DKW Hobby owners manual. English
Contents
1. 8 8 Chassis 15 a aT t Engins 22 55 steering lock Key No for saddle TECHNICAL DATA 1 Engine 1 cylinder two stroke with reverse scavenging Cooling by fan Bore 1 77 in 45 mm Stroke 1 85 in 47 mm Swept capacity 4 52 in 74 Compression 63 1 10 65 1 Max output 3 5000 rpm Mox torque 3 4 ft lbs 0 47 mkg at 4250 rpm Carburetter Bing with starter slide Main jet No 84 Needle jet No 2 17 Jet needle in Jrd groove Max speed solo with two passengers Fuel consumption under most economical conditions 37 mph 60 km h 34 mph 55 km h approx 160 mpg 2 Electrical System flywheel magdyno 6 volt 17 watt flywheel magdyno 6 volt 20 watt frem engine No 03042312 Sparking plug Bosch W 225 TI or Beru 225 14 92 Sparking plug 16 20 thou Contoct brecker 12 16 thou 102 110 in BTDC Advanced ignition twin filament 6 V 15 15 W bulb Headlamp Tail light 6V2W spherical bulb Teil light 6V5W spherical bulb from chassis No 03542304 al a 3 Power Transmission infinitely variable automatic V belt transmission her system fixed rat2. 20 eo T Q 6 es 3 7 dn 4 Bearings multi purpose greose um 2 Contact Breaker Cam BOSCH bearing grease FT 1 V 4 3 x 9 53 Y 28 Oo Disengaging Bearing DKW Special Grease UNIVISTON DB 414 23 2 22 97 ss l 3 E un 3 4 2 W Drive Chain DKW Chain Grease a as far as available 3 E only for first lubrication ofterwards take multi purpose grease o 3 8 a 3 sh e 3 26 Wiring Diagram LEGEND 2 OA Un sal of DKW Hobby standard and de luxe models with twin filament bulb Combined light switch 15 light switch AS dipper switch HK horn button Kk short circuiter button for ignition Tail light licence plate light Terminal strip a lead from dynamo to light switch b lead contact breaker to short circuiter button lead light switch to tail and licence plate light Sparking plug Ignition coil Condenser Contact breaker com Contact breaker lever Light coil Horn The following bulbs are fitted twin filament C 6 1515 Toil and licence plate lamp 6V2W WIRING DIAGRAM of DKW Hobby standard and de luxe models 3 64 1 57 273 IV DEFECTS AND THEIR REMEDY Even though your DKW
3. sn TT UU ncn M rr P Lc A oy DKW Hobby SOZIUSFEST AUTO UNION G M B H 5 GUIDE issued DKW 604 WILL TWO This instruction clearly explains the driving and maintenance of the vehicle and should be read before taking your DKW HOBBY on the road Only the objects of sale including accessories ond fittings stipulated in the Sales Contract will be supplied We reserve the right to make any necessary alterations for technical and manufacturing reasons No particulars in this booklet can be used os the basis for a claim for compensation of any kind against this Company HAPPY MOTORING Yours AUTO UNION G M B H Table of Contents TECHNICAL DATA AND DIMENSIONS 1 Engine 2 Electrical dum 3 Transmission 4 Frame 5 Dimensions and weights Important date Control levers of the DKW Hobby TECHNICAL DESCRIPTION The engine How a two stroke engine with DKW reverse scavenging works Jilustration of the engine unit of the DKW Hobby Illustration of engine and gearbox The gearbox Xt How the infinitely variable y belt gear Diagrams of the gearbox PREPARATIONS FOR DRIVING Filling and type of fuel used Mixture ratio How the DKW mixer porte Tyre pressure Pushing the DKW Hobby 11 EXPLANATION OF THE MOST IMPORTANT CONTROL LEVERS Petrol tap Air co
4. Brake bedding 4 1 250 Speedometer drive if any 1 250 Spring casing of hond starter 3 1 250 7 Bearing bolts of stand Xp 1 250 9 5 1 250 9 Clean and lubricate chain 2 7 500 10 Change in intermediate gear 2 500 11 Greose felt for contact breaker et 6 7 500 Wi cp bearing points of the drive 7 8 4 000 and secondary shaft 13 Top up oil in telescopic fork a 7 500 14 CPGE a 7 500 Dependent on the manner of driving and weather conditions the greasing be found necessary much earlier On first lubrication afterwards EXPLANATION OF MARKS Chassis grease WV Chain grease SAE 50 or 40 Motor oil SAE 20 Motor oil A SAE 90 Gear oil Bosch bearing grease FT 1 V 4 Multi purpose grease DKW Special Grease UNIVISTON DB 414 T 2 LUBRICANTS 237 e un 5 branded motor oils SAE 40 50 Engine 5 2 8 8 with ML use DKW Two Stroke Additive 7 2 dao 9 4 A 4 5 9 8 D Intermediate Gear bronded gear oils SAE 90 Ae att 25 S c m 2 Telescopic Fork bronded motor oils SAE 20 Ss a 2239 25298 25 chassis grease multi purpose grease 2
5. Contact beaker lever not moving c Fuel pipe or carburetter blocked or dirty 9 Heavy carbon deposits in combustion chamber Belt on gear box has too much play belt worn out f Air filler dirty Ignition timing incorrect Brakes adjusted too tightly i Cooling fins dirty engine gets too hot 5 Engine stops suddenly a Fuel tank empty switch to reserve b Fuel filter or jet in carburetter blocked c Plug lead fallen off from plug d Faulty plug e Nose on contact breaker broken or contact material broken off f Magneto windings short circuiting g Condenser defective 6 Headlamp fails to burn only lights when engine is running a Headlamp or dipper filament burnt out b Light switch on handlebars defective Break in leads 9 Dynamo faulty 7 Horn only sounds when engine is running a Horn defective b Horn button faulty c Breck in lead AUTO UNION G M B H Abteilung Ersatzteile und Kundendienst INGOLSTADT Edition June 1957 MB 261 0 4 F 114 XXII engl Printed in Germany 32
6. a t COM gt Due to the quality of to day s petrols corrosion moy under certain circum stances form in the interior of Ihe engine Corrosion may be prevented by regularly using DKW Two Stroke Additive Desolite if available This will also decrease the formation of undesirable combustion deposits carbon on piston head cylinder head ond in the exhaust system If the DKW two stroke additive is available in our DKW Service Work shops it is sold in special 0 5 litre 0 9 pts cans for motorcycles The lid also serves as a measure How the new DKW Mixer works The mixer is safely fitted in the tank Oil is first poured into the container A Petrol is then poured in so that due to the special design of the mixing pipe the oil and the petrol eddy backwards and forwards to thoroughly mix and flow as a mix ture into the tank Any oil not dissolved by the petrol is retained by filter C until further petrol is M AT added and mixes with this oil to Oil poured into the DKW mixer flow into the tank as a homogene ous mixture The flow of fuel in the DKW mixer Oil Benzin Petrol Krafistoff Ol Gemisch Fuel Oil mixture Tyre pressures The tyre pressures ore very important They are mostly responsible for the road safety of your scooter its road holding qualities its performance and last least the weor and tear on the tyres The rated ty
7. which represents the moin brake like on a motorcycle When descending long hills tt is advisable to use both brakes in turn The multi purpose switch This switch combines the light and dip per switch the horn button and the short circuiter knob in one single unit see illustration Lever No 1 is the switch E on off No 2 is the dipper switch dipper light high beam ight the rear button No 3 is the horn button and the front button 4 is the short circuiter button for stop The multi purpose switch 1 55 1878 19 ping the engine This lost button is to be pressed until the engine ceases firing he Hobby scooter is fitted with an A system without battery which means that the lamps will only light and the horn only sound when the engine is running The stand The stand on the left hand side under the bottom plate is used to prop up safely your DKW Hobby and is pressed outwards with the foot Steering and saddle lock A theft proof lock is fitted in the steering head which is accessible through an opening below the brief cose hook Turn the handlebar to the right as for as ossible insert the key into the lock and press forward slightly turning to the eft If the lock does not engage at once just waggle the handlebar slightly Return the key into vertical position ond remove it The saddle lock located on the left hand side secures the tool kit and fuel tank under the
8. 5 5 inch 23 1 5 4 inch 32 Ibs sq inch internal expanding brake on rear wheel operated over brake cable internal expanding brake on front wheel operated over brake cable 29 41 4 2 0 087 pts SAE 20 engine oil 0 15 pts SAE 90 gear oil 1 43 galls mixture including gall reserve 53 in 77 35 5 29 in 26 4 in 434 in 10 ft 507 155 27 8 88 degrees All rights reserved to alter technical data without previous notice dide en smit oe E 3 CONTROLLEVERS OFTHE DKW HOBBY 1 Fuel tap 5 Knob on frontal grill of the 10 Foot brake control lever 14 Dipper switch 2 Air control lever on carburetter engine cowling Steering lock catch 15 Light switch 3 Disengaging lever with catch 7 Saddle lock 12 Hook for brief case etc 16 Throttle twist grip 4 Short circviter 8 Lifting handle 13 Horn button gt 17 Hond brake lever 9 Stand 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 T TE 4 n T ye o The Hobby de luxe seen from the left Rr 4 e io d Am a TECHNICAL DESCRIPTION The engine The four working strokes of an internal combustion engine are suction com pression combustion and exhaust While a four stroke engine requires two complete crankshaft revolutions for these four phases in a two stroke engine suction and combustion ta
9. Hobby has been built on the principle the simpler the better and despite the fact that this small vehicle has a maximum degree of reliability and is childishly simple to drive it can the some as all other technical articles or appliances sometimes break down or refuse to work correctly In way can this be blamed on the design or construction of the scooter as supposed by the uninitioted but is in the majority of cases due to incorrect operation or insufficient maintenance ond service Below we ore listing a few possible failures ond their causes 1 Engine refuses to start A Engine not receiving petrol a Tank empty observe reserve position b Tap closed or dirty Petrol filter in carburetter dirty d Petrol filter in tank dirty e Jet in carburetter blocked B With plug lead removed no spark jumps across to earth when starter is pulled a Poor contact on plug lead b Ignition cable broken or shorting to earth Nose on contact breaker does lift or remains fixed one position d Contoct breaker contacts burnt Condenser faulty or wet C Spark jumps from plug lead to earth but no spark visible across electrodes of plug when this is laid on cylinder head between electrodes too large b Carbon bridge formed between electrodes of plug Plug insulator broken or wet outside 9 Plug oily or wet with fuel check heat value D Engine does not start readily when cold a Idling mixtu
10. shortly before the piston reoches Top Dead Center As described at the begin ning of this section the upward stroke of the piston sets up vacuum in the crankcase and the whole process is repeated The piston gives a power stroke each time it moves downward The crankcase itself is an integral part used in the completion of the four working phases For this reason it is not filled with oil The DKW engine is efficiently lubricated by the oil in the petrol and at each stroke a fresh supply of pure clean oil is fed to the engine That is the origin of the term DKW Fresh Oil Mixture Lubri cation This relieves you of all worry and care ond is the reason for the remarkably little attention required by the DKW two stroke engines The actual design of the engine is relatively simple as can be seen from the accompanying diagrams 8 THE ENGINE UNIT THE DKW HOBBY 1 54 4574 ENGINE AND V BELT HOBBY THE DKW P a 2 5 5 gearbox Normally gearbox supplied on vehicle is laid out with three or four forwards speeds In more recent times the large American automobiles have a standord fitting of a hydraulic type of infinitely variable gearbox These are termed infinitely variable because they have a vast number of geor stages and hydraulic because instead of gearwheels and chains very thin oil is used to transmit power from the engine to the driving wheels The D
11. the engine cowling or before carrying Frontal grill opend 1551879 any work on the carburetter The air control lever One end of this lever protrudes through the frontal grill and is used to help starting when the engine is cold For this reason the lever is raised upwards so that the air slide on the carburetter is closed The air slide is automatically re opened when accelerating Caution Never use the air control lever when the engine is warm The throttle twist grip The throttle twist grip which is on the extreme right of the handle bor controls the position of the throttle slide in the carburetter and thereby the speed and performance of the engine This twist grip is all you require fo keep your Hobby scooter under perfect control in all traffic conditions from slow walking pace to maximum speed only by twisting it forward and backward Caution Do not rev up your engine to maximum speed when the scooter is on stand as the control cable for the disengoging device and the disengaging device itself might be damaged The disengaging lever with catch The disengaging lever with catch on the extreme left of the handle bar is the most important contro lever beside the throttle twist grip and you ought to pay attention to it When the lever arrow Fig is tightly gripped the 18 ower transmission between the engine and the automatic gearbox is cut off is is completely different from other
12. type of scooter or motorcycle equipped with the normal type of gearbox requiring the engagement and disengagement of the clutch each time a gear is engeged or disengaged The disengaged lever on your DKW Hobby need only be actuated when your scooter is at a standstill ond the engine running idle Before starting your engine make certain that the disengaging lever is tightly gripped On the other hand there is necessity whatever to use this lever again thanks to the provision of the so called infinitely variable gearbox Only when starting off slowly release the disengaging lever by drawing the lever close to the handle and pressing on the catch a see illustration You need not use the disengaging lever again until you want to stop as described under Driving The starter handle The starter handle on the left hand side below the saddle is used to start the engine For this purpose quickly and vigorously pull the handle upwards to about the level of the saddle Retain a firm grip on the starter handle and return it to its original position after the engine has started The brake pedal The brake pedal located in front on the right hand side of the bottom plate controls the rear wheel brake when being depressed Disengaging lever with catch 1 55 1877 The hand brake lever The hand brake lever on the right hand end of the handlebor in front of the twist grip controls the front wheel brake
13. KW Hobby is the only two wheeled fitted with infinitely variable automatic gearbox the system used is called Uher infinite variability between engine and intermediate gear is obtained by using rubber V belt No matter what the conditions or circumstances there is no necessity whatever for you to pay any attention to your gears when the scooter is in motion The gearbox itself selects the correct gear ratio in accor dance with the prevailing conditions and the speed This is a gearbox which actually thinks for you This V belt gearbox works as follows A belt pulley is fitted on the crankshaft and the shaft of the intermediate geor In each case one half of each pulley and 1 can slide along respec tive shaft The adjustable pulley half A 1 on the crankshaft is moved along the axle its shaft by spring loaded centrifugal weights mounted on the fixed holf of the pulley When the engine is not running the springs on the centrifugal weights draw the movable half of the pulley A 1 inwards so that this butts up against the V belt on the centre piece of the pulley As soon os the engine starts up the pull exerted by the centrifugal weigths pulls the pulley half A 1 in towords the fixed half A 2 The adjustable pulley half B 1 on the shaft of the intermediate gear is forced against the fixed half of the pulley 2 by compression spring This causes the formation of an extremely narr
14. and the table of lubricants at the end of this Owner s Guide Cleaning carburetter filter A filter will prevent fuel flo wing from the tank into the buretter and affect the performance Close the fuel tap disconnect fuel pipe from carburetter and unscrew the brass hose nipple As shown in the accompan ing illustration care fully remove the filter from the hose nipple using your fingers ond clean by blowing Should the filter remain in the corburetter use the end of a needle to remove it From engine 03 037 381 on the carburetter filter is no longer fitted as for as available 22 Cleaning oir filter Remove the rubber sleeve between carburetter and engine and press filter out of the sleeve Wash the filter with petrol in a clean tin and blow clean When replacing the filter in the sleeve make sure that it snaps home in the slot wet with a few drops of engine oil When refitting the sleeve make sure that the filter is replaced correctly twisted as this would cause a decrease of engine performance Setting idling speed If when the throttle twist grip is fully closed the engine ticks over too slowly or stops altogether this will lead to difficulties when storting off The idling screw 1 shown in the accompanying photo is used to regulate the idling speed of the engine The engine will run faster as the screw is turned inwards to the right and more slowly as th
15. driver s saddle from unauthorized use In the same the steering lock the saddle lock and the key ore pulled out to the stop slightly to the left Then the saddle con easily be turned down to front DRIVING Starting the engine The engine is started as follows ol Pull disengaging lever into idling position Important b Le fuel pointing lever downward when reserve lever pointing the right Raise air slide lever but only when engine is cold accessible from outside through frontal grill 2 Open twist grip about 4 of total extension towards you i e backwards Pull starter hendle quickly and strongly upwards If the engine does not start at the first pull pull the storter handle again until the engine fires At most the engine should start after the second or third pull on the starter If it doesn t it is reasonable to suppose thot the engine is flooded due to the petrol tap being left open when the scooter was standing idle for some time Open up the twist grip throttle as far as it will go and then pull the starter vigorously several times As soon as the engine commences to fire immediately close the throttle down to its idling position In cold weather the engine is started in the same way Only between the operations 4 and pull out the starter handle four or five times with the short circuiter knob pressed down thus allowing the engine t
16. e screw is turned to the left Replacing and checking sparking plug The sparking plug is removed b first withdrawing the plug duh applying the plug sponner screwing out the sparking plug with sharp pull and checking the sparking plug The gap should measure 0 4 to 0 5 mm If necessary correct by bending the eorth electrodes In case you fit new sparking plug make sure that you obtain one as indicated on page 4 with correct sparking plug gap When screwing in the sparking plug do not forget the washer Setting idling speed 1 55 1876 Replacing bulbs of headlamp and tail lamp Loosen the slotted screw underneath the reflector ring screw is prevented from falling out and lift the reflector from the lamp housing Uncouple the tension spring from the bulb socket and carefully press the socket itself out of the reflector While turning the bulb to the left press it backwords and pull it out IF only the filament on the headlight side of the bulb is burn out you may continue your journey using only the dipped headlight If the dipper filament 1 burnt out however you cannot dip when another vehicle approaches you os you would be completely without light If you do quite a lot of night Iravelling it is advisable for you alwoys to c Vol socket BA 15 b Y ys to carry a 6 Volt 15 15 watt spare bulb The 6 volt 2 watt tail lamp bulb with special socket can quickly be replaced after screwing off the lamp hous
17. empty tank is first filled with approx half a pint of oil see lubricating schedule on page followed by 1 galls of petrol Naturally occording to the amount of petrol in the tank any quantity less than 114 galls can be put in the tank with the suitable amount of oil 2 In the winter months when the temperature is lower than 32 degress 09 a amount of core ond ottention is required when filling vehicles fitted with DKW Mixer is well known that a certain amount of care has to be taken in the preparation of two stroke mixtures used in winter time The oil must be warm enough to run reasonably easy and should be drawn from a tank stored in a room with a temperature of at leost 50 10 3 It is no longer necessary to use the so called self mixing two stroke oils which ore more expensive than the usual motor oils 4 The more expensive Premium oils are unnecessory for DKW From the mixture table you may easily see the ratio of petrol oil and Desolite DKW Two stroke additive if available We recommend always to empty the tank except for the reserve fuel Then you will know for certain that at least 834 pts of petrol plus 0 35 pts of oil can be filled Mixture table Petrol pls 1 3 5 7 834 10 19 169 2 50 40 V UNE 14 2 35 42 16 anmam ee A 5 gt gt
18. er in the right hond spindle head Then pull out the stub axle to the right Withdraw the distance piece between wheel and right fork leg Either ploce the scooter so that the rear wheel is off the ground or carefully turn the vehicle on its left side and then remove the wheel Caution Close the fuel tap When refitting moke sure that the three slots of the rubber damping disc the wheel hub fit on the three sleeves on the brake drum Refit distance piece ond stub axle and tighten the outer nut while holding it with a screw driver in the spindle head Drive chain and V belt The useful service life of the chain depends in the first ploce on regular correct servicing according to the Maintenance Chart The chain tension can be checked by an inspection hole in the lower part of the chain case remove rubber cap If the chain is properly adjusted it can be pressed upwards by 15 to 20 mm The rubber V belt is to be checked for wear when carrying out maintenance work the V belt itself needs no maintenance Its service life too regular maintenance lubrication of the shafts over which the two pu eys run and on the exact flushing of the pulley halves 24 e Lubricating Schedule for DKW Hobby standard and de luxe models 1 LUBRICATING WORK No Greosing point ree egram miles ing ees 1 250 2 Control cables 1 250 3 cable of disen A 1 1 250 4
19. ing Screw out the upper slotted screw and remove the housing Above all the tail light serves as a safety device 23 20 Adjusting the brakes The adjustment of the hand brake is effected by the adjusting screw at the lower cable end First loosen the lock nut b then unscrew the adjusting screw a a few turns and retighten the lock nut For adjustin the footbrake lift the rear whee cowling unscrew the hexagonal screws on both sides and remove the outer part of the chain case by simply unscrewing the nut of the swing bearing behind the exhaust pipel and the nut of the wheel axle he adjustment of the foot brake cable is carried out in the same way as described for the hand brake Adjusting hand brake Removing and refitting front wheel Place the DKW Hobby so that the front wheel turns freely Press the brake lever backwards ond uncouple the cable If necessary turn the adjusting screw downwards with loosened lock nut Remove the inner speedometer cable to the left after unscrewing the stud and withdrawing the outer speedometer cable to the rear Then unscrew the nuts of the front axle on both sides press apart the fork and withdraw the front wheel towards the ground The refitting is effected in the reverse order Removing ond refitting rear wheel Lift the rear wheel cowling hexagonal screws on both sides unscrew me left hand outer nut on the chain case and hold the outer nut with a screw driv
20. io intermediate geor chain drive to rear wheel Gear ratios j from engine to intermediate gear 1 1 5 to 1 1 93 infinitely variable V belt drive fixed ratio of intermediate geor 1 34 helical cut gear wheels intermediate gear to rear wheel 1 3 5 roller chain transmission total ratio Fee ee we 4 839 312 SE LaL BOFA ayes 3 roller chain with snap link joint 1 x 12 7 x 488 x 7 55 x 100 links DIN 8180 chain sprockets drive sprocket 16 teeth reor wheel sprocket 56 teeth The average consumption was determined at a uniform speed s of the maximum speed on a dry level road and with no wind Measurements taken in both directions and plus 10 percent 4 Frame central tubular frame with bottom plate struts Front forks xL Rear wheel suspension Stand Tyre size front and reor Tyre pressure front rear solo rear with pillion passenger Foot brake Hand brake Diam of brake drum front rear Width of brake shoes Capacities Oil in telescopic forks Oil in intermedicte gear Fuel tank 5 Dimensions and Weights Wheel base Overall length Overall height Saddle height Overall width Ground clearance Turning circle Rated total weight Camber of front wheel Hondlebor turning circle telescopic swinging arm with rubber buffers prop at centre of frame deep bed 1 50 167 2 50 16 18
21. ke place in half a turn of the crankshaft and exhaust and compression in the other holf turn the result being that the whole working stroke is effected in a single complete crankshaft revolution In a four stroke engine the four working phoses take place above the engine head in the cylinder combustion chamber whereas in a two stroke engine they are effected partly above and partly below the piston in the crankcase This allows the two stroke engine to be more simply constructed the engine having only three moving ports crankshoft connecting rod and piston The engine works as follows As the piston moves downwards a vacuum is set up in the airtight crankcase so that as soon as the intake duct leading to the carburetter is opened a stream of petrol oil air mixture will flow into the crankcase On its downward stroke the piston closes the intake and the exhaust ports and compresses the petrol mixture in the crankcase Approximately at Bottom Dead Center the piston opens up the overflow port to the cylinder the exhaust port being opened at the same time The mixture flowing through two slots into the cylinder moves upwards towards the cylinder head and drives the gases that are left after the previous combustion out of the cylinder through the exhaust system ond into the open By this time the piston is again moving upwards and closes the exhaust port again ond then compresses the gas mixture in the cylinder which will be fired
22. ntrol lever Throttle twist grip Disengaging lever with catch Starter handle Foot brake control lever Hand broke control lever Multi purpose switch Stand Steering and cadis 9 to 10 132 514 13 to 15 16 to 18 16 16 to 17 17 18 18 18 to 20 18 18 18 19 17 19 19 19 20 20 DRIVING Starting he engine Starting off Braking Stopping IV HINTS ON BREAKING IN V WINTER DRIVING The control cables The flywheel mogdyno The tyres ROM Protection against corrosion VI HINTS FOR MAINTENANCE AND SERVICING Cleaning carburetter filter Cleaning air filter Setting idling speed of engine Replacing and checking sparking plugs Replacing head lamp and tail lomp bulbs Adjusting brakes 1 Removing and refitting front Removing and refitting rear wheel Drive chain and gearbox V belt Lubrication schedule Table of lubricants Wiring diagram and Defects and their remedy Maintenance chart IMPORTANT DATA OF YOUR DKW HOBBY Licence plate Place registered EEE RARE E EHS TESST Date istered NA any S 8 24 25 to 29 30 to 34 3 to 37 Appendix t
23. o idle Only then release the short circuit knob and ull the starter hondle upwards Upon the first or second pull the engine should start providing the sparking plug and ignition setting ore in good order Starting off Start the engine push the stand back to rest position and mount the saddle With your left hand grip the disengoging lever press in the catch and slowly and carefully release the lever As soon as the scooter starts to move accelerate immediately by the twist grip The whole range of speed from starting off to maximum speed and down again to stop along the level uphill and downhill is controlled simply and solely with the throttle twist grip thanks to the infinitely variable gearbox and trans 20 exceed about mission fitted in the Hobby scooter Should the engine suddenly stop or stall as you are starting off you have probably either let out the disengaging lever too quickly or the engine was running too slowly You will soon learn to start correctly and the engine idling speed can very easily be set as described in the maintenance hints given on page After the cold engine has been started up the choke is better if for the first few hundred yards the throttle is only opened halfway to prevent the engine from stalling and a more uniform flow of gas is given Driving on half throttle in this way will ensure that the choke will not be opened fully this is cou
24. ow V so that when the engine is not running or is only ticking over the V belt C runs round the extreme outside edge of _the pulley The three schematic diagrams show the gear the idling position position when starting off lowest gear and position at top speed top gear The Infinitely variable V belt Gear used on the DKW Hobby Open outwords to the right 1 1 m maed 21 1 i 44 7 posti m Saas LM AU UE Idle Running 1 54 4571 b Starting 1 54 4572 Full Speed 1 54 4573 13 14 1 PREPARATIONS FOR DRIVING Filling and type of fuel used Fuel is filled into your Hobby scooter by tipping the saddle forward after releasing the catch holding the saddle at its rear end Turn the tank cop to the left and remove The tank itself holds roughly 1 galls gall being reserve Any commercial brand of petro may be used When filling 1 Switch off engine 2 In rainy weather protect filler from rain drops 3 Do not smoke or use open light of any kind The tank of your DKW Hobby is fitted with the new DKW mixer This means there is no necessity whatever to mix oil and petrol in the usual type of mixing can First pour the oil into the tank and then the quantity of petrol required Note the following carefully 1 The completely
25. pled with the throttle cable and the cold engine is given richer than normal mixture so that it performs better Braking Before carrying out any braking actions close down the throttle by turning the twist grip towards th front When the speed is not too high the best method of braking ts to use the front or hand brake In an emergency or when your scooter is travelling at a relatively high s applying hand and foot brakes simultaneously When descending a very steep incline it is better to brake with hand and foot brakes in turns to prevent the brake drums from overheating Stopping When you wish to stop slow down your vehicle by closing down the throttle and letting your scooter coast to the required sto mo point applying your brakes gently as you reach your stopping place Shortly before coming to a stop draw in the ditengoging lever until this is held in place by the catch The engine will continue to tick over even though the scooter is at a standstill To stop the engine press the short circuiter knob When you want to stop travelling downhill release the disengaging lever drivin bibl To a certain degree the engine acts as brake and prevents the vehicle from running away On steeper hills place a block or a stone in front of the wheel HINTS BREAKING IN We do earnestly advise that after registering your scooter you do not commence immediately to drive at fast speeds but rather for a short
26. re pressures ore solo with pillion passenger front wheel 18 ibs sq in 18 Ibs sq in wheel 23 Ibs sq in 32 Ibs sq in at a normal load 165 Ibs Though it is reasonable to have the tyre pressure checked and corrected every time you refuel there is a hand pump stored in the tool compartment under the saddle for emergency coses puncture When pushing the DKW Hobby be certain to pull the disengaging lever The slight scraping noise audible thereby is by no means defect but a constructional choracteristic of the stageless belt gear 3 17 Il EXPLANATION OF THE MOST IMPORTANT CONTROL LEVERS The fuel tap The fuel tap is three way tap only accessible when the frontal grill of the engine cowling is open as shown in the illustration The grill is opened by pressing the knob of the catch and turning the top downwards to the left The three positions of the tap may also be seen from this illustra tion The positions Auf and Zu are obvious In position a fuel reserve of approx gall is used with which you can drive about 30 miles according to the speed at which you are travelling Despite this reserve do not forget to refuel in due time ond to turn the tap to the usual position Auf before continuing The fuel tap should always be closed when the scooter is being used for any length of time e g at night Turn tap off also before raising
27. re too weak b Air leakoge somewhere hove repaired by DKW workshop E Engine does not stort readily when warm a Air lever choke accidently pulled mixture too rich 4 Me e b Carburetter not straight c Float needle not closing properly carburetter leaking d Leaky float gt 2 Engine runs irregularly four stroking a Air filter dirty b Float needle not seating or bent Needle jet faulty d Float faulty e Too much oil in fuel mixture Ignition timing incorrect g Too much carbon deposited in mixture ports or in exhaust system h Mechanical chonge in silencer i CarbureHer incorrectly adjusted needle in slot 3 3 Carburetter spits generally due to a too lean mixture or to incorrect ignition Fuel feed to engine insufficient due to dirty filters b Carburetter not straight c Carburetter loose air leakage d Faulty gasket on engine e Air filter either missing or at right angles to correct position Carburetter incorrectly adjusted wrong needle position 9 Ignition timing incorrect h Plug loose in its thread or worn out i Sparking plug gap too large or too small k Condenser defective I Insulation on ignition cable defective m Contact breaker nose not moving n Contact breaker contacts burnt o Piston rings burnt into their grooves 4 Engine fails to rev at high speed scooter not reaching maximum speed a Contact breaker gop too large b
28. time at least drive carefully During the first 65 miles the moximum cruising speed should not 28 to 30 m h Full throttle can be given for a few minutes or when overtaking another vehicle During the following 200 miles your scooter should not be driven continuously at its maximum speed but rather the c should vary between 30 ond top speed You can safely drive your Hobby scooter where ond how you will after the first servicing has been carried out at about 300 miles WINTER DRIVING cold weather you will especially appreciate the advantages of your DKW Hobby as it hos a two stroke engine with fresh oil mixture lubri cation so there is no trouble with frozen oil Without anxiety you may park your Hobby in the open even in the lowest temperatures The control cables winter the control cables ore especially exposed to y So there is a danger that the cables might freeze within the cable sleeves Deco attention should be paid to the gas control cable on the carburetter side If however 21 the maintenance jobs ore regularly carried out and the cables are carefully lubricated this danger is virtually eliminated The flywheel magdyno The flywheel magdyno should be checked by authorized DKW service station before the beginning of the winter as only its perfect working condition will guarantee winter driving without trouble The tyres If necessary drive with slightly less
29. tyre precessure on very icy roads in order to improve road holding quality Protection against corrosion If you garage your Hobby during the winter it is advisable to protect the interior of the engine Jack up the scooter so that the rear wheel can run freely Lift the rear wheel cowling pull the lower rubber sleeve off the engine cover and turn it upwards Keep about 10 of DKW two stroke additive handy Rev up the engine to a high number of revolutions with the disen aging lever released driving position quickly pour the DKW two stroke additive into the rubber sleeve at the some time pee the short circuiter knob until the engine has stopped The engine sucks in the DKW two stroke additive through the air cleaner After the operation the engine must not be started again as otherwise the protecting effect of the DKW two stroke additive would be eliminated Store the vehicle in a dry room if possible VI HINTS FOR MAINTENANCE AND SERVICE For all maintenance ond service jobs stated in the enclosed Maintenonce Chart our far reaching service organization is at your disposal There you will find experts trained in our works school who are equipped with the necessary special tools and will only fit genuine DKW spare parts in case of need The following poragrophs deal with few maintenance jobs which you may out by yourself providing you have some technical skill You will find the lubrication chart
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