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Summary of Contents for Maico MC 250
- Page 2 AfAICO MC250 MC400 MC440 MC501 '" .•.. Instruction book Service manual .•.. From January 1974 .•..
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Page 3: Table Of Contents
CONTENTS Page 3 Preface Page 3 Technical data Page 7 Description of the machines III. A - Motor B - Chassis Page 12 Service instructions A - Preparation for competition B - Assembly and repair instructions for engine C - Assembly and repair instructions for chassis Page INDEX... -
Page 4: Technical Data
I. PREFACE The Maico models MC 250, 400, 450 and 501 CCM are constructed and designed especially for compe- tition and off-road use. They are suitable for moto-cross and enduro competition, and for crossing any difficult terrain. The moto-cross models are known for their high horse-power... -
Page 5: Exploded View - Engine (Drawing)
Champion Champion Champion Champion Spark Plug: N2 or N2G N2 or N2G N2 or N2G N2 or N2G Type: In Moist or Cold N3 or N3G N3 or N3G N3 or N3G N3 or N3G Conditions: 35mm 3.5 to 3.7 mm 2.8 to 3.2 mm Timing Advance: BTDC... - Page 6 •• •• "'-- " " ,,--- 35---- " " •• " •• '" •• '" "...
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Page 7: Description Of The Machines
III. DESCRIPTION OF THE MACHINES The Maico MC 250, 400, 440 and 501 ccm Motorcycles are very high performance competition motor- cycles which are designed for off-road use in difficult terrain or on a moto-cross race track. MOTOR CYLINDER The cyl inder is a special moto-cross cyl inder con- structed of a light alloy material with a shrunken cylinoer sleeve. -
Page 8: Primary Drive (Assembled)
PRIMARY DRIVE The primary drive from the crankshaft to the clutch is by means of a double-row chain 3/8" 7/32" 3/8" in the MC and a triple-row chain 7/32" 400, 440 501. in the The chain is an endless type and has 54 links. The manufac- ture is RENOLD. -
Page 9: Transmission With Bearings Disassembled
There are 2 different types of systems available for each model. Unmuffled - Moto-cross - Competition Muffled . App. 94 Decibel muffled (For export to USA) There is a considerable difference between the MC 250 exhaust system and the 400, 450 and 501 exhaust system. -
Page 10: Frame (Bare)
Either Girling or Koni springs and shocks are available. The shocks dampening characteristics are especially developed for Maico. SEAT The seat is a one-man seat specially fitted developed after years of moto-cross sport. Spe- cial care was taken selecting the composition... -
Page 11: Front Wheel (Exploded Drawing)
FENDERS The front fender is rubber-mounted on the lower triple clamp. The rear fender is also rubber-mounted under the seat and on the rear frame member. Both fenders are made from vibration resistant fiberglass. FRONT WHEEL The rim is available in either chromed steel or aluminium alloy. -
Page 12: Setting Ignition Timing With Dial Indicator
SERVICE INSTRUCTIONS PREPARATION FOR COMPETITION USE TIMING Tools needed for setting the timing are a dial indicator, feeler gauge, and a buzz box or circuit breaker light. The dial indicator is either screwed into the vertical spark plug hole or mounted to one of the cylinder head studs with a special fastening plate, if the head is removed. -
Page 13: Clutch Adjustement At The Lever
Petcocks In the two petcocks are screens to prevent dirt from entering the float bowl. These screensmust be cleaned regularly. Caution - Only large volume petcocks can be used for adequate fuel flow. AIR FILTER Before each race the air filter should be checked and cleaned. A paper filter should be cleaned from the inside out, using compressed air. -
Page 14: Changing Fork Oil (Draining)
Next, the air release valves, located in the top oil filler caps, should be checked by compressing forks and observing air pressure release. The fork should return to its original position. If this is not the case, one must countersink the seating of the ball (for the air release valve) lightly, (app. -
Page 15: Chain Adjustement
3. The retainer nut and eye are replaced and re-tightened. The shock rod is pushed all the way to the bottom and rotated clockwise until it engages and drops into the shock adjustment slots. When the rod is rotated to the extreme counter-clockwise position, the shock is on the lightest setting. -
Page 16: Piston Disassembly
ASSEMBLY AND REPAIR INSTRUCTIONS FOR ENGINE Removal from Frame Remove the tank Remove the exhaust Remove the carburetor Remove the cylinder head and top engine brace Remove the ignition wire Remove the 10 mm x 1 engine mount bolts front and rear Disconnect the chain Loosen the 8 mm bolt on bottom... -
Page 17: Holding The Clutchbody With Special Holding Tool
with a screw driver. The puller is then remo- ved and the clutch plates and springs are lif. ted out. On the small clutch the clutch nut retainer is also lifted out. The clutch body is held stationary with a special tool (avai- lable through the dealer I while the nut is loosened and removed. -
Page 18: Shimming The Layshaft
3.5 The final drive gear, spacer ring and three needle bearings, main shaft with sliders, lay shaft with sliders, and shift forks are re-fitted. The shift fork shaft can then be re-Iocated. 3.6 A new greased center casegasket is fitted on the caseand the left case half is re-fitted with the eight 6 mm case screws. - Page 19 ASSEMBLY AND REPAIR INSTRUCTIONS FOR CHASSIS Disassembly of Forks 1.1 Remove front wheel 1.2 Remove handlebars and bar clamps 1.3 Loosen both top 10 mm pinch bolts and remove both fork caps. 1.4 Loosen both bottom pinch bolts and pull both fork tubes out of triple clamps. 1.5 Drain fork oil 1.6 Unscrew bottom fork caps and remove snap rings.
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