Sachs Madass Workshop Repair Manual
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DESCRIPTION:
This repair manual serves as guideline for professional repair activities. See the illustrated spare-parts catalog for further assistance. All fi gures, dimensions and descriptions correspond to the state of the version concerned. All changes are reserved in the interest of further development of the construction models. See also the “technical information”, which provides data about technical changes implemented after this repair manual was sent to the printer .
- The technical information is intended for master mechanics, since its careful and constant observation is a requisite for preserving the operability of the individual assemblies of the motorcycle. Apart from such information, the usual basic safety rules that apply to the repair of motorcycles must be observed.
- Use the tools provided for in the “Motor” section. The use of unsuitable tools may adversely affect engine operability. This manual is provided only for internal use within the Sachs organisation. It may not be reproduced or made available to third parties.
TABLE OF CONTENTS:
TECHNICAL DATA
Engine ignition system carburettor power transmission
Chassis lubricants and operating fl uids electrical equipment dimensions and weights
SERVICE DATA
Tightening torques for inspection plan
Spare parts for inspection plan
Inspection plan
GENERAL NOTES
TORQUE VALUES
Torque values engine and frame
Torque values general
MAINTENANCE
Spark plug
Valve clearance
Carburetor idle speed
Air cleaner
Adjusting the clutch lever play
Checking adjusting the drive chain
Brake system
Frontwheel
Rearwheel
Wheel bearings
LUBRICATION SYSTEM
Service information
Troubleshooting
Engine oil
Engine oil fi lter cleaning
Oil pump removal
Oil pump inspection and installation
FUEL SYSTEM
Service information
Troubleshooting
Carburetor throttle valve removal inspection and installation
Carburetor removal inspection and installation
Fuel cock
ENGINE DISASSEMBLY / ASSEMBLY
CYLINDER HEAD / VALVES
Service information
Troubleshooting
Camshaft removal inspection
Cylinder head removal
Cylinder head inspection
Valve guide valve seat inspection refacing
Cylinder head assembly
Cylinder head installation
Cam shaft installation –
Cylinder compression
CYLINDER / PISTON
Service information
Troubleshooting
Cylinder removal cylinder inspection
Piston removal piston piston ring inspection
Connecting rod inspection
Piston ring installation piston installation
Cylinder installation
CLUTCH / GEARSHIFT / LINKAGE
Service information
Troubleshooting
Clutch removal
Clutch disassembly
Clutch inspection
Clutch assembly
Gearshift disassembly and assembly
Clutch installation –
ALTERNATOR / CAM CHAIN TENSIONER
Service information
Troubleshooting
Alternator fl ywheel removal
Cam chain tensioner removal inspection and installation
TRANSMISSION / CRANKSHAFT / KICK STARTER
Service information
Troubleshooting
Crankcase separation
Crankshaft inspection
Timing sprocket replacement
Kick starter disassembly and reassembly
Transmission disassembly and inspection
Shift drum disassembly transmission bearing inspection
Crankcase bearing replacement
Transmission assembly
Crankcase assembly
ELECTRICAL SYSTEM
Fuse
Battery charging battery
Commissioning battery
Cockpit speedometer adjustment
Speedometer battery change
Changing bulbs
Assembly of indicator light bulbs
Adjusting the headlamps
IGNITION SYSTEM
Shema
Service information
Troubleshooting
CDI unit inspection
Ignition coil inspection
Alternator coil inspection
Ignition timing inspection
WIRING DIAGRAM
Wiring diagram without clutch switch
Wiring diagram with clutch switch
TROUBLESHOOTING
Engine
Electric
Battery
FILE FORMAT:
LANGUAGE:ENGLISH
PAGES:218
DOWNLOADABLE:YES
FILE TYPE:PDF
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