Puch Maxi - Service Manual

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Contents1
Routine Maintenance Schedule2
Lubrication and Maintenance Chart2
Changing Gearbox Oil3
Cleaning and Oiling the Chains3
Kickstand Lubrication3
Checking Spark Plugs3
Decarbonizing the Engine4
Cylinder Head and Piston Crown4
Exhaust Port4
Cleaning the Muffler4
Cleaning the Air Cleaner (Magnum/Maxi Series)5
Cleaning the Fuel Valve and Line5
Cleaning the Carburetor5
Cleaning the Main Jet, Needle Jet and Float Chamber5
Carburetor/Idle Adjustment6
Throttle Cable Adjustment6
Exploded View of the Carburetor6
Ignition Timing7
Breaker Point Gap7
Adjusting the Starting Lever7
Front Wheel Removal8
Checking the Brakes8
Front/Rear Brake8
Brake Linings8
Rear Wheel Removal9
Replacing Headlight9
Replacing Rear Light Bulb and Stop Light Bulb9
Tire Removal/Installation10
Exploded Engine View (Maxi Luxe)11
Exploded Engine View (New Port II/Maxi Sport MK II)12
Exploded Engine View (Magnum II)13
Exploded Engine View (Magnum MK II)14
Complete Special Tool Listing Usage/Kit Contents15
Special Tools16
Engine/Frame Torque Specification18
Engine Removal19
Disconnect Starter Cable21
Magnum MK II22
Dismantle Engine (1 Speed)23
Dismantle Crankshaft28
Checking Crankshaft by Sight31
Connecting Rod Alignment31
Crankshft - Testing, Balancing and Centering33
Big-End Bearing Clearance35
Small End Bushing35
Replacing Small End Bushing35
Sorting Table36
Magnum/Alu-Cylinder/Hi-Torque-Cylinder Sorting Table37
Piston/Cylinder Clearance Limits38
Ring Gap38
Measuring the Cylinder38
Maximum Permissible Ovality of Cylinders38
Assembling Crankshaft39
Automatic (One Speed)40
Assembling Engine43
Cylinder Head Gasket Sorting Table45
Clutch Lever and Shaft49
Adjust Idle Speed and Throttle Cable52
Carburetor Exploded View53
Carburetor Operation Trouble Shooting Tips53
Remove/Dismantle Engine55
Engine with Oil Pump Magnum MK II Dismantling61
Engine with Oil Pump Magnum MK II Assembling63
Installation of Seals64
Left Hand Crankcase Half64
Install Crankshaft65
Right Hand Crankcase Half65
Adjustment Hint66
Measuring Main Shaft and Clutch Drum End-Float74
Fit Carburetor78
Fit Exhaust Pipe and Silencer78
Air Filter Assembly MAGNUM78
Throttle Cable/Idle Adjustment79
Oil Tank-MAGNUM MK II80
Fuel Tank, MAGNUM80
Dismantle Front Fork81
Spring Dimensions82
Plastic Guide Bushing82
Assembling Front Fork83
Adjusting the Headlamp85
Dismantling/Assembling Front Fork, MAGNUM II (also Magnum XK)86
Dismantling Hydraulic Front Fork, MAGNUM MK II87
Assembling Hydraulic Front Fork, MAGNUM MK II88
Shock Absorbers91
Rear Swing Arm91
Checking/Fitting the Swing Arm92
Rear Wheel93
Mag Wheels94
Replacing Brake Shoes94
Front Hub (Leleu)95
Mag Wheel (Front)95
Brake Drum Diameter95
Rear Hub96
Idle/Drive Sprocket97
Spoking Wheels98
Installing Spokes into Hub99
Wheel Trueing101
Ignition Function102
Flywheel Magneto102
Electrical Equipment103
Lighting Function103
Breaker Points Gap104
Adjusting/Replacing the Breaker Points105
Engine Rotation107
Adjust Ignition Timing with Unmarked Flywheel (Without Dial Indicator)107
Fitting New Flywheel (Without Timing Mark)107
Tire Changing Schematic108
Removal of Tire and Tube108
Tire Mounting108
Engine Does Not Start or Is Hard to Start109
Other Common Complaints111
Malfunctions in Lighting Circuits111
Poor Performance113
Excessive Smoking or Transmission Shifting113
Enging Racing or no Idle113
Engine May be Difficult to Crank113
Wiring Diagram114
Wiring Diagram - Maxi, Maxi Luxe115
Wiring Diagram - Newport II, Sport MK II117
Wiring Diagram - Magnum II118
Wiring Diagram - Magnum MK II119
Spark Plug Conversion Table120
Metric Conversion Table121
Alphabetical Index123
Alu-Chr./Hi Torque Cylinder Exploded View130
Maxi-Motor139
1-Gears Automatic Knallert Motor Exploded View Maxi-1P)140
Rear Spoke Hub Exploded View141
2 Speed Automatic Engine Exploded View (New Port II/Maxi Sport MK II)145
2 Speed Automatic Oil Inject Exploded View (Magnum MK II)146
1 Speed Automatic Engine Exploded View (Maxi Luxe)147

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