MZ TS 125, Repair Manual

Page 1: ...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 ...

Page 2: ... 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 V E B F A C H B U C H V E R L A G L E I P Z I G Dead line June P 1983 Photomeohanfcal print Salzland Druckeref StaOfurt SG 157A30 84 RH TS 1251150 und ES 12511 U 15011 englisch g Aufl ...

Page 3: ...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 and means recom ended by MZ Authorised MZ Service shops may obtain them 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 ...

Page 4: ...e for Accidental Earth 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 in...

Page 5: ...k 5 7 1 l Fuel Shut off Cock 58 Brakes 58 1 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 1 Replacement of the Wheel Bearings 62 Inspections Required in the Case of Poor Road holding 62 1 Repairing the Spring loaded Suspension Units 63 Shock absorber Marking 63 Remo...

Page 6: ...Fig 1 TS 125 and 150 Fig 2 ES 12511 and 150 1 ...

Page 7: ...Fig 3 Sectional view of engine ...

Page 8: ...ht 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 Starter jet Slow running jet Slow running air screw Throttle opening Air filter Float valve seat 1 3 ElectricalEquipment Ignition Ignition timing Contact breaker points gap Sparking plug Electrode gap Dynamo Charging control li...

Page 9: ...Caster Suspension system front TS 125 and ES 12511 TS 150 and ES 15011 I 2 light system at the handle bar ends 4 light system in headlamp shell under fuel tank actuated by push button arranged below dimmer switch 6 V 45 40 W passing beam asymmetric 6 V 4 W BA 9 s cap 6 V l8 W S 8 5 cap 6 V 21 W BA 15s cap 6 V 5 W S 8 cap BA 15S 6V 18W S 8 5cap 6 V 21 W BA 15s cap 6 V 1 2 W 6V 1 2 W 6V 1 2 W multip...

Page 10: ...bout 100 kmlh for the TS 125and ES 12511 105kmlh for the TS 150and ES 1M 1 The maximum speed will only be reached if the re 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 150mm spring loaded suspension units with hydraulic d a m p ing total travel of spring 105 mm spring pre load ad justable wire spokes 1 ...

Page 11: ...ine 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 ...

Page 12: ... and piston Experiences gathered by us in the course of many years have shown that it is advisable to use exclusi vely M Z 2 2 t w o s t r o k e e n g i n e o i l This additive type oil meets the following technical re quirements viscosity at 50 C 20 to 25 cSt pour point maximum 30 C It contains additives which effect a high tem perature and pressure resistance Limited tendency to coking preventio...

Page 13: ...0 C should be used The damping characteristics of the telescopic fork and the spring loaded suspension units are based on this viscosity Springing and roadability will be impaired if shock absorber fluids of a different viscosity will be used 2 6 Contact Breaker Lubrication For contact breaker lubrication the special oil for igni tion circuit breakers in the GDR known as Unter brijl should be used...

Page 14: ...with awidthoverflats 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 an old clutch disk of steel The tool produced in this way similar to a signal disk can be used i...

Page 15: ...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 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 ones remove thc lock rings sec arrows by means of a pair of t...

Page 16: ...late and touched up if required using emery cloth until all scratches or sealing compound are removed Then and 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 24 Re finishing the sealing surfaces The next thing to do is to insert the circlips locking ring for the cranksh...

Page 17: ...tact breaker cam fails to raise at 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 T h e a m o u n t a c r a n k s h a f t m a y b e o u t o f t r U e at all measuring points is 0 02 mm Fig 28 Checking the crankshaft for true running The r a d i a l p l a y of the conne...

Page 18: ...transport or storage As a distorted or oblique connecting rod will wear down the small end bush before long check the con necting rod in any case Pig 32 Mounting the crankshaft W e a r l i m i t s a t t h e g e a r s h i f t m e c h 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 1 Bolt at the retaining plate has a clearance of mcjre than 0 3 mm 2 Cut out in the retaining plate worn down mo...

Page 19: ...o 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 the window are in a proper state and that there are no cracks Check the bush of the shaft wheel 6 for wear 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 o u t o f t r u e is 0 05 mm Realignement should only be effected by pressing but never by beatin...

Page 20: ... 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 Put the shaft whe...

Page 21: ...Fig 38 Power flow in the four speeds ...

Page 22: ...act breaker fails to lift at 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 as 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...

Page 23: ...d then use a coppci mandrel placed through the Fig 49 Aligning tlle gearbox shaft wheel to beat the shaft back upper arrow Now the end clearance shown in Fig 38 between the face of the keyway section of the clutch shaft and the shaft wheel must be present Slightly grease the lip of the sealing ring in the cover i plate put on the distance bush I in Fig 481 I Fit the gearbox sprocket recess pointin...

Page 24: ...f the starting segment a t the con tacting side 2 for wear Insert the offset end of the kick starter spring into the slot in the starting segment if necessary restraighten so that the end of the spring fits tightly Fit the g u i d e or thrust w a s h e r 3 0 X 17X and mount the starter shaft with spring Put the kick starter lever in place and pre load the starter spring by turning it through one r...

Page 25: ... prinlary drive Check the inner driver to see that the internal gearing is in proper mesh with the profile of the clutch shaft without excessive backlash Indentations in the grooved profile o the driver caused by the steel disks and which can just be felt or are just visible can be neglected In the case of indentations deeper than 0 1 mm the inner driver must be replaced T h e d r i v e r s for th...

Page 26: ... 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...

Page 27: ...ig 67 AI uring the cylinder Fig 65 h leasuring the piston All MZ n otor cycleshave a syn metric timing dia gram Related to the transfer angle of 115 that is to say that the transfer ports open 57 5 before bottom dead centre and close 57 5 after B D C Exhaust and transfer are measured from B D C inlet from T D C T i m i n g ES 125 ES 150 ES 12511 and 15011 TS 125 and 150 Inlet wlth point 142 142 5 ...

Page 28: ... 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 l Fig 69 Determining the timing If an old piston is reused the piston rings must be 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 be...

Page 29: ...it in the gudgeon pin boss N o t i c e i n a n y c a s e Do not use a piston with the marking GG piston head This type of piston is provided grey cast iron cylinders of the older MZ types on for the the Fig 73 Piston seizure 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 ti...

Page 30: ... 14 casing screws are tightened once more observe Fig 47 The bore for gearbox venting see arrow must be cleared by means of a wire in order that it cannot be clogged by hardened jointing compound D o n o t f o r g e t t o f i l l o i l 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 m...

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Page 33: ...re the field coil is also checked with the help of line continuity tester Here the use of an electric bulb and mains voltage 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 frame accidental earth is present Then loosen the in dividual coil connections and check each field coil s e p arately Defectiv...

Page 34: ...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 commutat...

Page 35: ... broken or loose D line at he regulator or in the dynamo he adjustable resistor is connected as follows long cable 1 to D positive carbon brush short cable 2 to DF positive pole of field coil socket 3 and negative pole of field coil to earth 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 cabl...

Page 36: ...ed switch contacts may be the result of an excessively high continuous load heated twist grips additional headlamps etc loose or broken D line at dynamo or regulator The same symptom can be observed as a result of riding without gear shifting as required too high an idling setting incorrectly connected battery positive and negative cables changed by mistake a broken adjustable resistor earth leaka...

Page 37: ... water 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 selected that the density of the complete amount of acid in the battery in fully charged condition will be 1 28 f 0 01 g cm3 If the battery is not used or if less than 50 km are cov ered daily the battery must be re charged once every month 5 4 Igni...

Page 38: ...ld a weak spark will result the engine causes the carburetter to spit back Fig 07 Ignition setting gauge H 8 1408 3 screwed In place 38 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 u...

Page 39: ...f the pad before long the dry felt then rises the temperature of the cam track premature wear of the nose at the contact lever will be the result The sparking plug in essence consists of three parts These are the central electrode and the carrier which also acts as the earth electrode The spark jumps over between these two electrodes igniting the fuel air mix ture The third part of the plug is the...

Page 40: ...starting irregular running loss of powei 2 Capacitor broken down due t a high rate of wear on the contacts ignition failure at 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 o large ignition failure at higher engine speeds weak spark loss of power Crankshaft bearing worn down Crankshaft a...

Page 41: ... backing between switch anc holder at the handlebars otherwise there is the ris of accidental earth 4 1 9 Fig 105 Connections a1 the drmmer switch 1 Access to the connections of the bilux lamp is obtained after removing the reflector In the TS 125 and 150 loosen screw 2 Fig 109 and remove the front ring with reflector As to the ES headlamp unscrew the polyamide ring draw out the two retaining clam...

Page 42: ...rame pn sition is changed dimmed iight Fig 110 ES headlamp focusing 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 5 8 Tail Lamp and Stop light Switch 1 Connection for stop light term nal 54 2 Negative line to stop light swi...

Page 43: ... 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 the slotted head screws until the stop light flashes up 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 adjustmen...

Page 44: ...harging Control light burns Engine runs flashing lights on dynamo charging Control light flashes in dark phase of flashing lights Control light flashes in the same phase as the flashing lights Control light goes out Engine runs flashing lights off dynamo fails to charge Engine runs flashing lights off dynamo fails to charge Control light burns Control light flashes in the same phase as the flashin...

Page 45: ...perating behaviour and the appearance of the sparking plug are the only criterions for evaluating the correctness of the carburetter tuning A short trial run is useless because a change in the carburette tun ing A short trial run is useless because a change in the carburetter adjustment will not be mirrored in the appearance of the sparking plug after a very short time Mixing Ratio of Rich Air fue...

Page 46: ...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 5mm open Do not accelerate for cold starting otherwise the start ing d...

Page 47: ...er and by opening the fuel shut off cock for a short time check that a sufficient supply of fuel is ensured If this is not the case any adjustment at the carburetter is useless Normal rate of flow through the filter cock is about 12 1in 60 min Causes for a reduced rate of flow may be a Vent hole in tank cap closed by preserving agent or polish b The ports drilled through the rubber packing were co...

Page 48: ... etl c ancl 2 Sealing washer milin S S Starter mixing tube F c lo l u n n i n p lcr 4 Float valve con pletc IT I I s I I IIOI P l 11 5 Starter duct ill I I I I I I I I I S I I I I I I 11 li I 6 a Starter jet 11 SICI L I I I I I I I I i i r ict Zum Motor to engine K r l f fuel Lul t air ...

Page 49: ...ty 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...

Page 50: ...o 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 at 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 t...

Page 51: ...vide the rings with 22 balls each 6 35mm in dia meter using highly viscous antifriction bearing grease The steering assembly must be adjusted in such a way that it is free from play but it must not jam because the steering stability of the vehicle depends on the correct adjustment For checking shake the mudguard up and down with one hand while feeling the upper and lower steering bearings with the...

Page 52: ...t pressed out and thcm l s o c w l plx ssure on the intermediate ring 54 mm in d r n t r X 20 mm in order that the innc 1 and outer rings of the upper bearing prop erly cont cctt h c i rmiltlng parts Since thc stc rlng components are mounted on ball bearings no rdjilst ngopc rations are required The steering bci r ii 1 s in p c f c w orking condition if the ball bearing l i a a propc press fit and...

Page 53: ... Nm 15 kp m 3 Clamping screws at the lower clamping head torque 34 3 to 44 1 Nm 3 5 to 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 to rebound while the mudguard screws are still loose to ensure that the knockout spindle assumes proper position in the opening provided for the spindle the s...

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Page 55: ...new ones if they are distorted by unusual outer influences do not straighten them experience has shown that guide tubes after straightening assume their original position of the dis torted condition permissible out of true error 0 05 mm or the chromium plating is worn away The portion of the guide tube subjected to the highest rate of wear is at the front end about 150 mm above the lower edge i e ...

Page 56: ...e this axial play This washer must exactly fit on the guide tube diameter 31 7 mm and its external dia meter must not exceed 35 5 mm to prevent these washers from rubbing against the inner surfaces of the sliding tubes at any rate process would be destroyed and lead to an unusual wear of the lower sliding bush If by extraordinary conditions foreign particles or similar things the interior surface ...

Page 57: ... the th1 ldof tlw thrcwdcd ring because the es c ssi e supply of ildhcsi c lacqucl vould be squeez c d U I I X I I I I Iw packing ring The x quirxd1orrlllcLi r s lichlcmin 1111 lhlwded ring i I K m 2 0 1 m panding the unit The damping effect must be clearly in expanding After the completion of the functional test the tele scopic units are completely assembled for this pur pose the unit is clamped ...

Page 58: ... Ac tuating lever and rubber packing can be removed after loosening the two fastening screws arranged laterally to the actuating lever On the occasion of repairs in the fuel shut off cock the fuel feed hose leading to the carburetter shou d also be inspected If this hose has become brittle leaks may occur in the connections Then the fitting of a new fuel supply hose having n size of 5 X 8 2 mm is ...

Page 59: ...t tybe is allowed to turn the prop stand drops dur For replacing one of the foot rest tubes use a sockct ing jding lvrench width ovei flats 13 to loosen ihc clip and p111 out the tube When fitting take cwc that the recess in the foot rest 7 6 Checking andChangingthe tube engages vith the nose at the flame This is of Secondary Chain Fig 154 Prop stand P To remove the secondary chain for inspection ...

Page 60: ...e spring clip at 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 or antifriction bearing grease after every 2 000 km of road operation Fig 159 ...

Page 61: ...mcm ber A In the casc of scverc distortions of or fissures in the opvnlngs for I tic I T I I viicel dogs indicated by sudden impacls d111 ingmoving o f f or gear sliiiting this mrmbol mllxr be c q l c l Fig 162 Rear wheel drive 2 lubricating nipple ior the speedometer drive Here use gear oil GL 60 as lubricant An addition of graph ite or MoSz is ad sable In vehicles from the 1973 model the speedom...

Page 62: ...nce The rear luggage carrier to be fastened to the saddle carrier should only be loaded with l i g h t W e i g h t small luggage For holiday luggage and similar loads side luggage carriers fitted to each side of the rear motor cycle part are required The track keeping of the two road wheels can be checked by means of a measuring rod or by sighting The rod must contact the rear wheel at two points ...

Page 63: ... 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 June 1978 A 22 120 5618 1 5011 Fig 170 Balancing the front wheel Where the meaning is as follo...

Page 64: ...special wrench unscrew the threaded member S in Fig 1721 and pull out the damping device Clean all parts ir Scn ine and pour in new oil Tighten the thrended meinjer with a torque of 49 Nm 5 kpm 7 12 5 Mating Shod absorbers To ensure good road holding properties the shock ab sorbers of one and the same axle must show equal damping values The marking of the tolerance group is located at the upper fa...

Page 65: ... springs Holder for loosening the nut at the clutch shaft Holder for loosening the nut at the drive pinion Puller for pinion on the crankshaft Drift for gudgeon pin Drift for fitting sleeves Casing separating screw1 Pusher for crankshaft1 Drift for 6303 and 6004 bearings Drift for 6303 bearing and 22 X 47 packing ring Fitting device for small end bush Setting gauge for gear shift detent axle Suppo...

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Page 67: ...Fig l Exploded view OS the engines MM 12513 15013 with revolution counter drive ...

Page 68: ...from the crank shaft by means of puller 12 MV 32 4 For this purpose the puller must be properly tightened MM 123 3 MM 15013 needle bearing on top K 15 X 19 X 20 FKI 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 1 230 cm3of damping liquid for each fork member Fig 3 Dismantling the primary drive In the case ...

Page 69: ... sequcntly thc bca in2 can be pressed off against the crank plate by altt nately and uniiormly tighten ing tnro M 8 50 s c s having a pin at the end nf the scivw Kolice The ball bearing extractor must not be allowed to turn when pulling the bearings otherwise the M C X 50 screws engagc with the bore holes in the crank plates I 1 X Fig 7a Pressing cl l the crankshaft bearings I Prchslng oJl scrcws ...

Page 70: ...tance between teeth in the 4th upeed A 0 8 mm If the setting gauge 11 ML 8 4 for adjusting the gbr ahlft detent axle is not available and the gearcahift detent axle ia to be adjusted by means of the U b l o measure 13 mm the distance A of 0 1 mm between gear shift wheel lstl3rd speed and the Axed gear of the 4th speed on the layshaft must be chedted with the fourth speed in engagement If necessary...

Page 71: ...g light lh Ground point 3a Revolution counter illumination lb High headlight beam 2 Speedometer 4 Flasher switch 1C Passing beam 2a Speedometer illumination Id Ignltlon V l 1 t o b L 5 Combined dimmer switch 13 Regulator cutout 14 Combined stop tall and number plate Lltttng l4a Stop lighting flttlng l4b Comblned tall and number plate 1 1 g IMng 7a Contact breaker IS Stop light awitch rear I Igniti...

Page 72: ...he 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 p...

Page 73: ...ush the sup porting tube downwards fitting direction of the tel escopic fork out of the guide tube 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 ...

Page 74: ... spring 19 mm in diameter 2 and packing plate 3 must be put in place then the uide tube slipped on and fastened by screws iii 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 Notice The vent hole in the protective bellows always must point to the rear Fig 22 Fitting the protective...

Page 75: ... for bearing 6304 8 2 Cycle Parts 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 Washer Plate Do1t Disk U steel 6 l2 3 50 long St 38 b 2 TGL 0 1026 St 38 b 2k 0 2 0 x 8 TGL 0 1026 St 38 ...

Page 76: ...g 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 TGL0 931 M e x 7 0 3 2 Hexagon head screw TGL 0 833 M8X100 ...

Page 77: ...all mfem 1X 45 No Quantity Dcllcription Material Standard Rough Size Runub Ring St 38 b 2 0 75X 20 TGL 0 1026 4 Ring for bearing 630422 50 434 all chamfers 1X 45 No Quantity Description MaterialIStandard Rough Size Remarks l Ring S t 3 5 hb TGL 9013 ...

Page 78: ...rw L Pulling sleeve 22 50 435 8 L A 5 No Quantltv Descrl tlon MaterlallStandard Rough Size Remarks 1 Sleeve ...

Page 79: ...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 ...

Page 80: ...7 Puller 12 MW 32 4 degreased electro galvanised No MaterialIStandard Rough Size Remarks Puller Screw M 1 6 x 6 0 St 38 b 2 0 36 X 45 TGL 0 1026 TGL 0 561 pin hardened ...

Page 81: ...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 2 1 Ring case hardened case hardened Kordel to be knurled ...

Page 82: ...1 1 SUpporunO dirk 2 l Guide mandrel 8 l Pruaing In mandrel St 38 b 2 K nidtd TCL 0 1026 Pl td ...