Messerschmitt KR200 and KR201 Workshop Manual | PDF Download

A comprehensive collection covering servicing, maintenance and repairs, with step-by-step workshop instructions, detailed Sachs 200 engine overhaul information, spare parts catalogues, wiring diagrams, fault finding and owner's information.

Manual Details

• PDF format – easy viewing on computer, tablet or phone
• Searchable text
• Fully bookmarked
• 350 pages

Models Covered

• Messerschmitt KR200
• Messerschmitt KR200 Cabrio-Limousine
• Messerschmitt KR201 Roadster
• Sport variants

What's Included in This Manual

Sachs 200 Engine Repair and Overhaul

• Sachs 200 engine removal and refitting
• Complete engine dismantling and reassembly
• Crankshaft, main bearing and seal inspection and replacement
• Piston, cylinder and gudgeon pin servicing
• Clutch dismantling, inspection and adjustment
• Transmission and internal gear components
• Engine bearing removal and installation
• Checking and setting crankshaft end float
• Removing carbon deposits from the cylinder head
• Decarbonising exhaust and transfer ports
• Carburettor removal, cleaning and adjustment
• Fuel pipe, fuel tap and filter servicing
• Dyna-starter carbon brush replacement
• Engine special tools and their applications

Starting, Ignition and Engine Fault Finding

• Starter does not operate and ignition warning light goes out
• Starter does not operate and ignition warning light stays on
• Starter turns the engine but the engine will not start
• Engine starts then stops shortly afterwards
• Engine stops when the accelerator is opened
• Engine will not idle correctly
• Engine pinks when accelerating
• Carburettor backfiring
• Engine overheating and piston seizure
• Excessive fuel consumption
• Engine vibration at particular speeds
• Engine continues running after the ignition is switched off
• Spark plug, contact breaker and ignition coil checks
• Fuel starvation, blocked jets and incorrect carburettor settings
• Cause-and-remedy information for diagnosing faults

Clutch, Gear Change and Controls

• Clutch cable removal and replacement
• Repair information for a clutch cable broken inside its conduit
• Repair information for broken clutch cable nipples
• Clutch adjustment
• Gear cable removal and replacement
• Teleflex gear cable installation and adjustment
• Throttle cable removal and replacement
• Repair information for broken throttle cables and cable nipples
• Accelerator and clutch pedal removal and replacement
• Complete foot-control assembly removal and installation

Brakes

• Front brake cable removal and replacement
• Rear brake cable servicing
• Front and rear brake adjustment
• Brake drum removal
• Brake pedal removal and replacement
• Handbrake linkage
• Brake cable routing and adjustment after replacement

Steering, Front Axle and Wheel Alignment

• Steering column removal and replacement
• Steering bar removal and installation
• Track rod removal and replacement
• Inner and outer track rod bearing replacement
• Steering lever removal and replacement
• Front axle and hub removal
• Front floating axle removal and installation
• Front shock absorber replacement
• Checking and adjusting wheel tracking
• Checking and adjusting front wheel camber

Rear Suspension and Drive

• Rear swinging arm removal and installation
• Rear wheel and brake drum removal
• Rear axle and bearing work
• Drive chain removal and installation
• Rear sprocket removal
• Rear shock absorber servicing
• Swinging arm oil draining, filling and lubrication

Electrical and Dyna-Starter

• KR200 wiring diagram
• Dyna-starter system wiring diagram
• Starting and charging circuit information
• Ignition and reversing circuits
• Battery and charging checks
• Headlight and dipped-beam checks
• Side, rear and number-plate lighting
• Brake light testing
• Indicator and warning-light testing
• Horn testing
• Windscreen wiper electrical checks
• Parking light checks
• Fuse information

Body, Windscreen and Wiper

• Rear body section removal and replacement
• Windscreen and window fitting information
• Hood and body fittings
• Windscreen wiper motor removal and replacement
• Wiper shaft removal and replacement
• Wiper arm and blade servicing

Servicing and Adjustment

• Lubrication chart and lubrication intervals
• Air filter servicing
• Front wheel bearing lubrication
• Rear axle and swinging-arm lubrication
• Gear oil changing
• Control and gear cable checks
• Brake checks and adjustment
• Clutch and accelerator adjustment
• Steering and wheel-alignment checks
• Electrical system testing
• Road-test checks after servicing

Spare Parts and Exploded Diagrams

• Messerschmitt KR200 and KR201 parts information
• KR201 Roadster parts information
• Sachs 200 engine parts catalogue
• Exploded engine and vehicle component diagrams
• Part identification and part numbers

Owner's Handbook

• Controls and instruments
• Starting the engine
• Forward and reverse operation
• Driving and gear changing
• Fuel and lubrication information
• Routine owner checks
• Tyre information
• Lighting and controls
• Operating and maintenance information