Instruction ManualNZ250+350

8/6/2019 Instruction ManualNZ250+350

1/56


2/56

CONTENTSA) Controls;

. .heir Position and Operation .- 7which is of vital importance . . . .+BB) Fuel and lubrication - A subject I) Proper care and maintenancereduce your running costs . . . -I IiD) The Carburettey. . . . . . . . . . *

.3

E) Electrical Installation . . . . . . . . ,F) Practical advice . . . . . . . . . .For fuiier details of contents See Page 4, 5 and 6.

3


3/56

S U M M A R Y OF CONTENTSA) Contro l s : .

A 1) Petrol-tap . . . . . . . . . . . . . . . . . . . . . 7A 2) T ickler on carbu retter float cham ber . . . . . 8A 3) Twist grip throttle control . . . . . . . . . . . 9A 4) Air control . . . . . . . . . . . . . . . . . . . . 11A 5) Ignition and lighting switches . . . . . . . . . 3A 6) Kick-Starter . . . . . . . . . . . . . . . . . . . . 13A 7) Exhaust. or decompressioii lever . . . . . . . 15A 8) Clutch lever . . . . . . . . . . . . . . . . . . . 15A 9) Foot control gear Change . . . . . . . . . . . . 16A10) Hand control gear Change . . . . . . . . . . . 19A l l ) Foot brake . . . . . . . . . . . . . . . . . . . . 21A12) Hand brake . . . . . . . . . . . . . . . . . . . . 21A 13) Steering damp er . . . . . . . . . . . . . . . . . 1A 14) Shock absorbers . . . . . . . . . . . . . . . . . 22A 15) Dimm er switch for head larnp and hornOperation . . . . . . . . . . . . . . . . . . . . . 22A 1 6 ) Stand . . . . . . . . . . . . . . . . . . . . . . . . 22A 17) Speedometer and mileage indicator . . . . . . 3A 18) Adjustable knee-grips . . . . . . . . . . . . . . 3A f e w prac t ica l h int s :

Running-in a new machine . . . . . . . . . . 24Starting-up . . . . . . . . . . . . . . . . . . . . 25How to Start . . . . . . . . . . . . . . . . . . . 5H o w t o stop . . . . . . . . . . . . . . . . . . . 25Ho w to repair a punctured tyre . . . . . . . . 6What to do in Winte r . . . . . . . . . . . . . 41@ 4

B) Fuel. lubrication. electrical equipment, etc..B 1) Petrol . . . . . . . . . . . . . . . . . . . . . . . 43B 2) Fuel admixture . . . . . . . . . . . . . . . . . . 3B 3) Lubricating oil . . . . . . . . . . . . . . . . . . 3B 4) Mixture proportions - oil and petrolB 16) Sparking plugs . . . . . . . . . . . . . . . . . . 5. B 17) Tyres - ir pressure . . . . . . . . . . . . . . 5B 19) Fuses - Lubricating chart . . . . . . . . 45. 46

. . . . 4B 5 - B 14) Lubrication of iransmission parts ai id frame 44

B 1 8 ) Battery . . . . . . . . . . . . . . . . . . . . . . . 45C) Care and rna intenance :

C I ) Petrol filter . . . . . . . . . . . . . . . . . . . . 47C 2) Air filter . . . . . . . . . . . . . . . . . . . . . 49C 3) Sparking plugs . . . . . . . . . . . . . . . . . . 49C 4) Decarbonising the engine . . . . . . . . . . . 1C 5) Cleaning the exhaust box (silencer) . . . . . . 1C 6) Ignition and lighting installation . . . . . . . 4C 7) Battery . . . . . . . . . . . . . . . . . . . . . . . 56C 8) Clutch and gear box . . . . . . . . . . . . . . 6C 9) Adjustment of clutch . . . . . . . . . . . . . . 8C 10) Liibricating the driving cliaiii . . . . . . . . . 9C i i ) Care of the chain . . . . . . . . . . . . . . . . 9C 12) Care of the frame . . . . . . . . . . . . . . . . 2C13) Brakes . . . . . . . . . . . . . . . . . . . . . . . 63C 14) Fork joint; wheel and steeriiig bearings . . . 6C 15 ) Rear wheel shock absorber . . . . . . . . . . . 66C17) Tyres . . . . . . . . . . . . . . . . . . . . . . . . 67C 18) Cleaning . . . . . . . . . . . . . . . . . . . . . 68C 16) B owden Connections an d control levers . . . 67. ~~~~ ~~

r


4/56

D) Carburetter:D 1) lmportant points . . . . . . . . . . . . . . . . . 2D 2) How 10 clean the main jet . . . . . . . . . . . 78satisfactory . . . . . . . . . . . . . . . . . . . 81

D 4) Normal factory adjustments . . . . . . . . . . 81E 1) Lighting System . . . . . . . . . . . . . . . . . 82E 2) Contact breaker. . . . . . . . . . . . . . . . . . 82E 3) lgnition adjustment . . . . . . . . . . . . . . 3E 4) Coil b o x . . . . . . . . . . . . . . . . . . . . . 5E 5) F u s e s . . . . . . . . . . . . . . . . . . . . . . . 88E 6) Head lamp . . . . . . . . . . . . . . . . . . . . 88E 7) Electric horn . . . . . . . . . . . . . . . . . . . 89

1) The engine fails to Start-up . . . . . . . . . . . 0F 2) The engine does not run smoothly . . . . . . 92F 3) What does the sparking-plug tell us ? . . . . . 4F 4) The engine stops suddenly . . . . . . . . . . . 96F 5) A few words on fuel consumption . . . . . . 6

Of f after starting-up . . . . . . . . . . . . . . . 7F 7) Main fuse blows . . . . . . . . . . . . . . . . . 8F 8) The head lamp does not burn . . . . . . . . . 98

Precautions against theft . . . . . . . . . . . . 9DKW-accessories . . . . . . . . . . . . . . . . 100Cpecifications . . . . . . . . . . . . . . . . Annex.

D 3) Slow-running and acceleration of eng ine un-

E) Electrical equipment:

F) Dractical advice:F

F 6 ) The charging control light does not switcht

Work ing of the DKW-two-stroke engine . 102@ - - 6

A l Arrangement of ControlsBefore starting out on your first ride, yousho uld m ake yourself th orou ghly familiar withthe Position and function of the var ious controldevices. It is essential that right from the startyou sh ould know how they operate .

etrol-tapBefore starting, turn on the petrol.The normal dr iving posit ion is withthe tap pointing dow n. With the tapin this position, the engine will rununti l the fuel supply is exhausted.Then turn the tap fur ther to the r ight(horizontal Position). This connects the reserve fuel supply, sufficient toCover about 12 miles.At the end of a run or when s toppingfor any length of time, the Petrol-tapshould be closed by turning i t to ~

.-

1~--Fig. 1.Petrol-tapN Z 250

left into it c horizontal Position.arid fi l ter an After filling petrol into the tank do

not forget to turn the tap f rom its 1reserve-Position (right) into the norm aldri vin g position (down), to be Sure to have afuel reserve supply, when required.ii


5/56

Tickler on carburetter f loat cham berTo start up a cold engine, depress the tickler

Fig. 2. Petrol tap and filter on an N Z 350.3 = Reserve. 3 a = Off. 3 b = on .2 = To unscrew filter screen, turn to ihe left.1 = To unscrew filter cap, turn to the left.

~ _ _

on the top of the float chamber until petroloverflows through the air port in the centreof the charnber Cover. This is not necessarywhen the engine is warm.1A3) wist grip throttle controlTo Open the throttle, turn the twist grip to theleft; to close, turn to the right. Th e more the

- 2Fig. 3. Tickler.grip is turned to the left, the more fully thethrottle is opened, thereby increasing the supplyof gas to the cylinder and accelerating theSpeed in proportion. When starting up the

'


6/56

8 engine, the grip should be given a turn ofabo ut one-f ifth.U s e of throttleAs the machine gathers speed the throttle shouldbe o pened gradually by mean s of the twist grip.A hill should be taken with the throttle fullyOpen and, as the engine begins to s low down,the throttle should be shut O ff slightly; i t willthen be found that the engine will pul1 better.When changing down to 3rd or 2nd Speeds ,more gas can be given. For normal travellingit is recommended that the twist grip be given

Fig. 4. Twist grip and air control lever.1 = Air control open. 2 = Gas. 2 a = Gas o n . i b = Gas O f f .

- 0_VJ

a turn of between two-thirds and three-quarters;ihe most favourable adjustment can be ascer-tained by "feeling". A speed alrnost equal fothat obtainable with a fully Open throttle canbe attained by proper adjustment, with a result-ant economy of fuel.jA4(Air ControlThe mixture of petrol and air supplied to the ~cylinder of the engine is controlled by meansof the air control lever.W h e n s t a r t i n g u p a cold e n g i n ethe control lever should be closed.W h e n s t a r t i n g u p a w a r m e n g i n e

the control lever should be fully opened.Shortly after the engine has started ru nning ,the lever should be pu t into the normal Position,i. e. fully ope n. In case of a short, but lieavy,,call being made upon the engine, as, forexample, at the to p of a hill climb, or whenaccelerating after slowing down at a Corner, theair control lever should be closed for a short vthe lever should always be fully Open whent ravel in g.Should it be found that the results are betterwhen the lever is half open, this is a sign

fmportant! -

space in Order to enrich the mixture; otherwise


7/56

Fig. 5. lgnition and lighting switches on tank.12_ _ _ . _ _ _ _ _

either that the jet is too srnall o r that the feedpipe or carburetter is dirty.lgn i t ion an d i igh t in g s w i tch ecTo switch on the ignition, remove Cover, insertkey crosswise and turn to the right. The light-ing of the red Signal lamp indicates that theignition is switched On.Operation of iighting switch:

Position 0 = DaylightPosition 1 = Parking i ightsPosition 2 = Main head light.In Pos i t ion 1 the key can be removed. Whenthe key is withdrawn, the switch is iockedand ca nnot be operated unti! the key is againinserted.In Posit ion 2 the key cannot be withdrawn.I t is therefore impossible 10 leave the machinewith the main head lamp burning by mistake.Dimming is effected by means of Contro! A 15 .Kick-StarterThe eng ine is started up by stepping sharpljon the kick-Starter. it ic advisa ble to push t heengine over by depressing the Starter slowlyonce o r twice and the third t ime more sharply.If the Starter does not move, the machine


8/56

Fig. 6 . Kick-Starter.1 = Swing foot pedal outwards.2 = Ctep on Starter.

.- . . . . . . . - 14

shouid be push ed forward or backward in gearand then placed in neutral again. I f the enginedoes not start up, refer to the Chapter Prac-tical Advice.Exhaust, o r decornpressionBy Operating the exhaust or compression releaselever, a valve in the cylinder head is opened;this reduces the pressure in the cylinder andfacilitates the starting-up of the engine. Thelever should, of Course, not be moved duringthe Operation of the kick-Starter, otherwise theengine will not Start-up; i t should be allowedto drop halfway. Th e lever shou ld not beoperated when the engine is running.ClutchThe clutch should only be used for startingand for gear changing. By pulling the levertowards the driver the power transmission be-tween engine and gear box is disconnected.Operation of Clutch: When the engine isrunnin g, the clutch lever should be pulledright back towards the rider and the Changespeed lever placed into first gear Position. Theclutch sho uld then be released gently and thethrottle opened gradually at the Same time bymeans of the twist grip; contact will then be


9/56

establishe d be!ween the eng ine and the backwheel and the machine will begin to moveslowly. The lever sho uld not be releasedsuddenly otherwise the s tart wil l be a jerkyon e, or, if insufficient gas has been given, theeng ine will Choke. After travelling for a bou t5-1 0 yards the clutch lever should again be dra wnback after closing the throttle, and the ChangeSpeed lever placed in second gear; then gradual-ly let in the clutch once more and Open thethrottle. The Operation is repeated when changingto third and top gearc.D o not attempt to avoid chaig ing down whennegotiating the top of a hill climb by allowingthe clutch to Slip, as this wears out the clutch.Change down as soon as the engine Showscigns of overstrain. Th e clutch hand levershould have a play of about one-tenth of aninch. Paragraph C 9 deals with the adjustmentof the clutch.(A9/ Foot contro l gear ChangeGe ar s are changed by O perating this control pedal.To Change from

Neutral into Ist gear = step on pedal1st to 2 n d g ea r = raise pedal2 n d to 3 r d g e a r = raise pedal3 r d to 4 t h g e a r = raise pedal

4 th to 3 r d g e a r = step on pedal3 r d to 2 n d g ea r = step on pedal2 n d to 1 s t gear : tep on pedal= raice pedal= step on pedal.

Thus : To Change iipTo Change down

Hints on correct gear-changingStartingWhen the engine has started-up and is runningin neutral, the clutch lever (A 8) should bedrawn right back and the clutch foot controlpressed down with the ball of the foot. 1stgear can then be easily engaged. If there isany difficulty, do not use force; just push themachine backward or forward abo ut a footand i t will then be found that the gear willengage noiselessly and with ease.The clutch lever should then be released and, asthe machine gathers Speed, the gears changedsuccessively u p to to p - he normal Speed fortouring in Open country - s described in A 8.C h a n g i n g d o w nA hill should be approached with a burst ofSpeed; the throttle should then be closed gradual-ly. it is bad riding to attempt to take a hillon top Speed o r to delay changing down until


10/56

the last moment. Th e good rider changes down

Fig. 7. Foot control gear Change.I = In Order 10 Change up , raise pedal.

2 = I n Order to Change down, step on pcdal.

in ample time and saves his machine froniunnecessary wear, at the Same time econ-omizing fuel. frnportant!To Change down, for example, from top to3rd Speed, the correct procedure is as follows:close throttle slightly, declutch and depress footlever t i l l the next lower gear engages, Slip i nclutch an d accelerate. T he difference betweenchanging u p to a higher Speed and changingdown to a lower Speed lies in the fact that inthe former case (changing up) the throttle iscompletely closed whereas in the latter case(changing down) it is not quite closed owingto lhe fact that the engine is travelling at ahigher Speed and rriust therefore be acceleratedduring the Change.Hand control gear ChangeT h e DK W Motor Cycle is also fitted with ahand con trol lever for gear changing. Whe nusing the foot lever, it is always possible 10see which gear is engaged, or whether themachine is in neutral from the position of thehand lever. Th e advantage of a duplication ofgear changes is that there is a choice of methodsavailable to the rider according to circumstances;

'

h e an Change gears either with hand or~~1918


11/56

foot. As the throttle must be operated by handwhen changing, i t i s i n itself an advantage tobe able to Change gears with the foot; aftershort practice the rider will quickly appreciatethe tact that gear cha ng ing with the foot is th ecorrect and most practical method.Wh en using the hand lever, care shou ld betaken to See that the lever is pushed inwardstowards the tank so a s to avoid missing thedesired gear and ensu re connecting with th enext highest Speed.

Fig. 8. Foot brake. '1 = Brakc pedal adjusting screw.

2 = Lubricating nipple.

Foot brakeTh is is located on the right hand side of th emachine and can easily be reached with theball of the foot without it being necessary forthe foot to leave the rest. Th e Position of thefoot brake can be adjusted to suit lhe riderby means of a screw.Hand brakeThis brake operates on the front wheel. Whendescending a long incline it should be used toassist and relieve the foot brake by alternateapplication. I f it is necessary to piill up sud -denly, both brakes may be applied simul-taneously, but not too sharply, as the wheelsare liable to jam if the lever is pulled backsuddenly the f u l l distance. A locked wheel islikely to result in skidding. The best brakingeffect is obtained by a firm but gradual applica-tion and not by a sudden jerk.Steering damperWobbl ing of the front wheel, particularly in trav-elling over bad roads, niay be counteracted byappropriate adjustment 10 the steering damperdevice. After a little experience the rider willbe able to make the most favourable adjustment


12/56

to suit hirnself. Rigid adjustrnent is obtainedby turning the knob to the right; to slacken-Of f turn in the opposite direction.Sh o ck a bso rbers fo r fro nt fo rkThe front wheel fork is fitted with shockabsorbers to counteract excessive springing whent ak ing a succession of bum ps. Th e shockabsorber is regulated by tu rn ing the screw for-ward to tighten up , or backward, to slacken Off,as desired. Tight screwing should be avoidedas this unnecessarily retards the function of thesprin gs.D i m m e r s w i t c h f o r h e ad l a m p and hornOperationi n Order to dirn or switch on the head iamp,operate the switch lever to its fuli extent in thedesired direction. Th e horn is operated bymeans of a press stu d conveniently placed fo r use.Sta ndThe rnachine can be placed on the stand with-ou t difficuity and bodily exertion i f the riderdoes not atternpt to iift the full weight on tothe sfand. The stand should be pressed d ownon to the ground with the left foot and thernachine pulled backwards (not upwards) byv 22

rneans of the luggage Carrier, the foot beingpushed against the Cross-bar of the rest. A lu -bricating nipple will be foiind on the axis of thestand.Speedo meter a nd mi l ea g e indica to rThese are instailed in the direct line of sightof the rider. T he face, which is iarge and easilyread, is indirectly illurninated for night riding.Adjustable knee gr ips- he rubber knee grips on the side of the fueltank are adjustable to the comfort of the riderby rneans of two nuts.

'


13/56

A few practical hintsR u n n i n g i n a n e w m a ch i ne

A careful study of this section will save youtrouble and expense!As in the case of all moto r vehicles, Speed lim-its must be observed during the first 1,200 miles.

250 an d 350 cc Speed l imits1 st. gear from 0 to 9 miles per hour2nd . gear from 9 to 15 miles per hour3rd . gear f rom 15 to 30 miles per hour

30 to 40 miles per hour30 to 43 miles per hour.In the early Stages of running-in a new engineslow travelling on top gear should be avoided;fo r town riding the 3 r d Speed should be used.To help the rider in keeping the Speed withinthe prescribed limitc, the carburetter is throttl-ed down by means of a pin which is remov-ed by the DK W dealer when the runnin g-inmileage has been completed. Yo u should askyour DKW dealer for a DKW Servicing Cardand take your cycle to h i m for inspection whenthe specified mileage has been completed.

250 cc. top gear from350 cc. top gear from

24_ - _----- --

447

'


14/56

A) Controls


15/56

S t a r t n g1. T u rn on Petrol-tap A l2. Fiood float-chamber by Operatingthe tickler A 23. Set the throttle by means of th e.twist grip an d the air c ontrol leverin the starting-up Position A 3 , A 44. Switch on ignition A 5 r. Operate the kickctarter A 6 .If after Operating the kickstarter severai timesthe engine fails to Start-up, refer to the chapterPractical Advice on page 90.Then proceed to operate gears and ciutch as ,described in A 8, 9 and 10.

_

S t o p p i n gTo save the engine from unnecessary wear,close the throttle and pu t the gear in neutralbefore the machine Comes to a standstillSwitch O ff the ignition and turn Off the petrolsupply. Before leaving the machine on the stand,look to see that it is standing ons a firm surface.You should get into the habit of removing theignition key when leaving your motor cycle.This is not only a police regulation but alsoautomatically ensu res that the ignition is switched


16/56

means of th e 22 mm spanner which will befound in the tool bag. The wheel is then freeand can then be lifted out without difficuliy.

Fig. 1 I . Removing th e front wheel; disconnecting the mileageindicator cable.1 = Press button. 2 =. Withdraw cable from scating.

R e m o v i n g t h e back w h e e lLoosen the two screws which hold the endsection of the mud guard in Position. Raisemu d guard as shown in illustration (Fig. 12).

Unscrew ihe axle nut on the left side (lookingtowards the front of the machine) with th e22 m m spanne r provided. After abo ut 5 or7 turns the axle spindle will beconie free and

r

' 44-

I 4I

Fig. 12. Removing the back wheel.1 = To loosen turn screw to left.

2 = Raisc end of mudguard and Support with strut.3 = Unscrew spindlc ri th left hand turn.


17/56

Fig. 13. Dismounting back wheel; withdrawing the spindle.I = Unscrcr spindle nu t with a left hand turn.

2 = Withdraw spindlc with a left hand turn.3 = Remove dislance Piece.-v 30

Fig. 14 . Removing the back wheel.

+ = Slip whcel of f scaling boit to left and Ihmriihdraw backwards.

31 --v


18/56

can be easily withdraw n. Remove the distancepiece, which will be found between the wheeland the frame, and the washer, between thenut and the frame. Do not lose these parts orforget to replace them when remounting thewheel.When replacing the back wheel take care to Seethat the nu t on the spindle is in the correctPosition in relation to the chain adjusting~ -~

Fig. 15. Spindle park.1 = Distance piece. 2 = Warher. 3 = Spindle.

32

screw, the otherwise wheel will not run true andunnecessary wear of the tyre and chain willresult.I t is also important 10 See that the mud guai-dis replaced correctly in its grooved seating.

R e m o v i n g tyre -DKW motor cycles are fitted with deep- bedd edrims. Expert knowledge is nol necessary toremove a tyre, but the method differs fromthat necessary for an ordinary bicyde tyre. I t -is useless to attempt to force the tyre rim overthe rim of the wheel by means of a lever,screw driver o r similar tool. This will onlyresult in damage to the wire beading and outerCover. The secret of easily and quickly remov-ing a tyre lies in following these directions.First release all air from the inner tube, usingthe reverse end of the valve dust cap as a key.Then, com mencing a t the valve, press the tyreinto the base of the r im. This may be doneby treading on the tyre.By pressing the edge of the tyre into the baseoi the rim, the tyre on the opposite side ex-pands and the wired edge can, with the helpof the levers supplied, easily be pressed over

j


19/56

the edge of th e rini. Having made a start, therest of the rim of ihe outer Cover can easilybe loosened and afte r removing the valve niitthe inner tube can be taken out.

Fig. 16. Press ihe outer Cover into the base of the wheelrim with the foot and press the tyre over the rim on theopposite side.M e n d i n g a punctured tyre

The surface of the inner tub e surroundin g lhepuncture - usually resulting froin a nail -Y-- 34 Fig. 17 Press the outer Cover over the ri m of the wheel. 1135 --___ -~


20/56

.

should be c lean ed, with a little petrol a ndslightly roughed by means of the file suppliedwith ihe puncture outfit . Then sprea d a littlesolution evenly over the surface. While thesolution is drying, Cut ou t a piece of rubberof the required size and shape - val or roiindif possible - and after removing the gauzeprotection, press i t firmly on the puncturedarea. Before replac ing the inne r tube, feel i i i -side the outer Cover to make Sure that thecause of the puncture (e. g. a riail without ahead) is no longer there.

A faulty valveA slow leakage of air from the tyre is gen-erally the result of a faulty valve. This can belocated by removing the d ust cap an d cov-er ing the end of the valve with a little spittle.In the event of there being a leakage, bubbleswill form. I f there is foiind to be a leak, thevalve should be screwed tight by means of th edu st cap which also serves as a key. Leakagemay also result from a faulty joint between thevalve and the inn er tube. This can also bestopped by remo ving the outer Cover and tight-en ing u p the valve nut adjoining to theinner tube.

36

Replacing a TyreAfter repairing a puncture, the inner tube shouldbe pumped u p slightly and then replaced incidethe outer Cover. Th e valve is then fitted intothe port in the wheel rirn and lightly securedby means of the nut. On e rini of the outerCover having been placed in Position inside thewheel rim, ihe other edge should ihen bepressed over the edge of the wheel with the aidof the tyre levers, comm encing at the valve.l h e foot should be used to keep the tyre i nplace once it has been pressed over the rim.The last piece can be easily pressed over therim by depressing the section of the tyre imine-diately opposite. Ac when removing the tyre,force should not be used in replacing it . Whenthe tyre has been finally closed over the wlieelrim, care should be taken to see that the valveis in an upright and not in a slanting Positionotherwise a leakage in the valve is liable toresult later. Th e tyre should now be pumpe du p about one-third f u l l and any kinks removedby bouncing the tyre a few times on the floor.Finally, look to see that the narrow rubberline on the side of the tyre is parallel to th ewheel rirn all round. I F i t is not, the outerCover is not seated properly in the wheel rim.The tyre should be punclied and kneaded rintil

-I

- -37 -


21/56

Fig. 18. Replace inner tube pumped up slightly.

38

i t Slips into Position. Th e tyre may then bepumped up to the correct pressure (See Page 45).After a little time the rider will be able to judgethe correct pressure, but it is advisable at the

Fig. 19. The valve must be upright. ' I

39 -@ it1


22/56

outset to have the air pressure tested a tthe first Service Station after repairing a punctu reon the road.

Fig. 20. Press the outer Cover into the base of the wheeirim with the feet and com mencing at the valve, press itover the rim.

40

-

ig.21 . The last section can be easily pressed over the rimwith the help of tyre levers.Special measures to be taken in Winter

When starting in the dark do not switch onthe lights until the engine is running.Step on the seif-Starter twice to loosen theengine before switching on the ignition; thenswitch on the ignition. Also declutch twicebefore starting to loosen the clutch and faciiitatethe Operation of ihe gears.

_

~ __41


23/56

Do not Start immediateiy after the engine hasbeen Set running; aliow the engine to run forabou t a minute with the machine at a standstill.Before the cold weather Sets in, test the batteryto See that the acid does not leak and that theacid is up to the correct ievel. It is also advi-sable to have the battery charged at a garage.i f the machine is not to be used during theWinter monthc, it should be jacked u p so thatthe wheels are ciear of the ground. Both tyresshould be defiated and the battery dismountedand stored in a warm room. I t shouid be sentto be charged every six or eight weeks.


24/56

B) Working parts requiring attention


25/56

6) Fuel, lubiication, electricalequipment, etc.PetrolWe recornrnend the use of only well-knownfuel products. If a Petrol-benzol mixtiire -which is not necessary for normal running -is used, no adjustments should be made to thecarburetter or the ignition timing. I t is notadvisable to niake frequent changec in the kindof fuel uced.Fuel admixtureWe suggest that during the running-in period- . e. fo r the first 1,200 niiles - uto-Kollagshould be mixed with the petrol in a propor-tion of 0,3 CU. in. to a f u l l tank of 3 gallonc.Lubricating OilFor eng ine lubrication use on ly best- knowiibran ds of m otor oil, havin g the followingapproximate specificationc:Specific weight at 6 8 O F . . . . approx. 0.908Viscocity at 122O F . . . . . . . approx. 12O EViscosity at 2 12O F . . . . . . . approx. 2.1 5 O EFlash point (Open) . . . . . . . approx. 428O FLo w cold test maximum . . . . approx. - 4 O FSA E rating . . . . . . . . . . . . . . . SAE 40

43 v

44789


26/56

For Summer and Winter lubrication, we recom-niend Triple She l l meeting the above speci-fications, which we have tested thoroughly inou r ow n plants and found especially suitable forengine lubrication.

'

*

Mixture proportions - Oil and PetrolOil and peirol should be mixed in certain fixedproportions. A mixture sometimes known as"Petroi l", in a proportion of 2 5 : 1, i. e.5I/z gallons of Petrol to 1% pints of oil shouldbe used, also for the running-in period. For anormal f i l l up of 2'ir gallons, .an addition O E25 cubic inches is required.

'1I

I B 5 B 14 ILubricat ion of transmiss ion partsand f r a meLike the engine, gears, transniission chain, frontfork, brake and speedometer drive, must belubricated periodically in accordance with in -structions. Lubrication Points, lubricating materialand lubricating periods are clearly indicated inthe lubricating chart at the end of this section.Details will also be found under paragraphs C 8,C 10, C 12 and C 14 .

II44

S p a r k i n g p l u g sTh e most suitable sparking plugs for DKW motorcycles, Type NZ, are Bosch plugs W 225 T 1 ,or Beru 2251b 16 . Plugs with a low sparkingvalue should not be iised.Tyre pressureThe air pressiire in the iyres should be checkedat least twice a monih.Fo r types NZ 250 and NZ 350 the pressuresshould be maintained as follows:fmporfanf! Front wheel Back wheelSolo. . . . . . . . . . . . 17 20 Ibs. per sq. in .With pillion or side-car . 17 27 Ibs. pe r sq. in .With pillion and side-car 17 33 Ibs. per sq. in.

4Battery 7Fuses 8Details concerning the maintenance of the Batteryare contained in Paragraph C 7.

Th e fuses fo r the electrical installation are tobe found i n the coil box. Th e main (dynamo)fuse is situated on the underside of the coilbox i n a screw cap, and the battery fuse isvisible when the coil box Cover is rernoved. 'For further particulars See Paragraph E 5 .9

_.45 -41


27/56

Lubricatingchart for NZ250 andNZ350 C) Care and maintenance-No.

B 1-BB f

B eB 7~aB . 9B 10B 11B 12

B 13B 14B 15

-ILubricatingpartEngine (Tank)Gear box andclutchFront wheelSaddle noseClutch wormSpeedometerdriveBrake key,frontBrake key,rearFOObrake leverStandChainCpeedom.spira1-ubricating feit.Ocont breaker

fork

Lubricatingmaterial~~Shell-Auto oilTriple ShellShell E. P. SpiralLight (in rinteiunder00C(320F lhSin l eShe i l + i i r~ he 'E. %.pirax Light,Shell HighPressure GreaseShell HighPressure GreaseShell HighPressure OreaseShell HighPressure OreaseShell HighPressure GreaseShell High,Pressure Greasejhell HighPressure Grease;heil HighPressure Grease;hell Chain Grease3oldcn Shell

;hellAmbroleum

-When Iiubricain mile--1,8006006006006006006006006006003,000

3,000

11

811111I1111

-No.ofpoinls.-

We recommend the use of only good quality oils and grrares as givcna b w e ; thcse have bccn thoroughly tested in our works and found to bethe most suiiable for lubricating purposes.

You will find in this section all you requireto know about the necessary care and main-tenance work which you yourself will be ableto carry out without Special expert knowledge.Many owners will take a personal pr ide andpleasure in looking after their machines or wil-lingly undertake the work to save time andmoney. But whether you d o he work yourself ornot, it is'essential that it should be carried out.We cannot too strongly emphasize the fact thatthe reliabie running and value of your machinedepends to a large extent upon the work ofcare and maintenance. There isalso, of Course,certain work, particg larly after lh e mach ine hasbeen in use for a cerlain length of time, whichcan only be carr ied ou t in recognised DKWWorkshops by experienced mechanics. T he eyeand ea r of a DKW expert Sees and hears m orethan the ordinary rider. Wh en yo ur machinehas completed, at the outside, 6,000 rniles, youshould take it to a DKW Workshopoverhauled. You will receive willin g advice asto any work necessary.The gauze filter to the petrol tap must becleaned after every 1,800 miles. In the case of


28/56

II Fig. 23. Cleaning the Air Filter.I = Wash filler with petrol.

2 = Then oil.v 48

th e N Z 350, remove the guard cap with a17 mm key and unscrew t he nut holding thefilter in Position (See Fig. 2). Wash the filtergauze thoro ughl y with petrol an d replace, takingcare to see that all pa rts ar e screwed firmly inPosition. 'In the case of th e N Z 250, the petrolfeed pipe should be detached from the petroltap; it can be unscrewed from the tank andthe filter washed out. The machine should betilted over to the right to prevent the petrol inthe 'tank from ru nnin g out.Air tilterThe carburetter air filter must be cleaned afterevery 1,200 miles. l t is removed by unscrewingthe retaining ccrew with a screw driver andwithdrawing the filter to the rear. It shouldthen be thoroughly washed with petrol anddipped in a bath of lubricating oil which ic nottoo thick; then allow it to drain well. A dirtyair filter causes the engine to run irregularly,and give Of f fumes; i t also increases the fuelconsumption.D o not attempt to ride without an airfilter.Sparking plugThe sparking plug should be examined afterevery 1,800 miles and the spark gap between

49 $5


29/56


30/56

Fig. 25 . Cleaning the E x h a u s t B o x (Silencer) Leistritz Type.+ = Remove end seclion and wilhdraw silencer.- - 52.. -. .VJ --

f Fig. 26 . Cleaning t h e E x h a u s t B o x (Silencer)Eberspclier Type.

+ = Wilhdraw cnd seclion togclhcr wilh silcnccr 10 Ihe rear.I

I @3 ___kc

I


31/56

,

.I

are liabie to accuniulate quickly. No adjust-ments should be made to lhe inside of theexhaust chamber otherwise the working of th eengine may be adversely affected.lgnit ion and Lighting InstallationThe cable laid along side the frarne of themachine c hould be exam ined fro m time to timeas to its condition. I f it has got out of posi-tion there is a possibility of its becoming bentor damaged and causing a short circuit. Slightlydamaged cables may be repaired with insula-ting tape; badly damaged cables must be replaced.The maintenance of the lighting installation ica matter for our DKW Workshops and DKWelectrical Service Stations.The periodical inspection and control of th econtact breaker, the s troke action, the tensionof the damper spring, the condition of the leverbearin gs and the lubrication of the contactbreake r cam sho uld not be neglected. T his isthe matter of a few moments but is very essen-tial to the efficient running of your machine.Under no circumstances should the ignitiontiming be readjusted by the own er himself. Th eadjustment made at the works has been found,after long tests, to be the best. Th e adjust-

--.-

Fig. 27. The battery uncovered.ment of the ignition timing need only be + = Correcl acid level 3 ni m ( ' l i o ' ' ) above the plates.

f


32/56

checked from time to t ime and then only b)means of the Special apparatus to be founconly at our DKW Service Workshops. Th e sec.tion "Practical Hints" will teil you what to d ain the event of a breakdown on the road.Battery

-".. Regular attention to ihe battery is essential forthe perfect functioning of the ignition and light-ing System. W he n new, i t must be taken to ;tService Station and charged slowly at leasttwice. Later, it shou id be topped twice a mo nthwith distilled waler. I f this is neglected and thetop plates are allowed to become uncovered,the Performance will be impaired and the bat-tery suffer. The acid solution chouid be testedat least twice a year. The cable connectionsshould be examined occasionally to See thatthey are in Position and a little Vaseline appiiedto keep them from becoming dry andcracking.[ Clutch a n d gear box

I The clutch r u m in an oil bath. The lubricatingmaterial ic fed through the filling openingon the left side of the gear box casingand simultaneously serves the power transmis-

c

jI

?Fig. 28. Filling up with gear oil.1 = Oil levcl indicator.

2 = Fill ing opening fo r gear oi1 I;Ii

i' - - .- ~ ... . . -..._ -


33/56

-- -7sion, clutch and gears. The lubricant recornmen-de d is Shell-Getriebeoel H D L (in Winter- nter 0 O - 12 Shell ,,E. P. Spirax Light"+ 112 Shell Auto Oil ,,Single Shell".The use of any o ther lubricant is liable to resultin a sticking, s lipping or breakdown of th eclutch. A co mple te f i l l is 1,76 pints (1 litre).At the outset the lubricating oil should bechanged after 1,800 rniles; iater, every 6,000 miles.The oil is drained out by removing the screwwhich will be found underneath the casing; itshould be run Of f when warm and the gearswashed with Shell Flush ing Oii". Frech gea roil c an then be r un in with the engine runn ingslowly until th e top level shown on the in-dicator is reached (See Fig. 28).Adjustment of ClutchThe adjustment of the clutch is simple and canbe m ade without the aid of tools. I f the amountof play in the clutch hand lever is greater thanthat given under Paragrap h A 8 (about l/lo"),resulting in the clutch not fully disengaging,this can be irnmediately remedied by giving theadjusting cap, shown in Fig. 29, a turn ofabout one revolution to the right. If the clutchSlips, thus indicating that the adjustment is toofine, turn the nut to the left.

IIIi

58___ ___ _ _ _

t

iFiiiI

bi

Fig. 29. Adjusting the Clutch.+ = T rcduce the clutch play turn to lhc right

Lubricating th e driving chainThe chain should be greased with Shell-Ketten-fett every 600 miles by being laid'in warmedliquid chain grease. I t should first be washedin Paraffin oii. After being dipped in chaingrease it should be allowed to drain well beforebeing replaced.(c11( Care of the driv ing chain

The chain should neiiher be too tight nor tooloose. In either case the chain and tooth crown


34/56


35/56

number of turns given to the nut should becounted, as a corresponding adjustment n~usibe m ade o n the oiher side and the Same nuni-be r of turns must be given to avoid irregularadjustment which would result in the wheelnot running true and unnecessary wear nfthe tyre. A test as to whether the chain is run-ning true can be made by sianding the machineupright and then from a distance of about2 yards behind the back wheel, taking a sightover the rear crown wheel to ihe front crownwheel. The chain should theii run exactly parallelalong the line of sight over the two crownwheels. Soon er or later, according to the workthe machine has been called upon to do, thechain will begin to show signs of wear and anew dri vin g chain will become necessary. If th echain can be lifted two-thirds of the height ofa tooth on the rear crown wheel it is time tohave a new chain.

--

Care of CycieThe regular lubrication of the cycle is absolu-tely essential. It is the cheapest way of keep-ing dow n the runni ng costs. The lubricatingpoints of the front fork and on other parts ofthe frame are show n on the lubricating chart.As the various lubricating points on the motor-j

cycle are everywhere easily accessible, the workcan be carried ou t by the owner. It scarcelytakes ten minutes to thorowghly lubricate themachine. A grease gun is included among thetools supplied.T o f i l l the grease g u n1. Remove Cover.2. Remove protection cap.3. Withdraw piston by means of chain.4. Fill the gun with the prescribed high press-ure grease leaving sufficient room for th episton. Shake the gu n vigorously wiih thenozzle pointing downwards in Order to ex-pell ail air and allow the grease to settle.5 . Replace piston by pressing firmly.6. Replace Cover.In the event of a foreign body having enteredthe gun and preventing the return valve in thepressure cylinder from functioning, it shouidbe removed by unscrewing the nozzle and liftingou t the valve spring and ball.BrakesThe adjustment of the front and rear wheelbrakes can be made in a minute by hand by

63


36/56

Fig. 2 . Adjusiing the front wheel brake.+ = To adjust brake turn 10 ieft.

I Fig. 33 . Adjusting the back wheel brake., + = To adjust brake turn nut to right.64

means o f wing nuts. The regular greasing ofth e foot h a k e lever and the brake key con-nections to both wheels is absoluteiy essentialfor the reiiable Operation of ihe brakes. Afterconipleting about 3,000 miies, the machine ~should be taken to a DKW Service Station forihe brake drum to be opened and cleaned andthe release spr ings an d bearin gs lighily greasedwith "Sheli High Pressure Grease".

-

... iS b 7 8Pig. 34. View of Brake drum opened.

I = Brake kcy conncction. 2 = Brake lining. 3 = Right hand axle nut.4 = Washer. 5 = Brake shoe. 6 = Release springs. 7 = Brake r im.

6 = Brake drum wilh tooth crown wheel.

65 -@? ;I


37/56

& Fork jo int , Wheel a nd s t eer ing bea r ing sThe ainoi int of play in tlie wheel and steeringbearings is iiriportant i n connection wiih themachine's road hold ing qualiiies and its reli-ability. The bearings should therefore be inspect-ed every sis nionths at a DKW Service Sta-tion and renewed whenever necessary.Ic15] R e ar w h e e l shock a bso rber

A shock ab sor ber ic mourited in the back wheelto iake hard joltc imparted by the powei-transrnission. Shock lugs on the brake driirii

Fig. 32. Clianging a sprocket wlieel sliock absorber.

66__ ~ -~

are mounted on rubber r ings and should berenewed afier every 5-6,000 miles. They canbe removed and replaced without difficulty.@ Bo w den Co nnec t io ns a nd co nt ro l l ev ers

Th e Bowden Connections should be examinedafter every 3,000 miles to cee that they haveno s l ia tp bends or have not come out of theirseat ings or are otherwise damaged. They arealso liable in time to fray at the ends. It is1 better to renew them in good time than tor isk a breakdown on the road. All BowdenConnections shou ld be slightly greased at poinlcwhere they join wiih control levers.

Ic17) TyresThe regular control of air pressure and of th econdition of the iyres is important not onlyning of the motor-cycle. Damage to surface oftyres can either be repaired with cold vulcan-ised filling Solution, or (i f the damage is exten-sive) by being sent to a good vulcanisingWorkshop fo r repair. Uneven treads (bunip s ordepressions) should b e repaired by an experti f further damage to lyres is to be avoided

--for the life of the tyres but also for the run-

-_____67


38/56

k,li e a n i n gI t is recomm ended that the motor-cycie shouldbe washed dow n thoroughly with luke warmwater at least twice a month, and then rubbedimmediateiy with a soft Cloth. lt should thenbe sprayed with DKW-Nebelwsche and givena final polish.

Side Ca rsi f a rnachine is to be ridden with a side cari t will be necessary to install a smaller drivingpinion in the gea r box having two teeth less.As the comfor t of a s ide-car depends upon i tbeing perfectly fitted, the work should beentrusted to an accredited DK W Workshop.

Racing rnachinesIf a rnachine is required fo r taking Part insporting competitions, a Special racing type,constructed by us from the practical experiencegained in such events over a number of years,can be delivered.

68v --

Customers Servicing StationsYou are invited to apply to any of the recog-nised DK W agents if you have difficulties inregard to repairs o r any other questions inconnection with your DKW machine. O ur agentsare in constant touch with us; they are expe-rienced, have at their disposal mechanics whohave been trained in ou r works schoo!s, haveSpecial tools and testing instruments and useonly original DKW spare parts. Yo u can alwaycrely upo n quick a nd expert attention to all Sourrequirements.

_


39/56

Teeh nica EnquiriesWritten e n q u i r i e s should also b e a d d r e s s e d toour recognised agents. I n O r d e r to save t i m ea n d ensure personal attention, t h e followingd e t a i l c s h o u l d be given:

1. Ty pe of ma chin e;2. Frame and engine number;3 Purchase date;4. Total mileage compkted;5. Adjustment of carburetter used;6 . Condition and adjustment of ignit ion;7. Fuel used (Brand-Petrol oc mixture);8. Lubricating material used (brand and quality);9. Petroil admixture (proportions);-


40/56

C) Care and maintenance

r

t

1


41/56

i

P

Attention necessaryafter :Front fork :

lubr ica te . . . . .Frame:lubricate . . . .Cha in: grease . ,.Clutch worm:lubricate . . . .Speedorn. connect.Brake key :f ront . . . . . .rcar . . . . . . .S;tddle nose . . . .Foot brake lever .S t a n d . . . . . .Tyr e pressure checkCparklng p lug -examineelectrodePetrol f ilter : c leanAir f ilter : c lean .Clulch: ad jus t . .Battery - cst . .Cablec: examiiie .Bowden connect. :cxarnine . . , . .Speedomeler con-nec t ions: greaseS p a r k in g ~ i l u g s :renew . . . . . .Ciear box :

rcnew grease . .Contact breaker :I iibricating felt:grease . . . . . .

What must I do?-I800ni-les

0000000000

_I

--0

00

-

-----

-

-3000m i-les

0000000000

-

------000--

0

-5000mi-le s

000

000000000

0

-

---0000

3

0

7or detailsrefer to

-

Lubricat. chartLubricat. chartLuhricat. chartLubricat. chartLubricat chartLubricat.chartLubricat. chartLubricat. charlLubricat. chartLubricat. chartPage 45 an d 67Page 49Page 47Page 49Page 58Page 56Page 54Page 67Lubricat char tPage 50Lubricat. chartand page 58Lubr ica t cha r t

- - --.-*


42/56

Df The carbureiierimportant P o int s


43/56

is drawn to the fact that i t has now been foundpocsible to introduce a Standard adjustment forthe carburetter which produces the best resultsunder almost any condition, both as regardsconsumption and Performance. You should ,therefore, not attempt to make special ad-justments of your own as these can seldom besaticfactory. As a recult of experience we havelimited the adjustment margin to the main jetto one stage either way. A larger margin of

17 2

Fig. 38 . Gas and air slide as well as float needle of AmalCarburetter.

I = Clamp spring. 2 = Pos i t ion 2. 3 = Ploat rieetlle.4 = Gas s l ide valve. 5 = Air s l ide valve.

_Fig. 39. Section of Amal Carburetter.= Ga s slide valvc. 7 = Petrol supply feed. 3 = Tickier. 4 = Float

needie. 5 = Float. 6 L Float chamber. 7 = Mixing chamber. 8 = Clampscie\v l o joint ring. 10 = ld l ing adjustment= Throttle check screw.screw. 1 1 = Float needle. 12 = Main jct.


44/56

-.-"iIc

!!!

I1i m 76ig. 4 1. Components of Graetzin Carburetter.

1 = Mixiiig chamber nut. 2 = Air valve spring . 3 = Air valve 4 = Tickler5 = Fuel connector. 6 = Float ch amber Cover. 7 = Float nnd le 8 = Float.9 = Float chamber. 10 = Onskcts. 11 Throttlc valve. I2 = Bowden 7cable adjuslinp. screw. 13 = Mixing chamber head. I 4 = Throttle valve 1spring 15 = J e t n n d l e 16 = Mixing chamber. 17 = Thro ttle check screw.18 = Idling air, reguialing screw. 19 = Idling fuel jet 20 - Needlc Jet '21 = Main jet. 22 = Filter sieve. 23 = En d plue. i a


45/56

adjustment is unnecessary and would only resuitin breakdowns . Shou ld you not be satisfied withthe working of the jet, i. e. if it functions iist-lessiy or tends to spit back in the carburetter,you should immediately seek the advice of a

FitE:i, D KW - Workshop.11How o clean th e main j e t

1. Turn off the petrol tap.2. Using a scr ew dr;ver, release the ai r fiiterfastening and remove the air filter by with-drawing it to the rear.3. Using a 14 mm spanner, loosen the screwand disconnect the fuel feed from the fioatcham ber.4. .Losen the nut on the carburetter flangewith a screw driver, or 9 mm spanner.5. Give the carburetter a siight turn to theside and, using a 17 mm Amal, 14 mrnGraetzin or 19 mm Bing spanner (as the

the mixing and float chambers.lose the two packing rings.

-iII case may be) unscrew the nut connecting1 6 . Care should be taken not to damage ori

7. Th e main jet can now be rem oved witha 6,5 mm spanner in the case of an Arnal,o r an 8 mrn spanner i n the case of Bingand Graeizin carburetters.8. The main jet should be cleaned by blowingair through it , not, however, by using awire or other sharp object. Unde r nocircumstance should an attempt be madeto increase the Sire of the jet bore. Everyjet bears the maker's name and it is advisablealways to use original spare parts.9. In the case of an Amal carburetter, it isalso recommended that the jet housing becleaned at the Same time by forcing air

through with the tyre pump.10. The jet can now be replaced in its housing, nd the float charnber screwed O n . Do no tforget the two packing rings.

Y ,


46/56

E) Electrical equipmentLighting SystemThe lighting equipme nt consists of a 12 poledirect ciirrent dynamo. The armature is of th ebell design and also acts as a flywheel. ASpecial device must be employed to removethe armature from its seating. The pole Systemis mounted on an alu minium base plate which1s screwed to the engine casing. Th e poleSystem consists of two Star shaped magnetcbetween which the magnet coil is housed.The main cable connection (white cable = 1 ;black cable = 20) is also attached to the baseplate. These two cables should not be confused,otherwise the correct functioning of the lighiingset will be impaired and the regulator destroyed.The lighting installation on all NZ motor-cyclescan take a total full load of 7 5 Watts; thenominal tension is 6 Volts.T h e iighting Set is protected by a light meta1cover secured with two screws to the base plate.C on tact BreakerTh e contact breaker is mounted on a U-shapedbr idge and is attached to two fittings on i h e

_ _ 82

alumin iuni base plate. Th e contact breaker iscentred in this bridge and the fixing screwspass through two slots, so that the Position ofthe contact breaker can b e adju sted withincertain limits. The gap on the contact breakershould not exceed 0,02". The cam whichoperates the contact breaker is connected to acentrifugal governor which prevents back firingwhen the engine is started up .

ignition adjustmentThe Performance and wear and tear of th eengine depend to a large extent upon thecorrect adjustment of the ignition timing. Th eadjustment must be made to the fraction of amillimeter and for this purpose a suitabledevice I is necessary and should be used in con-junction with the adjustment indicator installedabove the contact breaker. I t is absolutely uselessto attempt to obtain better results by means ofadvanced ignition; the experience of the makersshould be relied upon. As precision in theignition timing, viz:Type NZ 25 0 4 ,5 mm (0,177") from upper deadcentre with centrifugal weightsin their controlling Position;


47/56

Fig 43. Contact Breaker.1 = Adjustment gauge. 2 = Condenser.

3 = Lubricating felt. 4 = Contacts.

Type N Z 350 6,5 nim (0,256")from upper deadcentre with centrifugal weightcin their controlling Position;depends upon the perfect working conditionof the con tact- brea ker, centrifugal gove rnordevice and the condenser, i t is advisable tohave the adjustm ent tested twice a year at arecognised DKW Workshop, or at a DKW lec-trical Service Station.

Coil BoxThe coil box is installed on the side of tliebattery. It houses the following:1. right: voltage regulator;2. left: Cut-out armature;3. ignition coil;4. battery fuse;5. dynarno fuse;6 . the connection Clip.The coil box always must be kept clean. Thisapplies to all connections and particularly to th eearth connectionc and is absolutely essential forthe reliable working of the set. Th e presenceof dirt in the coil box will at once lead toa defect.

\I"

I

85-


48/56

@ 6 -

5

Fig. 44 . Coil Box.4 = Dynamo furc. 5 = Ballery fusc. 6 = Cut-out cwitch.

1 = IgnitiOn cable connection. 2 = lgnition coil. 3 = Regulator,I

I-VJ 86

4

8-9

Fig. 45 . Component parts of the Coil Box.I = Coil box (seen f rom above]. 2 = Ignition cable connection.7 = Contact spring. 8 = Dynamo fuse. 9 = Battery fuse.

10 = Plug.3 = Pilot light. 4 = Ignition coil. 5 = Cwilch. 0 = Regulator.


49/56

FusesT w o 40 Amp. fuses are installed. Th e batteryfuse is to be fourid below the Cut-out switch;the dyriamo fuse is to be found under the coilbox and is screwed in with an insulated cap.Car e should be taken to See that the fuses arealways securely in Position, as a loose fusegives a bad contact an d resulls in an over-heating of the a djoi ning parts. The sprin g willbecome s of t and the soidered par ts on the fusebecome disconnected without it being possibleto See from the outside that there is a breakin the contact.

IE6jHead LampTh e head light coinprises a 25/35 Watt, 6 voltsBiiux Lamp and a parking light of 3 Watts and6 volts. Th e rear light is also 3 Watts an d 6 volts.The correct mounting of the head lamp so a sto give the maximum lighting effect is impor-tant. A simple test is 10 place the motor-cycle on a level surface with the head lanip16 feet distant froin a white Wall. Th e centreof the reflection on the Wall should then be I "below a line taken from the centre of the headlamp. The rear light shows signal red.

88

Electric HornThe strength of the Signal horn should betested from time to time. Th e tone can Changethrough the loosening of the horn itseif or ofthe membrane adjusting screw. It is in th erider's own interest to have a properly tunedhorn. The adjustment of the membrane requiresexperience and shouid therefore be left to aDKW Workshop to carry out.


50/56

F] Pracfical adviceT h e e n g i n e f a i ls to s tart-up1 . Upon dep ress ing the tickler, petrol fails

to f low:a) petrol tank is empty,b) petrol not turned on, orc) i f tap is in Position A and there is onlya m a l l supply of petrol in the bottom ofthe main tank, switch over to R (reserve

d) filter gauze to petrol tap is dirty and is

e) air vent in tank Cover is blocked with dirt.2. Petrol flows after Operating tickler, but enginestill refuses to start-up:a) dirty jet,b) twist grip and air control lever no t se tin accordance with instructions (warm orcold engine),

SUPPlY),stopping flow of petrol,

c) ignition not switched On .control lamp signal does not burn:a) defective Signal lamp,

3 . The ignition is switched on but the charging

90~-

b) battery fuse blown,c) battery empty or not fully charged,d) bad contact in coil box,e) broken or damaged cable.

4. Signal lamp burns, but sparking plug doesno t spark (Simple test: disconnect cable fromplug and hold it by rubber insulation about3 m m from the plug, Operating kickstarterat the Same time):a) contact breaker rocker arm does not lift,b) rocker arm seating over-oiled or burnt out,c) rocker arm Sticks,d) bad ignition coil contact,e) defective ignition coil,f ) condenser burnt,g) bad cable connection in coil box.

5. Ignition sparks on plug:a) gap between plug electrodes incorrect(correct gap 0,024 "),) plug oily, old or unsuitable,c) engine has choked ("drowned") through

too frequent flooding of float chamberor continuous Operation of kickstarter.In this case rernove plug and turn en-91 __-


51/56

gine w e r several t imes by means ofkick-Starter until cylinder has been aired.d) too much oil in mixture.

6. Battery weak:a) incorrect acid solution (electrolyte),b) plates not covered with solution (topc) plates damaged,d) loose, or oxydised Connections,e) short circuit somew here in connections,mechanical defect in lighting set, dirtycommuiator , brushes do not connect , badearth Connection s froni battery, coils orlighiing set,f ) main cables, 1 o r 20 , defective,g) defective regulator,h ) Cut-out switch defective,i) make-shift or wrong fuse.

with distilled water),

-kl h e E n g i n e does n o t run s m o o t h i y1. Fou r- s trok in g

a) jet too large,b) incorrect jet needle adjustment,c) defective float needle or float,

d) too miich oil in petroil mixiure,e) ignition too far advanced,f ) accumulation of carbon deposits in engineg) dirty air filter,h ) mechanical adjustments to exhaust box.

or exhaust box,

11. Spit t ing back in th e carburetter:a) jet too small,b) incorrect jet needle adjustment,c) dirty petrol filter impeding flow of fuel,d ) dirty carburetter,e) carburetter improperly mounted (crooked),f ) carburetter loose,g) r ing nut on mixture chamber loose,h ) defective packing on engine,i ) retarded ignition adjustment,k) old or loose plugs, incorrect gap adjustment1) low sparking value of plugs,

m) too high sparking value of plugs,n) riding without air filter,0 ) defective condenser,p) contact breaker rocker arm Sticks,

to electrodes,

9 3 - - - - - . . _ _ _ ~- ~~

.-


52/56

h) plug loose o r old, packing r ing noti) defective packing of engine.

replaced,

-IF4( T h e e n g i n e s t o p s s u d d e n lya) empty petrol tank,b) petrol tap not switched o ver to reservec) jet biocked,d) ignition cabie to coil disconnected or ioose,e) insulation to sparking plug broken,f ) main fuse blown,

g) contact breaker rocker arm broken or otherh) broken or loose mairi cabie of battery,i) burnt condenser.

SUPPlY (R),

defect to make-and-break parts,

A few w o r d s on Fuel Consurnption-A s in the case of ali motor-vehicles, fuel con-sumption figures are based upon an averageSpeed of 37'/2 miles per hour on a level roadand for an uninterrupted journey. Unde r otherconditions the consumpt ion is naturally increased.

96~~ _ _ - __- _~

I f , under normal running conditions, the con-sumption is higher than it shou ld be, the fol-lowing points should be checked :a j Adjustment of carburetter, its correct func-tioning, iininterrupted feed, cleanliness of

air filter.b) Suitabiiity of kind of fuel use d, which is ofthe utmost importance; in this connectionthe advice given i n this maniial should befoilowed.c) Correct adjustment of ignition and perfectcondition of all rnechanical partc connectedtherewith.d i Are the controls (twist-grips, air controllever and clutch) being correctly operated ?

i f not, the consumption will be increased!e) The cleanliness and packing of the engine.- T h e c h a r g i n g c o n t ro l l i g ht d o e s n o tswitch O f f after s tart ing-upa) Cut-out switc h defective o r bad earthin gb) loose contactc, interriipted battery contacts,c) dynarno fiise blown,d ) defective regulator,

Connections,

!


53/56

e) defective lighting battery resulting from dirtycommutator, or short circiiit in excitedwinding.

I F 7 I M ai n fu s e blows-a) defective regulator, too high regulation,b) bad earth connection on coil box,c) short circuit in cables,d) cable Connections 1 and 20 to lightingbattery wrongly connected up.

E1T h e h e a d larnp d o e s n o t burna) faulty cable connection to lamp,b) fuse blown,c) loose fittings inside lamp,d) loose or defective bulbs,e) defective battery.

Precaitions against theft:I n addition to precaution against theft by re-rnoving th e ignition key, the NZ types areequipped with an additional rneasure of security.A lock is installed on the steering column of th ehandle bars to take a safety locking devicewhich can be obtained from ou r Spare PartsDepartnient.

M eth od of U s e :A) To lock the wheel and sccure inach ine against thef t :

I . T urn hand ie bars to l e f t .2 . Slide the meta1 disc cover protecting the lock to on e s idc .3. Insert thc locking device atlached to the key iiito lhe lock until theb rass par t d i sappears ( ihe screw and ra i sed f in on the brass device

should be in l ine)4. Give kcy i/ d tu rn to r igh t and wi thd raw. (T he b rass lock ing dev icei : l l remain in the lock.)B) To un loek wheel .

Insert key, give 14 turn to l e f t and wi thd rav . T he lock ing dev ice wi l lbecome atlached to the key and can be carried on a key ri i ig as partof the key. Th e lock cover shoul d be kept closed to protect the lockfrom dust and water .C ) Olhcr t ipa.

;I) T ake a no tc of the nuinber of your key.b) Keep a spare key in your pocket or purse.c) Do no t o i l a DKM safety key.d) Wash a dirty lock out with petrol (pa rticularly the screw groove) .e i A spare key may be obtaincd by g iving the nii ii iber of your key.

99 ~~ ~ .~ -~.

. 1 . . .=----c=~ ." . , , ... . , ..


54/56

DKW-sparepartsYou should always use DK W spare par ts fora DK W motor cycle. These can be purchacedat reasonable pr ices f rom DK W dealers . If forany reason you are unable to obtain what yourequire please communicate with our D K WSpecial Spare Parts Department which will beon ly too glad to give you advice.D K W spare parts are reliable and low-priced.We recomniend

DKW- Polishfor polishing all enamel parts. I t cleans andpreserves the surface and is economical in iise.Original tins supplied in

1/ z l i t re Order No. 08301 l i t re Order No. 0318

Motor-cycle driving chains of all the bect makecare s tocked. We invite your inquiries .Luggage Carriers can b e supplied in various designs.

We recommend under lays in fel t or rubber toprotect your luggage. Prices on application.100~ ~~ p___.__ .______

Pillion Seats with r ubb er o r iniitation leather Covers.Adjustable foot rests can be adapted to an yluggage Carrier. A number of different typesstocked. lnqu iries invited.


55/56

. Induction of Charge in the craiik case.Moveiiieiit of th e piston froin hottoiiid ta d ce ii t re to top.P re -c o m p re s s i o n of fresh Charge inc iank case. Movemeni of pistondovonaards to bottom dead centre.

Th e t r a n s fe r P o r t s r e l rd s e dby u p p e r e d y e of pis ton.lnward rush of fre s l i cha rg e10 combust io i i chamher

Lo m p re s s i o n of mixture in comhust ion I m i t i o n shortly b e i o re to p dead cent rechambe i . P is ton rnovement i ipward is reached, combust ion a nd expans ionof gases rerulling in power, and desccntof piston


56/56

Documents

Instruction ManualNZ250+350