+ 6 | Printed in GermanyDear NSU Friend, We would ask you to study this instruc- tion book carefully, and thus acquaint yourself not only with all the interesting detcils of your new machine, but especially with oll the hints and advices we offer you for the correct servicing of your machine Furthermore, we would ask you, according to the direc- tions given in the attached Service and Inspection Card, to take your machine to an NSU Dealer's workshop in ‘order to have the various jobs, suggested by the works, ‘carried out by experts. Only NSU Deorlers have, besides ‘original NSU spares, time-saving special tools and main: tenance manuals ct their disposal, as well as expert mechanics speciclly NSUstrained. We would therefore suggest that you take your machine, in case of repair ‘work, foo, elways to your NSU-Dealer. Any guarantee cloims that might orise are to be reported to your Dealer for his examination, who then hes to bring the case to the General Agent's attention. All guorontee claims submitted direct to the General Ageat can only be finalized on heving the Decler’s report. Repair jobs at tho Genoral Agent's can only be carried through on appointment made beforehand through your Dealer. Finelly, we would ask you to always adhere to our well: meant advice, and wish you Mony Milles of Trauble-free Riging on NSU! NSU WERKE AKTIENGESELISCHAFT NECKARSULM 2 CONTENTS Foreword Technical Data Description Riding Instructions ‘Maintenance Core of the machine . Routine Lubrication Laying up for the Winter Lubrication Chart. Flot rate times for repair tasks - Fault Tracing Air and Inlet Silencer . Brakes. Brakes — Adjusting Front Brake Brakes — Adjusting Reor Brake Corburettor Gorburettor — Jet Sizes ond ‘Adjustment | Carburettor — Operation of Carburetor fend Air Side Corburettor — Tickler Chassis Chossis — Frame’ Chossis — Sedalia : Clutch. . Clutch — “Adjustment Electrical Equipment — Adjusting Hato : Electrical Equipment — Botleries Electricol Equipment — Charging Batteries 1243 243Electrical Equipment Electrical Equipment Electrical Equipment Electrical Equipment Electrical Equipment Electrical Equipment Etectrical Equipment Electrical Equipment Electrical Equipment Electrical Equipment Electrical Equipment Dipper Switch 16117190 Electric Hom 2 Fan 213 Faults in Ignition System. 40)41 Faults in Lighting System - . 64 Flywheel Dynamo... 1 Headlamp - 2. 1242 Horn Button f 2 ype lanition Key 1292629 Lighting Switch = 1230 Lighting Switch Positions”. 30 Lubricating Pad on Contact Brecker 460 Sparking Plog arr Electrical Equipment — Stop Light 125s Electrical Equipment — Toil Lamp 1243 Electrical Equipment — Timing the Ignition 41 Electrical Equipment — Wiring Dicgram . 5 Engine. 8 Engine — Crankshaft 9 Engine — Lubrication 9120 Engine — Sterting 2% Exhaust System 181 Front Forks 2 5 Front Forks — Lubrication 5h Front Forks — ThiefProof lock... 2... Fuel Tank — Checking Fuel Supply - 2 Fuel Tank — Fuel Top and Filter... 3 Fuel Tank — Fuel Tap Position. |. 1... 24 4 Flat rate times for repair tasks Gearbox see ape Gearbox — Geor.change mechenism | | Gearbox — Oil change Hondlebors Power Transmission — Engine — Georbox Power Transmission — Gearbox — Rear Wh — Changing Down = Chenging Up — Engaging Nevirol Gear — Preparing the Scooter for Use — Running-in Speeds = Starting OFF Riding — Stopping Riding — The End of the Trip Riding — When Descending Long Hills | Speedometer Tyres — Check Tyre Pressures... Tyres — Removing Tyre from Wheel Tyres — Spore Wheel Wheels Wheels — Removing and Fitting Front Wheel Wheels — Removing and Fitting Rear WheelTECHNICAL ENGINE — CLUTCH — GEARBOX No" of eyindere Y Copsey lee Campresion “eas sa. Suipat She. S00 eam Speed Control of patil flow By oie paca cooling Fonceoled Font oF ein £25 nan G7 in) before TOC Corbwctor fing Tnglasaver carburetor Bieter aE Stier wih exooe ade i Ucliatesllch runing im al bath Eich one By hand Snort Eepeedguattox bal oot with Manseliy eperated tistario on lets Gearchange meconisn Mansy gyal Geer encagenent Orivig Be ratio, engine — georbox ams oe Fait rom ger 206m 2nd gece hana Top ‘aeor we oer rote, ootbox wear wheel 77 = ‘Overall gear ovis Se ham gtor Maes 2nd gear F297 1 Top ‘oeer Ga 1 “raneniesion Evgine-georbors spiral bevel dive Goothosreor wheel. shaft, pial bse! gear, ond. gear wheels ‘Nexto speed about 98 knihr 3 mpd The right fo make alterations In the design and specifications is reserved. DATA FRAME — WHEELS — BRAKES — EQUIPMENT Frone | Cento! subulr frome with sheet Sata hanes Front forks Foote forks ‘aps rm 3" {0 mm ("1 Meta iit 5 Wheels Inverhanaeete Tyree ito Front brake Interel expending broke oor broke Intemalexpancing breke rake “operation Frorh hand Tover: Rear, foot pedal Wht th fl ark 180 ke GF ah ‘Matin permite weight “200 tg a2 Io) EQUIPMENT Vevolt Hleteol Systom with Dynostorer Flyubes eynome, cn see, with barking light hd electie horns Inatroments inated speedometer, itd with Heetllns eke eo iano ond fit Fer operatty A nt Sofaty hook for hand bap, Rider's — Soudhe "Pition "seat Soa wheal sn log errata! The right to moke alterations in the design and ‘specifications is reserved,DESCRIPTION The NSU Scooter is filed with on air-cooled single: cylinder engine unit with a detachable light-alloy cylinder heed. 8 The Crankshaft is mounted in two grooved ball bearings on either side. The connecting-rod big-end becring is @ roller becring, Working Cycle The engine operates on the two-stroke cycle. The Flow of the gases is controlled in the conventional manner by means of the flet-crowned piston, which covers and uncovers inlet, trensfer, and exhaust ports cast into the cylinder os it ascends and descends. Engine Lubrieati ‘The engine is lubricated by mecns of oll mixed with the fuel. whi running in, or if the Isheavily loaded, e.g.| odd 1 part of cil to 20 if it is used In mountainous | ports of petrol. country otherwise odd 1 part of oll 10 25 parts of petrolCarburetor A filler Ae sneer cttor, Air Silen The covburattor, hich is,made by. Moses, Bins is a locttype singl-lever caruuretfor, controlled by means oF he Throttle twisigrp on the fighthand end of the handlebars, one = The inlet air silencer is fitted to the carburettor. The cir crown info tite engine enters through the air Fiter, nd posses Hrough the ar silencer and past the choke slide Into the corburettor, The carburetior float is depressed, or “tickled”, and the choke slide is opened and closed, by mocns’ of linkage controlled through o Bowden edie by a knob on the instrument panel. 10 Exhaust Syste The silencer, which con be dismantled, not only effecti- vely ‘silences the engine no'se, but clso.provices the fexhous! Bock pressures nacessary if a hwo-siroke engine is to ive of iis best. No alterations should therefore bbe made 1o the exhcust system, since these will in al probobiliy lead fo.a reduction in ihe engine power ond x increase In fuel Consumption. Te engine mey olso De damaged. Electrical Syste . ‘The source of electric current is a flywhee! dynamo, which olso serves az the starter, and which is pravided with a contact breaker and with an oulomotic centrifugal edvance-and-retard mechanism to assist in starting; tis is arranged so thot on starfing, the point of ignition eccurs approximately at the TD of the piston: As Ihe fengine speed increases (to about 500-600 p.m), the Flyawelght alters the position of the contact-braclcer cam 59 tha! the full amount of pre-ignition is obtained, and ignition wil then occur at 425 mm (0-17 in) Dsfare TOG, ie flywheel dynamo and starter is meunted on the lefsnend end of Ihe erankshal!, and 50, of course rune fot engine speed. This D.C. dynoino, which has an output oF 60 watts at 2 vals, sioplies the HT. curant Yo the sparking plug through ‘on ignition coll mounted on the frame, ond clso the lighting current ond the charging current for the batteries through the cut-out. nignition warning light will first come on when the switch is in position 1, this indicates that current is, available From the batteries. Pushing the ignition key right down will operate the dyname os @ starier. The headlamp is recessed into the fork cowling, and is fitted with a hwin-floment bub controlled by sme dipper Switch on the lef-hand hendlesers, ond so with @ por ing light, When the iantfon key ‘is in position 2, the forking light is switehed on, and in position 3 the head. famp. The ignition key. con be. vathdcawn, in either postion. The cap on te ignition switch is slidable, ond Shen Tis forned half-way Tt will Keep roin out of the ignition site, The hom, which is slvated under the headlamp, is connected #0 the batteries, in order to comply wih the reguoiions, wien require thar the horn shal be operative ven when the angine fs not running. The hor button wil Se"found on te ‘dipper switcr mentionea obove, The sparking plug fitted to the machine is © Bosch W190 MCS. All the famps run off 12-volt circuits. The batteries have o copacity of 10.omp. hr. at 12 valts. The rege light contains @ stop, lamp, which lights o then the feat bree fe ovate, ae Slop Light Swit Fan Aan is fled on the aya. Tis rua oon Speed and wil Supply fhe necesrery amount of cooking eErGnder ony conLliens, The of fs forced through ducts Sind cowlingy fo the eyticer ond the cylinder heed! The Primary Drive lengine-georbox) consists of @ pair of bevel gears, which transmit the power thraugh the clutch to the gearbox. The C1 is @ multi-plate clutch, comprising three outer steel plates and "Wwe imer fridion ploies. The necessary clutch pressure is produced by means of six radial compression Eprings. The eluich is oparaled by 0 Bowden coble con ifolled by a lever on the left-hand handleber. ‘The Gearbox The three-speed gearbox is builtin unit with the engine The geet pions sre. permonently engaged, and ore ipl tls oy eon” of ving in, Tho archenge mechanism is contraled by a twislerip on Weelihand hendlebors, enich is connacted wth the gearbox by @ palr of Bowden cables. Sapeed geben, ord: lich er thongs machenThe Secondary Drive (ecrbex — rear whee!) Power ig transmitted from the gearbox by means of a forsion ‘ber shaft fo the spiral bevel geers ond geor inions of the Intermediate gearbox. The casing fo! tis ‘belted fo the engine and gearbox unit. The recr Ino (ond the speedometer) is also flexibly driven, the trans. mission being mounted on a swinging arm, the bearings oF wich are'on the intermediate gearbox, and which 1s Supported by means of pare of helical compression spring placed underneath it these springs are erlosed ina Telescopic casing fo protect them from soray ond dit, The rear springing fs also domped, 0 hyerculc Shock abserbar Boing fted Behween ihe swinging arm fend o Frame mernber “ This forms the beckbone of the scooter, and so a tube with @ generous cross-section has been chosen for this duty, The various lugs and brackets welded to this frome, cand ‘such bolted-on body units as the floorboard and legshield, the centre section of the rear panelling, etc., ensure that the frame as a whole is very resistant to torsional siresses, The botiom link of the rear frame section is formed by the engine. Front Forks cre mounted in adjustable ball bearings in the steer heed on the frame, At the lower ends of the forks cre fifted Two pivoted fines, which cary the front wheel, 6Each link is ecuipped with @ compression spring bearing ‘against an anchorage in the front forks. luich Dipper swt iver hom button Honcbroke lever Th differ from the conventional tubular handlebars in that they are of U-section, open at the bottom. As o result cll the contrat cables ‘can be located out of sight 6 The following controls are situated on the handlebars: Left-hond-side: Goar-change twistgrip with clutch lever, dipper switch with horn button, Right-hand side: Throtile twistorip. Hane-brake lever. Both the saddle and the pillion seat ore pivoted saddles. A stronger spring can be fitted if @ heavy person is to bbe carried. The Whee! ‘re equipped with ball becrings, ond ore interchangecble. They take 400-8 tyres, and ore equipped with split, flat base 2.45-8 DIN 7824 rims. Brakes The front and recr brakes are both of the iniemel ‘expanding type, The front brake is actuated by meons ‘of the hand lever on the right-hand side of the hand lebars, and the rear brake by means of a pedal fitted in on easily accessible manner by the right foot rest. w‘To Support ‘he scooter, the prop. stand {ited on the lef-hand side SF the mete singed down, The eente stond is sed only to support the machine when removing a wheel, ffrto Take the weight off the Tyres when the machine is eid‘ For the winter. 2 either side of the rear of the machine, end fe held by mecns of lps fitted. with rubber pods, ‘hese ponels not only give the scooter a. most alfrac five appearence, But also keep crt and dust away from the engine’ the fuel tank, and the tool compart ‘ment, Ports at front ond rear of these side panels perm fhe ‘cit necessary for cooling the engine to ener. To Temove @ side penal push down the locking lever, rise the rear of the panel, ond then it it off The Instrument Panel On thisvere mounieg the speedometer, complet, with jl supply warning light ond ignition warning, ight, knob fer Geluating the. combined Hekler and ehokeside linkage, ond the starting, lighting, ond ignition switch ‘To. endble the instrument-panel Bulbs 10, be replaced, tnd’ to check the’ vartous connections, the insicument panel fs fited with id. Ris Is kept closed by means OF'a lock, the Key for which iz the. some os for the Thiet proot steeringhead lock 8 ‘The equipment also includes: The sofety hook for a hand ‘bag or similar iter; the thief-proof lock on the steering head, which is fitted at the front in the fork cowling, belweon the headlamp ond the horn; the spare whool: the luggage carrier; ond finally the tool kit in its box.RIDING INSTRUCTIONS 1 Engine Lubricat Even if you consider that you aro absolutely conversant with the proper method of running.in a now motor vehic- is postible that the following section may contain ing, which is new to you, But if you are @ novice, the following instructions are of vital importance, In out experience it is always advisable to read this through first. Soe alse the section on p- 26. When descending long hills”. Important wh ing Up with Petrol IF no oil is added to the petrol, the piston will seize in the cylinder, and this then hos'to be repaired, Always therefore add engine oil to the petrol” in the following proportions: While running-in, or if the engine | is heavily loaded, e.g. it it Used in mountainous country otherwise, 1:25 In other words use 1pint of oil to 24 or 3 gallons of petral 1:20 Changing ‘After the first 300 miles Unscrew the upper end lower pligst* on the gearbox ond doin off the ol, which Gontains sludge tormed from the metci porticés ‘worn off the vorloss parts os they bed down, while the engine fz worm, Then cal fresh oil fo the level oF the bottom of ihe fn the gearbox. Capecity of gearbox about 0. litres (05 pint) eee » In Speeds Do not run at full throttle for the first 600 miles On the other hand, do not er'Too much on ig side of caution by keeping down to too lowra speed. So far os possible Keep fos level rocd, or af lect one wiih only moderate, gradients, und moke full use of your gears end throttle, Change down in good time wher going up hil to Bravent The engine Speed dropping tse mc, otherwise the engine may suffer damage Let the engine fev freely, but don't care it. Don't carry o pillion pos. Sean dng the Tumingin period. . ie following speeds shovid be taken as a quid In Borork avoritereste bewees Band 0 keine (Gao 15 mkt tn Be gear afeincte belwean'*” 28 ond ae emir (4 ona 25 met] th fon Gor sicirale between, 36 Ord 35 Skt (5) cog 37 mod After line firs! few hundred ‘miles have been covered, 4% full speed cen” occasionally be exceeced! for short periods Yo check the engine power After the running-in petiad lover the jet neesle one groo- va fo reduce fuel consumption. And One More P After tho frst 300 miles and 600 miles Moke sre that allt nuts er bolls ore fight, ht. ening up where necessary. The principdl Tiers cre the ‘hel rots, the hondiebor ane slancer connections, Ihe Gylinger head bo's (eniy with engine cole) and the Term nls in the headlamp, Every 1298 lbs for ihert Bats hoiing the engine te throne (othe to in Sock on each a tethep oad bats BM Cap eet op ele Secs apt on rolightelad saree Preparing the Scooter for Use Charge the Batteries" The batteries are rormelly supplied uncharged. Since special instructions have To be followed when charging Baieres, especialy storjer batteries, it Ye best over ‘tus this worke fo your NSU Decler, or 10 a battery ser- vice siciion where there ie the necessary special equip: ment. nt * See oie instructions on page 42 2The two batteries, which are connectod in series, should bbe removed in the following manner: Unscrew the knurled bolt recessed into the top of the bltery caze lis, open the id, and iffitcleor. Disconnect The sovth lead! from. the frame, Lift yp the clip on one of the batigries, and lift it out of the cose complete wilh is Cartier, Push doven the top of the metal strap and unhook iis lower end. Toke ‘off the baltery lid, ond disconnect both leads. Then take out the otter botiery in the same way. Note: When removing the battery, disconnect the — lead first, When replacing the battery, fit the -} lead first. Cheek the Tyre Pressures Do nut run with the tyres either too hard or tos, soft. Ii‘ig best to Keep the tyres at the pressures which ex: perience hat shown to be the most suitable, namel; 08 to 0.9 atm 1. em for one person, 2-225 alma for two persons © The fuel fone has o copecity of7 lees (1% Imp. gallon) “The fills caps situated under the hinged lid placed on the ‘ighi-hond side of the paneling between the rider's sadiale and the pilion sect ck the Bael Supply Never Fill Up with Petrol only If there is no oil added to the fuel, the piston will seize in the cylinder, and straight eway’ you are landed with your first repcir bill. Always, therefore, add c good engine oilt to the fuel Always Mix the Petrol and Oil in the Right Proportions ‘See .Important when filing yp with petrol” on page 20. IF the scooter has been standing idle for some hours or hhas been left overnight, the petroloil mixture in the tonk should be well shaken up by taking hold of the handle- bars and saddle and pushing the scooter to and fro for ‘c number of times before the fuel tap is opened. See page 62 2Prepa Open the Fuel Tap 1g inthe tonk drops 0 1 fitro (1% pints) the fuel-supaly warning lamp en the instrument pene lights up i, Fuel top opened Foal top closed Now study carefully and note the effect the various posi fions of the starter knob have on the choke slide ond the carburettor: — Starter knob pulled right out: The choke slide closes first, ond then the fickler is depressed. mu Starter knob % out: The tickler is released, but the choke slide remains closed (sterting position). Stertr knob ou: The choke side i half opened (Sor ing poston #42 weofhr and wih mage Starter knob pushed in: The choke slide is opened, Make certain that tho gearbox Is In ngutral. If nocess- ‘ory. pull in the clutch lever and turn the ‘ange: fwistgrip ‘to "O", rocking the ‘Scooter 10 and fro 10 release the gears. BThe Throttle Twistgrip should be cbout to 1/5 open. Start th Pull out the starter knob, and in worm weather, push it back immediately into the %é-open position in ofder not fo flood ihe carburelioy Pasi the ignition key right down in the switch and hold it there. The ignition war- ning lamp will ight up as-qi sign thai the batteries ore ‘supplying current. Nover Try to stort the engine by jabb- Ing the Starter ‘a number of times in quick succession. IF the engine fails to start after the starter has been turing fr for 419 3 seconds, release the ignition key, gd pevie for 9 sort wife: Ik winter, extend ths pauls fo cbout 30 seconds, since the battery cannot sp fn Unlimited amount of current Py The mount of current available ig reduced consider- ably in cold weather, and so it is advisable not to keep the scooter in too cold 6 place. If the engine starts (the igrition warning lemp goes out) but stops again, close the choke slide, and keep it closed Unt fhe engine hes reached its preper operating tem: perature ond is running normally. If the tickler has been depressed too much, try to stort the engine with the throttle twistgrip fully open. This will introduce extra air info the excess OF fuel, and 50 produce @ suitable mixture. % If the sparking plug is wet, take it out and dry it, Close the fuel top. furn the enighe ver a few limes, and then replace tho. sparking plug. Do not open the fuel tap ‘again unl the engine hat started. If the batteries ore run down, stort the engine by push- ing the scooter with 2nd gear engaged. 1f, however, the batteries have been removed, connect the toring leet res tthe biek Teas aoced Fo terminal 20° 1f the engine stil foils to start after § have been made, find ond rectly the fo ing again. 6 ottompts before try Riding Starting oft Pall back the clutch lever and engoge bottom gear {gear ‘indicator Shows "I°). Open he troste. (urn the {Sterio slowly, mot violent), ond at the same. time ‘elocte the cinch ‘lave, slowly ond evenly” 20 shot the Scooter moves off witout @ fre When Riding Aciust the speed by altering the postion of the throttle {wisior. Changing Up At @ speed of obout 20 kmh (12 mph), close the throttle, dectuteh, change into 2nd gear, apen the throttle, cond ot the same time let the clutch in carafully and Steadily. At a speed of about 35 km/h (22 mph) change Up into top gear in the some way. When on the move, the process of changing gear, in cluding declitching ond adjusting ‘the throttle, must be Carried out ropidly. You will soon le able to do this without cifically. When Changing Down ‘Again dedluteh first, but do not close the thrattle com- pletely, to enable the engine speed fo increases; this will aenable the lower gear to be engaged without a jerk. Ghenge dovin in goed fime when about fo,clmb o steep ile" so" et the eluteh sip" instead of changing down ond 30 cvord stalling the engine when cimoina a fill, is cbsolvtely wrong, ond will Ieod fo dutch tovble. When Braking copaly the brakes carefully, ond not too violently. At the SERe fine close the throftie twistgrs. Do no! use the Front broke on wet or slippery bende (fallen leaves) Bouin hls ether use both brakes together, of the front tand roar brokes elternately, cepending on the steepness, When Descending Long Hills dlon't keep the throttle closed all the time, but rev up vary now ond again, Te reason for this ies flows {rl Be remembered thot when the ‘hrotile of @ twor sroke engine is opened the mixture. drawn ino the en Gine includes oil for lubricating the pision cad the bea Fings. Bu this no longer the case when The engine Is Used as a broke down hls th the tote closed In hig fase the engine Is 70 all intents and purposes, supple Sei no olla ll The iraveaole reals they the piston Will seze in the cylinder ond the eylinder will be Game 0d, this con clso result in o serious accideat. Never, therefore, cescend a long hill with the thrtile closed all the fine, but tev the engine up very fow fondred’ yards 10" Supply ‘lubricating ol 10 the roving ports: Use the brakes ond clutch of nacessery lo keep Your speed down when you do this. Iris of course pe: Tle Yo inereare the brodng effect of the engine by changing devin fo @ lower gear, but special eare fs ne edwiher this fs done with g two-stroke engine, since the engine then runs ef a mich higher speed, ond so requires sete cose he egg therefore ave fo Se speeded up more frequently than when running in top Gece lower gears should therefore be used fo assist re brakes only when descending very stoop hilt. 2 Stopping During temporary stops, such os of road junctions or other Tralfe obsteces, den? keep the engine running in goat sik ihe cbich ot but engage cost, end then Shot S4F again in bottom gear. Ab the End of the Journe: don't ty to stop withthe engine in gear, stling the en fine by'meons of the brokes: Instecd tnrotle dawn, = Gove feviral, and then usa the brokes ae necessary To Sop the machine Switching Off the Ignition ‘Withdraw the ignition key, or the electrical system will be damaged: Close the ‘Cap to keep rain out of the Always close the fuel tap at the end of each journey and when parking. To Par hinge down the prop siand, and lean the scooter over folie left Te Teck tum the handlebars fully Yo the lft. IF the scooter is not to be used for any length of time, it is advisable to use Up the petrol ond oil supply in the carburettor by running the engine in neutral gear in order fo prevent the jet becoming oiled up. Before using the scooter again, mix the petrol and oll in the tank thor. Sughly by’ swaying the Scooter To and iro as described 2»Pos Lights ewitched io oa If the brakes no longer grip properly, fon the front wheel: Loosen the lock nut, ond adjust the brake cable by means of the adjuster on the hand-brake lever until the front wheel just spins freely, but the brake starts to pulled. Tighten fon the back wheel: Adjustment is affected by meons of the furnbuckle in the rear broke rod. Tighten the nuts up ‘again when adjustment is complete. TUM gg Senate: aChanging Wheels To change the wheels, raise the scooter on its centre Mond. This is done by holding the stand down with the Fool, ond pulling the scooter upwards and backwards by the flder’s saddle — not by the handle on the pillion seat. To Remove the Front Wheel: Loosen the lock nut, and Tack bock the brake-cable adjuster until the brake cable an be removed from the cam lever ond the cable ancho Fage. Then unscrew the two axle nuts sufficiently For the (washers which are recessed in the pivoted links to be- Sime clear, and drop the wheel gut. When the wheel has Been removed, unscrew the five domed nuts and washers fond take off the hub. ‘When Replacing the Wheel Tighten the five domed nuts securing the hub to the whoa! nd donot forge! to Tit spring washers under ther, When fitling the wheel in tha front forks, moke certain That the anchorage plate for the brake back plate fils prenerl ote er ot the ah-hone pucted I nally screw the oxie nuts up tightly. Make certain that the woshers fit in the recesses on the pivoted links. ‘To Remove the Rear Whesl: Press down the locking pin holding the left-hand side panel; raise the rear of the ppanel, and lift it off. To remove the wheel, unscrew the five domed nuts and remove the washers. When Replacing the Wheel Tighton the five domed nuts securely, and do not forget to fit the spring washers under them. 33To Remave the Spare Wheel Changing Tyres First unscrew the front of the luggage carrier and hinge To remove « tyre from the rim, fist let all the air out of it back, The spare wheel can then be removed after un the tyre, ond then remove the ten hexagonal nuts and screwing the upper domed nut holding the wheel cise ond their washers. the three domed nuts holding tha wheel to its bracket.MAL TENANCE NGINE Adjusting the Cinch erating the clutch else releases the locking device on Re Gearatenue. separ, Teneke coats Se EP cables on be usted Gs necessary, the colch lever ‘must be 10 mm (04 in) clear of the clutch cover plate, iF acessny tds by means of Ihe adsense Tighten the lock nut ‘up well. Replace protection cover. Ti ditch over nut Nevers gear rain eye 005 in} measured ot the point of attachment of te cuten Uf there is too much play the clutch will not disen ‘goge properly. IF there is not enough play the clutch wal si The adjuster fer the clutch cable is sityated undernecth tne right-hand foot bsord. Tighten the leck nut up well, SS 10m Adjust the cable for the geor-chonge segment locking de- ‘ice so thot IF has.a ploy of about | mmm 0.04 in wt Ihe utch lever is pulled beck. Take off gearchange metho nism housing cover. Tighten the lock nut up wel 38 ‘The Carburetor is @ Bing single-lever carburettor. It is not advisable to modity the standard carhurottor seltings in any way. The cable adjuster is situated on the carburettor. ity filer gouze in the tap or a blocked petrol pipe fewe Ihe tine affest os eee 1, mall jet bi rough the peal pipe with tre fuel top open ond the ale lean sven te lefty Atvhe Rest spooriny flush out the fon end ie top complete with fifer gauze wiih poll, and cleo the main filer cad ils gauze. The est standard of cleonliness should. be ‘maintained when fling up the tank with fel. 3vetrical Equipment oot rn in ei ellen ee ml god on ow acting ed a eo re catia ar oe ie eos emg oe ron ten Sep ii a Pots Besta i ene ee og fea ge al ‘The gap at the contact-breaker points should be between 0.85 and 0.4 rom (0014 and 0016 in} when the contacts fe fly open ig. wien the arm is on the highest point (of the Cam, Check this gap by means of a clean fester ‘gouge which is free from grease. If cdjustment is necessary (worn contacts) loosen the bolt holding the contact bracket, ond turn the odjusting bolt carefully in the required direction until the correct ‘gop is obteined. Then iighlen up bolt helding the brecket goin. The adjustment can be carried out by wor ‘rough the aval hale in the fan. Adjusting bol. Contact bracket Breakes Bane Ignition Yokes placo 4.25 mm (0.17 in) before TDC, and must be set with the flyweight of the advance and retard mechanism fully extended. To check or aust the ign tion timing it is advisable to remove the cylinder head. (P however measurements are made through the spork- ing-plug hole, @ normal commercial type of gouge will be required. When the ignition is correctly timed, the com will be just ‘on the point of separating tho points when the piston is in the position specified. (Flyweight fully extended). A test lamp of the seme vollage as the betteries, con. nected betwean terminal 1 on the ignition coil and earth, ‘will light Up of the instont the contact-breaker points ‘open. IF the points are in good condition, itis also pos- sible fo determine the point of ignition with the aid-of a Clean end grease-free strip of metal, 003 mm (0.0012 in) “hice, which 2on just be drawn out from between the con: tacts os they open, Da nat use poper. IF the ignition tim- ing is not correct, the contact-breaker base plate will have to be displaced in the required direction. To do this slacken off bath the bolts holding it by #4 fo 1 turn, ‘and move the base plate by topping lightly @ screwdri= ver held against it. After recightening the bolts holding the bose plate check the timing in the manner described above. To prevent the fibre eam en-the contact breaker running dry, smear a. I-mm (0.04in) thick layer of high melting point grease (pour point 150—160"C = 300—320° F) on the felt pad, every 10,000 km (6000 miles) ond rub it in ‘well, Affer this distance has been covered it is also nk cessary to have the commutator and the carbon brushes inspected, ond this work should be entrusted to your desler. aSparking plug: Gop at electrodes should be 0.6 10 0.7 mm (0.024 to 0.028 in}. Check with a feeler gauge. Use o Bosch W190 M 11S of a similar suitable plug made by a well- known manufacturer when fitting @ new plug. Screw the sparking plug in ¢ few turns by hand first, ond then tigh- ton up with the spanner, De not forgot the sealing washer. In the headlamp ore fit- ted a Vovalt 25)5-wort twinfilament bulb and © T2welt Zwart bulb for tho parking light. Whon fitting @ new bulb make bsolutaly certain that is completely free from oll ond grease, since of herwise the reflector will become dimmed by the cil vapours that condense on it. Apiece of paper or a clean rag should therefore be used for halding the bulb, On rne cccount should the headlamp reflector be cleaned, otherwise it will tomish ond considerably reduce ligh- fing efficiency. a ‘The roar lamp bulb is rated at 12 volts, 3 watts, end that for the stop light ct 15 watts, witle the Ignition ‘warning light and the speedometer illumination bulbs cre eoch rated af 2 watts. The fuel warning light is fitted Vain a2 volt L2.wett bulb, The Batt hove 9 capacity of 10 cmp. hr. ot 12 volts. Note: When removing fhe batty, disconnect the ~ lead fist, When Teplacing the battery, fi thei lead first. Iie impor font that ol constant ‘check be! kept on the ed Tevel Use eistted water only. Water that fos been boiled is nol solsfoctory, since t conteins meralie end cigrde Fosidves when may harm the battery. See that there a good ecrth conection. The termifals must be kept cigan‘ond rth end eka oyna fo eat than wit om occ grease, preferobly a pecil boiery grease, i9 order t0 prevent corresion. Also. apply ts Grease’ to the thcood oF ine knurled bolt taoesied ine Heid of she battery cose ‘See cles battery monvfeclrers iniucions 4The most important points are briefly as follows: — 1 if the acid level is too low, the top of the plates will be ineffective, which is especially disadvantageous when staring The dey parton ofthe plots supa and becomes permanently useless. If the aeld level oo high there is the donger thot the acid wil be. thrown out of the vent eperings, ond will damage the metal forming the battery case, ond possibly even the fider's clothing. 2. Protect the batteries against oil, grease, petrol, ond paraffin. They should be washed with water only. 3. More frequent attention will be required i" the machine is used clot after dark ar in fog, and if edditional current consumers to those provided as standard are Kp} switched a7 ifthe Hine. The same gppies if the machine Is used for frequent short runs at low speeds, ‘and hence js storied freauently, especially when the lights ore also vied, 4, Ifthe machine is not used for any length of time or is laid. up for the winter, chede the acid level and state of charge of the batteries, have them fully chorged, fond then put them on charge agein every 6-8 weeks. Wis advisable to store the batteries n'a cool place + Both ee Ronnecton eetrical R Wy WA For insiructions on the removal of the batteries from the machine, see poge 22, “4sting the Headla For road-safely reasons, the boundary between the low: Crillumineted zone end the upper dork zone must be St least 9 em @ in) beneath the centre of the headlamp St @ distance of 5 metres (16 f!) when the headlamp beam is dipped. gee We To adjust the position of the headlamp, loosen both the upper and the lower slotted screws en the headlamp rim. CARE OF THE MAC Cleaning the Ma Only if you look after your “PRIMA” properly, i © youruse 'f conesiyr clean it regucrly, and hori tt Waccordance, with these insintonsy "an you rely en four machine belng clays ready tot instant vse. {Siprotect ihe polshed end celulssed ports, always vse a°sbit ily cloth for wiping the maching devin, even itt fb only diely. Any. dried mud should fist be! softened, Gnd age Tis of di clad otto The gemers wih Sweden silky Snaly wash fhe meehine down. Bek be Satoful way using whose, ond Kean the siream of water Guay fren the hubs One the carbetion weer pene. {tues fo the hubs, tne Boorings wil vst, wale water inilpe corburettos (or the fool tonk) wil maka Ihe eraine Gaitulrto stort or wil couse ft 0 stop while under wey. Any very grecsy pols should’ be cleaned down with pareffn or washing solvent, ond nstwih pets which Efccks the eliiose, Also clways wise oft at once any patrol plied when fing the tank Routine Lubrication {team the lubrication points or nipples before oling oF rearing. Bering Bad weather lubricate the running gear ond the conlals front springing, brake levers, plvol pins In roar Springing, foot-broke Inkage ete] more Frequently than Seectied! fe squeak develops, grease at once, of course Engine Lubrlcation is with engine ot, which should be well mixed with the peel before ths & poured info the Fonk. Tho proper of oto perl wie rring in of the jhe f heavily loaded, e.g. in mountainous country, os ‘should be 1:20; ‘otherRoutine Lubrication* and _Inspection* Tae omen | | |r ven | mile Cover plate (starter side) x Air Filter | Control cable for the tickler operating — x cn the choke slide % x ™ Levers ond joints 5g “ 5 | Front wheel springing x se | Rear wheel springing 7 se Control cables x je | Cilechonge in the gearsox lx x Rear wheel swinging arm x Se | Reoe whee! Tronsmission x se | Front whet Hb { Gear-change, and thrattle twist grips, Lobriceting Pad ore to have this work coried out by @ meter | 8 a7 a 8 ”Every 600 miles Every 600 miles The Cable for the Choke ond Ticklor should be oiled with very thin eil, end where the coble enters the adjustment screw, some grease should be pressed inEvery 1200 miles Every 1200 miles Levers and Joints Lubricate foot-brake pedal and linkage fork with cil Apply grease", to the saddle springs end saddle ball jeints dnd oil to the front saddle bearing and locking Bins for the side penelling.Every 1200 miles Apply @ few drops of cil to the front-broke comlever ond the is joinis on the handbrake ond clutch contral levers, Front wheel springing Apply 2 or 3 shots of grease* to the grease nipples on the’ Bearings for both ‘ont fork pivots, including the front springs beorings. Every 1200 miles Rear Wheel Springing Force grease* into both the front and the rear bearings {also the rearlrake lever bearing), ond also into the ripple on the spring casing; grease the latter point as soon at any noite is heard. Control Cables Disconnect the cables, ond allow a mixture of oil ond petrol to drip into the upper end of the casing until it ‘emerges at the bottom, Also grease the ends of the Replace butnes In pivoted links Remove ond fit font musouard Remove and fit bumper Remove and ft fork owing x S ees Ex ¥ RE REE (passiby 202) possibly 200) me 1, FT wit noua ve, ity alte Fo, Foe orb Fs N50, Fs on, eae Fo Fee FOveae Foe see EE ae FREES Ta Os) P10" Remore end fit handlebars ae fF A1 Rerove ond fit hondabor vend F 4 Remove end fit ipeecemater erove ied i pesdemeter FS Remove ond 1 ote Roperg on fi ofoehone Fa Ramon it niin or © 8 Ramos Ona fi tea wingre 50 Remove’ and fit ciech able F sa Remove ged fit able for peor Skange. lacking ‘mechan nt 2 Remove andr hottie eile FF 5L Remove ond ft goarchange cable na Fs Here and sae Ierrvenier ender epércing FB kemove ond ft frome F 41 amore end fi ta cant F & Remove ond ¥ recrdmudgvard FG kepore ind fe tecr xl [scan of paneling 3 F 4S Remve ond Tl tee! sock F 67 Remove and i rear sprincing SoeE RR BORE oe #40, 610 Feemen Enens i % 65TRE Asahional wea] Fault Tracing * ‘he enping fits tg stort, NO potrl floods out whee the carberator sea baal % Me SP Re asratea, 70 Remove and ft eehout yrtem | 4 Fuel top cored or racers spply ese. FA Remove ond pilin soede = % Fee! tank empty FM Remove and ft Socal « = & Feel top oF petal pipe Blocked up F72 Romove and ft roo ond | - “ Floot duploced on fast neale(aplee in groove A, Eimer cretiat ad rt % Thy engine fos te stort. Petro! floods eut when the corburettor F 76 Remove and ft fool bor | | i = Beka Fo} Romove and ft fuel ont” | 76 | dt Backed. Frain bodies test be removed ay with brat F at Remove and ft fel top ond Wioter in the carburetor ie se - | hong ocr epee 8 Rapve ad iy tale ene Chote ise wrorgy opera’ (lose only Ineo wee fond wees | % Highton Ined fucowered or Ison Indeten defdive, Tk F 99 Remove end BY Togmhld «Ve | FIQETS,E%S tetdepresned to mach so et spauing plug ts wel (Unscrew pls FAL Remove. gro i fgets, le. RB | ay lose Wai top. Open tala fy. Tum engirw over © munber ot foment * = % Times. Bry plug ond screw tt base and stor engine wit onl op tlorad Be nol open isl lap wil avin i ring ae Sparking pl clad up, sooled apy or slecrodes bridged by 2 fo PE cs lege i Pe scoot tod lesa aw | mew | au Teta £8 Shine Sieg othe ca Eo Reeves ae uoaae - « CContoctsoreaker points oiled vy Git, et wor. tear light % - % unas atege rode iseonen ‘ond rallector he eu % | Air supply incorrect (eorbureHer mounting lo ca teetedimme if] 2 | iS cone eee das as E16 fmove ora starlng oh 1 Remove ehdfiineroment panel % | 30,61 , Sporting pug fouty or of wrong type 4 = * Conactbrecker pols sled up, ity, oF worn “lo case of doubt ploase seek the advice oF Your NSUDeole.duly bat, The engine doesnot pall properly or becom luted slipping (ods. robes elected too tity (binding) Choke slide ineorecty operated (open if Is closes. tie fiter diy. ‘Kit subply ingreect lcarbyettor mounting loot bem Feet needa or ferlr sheeng Penal mixure Incotet. ieona sperkng poo Heavy carbon depots in exhaust pot Feouy eatbon deporte stoking silencer Paton sing atckng In groove, worn, oF broken, IMcclanical felt in power Irensnision wheels and bearings The onglee stops Reserve fuel weed Fst soppy exeuste. High-tenron Iecd connected. Sporting plug fauly or beads of meta deposited on pl Conte breaker sina ghts fot 10 go on Sulb burt ov Foulty eorh contact fomected, of oxidise, station warn off Teode Incorrect fuels, Obstacted fool supply. Igorect carburettor settings (Copesteter general in pose cancion Entry of oxcos air throvay (Rowy Tein. Engine gases not seaing propery. Carbon pent [Rigs ports and exhoust syst. fron timing insert igriian ‘olen in boos conden machaically or aleciialy. Faulty aperetion St ne thats fnsigrip or he choke alse Foulty use of gear Dex Weerin the power wansrisvon,Grokes in poor Conition toasted 100 ighly ena heretore bin) a