
Lifting 
the cor with  o 
Power  iock - 
When
r-rsing  o service 
Power iock, let the 
cor rest  on
the  points 
shown  in Fi1.1.412.
To tow  the  cor,  hook the  towing  rope on 
to
the brocket  under 
the cor nose.  Threod the  pin
through  the loop  of  the  rope 
ond the  brocket
lugs ond  secure the pin 
with o  cotter pin (both
thL  pin 
ond  the cotter  pin 
ore included  in the
cor  occessories).
1.5  SPARE  WHEEL 
AND  FUEL  TANK
Spore  wheel  - 
After  having  opened  the 
lug-
goge boot  lid, pull the  hondle  of  the spore
wheel  corrier  releose 
rod. 
The corrier  is 
re-
leosed  ond swings 
down (speciol equipment  of
the  cor  includes 
o sofety  lotch behind  the
bumper  which hos to be  pushecl 
oside to
releose  the corrier 
) . After 
hoving  closed the corrier  (by 
lifting  it),
push  the releose  lever under 
the bumper  to the
right  os for os  it will  go.
Fuel tonk  - 
The filler  neck with cop is in the
reor on the  right-hond 
side of the cor-  lt  con
be  locked  ond unlocked  by meons of 
the re'
spective key.
1.6  STARTING  THE 
ENGINE  AND CHECKING
ITS CORRECT  RUNNING
1. Moke sure thot  the  geor 
lever is  in  its
neutrol  position, 
switch on the  ignition (pos-
ition  I  on  the  switch  box)  ond wotch  the
coming  on  of the  oil  pressure ond chorging
worning lights,  i. 
e. check  the function of the
olternotor  - 
see  the  informotion in  porogroph 
4.
Prepore  the  engine
to its temperoture:
-  Storting  from cold in
the occelerotor  pedol
-  Storting  from cold in
the occelerotor  pedol
choke for 
storting  occording
winter  - 
do  not touch
ond  use the full choke
summer  - 
do not touch
ond  use only holf of the
Fig. 1.5/1  Hondle ot
Rod  (f ronr obove  )Spcre 
Wheel Lock
crnrl  Safety  Lotch - 
Storting  o  wormed-up  engine - 
depress the
occelerotor  pedol 
slowly  to tlre 
toe-boord,  do
not touch  the choke
2.  Depress  the  clutch  pedol 
(odvisoble 
in
summer, necessory  in 
winter)  ond stort 
the
engine by turning  the ignition key to  position 
ll.
Let  go 
of the key os soon  os the engine fires
ond  releose the occelerotor  pedol 
{if it hos 
been
clepressed).
It  the  engine  ,refuses 
to  fire, return the  key
to the  position  "0" 
ond  rePeot the 
storting 
Pro-
cedure.  lf the engine  is wormed  up, depress the
occelerotor  pedol 
to obout  one third  of its totol
trovel. lf  the  cold  engine stolls even 
ofter the
second ond  third storting  ottemPt,  enrich the
storting  mixture by  quickly 
depressing  the 
oc-
celerotor  pedol 
once or  twice to holf  of its
trovel  during the  next storting  ottemPt.
Never  let tlre  storter motor run for more 
thon
obout  5 seconds.  Woit 
some 5  seconds  before
repeoting the  storting.
Fuel  is injected 
by every quick 
depression  of
the occelerotor  pedol 
ond enriches  the mixture
so thot  it  is difficult  to ignite.  lf  the engine
is flooded,  stort 
it 
with  o fully depressed  oc-
celerotor  pedol.
3.  Increose the  engine speed corefully  while
releosing  the clutch  pedol. lf the 
engine shows
signs of  stolling, depress 
ogoin the  clutch
pedol.
Relecse
L.ever
Fi.1.5t2  Fuel Tcrtrk Filler 
Neck
16 

2.2-2.3
threods.  Fill the etrgine  with oil ond the cooling
systenr  with on ontifreeze,  ond 
bleed them.
2.3  REASSEMBLING  THE ENGINE
The  reossembly  procedure depends 
on the
extent  to which  the  engine  hos  been 
dis-
rnontled.  For better  understonditrg,  o 
reossembly
of o conrpletely  disnrontled 
engine is described
in  the  following 
porogrophs.
lnspection  of 
Cylinder  Block
1.  Clomp  the  thoroughly  cleoned 
cylinder
block  into the MP 9-101  stond with  the engine
corrier  type MP 1-101  ond check it  for complete-
ness  - 
see Chopter  2.6. Fit  the 
block with  its
lugs  on the engine  corrier pins 
ond use the  side
bolt for  ltolding  it down.
DK 1188
Fig.2311-  Cylinder Block Fostened  on the
Assenrbly Stond  by lVleons of the  MP 1-10-l
Corrier
2.  Rernove the  pressure 
relief  volve,  moke
sure thot  the  boll contoct {oces ore cleon, 
ond
refit the cleoned  volve. Forr 
f itting  o new volve
see  Chopter  2.6.
3.  Remove the cronkshoft  beoring 
covers ond
tlre  i;ylinder block  reor cover.
To  Refit  the  Cronkshoft
4.  Force the  beoring  shell  lrolves with  the
fingers into the cronkshoft  beoring bores so  thot
the  shell lip snops  home into the slot (cut-out)
in the block  ond so thot the  shells do not  pro'
trude over the  beoring surfoces for the  beoring
covers,  ond  lubricote  them with engine oil. Be
r;ure  to fit  shells  motching  the  cronkshoft
i":urnols  - 
see Chopter  2.7.
5.  Slip  the oiled  guide 
ring on the cronkshcft
"vith  oil grooves 
pointing 
toword the cronkshoft
'.veb  ond {it  the  cronkshoft  with the pressed-on
boll beoring  (see 
Chopter  2.7) 
into the  shell. 6. 
Inscrt  the 
beoring  shell 
holf ir-rto 
the cover
of  the  beoring  No.-l 
os described  in 
porogroph 
4,
ond fit  the cover  with the 
recess  for the  guide
ring  turned  outword.  Proceeding  from 
the front
of lhe  block, slip 
on the  next  guide ring  with
the oil  grooves  pointing 
owoy from the block so
thot  itJ 
lip engoges  ogoin into 
the slot  in the
cover.  Coot the ring 
with  oil ond  slip on the
thrust  ring. Fit the  MP -1'112 
thrust  collor on the
cronkshofi  ond 
tighten  the 
beoring  slightly
using  the belt 
PrrlleY  bolt.
7.  Instoll  the next 
two beorirrg  covers 
corl'l'
plete  with beoring  shells 
ond lightly 
tighten  l.he
cover  nuts. 
Press  the  cork 
seol 
into the 
reo'r
cover  moking 
sure thot  it 
f its the  groove 
snugly
ond  slightly  bverlops  the lower 
seoting  surfoce'
Before  titting the cork  seols, 
compress  them 
for
o  while  in o vice  to  distort  them. Insert the
distorted  seols in the  grooves 
or gops between
the  cover  qnd 
the  cylinder  block 
where  they
will  expond  onci provide 
for perfect  seoling.
lnsert  tob woshers  under 
the nuts  of  the
beoring  covers 
ond while  tightening  the rruts
check  their  correct  position  so  os 
to  enoble
o  subsequent  correct locking 
of the  nuts.
Fig.2.312  - 
Meosuring  Cronkshoft  Ploy
1  - 
Thrust collor,  type 
MP 1 112
2  - 
Diol indicotor  in o 
speciolly  mode yoke
8.  Rotote  the  cronkshoft  severol times  ond
using  o  mollet  top the covers  ond both  shoft
ends  to  ensure  o correct bedding 
of the  covers
ond  cronkshoft  guide rings.
9.  Tighten  the  belt  pulley nut 
to  clomp the
thrust  ring, ond 
rotote  ond  force 
off 
the  cronk-
shoft  to 
check  its ploy. The 
cronkshoft  must 
be
free to  rotote but 
without  ony 
noticeoble  ploy.
lf there  is o noticeoble  ploy, recheck 
its  volue
ond  odiust  it  by replocing  the guide ring  with
o  new one.  The 
moximum  ploy 
should  not ex-
ceed  0.10 mm, the recommended  minimum ploy
being 0.04  mm. 10. 
F
speciol
end onr Drive
suchr  o
be  turnr
cover.  I
ever,  tf
the  cyl
speciol note  in
11.  Ti
the tigh
in  the
covers. hoving
does  no
must ro
Then  lo,
woshers
ond nut
To  Refil
12.  R
greose  i
it  with  i
o  flywhr
engine,
with  rec
under  tt
Chopter
bending
shoft  og
powl  ins
For  flyw
Fig.2.3l3
Using  thr
Screw
holes,  for
con  be ur
further  o1
the hondr
30 

primory 
feed to the distributor coincides  with
the  connecting  line of  the 
distributor centre
line  ond the first cylinder 
heod 
bolt os 
per
Fig.2.3l10.  Secure the distributor  in this pos-
ition  by lightly tightenning the  tie-bolt ond
remove  the timing  geor 
cover from  the cylinder
block. The  used type of distributor is described
in  Chopter  13.5.
Fig.2.3l10  - 
Position of Distributor  on Engine
-l  -  screw  of primory power 
feed
2  - 
cylinder  heod bolt
3  - 
index  line  rnorking the  position 
of the
distributor  ornr when cvlinder No.  1 f ires
24.  Coot with  oil  the  moting 
surfoces  of the
timing geor  cover ond the cylinder 
block, locote
the  cover  gosket 
on the  block, 
oil the timing
choin  ond the comshott  worm geor. 
Remove the
f lywheel  powl 
ond rotote the 
cronkshoft  through
360o  so 
os to bring  tlre pistons 
of the cylinders
No. 1  ond 4  to  their  TDC position 
ogoin. This
position  corresponds  opproximotely 
to the volve
geor  position 
when the cylinder No.  1 f ires (the
tips  of the  coms  of 
cylinder  No. 1  ore turned
downword,  owoy from 
the  engine).  Lock  the
cronkshoft  in  position  by  refitting  ond  tight-
ening  the flywheel  powl.
25.  Turn 
the  distributor  orm  in  the direction
of  the 
screw (1)  in  occordonce with  Fig. 2.3110,
hold  it down  with the 
finger in this  position,
ond ref  it the timing  geor 
cover  on the cylinder
block.  By sliding the worm  geor 
of the  distribu-
tor  drive  into the comshoft worm  geor, 
the orm
is  turned  to coincide with  the timing 
mork for
cylinder  No. 1 
on  the  distributor  housing. lf
there  is no  coincidence  of the orm ond  timing
mork,  od just 
the position 
of the orm by 
slightly
rototing  the distributor.
lf  the 
misolignment of  the  distributor 
ornr
ond  the timinq 
mork of the 
cvlinder 
No'1 is so greot 
thot it  connot  be  corrected 
by rototing
the  distributor,  remove 
the timing  geor 
cover,
rotote  the distributor  slightly  ond  repeot 
the
entire  procedure 
of refitting  the  timing geor
cover. 26.  Smeor  the protruding 
end  of the  cronk-
shoft ond the  outer shoft end  (stem) 
of the 
belt
pulley  with oil, f 
it the belt  pulley, 
the nespective
wosher,  ond  tighten  the  bolt.  Bolt  the 
PumP
suction stroiner tothe cronkshoft  centre beoring
ond use o  spring 
wosher  under the bolt  heod.
27.  Bolt  down  the  timing  geor 
cover  using
spring  woshers  ond 
cheese-heod  bolts 
(exclus-
ively)  cnd f inolly fosten the  timing geor 
cover
in  such  o  position 
thot the contoct  breoker
points  open before the crronkshoft  with 
the con-
necting  rod  ond  piston 
hos ottoined  the  top
deod  centre  (TDC) 
position  (see 
the lgnition
Timing Toble in Chopter  15.3).
For checking  the ignition  odvonce,  on electric
power  supply is required  with o bulb  connected
in  o  circuit  with  the  distributor.  this 
circuit
being interrupted  by the oction of the  contoct
breoker. An  odopted  conventionol  torch with  o 
metol
iocket  con  be 
used  with  odvontoge for  this
purpose. Remove the  flywheel powl  ond 
set  the re-
quired  ignition  odvonce  by turning  the  cronk-
shoft with  o  screw'driver inserted into 
the geor
ring  ond  propped ogoinst  the cylinder  block
f longe. Rotote  the  shof t onticlockwise  o  bit
more  thon  necessory  ond 
bock  it off  so os  to
odiust the bocklosh  of the  timing  geors 
ond the
distributor  drive geors.
oK 6ls
Fi9.2.3111-  Lomp for Checking  the Opening
of Contoct Breoker  Points
-1  -  torch  complete with dry cell  ond bulb
2  - 
leod  with  olligotor  clomp
3  - 
botterv  cell
4  - 
torch  coo
5  - 
contoct spring
6  - 
insuloting plote
7  - 
electricol-contoct connection  of the  leod
with  the 
drv cell Con
using
torch.
the  br
slowly
indico
A  corr
is  not
timing 28.L
beorin
Then  f
while
oil  sun
the  thr
the  tyl
see  Cl.
shri  n ks
of  the
woter
move  i
ively.
To  Fit
Toppetr
25.  r
remove
positior
sure  thr
cylinder
cylinder nuts.  F<
first  bo
woteir  p
oir  clec
finol  ti1
2.16.
Ploin
heod  bo
which  t
woshers
no  wosl
heod  bo
cy  I i nder
the  outs
hove  to
of  the  rc
Tighte
broce  or,
30.  Sc
thermom
into  the
cosing  o
ofter  ho
Use  spri
thermost
cooted  g
with  the
with  the
The  th
should  br
34 

r
t
i
5. Prc
scri  bed
rods  onc
4th  spee
fork  rod,
irr  the  b
6. lnsl
guide  bu
cover inr heods.  S
tob  wos
edges  of
F it  thr
stri  ki ng
weoker  s
ing forks 7.  Tigl
the forks fork  rod
the  strik
function
Reverse-:
Fig
-1  -  Rever
2-1st-o
3-3rd-  o
4  - 
Rever
8.  Inst
press-f  ittr
verse-spe
inside  th
through  t
Turn  tl'
end  foces
lock  it in
hole.  Tigl
Pinion  Ar
9.  Instc
ing  ond,
r 
_-_--  -
.  i\:r,,,
\. 43
Fig. A.1l'l  - 
Power  Pock
1  - 
engine  with mounting,  2 - 
georbox/f  inol
drive  with 
mounting, 3  - 
reor  oxle  (holf-oxles),
4  - 
rodius  orms
retighten  it  using the  recommended  torque
(Chopter  1.8) ond screw  down the clinch nut.
lf  necessory,  top up engine  oil, f ill the cooling
system  witlr on qntifreeze, 
bleed the broke sys-
tem,  ond 
odiust the hond  broke. 
For the  fosten-
ing  of broke  hoses  (routing) 
see Chopter  9.7.
4.2  ASSEMBLING 
GEARBOX
Generolly,  the reossembly 
p'rocedure 
depends
on  the  extent,  to wlrich the  unit hos been token
oport.  For betterunderstonding, 
we  sholl des-
cribe  the procedure 
ond peculieorities 
of reos-
sembly  of o completely 
disossembled  unit.
Gear  Chonge  Mechonism
.  1. 
Clomp  the right-hond  holf of the  housing
(when  viewed  from the flonge  securing 
it  to
the  engine)  in the  MP  9-101 stond 
com-
plemented  with the MP 3-101  georbox 
rock, ond
check  the housing for  completeness.
2.  Instoll 
circlips  on the striking  fork rods 
of
the  reverse 
ond 1st ond 2nd  speed. The ring
with  the lower 
nose is  to be fitted 
on the 1st--
ond 2nd-speed  rods.
3. lnsert  the reverse  speed 
striking  fork rod
into  the housing 
so thot  the inserted 
end pro-
trudes  slightly  from its  guide, 
slip on  it  the
striking  fork with  the  longer 
side of its heod
first,-  ond  push 
the  striking  fork rod through
the  fork 
ond the end  of the guide 
os for  os=it
will go. 4. Fit tlre 
MP 3-109 jig 
into  the free holes for
striking fork rods  (both pins 
of the 
iig), ond
proceeding  through the  hole in  its  side ond
using  o stick or o length of wire,  push 
the lock
pin  into the  housing 
os for os it will  go. 
Proceed
in the  some monner for 
inserting the next pin
(use  one pirr 
of the 
iig). Shift 
it 
iust  so thot
the centre  lrole remoins free for  inserting 
the
striking  rod. 
Puslr the  lock  pin 
into  the  end
guide  of the strikirrg 
fork rods olso  os for os it
will  go. The 
iig is not required 
for 
the  instol-
lqtion  of this  pin.
Fig.4.2l1-  Clomping Georbox Housing in Stond
Using MP 3-101 Rock
Fig.4.212  - 
Locking  Striking Fork Rods in
Position bv  Meons of Lock 
Pins ond Bolls
78 Fig.4.2l3 
- 
Instolling  Lock Pins Using
MP 3-109 Jig 

(
1
z
Strike  the 
slip-over ring  off  the  circlip
(towords  the motor  windlng). Open  the circlip
ond  pull 
it  off the shoft  together with  the  re-
leosed  ports.
8.  lf  necessory, re-turn the  commutotor ond
scrope or mill out the  insulotion  between the
lominotions.  "Mikonit" 
should be 0.4  to 0.8 mm
below the octive  surfoce.
Note:  The 
switch  connot  be further  token
opat.  lf 
defective,  lt  hcs  to be reploced with
o new one. When  cleoning ports 
of the  storter
motor, do not  dip the  ormoture or the pinion
with  the idler  into petrol 
or onother  degreosing
ogent.The some opplles to the  end shieldswith
beorings. By  dipping  them  in  o  degreosing
ogent, the  beorings  become procticolly 
worth-
less"
Storter  Motor  Reossembly 1.  Lubricote  the hellx of the  ormoture  shoft
with  greose  - 
see Chopter  15.2 'Lubriconts 
of
foreing  mokeu ond fit  the  pinion 
with the idler
ond  the slip-over ring  in posltion. 
Fit the 
circlip
into  the groove 
in the shoft, ond drive the slip-
on ring  over it. The pinion 
with  the idler  must
move freely olong  the shoft.
2.  Slip the  respective 
woshers on the shoft in
their originol  sequence (corrier 
ring, distonce
ring,  fibre ring, distonce ring) ond insert  the
ormoture  with the engoging lever 
into the drive
end shield. 3.  Suspend  the  switch 
ormoture into  the
pre-engoging  lever ond bolt  down the  switch
lightly.  Fit  the  lever pin 
into  the  drive 
end
shield  ond lock  it in position 
with the retoiner.
4. Tighten  the copscrews  of the switch 
ond
fit the stotor  on the  drive 
end shield.
5.  Instoll  the respective 
woshers into 
the
commutotor end  shield in 
their originol  se-
quence  (the dished wosher with  its  centre
focing  the shield,  then the ploin 
wosher,  the
toothed  wosher,  ond the  drive wosher).
6. Fit the commutotor end  shield with lifted
brushes  on the shoft  (in 
the  position 
occording
to the  recess 
for the excitotion  outlet ond the
notch)  ond screw in the clomping  bolts.
7.  Instoll  the brush interconnecting  strip ond
bolt  it  down  together with  the  field  winding
outlets to the  positive 
brush holders, lower the
brushes. 8.  Fit  the Insuloting strip in  position 
ond bolt
down the cover. 9. Test  the storter  mottr.
Diognosing Storter Motor  Defects in  Cor
o)  lf  the storter motor  refuses 
to  operote,  look
first for on interrupted connection  between
the bottery  ond 
the storter 
motor, the engine
eorthing  ond the storter 
motor, or  the engine
eorthing ond  the  bottery. lf  these connec-
tions ore in  order (current 
flows to the ter' DK 
1575
Fig.  13.10/3  - 
Storter Motor  Testlng Connection
minols  u30" 
ond "50" 
with  switched  on
ignition),  stort looking  for o  foilure of  the
storter motor  switch. Even in this instonce,
the couse  con be o fully dischorged  or foulty
bottery.
b)  lf the storter  motor 
continues  running 
even
ofter the ignition  key hos been switched  in
the switch box  from the position "START",
it  hos to  be stopped without  ony deloy by
disconnecting  the bottery (using 
its eorthed
pole).
c)  lf the storter motor  hos no power 
to cronk
the  engine,  stort  with  switched-on  heod-
lights.  A 
morked  dimming  indicotes c  poorly
chorged bottery.
Tentotive  Checking of 
Storter  Motor
Outside  Cor
Connect  the terminol  "30'of 
the storter
motor  to o properly 
chorged  bottery ond  incor'
porote  on ommeter with  o wide 
meosuring  ronge
into  the  circuit - 
see  Fig. 13.10/3. 
Stort  the
engine  (feed 
current  to the terminol  "50"). 
The
volue of  the current  ot  idling speed must 
not
exceed 65 omperes  (not 
considering  the peok 
ot
the  first momentous deflection).
The  storter  motor must  run  noiselessly,
smoothly, ond the  pinion 
must move  smoothly
into  ond out  of the rest position 
(engoge 
ond
diesengoge).  The engoged  pinion 
must not ro-
tote direct on the  foce of the slip-on  ring. The
run-out of the storter  motor must not  lost longer
thon  8  seconds ofter the  disconnection of the
switch from  the current  supply.
Inspect  the  brush  pressure 
springs. The
brushes  must 
beor on  the  commutotor  by  ot
leost  two thirds  of their surfoce ond they  must
move  freely in  their cells.
The ormoture  should hove o noticeoble  oxiol
cleoronce  (ploy) 
not  exceeding  0.7 mm. 
At
o  slight rototion  of the pinion 
in the direction
of  the  storter motor  rototion, 
the idlor  must 
slip
freely.
186 

I-
.'t Fig. 
15.3/3  - 
Oil  Filter
oil f ilter  bowl 
witlr f ilter 
element
centre-boll oil  pressure 
switclr pressure 
oir. When  driving  often 
on dusty  roods,
ihe  cleoning  intervols 
should 
be shortened  by
holf. For  oir cleoner  mointenonce  in  tropicol 
re'
gions refer  to 
ChoPter  16.2.
Air  Cleoner  - 
winter  oPerotion
Remove  the rubber 
cop from 
the cover  exten-
sion orm  ond 
use it to  stop  the mouth of 
the
orm.  Fit o guide extension  into 
the cleored  hole
in the ornr  ond 
insert  the 
corrugoted  poper hose
(included  in the 
cor equipment)  into 
the 
ex-
iension  ond 
the holder  on the 
intoke  ond 
ex-
houst  monifold.
Give  the 
hose  the required  shope by 
bending
it  slowly  ond corefully.  Above 
oll, ploce 
it into
the  holcier  so thot 
there is 
o suff  icient  distonce
(wide  enough  to 
insert  o 
finger)  between  it
crnd  the exhot-tst  monifold.
Tightening  of 
cYlinder  heod bolts
The cylinder  heod 
bolts  should  be tightened
in  the  running-in  period before 
the gosket  gets
settled  ond then 
ofter  every  replocement  of the
gosket,  i.e., ofter 
obout  1,000 
kilometres'  For
itre  tightening  procedure, 
s9e 
Chopter 
-2'16'
Check'ilg  of vilve 
cleoronce  ofter 
every  tighten'
ing of  tlie 
cylinder  heod 
is o 
routine  procedure
which  must not be omitted.
Volve  Cleoronce
For  checking  procedures 
ond odiusting  volues,
refer  to ChoPter  2.13.
Alternotor  V'belt 
Tensioning
Loosen  the 
nuts  of the  bolts 
in the  olternotor
f  longe  (fostening 
it to 
the engine  ond 
the strut)
ond'of  itre 
bottJ  holding  down 
the strut on 
the
olternotor,  ond 
swing 
oside (tip) 
the olternotor'
Adiust  the 
belt  so 
thot  it gives 
woy 10- to
15  mm  midwoy  between  the 
belt  pulleys 
when
depressed  lightly (ot 
if o- weight  of  obout
2 kg  were  opplieal  with 
the 
finger  ot this  point'
LoCk  the 
olternotor  in 
this  position 
by tighten-
ing  properlY 
oll the nuts.
Belt  dimensions:  9x9.5x1,0O0  mm.
To Cleon  the 
Distributor
The  contoct  breoker points, the 
cover, ond
the  rotor  orm 
of the  distributor  must never 
be
greosy  or dirty.  Scrope  off 
ony  burns  on the
distributor  cover.
lf  you  hove 
cleoned the 
distributor  with
oetrol,  do 
not  ref it the  cover till ofter 
the petrol
hos  comPletelY  evoPoroted.
222
oll 
the  greose 
into the beorings.  Tighten 
the
cop  thoioughly  so 
thot  it connot  be worked
loose  by vibrotion.
Air  Cleoner  - 
cleoning  ond 
replocing  of 
filter
element
Unclosp  the  cover 
fostening  clips 
and lift
owoy  the lid. Depress  the 
cross  broce  in 
the
1ock6t,  rotote 
it 
slightly  to disengoge  it,  ond
withdrow  the filter 
element.  Wipe 
cleon  the
inside  of the 
iocket,  cleon 
the filter 
element  or
reploce  it  with o  new 
one, ond reclose  the  oir
cleoner  proceeding 
in reverse  order.
Shoke  ond 
top the  filtet  element  to 
rid  it  of
clirt  porticles,  oncl 
blow  it off  ond  through  with
Fiq.15314 
- 
Lubricotor  of 
Woter  Pump Beorings 

r 
5.9-15.  r 
2
Dismontle  the housing, remove 
old greose,
cleon  the individuol  ports, 
opply fresh greose,
ond  reossemble  the housing. Sook the  felt rings
on  the  links  (pull-rods) 
in engine oil.
15.10  WHEELS  AND TYRES, SNOW 
CHAINS
Tyre Inflotion,  Boloncing 
ond lnterchonge
of Wheels
The  procedures ore outlined  in 
Chopters  10.1
through  10.3. Snow 
choins ond their use ore
deolt with  in Chopter  10.6.
Wheel  Toe-in - 
see Chopter  16.1.
Shock  Absorbers  - 
see  Chopter  8.3 "Shock
Absorbers  ".
15.11  ELECTRTCAL  EQUTPMENT
Checking electrolyte  level ond topping up  --
see  Chopter  13.2.
Sporking  plugs - 
electrode  gop 
odiustment,
etc.  - 
see  Chopter  13.7.
Stqrter  motor - 
exqminqtion  ond  renewol  of
brushes,  etc. - 
see Chopters 13.11  through 13.14.
lgnition timing, odiustment  of contoct breoker
point  gop,  distributor  lubricotion  - 
see Chop-
ter  15.3.
15.12  BODYWORK  - 
UNDERBODY
Woshing  ond Mointenonce
The visible  ports 
of the  body qre 
f inislred in
o hord  synthetic boking vornish, the remoining
ports  in synthetic vornish.
The  underbody  is sproy-cooted 
with o plostic
compound  - 
for detoiled informotion, see  Chop-
ter  '14.9. 
Follow  the 
usuol  procedures 
when
woshing,  cleoning ond polishing 
the cor,  ond
observe  the specific instructions for 
the use of
woshing  ond cleoning  preporotions, 
issued by
their  monufocturers.
All  lights  with  the exception 
of heodlomps
hove  cosings of  plostic 
moteriols  qnd 
they
should  be cleoned onlywith woteror shompoos.
When hosing  down the corr 
cover  the voltoge
regulotor  of the olternotor  ond 
the ignition  coil
to  protect 
them ogoinst sploshing  with woter,
ond  do not 
sproy woter  direct on 
the door lock
ond  the lid covering  the fuel 
tonk filler neck.
Woshing  ond Core  of  Underbody 
Mechonisms
The  underbody  mechonisms 
ore protected
with  o synthetic vornish  which stonds 
well the
usuol  woshing  procedures. 
Protect oll rubberports 
ogoinst  direct contoct  with speciol  chemi-
col  solvLnts  or limit  the durotion  of this 
contoct
to o minimum  before 
o complete  woshing off of
the solvents  with woter  (by 
hosing  down, etc.)'
Keep  the oil cooler,  if  fitted  on 
the  cor,  in
cleon'condition.  Hose 
it  down  when woshing
the cor,  ond if  dirt  still 
sticks  to the  cooling
surfoces,  use some  of the  detergents.
Bodywork  Lubricotion
Routine mointenonce  includes the 
lubricotion
of door  hinges ond limiters,  hinges 
ond releose
mechonismi  of the engine  bonnet ond boot  lid,
the  releose mechonism  of 
the  spore  wheel, 
ond
the  leveroge  of windscreen  wipers. Lubricotion
of inner  dolor mechonisms  is 
included  in 
speciol
mqintenonce. Lubricote  oll occessible  mechcnisms 
with
high-quolity  greoses which 
do not 
dry,  do not
oxldize,  ond protect 
the mechonisms  ogoinst
corrosion  for o long time.  Oil is 
not  suitoble  due
to  its short-time  efJect. Any greose con 
be used
to lubricqte  the 
door  limiters  ond 
the front 
seot
slide roils.
Lubricotion  of SporeWheel  Corrier 
Bearings-
Remove the  spore wheel, 
cleon the hinges,  ond
opply oil  on iheit 
upper sides.  In oddition,  rub
in  greose of ony  brond.
Lubricotion  of Windscreen  Wiper 
Leveroge  -
Remove  the cover  of the 
ioint  (o 
plostic cup),
f ill  it with  greose, lubricote  the 
ioint,  ond 
rein-
stoll tlre  cover.
The  Lubricotion  of 
Inner  Door Mechonisms
is  possible only 
ofter removing  the 
door  ponel
ond the  inner 'door 
mechonism.  Use 
only  re-
commended  greose brcnds. 
Lubricote 
the bowden
coble  of thJwindow  wind-up mechonism 
with
Fig.15.1211-  Lubricotion 
of Windscreen  Wiper
Leveroge  Joint - 
ioint  cover
230