MZ TS 125 Betriebsanleitung

REPAIR MANUAL

for

the

MOTOR-CYCLES

TS 125

and

TS150

with

174

illustrations

and

drawings of special tools

4th

Edition

VEB

MOTORRADWERK ZSCHOPAU

Betrieb des IFA-Kornbinats Zweiradfahrzeuge

The motor-cycles of

types

125,

130,

12511

and

15011

are product8 from VEB Motorradwerk Zldropau

This Repair Manual was written by a team of engineers in the employ of VEB Motorradwerk Zschopau

VEB Motorradwerk Zsdropau reserve the right to modily or deviate from published specifications tor technical or

technological reasons at any time without notice.

VEB

FACHBUCHVERLAG

LEIPZIG

Dead line: June

1983

Photomeohanfcal print: Salzland-Druckeref StaOfurt

157A30/84

1251150

und

12511

15011.

englisch.

g;.

Aufl.

Preface

111the high latitudes of Finland, in the parhing heat of Africa, under the mort

different operating conditions

motor-cycles run to the retidaction of their

owners.

To ensure that the vehicles, remain in perfect working order and reliable .in

service after a long period of operation, involving a certain amount of wear.

we issue this Repair Manual to give the necessary instructions to our

work-

shops

home and abroad.

Repair

WOI'~~

is a matter of confidence in several respects:

reliability and workmanship of the mechanic; the safety of the driver

depends on them.

finding the actual cause of the trouble; this ensures that no material

is wasted and labour costs are restricted to a minimum.

from this. three advantages result: no retouching work, short times of

inoperatiun and low repair costs.

good worksmanship in repairs largely depends on the use of the special tools

and means recom~~~endedby

MZ.

Authorised

Service-shops may obtain them

from the

R1Z

Spare Sales Department, whereas amateur constructors only have

the

possibil~tyof making them themselves. But to do it yourself you shbuld use

the sketches given in the Append~x.

U'e should like to underline that especially customers of "self-service work-

shops" and amateur constructors bear this in mind to avoid considerable addi-

tional expenditure of labour and material.

We hope this book of reference offers the required information to the staff of

the workshops conlracted for servicing our products at home and abroad and to

le friends of

motor-cycles throughout the world, and wewish good success.

VEB MOTORRADWERK ZSCHOPAU

~etrieb,des IFA-Kombinats Zweiradfahrzeuge

Service Dept.

Table

Contents

Tedmiecrl

Data

....................................

Engine

.........

Carburetter

.......

Electrical Equipment

...

Transmission

.......

Power Train

.......

Cycle Parti

.......

Dimensions and Masses

...

Capacities

.....

Characteristics and Diagrams

...............................

Fuel. Lubricmts and Fluids

........................................

Fuel 12

......................................

Engineoil

Gear011

......................................

...............................

Lubricants for Cycle Parts 13

Shock-absorber Fluid

.................................

...............................

Contact Breaker Lubrication

Dissossembly of the Engine

............................... 13

Assembling the Engine

..................................

Electrical E~ulpment

.................................

Dynamo

Checking

...............

the Armature for Accidental Earth

the Armature for Shorted Turns

Checking the Field Coil for Accidental Earth

Checking the Field Coil for Shorted Turns

Servicing the Carbon Brushes

.......

Servicing the Commutator

........

Fault Indication by the Charging Control Light

Adjustable Resistor

...........

Polarity Reversal in the Dynamo

......

Regulator Cut-out

............

..............

Adjustment

Mounting and Servicing

..........

Faults and Their Causes

.........

................

Battery

.....

Putting the Battery into Operation

Servicing the Battery

..........

Ignition System

............

..............

Ignition Coil

.............

Ignition Timing

Ignition Timing by Means of a Graduated Dial

Setting the Firing Point

.........

Sparking-plug

.............

Plug Cable Connector

..........

...............

Troubles

Electric Horn

.............

Ignition-light Switch

...........

Headlamp

...............

.................................

5.7.1.

Focusing the Headlamp

.............................

5.8.

Tail Lamp and Stop-light Swit&

5.9.

Flashing-light Direction Indicator System

...................

......

....................................

5.10.

Speedometer

...................................

Induction System

..........................

8.1.

Carburetter BVF

1-3

and

1-1

.......................................

6.1.1.

General

6.1.2.

Description of the BVF Carburetters

1-3

and

1-1

...................

8.1.3.

Trouble Shooting and Tuning

..............................

Cycle Parts

.....................................

Exhaust System

...................................

Steering

......................................

51:

12511

and

15011

...................................

................................

Removing the Handlebars 51

.............................

Front Fork and Steering Bearing 51

Replacement of the Swing-arm Bearing Pin

.........................

51:

125

and TS

15C

...................................

Steering Bearing

...................................

Telescopic Fork (see Fig

136)

..............................

FuelTank

......................................

571

Fuel Shut-off Cock

..................................

Brakes 58

.......................................

Replacement of the Foot-rest Tubes

............................

591

Checking and Changing the Secondary Chain

........................

Adjusting the Clutch

...................................

Removing and Dismantling the Rear Wheel Drive

......................

Speedometer Drive

..................................

Replacement of the Wheel Bearings

............................

Inspections Required in the Case of Poor Road-holding

....................

Repairing the Spring-loaded Suspension Units

........................

Shock-absorber Marking

................................

Removal of the Shock-absorbers

.............................

Common Faults in Shock-absorbers

............................

Filling the Shock-absorbers with Fluid

...........................

Mating Shock-absorbers

................................

Cable Controls

.....................................

64:

us(

of special Tools

...................................

8.1.

Engine

.......................................

9.2.

Cycle Parts

.....................................

9.3.

Electrical Equipment

.................................

Sketches for

Making

Special Tools

............................

Supplement: Repair Instructions for the Engines

12513

15013

and the Telescopic Fork with Aluminium Slide

Tube

Fig.

125

and

150

Fig.

12511

and

150/1

Fig.

Sectional view of engine

Technical

Data

1.1.

Engine

TS 125and ES 12511 TS 150and ES 15011

Type MM 12512 MM 15012

Strokelbore 58/52 mm 58/56 mm

Swept volume 123cm:' 143 cm'

Maximum output 7.35 kW (10hp) 8.45 kW (11.5 hp)

(at 6000 to 6300 rpm) (11 SAE hp) (12.5 SAE hp)

Maximum torque 12.3Nm (1.25 kp-m) 14.7 Nm (1.4 kpm)

(at 5000 to 5500 rpm)

Type of carburetter 22

1-3 24N1-1

Number of cylinders 1 1

Piston mass, complete with two rings, gudgeon pin and

locks 160

5 g 200

Compression volume with the sparking-plug inserted

14.0 cm3 16.5cm"

Cycle two-stroke reverse scavenging

Cooling system air stream produced in driving

Connecting-rod bearing bottom, cage-type needle bearing

top, bronze bushing

Crankshaft main bearing 3 ball bearings 6303 c 3 f (silent, 17

14 mm)

lubrication by gear lubricant

Cylinder light-alloy, liner of special grey cast-iron onto which

the light metal is cast

Timing in crank degrees

inlet 150"

transfer 115"

outlet 165"

1.2.

Carburetter

Transfer

port

Main jet

Needle jet

Partial-load needle No.

Needle position, from top

Starter jet

Slow-running jet

Slow-running air screw

Throttle opening

Air filter

Float valve seat

1.3.

Electrical

Equipment

Ignition

Ignition timing

Contact breaker points gap

Sparking-plug

Electrode gap

Dynamo

Charging control light (red)

Regulator

Battery

Ignition coil

Headlamp (asymmetrical)

Tail lamp

combined with stop light

(3rd for running-in) (4th forrunning-in)

70 75

35 40

opened by

to 3 turns opened by 2 to 3 turns

3 mm 3 mm

dry air filter (paper cartridge)

15(1.5mm)

15(1.5 mm)

battery ignition

3.0-0.5

before T.D.C., fixed setting

0.3 to 0.4 mm

M 141260

0.6 mm

direct current 6

short-time operation

in speedometer

RSC 6016, under left-hand panelling

(flat lead storage battery)

under left-hand panelling

ESTypes fixed

lamp opening 136 mm

TSTypes movable

lamp opening 170mm

ESTypes lamp opening 95 mm

Types

lamp opening 100 mm

contact in rear brake

Flashing-light direction indicators ES

TSTypes

Flasher unit

Horn

By-pass light signal

Bulbs (data in parantheses apply to TSSpes)

bilux (twin-filament)

parking light

stop light

tail light

flashing-light indicator

charging control light

idling indication

speedometer illumination

1.4. Transmission

Clutch

Gear-shift system

Number of speeds

Gear ratios

1st speed

2nd speed

3rd speed

4th speed

Bearing on clutch shaft

Bearing on layshaft

Rearing on shaft gear

Idling indicating light

1.5.

Power Train

Transnlission

enginelgearbox

by sleeve-type chain

or double sleeve-type chain

(from 4th quarter of 1973)

Transmission

gearboxhear wheel

by roller chain

1.6.

Cycle

Parts

Frame

Steeringangle

Caster

Suspension system

front

TS 125and ES 12511 TS 150 and ES 15011

2-light system

the handle bar ends

4-light system

in headlamp shell

under fuel tank

actuated by push-button

arranged below dimmer switch

6 V, 45/40 W

passing beam asymmetric

6 V, 4 W, BA 9 s cap

6V, l8W, S 8.5 cap

(6 V, 21 W,

15s cap)

6 V, 5 W, S 8 cap (BA 15S)

6V, 18W, S8.5cap

(6 V, 21 W, BA 15s cap)

6 V, 1.2 W

6V, 1.2 W

6V,1.2 W

multiple disk clutch in oil bath

foot-operated, left-hand side

3.05

1.805

1.285

1 :l

6202 (15

11mm)

6201 (12

10mm)

6004 (20

12 mm)

electric control bulb (green) in speedometer

2.31

1 37;16 teeth

9.5

9.5 ('18"

3/e") 48 links

9.525

4.77 (3/8"

3/16")48 links

3.2

1 3.0

48: 15teeth

48: 16 teeth

12.7

6.4

8.51

('l2"

l/,") 120rollers

continuous pressed-steel, seamed

TS 60"

ES 61"

TS 90 mm

95 mm

TS telesco~icfork with hydraulic damping, total travel

spring

185

rear

Wheels

Rims, frontlrear

Tyres, frontlrear

Tyre inflation pressure when loaded with:.

75 kg front

rear

150 kg front

rear

Permissible total mass

front

rear

Drake actuation

Brake diameterlwidth of lining

front

rear'

1.7.

Dimensions and Masses

Wheel base

Length

Height withlwithout mirror

(flat handlebars)

Height withlwithout mirror

(elevated handlebars)

Height with mirror

Width withlwithout mirror

(flat handlebars)

Width withlwithout mirror

(elevated handlebars)

Width with flashing-light indicators

Ground clearance, loaded, at prop stand

Weight unladen,ready for operation

with

fuel andtools

Permissible total mass

1.8.

Capacities

Gearbox

Fuel tank

including reserve

Telescopic fork

Suspensions units, rear

1.9.

Characteristicsand Diagrams

The maximum speed,'depending on sitting position,

about

100 kmlh for

the

125and ES 12511

105kmlh for the TS

150

and

1M/1

The maximum speed will only

reached

if the

re-

TS 125 and ES 12511

150 and ES 15011

longitudinal swing

spring-loaded suspension

units

with hydraulic damp

ing, total travel of spring 150mm

spring-loaded suspension units with hydraulic damp

ing total travel of spring 105 mm, spring pre-load ad-

justable

wire spokes

1.60

1.85

2.75-18

3.00-18

150kPa (1.5 kp/cm2)

270 kPa (2.7 kp/cm2)

mechanically, by means of cable controls for both

brakes

about 1150

7301620

about 750 mm

140mm

0.45 1of GL

gear oil for summer and winter

12.5 1of petrol41mixture

about 1.5

220

cm3

of shock-absorber oil for each unit

of shodr-absorber oil for each unit

quired favourable conditions are given (rider stooping

almost "lying", tightly fltting motoring suit,

plane road, no headwind).

The engine charaderi$tics, traffic fuel consumption,

and acceleration are shown

the following diagrams

(Fig.

4 to

9).

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