Since joining MA I’ve read many a post on the various forums and spent more than a few hours in the Wiki educating myself on the workings of a two stroke. That said my foray into actual repairs was not exactly adventuresome with some basic maintenance and tuning on my few Puchs. One of those, a 1980 Newport with 368 original miles, was in need of a new ZA50 clutch cable. Every time I passed the bike I’d take a glance at that nub of a wire sticking out from the center of the engine!
The information on the forum posts and Wiki about replacing a ZA50 clutch cable are all over the map and the general sentiment about said repair was that it can be a pain in the ass. The Puch repair manual coverage is minimal and confusing. Even the replacement part description at Lucky 2 Strokes…’this moment of frustration brought to you by: Puch”, did little to instill confidence in this novice wrencher. So, faced with the decision of a $100 repair and several hours of driving to and from the nearest moped shop I opted to open the ZA50.
As I peeled my way to the back of the engine case no overwhelming sense of dread consumed my thoughts. I followed the instructions on the Wiki video and slowly but surely each part made its way in order the bench top and before long I was staring at the starting clutch. Seeing the actual mechanism brought a moment of clarity; there are two effing cables, not one! All of a sudden the rather confusing language in the repair manual made sense. What also came too light was the fact that I didn’t need to open the engine to make the repair. Oh well at least could flip the second clutch (another thing I had read about). Anyway, I put the new cable in, adjusted the tensioner according to spec, and worked my may in reverse order through each gear, nut, and shim. Little over two hours in and my ZA50 started for the first time in 37 years!
So, for all you other noobs out there…just open the case and have at it.