Zundapp 2-Stroke Engine Repair 1956

REPAIRING
TWO-STROKE ENGINES
of Models
DB 202, COMFORT, NORMA,
NORMA-LUXUS, ELASTIC 200;
ELASTIC 250, 200S, BELLA 150,
BELLA 151, BELLA 200, BELLA 201

Full service and repair manual
for this Vintage engine

Contents
A) Range of Engine Numbers . . . . . .
B) Technical Data . . . . . . . . .
C) Disassembling the Engine . . . . . .

1. Removing the Cylinder, Cylinder Cover, Carburettor,
and Piston . . . . . . . . . . . . 11
2. Demounting the Generator. . . . . . 13
3. Removing the Kickstarter and Protective Cover . . 14
4. Clutch Housing . . . . . . . . . . 15
5. Demounting Clutch Assembly and Flywheel . . . 17
6. Disassembling the Crankcase and the Transmission
Housing . . . . . . . . . . . . . 19
7. Right-Hand Housing Half (Clutch Side)
8. Left-Hand Housing Half (Generator Side)
8a Left-Hand Housing Half on Starter Engines. . . . 21
9. Disassembling the Connecting Rod . 21
10, Disassembling the K. S. Pawl . . . 22
11. Removing Internal Rings for Crankshaft Bearings . . 22
11 a Internal Rings of Crankshaft Bearing on Starter Engines 22
12. Demounting the Ball Race and Bronze Bushing for
Mounting the Sliding Shaft inside Clutch Hub . . 22
D) Re-Assembling
1. re- Assembling the Crankshaft (Fitting Connecting Rod etc.) . . . . 23
2. Right-Hand Housing Half (Clutch Side)
3. Assembling the Clutch . . . . . . 26
4. Left-hand Housing Half (Generator side) . . . 28
5. Dimensioning the Crankshaft Bearings
6. Joining the two Housing Halves . 32
7. Mounting the Clutch with Chain and Flywheel . . . 33
8. Determining Dimensions of Clutch Pressure Pin and Supporting Bolt . . 34
9. Mounting and Adjusting the Gearshift Mechanism . 37
10. Mounting the Clutch Cover .. . . . 38
11. Mounting the Drive Sprocket . . . 38
12. Mounting the Piston . . . . . . . 39
13. Mounting the Cylinder and Cover . 41
14. Mounting the Generator; Ignition Timing . . . . 41
15. Various Types of Carburettors and Their Adjustment . 44
E) Appendix
1. Special Tools . . . . . . . . . . , 54
2. External Treatment of Engines . . . 54
3. Engine Conservation . . . . . . . . 54
4. Shipping Engines . . . . . . . . 55
5. Running-In . . . . . . . . . . 55

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