Puch Magnum X Owner`s manual

PUCH PUCH PUCH IMPORTANT NOTICE PUCH PUCH PUCH
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Read this owner's manual careful ly
The Magnum X is designed for use only as fol lows:
• Off-road use only- not for use on public roads.
• Single rider only - weight l.imit 98 pounds.
• Parent supervision required during operation.
• Riders should always wear a helmet and protective clothing.
• Riders should always ride safely.
• Riders should be warned not to touch any moving parts or heated areas of the
machine.
• Observe maintenance requirements before rid ing- refer to applicable sections of
this owner's manual.
The Magnum X is designed and manufactured for use only off of public roads. It is not
subject to Federal Motor Vehicle Safety Standards as it is not equipped or approved for
operation on public streets, roads , or highways at any time.
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PUCH PUCH PUCH PUCH PUCH PUCH PUCH ·PUCH PUCH PUCH
Throughout this manual, WARNING, CAUTION and NOTE carry different degrees of
meaning:
I WARNING I
means that there is the possibility of personal injury to yourself and others.
I CAUTION I
means that there is the possibility of damage to the vehicle.
NOTE
indicates points of particular interest for more efficient and convenient operation. We
recommend that you take particular notice of these items when reading this manual.
All information, illustrations, photographs and specifications contained i n this manual
are based on the latest product information available at the time of publication.
The right is reserved to make changes at any time without notice.
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Dear Puch Parent,
Thank you very much for choosing the Puch Magnum X.
The Puch Magnum X is ready for your children to learn the fun of off-road riding. It is a
machine built with the best of what Puch has gained throughout nearly a century of
experience in the manufacture of motorcycles, and is specifically meant for use by
children.
The Magnum X is designed with features taking into consideration of children's
physical and mental capabilities. We on the part of Puch have to count heavily on their
parents for ensuring maximized safety. In this sense, this owner's manual is intended
for the parents, with a strong hope that it will also be read by th e young riders
themselves.
A machine needs care. We hope you will avai l yourself of the skill and faci lity of your
Puch dealer. If you are experienced in do-it-yourself mechanical work, please consult
the technical parts of this manual, or the Magnum X repair and parts manual, before
you do it yourself. Remember, safety comes first, this manua l has been written with this
thought as its governing principle.
Box 7777
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Greenwich , Ct. 06830
MESSAGE TO THE PARENTS
Children can be impatient; the sight of a new motorcycle often excites their
imagination ; and the expectation often overrides the importance of safety precautions.
This is your responsibility.
Please, go through this manual with the young rider, and have him or her understand
not only the mechanism but also the rules of courtesy and safety precaution.
Specific additional safety items to be considered include:
• Supervise operation of this Magnum X AT ALL TIMES.
• Do not allow the rider to operate the Magnum X beyond his riding ability.
• Use of the Magnum X should be controlled by the parents in relation to the rider 's
age.
• Beware of hazardous situations and instruct the rider to beware of hazardous
situations.
• Before first use of the Magnum X, read the Owner's Manual carefully to become
familiar with the features, and safety and maintenance requirements of t he
motorcycle, instruct and review these items with rider.
• Before rider's first use of the Magnum X, be sure that the rider is familiar with the
control and operation of the Magnum X.
PUCH recommends first use of the Magnum X in a safe, open area for the rider to
become familiar with the controls, operation, and handling characteristics of the
Magnum X.
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• Before each use, perform daily inspections with the rider to ensure safe riding.
Check specifical ly:
Brakes
Throttle operation (Smooth opening and smooth automatic return)
Control operation
Fuel line connections
Tire pressure
Oi I and fuel level
Chain tension
General condition
• Be sure that the rider wears a helmet and protective clothing (gloves, leather or
heavy cloth pants, shirt or jacket, goggles) .
• The Magnum X is not to be used on public roads AT ANY TIME.
• For single rider only.
• Drain the fuel tank and carburetor of fuel prior to transporting the motorcycle.
• Caution the rider and others near the Magnum X not to be close or to touch any
moving parts or any heated areas such as the engine and exhaust system.
• Do not modify the exhaust system. The excess noise antagonizes everyone and
creates a bad image for motorcycles.
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INDEX
1
2
3
4
5
6
7
8
Tips fo r r idi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehic le identi fication numbers . . . . . . . . . . . . . . . . . .
Technical data ... . . . . .... .. ... . . . ..... . .......
Con tro ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power/speed restr ictor removal . . . . . . . . . . . . . . . .
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . .
Lubricating and maintenance chart . . . . . . . . . . . . . . .
Wiri ng diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6
13
14
16
17
19
33
34
1
TIPS FOR RIDING
You must learn driving techniques yourself.
You may get some ideas from watching experts and professionals, and then try them
yourself. There is no such thing as a textbook
which you need only read through in order to
learn dirt riding. The following tips are merely
recommendations that may be helpful.
IwARNING I
Always wear your helmet and protective
clothing when you ride your new bike. Your
machine should only be ridden on private
ground and only under the supervision of an
adult.
Dirt riding is lots of fun but differs significantly
from riding on normal roads. Dirt riding requ i-
res a technique of its own, as well as excellent
physical condition. If you are as yet unexperienced in dirt riding, you wou ld be wel l
advised to follow the advice below.
Before beginning a ride:
Don't forget that for dirt riding you need not
only the right kind of bike, but also appropriate
clothing. Any dealer will be glad to advise you
regarding equipment:
leathers , boots, goggles, crash helmet and
gloves, etc. protect you from stones, tree roots
and so on.
Ride only on approved trails. Permission
should be obtained in advance from property
owners to ride on their land.
You should avoid going on long rides alone.
Be sure to take the weather into consideration.
Trails that present no problems in dry weather
may be impassable when it rains.
-6-
Riding tips:
Adjust the position of the handlebars, controls
and brake levers and the foot pegs so that they
correspond to your physical build. Remember, though, that you will sometimes have to
ride standing up on the foot pegs. Your arms
wi II be subjected to the least stress when the
. handlebars are adjusted as shown in fig. a.
The foot pegs and pedals should be so
adjusted that the foot remains horizontal (see
fig. b).
Fig. a
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!wARNING
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Pointing the toes downward should be avoided at all costs as when the foot is in this
position, stones or roots may force it under the
peg, leading to injury.
Fig. b
Don't begin w ith long rides but rather seek out
particular types of terrain to master, e.g. a hill,
a muddy stretch , etc. Practice, for example,
driving uphill until you can manage it with no
trouble and fee l sure of yourself. Then practice
other types of terrain in the same manner.
Only when you have thus become famil iar with
the most common types of terra in and have
learned the necessary riding techniques you
should undertake longer trips.
-7-
Driving uphill
Begin with m ild incl ines. Don't start from a
dead stop at the bottom; gather momentum on
the flat. Try to put weight on the front and rear
wheels by sitting back and lean ing forward
with the upper body. Incorrect weight distribution can cause the follow ing: if you sit too far
back the front part of the machine wi ll come off
the ground, while if the weight is too far
forward, the back wheel will hold poorly and
spin. In both cases there is considerab le
danger of a spill. The proper position is shown
in fig. c. The front wheel may lift slightlywhen you have more experience you will find
that in dirt riding it is often necessary to ride
without weight on the front wheel to compensate for unevenness in the terrain.
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Fig. d
Keep the engine speed up.
Fig. c
If you see that you won 't be able to make it up
the grade, turn the machine to the s lope and
lay it uphi ll (fig. d). Try to use both brakes . If
you can 't stop the machine , get off (fig.d). This
is safer than to try to stay on . If you 're
unfamiliar with the route, ride only with a
speed that w il l allow you to stop at any time;
you may otherwise be unpleasantly surprised
by an obstacle.
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Driving downhill
Ridi ng downhi ll is the most difficu lt part of dirt
riding. If the i ncl ine is s light, ride as if on a f lat
surface. On a steeper hill , don't accelerate
and use the engine to brake. With a yet greater
incline both brakes should also be appl ied, but
the wheels must not lock.
IWARNING I
Most importantly-never try to stay w ith an
out-of-control bike.
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Fig. f
Fig. e
Ridges, stones, small unevennesses
In this situation , ride standing up on the foot
pegs so that your body doesn't have to absorb
all the bu mps (fig . e). If you drive such a stretch
sitting you wi ll quickly lose contact with the
machine and will have to reduce your speed
drastically, or crash.
-9-
Narrow curves
Fig. f. shows the correct position for rider and
bike. The inside foot is used to push, but on ly
when the bike s lips. When this happens the
bike may be supported with the foot to prevent
a spill.
Riding in mud, sand, snow and ice
If you aren 't fam iliar with the route it's better to
ride slowly with feet off the foot pegs (fig. g). If
you already know the way, then ride as fast as
possible. In ice and snow, the more slippery it
is the faster you should drive, as this increases
the bike:s stabi lity. Brake only when absolutely necessary.
Start slowly and don 't accelerate abruptly. On
surfaces slippery with snow and ice tire
pressure should be reduced to increase tire
grip.
Fig. g
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Bumps, ditches, large unevennesses
All of these obstacles should be jumped. For
this, the front part of the bike should be lifted.
This technique requires practice and experience. Before the jump open the throttle. When
this is done correctly th e front wheel comes up
on its own with very little if any physical force .
If the throttle is operated correctly, the amount
of lift can be regulated.
Fig. j
Fig . i
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Fig. h shows the correct take-off and fig i the
cor rect landing.
Fig. j shows what happens when the machine
doesn 't lift or lifts too little.
Fig. I
WRONG
Fig. k
A correct jump over a bump or ditch is shown
in fig. k, while how a spill occurs at a too low
speed or when the machine isn't lifted in time
is shown in fig. I.
RIGHT
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2
VEHICLE IDENTIFICATION
NUMBERS
ENGINE NUMBER
FRAME NUMBER
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3
TECHNICAL DATA
Engine
Type
Maximum output
Maximum torque
Compression ratio
Bore
Stroke
Displacement
Cylinder materia l
Cylinder head
Crankshaft
Inlet and exhaust
Port control
Lubrication
Top speed
Carburetor
1-cylinder-2stroke engine,
air-cooled
3.5 hp at 7000 rpm
2.75 ftllb at 5000 rpm (0.38 mkp)
11 :1
1.49 in. (38 mm)
1.69 in. (43 mm)
48.8 cc
Alu-alloy with cast iron liner
Alu-alloy
Steel
Ports
Piston
Petroil lubrication 1 :50
20 m.p.h. (32 km/h) ;
without restrictive devices
31 m.p.h. (50 km/h)
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Type
Main jet
Needle jet
Need le
Needle position
Bing 1/17
84
2,20
1
3rd notch from top
Electrical equipment
Ignition
Magneto ignition, Bosch
Ignition tim ing
RCP 1, 6V 26-5/10W
.0~.05 in. (1,0-1,2 mm) in
advance of TDC
Spark plug
Bosch W 5A/W225 T1
Spark gap
.016-.020 in. (0,4--0,5 mm)
Transmission
Dimensions
1-speed gearbox
1-speed automatic transmission
Clutch
Centrifugal running in o il
Primary tr ansm ission Helical gears
Secondary transmission Chain 1 //'x 3 / , 6 "
Gear ratios
Engine gear
106:21, i = 5.05
Gear rear whee l
34:13, i = 2.61 *)
Frame
Tubular frame
Spring suspension front Telescopic fork, 3.14 in
(80 mm)
spr ing trave l
Suspension rear
Control arm wi th hydraulic
suspension unit, 2.16 in
(55 mm) spring travel
Brakes
Internal expanding shoe
brakes
3.49 in (90 mm)
Dia. of brake drums
Tire equipment, front 2.50 X 14
Tire equipme nt, rear
2.75/3.00 X 12
.
Tire pressure,
11,.4-18,5/14,2-21,3 psi
(0,8-1 ,3/1,0-1,5 bar) defront/rear
pending on the type of terrain
and the weight of the rider.
Fuel tank
0.93 US-gal ; 3.5 litres
Whee lbase
Overall length
Handlebar height
Handlebar width
Ground clear ance
Dry we ight
Permiss ible load
Gearbox
Type of gearbox
39.3 in. (1000 mm)
58.6 in. (1490)
34.6 in . (880 mm)
26 in. (680 mm)
6.8 in. (175 mm)
83.7 lb. (38 kg)
98 lb.
CAPACITY AND QUALITY OF LUBRICANTS (see
bypacked lubr ication tabl e)
ENGINE
Mixture of regular gasoline
with Puch Maxi Mix 50:1. For
further recommendat ions refer to page 22
GEARBOX
7,44 oz (220 cc~ Automati cTra nsmission- lui d
CHASSIS PA RTS Su mmer and w inter motor o il
WHEEL
Su mmer and winter Lithium
BEAR ING
base grease
,
CHAIN
Summer and winter SAE 90
*) 12-tooth-sprocket bypacked. It should only be
used when riding on soft terrain. When riding on
solid terrain the engine might be overrevved.
-15-
FRONT BRAKE LEVER
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CONTROLS
ENG INE KILL BUTTON
-16-
5
POWER/SPEED RESTRICTOR
REMOVAL
NOTE
Two restrictive devices are installed in the intake system. The
two restrictive devices, a metal plate on the front of the airfilter
and a restrictive orifice between carburetor and intake
manifold reduce the fuel-air mixture supply and the power
output as well. This enables the young rider to develope his
riding skills gradually with a reduced power output.
By removing the restrictive devices the engine reaches its
maximum output.
Fig. A
Fig. 8
IwARNING I
The two restrictive devices should only be removed , when in
the judgement of the parents, the rider has developed
sufficient skills to be able to safely operate the machine with
the two restrictive devices removed .
REMOVING BOTH RESTRICTIVE DEVICES
Remove fixing screws from the right side engine shroud.
Loosen clamping bracket of rubber boot (fig. A/1) and remove
rubber boot. Pull filter disc with metal plate (fig. A/2) out of
carburetor. Loosen clamping screw of carburetor (fig. B/1)
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and remove carburetor from intake manifold. Remove restrictive orifice (fig. B/2) from intake manifold. When mounting
carburetor note that the float chamber (fig. 8/3) is vertical.
Thereafter, if you intend to throttle the MAGNUM X again, use
a new filter part no. 362.1.15.040.2. If, however, you do not
intend to throttle the machine again, remove the metal plate
(fig. A/2) from the filter. The metal plate (fig. A/2) is welded on
two points of the filter (fig. A/3). Remove one welding point
with a file. Press metal plate out of filed point using a
screwdriver and move metal plate by hand up and down until
metal plate breaks out of filter. Fit filter so that welding points
are outside. Fit rubber boot so that the spring (fig. A/4) presses
the filter into the carburetor housing.
WARNING
On no account must only one restrictive device be removed. A
metal plate once removed from the filter must not be refitted
again. When mounting a filter with metal plate note that the
open end of the spring (fig. A/4) is between the four elevations
(fig. A/5) so that the bore of the metal plate remains free .
-18 -
6
INSPECTION AND
MAINTENANCE
FRONT BRAKE
IwARNING I
If an adjustment of the front brake is required, use the adjuster
at the brake cover plate {fig. 1). Turning the adjuster to the left
results in increase of the play, turn ing to the right decreases
the amount of play. The correct trave l measured at the end of
the hand brake lever is 3/4".
REAR BRAKE
IwARNING I
The play of the rear brake lever should be the same as the
front brake lever or 3/4". To adjust the play use the adjuster at
the rear brake cover plate (fig. 2). Turning the adjuster to the
left results in an increase of the play, turning the adjuster to
the right will decrease the amount of play.
-19 -
Fig. 1
Fig. 2
THROTTLE
The speed of the Magnum X is controlled by an automatic
return twist grip on the right control group. To accelerate twist
the th rottle towards you ; to decelerate s lowly release. The
play of the throttle is correct if the cover of the cable allows to
be pulled out from the carburetor approx. 0.08 in. (2 mm , fig. 3)
by hand, without lifting the throttle piston, i. e. before the
engine starts running faster.
Fig . 3
Fig. 4
ENGINE KILL BUTTON
The engine kill button is located on the left side of the contro l
group (fig . 4). The engine is stopped by pressing this control
button.
I CAUTION I
Be alert when rid ing on wet or sandy surfaces. Loss of traction
between the tire and the riding surface can be expected under
these cond itions. Be careful when braking, turning or accelerating under adverse conditions.
-20-
FUEL VALVE
The fuel valve is located on the right side
engine shroud/chain guard. The positions of
the fuel va lve are On, Off, Reserve as found in
the controls section of this manual. The capacity of the tank is 0,93 US gal. (3,5 1iters). In the
event you should run out of fuel, the reserve
position should usually give you adequate
range to get back to civi lization. Always turn
the fuel valve to the " OFF" position when the
mach ine is not in use.
IGNITION
The Magnum X is equipped with a Bosch
breaker point ignition.
If readjustment is necessary refer to the
Magnum X Repair and Parts Manual.
CARBURETOR
The carburetor used on the Magnum X is a
Bing 17 mm. The choke, primer, and idle
adjustment screw are on the right side of the
carburetor for easy access.
Component parts of the carburetor see fig. 11,
page 27.
SIDE STAND
The side stand is located on the left and is to be
fo lded down when the machine is not in use.
HANDLEBAR AND CONTROL CABLES
The position of the handlebar is adjusted by
the rider himself as per require ment. (For
proper adjustment see page 16). Afte r any
adjustment to the hand lebar check controls
and position of control cables and correct if
necessary.
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Ci
FILLING UP WITH TWO STROKE MIXTURE
I CAUTION I
Gas/oil m ixture
DO NOT USE UNLEADED GASOLINE
The Magnum X engine must be run with a
gas/oil mixture (regular gas). Th e recommended m ixing ratio
is 50: 1 when using special Maxi Mix two stroke moped oil. If
another oil used please refer to the fuel mixing chart.
I
Fig. 5
Fig. 6
l'TI
!wARNING
When re-fueling , have the engine shut down and keep away
two things: fire and children.
PUGH MAXI MIX
50 : 1 OIL MIXING TABLE
To 5 gallons gasoline add 12 oz. (355 cc's) oil
To 1 gallon gasoline add 2,4 oz. (71 cc's) oil
To 1 quart gasol ine add 0,6 oz. (18 cc's) oil
NOTE
To reduce carbon build-up within tour engine and exhaust
system, we strongly recommend the use of the special 2
stroke (MAXI MIX) oil. 50:1 ratio. However as an emergency
measu re, a regular 2 stroke oil can be mixed in a 25: 1 ratio as
shown below.
25 : 1 OIL MIXING TABLE (REGULAR TWO
STROKE OIL)
To 5 gallons of gasoline add 25,6 oz. (757 cc's) oil
To 1 gallon of gasoline add 5,1 oz. (151 cc 's) oil
To 1 quart of gasoline add 1,3 oz. (38 cc's) oil
-22-
STARTING
Open fuel valve (see fig. 7).
If the engine is cold, depress the choke and primer button on
the carburetor (fig. 8). K ick down smartly on starting lever.
I CAUTION I
After the above is completed do not open the throttle
completely as this will deactivate the choke. After the engine
is started the throttle should be gently opened as the engine
warms, to the full throttle position. This will ensure that the
choke will be completely disengaged .
Fig. 7
Fig. 8
RIDING
I WARNING I
The machine is equipped with Moto-Cross tires, which have a
knobby tread. These tires are intended for use off public
highways only.
STOPPING
If you want to stop the mach ine, throttle down and app ly front
and rear brake simultaneously. If you apply on ly one brake,
the machine is liable to skid.
-23-
BREAK-IN INSTRUCTIONS
I CAUTION I
In order to prolong the life of the machine a
certain running-in period is necessary. Since
the machine has been designed tor off-theroad operation, it will also be run in off the
road . Within the first hours of operation the
various parts of the machine are worn to such
a degree that they have the ideal clea ran ce.
In order to guarantee a proper running-in do
not ride on fu ll throttle right from the beginning, as the engine will be overheated.
Increase the stress on the engine only gradually and throttle entirely down for short
intervals. Within the first hour of operation ride
on half opened throttle, within the 2nd and 3rd
hour open throttle fully only for short durations. Careful handl ing of the vehicle during
th e runn ing-in period wi II prolong the life and
increase the power of the machine.
-24-
DECARBONIZING THE ENGINE (fig. 9)
NOTE
The combustion depos its on cylinder head,
piston head and exhaust port are in the long
run a source of trouble, and must therefore be
removed from time to time .
CYLINDER HEAD AND PISTON HEAD
0
NOTE
Use a blunt edged instrument to remove the
carbon deposits so that the surfaces of the
parts are not scratched. Every new scratch
furthers the deposit of new carbon residues.
Remove on ly the scaly spreading deposits
from the piston head , a fine , even layer of oil
carbon need not be removed.
Before refitting the cylinder head, remove all
carbon deposits from inner side of cy linder
thorough ly and apply a thin coat of motor oil.
Then by turning the crankshaft over a few
times make sure that the engine runs easily.
Wipe sealing surfaces on cylinder and cy linder head clean.
Refit cy linder head on to cyl inder (with gasket)
and the arrow pointing toward exhaust. Tighten the four cylinder head nuts crosswise to
7 ftllbs.
EXHAUST PORT
-25 -
Fig. 9
I CAUTION I
Remove the exhaust. Turn engine over by
means of kickstarter (spark plug removed)
until piston reaches lowest point. Carefully
remove oil carbon from the exhaust port
taking care not to damage piston or cylinder
working surface.
CHECKING AND CLEANING THE SPARK
PLUG
Screw the spark plug out of the cylinder and
ground it at its threaded end e.g. t.he cylin?er
head (plug still being connected w1th the H1gh
Tension cable). If the engine is kicked over as
in starting, a powerful spark should flash over
between the electrodes.
IwARNING I
Be sure no gasoline or flammable residue is
on cylinder head or engine.
Oily plugs or plugs w ith dirt deposits between
the electrodes will not produce any spark and
must be cleaned w ith a wooden splinter or
wire brush. The spark gap should be .0157.0197 in . (0,4---0,5 mm). If the gap is wider
regap by bend ing the outer electro?e·. W~en
screwing in the plug take care that 1t f1ts mto
the thread properly and can be turned easily.
Never screw in with force: First screw in by
hand- 2 or 3 turns - then use the spark plug
wrench.
When replacing the spark plug use only plugs
with long thread and the specified thermal
value. (See technical data)
CLEANING THE AIR FILTER
Remove fixing screws from the right side
engine shroud. Loosen c lamp ing bracket of
rubber boot (fig. 10/1) and remove rubber
boot. Pul l filter disc (fig. 10/2) out of carburetor.
Clean metal air filter with gasoline or similar
cleaning material, blow completely dry W'ith
compressed air and spray filter element lightly
with engine oil.
Replacing see page 18.
Fig. 10
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26-
NOTE
If the Magnum X is ridden in extremely dusty
areas the air filter shou ld be serviced at more
frequent intervals.
STRIPPING AND CLEANING THE CARBURETOR
I CAUTION I
The carburetor fitted to th e engine is tuned to
specifications established by intensive factory
research and should not be altered in any
way. Whenever dismantling a carburetor,
c lean all co mponents with gasol ine and blow
off with compressed air. Ensure that seatin0 .~f
the inlet needle is correct.
Fig. 11
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27 -
CHECKING THE CHAIN AND SPROCKETS
FOR WEAR
I CAUTION I
The most simp le method to find out whether
the chain can still be used is shown in fig 12.
Press the chain by hand upwards so that it is
tightly tensioned. If now the chain permits to
be lifted from the sprocket by the other hand by
more than half the diameter of the roller, the
chain must be replaced. If the sprockets are
worn as shown in figure 13 have them j ust as
well replaced. When installing the chain make
sure that the cha in master link is in the proper
position i.e. with the closed part in the direction the chain moves.
Fig. 12
Fig. 13
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areas the drive chain should be serviced at
/
more frequent intervals.
LUBRICATING THE CHAIN
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I CAUTION I
J
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The life of a chain depends greatly on the
maintenance. Therefore clean and lu bricate it
repeatedly. Never ride with a dry chain! A
badly soiled cha in must be cleaned and
washed in kerosine.
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'-~A. . . .
'•vvv-""
/
If the Magnum X is ridden in extremely dusty
/
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NOTE
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CHANGING THE TRANSMISSION FLUID
I CAU TION I
Warm engine up. Remove fluid level checking
screw (fig . 14/1) and drain screw (fig. 14/2).
Incline machine somewh at to the ri ght so that
the fluid may escape entirely. Through the
fill er hole (fig. 14/3) fill approx. 7,44 US-oz.fl.
(220 cc) of Automatic Transmission Fluid (Type " F" on ly). If the fluid level is correct, refit
checking screw and f iller pl ug . At any oil
change clean oil drain p lug from metal chips.
Fig. 15
SHOCK ABSORBERS
Shock absorbers on the Mag num X are not
serv iceable. Faulty suspen sion un its must be
replaced. Only the upper and lower rubber
mountings and bearing bushes are avai labl e.
The three lower mounting positions indicate
softer or harder rear suspensi on . Position (1)
ind icates harder r iding s uspension, position
(2) medium (or normal rid ing) and position (3)
gives a softer rid ing suspension.
-
29-
Fig. 14
LUBRICATING CHASSIS
PARTS
0
I
NOTE
With oil :
Cable adjuster at the
brake cover plate of the
front whee l (fig. 16).
Cable adjuster at the rear
wheel brake (fig. 17).
Chain adjuster (fig. 17).
Fig. 17
Fig. 16
Fig. 18
Fig. 19
Side stand bearing (fig. 18).
Bearing of the foot rests
(fig. 19).
-
30 -
REMOVING THE FRONT WHEEl
I WARNING I
Undo flexible speedo shaft at the speedometer
drive. (Hub end) fig. 20/1 .
Fig. 20
Fig. 21
Remove cable adjuster (fig. 21/1) and disengage .
brake cable. Unscrew both axle nuts (fig. 20/2 and
21/2).
Remove the wheel.
-
31-
REMOVING THE REAR WHEEL
IWARNING I
Loosen brake adjusting nut and disengage
brake cable (fig. 22/1). Remove both axle nuts
and remove axle (fig. 22/2 and 23/2).
Install wheel and axle in the reverse procedure to dismantling.
Fig. 22
Fig. 23
-
32-
7
LUBRICATING AND MAINTENANCE CHART
The following period ic maintenance can be carried out at home.
Pre-riding
check list
•
•
-•
-
-
-•
•
••
•
After 300 m i.
(20 hours)
•
-•
••
•
••
•
•
••
-
•
-
-
-
-
-
-
-
•
After 600 mi.
(40 hours)
••
••
•
••
•
•
••
••
•
•
••
••
Job Description
Check f ront and rear wheel bra ke , adjust if necessary
Check spark plug and clea n
Clean ca rb uretor, fuel cocks and fuel lines
Check air clea ner, clean if necessary
Check chain tens ion
Lubricate chain
Check t he chain and sprockets for wear
Check cables
Grease chassis parts
Check transmiss ion oil leve l
Check bolts and nuts for t ightness*)
Check tire pressure
Check positio n of inflation valves
Check wheels and tires. spokes for tightness
Check steer ing bearing
Decarbonize the engine
Decarbonize exhaust
Check hub bearings, replace if necessary
Check o il in transmission
-
..) Retighten cylinder head nuts every 5 operating hours.
-
33 -
8
WIRING DIAGRAM
®
G REY
BLUE
1
4
BRO
15
........
1 Flywheel magneto
2 Junction block
3 Engine kill button
4 Ignition coi l
5 Spark plug
-34-
-
WNl
s
s
!
IS)
~
I
®