Puch Mini Maxi Owner`s manual

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Puch Mini Maxi Owner`s manual | Manualzz

OWNER'S MANUAL

Dear Puch Owner,

This is your riding, maintenance and warranty guide.

By

following the instructions described in this booklet, we at Puch know you will enjoy many miles of pleasurable Moped Riding.

Should a need ever exist for parts or service, simply contact your Puch dealer. He also has available for your purchase a Service Manual.

Thank you for joining the Puch family, please ride safely and have fun.

INDEX

Vehicle Identification Numbers

Carburetor

Choke, Primer

Brakes

Brake lever Adjustment

Engine stop Switch

Fuel Valve

Gas Tank

Gas Oil Mixture

Head light

Helmet holder

Light and horn switch

Starter lever, adjustment

Steering lock

Transmission

fluid

Tire pressure

Riding Instructions

General Maintenance and Lubrication

Consumer Information

Warranty

see

page

8

6

5

4

12

14

4

6

11

4

13

1 1

17

1

9

24

25

3

5

5

7

VEHICLE IDENTIFICATION NUMBERS

The vechicle identification number (VIN) is located on the steering head tube .

The frame identification number ist stamped into the steeri ng head tube above the vehicle identification number.

The engine serial number is stamped on top of the right engine case.

Important: Please check these numbers at the time of sale and compare them whith your sales receipt or manufacture statement of origin.

3

Fig. 2

Fig. 1

Steering lock (Fig. 1 /1) helmet holder (Fig. 1 /2)

To lock: Turn handlebar to the right, insert key and push lock into position by turning the key counter clockwise at the same time.

The lock should stay in its position after turning the key clockwise. Pull the key off.

To unlock: Turn lock counter clockwise to free front fork.

Should you decide to lock and secure your helmet with your moped, simply place helmet strap into position (Fig. 1 /2) before turning front fork to the right.

Gas tank (Fig. 2)

The gas tank is located underneath your seat.

To fill gasoline just tilt seat forward to gain accesss to filler cap (Fig. 2) and storage compartment.

A tool set (Fig. 2/1) and measuring cup (Fig. 2/2) is inclu ded.

4

Fuel Valve (Fig. 3)

The fuel va l ve is posit i oned on t h e I. h. side of your seat bench .

Pos i tion 1 = c l osed

Pos i tion 2

= open

Po s ition 3 = reserve

Carburetor (fig . 4)

C h oke (Fig . 4 / 1) . Push down to ac t uate it. T h e choke w i ll be re l eased automatica l ly (see riding instructions).

P r imer (Fig . 4/2) . The primer button has to be he l d down in order to flood the carburetor .

S t op priming as soon as gas drips from carburetor.

Fig. 3

Fig. 4

5

Fig . 6

Fig. 5

Light and Horn Switch (Fig. 5)

The light and horn switch is located on the left hand side of the handlebar.

Position 1 = light off

Position 2 = light on

Press button to actuate horn .

Engine stop switch (Fig. 6)

The engine stop switch is locat_ed on the right hand side of the handlebar.

To operate moped, the switch has to be in RUN pos i tion.

Switch to OFF in order to turn off the ign i t i on, which stops the engine.

6

Brakes (Fig. 7)

The brake levers are mounted on both sides of the handlebar.

The left lever (Fig. 7/1) controls the rear wheel brake .

The right lever (Fig. 7/2) controls the front wheel brake.

Fig . 7

7

Fig. 9

Fig. 8

ADJUSTMENT OF BRAKES

Front Wheel Brake

The brake lever on the handlebar should have a play of app. 3/4" as measured at the hand brake lever (Fig. 8). The adjustment is made with the adjustment screw (Fig. 9/1) (loosen counternuts!).

8

Rear Wheel Brake

The brake l ever on the h and lebar sho uld hav e a play of app. 3/4" (see

Fig . 1 0) . Th e adj ustmen t i s r a de with the ad ju stme nt screw ( Fig . 11/1)

F ig . 10

Fig. 11

9

Fig. 13

Throttle twist grip (Fig. 12)

Located on the R .H. side of the handlebar , the twist grip co ntrols the speed of your moped.

The accelerate, twist the grip towards you.

To slow down:

- Release slowly

Fig. 12

Starter lever (Fig. 13)

The starter lever is mounte d-on the left hand side of the handlebar and is used only for the purpose of s tarting the engine.

Press lever hard while pushing the pedal down to start engine .

Rele ase le ver after engine is running.

(See also r iding in structions)

Warning: Do not press l ever while engine is running, since clutch damage can occure.

10

Adjustment of Starter Clutch Cable

The starter lever should have a play of app. 1 12 inch as measured outside at the le ver end. The adjustment is made with the adjustment screw

(Fig. 14/1 ). The rubber cap must be slid back first.

Tire Pressure

Recommended tire Pressure

Front tire: 32 psi

Rear tire: 32 psi

Caution: Proper tire pressure is important, since under inflated tires can cause hazardos riding situations and are subject to excessive wear.

Fig. 14

11

!" ....... ~ •.

· 'IEID

Fig . 16

Fig . 15

Gasoline/Oil Mixture

Filling up with two stroke mixture

All MAXI engi nes must be run with a gas/oil mixture (regular gas). Therecommended mixing ratio is 50:1 when u s ing s pe cia l Maxi Mix two s troke mop ed oiL

NOTE: DO NOT USE UNLEADED GASOLINE

PUCH MAXI MIX

50: 1 OI L MIXING TABLE

T o 5 gallons gasoline add 12 fl. oz. (379 cc) oi l

To 1 gallon gasoline add 2.4 fl. oz . (76 cc) oi l

To 1 quart gasoline add. 6 fl. oz. (19 cc) oil

Use measuring cup for pruper amounts of oil.

Ask your PUCH dealer for ma x i mix oil.

NOTE : When using other brands of 2 str oke oil , do not exceed the 50:1 mi xi ng ratio .

WARNING

NEVER REFUEL W I TH THE ENGINE RUNNING!

DO NOT SMOKE OR ALLOW OPEN FLAMES OR SPARKS IN THE AREA

WHERE YO UR MOPED IS REFUELED AND / OR WHERE GASOLINE IS

STORED! CHECK WITH LOCAL AUTHORITIES ABOU T THE STORAGE OF

GASOLINE. ,

12

Transmission fluid

The oil level screw (Fig . 17 I 1) serves also as the filler plug and is l ocated on the c lut c h cover.

The drain plug (Fig. 17 /2) is loc ated on the lower engine case.

To fill oil: The moped must be in a level position when oil is filled (off kick stand) .

Use automatic transmission fluid type ,F, only .

The quantity of oil is 6 s;4 fl. oz . (200 cc) or fill until oil level s off at the bottom of the thread of filler plug .

Fig . 17

13

Fig. 18a c

HEADLIGHT

Checking the Headlight Adjustment

Load vehicle (with one person or 150 LBS) and place it on even ground at a

5 m distance from a vertical wall (Fig. 18) .

Fig. 18

Measure at headlight glass:

He i ght of the center from the ground (H) in em.

Place on the wall:

A centerline vertica l to the longitudinal axis of the vehicle (C), and a horizonta l line at the height "H".

If the li ght is adjusted correctly, the light-dark limit should be 5 em below the horizontal line (H).

For higher or lower setting turn screws (Fig. 18a/1 ).

14

Exchanging the Headlight Bulb

Loosen screw (Fig. 19/1 ).

Push head l ight covering to the top and then pull it to the front. Twist bulb socket (Fig. 20) in the direction of the arrow. Exchange bulb. When remounting the covering, make sure that the pinion of the covering (Fig. 20/1) engages in the bore provided at the lower fork bridge .

Fig. 19

Fig. 20

15

16

Fig. 21

Exchanging the Tail and Stop Bulb

Loosen the taillight screw and remove lens. Exchange the bulb.

1 Stoplight

2 Taillight

WARNING:

Due to strict lighting regulations use only original replacement bulbs.

RIDING INSTRUCTIONS

Starting the Moped

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 is in the RUN position .

5 . If engine i s cold , depress the choke and depress the primer button on the carburetor until fuel drips from carburetor .

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 handleb a r . Position the pedal approx . parallel to the chain guard.

While holding the starter lever , push the pedal to start engine.

CAUTION: After completing step 5 and 6 do not open the throttle control, a s this will deactivate the choke . After the engine has started and warmed up , open throttle gently to the full position briefly . This will disengage choke. Avoid racing 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

Fig. 23

RIDING

Fig. 22

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 recommended even though optional in many states.

See your local PUCH DEALER or check with local law enforcement agencies for state law requirements.

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 PUCH saddle bags and baskets are availaple through your dealer.

5. Obey all traffic regulations. Use hand signals 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 a reduction in speed will hardly be noticeable, fuel consum ption however will be considerably reduced.

7. Closed throttle wi ll slow down moped when riding downhill.

8. To ensure engine lubrication on long downhill rid es, open throttle occasionally.

18

General Maintenance

Should you feel able to perform small maintenance work on your moped, make sure that all nuts and bolts are tight and all other co mponents are in good working condition.

A service manual is available through your PUCH dealer.

Any maintenance or service work requiring special tools and mechanical skills should be performed by your local PUCH dealer.

NOTE : The u se of non PUCH authorized spare parts can cause malfunction and hazardous riding situations for you.

Fig. 24

Fig . 25

Removal of front wheel

Unscrew speedometer cable (Fig. 24/1 ). Remove brake cable assembly

(Fig. 25/1 ), if necessary, lo osen setscrew (Fig. 25/3). Loosen axle nuts (Figs.

24/2 and 25/2). Remove wheel.

19

20

Fig. 26

NOTE : When reinstalling the wheel , make sure that the brake anchor p l ate

(Fig. 26/1) engages into the pinion of the front fork (Fig. 26 / 2) .

WARNING : Make sure both axle nuts (Fig. 24/2 and 25/2) are tightened.

Removal of rear wheel

R emove brake cable assembly , if necessary, loosen setsc rew (Fig. 27/4).

Loosen chain tensioning screws (Fig. 27/1 and Fig. 28/1 ). Loosen both axle nuts (Fig. 27/2 and 28/2). Detach chain tensionerfrom grooves. Push wheel forward. Remove chain (Fig . 27/3) from drive sprocket. Pull off the rear whee l with vehic l e tilted to the left.

When remounting the wheel, check chain tension and tighten axle nuts.

Fig. 27

Fig. 28

Retightening the Bolts and Nuts

Check bolts and nuts for tightness. Pay particular attention to engine mounting bolts, front and rear axles and spring strut fastening screws.

21

22

Chains

Engine drive-and pedal chain should be kept clean. Every few hundred mi l es wipe chains thoroughly clean with a cloth.

Lubricate with chain lubricant or SAE 90 oil.

Fig. 29

Always keep chains properly tensioned. The proper slack of the drive chain should be 3/4".

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.

When reinstalling the chain also pay attention as to the correct position of the chain lock (closed part in riding direction) and to proper chain tension.

If pedal chain tensioner catches or travels roughly as pedals are operated, rea lign tensioner so chain travels smoothly.

SUGGESTED MAINTENANCE AND LUBRICATION

CHART

A r egu l ar ma in tenance and lubrication schedu l e will help to ensure a long , useful life for your moped. Plea se refer to the mileage and lu br i cation c h a r t for detailed informat i on .

NOTE: Above mi l age schedule appl i es to moped used on dry paved surface . If used in wet, muddy or sa ndy a rea, maintenance interva l s shou ld be more frequent.

Always check contro l s and lights before using your moped.

Frequency

F i rst Every

300 miles miles

0 g

0

0

<.0

0

0

0) g g

,....

(")

~

OPERATIONS TO PE RF ORM

w •

()

> • a: w i I

·

w

~

~

0 •

() w a:

• • • • • • Ti re wear and condition

• • T h ro ttle cable adjustment

• • • • • C heck t i r e pressure

• • • • Check transmission ATF level

• • • • Clean and l ub ric a te c h ai n

• • • Clean air f ilte r

• • C han ge transmission ATF

1

!

• • ..

, .• C h eck spark plu g

• Decarbonize eng in e

• •.

j

•.

Clean ex h aust baffle

Retighten screws and n uts .

1

C lea n fue l valve a nd lines

• I • • Clean ca rburetor

• I : :

~~::~~;~ i t~ =~u t~ ::;t

:. :.

Adjust s ta rter cable

• •

.

I

I

•. •

Check brake cables/linings

Check/l ubr icat e hub bearings

Steer i n g b ear i n g adjust/l

• • Lubricate co ntro l ca bles

• • I • •

Ad ' t h ' t .

1 1 1 1 1

JUS c am e ns1on l l l l l I ubri cat i o n

23

CONSUMER INFORMATION

CONSUMER INFORMATION

Stopping Distance

Vehicle minimum stopping Distance on dry ground

This figure indicates braking performance that can be met or exeeded by the vehicles to which it applies, without locking the whee l s, under maximum condition of loading. The information presented represents results obtainable by akilled drivers under normal road and vehicle conditions,and the information may not be correct under other conditions.

Description of vehicles to which this table app lies: MINI-MAXI

Maximum load

Fully Operational Service Brake

28'

1,5 hp

38'

2 hp

10' 20' 30' 40' 50'

Stopp in g distance in feet at maximum speed

24

Technical Data

Speedometer

Steering lock

Light and horn switch

Starting lever

Primer

Choke

minlmaai

V.LN

.

plate

Frame number

Engine stop switch

Front wheel brake lever

Engine serial number

Pedal

WIRING DIAGRAM

@) cr

\2

-'

"'

T

®f

I

15

®~OWN

1 Headlamp

2 Speedometer bulb

3 Light and horn switch

4 Engine stop switch

5 Buzzer z z

"' w cr cr

\2 \2 w

..J w

..J ., "'

T z z

~ ~ a: cr

0 "'

~ >-

~

~

0

~ ~

"' t.:l >"' l

~

(,) l

BROWN

.L

GREEN

P -

L _ _j

®

BLUE/BLACK

®

B L ACK

- -

R

6 Stop light switch

7 Regulator

8 Fly wheel magneto BOSCH

9 Ignition coi l

1 0 Spark plug

11 Ta i llight bulb

12 Stop light bulb

13 Stop light switch

,.....

0

(j)

ENGINE

Maximum output

Compression ratio

Maximum output

Compression r atio

Bore

Stroke

Displacemen t

Cooling .

Lubrication

Carbureto r

Main jet

Needle jet

Needle position

Carbureto r

Main jet

Needle jet

Needle position

Ignition . . . .

Breaker point gap

Ignition timing

Spark plug

Spark plug

Spark ga p

Dynamo

POWER TRANSMISSION

Gearbox

Clutch

Primary transmission

Secondary transmission

Pedalling c ha i n

GEAR RAT IOS

Engine gear

Gear-rea r whee l

Pedalling t ra nsmt ss ion

Eng i ne gea r

Gea r rear whee l

Pedalling tr ansm i ssio n

1 .

5 hp at 5000 r .p.m

8.5

: 1

2 .

0 hp at 5500 r p.m

8 .

5 :1

1 496 i n ( 38 mm )

1.

693 in ( 43 mm )

2 .

97 cu . i n ( 48.8 cc ) ai r cooled gas/oi l mixture

1 .5 hp BING 1 / 12

52

2.12 A

1 st notch from top

2 .

0 hp BING 1/12

54

2 .

12 A

1 st notch from top magneto ignition

.

014.

018 in (0.35-Q.45 mm)

.032.

047 in (0 .

8 ·1 .

2 mm) BTDC- 14 17 .

50

1.5 hp BOSCH W8C

2 .

0 hp BOSCH W7C

.

016-.020 in (0.4·0.5 mm) flywheel magneto BOSCH 6 V 26-5 / 1 OW single speed automatic centrifugal clutch r unning in helical gears

ATF chain 1/2 " x 3/16 " chain 1/2 "x 1/8 "

1.5hp96

: 19; i 5 .

052

39 : 14 ; i 2.785

28 : 23; i 1 , 217

2 .

0 hp 96 : 19 ; i 5 .

052

39 1 5 ; i 2 .

6

28:23 ; i 1.2

1 7

CHASSIS

Frame

Fron t wheel suspens1o n

Rear whee l suspensio n

Brakes .

Dia . of brake drum

W id t h of brake l in i n g

Tire s i ze f ront and rear

Tire pressure front/rear

Fuel tank

WEIGHTS AND DIMENSIONS

Wheelbase

Overall l ength

Overall w i dth

Overa ll height

Ground c l earance

Curb weig ht

ELECTRICAL EQUIPMENT

Headlamp bulb

Rearlamp/Stoplamp bulb

Warning device

PERFORMANCE AND CONSUMPTION

Top speed . . . . .

Hill climbing

Standard f ue l ability consumption (

.

D IN 70030) tubular frame te

2 b

.

43

63.8

28

39 u le

50

.93

5.1

.

.

.

105 scop internal

3

.

· in

14 in. in.

4 in

8 in

. zzer

.

.

"

(1620 mm)

(720

(1010

81b ic

US gal

6V, 15W fork; shock absorbers

3.15 in (80 mm)

0.7 in (18 mm )

32 psi/32 psi (2

(3

(48

.

.

mm) mm) kg)

1

(130 mm)

.

;

(11 00 mm

6V, 4W/6V. lOW

96

1 expanding

)

.

5 litres in (

25 bar/2

)

50

.

mm) shoe brakes

25 bar )

1.5 hp 25 mph (40 km/h)

2 .

0 hp 30 mph (48 km/h)

11·14%

1 .5 hp 148m/US gal (1 7811100 km)

2 .

0 hp 144m/US gal (1.98 1/ 1 00 km ) spring

77 in (45 mm) spr i trave

T est commences on a f l at t rack i n top gear at 3/4 top speed . The t rack l ength of 6.2 m (1 0 km) i s used either wa y an d may have verv short upwar d and dow n ward gradients of a maximum of 1 , 5% . T he ve h ic l e must be ad j uste d to spec i fication and tires must have corrf!r: ...,ressure

T he rider must not weig ht more than 14 3.32 lbs ( 65 kg). The measured co nsum pt 1on is i nc r eased b y 1 0% to take i nto account unfavou rable conditions . Produ ct io n may diffe r up to 50fo from t h i s va l ue .

CAPACITY AND QUALITY OF LUBRICANTS l ng trave l

ENG I NE

GEARBOX

Mixture of regular grade gaso li ne with special two stroke 011 (M AXI MIX) 50 1.

Do not use un l eaded gaso l ine .

63f• oz. (200 cc } Automatic Transmission F l ui d "TYPE F "

GREASE NIPPLES. CABLES

Summer and winte r grease . For l ubrica t ion o f the grease nipples also SAE 90 can be used .

For l ubrication o f the cables also SAE 30 can be used .

I

WHEEL BEARING

CHA I N

Summer and wint er i..ithium base grease .

Summer and winter SAE 90 .

ASSENBLY INSTRUCTIONS PUCH NINI NAXI

1. Remove the Moped from i t s container.

2. Set the Moped on its kick stand.

J.

Remove accessory box from container.

4. Begin assembly by removing protective packing.

5. Install front fender and secure with the four (4) screws provided

(screws are located in the fork sliding tubes).

6. Install front wheel and torque axle nuts to 35-50 Nm (25-36 ft/lbs).

Note: Both axle nuts and washers are located on one (1) side of the axle. Install front \Yheel with brake reacting slot on l e f t hand side (operator's view).

Assure that brake stop on fork leg and brake backing plate inter lock. Connect speedo cable and check for speedo operation.

7. Position the handlebar on the fork bridge, making sure electrical wiring is not crossed. Attach with the four (4) allen head bolts provided. Before torquing bolts, align the handlebar so that i t is running parallel with the front fork. Torque bolts to 15-16 Nm

(10-12 ft/lbs).

8. Place throttle twist grip into shackle and mount to handle bar.

9. Hount both electrical switches and secure wiring with the tie wraps to the handle bar.

Caution: secure electrical wiring only, not brake cables.

10.Install front brake cable and adjust brake.

11.Install pedals. Note: Pedals are marked "L" - l e f t hand side, and "R 11

r i _

12.Install rearview mirrorand adjust as requJ..red.

1J.Installation of leg shield: a) locate the four sleeves

( 1) into the mounting holes. of' the leg shield, see arrow. b) place lower clamp (2) over frame tubing and position sleeve (3) in clamp. c) position leg shield (4) over lo1ver clamp (2) and install clamp stud (5) • d) install both upper mounting bolt (6),

Tighten all nuts.

14, Fill transmission with automatic transmission

(TYPE

-

F only) refer to owners manual. fluid to owners manual.

15. Fill gas tank with gas oil mixture, refer

16. Tighten all nuts and bolts

17. Short test drive and clean machine.

18. Please, carefully instruct customer the moped. how to safely operate

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