NSU max motorcycle manuals

s E R V I c E In using this manual please note the following points:- 1. Although reference is made throughout to both the ,Standard" and the ,Spedal" Max, only the latter is now used in this country. 2. The plates are more easily understood when used in conjunction with an illustrated spare parts catologue. 3. Unless otherwise stated all nuts and bolts have a rigth-handthreod. 4. The operations described in this manual con only be carried out satisfactorily with the Max SpeclaiTools supplied by us. A list of these, together with certain other recommended special tools, not comprised in the actual set, can be found at the end of this book. 5. Only genuine NSU Spare-Parts or Exchange Parts should be used in carrying out repairs. 6. Flat Rate Repair Times ore given in order to facilitate the preparotion of estimates and in- voices and the supervision of work in progress. 7. Index numbers ore used to designate individual operations; e. g.:. Removal and Replacement of Engine or Stripping and Reassembly of Engine M 01 M02 Token in conjunction with the use of Flat Rate Repair Times, these index numbers con abbreviate the preparation of orders, instructions, bills, etc. London, December 1955 NSU (GREAT BRITAIN) LTD. Head Office: 7 CHESTERFIELD GARDENS, LONDON. W. 1. Telephone: GROsvenor 4446 Telegrams: ENESU Cables and Telex: ENESU LONDON Downloaded from NSUSupermax.com

• SERVICE Engine Cycle . Number of cylinders Bore Stroke Capacity Compression space Compression ratio Max engine speed Output Compression pressure Piston clearance Gudgeon pin dia Connecting-rod little end dia lubrication Oil capacity Standard fuel consumption Valve gear Valve timing Tappet clearance . Dia. of vcilve stems Valve guide bores Valve spring pressure Carburettor Air cleaner REPAIR MANUAL MAX Technical Data I Page 1 XII. 1955 edition ENGINE = Type 251 OSB, unit construction, air-cooled = Four-stroke = 1 = 69mm = 66mm = 247 cc = 38.5cc = 7.4:1 = 7,000 r. p.m. = 17h.p. = 9.6 otm (141 lbfsq in) = marked .KSN 0.05-0.06 mm (0.0020-0.0024 in} = marked .Mahle" 0.04--C-0.05 mm (0.0016-0.0020 in) = 18 mm- 0.005 mm (0.7087 in-.: 0.0002 in) 18 0.034mm ( 07087 . +0.00134 1 -n) = mm + 0.016 mm · '" 0.00063 = Gear pump (dry sump) = 2litres (3% pints) SAE 30 in summer SAE 20 in winter, below freezing point SAE 10, if obtainable = 3.2 litresflOO km (88.27 m.p.g.) = Overhead valves mounted in light-alloy cylinder head. Overhead camshaft driven by eccentrics Inlet opens 2° before TDC l Measured with Inlet shuts 200 after BDC 2 mm Exhaust opens 36° before BDC J (0.08 in) tappet Exhaust shuts 13° before TDC clearance Inlet 0.05 mm (0.002 l Engine cold Exhaust 0.10 mm (0.004•n) J Inlet 8mm-0.040mm(0.3149-0.0016 in) - 0.055 mm ( - 0.0022 in) Exhaust 9 mm - 0.045 mm (0.3543- 0.00177 - 0.060 mm ( - 0.00236 in) = Inlet 8 mm + 0.015 mm (0.3149 + 0.0059 in} Exhaust 9 mm + 0.015 mm (0.3543 + 0.0059 in) 35 kg (77.2 lb) CARBURETTOR = Bing Type AJ 2j26j25, Main jet 105, Slow-running jet 45 Needle jet 2.68 Needle positins: 2 while running in, thereafter 1. Air regulating screw 1% turns open. Mixing chamber insert 5. = Decreases turbulence in the inlet air by passing it through the frame to the wet-air filter. Downloaded from NSUSupermax.com

REPAIR MANUAL MAX Technical Data/ Page 2 XII. 1955 edition SERVICE .. IGNITION Ignition timing Type of ignition Contact-breaker points gap Sparking plug, standard . Sparking-plug electrode gap = 7.6 mm (0.299 in) before TDC or 36° if adjustment is effected by means of graduated scale, with governor fully open. The lever without the stop is the one by which the timing should be adjusted. · = Coil ignition = 0.4- 0.5 mm (0.016- 0.020 in) = Bosch W 240 T 11 = 0.7 mm (0.028 in) (for Bosch plug) CLUTCH Clutch Clutch operation Pressure of clutch springs Clutch adjustment = Multi-plate dry clufch with rubber shock absorber = By hand = about 160 kg {353 lb) = 5.7 mm (0.224 in) from the top of the nut to the clutch drum. GEARBOX Gearbox Nature of engagement Axial play of gearbox shafts Reduction, engine: gearbox Primary drive, engine-gearbox Secondary drive, gearbox-rear wheel Solo Operation Gearbox ratios Bottom gear 2nd gear 3rd gear Top gear Reduction gearbox-rear wheel Overall gear ratios Bottom gear 2nd gear 3rd Top gear gear Chain sprockets Gearbox 16 teeth 3.15 :1 2.025:1 1.406 : 1 1 d 2.625:1 . 21.36 :1 . 13.73 : 1 9.53 : 1 6.78 : 1 1 5 teeth for cross-country work Rear wheel 42 teeth Rear chain, 15.87 mmx6.48mm, 106 links Tyre sizes: front 3.25x19 rear 3.25x19 . = 4-speed unit-construction gearbox - Dogs = up to 0.2 mm (0.008 in) = 2.583:1 = Helical gears = Chain, fully-enclosed Sidecar Operation Gearbox ratios Bottom gear 2nd gear 3rd gear Top gear Reduction, gearbox-rear Overall gear ratios Bottom gear 2nd gear 3rd Top gear ·- gear Chain sprockets Gearbox 14 teeth wheel 3.15 :1 2.025:1 1.406: 1 1 :1 3.0 :1 . 24.41 : 1 . 15.7 :1 . 10.89 : 1 7.75 :1 } 3 teeth for cross-country work Rear wheel 42 teeth Rear chain 15.87x6.48 mm, 105 links Tyre sizes: front 3.25x19 rear 3.5 x19 Downloaded from NSUSupermax.com

REPAIR MANUAL SERVICE MAX Tectrical Page 3 XII. 1955 edition WHEELS and BRAKES Wheels Tyre pressure, front Tyre pressure, rear Trail Toe-in of sidecar wheel Camber of machine Camber of sidecar wheel Maximum speed (as specified in DIN 70 020) Rims Spokes Leading dimensions for spoking up wheels Front broke Rear brake Broke operation = interchangeable = 1.25 atm. (181/21bfsq in) = 1.5--:-2.0 atm. (22-291b/sq in) depending on load = 60 mm (2 3/8 in) (fixed, non-adjustable} = 25-30 mm (1-1 1/4 in) (pointing inwards to front of machine) = 15-20 mm (1/2-3/4 in) (leaning outwards) = 10-15mm (3/8-1j2in) (Leaning outwards) Iff. see Instruction Book = about 116 kmfhr (72 m.p.h.) carrying two per- sons sitting upright. about 126 kmfhr (79 m.p.h.) carrying one person leaning forward. = Well-base rims, 2.15 Bx19 = Standard, Front and rear spokes the some. left-hand 3.5 mm (0.138 in) dio. . . 21 0 mm (8.27 in} long. Right·hand 3.5 mm (0.138 in) dia. 169 mm (6.65 in) long. Specialo Front and rear spokes the same, but the inner and outer spokes ore set at different angles. (From vehicle No. 1 290 150 /789 958 4 mm- 0.016 in- dia. spokes ore fitted). = Standard: Distance from outer = edge of rim to right-hand hub 11 mm (0.433 in) Special: left-hand edge of brake drum in line with edge of rim. = Mechanical internal-expanding brake = Mechanical internal-expanding brake = Fronh Hand lever Rear: Foot pedal OTHER DATA Wheelbase Overall length Maximum width Maximum height Ground clearance . Height of saddle Frame ' Front and rear forks Springing, front Springing, rear Permissible weight of machine Permissible all-up weight Fuel tank capacity = 1311 mm (51 5/8 in) = 2051rom (80 3/4 in} = 716 mm (28 1/4 in) = 984 mm (38 3!4 in) = 148 mm (57/Bin) = 780 mm (30 3/4 in) = Pressed-steel = Pivoted link sprung forks = Helical springs, hydraulic shock absorbers = Helical springs, hydraulic shock absorbers = Standard: about 155 kg (342 lb} = Special: about 165 kg (364 lb) = Standard: about 310 kg (683 lb) = Special: about 315 kg (695 lb) = Standard: 12 litres (2 5/8 gallons) of which 1.5 litres (21/2 pints) is reserve supply = Special: 14 litres (31/8 gallons) of which 1.4 fitres {2 1/2 pints) is reserve supply Downloaded from NSUSupermax.com

REPAIR MANUAL MAX Engine I Page 1 XII. 1955 edition SERVICE .. Removing engine from frame and replacing (M 01) Special tools required: none. 1. Disconnect positive lead from battery To prevent short circuit or battery discharging. 2. Remove foot rests Unscrew nut on right-hand side. 3, Remove silencer and exhaust pipe Unscrew bolt and screwed connector. 4. Remove air filter First take off connecting tube and cover plate. 5. Pull fuel pipe off reserve tap with cup filter 6. Dismantle carbjaetter' Unscrew carburetter cap, withdraw throttle slide with needle (take care not to damage the parts), and unscrew the clamping ring se- curing the carburetter. ' 7. Drain the oil out of the oil tank Disconnect both oil pipes from oil tank. 8. Disconnect cable for valve lifter from cylinder head 9. Remove the support plate Unscrew the bolts on the cylinder head and on the frame; take the horn cable out of the clip. Fig. M 01/1-9 10. Loosen the rear hexagon bolt on the cylinder head. Note: This bolt must not be finally removed until the engine is dropped out of the frame, since otherwise it is possible for the engine to tip forward and damage the mudguard .... ,. ·' 11. Remove the right-hand crankcase cover. Dis- connect the clutch cable from the fever, unscrew the adi1.1ster and nut, and the cable. '-'' 12. Disconnect the lead from the dynamo (30/51, 15, 61) and pull through the rubber sleeve on the cover. 13. Remove chain Turn until the spring link is on the gearbox sprocket, and undo the spring link. Unhook both ends of the chain from the sprocket and replace the spring link so that the chain con- not drop back into the chaincase. If necessary loosen the bolt on the clip for the chain lubricator, and push down the lubricator. 14. Drop engine out of frame. Push the lower section of the chaincase slight. ly away from the crankcase, remove the engine-attachment links, and withdraw the front lower hexagon bolt. Remove the cover plate, turn the front wheel to the left, wrap the cylinder head in a rag .(to avoid scratching the mudguard), hold the engine from the left-han{i_ side of the machine, and after removing the rear hexagon bolt drop the engine out to the left of the frame. ' ,. Downloaded from NSUSupermax.com

REPAIR MANUAL SERVICE .. Fig. M Olfl4 15. Replace the engine, working in the reverse order. Note: The rear hexagon bolt must not be tightened up until the lower clamps ond the front lower hexagon bolt have been tightened up in order to prevent any distortion occurring. Section 9. Assembly: The support plate should not be replaced until after the machine has been run and tested on the test bench, after the cylinder-head cover has been replaced and tightened up (see M 02, section 61). If necessary fit the lower cover plate afterwards. MAX Engine I Page 2 XII. 1955 edition Downloaded from NSUSupermax.com

REPAIR MANUAL MAX Engine I Page 3 XII. 1955 edition SERVICE Stripping the engine when it has been removed from the frame Special tools required: See sheets ,.Special tools and additional special tools for Max". (M02) Note: The engine can also be stripped in a sJighHy different manner, as 1. Drain oil 2. Remove rocker box cover 3. Strip upper valve gear 4. Remove cylinder head 5. Remove cylinder 6. Remove piston 7. Remove 8. Remove crankcase cover plate 9. Remove front bearing plate 10. Remove oil pump 1L Strip lower valve gear 12. Withdraw pinion from crankshaft 13. Remove dynamo 1-4. Remove crankshaft and gears 15. Remove gear changing mechanism 16. Remove the sludge traps and oil pipes 17. Clean and check att parts. 1. Secure engine to assembly stand. 2. Remove ignition lead, sparking plug, and ignition lead adaptor. 3. Remove the rocker box cover and gasket. Turn the engine so that the left side is on top. 4. Remove the kickstarter pedal, the foot-change pedal, and the dutch cover plate. Fig. M 02/1-5 5. Drain off oil. Remove both the drain plugs and also the plug on the front of the left half of the crankcase to allow air to enter. Stand the engine upright while the oil is being drained off. 6. Remove clutch. After taking off the dutch cover plate, remove 7 nuts, springs, and spring boxes, the inner housing, the dutch plates, and the thrust rod. Attach the holder (018 103 567) for the dutch back plate, and unscrew the nut from the gearbox shaft. Remove washer and clutch bock plate. Fig.M02/6 Screw withdrawing tool (038 .1 03 647) on to the outer dutch housing and remove the housing. Fig. M 02f6a 7. Remove the left-hand cover plate and gasket. Withdraw the kick-starter spindle complete together with the dutch pinion. Fig. M02{1 Downloaded from NSUSupermax.com

REPAIR MANUAL MAX Engine I Page 4 XII. 1955 edition SERVICE Tum the engine so that the right side is on top. Note: Two 5-mm {0.20-in) dia. balls and two thrust rods will drop out. 8. Remove the automatic timing control. To do this the screw must be unscrewed com- pletely. Fig. M02/8 Push bock the dynamo brushes, and hold by means of the spring (to assist reassembly). Re· move the bolts in the dynamo housing. 9. Remove armature. Place one of the clutch thrust rods in the arma· ture bore, and screw up the bolt holding the armature. This will force the armature off its shaft. Remove the key. Fig. M02j9 10. Remove balance weight. Stano the engine upright. Turn the crank until the balance weight points'·"d&wnwards, and loosen the nut on the camshaft spindle. Hold Fig. M 02/10 the nut by means of a 19-mm spanner and turn the spindle by means of a box spanner. Lay the engine sideways, so that the nut and spring wasQer do not fall into the crankcase when they'come dear. Turn the crankshaft until the baldnce weight points upwards. Remove the balance weight. .I Fig. M 02/10 a 11. Remove driving pin and ca.mshaft spindle. Stand the engine upright, and turn the crankshaft until the two connecting rods f6t' the eccentric drive are on their top . Pull out the driving pin and knock.•ltt. ··the camshaft spindle. · Downloaded from NSUSupermax.com

REPAIR MANUAL MAX Engine I Page 5 XII. 1955 edition SERVICE .. Fig. M 02/11 Press the tie rod away from the- camshaft housing, and push it sideways. Fig. M 02/11 a 12. Remove the camshaft housing Remove the nuts and lock washers from the bearing brackets, and take off the bearing- -bracket straps. Slide two screwdrivers or le- vers under the rocker arms and force up to remove the camshaft housing. Fig. M02/12 (Take care not to damage or lose the rubber ring on the bearing bracket (inlet side) or the shims}. 13. Remove upper eccentric disc Mark the front side of the eccentric. Push the tie rod into the groove cast into the· cylinder head, press the front connecting rod off the eccentric disc and to the left, and push the rear connecting rod with the upper eccentric disc to the right. Fig. M 02/13 Turn and withdraw the eccentric disc. 14. Remove cylinder head. Remove the M 6 nut on the cylinder head, and unscrew four nuts (left-hand thread) on the cylinder flange. Fig. M 02/14 Remove the cylinder head and gasket. Downloaded from NSUSupermax.com

REPAIR MANUAL MAX Engine I Page 6 XII. 1955 edition SERVICE Fig. M 02jl4a 15. Remove cylinder. Unscrew two M 6 nuts on the cylinder flange. (Cover the crankcase with a rag to keep out dirt). Fig. M02/15 16. Remove piston. Remove the circlips. Heat the piston until the gudgeon pin can be pushed out using the gudgeon pin extractor (088 891 908). ( \. Fig. M02/16 17. Remove Front Bearing Plate. Turn the engine so that the left-hand side is on top. Standard: Unscrew four nuts and one bolt on the ,bearing plate and one nut and lock washer on the lower eccentric shaft. Spedal: Unscrew three nuts and one bolt on the bearing plate and one collar bolt on the lower eccentric shaft. Support the connecting rod by means of a slotted piece of wood. Fig. M02fl7 Attach jig (088 891 900), with the extractor spindle removed to avoid damaging the sealing disc on the bearing plate. Screw the three M 8 bolts on the fixture up evenly, and the bearing plate will lift off. Downloaded from NSUSupermax.com

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