Puch Maxi Owners Manual

Puch Maxi Owners Manual
A) SERIAL NUMBER LOCATION
The engine -number is stamped on top of the right crankcase
half.
1-Speed Automatic
2-Speed Automatic
The specification plate is secured to the right side of the frame.
7
The frame serial number is stamped on the right side of the
frame, just beneath the seat post.
My key number is ------------ -------------------- --------------------------------------- _____ _
IMPORTANT!
Write down your
key-number at once.
This saves time,
money and
annoyance if the
keys are lost.
8
B) OPERATING CONTROLS
The positions of the controls are shown in the enclosed technical
data sheet.
Following some operating controls described in detail:
Locking and unlocking your moped
To lock, move handlebar to the right.
Insert key into lock.
Turn key to the left, push in and turn key to the right.
Remove key.
Unlocking is accomplished in reverse order.
Lock is optional on Maxi and may be service installed at your
PUGH dealer.
Fuel tank filler cap
To open turn filler cap counter clockwise .
9
Fuel valve
The fuel valve is located on the right side of the frame .
The positions are clearly indicated on the chain guard.
In the event you should run out of fuel , the reserve position
should give you adequate range to get you to a filling station.
Always turn the fuel valve to the " Off" position when the moped
is not in use.
Carburetor
1)
2)
10
Primer (see starting engine on page 17).
The choke is operated by depressing the black rod extending
through the left engine cover.
Air pump and tools
Thr air pump and the tool kit (on models where tool kit is supplied)
are stored in the right chain guard cover.
Optional tool kit may be purchased at your PUGH dealer.
Brake levers
The brake control levers are mounted on the handlebar.
Left (1) lever controls the rear wheel brake.
Right (2) lever controls the front wheel brake .
11
~·
··';)'.
~
Starting lever
The starting lever is located on the left side of the handlebar and
is used for starting.
Please refere to operating procedure on page 17.
Light and horn switch
This combination switch is located on the left side of the
handlebar. Thumb lever on the end of the switch activates the
lights. The small push button operates the horn.
12
Engine stop switch
This two position thumb switch is located on the right side of the
handlebar. The center position, marked RUN , is used to start
and run the engine. The lower positions are marked OFF and
are used to interrupt the ignition, wh ich stops the engine.
C) TIRE PRESSURE
Recommended tire pressure
Front 25 PSI
Rear 32 PSI
13
D) OIL, GAS/OIL MIXTURE
Checking transmission oil level
The 1-speed automatic has an oil le•,el screw (1 ), which also
serves as the filler plug, located on the clutch cover. The drain
plug (2) is located on the lower engine case half.
53 / 4 fl. oz. (170 cc) of ATF "TYPE F" is used for refill.
1-SPEED AUTOMATIC
The 2-speed automatic has an oil level screw (3) located on the
clutch cover. The filler hole (4) is through the top of the right
crankcase half. The drain plug (5) is located on the lower portion
of the right crankcase half.
.
9 1/ 2 fl. oz. (280 cc) of ATF."TYPE F" is used for refill.
CAUTION
The moped must be upright when filling ATF. Do not overfill. Leave
oil level control screw removed until excessive ATF drains off.
14
2-SPEED AUTOMA
nc
ATF change after the first 300 miles of operation is highly recommended.
Filling up with two stroke mixture
All MAXI engines must be run with a gas/oil mixture (regular gas).
The recommended mixing ratio is 50 : 1 when using special Maxi
Mix two stroke moped oil. If another oil is used please refer to the
fuel mixing chart.
NOTE: DO NOT USE UNLEADED GASOLINE
PUGH MAXI MIX
50 : 1 OIL MIXING TABLE
To 5 gallons gasoline add 12 fl. oz. (379 cc) oil
To 1 gallon gasoline add 2.4 fl. oz. (76 cc) oil
To 1 quart gasoline add .6 fl. oz. (19 cc) oil
NOTE:
To reduce carbon build-up within the engine and exhaust system,
we strongly recommend the use of the special 2 stroke MAXI
MIX oil, 50 : 1 ratio. However as an emergency measure,
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 24 fl. oz. (757 cc) oil
To 1 gallon of gasoline add 4,8 fl. oz. (151 cc) oil
To 1 quart of gasoline add 1,2 fl. oz. (38 cc) oil
15
Using cup to measure oil for gas/oil mixing ratio
When measuring oil for the gas/o:l mixture, use one cupful of
Maxi Mix to one quart of regular gas.
NOTE: When using other grades of 2 stroke oil , please refer to
previous page.
WARNING
NEVER REFUEL WITH THE ENGINE RUNNING!
DO NOT SMOKE OR ALLOW OPEN FLAMES OR SPARKS
IN THE AREA, WHERE YOUR MOPED IS REFUELED
AND/OR WHERE GASOLINE IS STORED!
16
E) OPERATING INSTRUCTION
1. Prop the moped on its stand.
2. Unlock fork .
3. Turn fuel valve to the ON position.
4. Be sure that the engine stop switch is in the RUN position.
5. If engine is cold, depress the choke and depress the primer
button on the carburetor until fuel drips from carburetor.
CAUTION: After completing step 5 do not open the
control , as this will deactivate the choke . After the
has started and warming up, open throttle gently to
position briefly. This will disengage choke . Avoid
engine.
throttle
engine
the full
rating
6. Keep . both hands on the handlebar with the weight of the
moped centered on the front wheel. Apply the front brake and
fully depress the starting lever located on the left side of the
handlebar. Position the pedal approx. parallel to the chain
guard.
While holding the starter lever, push the pedal to start
engine.
7. Alternate starting method:
The moped may also be started by pedalling as a bicycle.
When momentum has been gained, pull the start lever and
gently open the throttle . Release the start lever after the
engine starts.
17
Throttle
The speed of the moped is controlled with a twist grip on the
right side of the handlebar. To accelerate twist the throttle towards
you; to decelerate release slowly.
Note:
Depending on engine RPM , clutch will engage or disengage
automatically on the one speed model .
In addition, shifting into or from 2. gear, depending on engine
RPM and road speed , will occur automatically on the two speed
mode II.
Braking
To slow down , release the throttle control and apply equal pull
to both brake levers. Application of both brakes at the same time
is essential to prevent premature brake wear and/ or loss of
vehicle control.
CAUTION: Be alert when riding on wet or sandy surfaces. Loss
of friction between tire and road can occur under these conditions.
Be careful when braking , turning or accelerating under adverse
conditions .
18
To stop and park
Release the throttle and simultaneously apply both brakes
to stop.
Turn off engine with stop switch .
Close fuel valve.
Rest moped on stand and lock.
Securing your moped
(See page 9)
A high security locking device is recommended. See your PUGH
dealer for advice.
WARNING
After the engine has been run , the exhaust pipe and muffler
will become hot, avoid contact with them .
CAUTION
Two lenghts of screws are used to secure the chain guards.
Ensure that only the shorter version is used on the left rear
bracket. Longer screw will protrude too far through the bracket
and possible damage the rear tire .
19
F) RIDING INSTRUCTION
1. It is suggested to wear bright clothing, utilize eye protection ,
and proper shoes or boots when riding your moped .
2. Wearing a helmet is optional in most areas. See your PUGH
dealer for advise.
3. Be sure to switch on headlight at low visibility and/ or where
required by law.
4. The moped is designed to carry ONE person. Do not carry
a passenger or very heavy cargo. Approved PUGH saddle
bags and baskets are available through your dealer.
5. Obey all traffic regulations. Use hand s1gnals when turning or
changing lanes. Please respect property of others and ride
carefully . Keep your feet on the pedals at all times . Keep the
pedals level, especially on turns.
6. After reaching maximum speed, reduce the throttle opening
to 3/4. While the reduction in speed will hardly be noticeable ,
fuel consumption however will be considerably reduced .
7. Closed throttle will slow down moped when riding downhill.
8. To ensure engine lubrication on long downhill rides, open
throttle occasionally.
20
G) TROUBLE SHOOTING
Engine will not start or stops running
Cause
Remedy
1. Fuel valve closed
Open fuel valve or switch valve to reserve
position
Switch valve to reserve or refill tank with
gas/oil mixture
Switch to " RUN" position
Clean spark plug or replace
Replace
Note: Spark plug gap
.016- .020 in (0.4 - 0,5)
Reconnect it to spark plug
2 . Fuel tank empty
3 . Stop switch in "Off" position
4 . Spark plug is fouled
5 . Spark plug defective
6. Ignition cable has worked loose
from spark plug
7. Engine is too cold
8. Engine is flooded
9. Fuel valve is clogged or main
jet is clogged
Apply choke
Clean spark plug
Have it cleaned at your Puch dealer
21
Poor Performance
Cause
Remedy
1. Choke working all the time
Disengage it by opening throttle fully
2. Exhaust clogged
Have dealer clean exhaust
3. Spark plug defective or fouled
Clean or replace it
4. Clutch slips
See your Puch dealer
5. Air filter is clogged
Clean air filter
6. Fuel mixture incorrect
Drain tank and refuel with correct mixture
Note: see mixture chart
Please refer all questions, you may habe about your
Puch, to your authorized Puch dealer. He is trained and·
qualified to properly service your machine and can best
advise you on its maintenance and care.
22
H) OWNER MAINTENANCE
Spark plug
To check if plug is functioning properly, proceed as follows :
i
I
l
Disconnect plug wire from plug
Unscrew plug
Reconnect plug wire to plug and ground
same on cylinder head
WARNING ENSURE THAT NO FUEL IS ON
WARNING ENGINE AND/OR FLOOR
WARNING BEFORE PROCEDING
Continue as if starting engine and check for
a strong blue spark at electrode
If no spark, clean or replace spark plug
Note: Gap .016 - .020 in.
(0.4 - 0.5 mm)
Recommended spark plugs
•j
1 HP-AII
Bosch
W 10 A (W 95 T 1)
NGK
B-4H
Champion L 90
Alu. chrome
1,5 HP-cylinder
W 8 A (W 145 T 1)
B-5HS
L 88 A
Hi torque
1,5 HP - cylinder
W 7 A (W 175 T 1)
8-6 H or 8-6 HS
L 86
2 HP - AII
W 7 A (W 175 T 1)
B-6 H or B-6 HS
L 86
23
Chains
Engine drive-and pedal chain should be kept clean. Every few
hundred miles wipe chains thoroughly clean with a cloth.
Lubricate with chain lubricant or SAE 90 oil.
Always keep chains properly tensioned . The proper slack of the
drive chain should be 3 I 4 " .
To adjust chains, loosen the axle nuts and tighten or loosen the
adjuster nuts. Once chains are properly adjusted, tighten the axle
nuts. Make sure that wheel is properly aligned.
If pedal chain tensioner catches or travels roughly as pedals are
operated, realign tensioner so chain travels smoothly.
NOTE
Always keep brake cables properly adjusted and lubricated to
ensure safe riding . The play in the brake levers should not
exceed 1" after adjustment.
24
I) SUGGESTED MAINTENANCE
AND LUBRICATION CHART
Frequency
First
3 00 mile s
A regular maintenance and lubrication
schedule will help to ensure a long, useful
life for your moped. Please refer to the
mileage and lubrication chart for detailed
information .
0
0
(')
•
•
•
•
•
w •
u
•
>
a:
w
(/)
0
w
0
NOTE: Above milage schedule applies to
moped used on dry paved surface.
If used in wet, muddy or sandy
area, maintenance intervals should
be more frequent.
Always check controls and lights
before using your moped.
z
w
::2
::2
0
u
w
•
•
a:
•
•
•
•
Every
miles
0
0
<0
0
0
<0
0
0
0
0
CXl
0">
0
0
N
• • • • •
• •
• • • • •
• • • •
• • • •
• • •
• •
• • • •
• • •
• • •
• • •
• •
• • •
• • •
• •
• •
• • • •
• •
• •
• • • •
• I , I• •
I I
I
I
OPERATIONS TO PERFORM
1'-
(')
~
Tire wear and condition
Throttle cable adjustment
Check tire pressure
Check transmission A TF level
Clean and lubricate chain
Clean ai r filter
Change transmission A TF
Check spark plug
Decarbonize engine
Clean exhaust baffle
Retighten screws and nuts
Clean fuel valve and lines
Clean carburetor
Idle speed adjustment
Check ignition timing
Adj ust clutch
Check brakes I linings
Check I lubricate hub bearings
Steering bearing adjust/ lubrication
Lubricate control cables
Adjust chain tension
I
25
J) CONSUMER INFORMATION
CONSUMER INFORMATION
Stopping Distance
Vehicle minimum stopping Distance on dry ground
This figure indicates braking performance that can be met or exceeded by the vehicles to which it applies , without locking
the wheels, under maximum condition of loading. The information presented represents results obtainable by akilled
drivers under controlied road and vehicle conditions, and the information may not be correct under other conditions.
Description of vehicles to which this table applies: MAXI
Fully Operational Service Brake
17 '
1 hp
28'
• 1.5hp
Maximum load
38 '
2hp
10 '
20 '
30'
40'
Stopping distance in feet at maximum speed
26
50 '
TECHNICAL DATA
MAXI
2hp
CONTROLS
Rear wheel brake lever
Starting lever _ _.___.../
Light switch · _ _ _ __...)
Horn button _ _ _ _ _..J
Choke - - - - - - '
Frame number - - - - - - - + -
Front wheel brake leve
'------'---- - -'--- -- - HI- - - - - - -
Engine stop switch
Fuel tank cap
Fuel valve
V.I.N. plate
ENGINE
~- ~f ~t ~50fo-~~kp) at 4000 rpm
Maximum output
Maximum torque
Compression ratio
Bore
Stroke . .
Displacement
Cooling
_
Lubrication
Carburetor
Mainl·et
Neede jet
Needle position
Needle size
Thronle slide
Ignition
.
.
.
7 : 1 (9.2 : 1)
1.496 in !38 mm)
1.693 in 43 mm)
2.97 cu . on (48 .8 cc)
air cooled
gas/oil miX1Ure
Bing 1/14
62
2.22
2nd notch from top
1
24
.
Breaker point gap
klnition Uming
.
S'par1< plug
. Spark plug gap
Generator . .
Ignition coil
.
Cylinder material ,
magneto ignition
.014 - .018 in (0.35-0 45 mm)
_
.032 -.047 on (0.6-1 .2 mm) BTDC- 14-17.5°
Bosch W 7 A, Champion L 86
.016 - .020 in (0.4-0.5 mm)
flywheel magneto Bosch RDPt 6 V, 26·5/10 W
special coil for magneto ~nrt i on
Alu-alloy , cyl. wall hard chrome plated
POWER TRANSMISSION
Clutch
. . .
Transmission .
centrifugal clutch running in ATF
single speed automatoc
Engine/Transmission reduction
helical gears 21 : 106, i = 5.05
chain 172 x 3/16 in, 16: 45: i = 2.81
chain 1/ 2 x 1/6 in, 26 : 23; i = 1.217
Transmission/Rear wheel drive
Pedalling drive
CHASSIS
Frame . . . . .
Fron! wheel suspension
Rear wheel suspension
Brakes . . . .
Dia. ol brake drum
Width ol brake lining
. .
Total effective brake surface
Tire size front and rear
Tire pressure fronVrear
Fuel tank
shell type
telescopic fork ; 1.96 in (50 mm) travel
control arm; 1.96 in (50 mm) travel
internal expanding brake shoes
3 .15 in (60 mm)
.70 in (16 mm)
6.06 sq in (52 em')
2 1/4 - 17
26/32 psi (1.8/2 .25 bar)
.645 US gaL (3.2 I)
DIMENSIONS AND WEIGHTS
&::::~~~
Overall height
Wheelbase
:
65.7 in 11670 mm)
32.3 in 820 mm)
-42.5 in 1080 mm)
42.9 in 1090 mm)
.
.
4400k9)'"'"')
ory wetgm
!l7° 10i.~
ELECTRICAL EQUIPMENT
Headlight bulb
.
Ta1I_-/Stop light bulb .
Speedometer light bulb
Warning device
. .
PERFORMANCE AND CONSUMPTION
6 V, 21 W
6 V. 5 WI 6 V, 10 W
6 V, .6 W
horn
Q,..oun,d .ok.o ,..,.....,...
~?ifct~ng abmiy
30 mph (48 km/h)
15 %
. . .
Fuel consumption (DIN 70030)
150 mpg (1.6 V100 km)
Test conducted on a flat track in top gear at 3/ 4 top speed. Track ol6.2 miles (10 km) is used both ways and may
have very shorl upward and downward grads of maximum 1.5 % . The vehicle must be adjusted to specihcauon.
with ~res correctly inflated. Riders weight not more than 143 lbs. (65 kg). The measured consumption as increased
by 10%, taking unfavourable conditions in19 account. New vehicles may vary up to 5% from this value.
CAPACITY AND QUALITY OF LUBRICANTS (see Owner11 Manual)
L
ENGINE
Mixture of regular grade gasoline with special 2 stroke oil (MAXI MIX) - 50 : 1
DO NOT USE UNLEADED GASOLINE
TRANSMISSION
5 314 fl. oz (t70 oc) Automatic-Transmission-Fluid "TYPE F"
GREASE NIPPLE
Use grease or oil SAE 90
CABLE
Lubricate cables ·with oil SAE 30
WHEEL BEARING
Uthium base grease
CHAIN
Oil SAE 90
FRONT FORK
Uthium base grease
WIRING DIAGRAM
H
'JJ
_,
0
(]'.
00
l»
N
0
00
c
9
10
11
12
Ignition coil
Generator
Wire connector
Tail-/Stop light
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising