1980 SKODA 120 LS light

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Fig.6.5/5
-
Pressing-in Beoring Cups Using
MP 6-130 Jig
Fig.6.5/5 -
Instolling Seoling Ring
Using
MP 6-131 Jig 23-
Fit the disk broke bock plote
on the
steering knuckle ond fosten it by bolting down
the broke brocket. Use spring woshers to lock
the bolts. Drive home the wheel hub
on the
steering knuckle with light tops ond use o tube
to top home the beoring cone.
24. Fit the greose-pocked
cone of the outer
beoring on the steering knuckie, locote
the
shim on the beoring, ond tighten the nut with
o torque of 1.5 kpnr (15
Nm) while rototing the
wheel hub.
25. Top
the wheel hub ond the broke disk
with o mollet ond rotote
the wheel hub to bed
in the beorings. Bock off the nut
through obout
-180o
ond retighten it with o torque of obout 5 Nm
(0.5 kpm) while rototing the hub. Then bock off
the nut to the neorest cotter pin
slot (ot
the
most through 30"), ond lock it in this position
by inserting the cotter pin.
26. Check whether the wheel hub rototes
freely br-rt without ony noticeoble
cleoronce in
the beorings, ond secure the nut with the cotter
pin.
Fittirrg Steering Knuckles ond Wheel Hub
into Wishbones
27. Hoving thus ossembled the wheel, instoll
ii into the lower
wishbone, fit
o shim between
tl-re wishbone reor eye ond the resilient bush in
the king pin socket,
threod in the eccentric pin,
cind screw down the nut without tightening it.
28. Press
the wheel ogoinst tlre
upper wish-
borre ond connect it with it
by topping home
the wishbone pin
from the reor side
of the
oxle,
i. e., from the side of the shorter port
of the
king pin
socket. Slip the MP 6-108 pilot
pin
on
the wishbone pin
threod to focilitote threoding
of the pin
through the hole in the wishbone.
Tighten slightly the connection with the costel-
loted nut.
DK ? 2r+
Fig. 6.517 -
MP 6--108 Pilot Pin for
Upper
Wishbone Pin lnstollotion
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5. Ploce
the steering
box with its bottom
boll
beoring resting on the MP 7-102 jig
ond press
the steering screw
with both beorings into the
iig. Extroct the
bottom beoring using
the MP
6-111 king pin
socket remover
ond push
the
steening screw with the top beoring oert of the
steering box. Support the beoring by the Mp
7-102 iig crnd
press
it out.
7.3 REASSEMBLING STEERING BOX
1. Press the dust cup with its seoling
ring
into the steering
box with the pressed-in
bush
ofter hoving thorouchly
cleorred the box. Now
pf oce the box on the MP 7-102
iig oncl
press-in
the bottom boll beorinct
using tlrei pressing
mandrel MP 7-103.
2. Fit the lower beoring
cop seoled
off with
o poper
gcsket
ond seoling compound, slip
lpring woshers
on to the bolts,
ond tighten the
bolts with o torque os per
Chopter t.6. f it the
wosher on the steering screw
with its deflec-
tion focing
the screw threod ond press
the
top beoring on the screw
using the Mp Z-103
pressing mondrel.
3. Then ploce
ogoin the steering box on the
MP7-102 iig ond
press
into it ond into the bot-
tom beoring the steering
screw with the pnessed-
-on top boll beoring,
using ogoin
the Mp7-103
pressing mondrel. For further ossembly, use the
vice ond the dummy brocket.
Fig. 7.311 -
Pressing-in Bottom
Beoring
on MP 7-102
Jig (support
plote)
Using
MP 7-103 Piressinq
Mondrel 4.
Meosure the height of the beoring pro-
truding from the steering box ond odiust it by
fitting shims interspoced with poper goskets
cooted with o seoling
compound.
Fosten down
the cop by tightening the bolts. Check the
steering screw for free rototion
ond the obsence
of ploy.
The beoring should be without o cleor-
once or there hos
to be o prestress
of up to
0.07 mm.
5. Remove the bolts of the cop, slip the rub-
ber seoling ring dipped in oil on to the shoft,
ond fit the dust cup on the cop. lnstoll spring
woshers on the bolts. Should the cup be over-
stroined due to the toleronce
of the recess for
the seoling ring or the ring itself
, instoll
o poper
gosket under it os under tlre ccrp.
6. Locote the steering nut on the screw fol-
lowecl by the rocker shoft with pin, spring,
spring pin, ond the licl gosket
cooted with
o seoling compound, ond fit the lid with bush
in position to close the steering
box. Instoll
spring woshers under the bolts orrd tighten the
bolts with o torque os per
Chopter 1.8. Screw
the set screw into the lid ond rnove
the steer-
ing geor
so thot the drop orrn is swivelled
through obout one holf of its trovel from the one
or the other extreme lock position.
Witlr the
drop ornr in this position,
screw down the set
screw os for os it will go
ond then bock it off
through obout 95 to '120'.
This will provide
for
on odequote cleoronce of the steering geor.
[.ock the set screw in position
with the re-
spective nut.
7. Drive the key on to the rocker shoft cone,
fit the drop orm ond hold it down lightly with
the nut. Clomp the drop orm in o vice, tighten
fully the nut (for
the tightening torque see
Chopter 1.8), ond secure tlre nut with o cotter
pi n.
8. Clomp ogoin the steering box by meons of
the dummy brocket ond moke sure
thot the dnop
orm con swivel from one extreme lock position
to the other. A certoin
resistonce should olwoys
be present,
but if the resistonce is too greot,
decreose it by o slight slockening of the set
screw in the lid. The
rototing resistonce of the
shaft should not exceed 20 Nm (O.2
kpm). Refer to
page 117/118 for testing
procedure.
9. Set the ossembled steering box in its fit-
ting position
(inclined
by obout 40o) ond pour
in oil through the hole in the bbx lid (cover)
till the oil level reoches the bottom edge of the
filling hole. Then
screw down the topered plug.
7.4 RELAY (TDLER)
LEVER
For its instollotion (ond
removing in reverse
order) ond ony pertinent porticulors
see the
Chopter 6.5, porogrophs
2 ond 3.
122

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odiust,
if necessory, the driving dog of the di-
rection indicotor switch -
see Chopter 13.17.
Refit the steering wheel so thot its spokes
ore horizontol, lock it in position
with the nut
(for tightening torque, see
Chopter 1.8), ond
bolt down the spoke shroud.
7.8 STEERING WHEEL SHAFT AND SHAFT
BEARING
The steering wheel (column) shoft is built
up
of two ports
with the beoring in the uPPer port.
Usuolly, it is not necessory to disconnect the
two ports
of the shoft or to remove the beoring
ond steering lock. lt
con be removed from the
cor os o unit.
Removol 1. Remove the steering wheel -
see Chop-
ter 7.7. 2. Remove the screws on the lower port
of
the shoft cowling ond pull
the cowling off.After
removing two bolts, detoch the cluster switch
on the shoft from the upper port
of the shoft
cowling. 3. Remove two front screws of the upper
Port
of the cowling ond remove the cowling.
4. Disconnect the leods
from the switches
ond the switch box.
5. From under the cor, remove the bolt of the
coupling connecting the steering
column shoft
to the steering box ond detoch the dust boot
from the floor. Remove the
bolts of the shoft
beoring (from
under the shoft)
ond the bolts of
the steering lock (from
the front) fostening the
shoft to the body, ond pull
out the shoft.
Ref itting To ref it the steering column shoft
in the cor,
reverse the removing procedure. While reinstol-
ling the steering wheel (Chopter
7.7), do not
forget to check the direction indicotor switch
for correct function.
Use ploin
ond spring woshers under the bolts
of the steering lock
brocket. Reinstoll the shoft
beoring using spocing tubes, rubber bushes, ond
ploin woshers, ond secure the bolt of
the coup-
ling, connecting the steering
column shoft with
the steering box, with
o self-locking nut (for
tightening torque, see
Chopter 1.8).
To Disconnect Shofts
Remove the bolt
of the cross-pin
ioint con-
nection.
Connecting of Shofts
Fit o fostening sleeve on the tube
with the
shoft, dip the ring in oil ond slip
it on to the shoft end with
its wedge-shoped port
toword
the beoring, instoll the spring
ond the
ioint
socket of
the shoft bottom port.
Tighten
the
connection with the bolt with self-locking
nut
(tightening torque os per
Chopter 1.8).
The sleeve must be f irst built up if
the shoft
is refitted for the first time. Locote
both holves
of the sleeve on the tube ond fosten
them
lightly together by bending the tob of one holf
of ttre sleeve over the
other. The
sleeve must
on no occount clomp the tube tightly.
Bottom Port of Steering
Column Shoft
The shoft is provided
with cross-pin
ioints
ond connot be dismontled (token
oport). Before
fitting the shoft dust boot, smeor
it with
oil to
focilitote its slipping over the pcrrts
of the joint.
For this purpose,
it is clso odvisoble to wrop
the joint
in o plostic
foil or to moke o sleeve
with o pilot
cone.
Top Port of Steering Column
Shoft -
Beoring
Removol 1. l-ift owoy the fostening sleeve
ond check
whether the shoft rototes
freely in the tube. lf
it is not the cose, unlock the steering lock ond
press out the shoft proceedirrg
from the side
of its splined
end.
2. lf necessory, remove
the circlip of the shoft
ond lift owoy the beoring. The other beoring
hos to be driven out by topping it corefully
through the cut-outs in
the tube to ovoid domog-
ing it. 3. Remove the brocket with the steering
lock
- see Chopter 7.9.
Ref itting
1. Slip tlre beoring pocked
with greose
on to
the upper port
of the shoft, then the ring with
its wedge-shoped port
focing the beoring, ond
lock both ports
in position
with the circlip.
Press the shoft into the tube ond press-in
the
beoring (ogoin pocked
with greose)
from the
other end.
2. lnstoll the brocket with the steering lock -
see Chopter 7.9.
Shoft Beorings They hove to be thoroughly lubricoted
first,
since ofter their reossembly with the shoft od-
ditionol lubricotion is not possible.
lf there is
ony doubt concerning the greose
pocking,
re-
move the circlip f
rom the inner port
of the
beoring, toke the beoring oport, cleon it, ond
reossemble it ofter hoving pocked
it with the
recommended greose,
i. e., brond NH2 of Cze-
choslovok provenience
or one of the bronds
specif ied in Chopter 7.5, porogroph
3.
124

r 0.3-t0,5
Ihe permissible
out-of-bolonce must not ex-
ceed 50 grommes
on the rim rodius. Every new
tyre is provided
with o coloured dot on its side,
indicoting its lightest point.
Fit the tyre olwoys
with this dot focing
the tube volve.
ln this
position, the volve octs os on odditionol weight
compensoting the wheel overoll unbolonce to
o consideroble extent.
lf dynomic boloncing of the wheel is not
possible, bolonce the wheel stoticolly with the
greotest possible qssuroc|.
Boloncing weights
of 30, 50, 75,
ond 100 grommes
ore ovoiloble.
10.4 TUBED TYRES
For mounting,
dismounting,
ond repoirs of
conventionol tyres with inner tubes (for
por-
ticulors, see the preceding
Chopters), the usuol
procedures ore opplicoble. The permissible run-
out (untrue
running)
of the rim is the some os
for tubeless tyres (Chopter
10.5).
10.5 TUBELESS TYRES
The oir-tight seoling of these tyres requires
more core ond o different hondling thon thot of
the tyres with inner
tubes.
Preporotlon of Rirrr
13elore mounting the tyre, inspect the rim for
ony technicol defects. The points
to be checked
ore the rim shoulder ond the moting foce for
the tyre beods,
in oddition to the overoll con-
dition of the rim. lf ony defects ore found, the
rim must be reconditioned.
A sotisfoctory rim
nrust comply with the following conditions:
o) The
rim shoulder ond the tyre volve hole
must not be distorted;
there must be no
shcrp edges or protrusions
likely to domoge
the tyre beod. Minor unevennesses
con be
hornmered flot ond smoothed
with o file.
The moximum eccentric running
of the rim
side must not exceed 1.5 mm.
b) The moting surfoces
must be obsolutely
cleon (free
from stuck-on rubber, rust,
etc.).
Cleon them with emery poper
or o wire brush
ond coot them with point.
lnstolling of Tyre
Volve
Cleon the rim with o dry rog. Push
the rubber
volve into
the hole in the rim
or pull
it in
by
its threod using, for exomple,
o lever
os illus-
troted in Fig. 10.5/1. Fig. 10.5/1
-
Pulling Tyre Volve
irrto Wheel Rim
Mounting the Tyre
For mounting the tyre, use speciol mochines
ond procedures,
depending on the type of the
nrochine. lf such o mochine is not ovoiloble, in-
stoll the tyre using speciol tyre levers.
Ensure
thot the boloncing dot is next to the volve.
Tyre leverrs for fitting tubeless tyres
differ in
shope from conventionol levers. They
ore thin-
ner, without edges, ond polished.
Use them core-
fully in order not to domoge the
beod seoling
rubber bose. Insert the levers
under the beod
ot
short distonces ond refroin from using force. To
focilitote sliding of the tyre cosing beods over
the rim shoulder, moisten them with woter ond
top them with o rubber
mollet when eosing
them over the rim shoulder. Inflote
the mounted
tyre immediotely. Check the tyre for propei'
bedding in the rim ond
squore seoting
on it.
Holding the wheel perpendiculorly,
strike it
severol times ogoinst the f loor ot severol points
to force the tyre beods
to bed
correctly on the
bcad seots.
lnf lotion
Remove the volve
core to increose
the diom-
eter of the hole for oir inlet (oir
should be
iniected in quick
shots to force
the beods
on
to the beod seots) ond inflote the tyre. Use
o compressor with oir receiver, the
compressed-
.oir line of the
workshop, or
compressed-oirr
cylinders. The relief volves hove to be odiusted
to o pressure
of 350 kPo (3.5
kg/cmz).
Never ollow the inflotion pressure
to rise
unnecessorily. As soon os the tyre hos snopped
into position
on the rim
ond is free from leoks,
odiust the pressure
to 250 -
350 kPo (2.5 -
3.5
kg/cmz). lf the tyre refuses to
bed properly
on
the rim,
for exomple due to distorted beods or
beods compressed due to incorrect storoge,
press the tyre circumference inword to open
wide the beods which will then bed properly
on the rim. Use either o length of
rope or
o speciol tightener. Slip the rope over the
tyre
circumference with o certoin cleoronce, insert
o stick
between the tyre ond the rope, ond
twist the rope.
Adiust the tyre pressure
to specif
icotions ond
submerge the wheel in woter to check the
tyre
for oir leoks.
146

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Dissssembly
ond
Reossembly of Pedols
This is usuolly not necessory. The pedols
con
be disossembled ofter removing the oxiol screw
in the pedol
pin
ond slipping off the return
spring. Do not remove the switches if it is not
obsolutely necessory -
see odiustment. On re-
ossembly, lubricote
the pedol
bush with lubri-
coting greose
of the some brond os used for the
steering linkoge -
see Chopter 7.5, por.3.
Pedol Free Trovel
Adiustment
Adjust the free
trovel of pedols
ossembled
with moster cylinders so thot the pedol piston
rod hos o
cleoronce of 0.5
to 1mm
when beoring
ogoinst the piston
heods of the
moster cylin-
ders. The free trovel of the pedol pod
should be
from 3 to 5 mm. lt
con be odiusted by rototing
the eccentric pin
on the pedol
brocket -
see
Fi9.12.111.
For the odjustment of the broke pedol
with
broke booster ond/or levelling of the broke
pedol with the
clutch pedol,
see Chopter 9.6 -
Ad justment.
Adiustment of Switches The switches con be
moved in
the ellipticol
holes of the brocket ofter loosening the fosten-
ing copscrews with ploin
woshers under their
heods. A pocking piece
should be slipped
under
the switch of the broke pedol
trovel worning
light ond the powl
of the switch pin
should be
held down under the fostening copscrew.
Ad just
the stop-light switch
so thot it
switches on the stop lights ot o pedol
trovel
of 10 to 15 mm meosured on the centre of the
pedol pod.
Adiust the pedol
trovel signolling switch so
thot the pushed-in
side push-button
pin
is
re,ecsed ot o pedol
trovel of 100 to 110 mm
mecsured on
the centre of the pedol
pod.
Press
the push
button into
the switch ofter hoving
completed the
odiustment.
12.2 ACCELERATOR PEDAL AND CABLE
The occelerotor pedol
forms o unit with its
self-lubricoting beoring ond the lever.
lt is
bolted to the f
loor tunnel. A coble possing
through the tunnel is ottoched to the pedol
lever ond the reloy
lever on the engine by
meons of clomps- The coble is protected
by
o Bowden tubing.
Pedol Removing ond Refitting
1. Loosen the clomp holding the coble on the
engine-mounted reloy lever. 2.
Remove the copscrews holding
down the
becrring with the pedol,
depress lightly the
pedol, ond lift it out of the f loor
tunnel together
with the beoring. 3. Disconnect the pedol
from the coble ofter
ioosening the clomp.
Removol ond Refitting of Bowden Tubing
ond Cqble
The Bowden tubing is
fostened to
the brocket
irr the floor tunnel by
meons of circlips. After
their removol, pull
the Bowden tubing inside
the cor. On ref
itting the tubing, lubricote it with
o low-viscosity oil (of
the SAE 20
closs). lt hos
been lubricoted with greose
in the foctory.
Fit
the clonrps so thot their longer ports (from
the
screw to their end) ore on the side of the
I evers.
Accelerotor Coble Adiustment
Adjust the coble so
thot it is not
excessively
tensioned or too slock. Loosen the clomps on
the engine side of the coble, move slightly
the
clomp toword the reloy lever,
ond tighten the
screws of the clomp.
12.3 GEAR SHIFT LEVER
AND LINKAGE
The geor shift mechonism consists of two
units: the geor
lever with its housing ond oc-
cessories, ond the geor
shifter rod
ond the
shifter lirrk with joint
(ot the georbox)
for
domping the vibrotion of the power
pock
tronsnritted to the geor
lever.
Removing Geor Lever
Housing ond Link
1. Lift owoy the mot from the floor tunnel in
the front ond reor comportment. lf seporote,
remove the individuol floor mots ofter hoving
prised out their clips with o screwdriver or
o similor tool. lf o one-piece floor
covering is
used, remove the door sill strips
on one side,
tip the seot, ond bend over the
floor covering.
2. Remove the geor
lever housing copscrews
ond prise
out the lid (next
to the clip) between
the seots. Proceed through the
operture to dls-
connect the bolted connection of the link with
the housing shifter rod.
3. Lift
owoy the housing with the lever
through the operture. Swivel the lever so thot
the shifter rod
does not protrude
over the
housing beoring thus obstructiong the removol.
4. Usuolly it is not necessory to remove the
geor shift link from
the cor. lf
obsolutely necess-
ory, the link con be
disconnected only ofter
162

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iiiI 14. Fuse box
Centrol connection of conductors -
do not
seporote them from the bunch!
15. Direction indicotor switches, dip switch,
and horn switch
eight-pole terminol
boord
six-pole terminol boord
16. Porking light switch ond high beom feeder four-pole terminol boord
17. Switch box femole connectors 5.5 with symbols "15",
"30", ond '50"
to be
connected to symbols
"15u, "30', ond '50"
on the switch box
18. Instrument ponel
ten-pole terminol boord
six-pole terminol boord
eorthing coble with lug
'19. Heoter switch
four-pole terminol boord
20. Switch of disobility lights
six-pole terminol boord
21. Door switch, right-hond
green -
femole connector 5.5
22. Dome light,
right-hond
green -
femole connector 5.5
red -
femole connector 5.5
23. Stop switches
forked (yellow) -
femole connectors 5.5 .
red -
femole connector 5.5
white -
femole connector 5.5upper ond lower
switch
upper switch lower switch
24.Fuel gouge block -
femole connector 5.5
yellow -
femole connector 5.5
blue -
femole connector 5.5
to be connected to the respective pins
(blodes) of the some colour of the fuel gouge
25. Storter motor, reversing
lomp switch
conductors with lugs stater motor moin
terminol boord
storter motor
control switch
green -
femole connectors 5.5 heodlomp switch
26. Oil pressure
gouge,
thermometer, corburettor
iet seporotor
green -
femole connector 5.5 yellow
-
femole connector 5.5
green - telethermometer
primory element
femole connector 7.
corburettor
iet seporotor
27. lgnition coil, voltoge regulotor, olternotor,
tochometer
conductor with femole connector ond
bronching lug
femole connector-regulotor terminol 15/54
lug -
ignition coil terminol 15
blue -
femole connector 5.5,
symbol "R"
. regulotor terminol "R"
yellow -
femole connector 5.5,
symbol "M"
regulotor terminol "M"
blue -
connector "R"
. olternotor terminol "R"
yellow -
connector "M".
olternotor terminol "M"
lug terminol "+B"
conductor with
lug ignition coilterminol "1"
(tochometer operotion
)
28. Toil lomp cluster, right.hond
yellow -
femole connector 5.5 toil light
block -
femole connector 5.5 direction indicotors
red -
femole connector 5.5 stop light
green -
femole connector 5.5 reversing lomp
29. Licence plote light
conductors with femole connectors 5.5
30. Toil lomp cluster, left.hond
se point
28.
b) Connection
of free conductors
1. Storoge bottery
bottery coble positive
(*)
terminol -
storter motor
bottery eorthing strip negotive (-)
terminal -
bodywork (eorthing conductor)
2. Engine engine eorthing strip (fostening
lug) -
engine cross beorer (eorthing conductor)
3. Distributor speciol coble from distributor to
ignition
coil; end with interference suppressing
terminol to distributor
coble from distributor to ignition coil
terminol "1"
cylindricol
(pin)
connector
pressure gouge172

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1' 2
3
orotely
(
screen the other one) . With lef t
directionol heodlomps,
the borderline deviotes
towords the other
side.
lf the heodlomps ore neorer to the woll thon
the soid
5 metres, decreose the meosure indi-
coting the
deviotion of the light ond
dorkness
bordeiline from the
height of the heodlomps
obove the ground in the
direct proportion to
the
decreose of
tfre distonce, for
exomple when
plocing the cor 2.5 metres
from the woll, de-
creose the deviotion bY holf.
Light proiections "A"
ond "B"
correspond to
the spocing of heodlomPs on
the cor ond they
hove the following dimensions:
Heodlomps, dio. 160
mm 1,030
mm
Duol heodlomps, dio.
130 mm 1,114
mm
Auxiliory heodlomps, dio.
130 mm 790 mm
When odjusting the heodlomps, the cor must
be empty ond the
tyres must be correctly in-
floted. Hologen heodlomps should
not be left
switched on for too long o period os they build
up heot if not cooled by heod-on
oir blost when
driving. For lhe odiustment of
heodlomPs ore intended
screws in their fromes. The screws
ore occess'
ible ofter the removol of the side ports
of the
grille. Remove the copscrews of the corners
ond push
the grille
oside.
Heodlomp Assembly
o) The fundomentol fostening
Port of
circulor
heodlomps is the
so-colled support plote
(rec-
tongulor plote)
ottoched to the bodywork by
copscrews with lock woshers. The
heodlomp
housing is bolted to this suPPort plote by bolts
with nuts ond lock woshers. One of the bolts holds
down olso the
lug of the eorthing coble-
The inner frome,
forming the
odiusting element
of the heodlomp insert, is ottoched
to the
hous'
ing by two speciol odiusting screws
ond two
tension springs. The heodlomp insert
is ot'
toched to
the bezel by
three copscrews.
There is one left-hond ond
one right-hond
support plote.
Both should
be mounted with the
oriow ond the word "TOP"
upwords. With
the
exception of the ouxiliory heodlomps, the
heod'
lomp inserts ore different for
the left-hond ond
the right-hond troffic. The leods
enter the hous-
ing through o
rubber grommet.
When r-eplocing the insert, remove
the bezel
copscrews. After
hoving fitted o new insert, it
is necessory to reodiust the
heodlomps.
Front Direction Indicotors
The right-hond ond
left-hond direction indi-
cotors ore undisossembloble units
(the
lomp
fostening sockets (locks) ore
mounted in the
direction towords the cor longitudinol centre
line). They ore fostened to their brockets in the
bumper with o nut ond o ploin ond
o lock
wosher.
Toil Lomp Cluster
The lomp cluster is on undisossembloble unit
fostened to
the bodywork by
nuts with ploin
woshers ond the
respective bolts.
Scrope off
the enomel ot the
top bolt used for holding
down the eorthing coble.
For the sequence
of the individuol lomps ond
their bulbs see Fig. 13.111 ond the respective
porogroph on bulbs.
Fig. 13.812 -
Adiusting ond
Fastening Screws of Right-hond Heodlomps -
their locotion
on
left-hond he-odlomps is their
mirror ref lection
1 -
Sidewoys odiusting screw
2 -
Height odiusting screw
3 -
Fostening screws
182

1 3.9-1
3.10
13.9 HORN
It is situoted behind
the left'hond port of
the
front bumper. To
remove it, disconnect the
leods ond remove the
fostening screw. heor
the ormoture being ottrocted (o
cleor ond
loud click). Now continue to
switch the bottery
on ond off
while rototing
corefully ond
sloryly
the screw "1"
onticlockwGe till
the
horn sounds'
iune it by rototing the odiusting.:cr9ry slightly
clockwise or
bock.-After hoving
odiusted (tuned)
ih" honn, secure
oll
odiusting ports with
o
dob
of point.
12
volts
4 omperes
Operoting
voltoge
Moximum current demond
Horn Adiustment
Before odiusting (tuning) the
horn, clomp it
firmly by th'e brocket ond
tighten thoroughly
oll screws "4"
ioining the
horn cover
with the
housing ond the dioPhrogm.
1. The horn is "hoorse"
- Using o screwdriver
rotote slowly the screw "1"
clockwise to odiust
the current demond
till the tone is cleor.
2. The horn sounds weokly -
Using o screw-
driver, rotote the screw "1"
slowly onticlockwise
to decreose the current demond
till the tone is
loud ond cleor.
3. The horn does not sound ot oll-Proceeding
through the operture in the front cover, loosen
the nut "2"
using o socket
sPonner. Then
insert
o screwdriver ond rotote
the odiusting screw
clockwise till it
beors lightly on the core. Then
bock off the screw by 1lz
or moximolly 3/a
of
o turn to odiust the distonce
of the ormoture
from the core. Hold the screw in this position
with the screwdriver ond
tighten firmly the nut
by rototing it clockwise. After hoving
connected
the bottery (of
the specified voltoge), you
will Fig.
13.9/1 -
Sectionol View
of Horn ond
o View
of Reor
Adiusting Screw
13.10 STARTER MOTOR
This is o series motor for
intermittent oper-
otion with on
electromogneticolly engoged
pinion. -@
c@c
Specif icotions
TyPe Roted outputStorting torqueSpeed for roted output
Voltoge ocross terminol
No-lood storting current
Direction of rototion
Number of pinion
teeth/modulus .
Contoct spring pressure PAL-Mogneton
12 V/0.8
h.
p. -
443'115'142'070
0.66 kw (0.e h.
P.)
12.25 Nm (1.25
kgm)
'1,000 r. p.
m. moximum
9.5 V moximum
65 A moximum
onticlockwise (left'hond)
912.5
e.3 N (0.ss0 ks) +100/6
"30"
of roted output
Mointenonce The mointenonce consists of periodicol
in'
spections ond repoirs or replocement of foulty
ports:
o) brushes
b) brush springs
c) commutotord) storter pinion ond idler
e) self-lubricoting beorings The brushes
must
be sufficiently long
ond
they must slide
freely in
their-cells, their
press-
ure springs must hove o
sufficient thrust,
the
commutotor must not
show ony
domoge, ond
it
must be
free of dust ond dirt.
Cleon the
commu-
totor with olcohol, petrol or
trichloroethylene,
ond let it dry before closing it
ond switching
on the storter motor. A
burnt or mechonicolly
domoged commutotor must
be repoired or
re'
ploceJ immediotely. A commutotor in
good con'
dition hos o brownish red
hue.
184