Zundapp 2 Stroke Engine Repair 1956 (MT027588)

Zundapp 2 Stroke Engine Repair 1956 (MT027588)

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• Zundapp 2-Stroke Engine Repair 1956

  REPAIRING
  
  TWO-STROKE ENGINES
  
  of Models
  
  DB 202, COMFORT, NORMA,
  
  NORMA-LUXUS, ELASTIC 200;
  
  ELASTIC 250, 200S, BELLA 150,
  
  BELLA 151, BELLA 200, BELLA 201

  Full service and repair manual
  
  for this Vintage engine

  Contents
  
  A) Range of Engine Numbers . . . . . .
  
  B) Technical Data . . . . . . . . .
  
  C) Disassembling the Engine . . . . . .

  1. Removing the Cylinder, Cylinder Cover, Carburettor,
  
  and Piston . . . . . . . . . . . . 11
  
  2. Demounting the Generator. . . . . . 13
  
  3. Removing the Kickstarter and Protective Cover . . 14
  
  4. Clutch Housing . . . . . . . . . . 15
  
  5. Demounting Clutch Assembly and Flywheel . . . 17
  
  6. Disassembling the Crankcase and the Transmission
  
  Housing . . . . . . . . . . . . . 19
  
  7. Right-Hand Housing Half (Clutch Side)
  
  8. Left-Hand Housing Half (Generator Side)
  
  8a Left-Hand Housing Half on Starter Engines. . . . 21
  
  9. Disassembling the Connecting Rod . 21
  
  10, Disassembling the K. S. Pawl . . . 22
  
  11. Removing Internal Rings for Crankshaft Bearings . . 22
  
  11 a Internal Rings of Crankshaft Bearing on Starter Engines 22
  
  12. Demounting the Ball Race and Bronze Bushing for
  
  Mounting the Sliding Shaft inside Clutch Hub . . 22
  
  D) Re-Assembling
  
  1. re- Assembling the Crankshaft (Fitting Connecting Rod etc.) . . . . 23
  
  2. Right-Hand Housing Half (Clutch Side)
  
  3. Assembling the Clutch . . . . . . 26
  
  4. Left-hand Housing Half (Generator side) . . . 28
  
  5. Dimensioning the Crankshaft Bearings
  
  6. Joining the two Housing Halves . 32
  
  7. Mounting the Clutch with Chain and Flywheel . . . 33
  
  8. Determining Dimensions of Clutch Pressure Pin and Supporting Bolt . . 34
  
  9. Mounting and Adjusting the Gearshift Mechanism . 37
  
  10. Mounting the Clutch Cover .. . . . 38
  
  11. Mounting the Drive Sprocket . . . 38
  
  12. Mounting the Piston . . . . . . . 39
  
  13. Mounting the Cylinder and Cover . 41
  
  14. Mounting the Generator; Ignition Timing . . . . 41
  
  15. Various Types of Carburettors and Their Adjustment . 44
  
  E) Appendix
  
  1. Special Tools . . . . . . . . . . , 54
  
  2. External Treatment of Engines . . . 54
  
  3. Engine Conservation . . . . . . . . 54
  
  4. Shipping Engines . . . . . . . . 55
  
  5. Running-In . . . . . . . . . . 55

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