Dear friend of MZ,

these Operating Instructions are intended for you as a help to ensure that your motor-cycle will always be your reliable companion. Due to our experiences gathered in many years of motor cycle construction, the ETZ machine is a sturdy, highly efficient, reliable vehicle that requires but little maintenance. In order that this will remain so for ever, we ask you to observe the following information regarding care and treatment of your motor-cycle.

"Bon voyage"!


VEB Motorradwerk Zschopau
Betrieb des IFA-Kombinates Zweiradfahrzeuge

Table of Contents

1. Technical Data

1.1. Engine and Power Transmission

2. Fuel, Lubricants etc.

Engine

Petrol having an octane rating of 88 (ROZ) which is mixed with two-stroke engine oil in the ratio of 50:1.

Example: 10 l fuel to be mixed with 0.2 l of two-stroke engine oil.

Gearbox

Gear oil SAE 80 or non-additive type of engine oil SAE 40 for summer and winter. In the GDR, oil of grade GL 100 is used.

Cycle parts

Gear oil SAE 80 and antifriction bearing grease.

Electrical equipment

For a new battery use accumulator sulphuric acid having a density of 1.28 g/cm³ (in the tropics 1.23 g/cm³) at 25 °C. For topping up the battery, only use distilled water. Use grease battery terminals for protection against corrosion of the battery connections.

Use hypoid oil (gear oil of a high degree of viscosity) for the contact-breaker lubricating felt pad.

3. Operation

3.1. Controls

Figs. 1 to 9 show all control elements required for operating the motor-cycle and their functions. Please, familiarise yourself with them throughly before the first start.

3.2. Starting and Driving

Before any ride, check the vehicle for reliability of operation and roadworthiness according to the Maintenance Chart (see Section 4.2.).

Starting

1. Shift the gearbox to neutral position (Fig. 7).
2. Switch an the ignition system (Fig. 3).
   Control light for dynamo will light.
   Control light for idling will light (de luxe model).
3. Open the fuel shut-off cock (Fig. 6).
4. With the engine in a cold state: Open the cold-starting device (Fig. 5).
   With the engine in a hot state: Leave the cold-starting device in the closed position.
5. With the engine in a cold state: Throttle-twist grip is in the neutral position.
   With the engine in a hot state: Open the throttle-twist grip for about one quarter of a revolution.
6. Vigorously actuate the kick-starter.
7. Close the cold-starting device when the engine readily accepts gas.

Notice! In the case of extremely low ambient temperatures, and when the engine has been subjected to several starting trials in vain, allow the engine to rest for 20s in order that fuel in the cold-starting device can be restored to normal level.

Driving

The temperature of the engine need not be raised when the vehicle is stationary, it rises during road operation. Actuate the clutch lever and shift gears, starting with the first gear in engagement. The operating ranges of the various gears are shown in Figs. 10 and 11.

Notice!

Only use the clutch for moving off and for shifting gears. When stopping for a prolonged period of time, shift to the neutral.

Braking

Always use both brakes, applying them in accordance with the given situation. Blocking brakes extend the braking distance and impair roadholding of the vehicle.

Parking

Switch off the ignition system, withdraw the ignition key. Close the fuel shut-off cock, turn the handle-bars to the right and block the steering system by means of the thief-proofing device according to Fig. 8.

3.3. Information for Running-in

A distance of 1,500 to 2,000 km is considered as running-in period for the engine. During this time, observe the following information.

1. Allow the engine with the vehicle in a stationary Position to run for as short a period as possible but move off and then the engine will soon reach operating temperature; in the case of a prolonged stop, shut off the engine.
2. Observe the ranges specified for the various gears in Figs. 10 and 11 during running-in, and change gears in time.
3. Systematically increase the travelling speeds and engine speeds until the end of the running-in period.
4. Frequently change engine speeds and travelling speeds. - Normal highways are suited better for running-in than superhigways (Autobahn)!
5. Strictly adhere to the specified inspections in an MZ-Service Workshop.

4. Maintenance

4.1. General Instructions

The tool kit accomodated under the right-hand side panel enables you to perform almost all maintenance operations according to the Maintenance Chart. Take the Guarantee Regulations into consideration.

Have the faults removed that you found during the maintenance.

4.2. Maintenance Chart

Have the faults removed that you found during the maintenance.

x¹ On the occasion of the 1st and 2nd inspection under guarantee
x² or every four weeks

4.3. Lubrication Points (Figs. 13 and 14)

4.4. Gearbox Lubrication

Checking the oil level

For this purpose, the vehicle must stand horizontally. This operation should be carried out about 15 min after the stopping of the engine or the filling of oil. When the correct amount has been poured in, the oil level coincides with the lower edge of the checking hole.

Oil change

For this purpose, the engine must be in a hot state, i. e. it must have operating temperature in order that abraded particles are drained together with the oil. Unscrew the two oil drain plugs. Clean the magnet in the screw (3). Replace the sealing rings, if necessary.

4.5. Clutch and Brakes

Clutch

Adjust the clutch clearance of 3 mm by means of the adjusting screw (1). Lock the adjusting screw again. If the adjusting screw (1) is no longer sufficient for correcting the adjustment, then correct the coarse adjustment. For this purpose, slacken back the lock nut (Fig. 17) for one revo-

lution. Then screw down the adjusting screw until the stop can just be felt and then slacken it back through 3/4 of a revolution. Then fix this setting by means of the lock nut.

Mechanical brakes

Adjust the front mechanical brake at the hand lever to the dimension S = 3 to 5 mm (Fig. 16). When not actuated, the brake shoes must not slide. Adjust the pedal brake in such a way that, in a convenient sitting position, full braking effect is achieved with a short travel of actuation of the pedal. Then adjust the stop light switch:

• switch on the ignition system
• loosen the check nut
• actuate the brake lever - brake shoes are just applied enough to start sliding
• turn the contact screw until the stop light flashes up
• tighten the check nut

Disk brake

The brake lever is not adjustable. Screw the stop light switch (1) into the jointed piece (9) only to such an extend that the stop light flashes up immediately at the beginning of actuating the brake lever while the brake lever in its rest position still contacts the jointed piece. The brake fluid level must be between the marks 'max.' and 'min.' on the reservoir. When closing the cover of the reservoir, put the hermetic bellows and the vent ring in place.

The brake shoes must be replaced by new ones when their linings are worn down to minimum thickness.

Any work at the disk brake should be carried out by a specialised workshop.

4.6. Fuel Feed, Carburetter, Induction System

The fuel is cleaned in the fuel shut-off cock whose filter (F₂) (Fig. 6) can be cleaned after unscrewing the filter bowl. The Filter (F₁) (Fig. 6) in the fuel tank is only accessible when the fuel shut-off cock is unscrewed.

- Before screwing it off, drain the fuel.

Notice!

The screws for the spring plate for pressing an the lever (Fig. 6) must not be screwed down so far that they contact the housing.

Maintenance of the carburetter is limited to cleaning and the setting of the idling speed by means of the stop screw

(7). For cleaning the carburetter, dismantle it in the order 1 to 6 (Fig. 21).

Notice!

Do not distort the float. Do not push wire through the jets - blow air through them.

Adjust the friction brake (B in Fig. 5) at the throttle-twist grip in such a way that the twist grip does not return automatically into the initial position and that it can still be turned conveniently.

The paper air filter is accessible after the removal of the battery (Fig. 22). Carefully tap the filter - do not wash it. Moist air filters must be dried or replaced by new ones. The induction system must be tight, that is to say, it must be assembled with every care.

4.7. Wheels and Tyres

Removal and fitting the front wheel

Remove the wheel according to the sequence of numbers indicating the operations (Fig. 24). When having pulled out the axle, place it on the tool bag.

Press the brake shoes of the disk brake apart before fitting the wheel.

First tighten the axle nut (1), apply the hand brake and deflect the telescopic fork springs by hand, and then tighten the clamping screw (3) (Fig. 24).

Notice!

When the wheel is removed, do not actuate the hand brake lever of the disk brake.

Removal and fitting of the rear wheel

Place the wheel on the prop stand. Demount all parts visible in Fig. 25 and place them on the tool bag; bring the wheel into the position indicated and pull out the brake abutment.

When fitting the wheel, engage a gear of the gearbox - consequently, the dogs (Fig. 27) can be inserted more easily.

Changing tyres and inner tubes

Allow the air to escape and place the wheel on the ground. Protect the bearings by a rag placed under them.

At first, the tyre must be pushed off the rim round the whole circumference before it can be pressed into the well base opposite the valve. Then, starting from the valve, lift the tyre over the rim flange by means of the two tyre levers.

Then remove the inner tube. Before putting the new inner tube in place, check the interior of the tyre for foreign particles and damage; apply talcum to the new inner tube, put it in place and, starting from opposite the valve, fit the tyre.

Notice!

Do not squeeze or clamp the inner tube. After fitting, the tyre must run true; i. e. the check margin must be the same distance from the clinch at any point.

The inflation pump is arranged at the frame and accessible alter demounting the dual seat.

Care of the tyres

Before any ride, check the tyre inflation pressure. It must always correspond to the selected load on the vehicle. The tyres should be protected from intense direct insolation and fuel.

4.8. Rear Wheel Drive

Checking the chain sag

Place the motor-cycle without any load on the prop stand. The upper chain protection hose with the chain inside must be slack enough to be pressed just down to the cross tube of the rear wheel swing-arm by two fingers. Turn the rear wheel during this checking operation.

Tensioning the chain

The knock-out axle (1) and the nut for fastening the rear wheel drive must be loosened. Then uniformly turn the adjusting screw (3) of the two chain tighteners (2) and provide the screw with a check nut after setting (Fig. 31). Check the wheel track according to Fig. 32 by means of the check staff or by visual inspection from the front. The gap (S) results from the different widths of front wheel and rear wheel.

Replacing the chain

If two rollers adjacent to each other or more than 5 rollers altogether are broken, or if the play between the chain joints is excessive, replace the chain by a new one and remove

broken pieces of the old chain. You may attach the new chain to the old one and draw it through the chain protection. The locking spring clip of the chain connecting link must be inserted so that the open end is opposite to the sense of rotation.

4.9. Electrical Equipment

Take care to see to it that the insulation of the cables and electrical devices is always in proper condition and that all line connections are tight and free from oxide. Never replace blown fuses by other metal objects.

Electrical welding operations in the motor-cycle should only be done after the disconnection of the battery. No positive line must get into contact with the welding electrode.

Three-phase current dynamo

The three-phase current dynamo does not require any care. The charging-control lamp flashes up when the ignition system is switched on and will go out when the engine has started up. Faults are given when the control lamp fails to flash up or emits a dim light only upon switching an the ignition system or when it fails to go out when the engine is running.

Ignition system

This system includes contact breaker (Fig. 34), ignition coil (Fig. 35) and sparking-plug. Ignition timing and the adjustment of the contact-breaker gap must be left to a specialised workshop. Provide the lubrication felt pad withs 3 drops of Hypoid oil, if necessary. The felt should just touch the highest point of the cam. Clean the sparking-plug at the specified intervals and readjust the electrode gap. Keep the plug connector clean and dry inside. Colour deviations of the plug body - normal colour is, depending an the driving habit, grey-yellow to light brown - are indicative of faults or defects which have to be removed by a workshop.

Battery

The battery terminals and the pole connections must always be kept clean and, after cleaning, be provided with a film of grease for battery terminals. Check the level of the electrolyte (Fig. 12) regularly at an interval of about four weeks.

For topping up, only use distilled water.

When the vehicle is inoperative for a prolonged period of time, re-charge the battery once a month.

Notice!

When changing by mistake the battery cables (positive and negative), diode of the rectifier and battery will be destroyed.

Headlamp

When replacing the twin-filament bulb by a new one, take care that the lamp properly engages with the reflector.

The contacts must be clean and put on correctly. Do not touch the glass bulb of the incandescent lamps with your fingers!

Adjust the headlamp according to the schematic representation in Fig. 38. For this purpose, load the vehicle with the driver and set the suspension units to 'soft'. For adjusting, loosen the headlamp mounting - now, the headlamp can be turned to any side.

Direction indication

The operation of the flashing-light direction indicators can be observed at the edge (Fig. 39/1) or at the control lamp (Fig. 2/4 or Fig. 3/11). When one flashing-light direction indicator fails, the other one will flash, and thus the control lamp, at double the normal frequency.

4.10. Information about Winter Operation

We ask all of our customers who will use their vehicles in winter, to take into consideration the information given below.

Due to chemical thawing agents on the roads, severe damage due to corrosion can be caused in winter. Therefore, apply a film of a suitable anti-corrosion agent on the basis of wax or mineral oil to the chromium-plated or unprotected metal parts before the onset of winter.

Lubricate the vehicle according to the Maintenance Chart. Parts such as the guide tubes of the telescopic fork, which cannot be protected for a longer period of time, must be treated with an anti-corrosion agent after every ride in winter.

At the end of the winter season, the preserving agents can be removed.

5. Faults and Their Remedies

6. After-sales Service

In all of your inquiries, please, give full information both as to your vehicle and as to the defect presumed. As a rule, however, you should call on one of our authorised Workshops. We are not in a position to deliver spare parts directly to you. We only deliver spare parts to our authorised Workshops and MZ special sales shops and to our importers in foreign countries.

7. For Making the Motor-cycles Complete

For reasons of facilitating transport, a few parts have not been mounted by the manufacturer. These parts must be mounted subsequently in order to complete the vehicle. When connecting the rear lighting fittings to the line connector, ground point and fuse box, observe the wiring diagram. Correctly attach the flashing-light direction indicators and do not omit the packings between flashing-light direction indicator and its carrier. Remove the foil from under the oil filler screw plug in order that the ventilation of the gearbox compartment becomes free.

8. Fresh-oil Dosing Device

If your ETZ is provided with an oil proportioning device, please, observe the following instructions in addition to the explanations given in the general Operating Instructions.