutch and Crankcase Separation

Steps for removing clutch cover, crankcase screws, and separating halves.

Crankshaft and Primary Drive Dismantling

Procedures for removing primary drive and crankshaft assembly.

Crankshaft and Bearing Dismantling

Instructions for clamping crankshaft and removing bearings and shims.

Crankshaft Inspection and Alignment

Visual Inspection and Rod Alignment

Guidelines for visually inspecting the crankshaft and aligning the connecting rod.

Crank Web Trueness and Parallelism

Checking for crankshaft webs being out of true and parallel.

Crankshaft Testing and Straightening

Crankshaft Testing and Balancing

Procedures for testing, balancing, and centering the crankshaft.

Crankshaft - Wrist Pin Procedures

Bearing and Bushing Checks

Checking big-end bearing clearance and small end bushing for wear.

Piston - Cylinder Matching

Cylinder Measurements

Clearance Limits and Ring Gap

Specifications for piston/cylinder clearance and ring gap.

Assemble Crankshaft - 1 Speed

Installing Bearings and Seals

Using special tools to install crankshaft bearings and seals.

Assemble Clutch - 1 Speed

Clutch Drum and Shim Installation

Installing clutch drum, shims, and measuring gaps.

Assemble Engine - 1 Speed

Engine Assembly: Crankcase and Seals

Installing magneto seals, crankshaft, and primary drive assembly.

Piston and Cylinder Installation

Installing piston, cylinder, and base gasket with proper alignment.

Contact Breaker Points Inspection

Inspection and replacement of contact breaker points and wiring.

Install Engine - 1 Speed

Engine Mounting and Ignition Coil Installation

Procedures for mounting engine in frame and replacing ignition coil.

Clutch Lever and Shaft Reassembly

Reassembling clutch lever and shaft, and reconnecting electrical wires.

Starter Cable and Idle Adjustments

Procedure for filling transmission and adjusting starter cable and idle speed.

Carburetor Operation and Troubleshooting

Fuel Flow and Engine Adjustment

Procedure for checking fuel flow and adjusting engine settings.

Dismantle Engine - 2 Speed

Starter Cable and Oil Drainage

Disconnecting starter cable and draining transmission oil for 2-speed models.

Gear Shaft Locking and Clutch Removal

Locking gear shaft and removing clutch drum and lock washer.

Centrifugal Clutch and Shaft Removal

Procedures for removing centrifugal clutches and main shaft.

Assemble Engine - 2 Speed

Install Engine - 2 Speed

Front Fork - Maxi Procedures

Front Fork - Magnum MK II Procedures

Shock Absorbers and Rear Swing Arm

Rear Wheel and Brake System

Brake System Maintenance

Hub Maintenance

Electrical Equipment

Breaker Points Maintenance

Ignition Timing Procedures

Trouble Shooting - Engine Start

Engine Not Starting or Hard Starting

Troubleshooting steps for engines that do not start or are hard to start.

Trouble Shooting - Performance

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