REPAIR MANUAL

for the
M Z 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
l

I
The motor-cycles of types TS 125, TS 130, ES 12511 and ES 15011 are product8 from VEB Motorradwerk Zldropau
S

This Repair Manual was written by a team of engineers in the employ of VEB Motorradwerk Zschopau

VEB Motorradwerk Zsdropau reserve the right to modily or deviate from published specifications tor technical or
technological reasons at any time without notice.

All rights reserved

VEB FACHBUCHVERLAG LEIPZIG

Dead line: June P, 1983
Photomeohanfcal print: Salzland-Druckeref StaOfurt
SG 157A30/84
RH TS 1251150 und ES 12511 U. 15011. englisch. g;. Aufl.
 Preface

111the high latitudes of Finland, in the parhing heat of Africa, under the mort
different operating conditions MZ motor-cycles run to the retidaction of their
owners.

To ensure that the vehicles, remain in perfect working order and reliable .in
service after a long period of operation, involving a certain amount of wear.
we issue this Repair Manual to give the necessary instructions to our MZ work-
shops at home and abroad.

Repair W O I ' ~is

~ a matter of confidence in several respects:
reliability and workmanship of the mechanic; the safety of the driver
depends on them.
finding the actual cause of the trouble; this ensures that no material
is wasted and labour costs are restricted to a minimum.
from this. three advantages result: no retouching work, short times of
inoperatiun and low repair costs.

A good worksmanship in repairs largely depends on the use of the special tools
e dMZ. Authorised MZ Service-shops may obtain them
and means r e c o m ~ ~ ~ e n dby
from the R1Z Spare Sales Department, whereas amateur constructors only have
the possibil~tyof making them themselves. But to do it yourself you shbuld use
the sketches given in the Append~x.

U'e should like to underline that especially customers of "self-service work-

shops" and amateur constructors bear this in mind to avoid considerable addi-
tional expenditure of labour and material.

We hope this book of reference offers the required information to the staff of
the workshops conlracted for servicing our products at home and abroad and to
le friends of MZ motor-cycles throughout the world, and we wish good success.

VEB MOTORRADWERK ZSCHOPAU

~ e t r i e ,des
b IFA-Kombinats Zweiradfahrzeuge

Service Dept.
 Table of Contents

Tedmiecrl Data .................................... 8

Engine .........
Carburetter . . . . . . .
Electrical Equipment ...
Transmission . . . . . . .
Power Train . . . . . . .
Cycle Parti . . . . . . .
Dimensions and Masses . . .
Capacities . . . . .:. .
Characteristics and Diagrams

Fuel. Lubricmts and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engineoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gear011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubricants for Cycle Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shock-absorber Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Contact Breaker Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Dissossembly of the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 . Assembling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

. S .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical E ~ u l p m e n t 30

Dynamo . . . . . . . . . . . . . . .
Checking the Armature for Accidental Earth .
Checking the Armature for Shorted Turns . .
Checking the Field Coil for Accidental Earth .
Checking the Field Coil for Shorted Turns . .
Servicing the Carbon Brushes . . . . . . .
Servicing the Commutator . . . . . . . .
Fault Indication by the Charging Control Light
Adjustable Resistor . . . . . . . . . . .
Polarity Reversal in the Dynamo . . . . . .
Regulator Cut-out . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . .
Mounting and Servicing . . . . . . . . . .
Faults and Their Causes . . . . . . . . .
Battery . . . . . . . . . . . . . . . .
Putting the Battery into Operation . . . . .
Servicing the Battery . . . . . . . . . .
Ignition System ............
Ignition Coil ..............
Ignition Timing . . . . . . . . . . . . .
Ignition Timing by Means of a Graduated Dial .
Setting the Firing Point.........
Sparking-plug .............
Plug Cable Connector . . . . . . . . . .
Troubles . . . . . . . . . . . . . . .
Electric Horn .............
Ignition-light Switch . . . . . . . . . . .
Headlamp ...............
 5.7.1. Focusing the Headlamp ................................. 41
5.8. Tail Lamp and Stop-light Swit&. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ?
v
5.9. . . . . . . . . . . . . . . . . . . . : . . . . . . 43
Flashing-light Direction Indicator System :
5.10. Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 v.

6 . Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 l

8.1. Carburetter BVF 22 N 1-3 and 24 N 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.1.2. ...................
Description of the BVF Carburetters 22 N 1-3 and 24 N 1-1 45
.
8.1.3. Trouble Shooting and Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7 . Cycle Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 :
ES 12511 and 15011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removing the Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Front Fork and Steering Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Replacement of the Swing-arm Bearing Pin . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 :
TS 125 and TS 15C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Steering Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Telescopic Fork (see Fig . 136) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S !
FuelTank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7 1
l
Fuel Shut-off Cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Replacement of the Foot-rest Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9 1
Checking and Changing the Secondary Chain . . . . . . . . . . . . . . . . . . . . . . . . 59
Adjusting the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removing and Dismantling the Rear Wheel Drive . . . . . . . . . . . . . . . . . . . . . . 61
Speedometer Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replacement of the Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
!
.1
Inspections Required in the Case of Poor Road-holding . . . . . . . . . . . . . . . . . . . .
62 1
Repairing the Spring-loaded Suspension Units . . . . . . . . . . . . . . . . . . . . . . . . 63
Shock-absorber Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal of the Shock-absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Common Faults in Shock-absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Filling the Shock-absorbers with Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Mating Shock-absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

I
Cable Controls ..................................... 6 4 :

9. us(of special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.1. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2. Cycle Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.3. Electrical Equipment................................. 85

10 . Sketches for Making Special Tools ............................ 66

Supplement: Repair Instructions for the Engines 12513 .15013 and the Telescopic Fork with Aluminium Slide Tube
Fig. 1. TS 125 and 150

Fig. 2. ES 12511 and 150/1

Fig. 3. Sectional view of engine
 1. Technical Data

1.1. Engine TS 125 and ES 12511 TS 150 and ES 15011

-- -

Type MM 12512 MM 15012

Strokelbore 58/52 mm 58/56 mm
Swept volume 123 cm:' 143 cm'
Maximum output 7.35 kW (10 hp) 8.45 kW (11.5 hp)
(at 6000 to 6300 rpm) (11 SAE hp) (12.5 SAE hp)
Maximum torque 12.3 Nm (1.25 kp-m) 14.7 Nm (1.4 k p m )
(at 5000 to 5500 rpm)
, Type of carburetter 22 N 1-3 24N1-1
Number of cylinders 1 1
Piston mass, complete with two rings, gudgeon pin and
locks +
160 5 g 200 f 5 g
Compression volume with the sparking-plug inserted . 14.0 cm3 16.5 cm"
Cycle two-stroke reverse scavenging
Cooling system air stream produced in driving
Connecting-rod bearing bottom, cage-type needle bearing K 25 X 31 X 17 L
top, bronze bushing
Crankshaft main bearing 3 ball bearings 6303 c 3 f (silent, 17 X 47 X 14 mm)
lubrication by gear lubricant
Cylinder light-alloy, liner of special grey cast-iron onto which
the light metal is cast
Timing in crank degrees
inlet 150"
transfer 115"
outlet 165"

1.2. Carburetter
Transfer port
Main jet
Needle jet
Partial-load needle No.
Needle position, from top
(3rd for running-in) (4th for running-in)
Starter jet 70 75
Slow-running jet 35 40
Slow-running air screw opened by 2 to 3 turns opened by 2 to 3 turns
Throttle opening 3 mm 3 mm
Air filter dry air filter (paper cartridge)
Float valve seat 15(1.5mm) . 15 (1.5 mm)

1.3. Electrical Equipment

Ignition battery ignition
Ignition timing 3.0-0.5mm before T.D.C., fixed setting
Contact breaker points gap 0.3 to 0.4 mm
Sparking-plug M 141260
Electrode gap 0.6 mm
Dynamo direct current 6 V, 60 W, short-time operation 90 W
Charging control light (red) in speedometer
Regulator RSC 6016, under left-hand panelling
Battery 6 V, 12 Ah (flat lead storage battery)
Ignition coil 6 V, under left-hand panelling
Headlamp (asymmetrical) ES Types fixed - lamp opening 136 mm
TS Types movable - lamp opening 170 mm
Tail lamp ES Types lamp opening 95 mm
TS Types lamp opening 100 mm
combined with stop light contact in rear brake
i
 TS 125 and ES 12511 TS 150 and ES 15011 I

Flashing-light direction indicators ES 2-light system at the handle bar ends

TS Types 4-light system
Flasher unit in headlamp shell
Horn under fuel tank
By-pass light signal actuated by push-button
arranged below dimmer switch
Bulbs (data in parantheses apply to TS S p e s )
bilux (twin-filament) 6 V, 45/40 W
passing beam asymmetric
parking light 6 V, 4 W, BA 9 s cap
stop light 6 V, l 8 W, S 8.5 cap
(6 V, 21 W, BA 15 s cap)
tail light 6 V, 5 W, S 8 cap (BA 15 S)
flashing-light indicator 6 V, 18 W, S 8.5 cap
(6 V, 21 W, BA 15 s cap)
charging control light 6 V, 1.2 W
idling indication 6 V , 1.2 W
speedometer illumination 6 V , 1.2 W

1.4. Transmission

Clutch multiple disk clutch in oil bath

Gear-shift system foot-operated, left-hand side
Number of speeds 4
Gear ratios
1st speed 3.05 : 1
2nd speed 1.805 : 1
3rd speed 1.285 : 1
4th speed 1 :l
Bearing on clutch shaft 6202 (15 X 35 X 11 mm)
Bearing on layshaft 6201 (12 X 32 X 10 mm)
Rearing on shaft gear 6004 (20 X 42 X 12 mm)
Idling indicating light electric control bulb (green) in speedometer

1.5. Power Train

Transnlission
enginelgearbox 2.31 :1 37; 16 teeth
by sleeve-type chain A 9.5 X 9.5 ('18" X 3/e") 48 links
or double sleeve-type chain 2 X 9.525 X 4.77 (3/8" X 3/16")48 links
(from 4th quarter of 1973)
Transmission
gearboxhear wheel 3.2 : 1 3.0 : 1
f 48: 15 teeth C 48: 16 teeth
by roller chain 12.7 X 6.4 X 8.51 ('l2" X l/,") 120 rollers

1.6. Cycle Parts

Frame continuous pressed-steel, seamed

Steering angle TS 60"
ES 61"
Caster TS 90 mm
ES 95 mm
Suspension system C

front TS telesco~icfork with hydraulic damping, total travel

of spring 185 mm
 TS 125 and ES 12511 TS 150 and ES 15011

longitudinal swing
spring-loaded suspension units with hydraulic d a m p
ing, total travel of spring 150 mm
rear spring-loaded suspension units with hydraulic d a m p
ing total travel of spring 105 mm, spring pre-load ad-
justable
Wheels wire spokes
Rims, frontlrear 1.60 X 18 1 1.85 B X 18
Tyres, frontlrear 2.75-18 1 3.00-18
Tyre inflation pressure when loaded with:.
75 kg front
rear
150 kg front
rear
Permissible total mass
front 150 kPa (1.5 kp/cm2)
rear 270 kPa (2.7 kp/cm2)
Drake actuation mechanically, by means of cable controls for both
brakes
Brake diameterlwidth of lining
front

rear'

1.7. Dimensions and Masses

Wheel base

Length

Height withlwithout mirror

(flat handlebars)
Height withlwithout mirror
(elevated handlebars)
Height with mirror about 1150 mm
Width withlwithout mirror 7301620 mm
(flat handlebars)
Width withlwithout mirror
(elevated handlebars)
Width with flashing-light indicators about 750 mm
Ground clearance, loaded, at prop stand 140 mm
Weight unladen, ready for operation with fuel and tools
TS
ES
Permissible total mass

1.8. Capacities
Gearbox 0.45 1 of GL 60 gear oil for summer and winter
Fuel tank 12.5 1 of petrol41 mixture
including reserve about 1.5 1
Telescopic fork 220 cm3 of shock-absorber oil for each unit
Suspensions units, rear 70 a3 of shodr-absorber oil for each unit

1.9. Characteristics and Diagrams

quired favourable conditions are given (rider stooping
The maximum speed,'depending on sitting position, is
about so as to be almost "lying", tightly fltting motoring suit,
plane road, no headwind).
100 kmlh for the TS 125 and ES 12511 The engine charaderi$tics, traffic fuel consumption,
105 kmlh for the TS 150 and ES 1M/1 and acceleration are shown in the following diagrams
The maximum speed will only be reached if the re- (Fig. 4 to 9).
 L . . . ---
.. .. .
.:o,V 4 000 5000 bow
n in mm-'

Fig. 4. Full-load characteristics of the engine MM 125!3: Fig. 5. Full-load characteristics of the engine MM 150,/3:
rnas. output, mas. torque and specific fuel consumption max. output, max. torque and specific fuel consumption
-
Neo [PS] Neo [hp]
Mdo [kpm] -
Mdo [kp-m]
-
beo [g,WSh] beo [glhp-h]
-
11 [Ulminl n [rpm]

Fig. 6. Basic fuel consumption of the TS 125 and ES 12511 Fig. V.Basic fuel consumption of the TS 150 and ES 150/1
in top gear (4th) In top gear (4th)
Fig. I, Maximum acceleration when starting from sta- Fig. 9. Maximum acceleration when starting from sta-
tionary state (TS125 and ES 12511) tionary state (TS150 and ES 15011)

2. Fuel, Lubricants and Fluids

2.1. Fuel This additive-type oil meets the following technical re-
quirements :
According to the design of the engine, a petrol of an viscosity at 50 "C 20 to 25 cSt
octane rating of at least 88 (in the GDR abbreviated pour point maximum -30 "C
as "VK 88") should be used.
In countries other than the GDR, the use of a fuel with It contains additives which effect a high tem-
a similar rating is recommended. perature and pressure resistance. Limited
If fuels of a higher octane number are used, readjust- tendency to coking, prevention of carbona-
ment of the carburetter by resetting the partial-load ceous oil deposits or loosening of them. Wear
needle may be necessary. reducing and corrosion preventing properties.
Contains lead separating agents preventing
whisker formation in sparking-plugs.
For MZ motor-cycles operated in countries other than
2.2. Engine Oil the GDR we also recommend exclusive use of two-
stroke engine oils which possess these properties (e.g.
Engine oil is added to petrol in the Shell 2 T, Castrol 2 T, Arol 2 T, Mix01 'S", LT- 2 T).
r a t i o of 1 : 3 3
(e.g. 0.3 1 of engine oil are added to 10 litres of fuel).
For other units of measurement we refer to the con-
version table (see Section 11.). This mixing ratio also 2.3. Gear Oil
applies to the running-in period.
This simple and reliable system of petroil lubrication For gearbox and primary drive, an amount of 450 an3
supplies oil to the ?WOconnecting-rod bearings, cy- of GL 60 gear oil is required.
linder liner, and piston. This is an additive-type gear oil which is particularly
Experiences gathered by us in the course of many suitable for the lubrication of changespeed gearboxes
years have shown that it is advisable to use exclusi- and axle drives. It is an ageing-resbtant refined lubri-
vely cating oil with additives for an increase of load-bear-
MZ22 two-stroke e n g i n e oil. ing capacity and a reduction of wear.
It . a s favourablelow-temperature properties and meets
t h e following technical requirements:
viscosity a t 50 'C
(corresponds t o about 8 'E) 53 to 68 cSt
pour point maximum -25 'C
f lashpoint 180 'C
water content 0.1 O/O
In countries other than the GDR, a gear oil with sinii-
lar viscosity values and properties should be used.

2.4. L u b r i c a n t s f o r Cycle Parts

The swing a r m bearing and t h e worm for clutch oper-

ation must also be lubricated with GL 60 g e a r o i l .
(Oil-filled greasc g u n : swing a r m bearing to be lubri-
cated thoroughly until oil emerges from the lubrication
points: WOITII for clutch actuation to bc lubricated by
2 to 3 strokes.) Loosen thc t\vo f;~b~csn~ng sc;.\\h (SCY, ; I I . I . # ) \ of
~ S )t h e
The following lubricating points of the cycle parts must tc~.n-iin;llcasing ;ind rc~nio\.c~ 1hc7 I , I I I ~ ~ I . ( i t is mounted
bclubricated \ v i t h " C e r i t o l +
k2"or"Ceritol on a centring dcvice a n d locating pln).
+ k 3 " antifriction bearing grease: Unscl-c-\\. thc al,mntul.c f;~slcnlnl:.;cl.i5\\.( 1 ) a n d rcmove
steering bearing. wheel bearings, bearing for the Inlcl.1.uptci. tarn T;akc>c . ; I I . ~ nalr
~ 10 d;lm,rgc~the face
~.car-\vheeldrive, secondary chain, brake cam. of the con-rmutato~~ to insul.c, I ~ ; I Ithe' cam \\.ill continue
brake shoe bearings, and speedometer drive (the to run properly.
latter only \\.hen being n~ountedor repaired).
This antifriction bearing grecse has a pour point of
about 1 3 0 to 1 5 0 "C, can be used for a temperature
range f ~ w n-30 to + l O O a C , and is water-resistant c t
-+50 'C.
i n countries other than the GDR, an antifriction bear-
ing grease of similar characteristics should be used.

2.5. Shock-absorber F l u i d

For the telescopic fork and t h e spring-loaded suspen-

sion units, a shock-absorber fluid of a viscosity of 8 to
11 cSt (corresponds to 1.65 to 1.9? "E) a t 50 "C should
be used.
The damping characteristics of the telescopic fork and
the spring-loaded suspension units a r e based on this
viscosity. Springing and roadability will b e impaired F I G 11 Ren~o\lngthe pole casing
if shock-absorber fluids of a different viscosity will be
used.
Use puller 02-MW 39-4 or a screw M 10x100 for re-
moving t h e armature. By means of other tools, eg. a
claw-type'puller, either the winding will be damaged
2.6. Contact B r e a k e r Lubrication
o r the segments will b e deformed.
For contact breaker lubrication, t h e special oil for igni- Keep t h e plate disk ("key") in a safe place!
tion circuit breakers, in the GDR known a s "Unter-
brijl", should be used; it possesses a viscosity of from
500 to 1,300 cSt a t 50 OC.
If this special oil is not available, a high-viscosity gear
oil of similar viscosity properties can be used.

3. Disassembly of the Engine

Remove t h e closing plate a n d t h e dynamo cover, dirc
connect the cables from t h e dynamo (disconnect the
plugged connections).
If t h e identacation colours of t h e various cables are
not clearly discernible, it is advisable, especially for
amateur ccnstructors, to attach paper slips with mark- \1
ings (D+,DF a n d frame) t o the cables t o save the
work of measuring them f o r reassembling, f i g . 12. Pulling off the armature
For loosening the nut of the gearbox sprocket, bend
u p the lock plate, using the sprocket-holder 05-MW 45-3
to retain the sprocket. ( L e f t - h a n d t h r e a d ! )
Remove cover plate (1) and sealing cap (2).

1.'~; 1.5. D~smnntlin::the clutch drivel

Remove the dri\.ing :'p~.ockc%lby mt3;in.; t 1 1 p ~ ~ l l e r

12-MW 23-4 (A).
The vent bores at the pinion for the dupltss ch;tin are
Fi; 1'3 Removing the gearbox sprocket arranged closer together!
Remove pinion u i t h chain and clutch basket.
Keep the plate disk ("key") from the end o f ~ h t cmnk-
,
L f , ( w nthe clamping scre\v of the kick-starter and that shaft carefully so that i t cannot be lost!
trl ~ l i cgear-shift pedal and remove the two controls.
Looaen the clutch cover by tapping against it close by
tlie fitting pins (A), using a rawhide malle., and remove
the cover. D o n o t u s e a s c r e w - d r i v e r t o
f n r c e o f f t h e c o v e r because time-consuming
wfinishing operations will be necessary to restore the
cover to a proper leakproof condition! Press down the
spring plates by means of tool 11-MW 15-4 and p u ~ h
nut the pins.

Dismount cylinder with head (gradually loosen the

hexagon nut crosswise) and the piston. Remove the
,gudgeon pin lock ring by means of a pair of taper-nose
pliers and press out the gudgeon pin by means of the
Grift 22-50.010.

Fig. 14. Dismounting the clutch

Loosen the nut on the clutch shaft (use a spanner with

a w i d t h o v e r f l a t s 19). ( L e f t - h a n d t h r e a d !).For
this purpose use the holders 01-MW224 (1) and 12-MW
5-3 (2). Unscrew the nut (width over flats 19) from the
drive pinion (right-hand thread).
An amateur constructor may rivet or weld a round
iron bar having a diameter of 10mm and a length of
about 200 mm to a n old clutch disk of steel. The tool
produced in this way (similar to a signal disk) can be
used in the place of the two holders. The internal teeth
will retain the clutch driver, the round bar the clutch
drum. Fig. 17. Dvivinr: out thc. :udcer,n pin
 Remove all of the 14 casing screws from the right-
hand side of the casing.
For.= out the fitting sleeves at the front and rear en-
gine mounting by means of the offset drift 11-MW 3-4.

Fig. 10 U~srnnntl~ng
the geill -.4~1l
I ~nechan~bm

D o n o t b e a t o U t - c~,;~nkshafts
\vhohc cwds arc
heavily damaged will not bc accepted by iqxrir-shops.
If the gearbox bearings hnvc to be replaced by new
Fig. 18. Driving through the fitting sleeves ones, remove thc lock rings (sec arrows) by means of
a pair of taper-nose pliers.

Engage the fourth speed of the gearbox. Lift off thc

right-hand casing half by means of the separating
screw 22-50.012.
Facilitate this operating by slightly tapping uVitha
rawhide mallet (see arrows).
Then, proceeding from the bottom, beat out upwards
both clutch shaft and layshaft by means of a copper
mandrel (screw thread!).
For this purpose. move the gear-shift wheels so that
the slotted section easily slides through the gear-shift
wheels, otherwise the gear-shift dog will be deformed.

Fig. 21. Pushing out the crankshaft by means of the

22-50.013 pusher

For the removal of the ball bearings. h e a t the cas-

ing halves to a temperature of about 100 "C. This will
facilitate dismounting without damaging the bearing
seat.
Beat out the bearings for clutch shaft and layshnft
from the interior to the outside.
As to the 6303 crankshaft main bearings take into con-
sideration that a lock ring ( l ) is arranged between these
Fig. 19. Pulling off the right-hand casing half two bearings (see Fig. 3).
First beat out the outer bearing, from the inside of
the casing, using a mandrel. Then remove the circlip
by means of a pair of taper-nose pliers and push out
F
Gear-shift detent shaft (1) must then be screwed out the inner bearing - together with the packing ring -
after bending u p the lock plate and unscrewing the using drift 11-MW 7-4 and proceeding towards the
t r.ut at the clutch side. inside.
Bend up the lock plates for the fastening screws (2).
and (3) of the retaining plate with gear-shift segment
and loosen the screws.
Now, the complete gear-shift mechanism can be re-
moved.
 only then, the engine will become perfectly gastight.
If a surface plate is not available, the table of a ma-
chine tool, e. g. a column-type drilling machine, will
do good service.

Fig. 25. Dismantling the ball bearing

Push the crankshaft main bearing 6303 with packing

ring out of its seat in the heated right-hand casing
half, using a suitable drift and proceeding from out-
side to the inside. Fig. 24. Re-finishing the sealing surfaces
The delivery and return pipes for lubricating the
crankshaft bearing a1 the dynamo side and the lay-
shaft bushing must be cleaned to remove lubricant
remains, and then blow compressed air through them The next thing to do is to insert the circlips (locking
(see arrows). ring) for the crankshaft main bearing and the clutch
A careful cleaning of all engine parts is indispensable shaft and layshaft bearings into the left-hand half of
for reliable trouble-shooting. Do not only check and re- the casing, using a pair of taper-nose pliers; the half
place those parts which cause functional troubles hut of the casing must be h e a t e d to a temperature of
check and measure all parts and points subject to wear. a b o U t 100 "C on an electric cooker.
This is the only way to avoid another repair after a This is necessary to facilitate the insertion of all bear-
short time of operation. ings, especially, to prevent them from being tilted and
the casing bore-holes from being damaged (bearing
location). On no account use a welding torch for heat-
ing - due to local overheating the casing may get
distorted.

Fig. 23. Oil bore-holes of the right-hand casing half

Fig. 25. Heating the casing

4. Assembling the Engine

Please notice:
.After having cleaned the engine parts carefully, the Bearing for clutch shaft = closed end of the cage point-
first thing to do is to treat the two halves of the cas- ing to the gearbox.
ing, the clutch cover and the cylinder head. Bearing of layshaft = open end of the cage pointing
The joint faces are checked on a surface plate and to the gearbox.
touched up, if required (using emery cloth), until all For fitting use a bolt or a piece of a tube (must be clean
scratches or sealing compound are removed. Then and inside!) having a diameter from 35 to 32 mm.

C.!
 mounted in this improper condition, premature wear
of the crankshaft bearings and poor engine output will
b e t h e result because the contact breaker cam fails to
raise a t the specified point or raises twice.
If there is no test stand for true running available,
the checking operations involved may also be per-
formed between the centres of the lathe.
The amount a crankshaft may be out
o f t r U e at all measuring points is 0.02 mm.

Fig. X. Mounting the g e n r b o s bcnr.in;b

( A ) V r n l 0 1 thr g c n r b n x c n s ~ n l :

Fig. 28. Checking the crankshaft for true running

.The r a d i a l p l a y of the connecting-rod .provided

with needle bearings in new condition must be
0.015 to 0.030 mm
Maximum a m o u n t o f w e a r , l i m i t
0.05 mm
The r u n n i n g c l e a r a n c e o f the small-
e n d b u s h , new condition, is
0.020 to 0.030 mm
A m o p n t of w e a r , l i m i t
0.045 mm
I t should be noted that the small-end bushes normal-
ly a r e worn out in such a way that they become oval.

Pig. 27. Inserting the cl-anl<.li:ift henring a t the left-hand

bide

Note that all operations regardmg the mounting of

the crankshaft and of the gear-shift mechanism must
be finished before the temperature of the casing drops
below 70 "C.
Therefore. check all parts to be mounted before Etting
them or replace them by new ones, if required, and Fig. 29. Checking the connecting-rod bearing
place them on a clean surface. together \vith the neces-
sary tools, so that they a l c ready at hand for mount-
ing. W o r n o u t s m a l l - e n d b u s h e s a r e replaced
Every crankshaft, xvheter it is a new one or a regen- by means of. the 11-MV 60-3 fitting device. The new
erated one, must be checked for true running before small-end bush of f i n a l s i z e is put on the device
mounting. It may have been distorted during trans- and, 'when tighteningthe nut, presses theold bush out
port or when it was dropped inadvertently. When of its seat.
 Take care that the lubricating holes to be drilled end Do not force the crankshaft through a cold bearing b e
in the oil catch pockets. cause this will render it useless (out of true) before i t
Remove all burr from the holes. has run. Then the contact-breaker cam lifts anywhere
See to it that the fit is not too narrow - the sliding but not on the cam lobe! O r the primary &in is al-
bearing requires a continuous oil film. ternately slack and taut during one revolution.

Fig. 30. Replacing the sn)all-end bush

Pig. 32. Mounting the crankshaft

The a X i a l c l e a r a n c e (see double arrow) of the
connecting-rod in the crankshaft, in new condition, is
0.25 to 0.40 mm
Wear limits at the gear-shift mech-
When the connecting-rod is copper-plated on all sides,
a n i s m - c a u S e s of g e a r - s h i f t f a u l t s :
this clearance is reduced to
0.13 to 0.36 mm (1) Bolt a t the retaining plate has a clearance of mcjre
than 0.3 mm
With an axial clearance of 0.55 mm, the crankshaft is
worn out. (2) Cut-out in the retaining plate worn down more
The crankshaft (Fig. 31) is used unchanged for the than 0.4 mm (size in new state 20.6:., mm)
engines of the ES 12511, TS 125, ES 15011 and TS 150. (3) Window in the segment lever and dogs of the
gear-shift member heavily worn (round)
It may happen that the connecting-rod of a new crank-
shaft was deformed by improper transport or storage. (4) Return spring slack
As a distorted or oblique connecting-rod will wear (5) Gear-shift dog worn down more than 0.3 mm or
down the small-end bush before long, check the con- blue discoloration (size in new state 5 ~ :mm): ~ ~ ~
necting-rod in any case. (6) Spring or ball (6.35 mm) jams in the gear-shift
fork

Fig. 31. Crankshaft

. Fig. 33. Gear-shift mechanism

' Oil the crankshaft end.

At the re-heated casing half, h e a t the i n n e r Screw the retaining plate with gear-shift segment in
r a c e o f t h e c r a n k S h a f t b e a r i n g by place and fit the lock plates.
means of a heated mandrel. (l) in such a manner that Insert gear-shift shaft with gear-shift member; prior
the crankshaft slides to the shoulder due to its own to this operation slightly oil the bearing area of the .
weight. . shaft.
Screw the gear-shift detent axle in place and adjust it
by means of the setting gauge 11-M1 8-4 (the arrow
indicates the references groove).
The check nut (place a lock plate under it) must be
tightened b e f o r e t a k i n g m e a s u r e m e n t s .
tightening the nut changes the setting.
If the gauge is not available, adjust according to the
instructions given in Fig. 38, using a block gauge.

11 the edges of the keywas in the clutch shaft (1) and

layshaft (2) and their gear-shift wheels [2nd and 4th
speeds (3)] have become severely rounded or are even
broken out, then they must be replaced by new ones.
Check the woi-king surfaces of the bearing collar at
the pair of gear-shift wheels for the 1st and 3rd
speeds (4) for wear marks. When using new parts take
Fig. 34. Setting the gear-shift detent axle care to see that these parts are properly matched -
black colour dot to black and white to white!
Check the gear for the 1st speed (5) that the edges of
Gear-shift dog to be pushed on the gear-shifr detent the window are in a proper state and that there a r e
axle together with compression spring and ball. press- no cracks.
ing the ball into the bore-hole by means of a screw- Check the bush of the shaft wheel (6) for wear.
driver. The a m o u n t t h e c l u t c h s h a f t m a y b e
I- ~t the gear-shift lever in place and shift the gears. o u t o f t r u e is
During this operation check that the dogs of the gear- 0.05 mm
shift member properly engage ( e n g a g e m e n t Realignement should only be effected by pressing but
m i n i m u m 1 mm, m a x i m u m 3 mm) and that never by beating! It is advisable to check the shaft
the elastic segment lever does not jam when the gear- between the centres of a lathe and then adjust it.
shift member returns. If necessary, restraighten the
retaining plate.

Fig. 37. Causes of faults in the gear-shift set

Fig. 35, Inserting he gear-shift pawl

If the setting gauge shown in Fig. 34 is not available,
use a "block gauge" having a height of 13.0 m m ; this
Check all dogs of the gear-shift wheels for wear. The gauge should be specifically made for this purpose.
undercut of 5" must bear for at least ' 1 4 , otherwise this With the 3 r d s p e e d e n g a g e d it must be pos-
part and the gear with which the worn dogs engage sible to insert this gauge while a slight resistance can
must be replaced. just be felt. If this is not the case, readjust with the
The gears under load a r e retained in mesh by the un- gear-shift detent axle until the distance is correct.
dercut but not by the gear-shift mechanism detent de- W i t h t h e 4 t h s p e e d e n g a g e d , a distance
vice on the axle. of 0.1 to 0.2 mm is required between gear-shift wheel
of the 4th speed'&d the shaft wheel - the 6004 shaft Apply a t h i n f i l m of j o i n t i n g c o m p o u n d
wheel bearing must not be exposed to axial pressure! t o t h e s e a l i n g s U r f a c e s (most of the joint-
(See Flg. 38, page 21) ing compounds can be diluted with nitro diluent). Do
not smear over the tapped holes or the gearbox vent
(Fig. 26) ! Put the casing half i n place and properly Bt
Oil all journals and shafts. Put the gear-shift wheels it by applying slight blows with a rawhide mallet.
for the 2nd to the 4th speeds on the clutch shaft and Readjust t h e bearing 6004 a t the shaft wheel by means
push the latter into the ball bearing. At the same time of the 11-MW 7-4 drift.
insert the finger of the gear-shift pawl into the guide Drive the two fitting sleeves (see arrows) in place,
grooves of the gear-shift wheels. Use a rawhide ham- using the 11-MW 3-4 drift.
mer to drive the shaft u p . t o the stop. During this
operation, the gear-shift pa-wl is in the 4th speedy
At the layshaft, first fit the gear (provided with a
window) for the 1st speed (smooth side pointing up-
wards), then insert the pair of gear-shift wheels for the
1st to 3rd speeds with the guide collar into the mating
wheel and put the layshaft through. At the same time
turn sideways until the keyway slides through the
gear-shift \\-hecls.
Usc a i.i\\vhid(, hammer to drive the layshaft up to the
stop.

Fig. 41. Mounting the right-hand casing half

Tighten all 14 c a s i n g s c r e W s by means of a

properly fitting screw-driver (if possible use a breast
drill) [maximum torque 12.7 Nm (1.3 kp-m)).
Observe the correct succession, namely:
Starting in the centre of the casing, then tightening
alternately and crosswise right-hand and left-hand
Fig. 39. Mounting the gear-shift set screws (order indicated by numbers in the illustration).
Make haste to ensure that the casing is still warm
Put the shaft wheel (1) in place and check the contact enough for the next operations.
plate for the neutral indicator (2) - if necessary,
straighten the plate (dimension "A" 10 to 11 mm -
while the gear-shift shaft is pressed down).
Meanwhile, the r i g h t - h a n d h a l f o f t h e c a s -
i n g has been heated to a temperature of about 100 "C
and the crankshaft sealing ring (from the inside) driv-
en in (press in rings without steel coat) so that it is
flush with the inner edge of the casing - sealing lip
pointing outwards (see Fig. 3).
The inner race of the 6004 bearing must be heated by
means of a mandrel and then fitted into the casing by
means of the 11-MW 7-4 drift.

P .

Fig. 42. Tightening the casing screws

Use a heated mandrel to bring the inner race of the

6303 bearing t o a temperature of about 80 "C and,
using the 11-MW 7-4 drift, apply s l i g h t t a p s to
insert it until i t contacts the collar of t h e crankshaft
tail end.
Especially in the right-hand crankshaft bearing ev-
erything depends on the fact that the cold outer race
slides in the hot casing - and the hot inner race of
Fig. 40. Left-hand casing half readily mounted the bearing on the cold end of the crankshaft - when
Fig. 38. Power flow in the
four speeds
a few slight blows by a hammer are applied. If this is If the blows applied were still heavier, the crankshaft
not the case you could not feel whether or not the will be laterally displaced and will be forced out of
bearing already contacts the collar (see Fig. 3). true; then it is useless for the following reasons:
1. The contact breaker fails to lift a t the specified
point or the adjusting range of the contact-breaker
base plate will become insufficient.
2. The amount the crankshaft is out of true will cause
the engine to. vibrate and, a s a consequence, the
warranted engine output will no longer be reached.

If the bearing is driven in with undue force into the

cold casing and without the inner race being heated,
there is the additional risk of the outer race becoming
tilted, i.e. it will not fit axially parallel.
In addition to the state described in Fig. 44, the casing
becomes useless. A correctly mounted bearing would
again be tilted because of the damaged seat of the
bearing.
(For a better demonstration, the representation of the
sketches is slightly exaggerated.)
I.'& 13. Inserting the right-hand crankshaft bearing

One vigorous blow by a hammer more than required

may cause the following:
The crankshaft is exposed to axial thrust because the
bearing was driven in too deep. The inner race presse.i
back the slightly resilient crankshaft. As a conse-
quence, the bearing clearance (lubrication film!) in the
left-hand bearing is also removed. The balls no longer
bear radially but run on the sides, producing a "whin-
ing" sound until they will fail prematurely.

Fig. 46. Tilted bearing

Meanwhile the inner race of the third crankshaft bear-

ing has been heated to about 80 "C. The casing is
Fig. 44. Distorted bearing turned in the assembling device through 180" and the
bearing driven in until it contacts the lock ring by
means of the 11-MW 7-4 drift.

Fig. 47. Inserting the crankshaft bearing at the left-hand ,

Fig., 45. Displaced crankshaft side
 The distance between the outer edge of the casing and shaft wheel) to beat the shaft back (upper arrow). Now
the bearing outer race must be measured and, if re- t h e end clearance shown in Fig. 38 between the face
quired, adjusted to the correct dimension by means of of t h e keyway section of t h e clutch shaft and t h e shaft
spacers. wheel must be present.
A distance from 0.3 to 0.3 mm to the cover plate must Slightly grease the lip of t h e sealing ring in t h e cover i
remain. Thc thickness of the original packing (0.5 mm) plate - put on the distance bush [(I) in Fig. 481. I

must bc takcn into account. Find out whether t h e Fit t h e gearbox sprocket (recess pointing to t h e engine) I
spacel- bush (1) has been damaged by the sealing lip and lock plate. Tighten t h e nut with a width over
and check that thc scaling ring is in perfect working flats of 27 with 58,9 Nm (6 kp-m) ( l e f t h a n d-
condition. t h r e a d ) and flt the lock plate.
Propcrlg clcan thc joint surface of the cover plate, Arrest the assembly with the 05-MW 45-3 holder o r an
inscrt a pnpcr packing (use jointing compound). and old chain.
( i c h ~ tclie~ s~c ~ ~ \ \clms\vise
.s [Torque 4.9Nm (0.5 kpm)].
After checking the 17 X 30 X 7 sealing ring in the seal-
ing cap measure the distance (1) between sealing cap
and ball bearing by means of a vernier caliper and see
to it that the end clearance is 0.2 to 0.3 mm, if neces-
sary apply shims. The thickness of the original paper
packing (2) of 0.5 mm must be taken into account.

Fig. 50. Aligning the sealing cap

If (with the engine mounted) the green control light

Placc t h c cnfiinc ;n upright pobition - if there is no fails to light up, then loosen the clamp a t the lead and
a s s e n ~ b l i nfaull
~ (Flgs. 44 to 46). the crankshaft must apply the cable end from the control lamp to ground.
be free to bc mo\.c,d \vith case.
By \$.ay of trial. shift the gears of the gearbox - a:
the same time turn thc clutch shaft.
The clutch shaft must be free to move easily; if this
is not the case. use a rawhide mallet to drive the shaft
(lower arrou7) for\rnrd through a distance of 0.2 mm
and then use a coppci. mandrel (placed..through the

Fig 49. Aligning tlle gearbox Fig. 51. Adjusting the neutral control switch
I
 If the green lamp again fails to light, the lead or the Fit the lock plate (1) of the nut of the gear-shift detent
electric bulb is defective. If it lights, the fault is in the axle.
contact switch: the contact gap at the contact plate is Check the teeth of the starting segment a t the con-
less than required (Fig. 40). tacting side (2) for wear.
A distance of 12.5 mm is required between the outer Insert the offset end of the kick-starter spring into the
edge of the casing and the upper edge of the contact slot in the starting segment - if necessary, restraighten
plate. If necessary. use a n offset bicycle or motorcycle so that the end of the spring fits tightly.
wheel spoke to draw the contact plate to the desired Fit the g u i d e (or thrust) w a s h e r 3 0 X 1 7 X
dimension (for this purpose, the gearbox must be in and mount the starter shaft with spring. Put the kick-
neutral position). starter lever in place and pre-load the starter spring
by turning it through one revolution clockwise. For
this purpose withdraw the starter shaft just far enough
to ensure that the segment passes the stop (3). Press
Or the distance between contact pin (A) and contact the rolled up end of the spring into the holder.
spring (B) is too large because the latter is bent back.
Earth continuity is also lacking if the contact spring
is oxidised or dirty.
When replacing the contact switch only use original
parts, when the contact pin is too long it may be p3s-
sible that the p i n hooks on behind the contact plate
and thus o b s t ~ . u c t s t h e s w i t c h m e c h -
a n i s m , that is to say. the gear-shift pedal can be
moved without shifting gears.
Apply a thin filni o f jointing compound to the plane
surface of the switch and screw it to the casing.

Fig. 54. Mounting the kick-starter assembly

At the complete clutch drum check

(A) if the dogs of the frictional lining disks have pro-
duced indentations in the clutch drum.
Small notches are removed by means of a smooth
file. If there are deeper indentations, the part must
be replaced because in this state the clutch fails
Fig. 52. Neutral control switch to separate properly.
(B) if the edges of the window in the driver and the
dogs of the kick-starter wheel in engagement with
this window are heavily worn (rounded). If there
Shift all four gears by way of trial. At the same time is a large amount of wear, replace the part other-
check, by counter-rotating clutch shaft and gearbox wise the kick-starter will slip.
sprccket, that the gears properly mesh and engage.

Fig. 53. Gear-shifting test Fig. 55. Wear of the clutch drum

/ 24
 Check the sprockct on the crankshaft, the sleeve-type Check t h e inner driver to see that t h e internal gearing
chain and the clutch sprocket for wear. For this pur- is i n proper mesh with the profile of t h e clutch shaft
pose, pi~ovisionallyfit these parts. without excessive backlash..
With the engine standing vertically, the sag in one Indentations in the grooved profile o! t h e driver caused
strand of the chain must not exceed 8 to 13 mm if t h e by t h e (steel) disks and which can just be felt o r a r e
other one is taut. If the sag is excessive, the chain will just visible can be neglected.
"~vhip".mount thc teeth and perhaps break. In t h e case of indentations deeper than 0.1 mm, t h e
Whcn selecting a new chain, take the colour marking inner driver must be replaced.
into consideration and observe the stamp on the pack- T h e d r i v e r s for thedesigns d u p i e x o r s i m -
ing : p l e ~c h a i n a r e n o t e x c h a n g e a b l e be-
green = normal, for practically new sprockets cause of different heights of collar (A).
yellow = 0.1 nlnl less, to be used in the case of
11ttle \vear
\!,hit? = 0.3 mm Icss. to bc used in the case of

Fig. 58. Internal clutch driver

Insert the 12-MW 5-3 (1) holder, fit t h e inner driver (2)
and arrest it by means of the 01-MW 22-4 (3) holder.
First put the spring ring and then t h e lock plate on
the clutch shaft - place the eyelet over one of the
spring bolts with the drop downwards. Tighten t h e
Fig. 5 6 . Checking the primary drive nut by means of a socket wrench (width over flats 19)
with ti torque of 58.9'9.8 Nm (6+lk g m ) . ( L e f t - h a n d
i h r e a d.) Fit the Icck plate.

First d i p thc thrust \vashcr 25 X 15 X 0.5 and then Fit t h e spring ring on the crankshaft end and tighten
thc c l ~ i ~ cdrum
h with bush on thv clutch shaft and then the n u t by means of a spanner (width over flats 19 -
put the sprocket on t h e crankshaft. ight-hand thread) with 58.9'9.8 Nm (6+' kp-m).
Use a ruler or \.ernier caliper 10 check that the two
sprockets are in line. h'ecessary corrections -re made
neith shims (0.1: 0.2; 0.3; 0.5 mm thick) which a r c
placed bclween bush and thrust washer.
Not properly aligned sprockets cause premature wear
cf chain and s p i ~ ~ k c t s .

Fig. 59. Fastening the driver

Steel disks:
?
Use a ruler or a vernier caliper to check that
the surfaces a r e still plane - if necessary, use
Fig. 5 ; . Alignin:: the prinlary drive a surface plate for checking.
Disks with frictional lining:
Thickness, new 3.4 f 0.1 mm
maximum amount of wear - 0.2 mm

Compression springs:
Length, slack 49 mm
spring power 157 N (16 kp) with a
mounting length of 31.5 mm

Fig. 62. Fastening the clutch compression springs

Put the paper packing (without jointing compound)

and the touched-up clutch cover in place - uniformly
tighten the screws [torque 12.7 Nm (1.3 kp-m)].
Slip on kick-starter lever and control lever and tighten
the clamping screws. After the trial run retighten the
two screws.
Screw the oil drain plug 18 X 1.5 (with magnetic plug
Fig. 60. Clutch dismantled incorporated to retain metallic particles) into the crank-
( I ) Holding disk, (2) Spring plate, (3) Pressure pin case and the oil-level check screw (A) into the clutch
cover. Take care to see to it that the packing rings are
in proper condition.

First fit the retaining disk, which is slightly thicker

than the other ones, and then the other clutch disks
in correct succession (Fig. 60). Grease the p r e s s U r e
p i n on either side and put it into the clutch shaft.
Mount the spring plate (1) in such a manner that the
spring bolts (2) are exactly in the centre of the cir-
cular opening - this is ensured when the bolt (B) with
colour spot (or punch mark on the clutch driver) and
the curvature (A) of the opening are opposite each
other. The spring caps and the compression springs
must not jam or rub.

Fig. 63. Mounting th.e clutch cover

The markings on the piston head have the following

meanings :
(a) Arrow - when the piston is mounted as in nor-
mal use, t h - arrow must point in the direction of
the exhaust port.
(b) 51.98 - this is the "nominal size" of the piston,
that is to say, it is 51.98 mm in diameter. Matched
with a cylinder marked "+l", a fit L\-ith an as-
sembly clearance of 0.03 mm is obtained.
Fig. 61. Mounting the clutch Tolerances are allowed for cylinder bore (honed) and
piston diameter. as is the case with any other part, e.g.
the tolerance for the cylinder bore is + 4 to 6 pm.
I n o r d e r that the u p p e r t o l e r a n c e i . ' t of
Using the "Push pin for clutch compression spring" thepistonandthe l o w e r t o l e r a n c e l i m i t o f
11-MW 15-4, press down the nipples and compression the cylinder (or vice versa) do not coincide, the t , a
springs and insert the cylindrical pins. parts must be measured and selected according to the
Place the 20 X 30 X 1 washer on the kick-starter shaft. specified assembling clearance.
Fig 64. Piston marking

Fig. 66. Cylinder marking

The "nominal s i ~ ~i5. "measured a t the lower edge of
the piston skirt. The piston skirt is conical. the smallest To avoid c l ~ o i . sin measuring.. the internal-measuring
d i a m e t e ~:S
. t h ~~. i n gaec~ion. instrument must precisely be set to t h e relevant basic
size of 52 or 56 mm by mcana of a ring gauge (or a
A s s e m bl>- p1>:;:111- \year v a l u e microme~cr.as a makeshift).
clearance cylinder
ES/TS 115/150 0.03 mm 0.25 mm
O v e r s i z e s o f p i s t o n s for the two types
8 oversizes - each by 0.25 mm larger than t h e pre-
vious one - a r e available. More than 2 mm must not
be removed in internally grinding, otherwise the cyl-
i..der liner is liable to t h e risk of deformation.

Fig. 67. AI~,;!-uringthe cylinder

Fig. 65. h'leasuring the piston
All MZ n~otor-cycles have a "syn~metric" timing dia-
gram. Related to t h e transfer angle of 115" t h a t is t o
say t h a t the transfer ports open 57.5" before bottom
T h e wear value (assembly clearance) is related to the dead centre and close 57.5" after B.D.C.
values measured in t h e upper and lower quarters of Exhaust and transfer a r e measured from B.D.C.,inlet
t h e working surface of t h e cylinder. In the centre, be- from T.D.C.
tween t h e ports, t h e wear rate naturally is somewhat Timing
higher. The arrow shows the marking of the nominal ES 125 ES 150 ES 12511 a n d 15011
size on the cylinder.
- ---- -- -T S 125 a n d 150

+
0 = full size
1 = 0.01 mm over full size
Inlet wl th
point 142' 142.5' 1 1500
+ 2 = 0.02 m m over full size Inlet without
point 126" 126" I
The other numbers indicate manufacturing month (2) Transfer 110" 110" 115"
and year of manufacture (4); here, February 1974. Exhaust 152" 150" 165"
 W i d t h of p i s t o n Wear value
ring groove
2.04 +0.02 mm 2.10 mm
Pisto9 rings whose vertical play is excessive fail to
ensure a gas-tight seal and produce a "whining" sound.
If the locking pins in the piston ring grooves have be-
come loose, the piston cannot be reused.

Fig. 68. Timing diagram

OT TDC
UT BDC
Inlet o p m s
us Transfer port closes
Es Inlet closes
I)0 Transfer port opens
.4 0 Outlet opcns
AS Outlct closes
Fig. 70. Checking the ring grooves

As a makeshift a graduated disk (360" protractor) can For cleaning the piston ring grooves, a sharpened piece
be used which is available from any stationer's shop of piston ring should be used, because a scraper or
(teaching aid). The disk is reinforced for workship use screw-driver might enlarge the groove.
by riveting a sheet metal disk on it. Loose scale deposits on the piston head are removed
Clamp the cylinder before reading the values deter- by means of a wire brush. The firmly adhering layer
mined with the help of a pointer. is left on the piston head because it protects the piston
from an uncalled-for heat absorption.
The same applies to deposits on the ring section and
the piston skirt.

. . ,
Fig. 69. Determining the timing

If an old piston is reused, the piston rings must be Fig. 71. Cleaning the ring grooves
checked that they are f r e e t o m o v e in the p i s -
t o n r i n g g r o o v e S. Special attention must be
paid to the top ring because it is exposed to the highest Piston-ring gap
temperatures. In the case of abnormally high operating in new condition 0.2 mm
temperature due to wrong carburetter tuning or igni- Wear value: 1.5 mm
.tion timing, it may be distorted; this is indicated by
a corrugated contact surface. If the piston-ring gap is too small, the ends will butt;
Each ring must be placed in t h e same as a consequence of the increased friction the wear
1I groove (and not with the sides re-
v k r s e d ) i n w h i c h i t w a s l o c a t e d be-
rate will increase, too.
The view that by fitting a new set of piston rings the
f o r e r e m o v a l a n d r u n in. performance of an engine that has run for a long pe-
 riod will be improved is wrong. In accordance with port 22-50.412, the gudgeon pin can be pressed in place
the engine performance, the cylinder bore has become with the thumb with t h e help of the guide mandrel
more or less oval whereas the new rings are per- 02-MW 33-4 (F).
fectly cylindrical. As a consequence, exhaust gases es- The studs for fastening the cylinder must be tighten-
cape, the rings are heated, become distorted and may ed with a torque of 19.6 Nm (2 k p m ) .
eventually seize. This may lead to piston seizure!
If during assembly a piston ring is broken, the fitting
of a new ring is a proper remedy only up to a road
performance of maximum 3000 km. If this figure is
exceeded, the cylinder must be rebored or honed and
a new piston installed.

Fig. i 4 . Inserting the gudgeon pin

The locking rings are inserted in such a way that the

eyelets polnt upwards or downwards but not side-
ways. See to it that the rings have a tight fit in the
grooves.
In any case only use new locking
rings.
Fig. 72. Checking the piston ring gap
G U d g e o n p i n s are available in the following
oversizes :
Seizing traces are removed by means of a smooth-cut 0.01 mm
file or an oil-stone (emery stick) but not by means of 0.02 mm
emery-cloth or abrasive paper. 0.03 mm
The piston shown in the accompanying illustration When fitting the gudgeon pin, please, observe the text
was seized because the gudgeon pin had a too tight fit for Fig. 30.
in the gudgeon-pin boss.
Notice in any case:
Do not use a piston with the marking "GG" on the
piston head. This type of piston is provided for the
grey cast-iron cylinders of the older M Z types.

Fig. 75. Locking the gudgeon pin

When mounting the cylinder take care that the ring

gap is a t the locating pins, otherwise the ring in ques-
Fig. 73. Piston seizure
tion will break !
To protect the cylinder base gasket from damage, stick $a
it to the cylinder by means of two dots of grease. l

For fitting the gudgeon pin, the piston must not be too Then apply a film of engine oil to t h e working surface
d'
cold but "lukewarm" (about 35 to 40 "C). After oiling cf the cylinder and slip the cylinder over the piston
\ the small-end bush and putting the piston on the s u p without the application of undue force.
Withdraw the piston support. If the cylinder head fails to be gas-tight, this is ex-
During this operation, retain the cylinder with one clusively due to a n incorrect tightening of it. Always
hand so that it cannot go down. tighten "crosswise", that is to say, tighten in the se-
quence 1 - 2 - 3 - 4. First tighten only slightly; a t
the next stage in tightening use a torque of about
17.6 Nm (1.8 kp-m).

Fig. 56. Mounting the cylinder

There is n o g a S k e t between cylinder and cylinder Fig. 78. Fastening the cylinder he~tl
head.
Not for reasons of economy but to ensure a better heat
transfer. The sealing surfaces of the cylinder head (in After the casing has cooled down, the 14 casing screws
any case) and of the cylinder must be checked that are tightened once more (observe Fig. 47).
they are perfectly plane on a surface plate (see also The bore for gearbox venting (see arrow) must be
Fig. 24). cleared by means of a wire in order that it cannot be
If the head is significantly distorted, it can be returned clogged by 'hardened jointing compound.
by means of a turning mandrel with threaded pin M Do not forget to fill oil.
14 X 1.25. The pin is screwed i n t o the thread for the
sparking-plug.
Remove not more than 0.3 mm of metal in re-turning,
otherwise the compression ratio becomes excessive.
The four support corners must be recessed by no more
than 0.1 to 0.15 mm.
C o m b U s t i o n c h a m b e r with the sparking-plug
screwed in place:
ES 125 = 15.4 cm3
ES 150 = 18.0 cm3 .
ES 12511 and TS 125 = 14.0 cm3
ES 15011 and TS 150 = 16.5 cm3
When measuring, use petroil mixture, pour in with
graduated measuring glass.

Fig. 79. Completing the engine

5. Electrical Equipment

If repairs in the electrical equipment are required

which call for expert knowledge, it is advisable to call
on an authorised workshop for repairs in vehicle elec-
trical systems.
All denotations of connections for electrical devices
and lines occurring in the following text a r e also shown
in the wiring diagrams (Fig. 80 and 81 a s weh as the
Fig. 77. Measuring the chamber of combustion coloured supplement, Fig. 82).

30
 5.1. Dynamo Before removing the coils, mark their location and
that of the poles with respect to the terminal case.
5.1.1. Checking the Armature for Accidental Eerth If, however, the tubular lamp does not light when t h e
two terminals of the tester a r e applied to DF and t h e
For checking the armaturc for accidcnlal earth, a line frame, all coils a r e in order as far as earth leakage is
continuity tester also kno\vn as "Priif-Fix" (trade concerned.
name) is used.
Checking by means of an electric bulb and mains
voltage (110/220 V) is forbidden.
The tapping terminal of thc Ilne continuity tester is
applied to earth (arnx1tu1.c lamination pack) of thc
armature removed from the englne and the individual
laminations of the arn1ntul.r arc touched with the feel-
er pin tip in succession.
When the insulation of the al.matuw \vinding and of
the commutator arc in o ~ . d (the ~ . t~rb~rlaulamp in t h r
tester \vill not light du~.ingtosting. I f thc tubular lamp
cnlits a dim or e\.rn br~glit11ght.thcn ii slight or an
intcmsc accidental c ; r r ~ hl ~ ~ a k : ~
1sggi\.cm.
c ~ The armaturr
ninst bc ~vplacrdb). ;I n c w o n , , 01. I T ~ ; I ~ I X ~ .

Fig. 84. Checking the field coil for accidental earth

5.1.4. Checking the Field Coil for Shorted Turns

For this test, an ohmmeter is required.

The two tapping terminals connected with the measur-
ing instrument are applied to the negative and positive
sides of the field coil.
If there are no shorted turns in the field coil, the read-
ing of the measuring instrument will be anything be-
tween 1.7 to 2.1 ohm. When the indicated value is be-
low 1.7 ohm, turns are shorted.
If the pointer of the measuring instrument fails to
deflqct, the field coils is interrupted. For the replace-
Fir, 33. Checkin:. thr nrm:!ur'c ftnr' acc~tlenl;llearth ment of the defective coils, the same as has been said
in Section 5.1.3. applies.

5.1.2. Checking the Armaturc for Shorted Turns

Before checking the almature for shorted turns, clean

and blow out the commutator In any case. This is nec-
essary to prevent two coppcl segments from being con-
nected with each other and ~ h u sproducing a short-
circuit. When the armature is removed from the en-
gine, it is tested by means of a shortcd-turn tester
(220 V a.c.).

5.1.3. Checking the Ficld Coil for Accidental Earth

Before checking the field coil removed from the as-
sembly for earth leakage. disconnect the end of thc
coil connected to earth and the adjustable resistor.
Like the armature, the field coil is also checked with
the help of line continuity tester.
Here, the use of an electric bulb and mains voltage Fig. 85. Checking the fleld coil for shorted turns
(110/220 V) for testing 1s also not allowed.
If the tubular lamp llghts up when the tapping ter-
minal is applied to DF and the feeler pin point to the 5.1.5. Servicing t h e Carbon Brushes
frame, accidental earth is present. Then loosen the in-
dividual coil connections and check each field coil s e p e the high electrical load (2 X 21 W flashing-
B e ~ u s of
arately. light indicators and 21 W stop light), the carbon
Defective coils must be replaced by new ones in a spe- brushes should be checked for their condition after
cial workshop. every 5,000 km of operation.
 5.1.6. Servicing the Commutator
The commutator surface on which the brushes slide
must be clean and smooth. A uniform brown to grey-
black colour of this surface is without any significance.
If this surface shows scratches, however, the commu-
tator must be turned down in a lathe in a special
workshop (the commutator must not be more than
0.03 mm out of round). If the eccentricity of the com-
mutator exceeds this value, the brushes will jump and
thus impair the reliability of the dynamo.
The brushes may also be caused to jump by crank-
shaft bearings having an excessive clearance in radial
direction.
After turning the commutator, scrape out the slots
between the commutator segments on a milling ma-
Fig. 86. Replacement of the carbon brushes
+
chine or a saw (about 0.4 0.2 mm deep and maxi-
mum 0.7 mm wide).
Use very fine emery cloth to remove the burr while
The brushes can be withdrawn after loosening the con- the armature is rotating. The mica dust thus produced
nections and slackening back the springs. must be blown away by means of compressed air and
On this occasion, the brushes, brush holders and the the commutator surfaces are cleaned by means of a
surrounding area should be cleaned (use a clean rag non-fluffy piece of cloth.
soaked in benzine).
When re-inserting the carbon brushes. observe the
following instructions: 5.1.7. Fault Indication by the
1. The brush must be capable of easily moving to and Charging Control Light
fro in the holder. The copper pigtail at the carbon
brush must also be free to move. If the charging control light does not go out at higher
2. Brushes shorter than 9 mm must be replaced by new speeds, the lines R+, 61 or the field coil have acciden-
ones (use brushes of the same dimensions). , tal earth contact or the regulator fails to operate prop-
3. The spring must be engaged with the pin of the erly.
brush and the spring clip, otherwise the spring may If, with the engine stationary, the control light fails
jam in the brush holder. to light, the following defects may be present:
4. Only use springs and spring clips that are in proper 1. battery discharged ;
condition, 2. the fuse in the fuse box is blown;
5. The cable (copper braid) embedded in the brush 3. the line 30 from the "positive" terminal of the bat-
must be checked for tight fit. If the cable is loose, tery to terminal 30 of ignition lock is interrupted
the brush must not be fitted. Due to the high con-
tact resistance, brush and commutator will be heated
and, as a consequence. the dynamo destroyed.

Fig. 88. Circuit diagram dynamdregulator cut-out -

3 control positions
(1) Lower Position
(1) Suspended positlon
(3) Upper position
(4) Reverse-current switch
(5) Charging control light
(6) Ignition, terminal 15
(7) Ignition switch
(8) Battery 6 V. 12 Ah
Fig. 87. Milling out the mica segments (Q) Dynamo 6 V. 80 W
falsdl wrong (10) Field coil 1.7 to 2.1 ohm
dchtlg correct (11) Adjustable resistor 4.5 ohm
 or the line 31 from the "negative" terminal of thc
battery to the earth point is interrupted;
4. the line from dynamo D+ to regulator D+ and
from regulator 61 to ignition lock 61 and control
lamp is interrupted ;
5. the control lamp is blown;
6. the regulator cut-out is defective.

5.1.8. Adjustable Resistor

Together with the regulator cut-out, the adjustable re-
sistor has the task to keep the desired voitage constant.
Current passes through the adjustable resistor a t that
instant when the regulating armature is in suspension
:late because in this position the adjustable resistor
and the excitation winding are connected in series.
In the lower position, the adjustable resistor is bridged
by the regulating armature and thus is of no impor-
tance to voltage regulation. Fig. 90. Adjustable resistor
In the upper position. the armature has also no func-
lion to fulfil because the excitation winding is short-
circulted and t h ~ the
s voltage breaks down. In any case, the regulator must be checked in a \vcrk-
I f the adlustablt I esistol. is blo\vn, this will be indi- shop. In order to restore the dynamo to the o r i g i ~ x l
firing ~ , r d e rA. charred insulation
crtted b\. .in irl.~~gular polarity. the following has to be done:
varnizh on t11c iuL.lib of thi' i ~ d j ~ ~ t a~xxiistol-
ble and cav- Put the negative cable of the battery to earth and usc
boniwd cuntacts of the 1.cgu1~tor \vill then be the proof. the positive cable of the battery to touch thc D + ler-
When the charging conllol light flashes up \\.bile the mina1 of the dynamo. The same \\.ill be achieved \\hen
cnjilne 1s running. t h e adjustable resistor may have pressing the reverse-current cut-out for about 2 to 3 s
earth contact. \Vhen ;l blown adjustabl~)resistol is IT- (the battery is connected to the electrical system oi
p1;tccd by a ne\v one. first find the cause of the troublc the motor-cycle). If with the wrongly connected bat-
mless the ne\v resistor will be exposed to the same lery the motor-cycle was operated for some time. dis-
hazard. charge it. with 0.6 A and subsequently charge it with
Another cause may be a broken or loose D+ line at the same current intensity (Section 5.3.1. should be
'he regulator or in the dynamo. observed in this connection!).
? h e adjustable resistor is connected as follows:
long cable (1) to D+ (positive carbon brush),
short cable (2) to DF (positive pole of field
5.2. Regulator Cut-out
coil). When replacing the regulator take care that one 01
socket (3) and negative pole of field coil to the original regulators is used. If this is not possible.
earth. especially in countries other than the GDR,see to it
that the regulator to be installed shows the following
parameters:
Voltage 6V
Wattage 60 W
Type of positive regulation! - three
regulation contact regulation

Fig. 89. Dynamo with& armature

5.1.9. Polarity Reversal in the Dynamo

If, inadvertently, the wrong cables are connected to
the two terminals of the battery (red cable to the
negative pole and brown cable to the positive pole)
and then the engine started, the polarity of the dy-
namo is surely changed. In most cases, the contacts of
the regulator cut-out a r e also carbonised. Fig. 91. Regulator cut-out
5.2.1. Adjustment too dim, if there are troubles in starting and the like,
do not blame the regulator cut-out immediately and do
It should be underlined that a proper adjustment of not interfere with it but flrst check the lines and their
the regulator cut-out can only be carried out with n plug-type connections for proper contact and corrosion.
dynamo of the specified type which is in perfect work-
During a general overhaul of the motor-cycle, in any
ing order on a test bench which is infinitely variable
case have the regulator cut-out checked by an expert
within the speed range from 0 to about 6000 rpm.
and, of required, replaced by a new one.
The mechanical adjustment of the regulator and of the
reverse current cut-out is a precondition for the sub-
sequent electrical adjustment. It can also be used as a 5.2.3. Faults and Their Causes
provisional adjustment. It must be effected according
to the adjusting scheme (shown in Fig. 92). Carbonised switch contacts may be the result of an
Setting values for electrical setting : excessively high continuous load (heated twist-grips,
additional headlamps, etc.), loose or broken D+ line
regulator regulator a t dynamo or regulator.
8106.711 8106.712 The same symptom can be observed as a result of
(temperature- riding without gear-shifting as required, too high an
compensated) idling setting, incorrectly connected battery (positive
Switching-on voltage 6.5 to 6.9 V 6.5 to 6.9 V and negative cables changed by mistake), a broken
Switching-off voltage 5.4 to 6.2 V 5.4 to 6.2 V adjustable resistor, earth leakage of the adjustable rc-
No-load voltage 7.1 to 7.6 V 7.3 to 7.8 V sistor or shorted turns in the field coil.
Rated-load voltage at 6.2 to 6.8 V 6.5 to 7.1 V If the protective cap of the regulator cut-out is not
a rated current of 10 A properly fitted, accidental earth may be the result if
and 1,800 to 2,200 rpm the cap gets in touch with the core or with the contact
angle of the regulator cut-out. The lugs a t the sides of
the cap must be properly inserted into the recesses at
the regulator base provided for this purpose. The wire
bow must tightly press on the cap.

5.3. Battery
5.3.1. Putting the Battery into Operation
The electrical equipment includes a t flat lead battery
with a rated voltage of 6 V and a rated capacity of
12 Ah.
When putting the battery into operation, sulphuric
acid for accumulators (in the following text called
+
electrolyte) of a density of 1.28 0.01 g/cm3 (in the
+
tropics 1.22 0.01 g/cm3), measured a t a temperature
Fig. 92. Mechanical adjustment of the regulator cut-out +
of 20 2 "C, is poured in the battery.
In the filled state, the liquid in the three cells of the
battery should be 5 mm on top of the separator plates
or reach up to the given level mark. When pouring
in, the temperature of the electrolyte should not ex-
ceed 25 "C.
After about 2 to 3 hours, plates and separators have
soaked in enough electrolyte so that the electrolyte
5.2.2. Mounting and Servicing level has dropped.
In general, servicing the regulator cut-out is limited Top up with a n electrolyte of the same density and
to the cleaning of the connections. If the headlight is temperature to reach the original level. Then charge

Fig. 93. Assembled position of the regulator Fig. 94. Battery 6 V, 12 Ah

 the battery with direct current of 0.6 A. During charg-
ing, the screw plugs must be unscrewed!
Charging must be continued until all cells uniformly
and briskly evolve gas and the desired voltage is read+
ed, i.e. about 2.5 to 2.7 Vlcell.
Two to three measurements taken a t an interval of
one hour must show a constant electrolyte density
(1.28 f 0.01 g/cm3) and cell voltage. The specified cur-
rent of 0.6 A must be maintained a t any rate.
During charging, the temperature of the electrolyte
must not exceed 50 "C.
Please notice!
Do not subject the battery to a rapid
c h a r g i n g process! As a consequence,
t h e b a t t e r y will become useless bo-
f o r e l o n g a n d y o u w i l l l o s e t h e rig111
t o r a i s e g u a r a n t e e claims.
Before connecting the battery to the vehicle, connect
the tu.0 battery cables to the poles (red cable to thc
positive pole - bro\vn cable to the negative pole) and
apply a thin film of grcase for battery terminals 01.
acid-frec Vaseline to the poles.
After fitting the protective cap in place. the battery Fig. 95. Ignition coil
can be installed and the two battery cables connected
to the lower contact blades of the plug-type at the
fuse base [ ( l )in Fig. 93). rent, liuwever, a continuous voltage change must be
Again pay attention to the correct caused, and this is effected by the contact breaker in
w a y of c o n n e c t i n g : conjunction with the capacitor. The normal voltage of
the electrical system of the motorcycle of 6 V is step-
rcd cable to the red cable, ped up to an ignition \.oltage of about 12,000 V.
bro\vn c a b l e to t h e brown cable. The t\vo terminal pins of the ignition coil are marked.
The vent hose must be placed in such a way that acid
Terminal 1 is connected with the contact breaker and
that may be spilled through this hose cannot damage
terminal 15 with the terminal 15/54 a t the ignition
lacquered or other metal parts.
lock.
Please notice!
5.3.2. Servicing the Battery
With the engine stationary, the ignition system switch-
The average life of a battery is about two years. This ed on and the contact breaker closed, the igpition coil
time can be extended or shortened by good servicing will be energised; if this condition is maintained for
or by neglecting it. In the main, servicing operations a longer period of time, the current passing through
are restricted to the cleaning of the terminals - a thin the coil will cause the temperature of the coil to rise.
film of grease for battery terminals m u ~ tallVags be As a consequence, the insulating material will be de-
applied - and the checking of the acid level at r e g - stroyed. The igniticn coil will b u m down and thus
u l a r intervals (every four weeks during the warm become useless.
season of the year, every two weeks during the cold When using ignition coils of Polish origin, the cor-
season of the year). responding terminal designations should be taken into
When greasing the terminals take care that no grease consideration:
enters the cells. If the acid level has fallen below the Terminal 1 = 22
desired level, only top up with distilled water. Terminal 15 = 21.
Do not use so-called improving agents! . .
If, nevertheless, acid is spilled from the battery, the
density of the acid used for topping up should be so 5.4.2. Ignition Timing
selected that the density of the complete amount of
acid in the battery in fully charged condition will be A precondition is that the cam is not out of true a n d
1.28 f 0.01 g/cm3. that all parts of the ignition system a r e in good re-
If the battery is not used or if less than 50 km are cov- pair.
ered daily, the battery must be re-charged once every Ignition timing starts with checking t h e contact break-
month. ter points: Loosen the terminal screw (1) of the con-
nection from the capacitor, remove t h e contact lever,
and clean the contact face by means of a n emery stidt
5.4. Ignition S y s t e m If they a r e seriously pitted, insert new parts.
The breaker points must make contact with their full
5.4.1. Ignition Coil face; adjustments of t h e contact angle are possible.
Remove remains of lubricant from the pivot (2).
The ignition coil may be compared with a transformer Uniformly apply a few drops of special contact breaker
which transforms a low voltage into a high one. As oil (viscosity from 700 t o 1,300 cSt at 50 'C). ReAt t h e
only a n alternating current can be transformed, the contact lever.
vehicle electrical system is supplied with direct cur- Seriously burnt contact faces a r e indicative of a de-

37 1
 Screw in place the ignition timing gauge 29-50.801
(spccial tool) or a similar gauge ensuring accurate
mei~surements(dial gauge).

5.4.2.1. Ignition Timing by Means of a

Graduated Dial

If thc +.pc~ial tool "timing gaugc 29-50.801" is not availa-

blr. a graduated dial may bc used which can be
bought at any stationer's shop (teaching aid).
In ordri to bc in ;I position to check the contact points
1:';1p during t hc. timing opei.ations. the dial is provided
\ \ . ~ t i ) thccc. \\indo\vs (drill. 01. lile them out).
Ti~c.pointcl. ( Z ) must bc at Ic.;ist 3.5 to 3 mm thick to
a\.oid t ~ m i n gcn.ol.s d w to inadvc.rlcntly bending it.

Fig. 96. Contact breaker

fective capacitor (initial stage). If several plies of thc

capacitor winding break d m m . the engine will be abie
to idle but will stall \vhen it is accelerated (any at-
tempts to adjust thc carburetter will in this case be i~
\ w n natu:.::l!\~). Make, ,sure thc, earth contact 1s in or-
dcr !
To adjust the contact-brcaker points gap. the crnnk-
shaft must be turned until the high-level portion of t h t
cam ("0") lifts the contact level.. The feeler gauge must
lightly contact both breaker points. in other words,
i t must not be tight or loose.
After loosening the setscrew (3). adjustments are made
by means of the eccentric screw (4), Fig. 96.
The specified gap is adjusted by turning the latter.
Then properly tighten the setscrew and once more
check the gap.
Contact-breaker points gap: 0.3'O.' mm
Measure t h e gap with particular care when the firing
point has already been timed and only the contact-
breaker points are readjusted.
Note:
If the contact-breaker points gap is increased, the Flg. !H. Ignition t ~ r n i n x\vith graduated dial
ignition is advanced (the cam starts lifting the con-
tact breaker a t the beginning of the cam lobe); if the
contact-breaker points gap is reduced (due to wrong A piwondition for the correct ignition timing is the
adjustment or wear) the ignition is retarded (in this accurate determination of the top dead centre (T.D.C.).
case, the contact breaker only slightly contacts t h e For this purpose, a stop for thc piston must be prc-
high-level portion of the cam. The ignition coil is pared (Fig. 99).
not in a position to built up the required strong mag- The, stop is made of a useless sparking-plug by remov-
netic field, a weak spark will result - the engine ing thc insulatoi and fitting a bolt in its place. A hole
causes t h e carburetter to spit back). is drilled in the sidc to allo\v thc compressed fuel-air
mixture to escape. The hole is drilled in the side be-
cause in the front part an M-4 wtting screw should be
scr.ewed in if required. In this way, the stop can also
bc used for other engines. After having tightened the
T.D.C. stop ( i t must not be loose!). turn t h e crankshaft
anti-clock\vise u p to the stop. using the dynamo ar-
mature scre\v (1) for turning - then record t h e de-
jirces indicated by the pointer. Prior to this adjust t h e

Fig. 07. Ignition setting gauge H 8-1408-3 screwed In place Fig. 99. Stop for piston

38
 dial to a whole number of degrees, if necessary. Then If the pad contacts the full cam profile, the lubricant
turn bqck until the piston contacts the right-hand stop will be pumped out of the pad before long, the dry
and record the degrees (and minutes). felt then rises the temperature of the cam track -
It follows that the T.D.C. is exactly in the centre of premature wear of the nose a t the contact lever will
the section t h r o u g h w h i c h t h e p o i n t e r be the result !
d i d not pass.
Record this number or mark it a t the graduated dial
but do not displace dial or pointer!
Then, proceeding from the determined T.D.C. count
22" 45' to 23" 45' in the sense of rotation of the engine The sparking-plug in essence consists of three parts.
and mark at the point thus found the f i r i n g These are the central electrode and the carrier which
p o i n t. also acts as the earth electrode. The spark jumps over
Then unscrew the stop for the piston and set the firing between these two electrodes, igniting the fuel-air mix-
point by means of a test lamp. ture. The third part of the plug is the insulating body
or insulator. It must have a high dielectric strength.
To ensure this dielectric strength at all times, the
sparking-plug must be treated gently. By improper
5.4.2.2. Setting the Firing Point

Fil.ing point: 3 . 0 - 0 s mm before T.D.C. or

22" 45' to 23" 45' before T.D.C.
When setting outside the. vehicle, connect a 6 V bat-
t e r \ . interposing a 1.2-W test lamp (2), with the po-
sitive pole to terminal "1" (A) and the negative poie
to c ~ ~ r t(lamph flashes up lvhen the contact breaker
rlosrs).
If setting in the vehicle. apply one terminal of the
lamp ( 2 ) to connection "I" (A) at the capacitor (or
coii: L I C I rail) i ~ n dthe second terminal to earth.
For the timing operation switch on the ignition.
\:'it11 ;l;c, 29-50.801 ignition tinling gauge screwed in
pl;~ce. use the armature screw (1) to turn the piston
o \ . ~ ther T.D.C. - the scale of the gauge automatically
adjusts itself to the T.D.C. Continue to turn the crank-
shaft in the sense of rotation of the engine until the
firing point is reached.
At this instant, the test lamp must flash up. If this is
not the case, loosen the two screws (3) and shift the Fig. 101. Improper screwing-in or screwing-out of the
contact-breaker base plate sideways. sparking-plug
After setting. apply a few drops of special contact- l
l
breaker oil to the lubricating felt pad. Adjust the pad handling (impact and the like), almost invisible hair
so that it just slightly contacts the high-level portion cracks may be brought about which render the plug
of the cam. useless.
The average service life of a sparking-plug in two-
stroke engines is equal to about 10,000 to 15,000 km
of road covered. When this mileage has been reached,
it is advisable to replace the sparking-plug by a new
one. The TSlES 1251150 are provided with an M 14!260
sparking-plug. It is advisable to use always the same
type of plug (the specified thermal value should be
observed). The use of a plug of a lower thermal value
in winter or of a higher thermal value in summer will
not offer additional advantages but disadvantages.
If difficulties are presented (poor startability in winter
or overheating in summer), they should not be attri-
buted to the thermal value of the sparking-plug.
The correct seat of the plug must also be faken into
consideration. The thread of the plug must be flush
with the thread in the cylinder head. If the plug pro-
jects too far into the chamber of combustion (packing
ring under the plug missing or pressed flat) or if the
plug is not properly down on its seat (two packing
rings placed under the plug), heat will accumulate and
symptoms of overheating will appear.
The servicing requirements of the plug are relatively
small. The spark gap must be checked from time to
time (0.6 mm).
For changing sparking-plugs, a properly fitting plug
Fig. 100. Ignition timing with ignition getting gauge spanner should be used to avoid breaking of the in-
 sulator. In any case, pay particular attention to the ignition failure a t . higher engine speeds; weak
appearance of t h e plug. After a longer period of oper- spark; loss of power
ation of the plug, the appearance is indicative of the Crankshaft bearing worn down
action of the engine, the formation of fuel-air mixture, Crankshaft and thus cam out of true by a n amount
of the petrol used, of the carburetter tuning and suit- that exceeds the permissible limit
ability of the plug for the engine. Carbon brushes "jump" =
ignition failures
Contact pressure exerted by contact spring too low
5.4.4. Plug Cable Connector Contact arm has no exact guide on the cam track =
The function of the plug cable connector is to estab- ignition failures a t higher engine speeds
lish a connection between sparking-plug and ignition Plug cable connector:
cable and to screen the electric field of the sparking-
plug from the environment. 1. Dust and water between insulating body and she&-
To ensure a proper radio-shielding of the sparking- metal shell =
plug, take care that the sheet-metal shell fastened to difficulties in starting; ignition failures
the plug cable connector is properly fitted on the hex- 2. Fissures (hair cracks) in insulating body due to im-
agon of the plug. proper handling
In the case of ignition failures and difficulties in start- Leakage path to ground forn~ed=
ing. especially in wet weather, thoroughly clean the difficulties in starting; weak ignition spark; loss
plug cable connector with clean petrol and dry it. If this of power
does not improve the conditions, replace the connector
by a new one. Lines:
On no account should the sheet-metal shell be removed Defective insulation of high-voltage line (ignition
because this will lead to interferences with VHF and cable)
television reception. Spark flashing over to ground (cylinder head) =
The plug cable connector, must be handled as gently difficulties in starting, especially in wet weather;
as the sparking-plug. Hair cracks in the insulating ignition failure at high engine speeds
body which lead to the formation of leakage paths Broken wires
render it useless. Short-circuit 4
blown fuses;
when D+ line is interrupted, the adjustable re-
sistor frequently is blown
Flat connectors heavily corroded
Very high contact resistance =
the voltage applied to the various devices is tm
low

5.5. Eiectric Horn

If on actuation of the push-button switch, the electric
horn fails to produce the desired sound level, the feed
cables, their connections and the push-button switch
must be checked for dirty contacts. In this case, the
voltage applied would be too low.
If this is not the cause, by way of trial turn the screw
(E) clockwise or anti-clockwise until the sound is loud
Fig. 102. Plug cable connector with ignition cable enough.

5.4.5. Troubles
Faults in the ignition system may be caused by wear
and ageing of the indikidual devices and components.
Below follow brief descriptions of main causes and
their effects.
1. Cam track insuff cirntly lubricated
Wear of the lobe,
no contact-breaker poir.ts gap or it is too small
difficulties in starting: irregular running;
loss of powei
2. Capacitor broken down due t:,
!
a high rate of wear on the contacts =
ignition failure a t higher engine speeds
3. Variations of the contact-breaker points gap in the
case of intense pitting on the contact surfaces, as a
consequence, the true gap is t ~ large
o = Fig. 103. Electrical horn
 5.6. Ignition-light Switch Access to the connections of the bilux lamp is obtained
after removing the reflector:
Dismantling the ignition-light switch is very simple. In the TS 125 and 150, loosen screw (2) (Fig. 109) and
Only one screw must be loosened which is arranged in remove the front ring with reflector.
the front part of the headlamp in the centre, and then As to the ES headlamp, unscrew the polyamide ring,
the ignition-light switch is drawn out of its guide to- draw out the two retaining clamps (1) and hook them
gether with the insulating foil and the fastener. Now on the sides. Reflector and diffusing screen are glued
the ignition-light switch and the cable connections can together - do not separate them.
be easily inspected. Carefully remove the connecting piece (2) - distorted
To be in a position t p plug the cables to the correct c o n t a ~ tblades may no longer establish contact. With-
lugs after a replacement of the ignition-light switch, the draw the parking light cable after pressing down ter-
various connections are once more clearly indentified minal (3).
in Fig. 104.

Fig. Ill(;. ES-heatllanil~cpen

5.7. Headlamp
P~wperly clcan all contacts. straighten the blades, if
IT the road is not sufficiently illuminated, check the
contact points in the leads to the bilux lamp because
required. In vie\v of the high current intensity for
45/40-W lan~ps.see 10 it that the earth connections (M)
are in perfect order.
~
l
dirty contacts cause consider-
able voltage drops!
The bilux lamp can be replaced by a new one after re-
moving the spring (4) and withdrawing the bulb hold-
~
Particular attention should be paid to the combined ing device. The glass bulb of the bilux lamp must not
dimmer switch a t the left-hand side of the handlebars.. be tcuched \vith bare fingers!
The contact screws must be properly tightened - b ~ t
care must be taken not to pinch off the cable ends -
and then they must be protected against loosening by
a dot of paint.
It is advisable to protect the contact blades from cor-
rosion by the application of contact grease. Do not
forget to place the rubber backing between switch anc
holder a t the handlebars (otherwise there is the ris!;
of accidental earth).

Fig. 107. Connecting piece for bilux lamp

5.7.1. Focusing the Headlanlp

The vehicle is placed according to the schema and
loaded with the rider. The suspension units of the rear
41 wheel are to be set to "soft".
The light dark-boundary must not be above the "Z"-
9 Fig. 105. Connections a1 t h e drmmer switch line, and the angular deflection of the asymmetrical
1
passing beam must lie in the centre between the " V A rough adjustment of the ES headlamps is possible
and "W" lines. , after having loosened the lower fastening screw (1).
For checking, the suspension units of the rear wheels For precision adjustment turn the screws (2) and (3)
are set to "hard" and the vehicle additionally loaded - as a consequence, the reflector holding frame pn-
with the pillion rider. sition is changed.
The "Z"-line complies with the statutory regulations
regarding the illumination of the road of 25 m for the
dimmed iight.

Fig. 110. ES-headlamp focusing

5.8. Tail Lamp and Stop-light Switch

(1) Connection for stop light. term~nal54
(2) Negative line to stop-light switch at rear brake
cover, telminR1 31 b
,(3) Connection for number-plate lamp, teiminal 58
(4) Connection for negative line (leads to terminal strip
to terminal 31 or to regulator base)
Wipe the reflectors with a dry piece of cloth only.
Fig. 108. Headlamp focusing scheme
Schirm Screen
Scheinwerier-Mltte Centre of headlamp
Obere Grenze Upper limit

For TS vehicles, the headlamp is adjusted in the direc-

tion of the arrow after having loosened the fasten-
i n g ~(1).

Fig. 111. E S 12511 and E S 15011

Fig. 109. TS-headlamp focusing

42
 31 Earth
54 Stop light
58 Tail and number-plate lighting fitting

Q o o

Fig. 114. Stop l i g h t conlacl

5.9. Flashing-light Direction Indicator

Systeni
The flasher unit (B) shmvn in Fig. 106 in sensitive to
impacts and the like and. tl~erefore.i t is embedded in
foamed plastics.
1 L I o u n 1 1 n g position 01' f l a s h ( > r : V e r t i -
c a l . c o n n e c t i o ~ : . p o i n t ~ n gd o \ v n w a r d .
Withdra\v the ignition kc,y al\\.ay> \\-hen subjecting thc

Fci ~c-adjusting the stop-light s\\,itch (here the brake

lamp has xcidental earth contact!) pull the plug m d
slacken back the two nuts (width over flats 9) through
. quarter of a revolution. An assistant steps on the
brake pedal until the brake shoes arc applied to the
rear uvheelwhile the latter is turned.
In this position retain the brake lever and turn t h e
slotted-head screws until the stop light flashes u p with
the ignition system switched on (plug put in place).
Gently tighten the rear nut - the insulating bush is
of plastic. Check with a second nut.
If the range of adjustment is insufficient. the contact
spring at the cam spindle can be re-adjusted.

Fig. 115. Connectrcm at the flashing-lryht ~ndicator

Fig. 113. Re-adjusting the stop light s\vitch

Rear brake cover, one brake shoe removed.

(1) is the stop light contact (earth) which is adjustabl!!
from outside. The contact 'spring (2) must be re-ad-
justed in such a manner that it is applied with a slight
pre-load. Fig. 116. Flashin:: contiwl
 flasher unit or the flashing-light indicators to any re- and 150), other loads, e.g. 15 W, change the flashing
pair work or the like. frequency of 90 f 30 cycles per minute.
To protect the flasher unit from damage due to short- It should be w t e d that for the Clamp flashing direc-
circuits, a 4-A fuse is interposed. By counter-rotating tion indicating system (TS 125 and 150) a flasher unil:
the tow halves of the moulded enclosure (bayonet of 6 V, 21 W is required. The flasher unit of 6 V, 18 W,
catch), the fuse can be replaced (recently a fuse sleeve can only be used for the 2-lamp system (ES 12511 and
with a transparent plastics enclosure which can be 15011). The cables are clamped in the flashing-light
drawn off has been fitted)! fltting of the TS 125 and 150 [(K) in Fig. 1151.
When the flashing-light system fails, first check the The function of the 4-lamp system can be checked by
fuse and then remove the fault. (TS flashing light means of the rim (B) of the diffusing screens of the
system is protected by a n 8-A' fuse). front flashing lights or via the flashing charging control
For the flashing-light fittings only use 18-W festoon light (A). If one flashing light fails, the f l a s h i n g
lamps (ES 12511 and 15011) or such of 21 W (TS 125 f r e q u e n c y of the other lamp is increased.

Function of the Flashing Charging Control Light

Ig~~itionswitched on, Control light burns Engine runs, Control light flashes in
engine stationary, flashing-lights on, dark phase of
flashing-lights off dynamo charging flashing-lights
. -

lgnition switched on, Control light flashes in Engine runs. Control light burns
engine stationary, the same phase as the flashing-lights off,
flashing-lights on flashing-lights dynamo fails to charge
----- - .. - ~ - -- - - --- - --

Engine runs, Control light goes out Engine runs. Control light flashes in
flashing-lights off, flashing-lights off, the same phase as the
dynamo charging dynamo fails to charge flashing-lights

5.10. Speedometer 6. Induction System

In the speedometer - mounted in the headlamp by
means of a metal strap and a plastics nut - four lamps The carburetter is not an independently operating
with plug-socket holder are arranged which have the part but a component of an integrated system. It starts
following functions : with an air filter and ends in the silencer tail piece.
The timing diagram is also included. If, after a longer
period of operation, the fuel-air mixture becomes too
lean or rich, it is not necessarily the carburetter which
is to blame. All members which operate in conjunc-
tion with the carburetter must be checked together
with the carburetter.
C a u s e s of f a u l t s :
a) Closing plug (1) of the varnish draining hole
missing
b) Filter not in the centring ring (2)
c) Induction tube (3) leaky (cracks) .
d) Filter defective

Fig. 117. Speedometer

The two lamps (1)serve for illuminating the speed ill-

dicator and the odometer during night operation.
,Lamp (3) is a tell-tale light indicating whether or not
the neutral is engaged in the gearbox. With the igni-
tion system switched on and the neutral engaged, the
lamp will emit a green light.
Lamp (2) is the flashing charging control light. Its func-
tion is described in the Table in Section 5.9. Fig. 11IJ. Induction system

44
e) Cover cap (4) at the face cracked run is useless because a change in the carburette: tun-
f) Screwed connection loose [2 nuts (5) to be locked !l ing. A short trial run is useless because a change in
the carburetter adjustment will not be mirrored in the
Dirty paper air filter to be cleaned by tapping or re-
appearance of the sparking-plug after a very short
placed (every 30,000 km on an average).
time:
Mixing Ratio of Rich Air-fuel Mixture
6.1. Carburetter BVF 22 N 1-3 a n d 24 N 1-1 Below ?, = 0.9
6.1.1. General Since the mixture is too rich a lack of oxygen is localiy
given, consequently "retarded combustion" = poor
The correct tuning and proper functioning of the
carburetter is not only decisive for a good engine out- engine output! Due to the incomplete combustion, not
only the relatively harmless carbon dioxide (COP) but
put, a reasonable fuel consumption, and excellent
startability, but also for reliability in operation and also the colourless but poisonous (!) carbon monoxide
minimum wear. If, however, with an adjustment that (CO) are produced. The latter is combustible, that is
provides too lean a mixture or secondary air, the op- to say, fuel eqergy is wasted!
erating temperature rises considerably, the mainte- Especially in short-trip driving hydrocarbon particles
nance of a minimum wear rate is doubtful. remain in the engine which cause corrosion at the
The phrase "to step on the gas", which is used in some big-end bearing. cylinder liner and piston. This is the
countries, is incorrect. The carburetter is not used to cause of premature wear.
A certain quantity of oil found in the crankcase after
"gasify" anything because this would require heat from
\\hi& the carburetter must be protected (thermal in- its dismantling is no sign of normal operating con-
ditions. This enlulsion is engine oil which is "saponi-
sulation flange). Heated air has a larger volume than
fied" \vith hydrcgen and has no lubricating pi-operties
cold air and would impair the charge of the cylinder
and thus reduce the power output. (That is \vhy the but should L-e considered an acid.
S >. m p t o m S : Engine starts from cold even with-
engine lacks power in the heat of mid-summer. whereas
the full output is given in the cool morning.) out the choke pulled. The output of the engine is satis-
For the internal combustion of 1 litre of petrol about factory as long as the engine is cold, but decreases
with increasing engine temperature. Inclination tor
9.300 litres of air are required. This enormous quan-
tity of air (with only about 20 per cent of osygen) "lour-stroke cycling". Black exhaust gases, high con-
must be mixed \\.ith fuel by the carburetter so thor- sumption. sparking-plug of correct thermal value is
oughly that a fine fuel "mist" is produced. Everything oiled up.
depends on the correct "density" of this vapour for the C a u s e s : Dry filter dirty, has become wet or is too
engine to produce the rated output. old (over 15,000 km). Float needle seat pocketed. Nec-
In this connection the terms "fuel-air mixture too dle jet loose or worn (with partial load needle). Central
lean", and "fuel-air mixture too rich" are used. Hcw float bent so that float needle valve does not close
can this be distinguished? Which effects are produced? prcperly. Main jet too large (rebored?).
For the ratio of air to fuel in the mixture the unit 1 Mixing Ration of Lean Air-fuel Mixture
(Lambda) is used. The mean value adopted for 1, = 1 Over 1. = 1.0
( S 13.8 parts by weight of air and 1 part by weight of
fuel). Values over 1 have a surplus of air, values below The air percentage in the mixture is excessive, the
1 lack air. [ l m3 of air has a weight of 1.2 kg at 10 "C speed of combustion is extremely high, the exhaust
and a pressure of 0.1 MPa (1 kp/cm2)]. gases are not visible and contain only little poisonous
The tuning of the carburetter must be correct at an gases, there are no deposits in the engine which in-
ambient temperature of plus or minus 20 "C, there- crease the rate of wear.
fore, the standard tuning provides for a slightly richer S y m p t o m s : Engine starts well with correct set-
mixture (?. = 0.95 to 0.90). ting of the slow running air screw, however, it must
be run with a more or less pulled choke for a longer
This small lack of air ensures: period. The engine output is satisfactory up to about
a) a good full load performance (full load operation half of the throttle valve opening, with increased throt-
requires a slightly rich mixture because the suc- tle opening drop in output. If the engine is run within
tion a t the needle jet is silghtly reduced due to the the range from half to full load, the operating temper-
completely open carburetter passage). ature will raise abnormally.
b) good cold starting and proper transition (the slight- The engine causes the carburetter to "splash". Pinlr-
ly rich mixture provides for a compensation for ing and even inclination to seize. Due to overheating
the fuel drops condensing in the cold intake pipe the sparking-plug shows blue-grey deposits, beads,
and crankcase). and heavy consumption of the electrodes. .
The permissible carburetter tuning range (partial load C a U S e S : Air leak in induction system or directly
needle) is given with A = 0.95 to 1.0. Since neither a at the engine, central float bent - fails to open suffi-
repair shop nor an amateur constructor normally has ciently, float needle sticking, fuel feed obstructed (tank
an engine test bench with the required measuring cap, fuel shut-off cock?). Silencer inserts removed.
equipment, a test run over a distance of least 10 km therefore, back pressure too low (losses of fresh gas).
is the only alternative for adjusting the carburetter.
The engine must have reached normal operating tem- 6.1.2. Description of the BVF Carburetters
perature, otherwise misinterpretations of the engine 22 N 1-3 and 24 N 1-1
behaviour will be inevitable.
Engine operating behaviour and the appearance of the These tow types of carburetters are starting carbu-
sparking-plug are the only criterions for evaluating retters which are basically of the same design. They
the correctness of the carburetter tuning. A short trial are only distinguished by different throttle opening
 I t is actuated by the starter lever at the right-hand
handlebar:
Starter lever drawn (towards the driver) =
position for cold-starting
Starter lever pushed forwards = driving po-
sition
With the starter lever closed, the starter piston (1)
and the sealing disk attached to it (2) must close the
starter mixing tube (3).
For this reason, a clearance of 2 mm is required be-
tween cable control setscrew (4) and cable control
sheath so that the compression spring can completely
close the starter piston. In the case of high fuel con-
sumption, always check the sealing disk for leaks be-
cause the engine may get additional fuel if the piston
fails to close or the sealing disk is damaged.
When starting from cold, the starter piston is lifted
by drawing the starter lever. The fuel in the starter-
mixture delivery duct is carried off and sucked up by
the engine through the starter duct (5). This duct dis-
charges into the intake pipe behind the throttle valve
(see diagrammatic representation, Fig. 122).
To provide the required intense suction in the starter
system, t h e t h r o t t l e v a l v e m u s t b e i n
i d l i n g p o s i t i o n (about 1.5 mm open).
Do not accelerate for cold-starting, otherwise the start-
Fig. 119. Starter piston closed (driving position) ing device is of no effect!
The starter-mixture delivery duct discharges into a
duct which is in connection with the float chamber
through the starter jet (6) whose bore is designed in
widths, different sets of jets and tuning characteristics. such a way that, after the full quantity of fuel has
The name "starting carburetters" indicates that these been sucked up from the duct, only such an amount
types of carburetters are provided with a cold-starting of fuel is allowed to pass through the starter jet that
device in the place of the conventional "choke". This the engine may operate as if in a four-stroke cycle
cold-starting device practically is a small carburetter but will not be "flooded" completely.
in itself. Pre-mixing is effected in the starter duct, the air is
allowed to enter through a recess at the upper edge
of the duct from the float chamber. Air is admitted
through the overflow bore below the carburetter outlet.
The starter air duct has no passage to the mixing
chamber (A).

Fig. 121. Float valve, section view

Kroltstoff-Zulauf Fuel supply

The float needle (7) is of the elastic type in order to

reduce wear and to keep the fuel at an almost con-
stant level. In the event of a worn float valve (over .
Fig. 120. Starter piston raised (cold-starting) 30.000 km) the float needle and the valve seat (8) only

46
 must be replaced. When ordering valve seats, state the resistant hose from the nipple of the carburetter and,
size - besides the part No. - as in the case of the jcts. by opening the fuel shut-off cock for a short time,
Treat-the central float with every care when disman- check that a sufficient supply of fuel is ensured. If this
tling the carburetter. If the two bodies are displaced is not the case, any adjustment a t the carburetter is
in relation to each other or the link (9) lifting the float useless. Normal rate of flow through the filter cock is
needle or limiting the stroke (10) distorted, the fuel about 12 1 in 60 min.
level is no longer as required for a proper functioning.
At the top of the jet holder, the needle jet (11) and at Causes for a reduced rate of flow may be:
the bottom the main jet (12) are screwed in place. a) Vent hole in tank cap closed by preserving agent
Wear limit for needle jet and stepped needle is or polish.
30,000 km.
The diagrammatic representation shows the arrange- b) The ports drilled through the rubber packing were
ment of ducts in a horizontal sectional view (Fig. 122). compressed by tightening the two screws of the
retaining disk a t the filter cock too much or t h q
were partly obstructed by abraded material.
The fuel passing through may suffice for half
throttle, for full throttle the output drops or the
6.1.3. Trouble Shooting and Tuning engine stalls because the float chamber of the car-
The appearance ol the sparking-plug is always and ex- buretter is almost empty.
clusively decisive for carburetter tuning. The interiur c) Due to an additicn of graphite or MoS, prepara-
of the sparking-plug must be light sand-coloured. tions to the fuel, the inlet filter at the fuel shut-off
Light, because the additives included in the two-stroke cock is clogged by deposits. This will also result
engine oils prevent the deposition of products of com- in an insufficient supply of fuel - see above!
bustion not only in the engine but also in the interior
oi the sparking-plug to a large extent. If the specified
sparking-plug hl 141260 shows heavy beads with a Trouble shooting in t h e c a r b u r e t t e r
normal driving performance, do not use a sparking- should be started with checking the partial load need!e
plug with a higher thermal value but find the cause position. For normal operating conditions. the needle
and remove it. positions 2 to 4 are sufficient (see setting table). But
Do not extremely change the basic carburetter tuning one should not proceed without discrimination; it is
by reboring the jets but take into consideration all always the appearance of the sparking-plug that is
factors associated with the function of the carburetter decisive for the selection of the needle position. Thus,
and restore the latter to the standard condition. it may be possible, to use ne,edle position 5 for the
running-in period and then position 4 in order to en-
sure optimum operating conditions.
In the case of s i g n S o f o v e r h e a t i n g , the fol- The correct setting also is the most economical! With
lowing is involved: a setting for an extremely lean supply, you have to
a) Air leaks in the intake socket between carburetter shift gears earlier and more frequently (inclination to
and cylinder (insulating flange, packings). pinking) - this will cost you fuel!
b) Air leaks in the induction systeq - filter box leaky. A resilient double plate, the needle holder, guides and
Filter is seated near the centring edge. Rubber retains the partial-load stepped needle. For setting take
suction tube defective. care that the l o W e r p l a t e (A) is used as reference
in connection with the notch to be used (to be counted
c) Paper element of the filter damaged due to i m p r o p from top to bottom). The upper plate engages with the
er handling, therefore unobstructed air passage. notch above the selected one.
When mounting the needle holder with stepped needle
The opposite, namely, f e e d i n g t o o r i c h a take care that the former fully contacts the bottom of
m i X t u r e , as indicated by the appearance of .the the throttle valve, otherwise there will be setting er-
sparking-plug (with normal carburetter tuning!) may rors (difference in level) or the partial load needle may
be due to the following faults not caused by the car- be deformed.
buretter:
a) Paper element of the air filter dirty (clean by F l o a t b o d i e s d i s t o r t e d due to improper
tapping) or wet, therefore, no or a reduced air treatment can be aligned by means of easily made
passage. Paper filters that have become wet are control devices. Either prepare a U-shaped wire stir-
useless in spite of their impregnation. r u p or a sheet-metal template of t h e desired dimen-
b) Silencer (especially its tail piece) clogged by de- sions. If a vernier caliper is available, use it for taking
posits left after corribustion.. The back pressure be- measurements.
comes higher than permissible, burnt residual gases For checking, unscrew the needle jet carrier and hold
remain in the cylinder (poor degree of filling). Due the carburetter in the way shown in Fig. 125. Measure
to-a retarded combustion the sparking-plug appear- at the point indicated by the arrow.
ance shows a dark colour. A uniform distance of anything between 0.3 to 0.5 mm
must be present between the two float bodies and the
c) The specified mixing ratio of 33:l was not observed ruler (see arrow). If this is not the case, realign the
and 25 :l used. valve lever (A) as required. This measure must be ad-
hered to because the correct fuel level is dependent
A n o r m a l f u e l f e e d is a prerequisite for p r o p upon it; below 27 mm there is the risk that the floats
e r carburetter function! Therefore, before any car- contact the carburetter casing and. consequently, fuel
buretter re-adjustments take place, pull the petrol- flows over the carburetter.
 Zum Motor to engine
K r l f fuel
Fig. 122. Starter carburetter, sectinn:ll \.ie\v Lul t air
(1) Starter piston 1;) Jet cal I I C I ' \ v ~ t i lnc.etl!c ancl
(2) Sealing washer milin !?!S
(S) Starter mixing tube (F) .c:lo\\' l u n n i n p l c r
(4) Float valve, con~pletc [#!IT I ' ; I ~ s I IIOI'P
~ ~ ~ l, 11I ~ '~",'.
(5) Starter duct I . S11 li : .!>I
(;ill ~ I I . \ ;\ .. ~ I I I I II III II I ~

&6 (a) Starter jet ( : 11 SICI\\ L ' I I I I ! I I i iI ~ I~ ict',.!,:

r
Fig. 123. Needle holder

Fig. 124. Partial load

needle with needle Fig. 126. Float valve open
holder inserted (A) valve lever
in throttle valve (B)s t o p lever for r n a x i ~ n u mfloat I I ~ I
. m m thick
(C) Original p a d c ~ n g 1.5
0.5m m dick 0.5 mm t h i c k
If the floats are higher than 28 mm, difficulties will be
presented in starting, poor transition. etc. because the
l
fuel level is too low. The fuel-air mixture for the slow-running range 01 i
Naturally, one float body or both of them must not the carburetter is prepared in the S l o W - r U n n i n g
be tilted, that is to say, you have to look for a proper d e v i c e comprising the slow-running air screw (11)
lateral alignment. (see diagrammatic representation in Fig. 122) for dos-
In order that the float valve opens wide enough, the ing the air for slow running and the slow-running fuel
position of thc stop lever (B) is of importance. Tlw jet (8). As in the partial load and full load ranges, in
measure of 34 +
1 mm shown in Fig. 126 - measured this range, too, the engine must get fuel and air in the
from the sealing face of the casing to the lower edge correct ratio, i.e. iri an ignitable ratio. An excessive
of the float - must also be set correctly, otherwise an supply of air in the slow-running range will result in
insufficient amount of fuel will be fed in full load erratic running of the engine - when suddenly accel-
operation and the engine will stall or the maximum erating, the engine will stall.
speed will not be attained. When the slow-running air screw is almost closed, the
If this measure is exceeded, the floats may contact the engine tends to cycle as a four-stroke engine - a lay-
casing and will be damaged. man then thinks the connecting-rod is defective. Be-
By moving the float in working direction check that sides good startability, proper transition also depends
the float needle actually is free to move easily and does on the correct setting of this screw. When opening the
not stick now and then (check several times!). throttle valve, the transition bore (9) (Fig. 122) becomes
If this is the case, the fuel level will occasionally be effective additionally, but this also depends on the
too low and then again normal. Perhaps the fuel sup- position of the air screw. To ensure smooth running
ply will also be interrupted sometimes. and good road performance, particular attention should
be paid to the adjustment of the slow-running device.
/ With the engine having normal operating temperature,
regulate the idling speed by actuating the cable control
setting screw for the throttle valve in such a manner
that the engine just continues running when the twist-
22N grip is in idling position. (A high idling speed causes
24 N noise in shifting gears!) Then - starting from the
position "for 2 revolutions open" - slowly turn the
slow-running air screw down and back by way of trial.
Find the position with the highest engine speed.
Proceed slowly enough so that the engine can respond
to the change. l

After having regulated the idling speed down to nor-

mal, screw in the air screw for about ',;
of a revolution
- this is necessary for a good transition in cold start-
ing!
Precondition for a correct idling setting (i.e. idling
speed and slow-running air) is the fact that the set-
~ i g 125.
. ~ l o a tvalve closed, spring plunger pressed down ting of the partial load and full load range is correct,
(A) Valve lever
otherwise the engine will not respond to adjustments
of the slow-running a i r screw!
Only use original pakking rings having a thickness of It should be noted that all jets a r e subject to toler- f
1.5 mm, otherwise deviations from the specified fuel ances, i.e. they have different flow values. Therefore, e
level will occur. for carburetter adjusting, one should have available

7 RH T S 1251150 U. ES 125/1. 150/1, englisch

 4
several jets of the same dimension in order to be in a To stop the engine, the twist-grip must be closed over- a

position to exchange them. coming the resistance offered by the spring which is ,1
For needle jets, for example, the dimens according to compressed to about 5 mm. Now the throttle valve d
darwing is 2.65+0.009mm. completely closes the air passage. #
The types ES 12511- 15011 and the types before them
are provided with a small compression spring arranged
between twist-grip control member and cable control
retaining member.
In relaxed state, this spring is the stop for the idling Please, notice in any ease:
speed. In this position, the throttle valve is open for A proper carburetter tuning is always associated with
a distance of about 1.5 mm. the correct ignition timing and contact breaker points
gap.
If, for example, the cam is out of true, the contact
breaker lifts two times per revolution. At high speeds.
a strong magnetic field cannot be built up in the igni-
tion coil - ignition fails. Then you may presume fuel
to lack; the dark appearance of the sparking-plug,
however, shows that there are ignition faults. Similar
Fig. 127. Stop spring symptoms can be observed in the case of insufficient
'St" = Idling fuel supply with the motor cycle stationary or in contact-breaker points gap, retarded ignition, capacitcr
neutral posjtion
" A " = Switching off (throttle valve completely closed) defects oc defects in the adjustable series resistor.

1. Cycle Parts
7.1. Exhaust System The exhaust muffler (Fig. 128) is welded and no longer
of the detachable design.
The exhaust system is so properly matched with the In the case of unusual contamination, check the car-
engine that, firstly, the desired performance charac- buretter tuning and critically consider your driving
teristics are reached and, secondly, the permissible habit (driving a t too low engine speeds in the various
noise limit is observed. It sould be noted that the ex- gears?).
haust should not be subjected to any changes. Clean the muffler by riding at high speeds on an auto-
bahn or highway.

Fig. 128. Sectional view of the exhaust muffler (1) Exhaust shell (3) Silencer
(2) Weld (4) Exhaust pipe tall piece

The exhaust pipe is attached to the cylinder by a union nection, rear brace) are firmly fitted and fastened. I1
nut which presses the tapered and knurled edge one of these points is defective, the other two will be
against the cylinder (without packing). subjected to excessive stresses and work loose.
In new condition, the union nut should be tightened
with a torque of 147 Nm (15 kp-m) and must be re-
tightened after having covered a distance of about
500 km, using the same torque value because the taper
of the exhaust pipe will require this period of oper-
ation for properly matching with the jointing face at
the cylinder and thrust point of the union nut.
Fore re-tightening, a hook spanner of type B
TGL 39-442 (or No. 00-04.215) with a plugged-in ex-
tension tube (Fig. 129) should be used.
If, after repeated disassembling and assembling oper-
ations, the joint between silencer and exhaust pipc
has become leaky, a strip of sheet metal having a
thickness of 0.2 to 0.3 mm and a width of 20 mm should
be fitted between exhaust pipe and silencer.
In mounting the exhaust pipe, care should be taken
that all three suspension points (cylinder, lower con- Fig. 129. Re-tightening the union nut for the exhaust pipe
 7.2.1.1. Removinl the Handlebus
After removing the plastic cover, loosen the nut (width
over flats 26) by means of a socket wrench or a t w e l v e
point box wrench with offset head. To avoid damage
to the coat of varnish, place a paper packing or the like
under the wrench. '

Fig. 132. Handlebars mounting

72.12. Front Fork and Steering Bearing

Replace the "dotted" frame and fork bearing rings on
the ball races. Touching-up by polishing or grinding
is not recommendable because this changes the radii
of the races in an uncontrollable way.
Fitthe l o w e r f o r k b e a r i n g r i n g i n a h o t
s t a t e (about 100 'C) and press it down by means
of a suitable piece of tube until it properly contacts
its seat.
Fig. 130. Loosening the end nut Provide the rings with 22 balls each (6.35 mm in dia-
meter), using highly viscous antifriction bearing grease.
Renlove the intermediate ring, slacken back the clamp- The steering assembly must be adjusted in such a way
ing screw for about 8 revolutions by means of a socket that it is free from play but it must not jam because
wrench (width over flats 14). the "steering stability" of the vehicle depends on the
C bserve in assembling: correct adjustment.
The cone head is clamped a f t e r the tightening of For checking, shake the mudguard (up and down) with
the hexagon nut (chamfer on top). The last member one hand while feeling the upper and lower steering
to be fitted is the plastic cap. bearings with the other hand.

Fig. 131. Loosening the cone head screw

When applying a blow of a hammer on the clamping

screw, the cone (1)moves downwards and the expand-
ing sleeve (2) becomes loose.
The central part of the handlebars fitted with its Fig. 133. Front carrier with lower and upper fork
two webs (3) into the recesses (4) of the tube. That is bearing rings
the reason why the handlebars cannot be screwed out
but must be drawn out, while slightly tilting them. 7 . 1 Replacement of the Swlng-arm Bearing Pin
Do not beat the handlebars out of the assembly, other-
wise the handlebar accessories o r the handlebars them- The bearing pins a r e made of seamless tube; that is
selves might be damaged. why old pihs should not be beaten out (because they
Always make sure the expanding cone is actually may be distorted) but pulled out by means of the
loose. adjusting nut.
 First insert short pjeces of tubes, then larger ones. Fix 1. Press th,c lowcl. txiaring down to the stop, using the
the swing arm by means of the 05-MW 26-4 centring intermediate ring 5 4 mm in diameter X 20 mm, so
bolt (1) and push the new pin in place from the left- that pressurc3 is exerted on the outer ring;
hand side (see arrow). Make sure the indicated sur- 2. Insert the disl;~nccsleevc:
faces (see arrow in Fig. 135) of the bearing pin are 3. Press thc upper bearing down until its inner ring
located below the retaining screws of the front carrier, contacts thc distance sleeve; in this operation take
otherwise the next dismantling operation will meet care that the, distance ring, 54mm i n diameter
with difficulties. X 40 mm. i h placed under the lower bearing in
The end clearance is balanced by means of the lock order thal the l o w c ~bearing is not pressed out;
nuts; the swing arm must slide down by virtue of its and thcm ~ ~ l sc ow ~ plx,ssure
l on the intermediate
own weight. Tighten the retaining screws and lock ring, 54 mm in d ~ ; ~ r n X ~ ~20t ~
mm,
~ r in order that
them by means of nuts. the innc.1 and outer rings of the upper bearing prop-
erly cont~cctt h c ~ i rmiltlng parts.
Since thc s t c ~ ~ r l ncomponents
g are mounted on ball
bearings, no ;rdjilst~ngopc'rat ions are required. The
steering bci~r~ii::1s in p c ~ f c w\\.orking condition if the
ball bearing:; l i a \ . ~a ~p r o p c ~press fit and the covering
nut is propcrly tightcmcd. The specified torque for this
operation is 147 N m (15 kp-m) (use a box spanner or
socket \v~.cwc.lio!ily). Tlio screwed joint need not be
locked.

Fig. 134. Replacing the front swing-arm bearing bolt

I

The two bearing points of the front and rear swing-

arm bearing pins are provided with two rubber pack-
i n g ~each to prevent the lubricating oil (only use en-
gine oil or gear oil) from leaking away sidewards.
For fitting the packing rings, use the 13-MV 26-4 tap-
ered sleeve to prevent damage.
Bearing pins lubricated with grease by mistake must
be taken out and cleaned thoroughly.
Only use g e a r o i l because of the narrow fit (cf.
Section 2.4.). Use perfectly tight lubricating nipples;
the bearing pins must be provided with an ample
supply of oil. Fig. 137. Press the inner part of the puller into the ball
In order to ensure a certain permanent lubrication, bearing and pull up\v:~rdsby means of the cross pin
the use of molybdenum sulphide suspensate is recom-
mended.
The ball benling should be removed from t h e frame
in the manner illust~xtcdin Figs. 137 to 139, using the
22-51.006 ex t rnctor. For fitting and removing the
clamping heads and the. other components of the tei-
escopic fork sec Section 7.2.2.2.

Fig. 135. Swing-arm bearing bolt

(See Flg. 136. page'%)

v.2.2. TS 125 and TS 150

7.2.2.1. Steering Bearing
The ball bearings are driven into the frame in the
following manner: Fig. 138. Fitting t h e upper part of the puller
7.2.2.2. Telescopic Fork (see Fig. 136)

T h e front part of t h e machine is disassembled into its

main components a s follows:
1. Remove front wheel and front wheel mudguard.
2. Remove handlebars and place them on the fuel tank
(place a protcctivc cloth underneath).
3. Loosen cable connections and speedometer spindle
from headlamp (mark thc plug-in type connections
for identification) and dismantle head-lamp.
4. Loosen scre\v plugs and covering nut.
5. Remove thc uppcr clamping head (drive upwards
by means of a rubbcr mallet) together with head-
lamp holdcl and rubbcr pad for headlamp holder.
6. U'ithdraw t h r lowcr clanlping head together with
thc guide tubes do\\n\\i~~.ds.tapping the control
tube by means of a ~ . u b mallet. b ~ if required, (note
that t h r guidr tubes should remain clamped in the
lo\vcl- clanlping hcnd. unlcss t h r telescopic uni!s
ha\^ to br d i s n ~ ; ~ n t l e d ) .

Fig. 140. Sequence in tightening the screws; Take csre:

before operation (5) compress and expand several times
vigorously

Repairing the telescopic units of the fork

The permissible amount of wear is reached if the fully
cstended d i d e tubes of the units can be moved to and
fro a t the spindle bush through a distance of more
than 3.5 mm.
In this test. the two fork units must not be subjected
to a n y deformation because this would reduce the actual
play. In cases of doubt, the telescopic units must be
completely removed from the assembly. the guide
tubes gnetly clamped in "soft protective jaws", and t h e
Fig. 139. ScreLving i n the sc~.t.\\',tightening and in this w a y actual play measured a t the spindle bush by means of
pulling the bearing out of the frame a dial Sauge.
When completely removing the telescopic members,
the clamping heads and the headlamp holders can b e
Mounting is to bc done in the inverse order of the left a t the vehicle.
disassembling opclxtions. After removing the front wheel a n d the front wheel
The screwed joints should be tightened in the follow- mudguard. and after loosening the screw plugs a n d
ing order: the clamping screws from the lower clamping head,
1. Covering nut. the telescopic units a r e driven out by means of t h e
combined 19-MW 22-1 assembly spanner.
2. Screw plugs for telescopic units, applying a thin
film of the "Chcmisol 1405" adhesive lacquer (manu-
facturer: VEB Schuh-Chemie, Erfurt) to the thread
of the screw plug? for sealing them. ..
("Chemisol" is made on the basis of synthetic caoa-
tchouc, viscosity: 30 s run out time of 50 m1 with a
5-mm jet. In countries other than the GDR, a n ad-
hesive lacquer of similar properties should be used
for sealing.)
Torque: 147 Nm (15 kp-m).
3. Clamping screws a t the lower clamping head -
torque 34.3 to 44.1 Nm (3.5 t o 4.5 kp-m).
4. Nut of the knockout spindle; then, while the motor-
cycle is stationary, vigorously more the system
several times through the full travel from bump t o
rebound (while the mudguard screws a r e still loose)
to ensure that'the knockout spindle assumes proper
position in the opening provided for the spindle,
t h e spindle bush, where a sliding fit must be ensur-
e d ; if necessary, finish ream the left-hand spindle
receiving bush t o a size of 20 mm in diameter. Fig. 141. Assembling and removing the gyide tubes
5. Clamping screw for knockout spindle. with the help of the combined assembling spanner
 ing t h e circlips (Fig. 143), t h e telescopic unit can be
dismantled into its parts.
The D 32 X 45 X 7 packing ring will b e destroyed when
being pressed out of the threaded ring.
When inspecting and repairing t h e parts, t h e following
. .
should be observed :

FOI. hi, purpose. thc apnnncl is scre\ved into th(,

h1 27 X 2 thread of the guide tubes. The assenlblerl
position of the guide tubes must be marked bp coloui~
dots bclo\v the lo\ver clamping head before disman-
tling. Fig. 143. Loosening the lower circlip
To iacil~tateI-e-assembling. i t is advisable, immediately
after ha\.ing ~.emovedone telescopic unit, to insert an-
other guide tube or a suitable piece of pipe with a di-
ameter of anything between 31.7 and 31.8 mm form Guide tube
the bottom and in order that the rubber pads for t h e The tubes must be replaced by new ones if they a r e
headlamp holder \\.ill not be dislocated. distorted by unusual outer influences (do not straighten
For assenlbllng and disassembiing only adequate tools them, experience has shown that guide tubes after
should be used. With makeshift tools, damage will be straightening assume their original position of t h e dis-
caused and successful repairs \\rill not be ensured. torted condition; permissible out-of-true error 0.05 mm)
For disnlantling a telescopic unit, it is to be clamped or t h e chromium plating is worn away.
at the spindle bush but not at the guide tube! The portion of the guide tube subjected t o the highest
rate of wear is a t the front end, about 150 mm above
After 1.en1oving the protective cap or protective bush, the lower edge, i.e. where the most intense sliding
the threaded ring can be loosened by means of the takes place of sliding bush and packing ring. Wear of
combined assembling spanner and the guide tube to- the chromium coat is indicated by dark spots and
gether with the lower slide bush and the damping grooves. If a telescopic unit is to be reassembled with
valve withdrawn from the sliding tube. After loosen- a new packing ring and+a used guide tube, which still ,
.. . r

I,egr.:11!lrw Fig. 136 on page 51 (12) 6006 ball bearing

(13) Lower c l a m p i n g head
l e f t - h a n d h a l f of i l l u s t r a t i o n : (14) Wire circlip 38
(15) Protective sleeve
Design "guide tubes exposed", completely espanded (16) Wire circlip 30
417) Guide t u b e
(18) Supportlng rlng
(19) Radial seal ring D 32 X 45 Xi
r i g h t - h a n d h a l f of i l l u s t r a t i o n : (20) Threaded ring
(21) Slide tube
Desijin "cuide tubes co\.ered with protective sleeve". (22) Upper sliding bush
completely compressed (23) CircliD 32
(24) Compression spring
( 1 ) ~ n nil!
d (25) Padring ring for damping valve
( 2 ) onl~tted (26) Wire circlip 32
(31 Uppcr rlamplng he~d (27) Lower sliding bush
( 4 ) 600'3 ball b c a r l n g (28) Same as part ( D )
(5) Slcer~ng
head t u b e of the franic (29) Protective cap
(G) scre\'.'plug (30) Felt ring holder
(7) R u b b c r ring for h e a d l a m p holder (31) Felt ring
(8) Headlamp holder (32) Axle bush
(!l) Compression spring for telescopic fork
(10) S p a r e r sleeve
(11) Control tube
is in perfect working order, it is advisable to mount process would be destroyed and lead to an unusual
the guide tube in such a manner that it is displaced wear of the lower sliding bush.
through 180" with respect to its former assembled pc+ If, by extraordinary conditions (foreign particles or.
sition. similar things), the interior surface of the sliding tube
When reassembling telescopic units which were not is damaged, the surface may be restored to proper
disassembled into their component parts, it is advisa- working order by honing (in a manner similar to that
ble, however, to At the guide tube in their original po- used in finishing the cylinder bore). The required di-
sition in the assembly. Over its entire length, the guide mension of the diameter of the sliding tube hole is
tube must be free from impact marks, grooves and 38.00 to 38.05 mm.
other surface irregularities to ensure that the packing
ring will not be damaged when it is slipped on the Damping valve
assembly. Surface irregularities must be removed by In this part, only an insignificant amount of wear is
a fine-grained oilstone moved longitudinally. involved so that a replacement of the components is
practically not necessary.
The sealing rings for the damping valve. made of
Upper sliding bush
piston ring material, must be free to move easily. free
The required measure of the hole is 31.850 to from burr and absolutely clean. Small contaminatio~s
31.889 mm. Experience has shown that limited wear may easily lead to jamming of the sealing ring or to
occurs so that replacement practically is not necessary. leaks in the valve.
The inner surface of the hole partly exhibits a non-
uniform appearance caused by a small eccentricity in
the position of the assembled components parts due to
manufacture; this is not associated with any drawback,
however.

Lower sliding bush

The outer diameter is 37.875 to 37.900 mm. This part
is also subjected to a low wear rate so that replacement
\vill become necessary only after 30,000 to 50.000 km
of road operation.
The given axial play of the sliding bush between the
circlips of the guide tubes can lead to a clicking sound
emitted from the telescopic fork on the move which
has no influence on the function. This insignificant flaw
can be removed by fitting an adequate spacer between
circlip and lower edge of the sliding b l s h to remove Fig. 145. Pressing the packing ring into the 1111.eadedrin;
this axial play. This washer must exactly fit on the by means ol the combined assembling spanner ( ~ na vicc
guide tube, diameter 31.7 mm, and its external dia- or under a hand-lever press)
meter must not exceed 35.5 mm to prevent these
washers from rubbing against the inner surfaces of the
sliding tubes at any rate. In ordcr that the packing ring is not damaged when
pressed into the threaded ring. the combined assern-
Sliding tube
The surface of the hole exerts a great influence on the
ease of motion and wear of the interior of the telescop-
ic fork. The drilled hole is not mechanically finished
because by emery grinding or similar processes the ex-
tremely smooth surface obtained in the manufacturing

Fig. 146. Fitting the threaded ring (with Lhe packing ring
Fig. 144. Combined assembling spanner for pressing the pressed i n place) on the guide tube by means of a fitting
packing ring into the threaded ring sleeve
 bling spanner should bc used for this purpose (Figs. panding the unit. The damping effect must be clearly
144 and 145). in expanding.
This special tool is designed in such a way that the After the completion of the functional test, t h e tele-
packing ring is not placed on the lower face and the scopic units are completely assembled; for this pur-
fitting tool does not press on the upper face wherc pose, the unit is clamped a t the spindle bush.
damage to the rubber lining of the packing ring would The telescopic units a r e also mounted in the vehicle
bc caused. After prcssing the packing ring in place. by means of the combined assembling spanner (cf.
back-up washer. felt ring and felt-ring holder must be Fig. 141).
fitted. Then the complete threaded ring is slipped over Sequence ol tightening the screws according to Fig.
the guide tubc iron? top by mcnns of the fitting sleeve 140.
(Fig. 146). The correct oil level in assembled condition is checked
To provide ;I p r o p c ~seal bctween sliding tubc an(? according to the manner shown in Fig. 145.
threaded ring. apply ;I thin film of "Chemisol 1405"
adhesive l a c q w r to the, ihread of the sliding tubc be-
fore i~ssenibling.O n n ~ account ) sh(:u)dadhesivc be ap- 7.3. Fuel Tank
plied to the th1~;ldof tlw thrcwdcd ring because the
es~c.ssi\~ supply
e of ildhcsi\,c lacqucl \vould be squeez- Because of the danger of explosion. rcpai1.s at the fuel
c,d U ~ \ ~ ; I I X . I<I I I Iw packing ring. tank should only be carried out in a spccial workshop.
The ~x,quirxd1orrlllcLi r s ~ . lichlcmin!: 1111. l h l w d e d ring Repairs oi thc mounting for fuel lanks (chassis) and
i~ I!)(; K m ( 2 0 1.;))-m). a t the fuel shut-ofl cock can be done by the rider him-
self.
To remove the fuel tank, unscrew the two screws (1). The flrst one becomes accessible after unscrewing the
After having turned the fuel-shut off cock, remove the fuel shut-off cock from the fuel tank, t h e second one
tank in the direction of the arrow (bend open the cable after loosening the lower plastics screw joint and the
holder!). fastening screw beneath it. I t is advisable, to clean the
At the ES 12511 a n d 15011 remove the handlebars strainers thoroughly after every 5,000 km of road oper-
in order not to damage the coat of varnish of the tank ation or once a year.
(location 2). If attached, separate the legshields from Another source of troubles may be the rubber pack-
the holding plates. ing under the actuating lever of the fuel shut-off cock;
In assembling take care not to clamp the cable con- the holes in the rubber may be clogged o r closed by
trols - correctly fasten the handlebars (ES 12511 and swelling or by too tightly fitting fastening screws. Ac-
15011). tuating lever and rubber packing can be removed after
After removing the fuel tank (Fig. 150), the rubber loosening the two fastening screws arranged laterally
parts can be subjected to inspection. to the actuating lever.
When the front rubber parts are worn, they should On the occasion of repairs in the fuel shut-off cock.
be turned through 90" as a first remedy. If the rear the fuel feed hose leading to the carburetter shou!d
rubber parts are damaged. they must be replaced by also be inspected. If this hose has become brittle, leaks
new ones. may occur in the connections.
On no account should the elastic mounting be changed Then the fitting of a new fuel supply hose having n
into a rigid one. size of 5 X 8.2 mm is required.

4 Brakes
The two bearing bolts (1) must firmly fit in the cover,
otherwise the brake tends to block.
The two bearing bolts and the cam spindles (2) must
be lubricated with high melting-point grease (clean
them every 10.000 km or once a year). In continuc~us
braking, temperatures up to 150 "C may occur for a
short time!
Eefore removing the brake shoes, mark them for ider.-
tification so that they can be re-fitted to their original
place where they have run in.
Clean all parts thoroughly, remove abraded particles,
chamfer the leading side of the shoe.
Fig. 150. Removing the fuel tank When exchanging the brake shoes (that are capable
of being restored to proper working conditions) it
should be noted that brake shoes that have already
7.3.1. Fuel Shut-off Cock been reworked are ready to be fitted (provided they
were machined in a special device at their circum-
The condition of the fuel shut-off cock effects a signi- ference), whereas brake shoes that are non-reworked
ficant influence on the proper function of the engine. at their outside have to be returned in a lathe. For
Insufficient fuelmpply may also lead to pistion seizing. this purpose, they are mounted on the brake backing
The fuel passes through two strainers in the cock. plate by means of the return spring, the brake back-
ing plate is centred in its bore and the shoes turned
down to such a degree that the difference between
the diameter of the brake ring and the diameter of
the brake shoe is at least 0.6 mm.

Fig. 151. Fuel filter cock dismantled

(l) union nut
(2) Retaining screws
(S) Rubber packing
(4) Actuation lever Fig. 152. Front brake cover, one brake shoe removed
 F I G .l>:{. Sectional view of front wheel h u b
lil \ \ ' h v c . l Lmd? \:::h [,ast-onbrake ring (2) (10) A s k holder right-hand s l d c
12) i ~ l . i ~ I,.vcr
kc (11) S p a r i n g sleeve
(4) \Vhccl hod?. c i x c r (12) Ball bearing 6302
15) F7ctul.n spring I<.I.Wakc s h o c (13) Rubber sealing ring
16) Blxkc Iioldcr (14) Anchoring bolt
(7) H?x;lwn 1111131 14 X 1.5 (15) Lock ring l2
(8) \V;ish(.r (16) B r a k e s h o e
[!I) A\]<, ( l i ) A s l e holder left-hnnd s i d e

7.5. Replacement of the Foot-rest T u b e s particular importance a t the left-hand side. If the foot-
rest tybe is allowed to turn, the prop stand drops dur-
For replacing one of the foot-rest tubes. use a sockct i n g ,.jding.
lvrench (width ovei. flats 13) to loosen i h c clip and p 1 1 1
out the tube.
When fitting take c w c that the recess in the foot-rest 7.6. Checking a n d C h a n g i n g t h e
tube engages \vith the nose at the flame. This is of Secondary Chain
To remove the secondary chain for inspection, open
the chainconnecting link, and attach a n old (but clean)
chain to it. The locking spring must be placed on the
connecting link. Then draw out t h e chain to be checked
until the connecting link is accessible.
Re-insert the checked chain in the inverse order.

Fig. 154. Prop stand Fig. 155. Pulling out the chain

P 59
 If the backlash between chain rollers and pins is ex- Only use original chain links, t h e pin diameter of the
cessive, a new khain must be used. The damage d u e various chain makes is different. A connecting link in-
t o chain breakage is more cxpcnsive than a new chain. serted in the chain sleeves where it has too much play
A gearbox sprocket worn to such an extent (as shown causes the chain to "mount" t h e sprocket a t this point
in Fig. 156 where it is compai,cd with a new part) - this may also lead to chain breakage.
must also be replaced. It \vould cause premature wear
of the chain. The spring clip a t the connecting link must fit in this
way!
The internal profile of the chain protective hoses
guides the chain: as n consequence. the "whipping"
of the chain increasing the rate of wear is thus re-
duced to a minimum. To avoid resistance to sliding in
the profile, the chain must be lubricated with GL 60
gear oil o r antifriction bearing grease after every
2.000 km of road operation.

To fit thc new chain c~l111c1. ; I I I , I ~ i ~t to the‘ old chain:

a s sho\vn in Fig. 155. 01. d ~ . , i \ i\t through thc chain
protective hoses by mcan- , ' I ' .I \ \ . I I x , hook.

Fig. 159. Correct f i t of the spring

Placc thc \ehiclc un its prop stand wilk~c~ut load and

check the chain over one full revolulion of t h e chain.
Apply an intermediate piece (1) 20 mm 0. a s demon-
strated in the illustration to the foot-rest for the pillion
rider and rear wheel swing.
The chain shows the correct tension. when t h e lower
chain pimlection hose \v i t h c h a i n can be pressed
to (1).
Adjustments a r e madc by means of the chain tighten-
cr.; (also observe the text for Fig. 169).

Fig. 157. Fitting the chain

I To insc1.t he cunnccting lmk. prcw the cnd links to-

l gether by means of a pail. 01' pointed plicix and insert
l the link from t h e rear.

Fig. 1 6 1 ~Adjusling
. the chain sag

F -
r .c. Adjusling ihc Cluicii
Before opening a n engine because oI a slipping clutch,
check that the specified play is present between clutch
thrust bolt (threaded stud) a n d push rod (Fig. 3, ob-
Fig. 158. Fitting the connectmg l ~ n l i serve the sectional view of t h e engine).

60
 Looscn the lock nuts and screw down the thrust bolt (1) Properly tighten thc nut ( l ) but d u e not u f r u n d u e
~ n t i the
l stop is just felt. Then slacken back the thrust forcc 1101 to dislo1.1 the c.h;rin covrr of plastic.
bolt for three quarters of a revolution, retain i t and
tighten the lock nut. Due to wear of the set of disks,
t h e distance is not enlarged but becomes smaller.
Because o i t h r sliding (scraping) motion of the clutch
\vorm, the u w o f molybdenum sulphide is advisable.
Either apply hloSz po\\,der to t h e clutch \vorm (2) by
111cans o i i1 brush 01 add this substance to the lubri-
cant in th(, 1'111.mof ;~'.;uspcnsnteand lubricate thi.oug11
nipplc (3).

Fig. 161. Clutch worm

7.8. Rcnmving a n d Dismantling the

R e a r Wheel D r i v e

The elastic connection between rear wheel dri\,e ant1

rear \i..hccl is c4Tcctcd by thc damping rubber mcm-
ber (A). In the casc of scverc distortions o f . o r fissures
in, t h e opvnlngs for I tic I T ~ I I ' \viicel dogs (indicated by
sudden impacls d111.ing moving off or gear-sliiiting).
this mrmbol. mllxr be ~ , c q ~ l ; ~ c ~ ~ l .

Fix. l(i4. Removing the circlip

Use ;I screw-drivel to i i f t thc c.ngaging hook of t h e

h0t)kcd ci~,clip1'1~.111 tlw bc.118 in 11ic helical wheel a n d
pull ol'f the lattcr.

Fig. 162. Rear wheel drive

(2) lubricating nipple ior the speedometer drive. Here,

use gear oil (GL 60) a s lubricant. An addition of graph-
ite or MoSz is ad\.~sable.
In vehicles from the 1973 model, t h e speedometer drivc?
is self-lubricating: provided with "Ceritol k 2"+
antifriction bearing grease.
-
Do not provide the speedometer shaft (3) with too
ample a supply of lubricant, otherwise the lubricant
will get into the speedometer. Fig. 165. Removing the helical gear
 In order that the first thread is not distorted when
driving through the flange bolt, screw the nut down
until it is flush with the bolt.
The 6004 bearing (20X42X12) will come out together
with the bolt in almost all cases.
Sprocket and damping body were cast together and,
therefore, should be replaced as one complete part.

Fig. 168. Dismantling the wheel bearing

Fig. 166. Dismantled rear wheel drive

7.11. Inspections Required in the Case of
Poor Road-holding
An inadequate load distribution when transporting
7.9. Speedometer Drive luggage is of great influence.
The rear luggage carrier to be fastened to the saddle
When the grease nipple (from the 1973 model a coun- carrier should only be loaded with l i g h t - W e i g h t
tersunk screw BM 6 X 8) is unscrewed, the bearing small luggage. For holiday luggage and similar loads,
bushing becomes accessible and can be withdrawn to- side luggage carriers fitted to each side of the rear
gether with the pinion. motor-cycle part are required.
The chedr nut at the speedometer shaft should only be The track keeping of the two road wheels can be
tightened by hand (the drive shaft can be clamped in checked by means of a measuring rod or by sighting.
the speedometer).
The rod must contact the rear wheel at two points
while, at the front wheel, the same distance between
rod and two points must be present (to allow for the
different tyre widths). .
A good road-hugging quality is dependent upon proper
tyre fitting (observe the control line!), correct tyre
inflation pressure, perfectly true-running wheels (no
vertical or lateral amount out of true).

Fig. 167. Replacing t h e speedometer pinion

7.10. Replacement of the Wheel Bearings

For replacing the wheel bearing, the H 8-820-3 e

~ a n d i r gmandrel should be used.~he M-8 screw must Fig. 168. Aligning the wheels
be slackened back until the tapered pin not longer
contacts it.
After having driven out the bearing, tighten the screw, The tendency to flutter of the handlebars may be due
as a consequence, sleeve and pin will be separated to an inbalance of the wheels, besides loose steering
and the bearing can be withdrawn from the former. bearings, worn down wheel bearings and loose d n g -
arm bearing pins. It may be the rear wheel that causes The second tapped hole must be Aniah reamed until
these troubles in the front fork. it is restored to proper condition. Produce a n oversize
To balance a wheel statically, it must b e free to move screw and fit it in place (a threaded bolt with two nuts
with ease, or it must be removed from the vehicle will also be suitable). After having tightened the new
and with its knockout spindle placed on two prisms. screw with a torque of about 49 Nm (5 k p m ) , prepare
When the wheel has come to rest, the lightest point the second screwed connection in the same manner.
(on top) is provided with such a n amount of lead wire
(the illustrations shows a piece of lead clamped to the
wheel) which is required to remove the inbalance. In
order that the weight,cannot work loose, it is wrapped 7.12. Repairing the Spring-loaded
in insulating or adhesive tape. After a flat, the wheel Suspension Units
should be still in balance; for this purpose, the valve
location at the tyre is marked by a colour dot so that All that has to be done for this purpose is the replace-
you are in a position to find the original location. ment of defective suspension unit parts and the lubri-
cation of the adjusting sleeves in the rear spring-
loaded suspension units.
The shock-absorbers must be replaced completely and
sent to a workshop for regeneration. I t is not possible
for you to restore the shock-absorber to proper con-
dition yourself. If oil is lacking, the required amount
can be topped up (using special wrench 05-MW 82-4),
in most cases, however, the sealing of the piston rod
will be defective - so that the shock-absorber must
be sent to a specialist for regenerating.

5.12.1. Shock-absorber Marking

The marking is located on top of the lower fastening
eye.
Example: A 22 - 120 - 5618 MV 1.5011 or, from J u n e
1978, A 22 - 120 - 5618 1.5011
Fig.170. Balancing the front wheel
Where the meaning is as follows:
A 22 design
120 rated stroke in mm
Noise may be emitted from the chassis by loose screwed
connections between frame and saddle carrier. The two 56 damping power i n the direction of pull in k p
xl.c\vs (see arrows) must be precision screws, i.e. they 8 damping power in the direction of compres-
must fit in the tapped holes without chattering. Therc- sion in k p
fore. scre\i8swith rolled-on threads are unsuitable be-
cause their shank diameter is smaller than that of the OV (MV) German abbreviation for "without adjust-
ment" (with adjustment)
thread.
When the two bore-holes are distorted because the 1.5011 number of manufacturer
motor-cycle has been operated with the saddle carrier
loose for a longer period, the latter must be placed From June 1978, the letters OV or MV are omitted.
in its original position and clamped by means of a "With adjustment" is identified by " M .
SCtF\V,

The following shock-absorbers are used:

ES 12511 and 15011 TS 125 and 150
front A 22-120-5618 OV a component of the
ielescopic fork
A 22-120-5618
(from June 1978)
rear A 22-100-7618 MV
(until April 1970)
A 22-100-9418 MV
(until May 1973)
A 22-100-8818 MV A 22-100-8818 MV
(from June 1973,
can be used in pairs
in older vehicle
designs)
A 22-100-8818 M A 22-100-8818 M
Fig. 171. Fastening the saddle carrier (from June 1978) (from June 1978)
7.12.2. Banoval of the Shock-absorbers The yellow colour dot means positive deviations, the
green colour dot negative deviations from the rated
Clamp the lower eye of the suspension unit in a vice. value of damping power. In shodr-absorbera of a more
Press down the protective sleeve (8) and remove the -nt design, the colour marking *yellow" is omitted
two ba*g-ring halves (1). Now, the Parts (811 (9). for a positive deviation of the damping power; the
and (11) can be removed. negative deviation will be marked "green" now as
before.
Always mate yellow with "yellow" or "green"
7.12.3. Common Faults in Shock-absorbers with "green".
l. The shock-absorber is inactive, although there is no
visible oil leakage (foreign particles between the
diaphragms of the piston valve).
2. The damping action fails to start smoothly but starts 8. Cabk Controls
jerkily. The spring-loaded suspension units are said
to "stamp" (insufficient amount of damping fluid The cable controls of a motor-cycle are frGuently
or bottom valve leakvh " V
exposed to external influences such as rain, dirt and
3. Damping liquid leaks. lye. In the case of motor-cycles which are ridden every
day and frequently parked in the open, the interior of
the cable controls is subjected to great frictional stres-
ses so that, eventually, the control lever offers resis-
tance to pulling and control efforts are increased.
Service life of cable controls can be improved and ease
of control ensured by protecting the cable controls
from water and dirt and lubricating them.
The simplest manner of sealing is by applying a film
of water-repellent grease such as Ceritol to the pro-
jecting end of the cable and to the slot in the adjust-
ing screw at the control lever.

Fig. 172. Design of the Shock-absorber

(1) Halves of the supporting ring
(2) not aDDliCable
(3) Stop ribber pads
(4) Threaded piece wlth radial seal ring AC 10 X l 0 X 7
(5) Piston with non-return valve (top) and damping valve .
(bottom)
(6) Bottom valve wlth badcing ring
(7) Marking of tolerance group
(8) Protective sleeve
(B) Compression spring
(10) Piston tube
(11) Adjusting sleeve

7.12.4. Filling the Shock-absorbers with Fluid

Using the 05-MW 82 special wrench, unscrew the
threaded member [(S) in Fig. 1721 and pull out the
damping device. Clean all parts ir Scn~ineand pour
in new oil. Tighten the thrended meinjer with a torque
of 49 Nm (5 kpm).

Fig. 173. Device for lubricating cable controls

7.12.5. Mating Shod-absorbers Tell A (
.
u
s -utter Part A (made of union nut
fur Steuerrohr m =/l50 ge- for control tube o t ES IH/MO)
To ensure good road-holding properties, the shock-ab- fmut)
Tell B (Hartpummi) Part B (hard rubber)
sorbers of one and the same axle must show equal TeU D (Zyllnder und Kolben Part D (cylinder and piston
damping values. einer handelsublichen of a cornmerctpl lubclcnting
The marking of the tolerance group is located at the Srhmietpreaae. d a u Ce- gun and M 8 threaded pin
wlndestlft M 8 mit Knebel with grlp and M 8 nuts)
upper face of the pistcn rcd ((7) in Fig. 172). und Muttern M 8 )
 Fitting a rubber gaiter, Part. No. 05-44-050, as a means
of protection, is another possibility of extending thc
service life of cable controls. The interior of the gaiter
must be filled with a water-repellent grease.
For lubricating the cable controls, use the device shown
in Fig. 173.
As a lubricant, either a mixture of gear oil and gear
grease, prepared in the mixing ratio of 1 : 3, or a mix-
ture of Ceritol +
k 3 and fuel, mixing ratio of 1 : 1.
should be used.
The cable controls are clamped at one end of their
sheaths in the tapered rubber cap and, together with
this rubber cap, screwed to the lubricating device by
means of union nut (Fig. 174).

Fig. 174. Cable control Inserted in n lubricating device

9. List of Special Tools

9.1. Engine Drawing

Engine assembling fixture none
Armature puller 1.
Gearbox sprocket-holder 2.
Push pin for clutch compression springs 3.
Holder for loosening the nut at the clutch shaft 4.
Holder for loosening the nut a t the drive pinion 5.
Puller for pinion on the crankshaft 6.
Drift for gudgeon pin 7.
Drift for fitting sleeves 8.
Casing separating screw1) 9.
Pusher for crankshaft1) 10.
Drift for 6303 and 6004 bearings 11.
Drift for 6303 bearing and 22 X 47 packing ring 12.
Fitting device for small-end bush 13.
Setting gauge for gear-shift detent axle 14.
Support for piston 15.
Guide mandrel for inserting the gudgeon pin 16.

9.2. Cycle Parts

Centring bolt for fixing .the swing arms
Sleeve for fitting the sealing rings on swing-arm bearing bolts
Expanding mandrel for wheel bearing
Special wrench for loosening the lock nut
(spring-loaded suspension unit)
Combined assembling spanner for telescopic fork
Fitting sleeve for radial seal ring (telescopic fork)
Extractor for steering bearing

9.3. Electrical Equipment

29-50-801 Ignition setting gauge none

i . l) Can be replaced by 22-50.430; 22-50.435; 22-50.437 (see Supplement).

l
 -
Fig. l. Exploded view OS the engines MM 12513 15013 (with revolution counter drive)
1. Technical Data

1.1. Engine MM 123!3 MM 15013

.-

Connecting-rod bearing needle bearing on top

K 15 X 19 X 20 FKI
Crankshaft main bearing 2 ball bearings 6204 TN W C 4 f
(20 X 47 X 14) TGL 2981
1 ball bearing 6304 S C 4 f
(20 X 52 X 15) TGL 2981
lubrication by fuel-oil mixture 50 : 1

1.8. Capacities
Telescopic fork 230 cm3 of damping liquid
for each fork member

2. Fuel, Lubricants and Fluids .

2.2. Engine Oil

The two-stroke engine oil is added to the fuel in a
mixing ratio of
1 :50
This means that, for example, 0.20 1 of engine oil are
added to 10 1 of fuel.

2.5. Damping Fluid

The shock-absorber oil must be mixed with molyb-
denum disulfide oil suspension (Molykote, Fimol or
the like) in the mixing ratio of 45 : l.
Fig. 3. Dismantling the primary drive

In the case of the changed engine. the pulling of the

right-hand casing half by means of the assembling
3. Disassembly of the Engine bridge 22-50.430 (1) and the extracting sleeve 22-50.435
(21, which must be completed by the extracting screw
The sprocket wheel on the crankshaft is provided 22-50.437 (3). is possible.
with a M 26 X 1.5 thread (arrow-head) and one screw Before screwing the assembling bridge in place (alx-ow-
M 10 X 25 is used to press it on the tapered end of the heads), unscrew the clamping members of the assem-
crankshaft. bling device (4) or turn them away (5).

Fig. 2. Primary drive

Fig. 4. Pulling off the rig!, and casing h a l f
(1) Assembling bridge
The sprocket wheel can be removed from the crank- ( 2 ) Pulling sleeve
(3) Pulling screw
shaft by means of puller 12-MV 32-4. For this purpose, (4) Rear clamping device
the puller must be properly tightened! (5) Front clamping device
For pushing out t h e crankshaft, t h e assembling bridge
22-50.430 i s screwed to the left-hand casing half (ar-
row-heads). For this purpose, use the two front fasten-
ing bore-holes for t h e dynamo cover. The 22-50.435 ex-
tracting sleeve is again used as pressure tool.

Fig. 5. Pressing out the crankshaft

Fig. 7. Applying the ball-bearing extractor
(1) Hlng 24-50.412 f o r b(:,lrlllx'. li?llR ilntl l2114
(2) Hlng 22-50.434 [or' 1 x . 1 1 I I I R 61
:114
( S ) Hulc.; f u r p r r h \ ~ n g - r ~ f s
Tr r r \ v s
h f t r r heating thv two casing halves to a tempcl atul e (4) Cl.~mpingp ~ c c n
o i about 100 'C. the crankshaft bcarings can bc dl ivcn
out by means o f suitable mandrels. As to the bearing.
of the left-hand casing half. use the mandrel and place Sul;sequcntly, thc b c a ~in2 can be pressed off against
it against the i n t c ~ n a lrings. the crank plate by a l t t ~ n a t e l yand uniiormly tighten-
The packing ~ ' i n gC;II.I,~~>I.(13) is n o t ~ x ~ n ~ o v1c' d1 . c ~ the
~~ ing tnro M 8 ): 50 s c ~ ~ having
~ . s a pin at the end nf
shait seal ring, D 22 X 30 X 7 at the clutch sidc, to- the scivw.
wards the outside, a i t e ~ .h n v ~ n g1.cmoved the c i l ~ l i p Kolice! The ball-bearing extractor must not be allowed
30 X 2. to turn when pulling the bearings otherwise the M C
X 50 screws engagc with the bore-holes in t h e crank
plates.

,I
1

,X
/'
'/

Fig. 7a. Pressing-cl'l' the crankshaft bearings

( I ) Prchslng-oJl scrcws M H >: i l l wilh herdcncd pin

Fig. 6. Dismantling the ball bearings

For changing the packing r i n ~ j the

, engine need not bc
dismantled !
When the crankshaft bearings have been left on thtt
crankpins during the dismantling of the crankslxft,
they can be pulled off,as is shown in the Figs. 7 and 7a.
by means of the ball-bearing extractor 22-50.431 and
lhe rings (1) 22-50.432 (regarding the engines MM 125'2
- 15012) and (2) 22-50.434 (regarding the engine:;
M M 12513 - 15013) on the sidc of the dynamo. Th(.
clamping pieces (4) have to be pressed between crank- Fig. 8. Lubricating channel, lelt-hand side
shaft and bearings by means of + vice or the two (A) Oil o u l l c l
(R) Oil collecling groovc
screws M 8 X 100. (T)Separating dlsk
The l u b r i c a w channels in the left-hand and right- If the setting gauge 11-ML 8-4 for adjusting the g b r -
hand cadng halves must always have free passage. ahlft detent axle is not available and the gearcahift
The separating d k k made of rubber k to be placed detent axle'ia to be adjusted by means of the U b l o ~
Into the reccstr in'the &sing separating a m at the oil measure" 13 mm, the distance (A) of 0.1 mm between
collecting groove (B) when the engine L assembled. gear-shift wheel lstl3rd speed and the Axed gear of the
The dbk separates this oil collecting grqove into a left- 4th speed on the layshaft must be chedted with the
hand and a right-hand part. In thin way, it ensuns that fourth speed in engagement. If necessary, the gear-
all crankshaft bearings a n properly lubricated even nhift detent axle must be re-adjusted even when the
when the engine is pasaed through fairly oblique po- measure of 13 mm will be changed as a consequence.
sitions. Notice! Carry out measurements only with the gear-
shift detent axle locked by means of a lock nut.
Any change in the gearbox adjustment with the en-
gine not opened is not advisable.

4. Aaaembling the Engine

Mounting the crankshaft bearings at the side of thc
clutch
In contrast to the old mounting of the crankshaft, the
left-hand casing half must be pre-assembled in such a
way that the two crankshaft bearings at the side cl
the clutch (mated - selection with similar bearing clear-
ance) are fltted into the casing that is heated to a tem-
perature of about 100 'C.

Bearing of the Gudgeon Pin

In the new design, the gudgeon pin is mounted in a
needle bearing. Crankshafts for replacement or as
spare-part will be delivered with adapted needle bear-
ing. The three possible dimensional variations (grey,
(1) Bearing bush
(U Shah with pinion
'
Fig. 10. Arrangement of the revolution counter drive

white, black) of the gudgeon pin will flt to this assem- (3) Double wheel
(4) Beadng bolt for double wheel
bly. If, after a longer service life, the clearance of (S) Locking plate
the gudgeon pin becomes excessive, needle bearings
with other dimensional variations can be fitted.
Take Into consideration: The oil-free gudgeon pin must Mounting the crankshaft bearing 6304
be capable of being turned, without any clearance and The bearing a t the side of the dynamo is fitted in the
without jamming, in the also oil-free needle bearing. same way as in the former engines, but with the help
of the 12-MW 31-4 drift. Compensation of the sealing
Regarding the adjustment of the gear cap is effected in the same way as in the former design.
Our experiences have shown that the dogs of the geap
shift member must engage with the segment lever as Regarding the primary drive
far as up to half the thickness of the material. The
dimensions given in the text for Fig. 35 in the Repair -
From January 1978, the engines MM 125'3 150t3 in
Manual for TS 1251150 are, therefore, extreme values the form of the de l w e models are provided with re-
and must not necessarily be correct in the case of any volution counter drive. Older engines and engines of
gearbox. the standard design cannot be equipped with this drive.
The double wheel (3) is only accessible when the clutch
drum is removed.
Observe when mounting:
Press the bearing bolt (4) for the double wheel in
place in such a manner that the bolt, measured
from contact area for the double wheel at the gear-
box casing, project for 29 f 0.2 mm into the:com-
partment for the primary drive.
Mount the double wheel (3) when having provided
it at the bearing area and at the teeth with oil.
Fit the shaft (2) with grease.

Regarding the cylinder

From 1978, the cylinder is only provided with the
marking of the nominal size, in contrast to the in-
Fig. 8. Chcdting the distance between teeth in the formation given as an explanation to Fig. 66 in the

A -
4th upeed
0.8 m m
Repair Manual for the TS 1251150. Month and day of
manufacture are no longer stamped in it.
5. Electrical Equipment Colollr ade
German
abbrevlatlon meaning
blue
rcd
btopm
Whlte
m y
blad
g==
yeuow

X Plugged connectlon
0 Screwed or clamped connection
Soldered connectlon or flxed connection
nur bet Bremslichtschalter vorn only for stop light switch. front
nur fur BRD-Ausfuhrung only for FRG-destlned types

U !
(13) Regulator cutout
(14) Combined stop. t a l l and number plate Lltttng
Fig. 11. Wiring diagram for 'h 1251150 de luxe (l4a) Stop lighting flttlng
(1) Headlamp (10 Receptacle contact atrip .%pole (l4b) Comblned tall and number plate 11-g IMng
(S) Revolution counter (7a) Contact breaker (IS) Stop light awitch. rear
(18) Parklng light (lh) Ground point (3a) Revolution-counter illumination (I) Ignition coil (16) Flashing-light direction Indicator. front. left
(lb) High-headlight beam (2) Speedometer (4) Flasher switch
(1C) Passing beam
(S) Sparking plug (17) Flashing-light dlrection indlcator, front, fight
(2a) Speedometer illumination (5) Combined dimmer switch
(Id) Ignltlon-:;,?V ' .+l1 . ...., ,......- (10) Battery (18) Flashing-light direction indicator, rear. left
to* -,--b.-- ,:.-L. -,

-
(?c rdq!E'_?dicator switch !fN) ;a-g-light direction lndlcator, rear, fiat
- . -
 -
7. Cycle Parts After externally cleaning the telescopic fork members,
loosen the fastening nut (Fig. 1511) for the supporting ,

71.3. Beplacement of the Swing-erm Bearing Pin tube, using a n handled socket wrench (width over
flats 10), and then remove the supporting tube together
Since April 1975, the swing-arm bearings have been
mounted in rubber bushes in the place of the former
slide bearings. The new bearing is free from mainte-
nance, and older vehicles can be provided with it. For
this purpose, a swing-arm bearing bolt of the new
design. (solid material, not hollow) and a complete
swing-arm with the rubber bearings pressed in place
are required.
Important! When tightening the nuts of the swing-arm
bearing bolt with 70'10 Nm (7' kp-m), the swing-arm
must be in its position "fully sprung out".

Replacement of the rubber bearings with the 22-50.445

assembling device
- Pressing out the internal tubes (1) and (2) with the
help of the mandrel (3) in a mandrel press in one
pass.
- Cutting up and pressing out the rubbers (4) and (5).
- Pressing the new rubbers (4) and (5) in place, using
the short collar of the mandrel (6) and approaching
from outer ends of the swing-arm. In this operation,
place the intermediate ring (7) between table of the
mandrel press and swlng-arm.
-Apply soap solution to the rubbers (4) and (5) - no
oil! The mandrel (3) - slip the internal tube (1) or (2)
on the cylindrical end prior to this operation - with
its tapered end ahead must then be pressed in, in
one pass, until the inner tube uniformly projects
from hnth sides of thc swing-arm tube.
Fig. 13. Telescopic Lork with aluminium slide tubes

with the washer (Fig. 1512). If, during loosening or

tightening t h e nut, the supporting tube also starts
turning, then use a screw-driver, put it through the
socket wrench and retain the supporting tube in place.

Fig. 12. Fitting the rubber bearings

:l) Internal tube
(2) Internal tube
(3) Guide mandrel
(4) Rubber bush
(5) Rubber bush
3) Pressing-in mandrel
(7) Intermediate rlng
(a) not applicable

7.2.2.2. Telescopic Fork

: Dismantling the telescopic fork members
Remove the protective caps or protective bellows from
the slide tubes. Then pull the compression springs out Fig. 14. Loosening the fastening nut tor the supporting \'
of the guide tubes and pour out the damping liquid. tube

94
t'
f > 'I
The guide tube (A) must be pulled out of the slide Remove the parts (3), (4) and (5). For a clearer dem-
tube (B) and the parts (3), (4), (5) removed. Put the onstration, the supporting tube (2) is here shown in
supporting tube p)
into the guide tube. the withdrawn condition.
"
- A
V. . .. , .. ,:.?. 9,- :-h -,
r:, .. .: .. 3'

Fig. 18. Removing the thrust washer

Fig. 15. Dismantling the slide tube (1) Circlip
(a) Gulde tube (2) Thrust washer
(b) Sllde tube
(1) Nut M G
(2) Corrugated washer G
(3) Sealing washer Remove the lock ring (1) and the thrust washer (2).
(4) Compression spring
(5) Disk (old design) or cup for end stop
Use a piece of round timber (Fig. 1716 about 600 mm
( 6 ) Supporting tube long and having a diameter of 22 mm, push the sup-
porting tube downwards (fitting direction of the tel-
Remove the circlip 32 X 1.6 (1) out of the guide tube escopic fork) out of the guide tube.
by means of a screw-driver. In this operation inscrt
the screw-driver into the groove at the external di-
ameter of the throttle. Mounting the telescopic fork menibers
Clean parts which are fully serviceable and in perfect
working order have only to be used. The guide tubc
must not show any ridges or any damage to the chro-
mium plating; it may be distorted for maximum
0.05 mm. When distortion are larger, do not straighten
the tube but use new parts.
Check the sealing lip of the seal ring D 35 X 47 X 7 ST
for wear and the spring for the sealing lip for sufficient
._
I. tension. In the case of doubt, use new seal rings for
mounting.
Press the seal ring in place. Do not strike against it,-
1 this may cause the spring of the seal ring to jump off.

Fig. 1G. Dismantling the throttle mounting

(1) Circlip 32 X 1.6

Fig. 17. Removing the throttle valve

(1) Circlip 32 X 1.6
(2) Supporting tube
(3) Throttle
(4) Valve plate
(5) Valve spring Fig. 19. Fitting the seal ring
(6) Piece of round timber 22 mm in diameter, 600 mm long (l) Drift 11-MW 7-4
(A) Guide tube (2) Seal rlng D S5 X 47 X 7 St
The piston ring of plastic (arrow) should not show any Notice! The vent hole in the protective bellows always
ridges in its sealing area. The damping bore-hole must must point to the rear.
be free from burr. Do not change the diameter of the
hole !
Insert the valve spring (Fig. 1715) with the large di-
ameter pointing to the lock ring and the valve plate
(Fig. 1714) with the ground side pointing to the throttle.
Fasten the throttle (Fig. 1713) by means of the circlip
(Fig. 1711).
Using the piece of round tiiber, push the supporting
tube downwards, from the upper end of the guide
tubes, and retain the supporting tube.

Fig. 22. Fitting the protective bellows

Oil levels and capacities

The oil level can be checked by means of a piece of
wire to be introduced down to the bottom of the tel-
escopic fork, the wire has a diameter of 4 mm.
Fig. 20. The supporting tube Normal capacity: 230 cm3 (oil level 350 mm) in each
(1) Damplng bore-hole
(2) Supporting tube member of the fork
(arrow-head) Seal ring 01 therrnoplastlc material
Maximum capacity: 250 cm3 (oil level 370 mm) in each
of the two members of the fork
Turn over the guide tube. Disk and cup for end stop
(l), compression spring 19 mm in diameter (2), and
packing plate (3) must be put in place, then the &uide Compression spring
tube slipped on and fastened by screws.
For each of the two members of the fork, 1 helical
spring with 78.5 turns and 4 mm wire diameter.

ii -.
Fig. 21. Connecting the slide tube ar.d the guide tube

Put the protective bellows and protective cap in place.

The collar of these parts must be engaged with the
groove (A). Fig. 23. Chedring the oil level in the telescopic fork
I
9. List of Special Tools
, .
8.1. Engine Drawing
2250.430 Assembling bridge1) 1.
22-50.431 Ball-bearing extractor 2.
, 22-50.432 Ring for bearings 6303 and 6204
-
(engines MM 12512 13012)
22-50.434 Ring for bearing 6304
-
(engines MM 12513 15013)
22-50.435 Pulling sleeve1)
22-50.437 Pulling screw for pulling sleeve')
89-99.305 Puller 12-MV 32-4 for sprocket wheel on crankshaft
89-99.304 Drift 12-MV 31-4 for bearing 6304

8.2. Cycle P a r t s
22-50.445 Assembling fixture for rubber bearing of swing-arm

10. Drawings of the Special Tools

1. Assembling bridge 22-50.430
Weld seani: h2.5 SG (CO2) I1 B TGL 1490413-10 Mn S/5, 0 1.2 TGL 7253

No. Quantity Description MaterialIStandard Rough Size Remarks

Basic body U-steel 6 !l2 3.50 long

St 38 b-2
TGL 0-1026
Washer St 38 b-2k 020x8
TGL 0-1026
Plate St 38 b-2 FXBOX115
TGL 0-1026
Do1t St 38 b-2 012x55
TGL &l026
Disk R 5.8
TGL 0-440

without rcldaeam
to .be face4 properly ;

9 R e p l a c i n g : 22-50.012 separating screw

22-30.01 1 pusher tor crankshaft
2. &U-bearing extractor 22-50.131
I
..Na Quantity Dcrcriptton MaterIal/Standard Rough Size Ramukr

1 1 Puller C I5 20 X 100 X 105 carbo-

nitrated
2 2 Hexagon-head screw TGL 0-931
M ex70
3 2 Hexagon-head screw TGL 0-833
M8X100
3. Ring for b w l n g s 6303 mud WO4 U-50.432
all &mfem 1 X 45'

No. Quantity Dcllcription Material/Standard Rough Size Runub

Ring St 38 b-2 0 75 X 20
TGL 0-1026

4. Ring for bearing 6304 22-50.434

all chamfers 1 X 45"

No. Quantity Description MaterialIStandard Rough Size Remarks

l Ring St 35 hb
TGL 9013
 rw' -.
5. Pulling sleeve 22-50.435 8 . , . ?
L.
- L
-
,A .

No. Quantltv Descrl~tlon MaterlallStandard Rough Size Remarks

1 Sleeve
6. Pulling screw for pulling sleeve 2240.437 I
/
No. Quantity Description Material/Standard Rough Size Remarb

1 Screw COOK 0 m X 169.5

7. Puller 12-MW 32-4
degreased, electro-galvanised

No. MaterialIStandard Rough Size Remarks

Puller St 38 b-2, 0 36 X 45
TGL 0-1026
Screw TGL 0-561 pin
M 16x60 hardened
8. Drift 12-MV 31-4
immersed, hardened all radii without dimensions R = l mm

No. Quantity Description ~aterialktandard Rough Size Remarks

1 1 Shaft case-
hardened
2 1 Ring case-
hardened

Kordel to be knurled
1 1 SUpporunO
dirk
2 l Guide mandrel

8 l Pruaing-In
' mandrel St 38 b-2K nidtd-
TCL 0-1026 Pl.td