Puch Magnum II MKII Owners Maintenance Service
Contents
1. lassicCycles org2. THE LOW SPEED PASS ASSUMES AN INITIAL SPEED OF 20 MPH AND A LIMITING SPEED OF 35 MPH THE HIGH SPEED PASS ASSUMES AN INITIAL SPEED OF 50 MPH AND A LIMITING SPEED OF 80 MPH NOTICE THE INFORMATION PRESENTED REPRESENTS RESULTS OBTAINABLE BY SKILLED DRIVERS UNDER CONTROLLED ROAD ANO VEHICLE CONDITIONS AND THE INFORMATION MAY NOT BE CORRECT UNDER OTHER CONDITIONS DESCRIPTION OF VEHICLES TO WHICH THIS TABLE APPLIES MAGNUM SUMMARY TABLE MAGNUM 2 hp MAGNUM 1 5 hp MAGNUM 1 hp LOW SPEED PASS 530 FEET 13 3 SECONDS LOW SPEED PASS 785 FEET 22 SECONDS LOW SPEED PASS NOT CAPABLE HIGH SPEED PASS CAPABLE HIGH SPEED PASS NOT CAPABLE HIGH SPEED PASS NOT CAPABLE Maximum speed attainable is 30 mph Maximum speed attainable is 25 mph Maximum speed attainable is 20 mph www ClassicCycles org 27 GRAPHIC DETERMINATION OF PASSING TIME AND DISTANCE LOW SPEED PASS MAGNUM 2hp LOW SPEED PASS MAGNUM 1 5 hp HEHA HE UK 4 F RR GEN 2 4 6 8 10 12 14 16 18 20 22 SEC 2 4 6 8 10 12 14 16 18 20 22 SEC HIGH SPEED PASS NOT CAPABLE HIGH SPEED PASS NOT CAPABLE 28 LOW SPEED initial speed 20 mph limiting speed 35 mph TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME SECONDS To constant 20 mph i HIGH SPEED initial speed 50 mph limiting speed 80 mph TOTAL PASSING DISTANCE FEET TOTA
3. 052 067 1 3 1 7 mm BTDC 18 219 Bosch W 74A Champion L 86 016 020 in 0 4 0 5 m m flywheel magneto Bosch RDPI 6V 26 5 10W special coil for magneto ignition Alu alloy with cast iron liner 2 separate centrifugal clutches running in ATF 2 speed automatic Le 16 70 i 4 375 nd 22 64 i 2 909 helical gears 14 af 2 214 chain 1 2 x 3 16 in 18 40 I 2 22 chain 1 2 x 1 8 in 26 23 i 1 13 tubular frame telescopic fork 2 95 in 75 mm travel control arm 2 36 in 60 mm travel internal expanding brake shoes 3 15 in 80 mm 70 18 mm 8 06 sq in 52 cm 2 1 2 17 26 32 psi 1 8 2 25 bar 1 85 US gal 7 1 www ClassicCycles org DIMENSIONS AND WEIGHTS Overalllenght 7039 in 1800 mm Overall width 323 in 820 mm Overalheight 45 3 in 1150 da Wheelbase 5 s y 483 NY 1150 mm Ground clearance 4 4 a 90mm Dryweight 1289 Ibs 58 5 kg ELECTRICAL EQUIPMEN Headlight bulb 6V 21W Tail Stop light bulb 6 V 5W 6eV 10W Speedometer light bulb 6 6W Warning device horn PERFORMANCE AND CONSUMPTION Topspeed a s s e 30 mph 48 km h Hill climbing ability 5 oo de MERO Fuel consumption DIN 70030 150 mpg 1 6 1 100 km Test conducted on a flat track in top gear at 3 4 top speed Track of 6 2 miles 10 km i
4. Dear Puch Owner This is your riding maintenance and warranty guide By following the instructions described in this booklet we at Puch know you will enjoy many miles of pleasurable Moped Riding Should a need ever exist for parts or service simply contact your Puch dealer He also has available for your purchase a Service Manual under the part Nr 907 2 71 894 5 0180 Thank you for joining the Puch family please ride safely and have fun P O BOX 7777 Greenwich Ct 06830 www ClassicCycles org CONTENTS PAGE sn ee ew mo wo sh OR CR 1 Warranty PORE DONNE uus ses MIR mom ee mm TES 3 EXIGRIGILUOGVDIE 4 ENSE oY A OWE Eee CRM RBS Ewe RR ee 5 FATE 6 A 2 4 4 RSEH RED EE TS Z ObperainacDEOIS ausus dtd ew dered tne 9 b uod xu doe cae EH eee wee eee ewe ee 14 Aecio T 24 eek ea iC Rew ee eR KE 14 ese man homm RERO 17 P ROUEN oqa mesa wa Reem ee eR eee EE a 20 OG cee eee see ORR RHR Rew RR EO ES 21 H Owner maintenance 23 Suggested maintenance and lubrication chart 25 4 ConsUmerinonBNO 5 55 dk XGRERRE ROB E EUN REOR E 26 THE WARRANTY Terms amp Conditions Subject
5. Always turn the fuel valve to the Off position when the moped is not in use Carburetor 1 The primer is operated by depressing the black rod extending through the left engine cover 2 The choke is operated by depressing the metal thrust pin which extends upward toward the opening in the left engine cover 10 Air pump and tools The air pump is located on the left side of the luggage carrier The tool kit is stored behind the cover in the rear of the seat Brake levers The brake control levers are mounted on the handlebar Left 1 lever controls the rear wheel brake Right 2 lever controls the front wheel brake www ClassicCycles org 11 12 Starting lever The starting lever is located on the left side of the handlebar and is used for starting the engine Please refer to operating procedure on page 17 Light and ignition switch The Magnum MK ll has a two step combination key switch located on the right top side of the instrument panel A key is needed for switching Fully to the left ignition and lights off Step 1 to the right ignition on Step 2 to the right ignition and lights on Horn button Light switch and horn button The Magnum MK II has a two function switch located on the left side of the handlebar which incorporates the red horn button and the directional light switch The Magnum MK I is pre wired for the use of a turn signal kit p nr 321 1 54 890 9 which is avail
6. to the terms set forth below the Puch motorized bicycle is warranteed to be free from defects in material and workmanship for a period of 6 months from the date of original consumer purchase While under this warranty Steyr Daimler Puch of America hereafter SDPA will at its descretion replace or repair without charge any product or part which an authorized service representative determines is defective in material or workmanship This warranty applies to the original consumer purchaser only This warranty gives the original consumer purchaser specific legal rights The original consumer purchaser may also have other rights which vary from state to state www ClassicCycles org 3 EXTENT OF WARRANTY COVERAGE The warranty will not be extended to any machine that has been subject to mis use negligence alteration use of non authorized spare parts improper maintenance including improper fuel mix ratio lack of oil or use of poor quality oil or modification of assemby Additionally this warranty will not apply if the machine is damaged by fire flood accident acts of God or any other cause of a similar nature beyond SDPA s control Under no circumstances will SDPA be liable for damages due to loss of use loss of business or profits or for any other incidental or consequential damages Some states do not allow the exclusion or limitation or incidential or consequential damages so the above limitation may not apply This warranty w
7. 1 W 7 A W 175 T 1 NGK B 4H B 6H or B 6HS B 6H or B 6HS Champion L 90 L 86 L 86 www ClassicCycles org 23 24 Chains Engine drive and pedal chain should be kept clean Every few hundred miles wipe chains thoroughly clean with a cloth Lubricate with chain lubricant or oil SAE 90 Always keep chains properly tensioned The proper slack of the drive chain should be 3 4 To adjust drive chain loosen the axle nuts and tighten or loosen the adjuster nuts Once chain is properly adjusted tighten the axle nuts Make sure that wheel is properly aligned If pedal chain tensioner catches or travels roughly as pedals are operated realign tensioner so chain travels smoothly NOTE Always keep brake cables properly adjusted and lubricated to ensure safe riding The play in the brake levers should not exceed 1 after adjustment 1 SUGGESTED MAINTENANCE Frequency AND LUBRICATION CHART First Every 300 miles miles o o 8 8 8 8 OPERATIONS TO PERFORM www ClassicCycles org 25 regular maintenance and lubrication schedule will help to ensure a long useful life for your moped Please refer to the mileage and lubrication chart for detailed information 3600 7200 Tire wear and condition Throttle cable adjustment Check tire pressure check transmission ATF level Clean and lubricate chains Clean air filter Change transmission ATF Check spark plug Decarbonize engine Clean exhaust baffle R
8. L PASSING TIME SECONDS constant 50 mph D 55 truck www ClassicCycles org 29 TECHNICAL DATA MAGNUM 2hp CONTROLS Speedometer Plate Frame number Steering lock A Rear wheel brake lever EN Front wheel brake lever CUS Light switch EA NS y A Q Throttle twist grip Starting lever Butte Engine stop switch h Primer CY N E Fuel tank cap Choke destin Sabe Fuel valve Pedal 7 NLL Tool compartment 1 ENGINE Macmum output Maximum torque ratic E Displacement Cooling Lubrication Carburetor Main jet Needlejet Needle position Needle size Throttle slide eed point gap ition timing lem plug 5 plug gap Generator GO an ylinder material POWER TRANSMISSION Clutch Transmission Engine Transmission reduction Transmission Rear wheel drive Pedalling drive CHASSIS Frame Front wheel suspension Rear wheel suspension Brakes gt Dia of brake drum Width of brake lining Total effective brake surface Tire size front and rear Tire Fuel tank ft 05 0 ss at 4500 rpm 1 496 ii 95 m 1 693 in 43 mm 2 97 cu in 48 8 cc air cooled as oil mixture ing 1 12 322 60 58 by packed 2 12 A st notch from top 2 3 at 5000 rp 63 magneto ignition 020 in 0 4 0 5 mm
9. TRATION FORM Part 3 which is self addressed and stamped must be mailed to Steyr Daimler Puch of America Corporation P O Box 7777 Greenwich Connecticut 06830 not later than ten 10 days after purchase of vehicle All information on the Form must be written legibly The serial numbers on the Registration Form must agree with those on the Moped A SERIAL NUMBER LOCATION The engine number is stamped on top of the right crankcase half The specification plate is secured to the steering head www ClassicCycles org IMPORTANT Write down key number at once This saves time money and annoyance if the keys are lost The frame serial number is stamped on the steering head just above of the vehicle identification number plate B OPERATING CONTROLS The positions of the controls are shown in the enclosed technical data sheet Following some operating controls described in detail Locking and unlocking your moped To lock move the handlebar to the right Insert key into lock Turn key to the left push in and turn key to the right Remove key Unlock in reverse order Fuel tank filler cap TO open turn filler cap counter clockwise www ClassicCycles org Fuel valve The fuel valve is located on the left side of the fuel tank The positions are clearly indicated on the tank In the event you should run out of fuel the reserve position should give you adequate range to get you to a filling station
10. able for purchase through your PUCH dealer The Magnum II has a two function switch located on the left side of the handlebar which operates the lights and horn The thumb lever on the end of the switch activates the lights and the small red push button operates the horn Engine stop switch This two position thumb switch is located on the right side of the handlebar The center position marked RUN is used to start and run the engine The lower positions are marked OFF and are used to interrupt the ignition which stops the engine NOTE The Magnum MK has an igniton switch also please refer to page 12 www ClassicCycles org 13 C TIRE PRESSURE Recommended tire pressure Front 26 psi 1 8 bar Rear 32 psi 2 25 bar D OIL GAS OIL MIXTURE Checking transmission oil level The oil level control screw 1 on the 2 speed automatic is located on the clutch cover The oil filler hole 2 is trough the top of the right crankcase half The drain plug 3 is located on the lower portion of the right crankcase half 91 5 fl oz 280 cc of ATF TYPE is used for refill CAUTION The moped must be upright when filling oil Do not overfill Leave oil level control screw removed until excessive ATF drains off Oil change after the first 300 miles of operation is highly recom mended 14 Filling up with two stroke mixture Gas oil mixture on model without oil pump Magnum II The Magnum 11 engine mu
11. eeder hose although sufficient oil is in tank stop engine Drain gas and refuel with gas oil mixture See Oil Mixing Table on page 15 WARNING NEVER REFUEL WITH THE ENGINE RUNNING DO NOT SMOKE OR ALLOW OPEN FLAMES OR SPARKS IN THE AREA WHERE YOUR MOPED IS REFUELED AND OR WHERE GASOLINE IS STORED E OPERATING INSTRUCTION 1 Prop the moped on its stand 2 Unlock fork 3 Magnum MK II only Turn on ignition Ist step to the right on the switch 4 Turn fuel valve to the ON position 5 Be sure that the engine stop switch is in the RUN position 6 If engine is cold depress the choke and depress the primer button on the carburetor until fuel drips from carburetor CAUTION After completing step 6 do not open the throttle control as this will deactivate the choke After the engine has started and warming up open throttle gently to the full position briefly This will disengage choke Avoid racing engine 7 Keep both hands on the handlebar with the weight of the moped centered on the front wheel Apply the front brake and fully depress the starting lever located on the left side of the handlebar Position the pedal approx parallel to the chain guard While holding the starter lever push the pedal to start engine 8 Alternate starting method The moped may also be started by pedalling as a bicycle When momentum has been gained pull the start lever and gently open the throttle Release the start lever after the eng
12. etighten screws and nuts Clean fuel valve and lines Clean carburetor Idle speed adjustment Check ignition timing Adjust clutch Check brakes linings Check lubricate hub bearings Lubricate front fork Steering bearing adjust lubrication Lubricate control cables Adjust chain tension NOTE Above mileage schedule applies to moped used on dry paved surface If used in wet muddy or sandy area maintenance intervals should be more frequent Always check controls and lights before using your moped RECOMMENDED SERVICE Hydraulic front fork Magnum MK II J CONSUMER INFORMATION CONSUMER INFORMATION Stopping Distance Vehicle minimum stopping Distance on dry ground This figure indicates braking performance that can be met or exceeded by the vehicles to which it applies without locking the wheels under maximum condition of loading The information presented represents results obtainable by skilled drivers under controlied road and vehicle conditions and the information may not be correct under other conditions Description of vehicles to which this table applies MAGNUM Fully Operational Service Brake Maximum load 20 30 40 Stopping distance in feet at maximum speed 26 ACCELERATION AND PASSING ABILITY THIS FIGURE INDICATES PASSING TIMES AND DISTANCES THAT CAN BE MET OR EXCEEDED BY THE VEHICLES TO WHICH IT APPLIES IN THE SITUATIONS DIAGRAMMED BEL OW
13. ill be null and void if 1 Any part of the serial numbers are removed defaced or altered 2 f any unauthorized modification or alteration is made If any unauthorized or non standardized spare part is installed 4 If any maintenance or repair is perfomed during the warranty period by anyone other than an authorized Puch Dealer EXCLUSIONS Normal wear parts are excluded from this warranty Normal wear parts include Tires tubes spark plugs brake linings clutch hub chains spokes sprockets ignition points condenser brake cables throttle cable air filter Routine maintenance No one has the authority to orally change the terms conditions or exclusions of this warranty or make any representations or express warranties other than those contained here SDPA is proud and confident of its dealers and products and wants to assure that each new Puch owner receives full satisfaction In the event satisfaction is not obtained at the dealer level however the original consumer is invited to contact SDPA directly at P O Box 7777 Greenwich Connecticut 06830 www ClassicCycles org 5 WARRANTY REGISTRATION The Warranty Registration form should be completed by the dealer and the consumer purchaser at the time of sale Part 1 shall be kept by the selling dealer Part 2 should be kept by the original purchaser in his her possession ANY CLAIM MADE UNDER THIS WARRANTY MUST BE ACCOMPANIED BY PART 2 OF THE WARRANTY REGIS
14. ine starts www ClassicCycles org 17 18 Throttle The speed of the moped is controlled with a twist grip on the right side of the handlebar To accelerate twist the throttle towards you to decelerate release slowly NOTE Depending on engine RPM cluch will engage or disen gage automatically Shifting into or from 2 gear depending on engine RPM and road speed will occur automatically also Braking To slow down release the throttle control and apply equal pull to both brake levers Application of both brakes at the same time is essential to prevent premature brake wear and or loss of vehicle control CAUTION Be alert when riding on wet or sandy surfaces Loss of traction between tire and road can occur under these conditions Be careful when braking turning or accelerating under adverse conditions To stop and park Release the throttle and simultaneously apply both brakes to stop Switch off engine with stop switch Magnum II only Turn off ignition and remove key Close fuel valve Rest moped on stand and lock Securing your moped Please refer to page 9 A high security locking device is recommended See your Puch dealer for advice WARNING After the engine has been run the exhaust pipe and muffler will become hot avoid contact with them 19 www ClassicCycles org 20 F RIDING INSTRUCTION 1 It is suggested to wear bright clothing utilize eye protection and p
15. re regular grade gasoline Magnum MK Il Switch to RUN position Clean spark plug or replace Heplace Note Spark plug gap 016 020 0 4 0 5 mm Reconnect it to spark plug Apply choke Clean spark plug Have it cleaned at your Puch dealer www ClassicCycles org 21 22 Q O A onm Cause Choke working all the time Exhaust clogged Spark plug defective or fouled Clutch slips Air filter is clogged Fuel mixture incorrect Poor Performance Remedy Disengage it by opening throttle fully Have dealer clean exhaust Clean or replace it See your Puch dealer Clean air filter Drain tank and refuel with correct mixture Note see mixture chart on page 15 Please refer all questions you may have about your Puch to your authorized Puch dealer He is trained and qualified to properly service your machine and can best advise you on its maintenance and care H OWNER MAINTENANCE Spark plug To check if plug is functioning properly proceed as follows Disconnect plug wire from plug Unscrew plug Reconnect plug wire to plug and ground same on cylinder head WARNING ENSURE THAT NO FUEL IS ON WARNING ENGINE AND OR FLOOR WARNING BEFORE PROCEDING Continue as if starting engine and check for a strong blue spark at electrode If no spark clean or replace spark plug Note Gap 016 020 0 4 0 5 mm Hecommended spark plugs 1 hp 15 hp 2 hp Bosch W 10 A W 95 T 1 W 7 A W 175 T
16. roper shoes or boots when riding your moped Wearing a helmet is optional in most areas See your PUCH dealer for advise Be sure to switch on headlight at low visibility and or where required by law The moped is designed to carry ONE person Do not carry a passenger or very heavy cargo Approved PUCH saddle bags and baskets are available through your dealer Obey all traffic regulations Use hand signals when turning or changing lanes Please respect property of others and ride carefully Keep your feet on the pedals at all times Keep the pedals level especially on turns After reaching maximum speed reduce the throttle opening to 3 4 While the reduction in speed will hardly be noticeable fuel consumption however will be considerably reduced Closed throttle will slow down moped when riding downhill To ensure engine lubrication on long downhill rides open throttle occasionally G TROUBLE SHOOTING Engine will not start or stops running Cause amp Ww Co Fuel valve closed Fuel tank empty Stop switch in Off position Spark plug is fouled Spark plug defective Ignition cable has worked loose from spark plug Engine is too cold Engine is flooded Fuel valve is clogged or main jet is clogged Remedy Open fuel valve or switch valve to reserve position Switch valve to reserve or refill tank with gas oil mixture Magnum 11 On model with oil pump use pu
17. s used both ways and may have very short upward and downward grads of maximum 1 596 The vehicle must be adjusted to specification with tires correctly inflated Riders weight not more than 143 Ibs 65 kg The measured consumption is increased by 10 taking unfavourable conditions into account New vehicles may vary up to 5 96 from this value CAPACITY AND QUALITY OF LUBRICANTS see Owners Manual Mixture of regular grade gasoline with special 2 stroke oil MAXI MIX 50 1 ENGINE DO NOT USE UNLEADED GASOLINE 9 1 2 fl oz 280 cc Automatic Transmission Fluid TYPE F 0810 29869171 706 WIRING DIAGRAM BLUE GREEN GREEN BLUE GREEN GREY YELLOW GEN x i O 4 H 1 Headlamp 5 Brake light switch 9 Ignition coil 2 Speedometer bulb 6 Brake light switch 10 Generator 3 Light switch Horn button 7 Horn 11 Wire connector 4 Engine stop switch 8 Spark plug 12 Tail Stop light www ClassicCycles org amp Click on links below OFM D OEM parts amp online schematics EU OEM parts amp online schematics US Cruiser Customizing J amp P Cycles Motorcycle Parts Save Up to 45 on Motorcycle Tires JC Whitney Motorcycle Parts amp Accessories Motorcycle Boots Motorcycle Helmets Motorcycle Jackets Rocky Mountain ATV MC Mega Motor Madness Shop Revzilla for the latest in Mot rcycle Accesories Cycle Gear Direct Free Shipping mem 7 gom Ot se
18. st be run with a gas oil mixture regular gas The recommended mixing ratio is 50 1 when using special Maxi Mix two stroke moped oil If another oil is used please refer to the fuel mixing chart a NOTE DO NOT USE UNLEADED GASOLINE 4 50 1 OIL MIXING TABLE WITH PUCH MAXI MIX To 5 gallons gasoline add 12 fl oz 355 cc oil To 1 gallon gasoline add 2 4 fl oz 71 cc oil To 1 quart gasoline add 6 fl oz 18 cc oil NOTE To reduce carbon build up within the engine and exhaust system we strongly recommend the use of the special 2 stroke MAXI MIX oil 50 1 ratio However as an emergency measure a regular 2 stroke oil can be mixed in a 25 1 ratio as shown below 25 1 OIL MIXING TABLE WITH REGULAR TWO STROKE OIL To 5 gallons of gasoline add 24 fl oz 710 cc oil To 1 gallon of gasoline add 4 8 fl oz 142 cc oil To 1 quart of gasoline add 1 2 fl oz 36 cc oil www ClassicCycles org 15 16 Using cup to measure gas oil mixing ratio MAGNUM 1 without oil pump When measuring oil for the gas oil mixture use one cupful of Maxi Mix to one gallon of fuel NOTE When using other grades of 2 stroke oil please refer to previous page MAGNUM Il only with oil pump Use pure regular grade gasoline only Check oil level in the oil tank each time you refuel your machine CAUTION If oil level in oil tank drops to half top off with Maxi Mix Should you notice that no oil is passing through oil f
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