Puch Maxi (49 cc) — Example photo: Paolo2710, CC BY-SA 3.0, Wikimedia Commons

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Puch · Two-stroke single, premix, chain drive

Maxi (49 cc)

Library entry covers 1976-1977

21 factory 65 guideline

Published source

Puch Maxi Owner's Manual 1978, Suggested Maintenance and Lubrication Chart p.25 (Moped Army library)

Factory owner's handbook. Covers Puch Maxi owner's manual 1978 (Steyr Daimler Puch of America), 1-speed and 2-speed automatic.

86 items for a 1977 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Automatic or semi-automatic
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1977 Puch Maxi (49 cc)

On the road: every 200 km

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Guideline

Old machines shake things loose: exhaust nuts, mudguard stays, footrests, tank mounts, battery strap.

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

On the road: every 1,600 km

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

Every 960 km

1 item

Tire wear and condition

Wheels and tires

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 300 mi (owner); every 600 mi (dealer)

Every 1,450 km

6 items

Check spark plug

Engine

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 and 900 mi; every 900 mi
Check gearbox oil level

Primary and gearbox

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 900 mi; every 900 mi
Clean and lubricate chain

Final drive

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 900 mi
Check brakes / linings

Brakes

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 900 mi
Check tire pressure

Wheels and tires

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 and 900 mi; every 900 mi
Lubricate control cables

Controls and cables

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 900 mi

Every 1,600 km or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,600 km or 6 months

4 items

Check gearbox oil level

Primary and gearbox

Guideline
Adjust front drum brake

Brakes

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,500 km or 6 months

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 2,900 km

6 items

Clean exhaust baffle

Engine

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). every 1,800 mi
Idle speed adjustment

Engine

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 1,800 mi (dealer)
Retighten screws and nuts

Engine

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 1,800 mi
Clean air filter

Fuel and air

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 1,800 mi
Clean carburetor

Fuel and air

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 1,800 mi (dealer)
Decarbonize engine

Fuel and air

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). every 1,800 mi (dealer); also marked at 7,200 mi

Every 3,000 km or 12 months

4 items

Inspect, clean and gap spark plugs

Engine

Guideline
Replace spark plugs (two-stroke)

Engine

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline

Every 5,000 km or 12 months

16 items

Check engine mounting bolts and plates

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Adjust automatic / semi-automatic clutch

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 5,000 km or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 5,800 km

6 items

Check / lubricate hub bearings

Engine

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 3,600 mi (dealer)
Clean gasoline petcock and lines

Engine

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 3,600 mi
Check ignition timing

Ignition and electrics

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 3,600 mi (dealer)
Adjust clutch

Primary and gearbox

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 3,600 mi (dealer)
Change gearbox oil

Primary and gearbox

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 3,600 mi
Throttle cable adjustment

Controls and cables

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 3,600 and 7,200 mi (dealer)

Every 6,500 km or 12 months

2 items

Replace spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 8,000 km or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 9,500 km or 12 months

5 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 9,500 km or 2 years

3 items

Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 11,600 km

1 item

Steering bearing adjust / lubrication

Front end

Factory

Factory: Suggested maintenance and lubrication chart: columns after 300, 600, 900 miles and every 600, 900, 1,800, 3,600, 7,200 miles (dot by owner, star by dealer; dry paved use, more often in wet, muddy or sandy use). after 600 mi; every 7,200 mi (dealer)

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 16,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 19,500 km or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 19,500 km or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 24,000 km or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

1 item

Chains (wipe clean and lubricate)

Final drive

Factory

Factory: Every few hundred miles wipe chains with a cloth and lubricate with chain oil; keep drive chain slack 1 inch

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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