Puch Maxi Owners Manual

8/13/2019 Puch Maxi Owners Manual

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A SERI L NUMBER LOC TION

The engine number is stamped on top of the right crankcasehalf.

1 Speed Automatic

2 Speed AutomaticThe specification plate is secured to the right side o the frame.


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IMPORTANTWrite down yourkey-number at once.This saves timemoney andannoyance if thekeys are lost.

The frame serial number is stamped on the right side of theframe just beneath the seat post.

My key number is - - - _


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B OPER TING CONTROLSThe positions of the controls are shown in the enclosed technicaldata sheet.Following some operating controls described in detail:Locking and unlocking your mopedTo 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 yourPU H dealer.

Fuel tank filler capTo open turn filler cap counter clockwise .


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Fuel valveThe 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 positionshould give you adequate range to get you to a filling station.Always turn the fuel valve to the Off position when the mopedis not in use.

arburetor1 Primer (see starting engine on page 17).2 The choke is operated by depressing the black rod extendingthrough the left engine cover.


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irpump and toolsThr 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 leversThe brake control levers are mounted on the handlebar.Left 1) lever controls the rear wheel brake.Right 2) lever controls the front wheel brake.

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Starting leverThe starting lever is located on the left side of the handlebar andis used for startingPlease refere to operating procedure on page 7

ight and horn switchThis combination switch is located on the left side of thehandlebar Thumb lever on the end of the switch activates thelights The small push button operates the horn


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Engine stop switchThis two position thumb switch is located on the right side of thehandlebar. The center position marked RUN is used to startand run the engine. The lower positions are marked OFF andare used to interrupt the ignition wh ich stops the engine.

C TIRE PRESSURERecommended tire pressureFront 5 PSIRear 32 PSI


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1-SPEED AUTOMATIC

D OIL GAS/OIL MIXTUREChecking transmission oil levelThe 1-speed automatic has an oil le,el screw 1 ), which alsoserves as the filler plug, located on the clutch cover. The drainplug (2) is located on the lower engine case half.53 4 fl. oz. (170 cc) of ATF TYPE F is used for refill.

The 2-speed automatic has an oil level screw (3) located on theclutch cover. The filler hole (4) is through the top of the rightcrankcase half. The drain plug (5) is located on the lower portionof the right crankcase half. .91 2 fl. oz. (280 cc) of T .TYPE F is used for refill .

CAUTIONThe moped must be upright when filling ATF. Do not overfill. Leaveoil level control screw removed until excessive ATF drains off.ATF change after the first 300 miles of operation is highly recom


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Filling up with two stroke mixtureAll MAXI engines must be run with a gas/oil mixture regular gas).The recommended mixing ratio is 50 : 1 when using special MaxiMix two stroke moped oil. If another oil is used please refer to thefuel mixing chart.NOTE: DO NOT USE UNLE DED G SOLINEPUGH MAXI MIX50 : 1 OIL MIXING TABLETo 5 gallons gasoline add 12 fl. oz. 379 cc) oilTo 1 gallon gasoline add 2.4 fl. oz. 76 cc) oilTo 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 MAXIMIX oil, 50 : 1 ratio. However as an emergency measure,a regular 2 stroke oil can be mixed in a 25 : 1 ratio as shownbelow.25 : 1 OIL MIXING TABLE REGULAR TWO STROKE OIL)To 5 gallons of gasoline add 24 fl. oz. 757 cc) oilTo 1 gallon of gasoline add 4,8 fl. oz. 151 cc) oil

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W RNING

Using cup to measure oil for gas oil mixing ratioWhen measuring oil for the gas/o:l mixture, use one cupful ofMaxi Mix to one quart of regular gas.NOTE: When using other grades of 2 stroke oil , please refer toprevious page.

NEVER REFUEL WITH THE ENGINE RUNNINGO NOT SMOKE OR ALLOW OPEN FLAMES OR SPARKS

IN THE AREA, WHERE YOUR MOPED IS REFUELEDAND/OR WHERE GASOLINE IS STORED


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E OPERATING INSTRUCTION1. Prop the moped on its stand.2. Unlock fork .3. Turn fuel valve to the ON position.4. Be sure that th engine stop switch is in the RUN position.5 If engine is cold depress the choke and depress the primerbutton on the carburetor until fuel drips from carburetor.

CAUTION After completing step 5 do not open the throttlecontrol as this will deactivate the choke. After the enginehas started and warming up open throttle gently to the fullposition briefly. This will disengage choke. Avoid ratingengine.6. Keep. both hands on the handlebar with the weight of themoped centered on the front wheel. Apply the front brake andfully depress the starting lever located on the left side of thehandlebar. Pos ition the pedal approx. parallel to the chain

guard.While holding the starter lever push the pedal to startengine.7. Alternate starting method:The moped may also be started by pedalling as a bicycle.When momentum has been gained pull the start lever andgently open the throttle . Release the start lever after the

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ThrottleThe speed of the moped is controlled with a twist grip on theright side o the handlebar. To accelerate twist the throttle towardsyou; to decelerate release slowly.Note:Depending on engine RPM clutch will engage or disengageautomatically on the one speed model .In addition shifting into or from 2. gear depending on engineRPM and road speed will occur automatically on the two speedmode .

rakingTo slow down release the throttle control and apply equal pullto both brake levers. Application of both brakes at the same timeis essential to prevent premature brake wear and /or loss ofvehicle control.

CAUTION e alert when riding on wet or sandy surfaces . Lossof friction between tire and road can occur under these conditions .e careful when braking turning or accelerating under adverse


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To stop and parkRelease the throttle and simultaneously apply both brakesto stop.Turn off engine with stop switch.Close fuel valveRest moped on stand and lock.

ecuring your mopedSee page 9A high security locking device is recommended . See your PUGH

dealer for advice.

W RNINGAfter the engine has been run , the exhaust pipe and mufflerwill become hot, avoid contact with them.

C UTIONTwo lenghts of screws are used to secure the chain guards .Ensure that only the shorter version is used on the left rearbracket. Longer screw will protrude too far through the bracket


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F RIDING INSTRU TION1 It is suggested to wear bright clothing utilize eye protectionand proper shoes or boots when riding your moped.2 Wearing a helmet is optional in most areas. See your PUGHdealer for advise.3. Be sure to switch on headlight at low visibility and/or whererequired by law.4. The moped is designed to carry ONE person . Do not carry

a passenger or very heavy cargo. Approved PUGH saddlebags and baskets are available through your dealer.5. Obey all traffic regulations. Use hand s1gnals when turning orchanging lanes. Please respect property of others and ridecarefully. Keep your feet on the pedals at all times. Keep thepedals level especially on turns.6. After reaching maximum speed reduce the throttle openingto 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


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G TROU LE SHOOTING

Engine will not start or stops running

Cause

1. Fuel valve closed2 Fuel tank empty3 Stop switch in Off position4. Spark plug is fouled5 Spark plug defective

6. Ignition cable has worked loosefrom spark plug

7 Engine is too cold8 Engine is flooded9 Fuel valve is clogged or main

Remedy

Open fuel valve or switch valve to reservepositionSwitch valve to reserve or refill tank withgas/oil mixtureSwitch to RUN positionClean spark plug or replaceReplaceNote: Spark plug gap. 16 .020 in (0.4 - 0,5)Reconnect it to spark plugApply chokeClean spark plugHave it cleaned at your Puch dealer


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ause1 Choke working all the time2 Exhaust clogged3 Spark plug defective or fouled4 Clutch slips5 Air filter is clogged6 Fuel mixture incorrect

Poor Performance

RemedyDisengage it by opening throttle fullyHave dealer clean exhaustClean or replace itSee your Puch dealerClean air filterDrain tank and refuel with correct mixtureNote: see mixture chart

Please refer all questions you may habe about yourPuch to your authorized Puch dealer. He is trained andqualified to properly service your machine and can bestadvise you on its maintenance and care.

H OWNER M INTEN NCE


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Spark plugTo check if plug is functioning properly, proceed as follows :

Disconnect plug wire from plugUnscrew plugReconnect plug wire to plug and groundsame on cylinder headW RNING ENSURE THAT NO FUEL IS ONW RNING ENGINE AND/OR FLOORW RNING BEFORE PROCEDINGContinue as if starting engine and check fora strong blue spark at electrodeIf no spark, clean or replace spark plugNote: Gap .016- .020 in.0.4- 0.5 mm)

Recommended spark plugs

BoschNGK1 HP AIIW 10 A W 95 T 1B-4HChampion L 90

Alu. chrome1 5 HP cylinderW 8 A W 145 T 1B-5HSL 88 A

Hi torque1 5 HP- cylinderW 7 A W 175 T 18 6 H or 8 6 HSL 86

2 HP - AIIW 7 A W 175 T 1B-6 H or B-6 HSL 86

3

hains


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Engine drive-and pedal chain should be kept clean. Every fewhundred 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 thedrive chain should be 3 4 .To adjust chains, loosen the axle nuts and tighten or loosen theadjuster nuts. Once chains are properly adjusted, tighten the axlenuts. Make sure that wheel is properly aligned.

f pedal chain tensioner catches or travels roughly as pedals areoperated, realign tensioner so chain travels smoothly.

NOTEAlways keep brake cables properly adjusted and lubricated toensure safe riding. The play in the brake levers should notexceed 1 after adjustment.

I SUGGESTED MAINTENANCE Frequency


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AND LUBRICATION CHARTA regular maintenance and lubricationschedule wi ll help to ensure a long usefullife for you r moped. Please refer to themileage and lubrication chart for de tailedinformation.

NOTE: Above milage schedule applies tomoped used on dry paved surface.If used in we t, muddy or sandyarea maintenance intervals shouldbe more frequent.Always check controls and lightsbefore using your moped.

First Every300 miles miles0 0 00 0 0( )

w u> a:w/)0w zw::::0 wa:

I

00CXl

II

0 00 0 OPERATIONS TO PERFORM


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J CONSUMER INFORMATION

CONSUMER INFORMATIONStopping Distance

Vehicle minimum stopping Distance on dry groundThis figure indicates braking performance that can be met or exceeded by the vehicles to which it applies , without lockingthe wheels, under maximum condition of loading. The information presented represents results obtainable by akilleddrivers under controlied road and vehicle conditions and the information may not be correct under other conditionsDescription of vehicles to which this table applies: MAXI

Maximum load

10

17

Fully Operational Service Brake

1 hp28

20 30

1.5hp38

40

2hp

Stopping distance in feet at maximum speed5


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TECHNICAL DATA

CONTROLS

Rear wheel brake lever

Starting lever __ ___.../Light switch ____ ...Horn button _____ J

Choke - - - - - -Frame number -------+-

M XI hp

Front wheel brake leve

------- Engine stop switch--- Fuel tank cap

Fuel valveHI V.I.N. plate

ENGINE


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Maximum outputMaximum torqueCompression ratioBoreStrokeDisplacementCooling _LubricationCarburetorMainletNeede jetNeedle positionNeedle sizeThronle slideIgnition . . . .Breaker point gapkln ition Uming .S par1< plug . -Spark plug gapGenerator . .gnit ion coil .Cylinder material ,POWER TRANSMISSIONClutch . . .Transmiss ion .Engine Transmission reductionTransmission/Rear wheel drivePedalling driveCHASSISFrameF ron wheel suspensionRear wheel suspensionBrakes . . . .Dia . ol brake drumWidth ol brake lining . .Total effective brake surfaceTire size front and rearTire pressure fronVrearFuel tank

~ ~ k p at 4000 rpm7 : 1 (9.2 : 11.496 in 38 mm)1.693 in 43 mm)2.97 cu . o (48.8 cc)air cooledgas/oil miX1UreBing 1/14622.222nd notch from top124magneto ignition.014 - .018 in 0.35-0 45 mm) _.032 047 o 0.6-1 .2 mm) BTDC- 14-17.5Bosch W 7 A, Champion L 86.016- .020 in 0.4-0.5 mm)flywheel magneto Bosch RDPt 6 V, 265/10 Wspecial coil for magnetoAlu -alloy , cyl. wall hard chrome platedcentrifugal clutch running in ATFsingle speed automatochelical gears 21 : 106, i = 5.05chain 172 x 3/16 in, 16: 45 : i = 2.81chain 1/2 x 1/6 in, 26 : 23; i = 1.217

shell typetelescopic fork ; 1.96 in (50 mm) travelcontrol arm; 1.96 in (50 mm) travelinternal expanding brake shoes3.15 in 60 mm).70 in (16 mm)6.06 sq in (52 em')2 1/4 - 1726 /32 psi (1.8/2.25 bar).645 US gaL (3 .2 I)

DIMENSIONS AND WEIGHTS


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: : : : ~ ~ ~ :Overall height .Wheelbase .Q,..o u n,d .o o ....,...ory wetgmELECTRICAL EQUIPMENTHeadlight bulb .Ta1I_ /Stop light bulb .Speedometer light bulbWarning device . .PERFORMANCE AND CONSUMPTION

~ i f t ~ n g abmy . . .Fuel consumption (DIN 70030)

65.7 in 11670 mm)32.3 in 820 mm)-42.5 in 1080 mm)42.9 in 1090 mm)l7 4400k9) )

6 V, 21 W6 V. 5 W 6 V, 10 W6 V .6 Worn3 mph 48 km/h)15 %150 mp (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 mayhave very shorl upward and downward grads of maximum 1.5 %. The vehicle must be adjusted to specihcauon.with ~ r s correctly inflated. Riders weight not more than 143 lbs. (65 kg). The measured consumption as increasedby 10 , taking unfavourable conditions in19 account. New vehicles may vary up to 5 from this value.CAPACITY AND QUALITY O LUBRICANTS see Owner Manual)

ENGINE Mixture of regular grade gasoline with special 2 stroke oil (MAXI MIX) - 50 : 1DO NOT USE UNLEADED GASOLINE

TRANSMISSION 5 314 fl. oz (t70 oc) Automatic-Transmission-Fluid TYPE FGREASE NIPPLE Use grease or oil SAE 9CABLE Lubricate cables with oil SAE 3

WIRING DI GR M


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9 Ignition coil10 GeneratorWire connector

2 Tail-/Stop light


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Puch Maxi Owners Manual

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