motobecane repair manual

8/21/2019 Motobecane Repair Manual

http://slidepdf.com/reader/full/motobecane-repair-manual 1/89



TA8LE Of CONrENTS

DE:S

IGlAT ION

Techni

cal

~

T001s (sPec 'a l ~

Use

of the

Stro

ke

[ngine

Refi t t i ng

t he [ nqi ne

on

the f rao@'

D u ssellbllng t he hg t

llP

Pl s t on

C,llr'lder

H.lt

dl

lng

£UIlll\i1Uon of tlle ty

i

nller llead , nd

t) '

l hl<ler

Re ,ss_ lIng the Eng i ne

Dearbollil

lng

th e

En

,ln

e

llsIo ¥1 ns· Dec: ,

rtoorI

l l ln, · llef l t t l n.g the

Tes

tf

\l Ign

it

ion TI., I

,

Rewvl nll An d Rtf i

ttill9

t ile Hlqne lo

Adjllst i pg the Ignit

ion

PoinU and f Jni thm TiJlli ng

. , v l f t

g Iletl t t l l19 tile C.rtlilrelor

D n ~

...d ANn_ l , of

~ r t o

~

and DpeAt ion of n e

l'KIIl

nu.nc Varf' t or

V r1a

to

r Ic

. .

o p

. r t

s )

llew: w n, 1 r 1 a

t t luu

en

l ,

and h

l

S4'riI

ly

of

Va

r

1l

t o

l

Adjust l nli and ltefi t t lng t ile

V.M.

tor

s , S ~ ~ the ~

IlietIovhg . d Ref l t t l n9

Or1

Ye

fl

ul l

trl d

Rle f i t t ln,

0 8

~ 1leplac in,

C

ran t

... r

8usMngs

~ Oppe r En9in t Nountt

nCj

f l e x i ~ l e

~

Replaei na

cabl es

Replaei ll t the

r,.....

~ ~ t ile 1'1$1. f ort An NQly

RefItU 9

t le II IIt

Fo

rt

As

I_

l ,

.

Rerr'O'rillq

ltCIlll

f

-j t t

h

llJ

tt-e fo

r t

Rrpl l

ebg

Fort.

I.4

Mngs and SprinllS

Itso lng

th

e lIrIfIdlelMrs

PA

GES

I

.

7

e.s

10 .

11

12,13

S,16

11,11.rs.zc ,21 ,22

6,21

re

30,31

12, 33

4.

8,39

40,

41,1.2

4 4

45.16

H,U

,so

5 st ]

5-4

,55

Sfi,n

,5

8

S9,60



ALPHABET I

CA

L INDEX

DES IGHATlCNt

Brolkes ( replolcl lHJ tile

brak

e shoes)

Cables ( replolclng)

Colrlluretor (re-:ovillg olnd

refittill9

)

Col rbureto r

s

t ripp ing olnd reolss e.b l inQ)

Ce

nter

SU nd

re-ov

l ng)

Ch

a

ins

(

re

placi ng)

Cl utc h

re-o

vlnq. ref i t t i ng . replacinq .

reolsse.blln

q )

Cr

oln

kge

ol

r (rernovillg. refi t t inq .

re

p

laci

ng c rolnkqear

b1l5hing5 )

Cy

l i

nder

He

o

d • Cy

l i

nde r

exol

m

inati

on )

Engi ne (

remo

vi ng)

Engine ( refl t ti llq)

Ellgine (dh .S5 ed>

li

llj '

( llgi ne {re

.ss

entl

li

ng

Engine (decolrbollizing )

( Xh

ol llst

(reMOvi ng . dec arboni zi no, olnd ref i t t inQ)

Fron t olnd Ru r Fenders (

relIlO

vlng and

ref i t t

ing )

Flnib le

~

( replol<:ing)

Flywlleel

Ma9'M to

(re-:av

ing

oln

d

refittl/IQ

)

For k (

rem

vi ng t he In fort as se-Clly )

Fork {

re

f i t t i ng

the

In f

ork

a

sse-b

l y .

reMO

vi ng . nd

re f i t t

i ng

th

e fo

rt ~ l e t e

Fork

n g b v s

l ~ and sp

ri

ngs)

Fr

a..:

replacing

)

r e e w ~

(

replac

illg)

Kalldleba

rs

(reIIOvi nQ)

Ign l t i

Oll

(ch

ecking t i l

ling)

Igni t ion (

adj

U t1ng the

ig

n

i t i

on po

illt5

o nd t i . i ng )

Match

ing

( p l s t oll

-c

yli

nder )

D

ri

ven Pu

l l

ey ( removi ng

olnd ref i t t illq)

Saddl e (

rep,aci

n

l

Shock Abso

rbers

relllOv n<J

and r

ef

i

t t

i no)

'

S4

.55

32 . 33

5

9 1

45.46

49,50

15,16

'.'

0 . 11

12.13

17, 1 l. 19.

ZO

. 21.22

ea

24.25

76.77

51 .52.53

28 .29

59.60

51

62

56.57.58

6 .27

JO

. 31

U

41.48

8.79



TECH N IC l \ l

PEC

I IC \ T IO NS

DI

ME

NS IONS

Ov e rall l engt h

i

nches)

Overall

Wi

dth

inc

hes)

Overall Height inches)

Weight (pounds)

M8 TOBEC N E

4 _ SERIES

66. 19

24.82

3'1.00

90

l bs .

69

.34

24. 82

39. 79

103 l bs .

/10TOBEC N E

Z

SER

IES

63. 40

24. 82

38.80

88 l bs .

FR ME

Type : Pressed Steel

Suspe

nsion;

Telescopic

Front For k

YES

Rear

Suspe

nsio

n .

Shock abso rbe rs NO

Brakes: Fron t and

e

ar DrLlll

Tires: Pressu re Front 21 p .s .1.

Pressu re Rear 26 e s t

Fuel Capaci ty: (U.S . G

allo

n)

Fue l Mxture : 4 oz .

of hig

h

qual i ty 2·cyc le

011

ga

l l

on

of gaso line

M l es P

er

Gallon : 143

ENGI NE

Type: Si

ngle

cyl inde r , ai r- OO l ed , z-cyc t e

ore and St ro

ke:

1.53 X 1.64 Inches

Comp re s s i on Ba t io: 7.8:1

Ca

rbure

tor;

Gurt ner

En9i ne i s p l c

~

49cc

19ni t ion: Flywheel Ma gnet o

s

V£S

143

.8

143



SP

EC

IAL SERV ICE TOOLS

PART NO 100001

CIRC P PLIERS

PART NO 100002

CIRC p PLIERS

PART NO 100005

FLY

WH

EEL WREN CH

PA

RT

NO l ll XlO6

BUSHI N EXT RACTOR



SPECIAL SERVICE TOOLS

~

~

(1\

w

PA

RT NO 0008

PISTON PIN TOOL

P R

T NO 1 9

PED L BUSH

IN

G TOOL



SPECI L SERVICE TOOLS

PART NO 100012

FORK TOOL

PART 3

.

TIM IN

G TOOL

PART NO. 100016

__.PRESS - STEERI NG HEAD RACES

PART NO. 100017

THI K

NESS GAUGE - METRI C



PART NO 19

FORK PIVOT

WREN

CH

PART NO

ZO

CLU

TCH

PULLER

SPECIAL

SERV IC

E TO

OL

S

PAR

T NO 100023

SQUARE DR IVE

PAR

T NO

l

OG

ON

FL

EX IBLOC

EXTRA

CTOR AND

INSTAL

LIN

G TOOL



SPECIAL SERVICE

TOOL

S

P

AR

T NO. 1000. 6

VARIA

TOR

HOLDER

PART NO.

OOOZ8

GREASE GUN

PA

RT

NO. 1000 9

SPARK

PLUG

W

E

NC

H

iWlT .NO. 1 31



USE OF T

HE

STROKE

LIM

I

TE

R

I MPORTA N T

For

all

types

of

n ~ n s to be se r v

iced

the use of the

stro

ke

limiter

No. 100004

is

requ i red i n lll ls t disasse

mbl

y and reas-

sembl i ng operation

s

This tool is designed t o lock cra nksltaf t revol ut i on at mid s t roke

and off e rs tlte advantaqe of leaving both Itands f ree t o per fonn

the

ope rat ions requi red.

O NOT USE THE

STR

O

KE

LIMITER ON ENGI NES FI

TTE

WITH FL T

TOP

PED

PISTO

NS.

After Itavi ng screwed t he

limite

r into t he wlto

le

tltreaded l ength

of t he spark plug Itole br ing t lte p

is

ton t o

re s

t aga

in

s t

gen

tly



ENG NE

R

MOV L

Remove both

side

covers screwd

river .

Disconnect t he

suppressor

cap.

F

ree

t he

ceccecresscr cable

nipp

le

using a sc rewdriver f ig . 1 a nd

disco

nnect t he cable.

lOl sen the nut securing t he carburetor c ~

llimI

socket and remove

the

u ~ t o

Disconnect t he w

es

at

t he t e

rm

i na

ls

behind the fl \ heel maqneto

stato r plate and

sl

ide them out

of

t he guide

sprinq.

D

sco

nnect t he grey w ir e at th e ignition

coll

and slide

t

out of

the

s upport bracket i n the f rame

Remove the belt from t he pulley groove a nd pass i t in front of the

pedal fig .

2 .



ENGI

NE

REMOV L

ONT O .

Loos e n the

lowe

r engine moun

ting

n

ut

dnd w

i t

hdraw t he bo

l t

l rrrn open

wre nch and so cke

t

.

Loosen the se

lf

loc ki ng

nut

of the upp

er

engine moun t

m

wrench) .

Drive out t he upper engine mounti ng u

le

only as fa r as t he f

ir

s t

spacer f

ig .

3) .

Be f

or

e

renJ

v

in

g t he engi ne , ca r

ef

u

l l

y no te th e l ocat i ons

of

th e upp

er

engine

mo

unt s pacers .

Tilt th e engine and remove i t f i g . 4) .



REF

ITT

ING THE EN

GI

NE

ON THE FRAME

nS

ll@

c t tile

upll@r

en9 tne

u n

tl nq

fl

exib

le

bushi n

as

. nd In

sul

lon

rin

g

for good condition (fig I ) .

Fit t ill engine throu9h upper . untt nq bo l t oll@ ,-, te n for ~ v l

Check tha t sp cers ~

lined

up and

IloI

ke sure t o i nse r t t he

ring of the 9round Iu d between t he spacer

n d

C1

l i

nder

he d

(R.H. , f

ig

2) .

Tt911ten

but

do no t

loc

k u

pper

en

ine

lOunt i ng nut

Inser t the SCl @Of

in

t o till l oooe r en9ine _ unt in9 br l cke

ts n

d Into t he

space

r

which is

f i t

In

with

t he tens ion Sp

rin

9s (f ig. 3) .

o

. 2



R FI

TTING THE EN

GIN

E ON THE FRAME

O

N

T n

,

Tigh ten and lock lower engine lOOun t1 n9 nut lOIml wrench

).

R efit the ca rbur eto r all t he way onto t he i nl e t pipe dnd lo ck t he

carbure t or secur ing clamp nut

llmn

soc ket .

Reconnect t he eecore

ressc

r cab

le

{screwcr-tver }.

Re

conne

c t

t he

wi

re s t o t he spade

connection

s behi nd t he

fl yw

hee l mag

ne t

o

stator

pl a

t e [pas s t hem t he guide spring.

equipped

f

i g.

4).

Slide the grey wi re through the suppo t brac ke t on the f r

ame

and re-

connect i t t o t he ign

t

ion

coil straig

ht t e rmina l .

Lock

t he upper engine

mo

unti ng nu t

while

hol ding the

o t

her end of

th e

bolt

- 1

nTn

wrench a

fte

r havi ng i nst

all

ed t he bel t

fig . 5).

NO

TE

: Mke ce rta in to lock upper engine mo

unting

nut a

ft

er having

in

s t

a ll

ed

th e

belt.

Th

en

th e

eng

in

e

is

i n a medium swing

ln q

position

,

which will preve nt the f lexi bl e bushings f rom

susta

in i ng damage.

Refit th

e suppre ssor .

Refit b

ot h si

de covers .



DIS SSE

MBL

I

NG

THE

EN

GINE

Engi ne r

emo

ved .

Remove th e exhaust us i ng 10 ,

ll

soc kets to loosen exha us t c

la

mp

and a

32 ,

open wrench t o l oosen t he nut connect i ng t he exhaus t to th e

cy l inde r .

Set th e enct ne i n a vi ce by Inse r t i no a space r be tween t he

lo

we r enatne

mo

unt pl a t es so t hat t he as se

mb

ly may be f i

rm

ly c lamped (f

io .

2) .

Remove belt c

over

usfnq a screwd r i ve r

for

var

eter eeetnes or a 1

m

soc ket fo r D

imo

by cl u

tc

h engi nes .

R

emov

e t he flywheel magne t o· See page 28) .

Remove t he va r

ia t

or

or

the c l u

tc

h

ass

emb

ly

accord i nq

to

t he type of

mach i ne se r viced See pages 38 and 43) .

Progres s i

vely

loosen t he cyl i nder head nuts at opposite

corne

r s .

Re

mo

ve t he cy

nder head and t he qa s

ket

Hlmn

sock

et

) .

Re

mo

ve the cyli nder and cyl inder base gas ket.

NOTE:

Aft

e r

Ju l

y , 1975 , our en9ines are f t

ted

w th pis tons havinq

LEV LL

O

UP

RI

NGS

I

CH CO

VER THE LOCAT

IN

G PINS fig.

1).

W

t

hdra w t he piston ri ngs .

St uf f a ra9 i nto t he c rankcase mout h and remove t h wri st pi n clips usinc

fl

at no

se

pll

er

s f i g. 2 ).

Drive out t he pi s ton pi n lIsi nq t he pi n ex t ract or

tool ,

100025, f ig , 3) .



I

S SSE

MBLI

NG

THE ENG INE

CONT D.

Wt lldril., the needl e cage f ro. t he con

·rod

s II end .

l oosen illl c r ilnku se

reU

in ill9 nuts .

~ e t he c rilnkcase f ro . t he ylce .

Re.Jye t he c rankcase

reta1

nl1l9 bol ts alld l

owe

r

~ i -oun

tillCl s tllds

(note the pos

i t

ion of t he

studs

alld

of

t he br ilcket for the bel t

lIUa

r4 .

To prewetlt th e

crilnksh

f t JourMl ~ r h e i l

t i n ~

i llse

r t

t he blade .

100015 .

i t Repeat t he ope

ra tlo

ll fo r t he o the r joorna

l

Hut

.,Uh a propane t orch t he crankcu e ha lf fil

cin

g t he c1u t ctl s ide

ilround the o

uts

ide of the cranks tl..f t bu r i ng (beg in wi t h t

his

s i de be-

cause i t s t hen easy t o n par. te c r..nkcase she lls ) ( fig. 4 .

The creeeeese ha l f w

i l l

drop ilway on n s own (fig.

4 ).

Re

pe..t t he ope ra t

io

n f

or

the

ot

he r

c r..nkc..

se

h..

lf

( f 1g. 4) .

While hilhes e re hot

. r

may t he o il h with

screw-

driver u pping f rom th e outs i de t o th e In

si

de of t he u ha

lf

h t ract the crankshaf t bear1ngs th e crankshaf t bea ri no pull er,

100011 (f ig . 5 .

Not e the ilr ran

geme

nt o f shllllS beh1nd t he c ranksha ft suppor t be. r 1nn 1f

t he c

ra

nksha

ft

Is so f

i t

ted.



PISTON CYLI

NDER

M T HI

NG

The s

poo

re

poort n

n

l

iste

d bl l

ow

conce rn

pis

tons fi tted with l n e ll 'd- up ri ngs t hn . re _ nted

In

l i

eu

of

f

o

r pistOflS

Ise rtes

168 3 t o 168591.

12273 • • • • • ••••• •• • •

- - - - - - . . .

21274

••••

• • • •• _ _ ••_.

__

. _• • __• •• • • _

o

22275 - - - - - - - - - - - -•• • • • • • • • • • •• • • • -

21276 • • • ••• • • • • • •• • •• • • • _ _. _. ________ _ C

22271 •• •• - - - -

••••

- - - - . . . . [

22218 • •• • . - - - - _ • • _•• • • • __ G

22219 • •• •••

••••

• ••• • • • J

2228

- - - - - - - • •••••• ••••• • - -

. l

2228

•• •••• _• •

•••

_•• ••

__

• ••• • •

II

22435 • • • ••

- - - - - - - • • • • • • • • • • • • •

-

- - P



EX M IN

T

I

ON

OF THE

Y

LINDER H

E

D AND CYLIN

DER

b ami

nation

of

tile Cy l i nder H

ead

:

Clleck tllat

the

cy l i nder head bot t om base i s fla t qr i nd I t with sur -

face pla t e necessa ry .

Refit

the

spa rk plug nd check t he dec

o-press

or va lve for l eakage by

pouring

fuel in the ck oo er

fiq.

1 .

in of absolu

te

~ s s the ~ r s s

should not

be

n IIOv

ed f roll t he cy l i nder Ilead asse-b l y.

In case of le<1kage and i f

th e

valve i s not wo rn ou t .

ta

p the va

lve

head

gent

l y t o seat .

E

um

in4tion of the Cy linde r :

Hak

e su re t

ha t

the cyl imler ....11 ne ither scuffed not scored

l

ck of

chno-Iu- pl at ed surface .

Meuure the p

iston

e t ee renee d fe rence between t he . i n

cyl nder

bo

re

and t he

~

piston

diamete

r

. t he p

is

to

n r

in

q end gap f i g . 2

and t he cl earance between r ing and groove .



EX AM IN

AT I

ON

OF

THE

CYLIND

ER HE

AD

AND

CYL INDER

CO NT D

i

nsta lling

a new p

iston

refer

to

t he matching

l is

t on page 14.

CLE

ARA

NCES

IN

1 1

ST

ANDARD

MAXI

M

Pis ton Clea rance

sldrt}

0

DD5

to 0 . 010 0.050

R1 ng end gap

top ri ng

0

.10

0 .10

0 .40

second

ring

0.10

Ring groove

to

p ri ng

0.03 to 0.060 0.15

Side gap

second

ring

Fit

the small end needle cage and

insert

t he wr i s t pin in

fiq. 3 .

Th

e pin should t urn

fr eely

wi t hout ve r t t ea t play .

c>



REASSE

KBL IN

G

TH

E ENG INE

NEYER IItST

AL

L LlSED GAS

KETS

;

A1.lIAY

S lISE MW ONE S•

• Whtn f i t

ting

a _ enll i ne crankcase or a _ c ra

nhhff t

tile s ide ph y

Sh

Ol.l

l d be a

dj

u

ste

d.

SIll[ PLAY ADJUSTI£NT :

To

er

tect

th is operation

. you need two

dUllll)

bearlnlls that you u n lUke

yo

urself

.

use emery cl

oth

on the inner and oute r

races

of two new bea ri ngs {dia .. .

16 x 42 x 13 - No. 16906} until the be

aring

s can ro tate f ree ly on t he

cr anksha f t j OUrmNS and the crankcase she ll hous

in

gs , This opera t i on

mus t be done without

cr

ankcase sea ls:

Place the dlJlllll} bearlnlls on th e c rankshaf t tape r ed ends .

Place th

is

u s

edll

y in to t he crankcue .

FH t he c rankcu e

p,fi

per gas ket .

NOTE : FrGlI Janua ry

I

1916,

the

paper yu ke l

I

t>t

o:.unku se

h.olvu

has been subs t i t uted by a spec ial ca.pound.

Ki Ye

r t hel

ess

. when

u n ic in ll an en ll 1ne, we

r e c _ n d

c lun in ll tho roughly tile lUt i ng su rfacl S

and f i t t i n ll a p,fipe r 9ISke t .

Place

t s

asu b ly In a

vice

(oYe r lower l uqs and cr ankc

as

e upper sc

s

) .

lto

ll9 h assu s the t x l s

~

side play with a depth

ul lpe

r lla

ullE

.

Disjo

i nt cr ankc

ase

halves and p

la

ce washers between

the

two

c

ra

nkshaft

balance wel llhts and beari ngs i n order

to

balance t he con rod between t he

shel ls

.



RE SSEMBL ING

THE

ENG I

NE

CO NT D.

lWl

KSHAFT

FI

N L

SS

MBLY

Inse

r t

a

stee

l blade l ength - 120 X 30 X 7rrJ l - No. 100005) between

c rankshaft balance we i ghts

fi

g . 1) .

Ins t a l l

the

asselllbly wi thout squeezing) in the j aws

of

a vi ce opened

at

m t e y 75....

fi g

. 1

.

shims were f

i t t

d to t he end of

cr

ankshaf t

refi t

them.

In s t a l l the bearing on cranksha

t

j ournal .

NOTE T

HE DIRE TION in whi c h the bearings

are facinq

. The rounded Chamfe red

side

must face t he crankshaft balance weight fig . -2 .

Dri ve t he bea ring hOOl > agai ns t the count er.le i ght with a tube diam.

18 X 22 X ISOnm - No. 10001

4.

f ig . 1) .

Procee d

l i

kewise for the other cranKshaft end.



RE A

SSEMBL IN

G THE ENGINE

CONT D.

REASSU I3l

..

1NG

1M CRAIIKCASE

:

O

il

t lw c

ra

nksh. ft

~

ends , tlw bloari

nqs.

and tile

beari nC)

C Q

U

HeH t ile s e

l l

( facing tile f l y w h ~ l

II I

gneto ) artly nd the

bea ri ng housinq unt il smo ke appea rs .

Fi t a

new

oi l

seal

wi t h tile c rankcas

su I

f i

t t in

Q tool , No.

100010 ,

f i9 .

3.

N

OTE

:

Sea

ls

s t

be

f

l t t d with

t he sprinq and lips fK 1ft9-oa

blard

s .

V ry Quldly f it t ilt c

r

nksha f t n sf lllbly ( fl ywhef 1 one to s ide ) In

t he cr . nkcas 1I.1 f ; tilt be. ring . .i l l loc te itSf 1f co r.-ect

ly.

Fi t t he oiled p,lPf r C)asket t o til@ crankcaSf

IIoJIf

(s

ee NOTE

p,l

11

RePf

t the OPf ra tiOll fo r

the

ot he r cr . nkus h. l f.

Tl

gHen

but

do

n

ot

lock tlw two UpPf r sc rews . f

ter

havi

nQ

lII)

un

ted

t he

l uq fo r secyring tile belt cove r v r h t or engi nes ) 4 ) .

Ch

mp mocle

rHe ly ) t he eng ine i vice over the cra ntc . se lowe r bos

se

s .

Ma k sure t he c

ylinde

r-c r . nkcas e IIIoltlng su

rfac

es are comp l e t e l y r

f

r OOl

d

is tor

t i on ;

nece

ss.ry

, t . p on t ile upper

p.rt

of a s t ud

n

selll

bli

flC)

cylinder

. nd

cy

li

nder head ) witll •

l

e

t

1

r i

t he paper

C)as

ket w

ith

a s

cr

Pf

r .

NOTE

: As fa r

as v.rlato

r ,, q

ines

we

of

t ile belt cover

t ge r

. . .m t l 9 l Ull before l ockinq

.-ec_ nd the positlonlno

t ile c r,)nkcase I. 1f lJl)pe r



RE SSE

M

LING THE ENGINE

CO NT O

,

-

.loc

k two upper mounting screws .

F

t

th e l o

we

r engine

mou

nt ing brac ke

ts

and the dual lug secur i ng

belt cover va rl ato r engines .

Fit and l ock t he cranh:ase moun

tin

g nut s nuts on flywheel magneto

s i de wi th a l

Omm

w r e n

Place a between the lower engine

mo

unt ing brackets to hold the

engi ne firmly i n

the vice

f

ig . 5

.

Rotat e th e crankshaft. ~ t reta t e f ree ly , s l igh

tly

ta p on

the cr ankcase She

l l

c l utch side and var ia to r s ide with an aluminum

mal l t to pos t ion th e bearing.

RE SSE MBti NG THE PISTON:

Smear the needle cage with

oil

and i nsert t i n con-rod sma l l end.

P

osi

t ion t he pi s t on over the con-rod in such a way t

hat

the

ring

groove

pegs fa ce t he e ~ h u s t por t .

Inser t t he dunmy wr is t pin wh ich comes w

i t

h Tool No. 100008 t o alliqn

asseooly fi g. 6 .



REA

SSEMBLING TH E EN GINE

CONT' D.

f

i t

t ilt

p l « l l t

wrht

pin II1lnq p

iston

pin an

ftllb ler No.

100008.

Hea t (-:ldera te l ) ') thl piston ( to rch) un

t i l

s-:lke

aPlll

ars .

This

is not

I Il

Cl ssary fo r a wris t pi n tha t

is

an en y s l i di ng

f i t

Inser t the n

s _ I e r

ti p i

nt

o t hl w

r ist pin fig

. 7) .

Push

he.

wh i le

p ~ s s i n g

aga in

s t th

e oppos i te s ide of tile

pis to

n

to

prevent unnec

essary

pr essure on t he bi

g·e

nd bearing. The nseftJl e r

stop

w

il

l cor rec t l y posi t

io

n t he pin i n the piston ( f

ig

. 7) .

Pla

ce the cy li nde r on t he

heated

piston without the r i ngs or pi ston

pin

clips

i ns

ta ll

ed. The

cyli

nde r wi l l s

lide

down as th e t

empe ratu

rl

evens

out. This

opera t i on pre vent s pi

s t

on di s t o

r t

i on whi ll cool i ng

fig .

8 .

When t ~ pi stoo/cy l inde r nse-lb

ly hn

cool l d off , check coo- rod

alig

n

nt

OI

ECl

WtG

ROD

secere

cy

l i

nder with

two washers

and two opposltl c)' l lnd r

lIl

ad

nuts . Bring till'

pis

ton

to

T.D.C.

Sl i d In a

tapered

0.01

tee te

r gauge

eeween

t hl piston I t pin

holes ) and cy l

inder

.

f

the

g lIgt

s l idl s f rel ly t hrough one

the rod pro'tl S to

be

ou t of a

l lg

llll ll n t .

e

eee

w

i t

h s t ralght l ning.

si

de and not t hrough

e l

l

tiM

cyl1ndl r

<h.

d

ot hl r .

,

ro

-



REASS

EMBLI

NG TH

E E

NG

I

NE

CONT

D

.

STRA

IGHT

ENIN

G CONNECTING

RO

D:

CI p the crallkcue III the etce alld III$er t a b.Jr t hrou<JlI pluon pi ll U

$hown

I

II fI<;Iu I .

To U rd

l

ll tell tile rod . awly force t o the ba r .

Check rnd allgnllll lIt and U ralglltell alla l n unt

il

tile ph ton t s correct l y

cente red In t ill' cy

li

nde r.

Fi t

wr h t pi ll lo ck rin

l

s USi n<l

fl

at nose pl

ier

$ .

Slnea

r t he piUon ri

n< lS

wi th o j 1 and f i t t llee on the

phto

n.

R£ASS£

MBLI

NG

CYLI

NDER· C

YL

IN

DE

R

HEAD

:

Bri ll< l the ph ton t o T.D.C. and ke ce

rtai

n t ha t the

pino

n rln<;lS seat

f i ...l y in <;Iroo es .

Fi t

the

oOed

'}Isket on the

b J

se of

the

cyli

nder .

Place the cyli llder on the unt inq UU(h, .

s

a r

Ultbo

.-.

wi

th 011 and

lower

e»e

llt

Iy

.

Fit

t cyli llder head IIolkin<;l sure

i t

$

boUOIl

bu e

h

r ~ t y c lean.

Fit wn

he

n 0

t he 1\l<Is and t i 9 t en prngrl sively t he nuts at oP

l Osit

e

ee-

ee-s

t o

s

ft

.

M

Ins t al l the arla t or Or cl utch (See page 43).



DECARBONIZING

TH

E ENGINE

loo

se n but

do

not

cy l i nde r head nu

ts

loo

sen t he upper

engin

e mount ing nut .

Dr

ive

out t he upper engi ne mountlnq as

far

a§ t he f

i rst spacer

only .

Til t thl engi ne and r ( lll(lve i t f r

OlII

t he

Disconnec t t he wire s at t hl tenllln. 1s behi nd t he

fl yw

hl l l maqll( to s ta to r

plate

and s

lide

t h

em

t hrough t he gu ide sp

ri

ng.

P

laCE

• b

loc

t u

l lde

r the en9ill( t o pre

-..e

nt t he 1

00000

r

t i

n9

fl

e_l bl e

il

i ng

bei

nc;

da-.oged.

R e ~

t he

cylinder he d

n

uts

us in

c;

• 1

00

soct e

t

RHo:lve the

cy l i n

der

head

and

t he 9oI§k

et

:tEVER USE

H DEN

ED

TOOL S T

HAT

W

l l

SC RA TOI

DR NICK THE COI IISTI O l OW SER AN D

PIST

ON

B

ri

ng

pis

ton to

LD t

Scr ape t

h ,

ca rbon

d ,po

i t

fr Olll the ex

hau§t po

r t

( fiq .

1



R

EMOV IN

G. O

EC

AR ONIZING.

RE

FITTING THE

EXH UST

REMOVING

T

HE

EX

H US

T PI

PE

{Bl underbu

ss

type · fig_ I }

loosen

th e

nut and 11. .. wrenches and 1 N l I W

th e

c aoop

nut , but

do

ee t 1 N l I W

th e s ~

between the enlli ne -: unt l nllS f lq . 2 .

loosen t he nut 3

ml

wrench threaded i nto the cylinde r and reeove t he

u aus t comp le tely fig. 3 .

DE C R ON IZING

•

loos

en t he locknut and

th e

nut

sec

uring

t he exha

ust

un

t i

p.

•

RemD t th e baffle

pl

ate

and the

ta l l

cap.

• Clean

out

t he ho

le

s In

tile

inner

baffl

e p

late

and

t a l l

pi pes f l

q.

4 .

• Scrape

out

the

uhaust

pipe ent ry .

_ .

,

~

I

I

,

-



REM

OV

ING, DE

CA

R

BO

NIZING, R

EF

I

TT

I

NG TH

E E

XH

A

US

T

CONT

D,

REMOVING THE EXH

AUST

PIPE Oval ty pe wi t h c

ros

sed chamt>ers , Ftq , 5)

Remo

ve the t

wo

bolts on t he exhaus t clamp us i ng a

1

rm

socket. .

Loosen t he nut connecti ng th e exhaust tc t he cyl tncer 32 m wre nch ) and

remove t he exhaust completely.

D

ECA

RBONIZING:

Loosen

the nut

en

th e

cla

mp

se

cu

ri

ng t he muff l er t o t he p

ip

e

( 10rml

wrench ) .

eeeove the muff

ler .

Insert

a t r i angula r scr

aper

t hro u

<jh

t he hol e and sc rape all car bon depcs l ts

f rom around t he edges as shown i n f i gure

6.

Insert

a

steel

cable

{die

m. 7 - l eng th : 25

lTJn

in to t he ta l l pi pe and

c lean i t out.

L

astly

, s hake t he exhaus t

vertic

a

l l

y

to

r

emo

ve

deposits

f rom t he ent ry

hole.

RE FITTING:

Rev

erse the

procedure and f i t

a

new seal i ng was her in th e

exha

ust por t of

t he cyl i nder .

-- --:

,

.

,

I

I nse r t a s t ee l



TESTING IGNITION TIMING

WTHOUT REMOV IN THE ROTOR)

-

Re

mo ve ri ght hand si de cove

r.

- Disconnect the grey wi re f rom t he igni t ion co il fig.

I .

- At tach one probe from the ohm me

te

r to t he grey w

ir

e f

ig .

4)

- At t ach t he ot h

er ohm me

t er lead to a 9round poi nt . amp l

e:

Cylind

er

head )

fig.

4)

- D

s

connect t he black wi re

l

ig

hti

ng sys tem) f

rom

t he s

t r

ai nht female

6.35T t e inal at the

st

ato r pla te.

- Remove the r adi o suppressor and sp

ar

k pluq.

1.

Scre i n t he t imng tool No .

lO

OOlJ i n place of spark pl uq

fiq.

2 .

2. B

rin

g pis t on t o

T O C

by ro t at i ng the rotor i n t he nonnal runni ng di-

rec t ion.



TEST

IN

G IGNITI ON TIM

N

G

(WTHOUT R MOVING THE ROTOR )

CONT D .

3. Tum

the ti

. i llg

tool untll th e top

edge of t he

too

l

is

.

lIgne

d

.

It h

the

low

r

of the blue st

ripe

fig . 3) .

4. Ra

t . t e

th e roto

r

cloctwise _

full

revol

utloll . Id

IS th e

blue

s t r ipe begill to ppe r the ot should dl f

le<

t t o

0<0 .

Poi llU beglll

to

eeee. I f . t l . l ng

l t / teste

r

is

und o

the

l ght

. i1 1

go

- -

(fier. 4) .

(See

eete , P' 'll l6



REMOV I

N

AND

RE

FITTI NG HIE FLYWHEE -

M

GNETO

R

EWJVAL

Remove

the right

hand

side

co

ver

Remove the fl ywheel magneto cover

Remove t he r adio suppressor and spark pluq. Disconnec t the wires

fl lJl l

t he t ermi na ls behind t he fl ywhee l magne

to

stator

p

te and t he grey w r e

fJ Qlll the i gn t i on coi

l

- At

ta

ch t he flywheel wr ench

to

t he rot or (Tool No. 10(1005).

- Loosen t he rotor

nu t

left hand th read) usi ng t he squar e drive wre n

ch

100023, ( f1g . 1) .

-

Remo

ve t he rotor .

\



REMOV ING AND

REF

ITTING THE

FL

YWHEEL MAGNETO

CONT O.

•

t ~

Cill

p u l

11 . 10002 1.

OIlto ea• .

• Sl

ow

ly In t he

eeeeee

sc

Of t he

p u l l ~

and

pull

t he

u off

t he

cr antSlla ft ( f i g. 2) .

• stator ~ retai

ni ng

nuts

wrencll) and

re-ove the

conica l spr ing

wa

sher5 (f ig .

2).

•

t lf s tilto r

the

p< Pt

r and

th e

rubber ( f i g.

n

FITTI

NG:

- Fi t

t

paper gas

te t

and rllbtwr

a s t ~

•

test

i ng or a

te

tee

rep ce-en t . position

the sta to

r on t he two

studs . O

ri W

f

ully

0f t

l

crantcase .

Fit

tile four con

ica

l spr i ng wnller5 and tile t

wo

se

l ret.ining

nu

ts

.

Screw on gradua

l l

y and loc t tile

se

l re tain ing nuts 8nJn wrencll) ( f iq . 2) .

Adjus t ignition t imi ng and

br

eak

er

poi nt gap as des

cr

ibed on t he follow

ing page .



ADJUS TI

NG

TH E

CO

NT

AC T

BREAKfR AN D IGN[TION TIM ING

A

OJUST E

Of

T

HE

8ll£AKIR POIIlT

GAP

:

ItlIIPO

i1y

ins t . l l [h@

t • • on t ..

ankstwft

f fld and

n t ~

i t

Qf fl

t ly

to

ob ta in 1 _

g.ap

be

tW etl to

nta

t t poh.ts

{f ier.

I I .

Adjust the g.p ..ith

til

reete .. gall )e (110. 100017. fi g . 21 t o bet , ,

3

5/100- . i n

.nd 4

0/100- . . . .

t_ .

If NE

CE

SSARY PROCEED A S FOLLOW S :

Loosen

tee

retdnin9

Strew of

the fixed

. . . .

lIsinQ a st rewd..

ive

.. {

fig

,

l l

,

P

ivot

tlle b . b ..

a s s _

Iy t e

.djl l

s t t o

the

sPetifiM <I.p

f

tq . 2

).

Tlqhten the .

... ,Ulnln

9 St

li

tile

~

poi

nt

q. P d t e .. t i qhteninQ t he

fix

ed anll ..e

tain

i ng

screw,

SE

TTI

TilE IGN[Tl

O

TIM ING:

Remov

e spa..k pl ug .nd Ins t l l t iming t oo

l .

8 ;

ner t he pi

ston

to top de. d cen te r ,

Tum t he tim inq t ool unt

i l

the t op

q

of t he body of

th e

tool

is

a

llon

ed

wit

h t he l

owe

.. edge

of the

bl ue

stripe.

Rota

te tile en

er

ine counte

rcloc

kwise (vi

l W e

d f

reon

lIIIoneto s ide) unt

i l

t he blue s t

rip

e

ju s

t c luppeus .

Disconnect t he g....y

..

i

re

f..-c. t he

H,

I . co l i . and . U.ch one

probe fro ll

t he

mete .. to th e g....y .. ire ,



ADJU

STING THE

CO

NT

AC

T

BREAKER AND

IGNITI

ON

TIH IHG

CON

T D.

II f OR

TAN

T:

SH No te

. Page 26 .

At

t t

ch t ile

otlle

r

or. I I l I t

pro

b@

t o ground h o t he c) l lnde r head}.

O h c

n ~ c t

tile bl ac k wi

re

f

.-c.

t he s ta

to

r

I I l a

pluq (on t he

9 n ~ t

1 a c ~

tilll

in

g

cam

on c ranksh4

f t

and I t

sl

owl)

etcee-t se (viewed from the magneto

i d ~

until the ohmmeter needle

defle

cts f rom

0

to Inf1ni t) oo . Tha t is whe r e the poi nts have opened.

a t im1ng l i te/ t ester used , th e l 1 lt wi l l no ON .

--STOP - -

T.p t he t l.

ln

g c

on to t he c

r

ntsr.a f t w

i t

hout

ro t a t i _ i t

. ny furthe r

lf1g.

n

In

s t

a

l l

t ile ro

to

r .

tlgh

Utl ro

to

r

nut

t h

re-

ad) t o

J.4 f t

.

l

bs .

of

t orque .

Reeheck

tI . i n9 by ro t

t l

ng f l Wheel

o c : k w

t he a q n ~

side) . As t he blue

r k il@q i ns t o appear. t he points should beoln to open.

The 0 - _ t e r shoul d j u

s t

bellin t o

IIO

ve f

N lll

to

In

fln

i t

y

o

t imin g t e s t

is

used .

the

lig ht wi l l - ON- . see I0te . lIaoe 26 ,

Timinq Spec :

2Tm BT

OC; Poi

nt

Gap:

.]5

t o . 4Ormt ; Spark Pluq : .

41 nm



R

EMOV IN

G A

ND

RE

IN

S

TA

LLIN

G

TH

E CARB

UR

E

TOR

REt Y L

:

~ Y e

t he s ide CO .

CloS t he

fuel

h p and dfsC

Olln

l ( t t l e fuel pi pe t he u rbu re to r.

rote.l

t he f

il ter

box

f ~

t he

urbu

re

tor.

teesee the

c

ubu reto

r c

l.. p

bol t

a

nut d

riv

er ) .

~

t he

urbu

re

tor

t he

l nl d

pipe.

tecse

e t l e ~ h

~ t he carbure

to

r {f ig .

REI NST lLI NG ONM HINE:

Helke su

e

t he

phs t i

c

bIl

slll nq on the fnl e t pi pe is in oood cond t on.

f

so

~

Molk

e t he nut s se c

llrin

g t he to

cytt

ncer are tig htened

t o the cor rect t orque (7 f t . lbs . )

IIs

lllQ a t orq ue wrench and 10 , socket .

f the i nl et pi pe I dS

remov

ed , make sure t hat t he ma ti ng SlI r fac es are

cl ean. F

t

a n

ew

gas ke

t

Inse rt

the

r l t t s l i de (I IO te the position of

the

gllid lng pin ) and the

choke s

li

de.



REMOV ING AND REI

NST

ALLING TH E C R UR TOR

C

ON

T D .

- Fi t

~

challlbe .. cap and t igh

t t

n (sc

re

wdri ver the

sc

rew

sec

u..i n

i t

ke

ce..tain

that

t t r t t s l ldt ope..ate s

freely

and full y opens

thrott le g..ip

is fully

opened. If neCeSHT ) . sc rew the

adjust

nt

screw on the

ch oe

.. cap to keep an accu ..ate i dle

Ftt

the ca ..b

uret

o..

to

t he in le t pipe and push full y homt.

Pos i t ion the ca rb ure t o.. body ve..

tically

.

Tighten

~ r e t

.. retain ing l ~ ~ nut d..

ive

..) .

( l u n t he f i l te .. ~ n and f i t t ile

f i l t

.. plastic box.

onne

ct t he fue l pipe .

Fin

al i dl e adjustment can be IIIolde

with

t he enetee ..unn

tne

by sc rewin l

0 u ns

cre

wing

th

e idl e adjustlnent sc rew on t he l e ft of the ca ..bu..et c ...

t the si de covers



DISASSEMBL ING AND RE SSEMBLING THE CAR BURETOR

DIS

ASS

lll1

If ;

THE

CARBURETOR

;

the float

bow

l cove r using a IOmm wrench.

Check the paper gasket and tile

·0 rinll

.

l oosen t he screw us i nq a small Phi l i ps head sc rewdrive r ) or t he

p lu t

i c

cap fi g. 1 and 2).

Clea r thls pipe

i

necessary with an ai r s t

re

all.

Fit the screw o r p la st ic cap.

Check t he f1o.Jt f

or

l OOd condi tion.

~ the fue l j e t

wnench or

and c l ea r i t 1f nec

ess

a ry

with

an air streall f ill. 3) .

Un sc rew screwdr i ve

r)

th diffuser holde r.

t ile di ffuser

cannot

be

easily relQv

ed .

s

lig

ht l y push on the di

ffuser

end In the .

h i

n ch...t>e

r.

Clea r the d

i

f

user

w

i t

h a hi gh

pre

ssure

a i r l i ne.

NOTE :

Some

c

u

ure

tors ar

e not equi pped with a di

ff

use r h

old

e r . These

carbureto

rs

do not have a remo veabl e di

ff

use r . not t ry t o

remov

e

th

e

diffuu

r froPl t his t ype of carburetor. Simply leave Ins tall ed and clea r

wi

th

an a

ir

s t ream.



DIS SSEMBL

ING AND REASSEMBLING THE CAR BURETOR

CONT D .

-

Clu

n

t ~

fue l fi l te r ,

t ~ fi l ler

bowl, and carbure to r

fl

oat bow l

{fig. f l .

•

Un

sc rew

th e

plug sc rew Phi l i p s head screwdrive r) and if

~ s s

c lean

wlth an air u re

a .

fi

g. 5) . Th

is

s c rew gives you access t o t he

id l

e

circuit . )

-

Re install t ~

pluq

sc. . . .

.

Rr

AS

SOIlLlNG T

Ht:

C RBURETOR

:

•

r i t

the ~ r

.

ki

l lg

s ure tha t the d

iffu

se r flatt ened side coi

ncides

with the ca rOu re tor or bu

l l l

·in

fl

a t luq ~ r i

Locate t diffuser

fully

- e .

n t the

diffuser :

olde r

hc rewdrher)

and t he j et

8rmI

wrench).



DESCRIPTION AND OPER TION

OF

THE MOBYMATIC V RIATOR

DESCR IPTIO

N:

l

ke a

l l

'klbylettes . t he

Iobyma

t l c has a primary rubber

belt

dri ve whi ch

provides the well

-known

srmothness and

fl

exibil

t

y , and a seconda ry chain

dri ve.

But t he

Mobymati

c pr imary d

rive

i s specia

l .

The drive pul ley locked on

the engine

a spec

ia

l

collaps ible one. whose

cheek spacing is

variable

under t he i n

fl

uence Of c e n t r u ~ l l y

moved

b

alls

p u s h i n ~ on t he chee k

sid

e wh i ch is opposite the belt.

As

t he cheeks spread apart

or close in

,

the wi ndi ng diameter of the

V belt varies

and this in t urn

modi fies

the

reduct

ion

ra t i

o from 18.7 :1

to

1

1.8

: 1. The engine t i

l t

s around

its

upper

attachmen t axi s . A spr ing tends

to

push t he engine fo

.....

ar d. thu s e

nsur-

i ng bel t t ension .

O

PER TION

On

s ta

rt i

ng,

.tlle

engine revo lves s l owly as soon as

i t

engages .

Th

e

springs

Wi ch push the engine fOn/ard

com

pel the b

l t

to rest on t he s

ma lles

t

drlve-

pulley diameter .

Th

e reduction ratio is at

its

highest , we are i n l ow gear.

As

soon as engine speed

increas

es

the

b

alls

push t he movable cheek, txus de

c rea

si

ng the reduct ion ratio. which

means

that

fo r

a gi ven engine .rpm, the

speed

of

the machine

is

i ncreas ed.

If

the

Mo

byl

t t

e

is

on a

fl

at road the

be

l t

goes on i ncre

n

ng to

r ~ e r

and

larger

drive

pull

ey diame ters un

t l

top

speed

is

reached .

t he Mobyl

ette

enqaces an up-grade . t he speed of both

ma chine and engine tend to decreas

e.

The ba

l l

s exert

less

push on t he

mov

ab l e chee k which then tends to

move

away f rom the fixed one . thereby decreas-

ing t he belt winding diameter.

s

this change

of

speed is con

t i

nuous. the

modifica t ion

in

reduction ratio al though

fast

. occu rs and smoothly .

The

Mobymat

ic

responds

to

all

road con

ditio

ns.



V R TOR

O P

ON NT P R TS

,

,

/

,

\

\

\

\

,

,

,

\



R

OV

G THE VARIATOR

aeeove t he le f t hand

side

cover .

R _ ve tM v.

rhto

r cover usi ng a screwdr iver ) ; re-Qve t he bel t .

Unscrew

.nd ~ the

spa

r t

pl 'i .

Fit

the

s t

roke Ii_He r (100004) as shown in fi gu

re

Rota t e t he engine counte rc locb lse

h

cinq t he varia tor and bri na the

pis

ton t o rest on t ile limi te r .

Gently loosen tile var l

tor

d...... lockn

ut

socke t f ig. II .

Unscrew t he qrease ni pple us ing t he _ nut driver (

fig.

21•



REMOVI NG THE VARIATOR

CON

T O.

NOTE

: REPLACING TIC GRE

ASE

Ni PPlE

s tece Otctdlt r IS, 1976,

tilt

crenksh, f t . nd 9

re

u nipplt thre.c1s hUt

slli f t t d 4 I 7S t o S I SO .

• Ro t t ilt tn9 i nt in , c1ock ...

tse

di rec

t i

on

flcl

ng tilt

¥ r l tor ) .nd

b

ri

n9 t ilt piston t o

rest

on tilt I i

i te

r .

i t t ilt varhtor

pull t

r 1 00020 . I l

OCI

) .nd qr. du. l ly sc rew to

tilt

hub

of

tht

vari

. t

or

d......

.

T19ht

t n

the

cente

r

bol t of

tIM

p uller

tl 1

t

il t

dr. .. is fret

lh n soc

te t , fl o. 3).

Withdr.w tilt tnte..... l

r l

n9 {dos i ll pli t rs . {fig . 4} .

- Withdr.... t he shi.s

( 1

ne

t i

c extr. c

tor

.

(flq

. S) .

Wthdraw the ex t

erne

t rinD ope ni nq

pll t rs

,

ס ס o o

fi q, 6 ) .

Varil to r asseri:lly is

now

fret for r

t<l lOval.



DISASSEMBLING ND RE SSEMB

LIN

G TH E V RIATOR

OI

SASSE

KaL III

l

:

• I

s

u l l

th@ dis

nt l l ng tool, Ito. 100026. In t he J.WS O f vic (fiq . .

• Ph u t ill var h tor on th is tool (fi q. I .

- Uns crew th lock nut (l H. th

read

) on fhe d cheek us l nQ 35nm box wrench

(f ig.

2) .

Unscrew .nd re lllOve the f bed cheek u

sino

Tool Mo. 100027 (f i q. 31.

RelllDve t he s 11dl q cheek , the b,,11 qui de , d t he bill

Is .

Loo

s n

.nd

reecve

ue f

eecet

ers .. .

k screws

holdln

q till

dr

.... to

the

hub

l I5i g • screwdr h r or an

IlIpI;

c t

screwdrh

r

(fill

. f l .

Re.lve tile

dr

....

asse-b

l) '

th

till flywe

ights .nd

sp d nq .

ash

.

Re.lve t he flywei9hts by

sl1

di ng t

helo vert ica lly

long

the

i r piv

ot.

1.

' J

\ ,

\;.

• •

: •

C

• 0; \ :.:.



DI SASSEMBLING AND

RE

ASSE

MBL

ING THE V R IA

TOR

CONT ' D,

R

E SSEMBLING

In

s t a l l

t he u rl

Uo

r nub on t he di sma nt

linn

too l . No. 100026 (fio. I ) .

Insta ll t he flywei ght s connec t ed by two

spri

nqS onto t he pi vots. When

ful ly fitted in, t hey should spread out f ree

ly

( fi 'l . SI .

NOH

Prev ious

ve-te tc -s ar

e f

t t

ed w

it h

flyweinn

ts

d

ri l le

d wi t h four

2 , notes for hookino

return

You

y

hook

th

e sp-mcs in

th e

ho

le s

nearest

to

eacn ot he

r.

Thi s w

l l

de

crea

se

sprin ls

t ension and

allow be

t t

e r st a r ti ng at l owe r spee

ds .

Fit t he two sprinq washe rs on the pivo t s L preven t flywe iqht

side

p

lay,

f iq . 5) .

F it t he varia to r bel l onto th e hub/ flyweiohts as semb ly ( f

iQ

. S .

IN THE

S

E OF NEW VAR

I T

ORS:

Clean the t hread and put some tO

T

IlE and

t

t he four count e

rs

unk

screw

s.

Tighten progre ss ive ly and lack t he se -e..s by means of

heavy

scre

w

driv

e r .

IN TIlE

SE

OF

OtD V

R I

TORS :

Fi t faur

new

count ers unk screws and t i oh

te

n prao ress ively. By

me

ans

of

heavy sc rewdr iver ,

la c

k tile screws .

Punch lock the ccunteesonk screws i n the n

ot

ch provided fa r this purpose

(fiC . 6

.



DISASSEMBL

IN

G AND REASSEMBLING THE VARIATOR

CONT O .

h slid inCl ~

( t

h

hub pw.l

n:

s

.

InH a11 t h@u ll U

lle

and inst r t tM b.1lh in t ht ~ u {f ig . 11.

~ t

t ile wa r jUo r

m..

b fl Oll t he suppor t t ool and i t

tee

scl @Wd

h

~ t

fi

t ass

edll

y on t ile suppo r t t ool {llo. 100026 1.

N

OTE

: Var la

tors

fo r V·t>t

l t

s

_

na wid

th * 1_

are

t t ~ d

w

ith

thfo

~ r ing and t

hfo

wa shtr p

la

pd be fore t ht

~ k

Insta ll t

hoP

(R. H. th

re

ad ) and lock i t i t h Tool 60 .

1000l7.

Tiqht t n lod n t

H.

wi th a

35nn

wrench.



DJUSTI

NG A

ND RE

FITT

IN

G THE

V

R

I TOR

sur e that the small r in g qraave an

th

e c ra

nk

sh

af

t t apered end

is

in aood condi t ion f i o .

n

Clean

tharo

unhly and

remo

ve grease f rom t he threaded end

wi

re bru sh .

Ins e rt the caged needle beartnq in

to

t he varte tor- hub.

Place a O.8mu sh im on

the

n

eedle

ca-re.

Fit

the small r i nn on top

cr

the shi m fi 5. 2 .

Inse the o ther O.8nm shims and t he

otter

r inq cl osinq pl

iers

fiq. 3 .

Sl OE PL

Y

A JUSTM

ENT

:

M X

I

MSlOE PL Y O.

lMM

The shims and re

ta

in ing r inqS should have a side play s l iqht a l l owance .

t he re

is

too much s i de pl

ay ,

perform an ad

ju s

t-rent usi ng O. lm shims

fi g. J .



ADJUST ING AND

RE

FI TTING THE V

R

IATOR

CONT D.

c-eese .ooe ri te l) t he i nner p, r t of th e

hub

c

tIP

d

n «

dl e bu r l n q) .

The v d i tor ca n _ he rei nsUllt<t

f

iQ. 41.

r ~ the

va r i tor

f u l l

It wil l Icc a te i

ts

e

lf

in th e r lq t pos I

t i on.

The u s e - b l) will rou te f retl) wi thout p1l) t he si de p l.) h.s bt tn

, dj

uste

d as des c

ribed ,bove

.

Br ing t he piston tQ rest on

the

stro ke I i. i ter , nd f it t he var h t or

dr um f orget th e o- r i

nQ

on the hub) .

Tighten t he nut to 22 ft . l

bs .

{

to

rque w

re

nch }

f t

e r h. vi no ,pPcl1ed .

si

ngle dro p of t

OC

TIH

fig

. S

).

F

i t

t he qre es e ni pple nut dr i ve r ) refe r t o I0TL P. I t 39.

g

ee c

ve t he

s t

roke l i mi t e r , t he

spar

k pl uq and ra di o Supp

re ssor

.

F

i t

t he be

l t

, t he var i H or cover , and s r ue co ver.



REMOVI NG - RE FITTING - DISASSEM

BL

ING - REASSEM

BL

ING TH E LUTCH

REMOVINGT CLUTCH

not re

move

the

be

l t guard. Slip t he drive belt off f

rom

t he pedal shaft

pull ey.

Re fe r to page 38 same procedure as f

or

the ver

ato

r }.

DISASSEMBLINGTHECLUTCH:

- Remove caged needle be

aring

.

.•

Mo

derately

cl

amp the pull ey cn.tne c lut ch in a vi ce fi t te d wi th copper j aws.

Loosen and

remove

the t

wo

counters unk screws {impack sc rewdr ive r } fig. lAl .

Remove t he count er flange fi g . lB .

R

em

ove t he two spr i ng washers .

-

Remove

t he flyweight s by

slidin

Q t hem vertical1y alono

their

pi vot c are fu l ly

not e flyw

ei

ght

s pos

i t ion.

f

ig .

Ie .



REMOVI

NG

- REFITTI

NG

- DISASSE

MB

LING - REASSEMBLING THE CLUTCH

R

SSEMBLI

NG

T

H tuT H

:

FIt bot h flyw

ei

g

hts

connect ed w h two springs on t

mCllmtinq pil lar

s

fig. IC .

Place both sp

ri

ng was he

rs

on t he

moun

ting pi l l

ars.

Place t he counter fl ange on the was hers fi g. 1B .

Secu l Ole counte r fla nge wi th two new countersunk SCI WS f ig .

1A .

A

fter

f ina l t ight eni ng . punch lock both sc rews i n the notches prov ided

for t hi s purpose f ig. I A

SIDE PL Y ADJUSTM NT ND

REFITTI

NG TH LUT H:

Re fe r t o pag

es

43 and 44 same orocedure as for

variHor

.

F t he belt on clu t ch pulley.



RE

MO

VI

NG AN

D REFITTINr.

TH

E DR

IVEN

P

UL

LEY

ROOVAl. ;

Jleftlve the LH. stee cover us i 9 a screwdri ve r .

I t s

unnec

nsal )

to

~ th e

d

rive

cha i n. but

i

you

neell to pla ct it

me

-.<I

s t t r

lin

k.

In th

t

cne of a

nr i a t

or engi llt .

re-:l

ve the beo l t cover (sc rewdr i ve

r) .

~

t he ped. l pin

nut

wrench ) and dri ve out t he

o .

c

ra

nk co

t t

e r

p

in.

,,,ve

the pedal c r ank wi th the p@da l a ttached.

Slip the dri ve belt off f .-u. the pul ley groove .

lIsi ng a mu i t i ·lock pliers 1 t 1O)'It ' t he dun c.p ( fi Q. 11.

R

emove

t he

I t U

ining r i ng (open ing p

l l

t

rs

. No.

100002

)

.n

d the

thrust

wn

her

( f ig . 2

).

Turn the engi ne n g q ~ n t lever t o V Ienqtne d

is

engage

d).

The pulley asse mbly can now be pu

lled off th

e

shaft.

Ho ld t he dual sprocke

t .

Ro t at e t he

pull

ey and pu

l l

on It .

Remove

the pul

le

y.

L

i t t

t he ch. i n off the T1 ar sprocket w

h11

e roU

tin

g

tht

wtle-el and

remove

t he

du

al

sprocket .



RE MOVI

NG AND REF ITTING THE DR

IVE

N PU LLEY

ONT D .

RU

ITTI

NG

Fit t he dual sp rocket on the pedal s haft smaller t e

et

h facing the fra

me

) .

Fit t he ch

ain

on t he dual spro

cket

mak

i nq

sure

that the mast er

lin

k clip

is facing the

correct

way . The cl osed end

of

the sp rlnq clip

mus

t fac e

the

d irec tion of

Chain travel { q . J).

Fi t t he chain on the rea r

whee

l sp roc

ket.

Place the pull ey engine enna

jell'e

nt le ver

set

to V) on the pedal Sha

ft .

Cen

te

r t he dual sprocket

manu

a

lly

and

it i t

on pu

l le

y hub.

Press on t he pulley t o dr iv e the sproc ke t fully home.

Fit t he t hrust waSher and th e re t a

ini

ng ri ng openinq

pli

e rs No. 100002).

Fit

t he d

us t

cap

repl

ace

i t

I t was

damaged

du

rinq

dismountin

g).

F

i t

t he b

elt

, t he cover i var

ia

to r engi n

e)

and si de cover.

M ke certain t he ch

ain

Is correct ly t ens ioned this operation mus t be done

wi t h a ri der on

the

machine).

The adj us t in g

of

the

chain is carr i e d out by means of t he chain

adjust

e rs

s itua ted a t th e end

of

t he swi ng ann . Do n t f oroe t to l oosen t he

whee

l

ax

le

nuts

( rm

wrench )

fig

. 4) .



REMOVI

NG AND REF ITT ING TH E CRANKGEAR

REPLAC ING CRANKGE

AR

BUS HINGS

R(llIYI

NG

l H[ CRANKG£ All :

thop driw 'n pu

l l .

y (l I 'f.r to 1N9I ' U

).

tht' t?

t ai ni nq

rinq

(OPf 'i no

pl t . r s .

. 100002 )

.nd thrust wnhop

r

{

fiq

. II.

t ' R.H. s id ' cow

r.

~

s.

thE>

el l . in

tens

lOftl 'r

(fiq

. 2 ) .

Sl ip thi ' PI '.s.l e i n oft ......w It

i t

dUl ' for l I 'jl

l , , _ n t .

~

the

( ra n

tq

eu wi t ll the R.H. c

r.n

t . nd thrust

.nheM.

(di u n Mlb l e

t hop vant t he crankqu r is due for rep l a c _

nt

: II ' wrench) .

ADJUSTING

TflE

CRAN U l LE SlOE PLAY :

Fit t he tll

rus

t wasller on t he c rank ax l e .

fi

t t be

eu

nk axl e i nto t he bush inqs .

f i t t ile ri nq and thru

s t

was

her (f

io .

I

The ShaH should h

a.

e almos t O.

TY

sid ' play.

If neces

sary, per

fo .... a co r

rect

0.

1

. . .

; No . 1486S,

O.)rn)

.

ad

juStml '

nt by us inq s

hilOS

(No. 14863 ,



REMOVI NG AND REF ITTING THE CRA NKGEAP.

REPLACING

CO NT D .

REFi n iNG THE CWlK

GEAR;

like

u rt in positioning t

ilt

u r l ink in t hf ee r -ec t ...y h l t 4ft).

REPlACING CRAl(KGEAR

BUSHINGS :

Fte-ovot the driven pulley

rt f r

t o 411 .

RelllO vot the cr . nkge. r (see pl t ceed ing Il

.qo '

}.

Dr ive t he bushi ng ou t by I,I$t ng • s tee l dr if t Il..,ch {I 2....1 ( f tn . 1) .

Drive t ile r

fllloli

ni nq bushi ng out with t ile 2Dnn H eel t ube .

r i t new bushings by usi

nQ

Tool No. 100009 (

fio

. 41.

Inse r t t he crank axl e in t he bush in\ls. The u le should t rn frt ely

with

out ph

y

if

neces

ury

us 1

6Irm

re allll r on the buslli

n<l

\ l .

Fi t the cr ankgea r . nd t he pulley (see ebeve and paqe 41J ) .



REPLA

CING

UPP

ER

ENGINE

MOU

NT ING FLEXIB

LE B

USHI

NGS MODE

LS

AND

50)

TOOL

N

O l ~

IS

ABSOL

UT

EL

Y NECESSARY TO E

FF

ECT THESE

OPERAT

IO

NS

Remove bot h si de covers us ing a sc rewd

rive

r

Remove t he bel t f r

om

t he pull ey groove

loosen the upper engi ne moun t inq nut 12 and

J

ll1II wrenche s ).

D

rive

out t he upper engi ne

mo

unting axl e whi le holding the enetne .

le

t t he engi ne Jean downwards but pl ace a block und

er t for

suppor t

For re

mova

l

or

i nsta l l a t i on ope

ratio

ns , the

fl e xible

bushtnos must be

re

mo

ve d Or

in s ta l led fro

m

insi

de to ou

tside

.

TH

E F

LEX

I

L

E BUSH iNG:

- Pos t ion the

tool

in alignment

fig

I

Ho

ld t he nut with a 17 m wre nch

and screw in pul l e r s sc rew by usi ng a 12

m

wrench.

POS

IT IO

NI

N

THE F

LEXI

BLE

BUSHING:

I

nser

t the

st o

p washe r this wi l l loca te the bushing cor re ct l y in the f ra

me

)

as shown on f i g. 2.

Position

the

fle

xible bushing chamfered end) on the sc rew and proc eed as

wh

en remov i n

1

t he

flexible

bushing.

Replace nece s

sary

t he l e

f t fle

xi bl e bush

in

su

lation rin

g.

t

the upper engine

mo

unti ng ax le , t ighten

r f

to the

NOTE

on page

11

1.

th

e nut without l ocki ng t



REPLACING UPPER ENG

INE MO

UNT

IN

G FLE

XIB

LE BUSH

IN

GS ~ E L

]>

NOT[:

A

l l

service ecerett ees ~ a r i n the en91ne and the r Indicat.M

th rou9hO ut our

Jl£PA

IIl

OPERATIONS

a ~

v

alid

fo r

~ ~ d

t y ~

-1- .

1001. 0 . 100024 IS

A8SOlllTHY

IIECESS.lIl

TO

EffECT

TH

IS OPtRATlON

Slip t l

be

l t off fn t he

pulley

orooVE .

l oosen tlf@ nut

IOrrrn

soc k

et

on t ile 1

0000r

enai ne ..aunU no

~

and r

emo

ve

I

t

l oosen the t

wo

n

ut

s

{I

3nm

socke

t

on the upper enaine

mou

n

ti

nq.

Remove

the

en91ne and le t i t de t ach f

rom

the f rane. Suppor t the enoine by

p

lacin

g a blOCk under I t

Fo r I

llI)

vlng or i t tlnq operations t he flexi bl e btlshes will be removed

or

fi t ted f r{lnt f

ront

t o re er of U.e ..achlne flq 1 and flq 2 .



REPL CI

NG UPP ER E

NG

INE MO

UN

TING FLEXIBLE BUSHI NGS MODEL

7)

cONT n ,

RE

VING THE FL

EXI

BLE BUSHI NG:

- Ali gn the too l Shown in f i g . 1, and hold the nut. with a 17 , wrenc h

screw i n the too I s screw us i ng a 12 , wrench.

FITT ING THE FL

EX

IBLE B

USHI

NG :

Reverse the body of the too l and in se rt t he screw i n t

f

t

t he fl e xib le bushi ng (chamfered s i de ) on t he screw,

of

t he too l as indi c

ated

f

ig .

2)

and sc rew t he

wide r rests g ~ i n s t the f lexi ble bush inq housinq

r ~ r r

pile

up t he

two

nut unt

t he

welded t o

th

e

fi g. I - Location of part s for bushinq ren> v a l



RE PL I

NG

CABLES

FRONT

OR RE R BIU K[

t

ABU

Leesen t he c

able

end

us i lHj

a

open _ ch and s l ide t he inner .. I

re

out

t hrough the brake l eve r f

ig

.

2) .

Tight en t he brake adj uste r at t he handqri p f ully (Hi) . 31.

G

rene

the

new

inne r wi

re

and fee d

t hrouqh the lever anchor pi n , the

a

dj

u

s t

e r and outerc

n l

n9.

Whe

n

rep la

c ini) the re

ar

brake inner w

ir

e ,

IIol

ke su re t h

il t th

e fe r ru

le is posi-

tione

d cor rec tl

y.

ADJUSTMENT: rig.

Ho l d the cable 11th pli e rs ( ri ght hand) , Push On t he cable a r lp

with

a

second pa

i r of pl iers . Pi nch t he Inner wire at t he poi nt where the cam

lever

t ouches . Rel

eas

e t he end of

th

e cab

le

and t1qhten Ub le

qr

i p screw

ig 2

If

~ s s

adjus t the brak es us i nq t he adj llSt e

rs 11

the leverli ( f

lC

. 3) .

merrne

CA l

E:

Re-ove t he R.H. enqlne cover and t i l t th e u rbu re t or ( to the left s i de ) by

l n i h e u r c l . p a nut driver . RMove the sc rew on the .

h_

i nq c h a r cover .

Re.:lW

th e cover c

lete

.. I

th th e

t h

rottl

e s

l i

de and

choke s

l i

de (

sc rewd ri

ve r .

l oosen t he ca

ble

l ock

f

nll t he U

lrottl

e twts t gr

ip

open wrench) . Pul l

out t he Inner wi

re

.

Rea

ss

emble i n

reverse

sequence and q

re

n e the

new

inner

w

ire

befo

re

s

l id

in

H into the out e rcn l nq.



REPLAC ING

CABL

ES

CO

NT O.

CNO

l C L£

:

foll ow the procedure IS dl scribed f

or

tile t hro t t l e inn

er

wi re .

Sla

cken t he

nut

at t he chOke l e

ver

mI

open wrench) and pu

l l

the i nner

wi re out f rom t he bottom of t he choke slide .

Rever

se t he procedure t o re as

se

mb le a

fte

r havinq lUbr i c

ate

d t he

re

place

me nt inner win and feed up t hrouqh t he choke s lide .

Adj

u

s t

the t

ens

ion

at

the choke

leve

r adjl,lSte r

(a

S llolJ

a

.-:)

unt

of free

l

nt

is

requ ired and should not e .cee d f

ig

.

4) .

DECOlf ft£SSOR CABLE

t he caete end .,sin9 a 6no open end wrench .

Remove

the radio S

llPre

S50r and depress the deco-pnes

sor

spr i no us i nq a

and relDve t he fe

rrule

f , . , .

t

s hol der .

Pull out the inner ..i re from the out e rcasing.

Grease t he new i nner wire and reroute t hrouoh t he ou tercas i ng and i nto

t he shou ldered ferrule . Reverse di u u emblinq procedure.

Adj

llS

t the cabl e tension at the

detOqlreno

r adjuster on t he twist qr

lp

(a s...

l1

of free eoveeent is rt q\lired and shoul d not

exceed t t e .

5).



RE

PLA

CI NG THE FR ME

bot h s ide cov t n .

t ilt r

ad i

o S

uPJI

re sso r . nd di

C ltlM t

t t il t

d ttooopre

ssi on eee te .

Jlea)ve t he H. bla ck pl a s t i t fIg. .

Re nDve rew

011

t he .. I xing ch.llber cover , .n d t he cover c

ooop

le t e with

th

rott

le

sli

de and choke sl i 6l f rom the t arbure to r .

Re

mov

e t he out e

r t u

i ng re ta iner wi t h th e ig ni tion coil Brrrn

wre nch .

fi

g. 2) .

Dis connec t the

reer

brake i nn

er

wi re . eeecve the sc t eer-tess l p p l

.n d

t he o

ute

rca

sln

g shoul der ed end.

Di

sconn

ect

t il t four -way connec to

r . wire

s the fl

ywheel ....

gne

to

.

and zener d iode s t ra

ig

ht

te Tll

ina

ls

.

R

e.; l t e

t he

R

.H

.

b

lat

t

p h s t i

t

O f t

l .

Dl

y t

h all te

ee s

,

Set t he

thi ne

on

a 11ft benth and clUICI t he

rear



REPLACING.THE

CONT n ,

n s ~

and ne-ove t he nuts secu ri ng

of

·U· c

l .-ps

on

the ~ a n d

bar . is not required I f the h i ~ i s f i t ted w t.1I U·

ct.mps

.

US

e

w r e n Ito.

1129 to r@

lIIOve

the top s t ee

r i

ng locknut ) .

~ the

.a. . , t l

ng b

loc

h .

Unscrew.nd

reIIIO

I t the

s t ffr l 9

locknut :n wrench ) .nd the washer .

...-f

la

t ten the

lo

ck

pt.te

and

I f1IIOve

the botto- pivo t ~

~ w r n

e l t

the

front

wheel

assedl ly.

fork . h

.n

dleb,)

n

and cO

ntrols

.

fte.n)

ve the s tl.

l rl l he.d

se t (

refl

r t o P lJI. 64

Rl IIIOvl. the belt ccve r .

utsccn

nec t t re fuel pIpe , and reecve t he I n 9ine asserrbly w

i t

h t he carbure

t

or

(refe

r to p

agl.

e

Remove the dr iven pull ey , and the chai ns Ir e fe r to paqeS

47

- sol.

Remo

ve loading spr i nqs and the s top bracket (ll)rrn wrench , fig . 3) .



R

EPLAC

I

NG

YHE FRAM

CONy D.

u u ddlt and tile ch

around f r_ sut pilla r (13M wre

no h

l .

~

,

fue l cap . decals . s t ri p and too l

box

cevees,

Zent r diode

to

wrench . equi pped.

.

.

shock absorber upper mount ino bol t s

(1

3mm w

r t

nch l .

Remove

.

se -locki ng nut

I7

rrrn wrench) and dr ive out swing arm sha

ft

.

Remove t he swi ng arm compl e te wi th shock abso r

bers

and th e re

ar

whee l (

fiq

. 4 .

Re

mo ve the rear fender wi th wi ring and l uqgage ra ck l owe r suppor t br acke t s

( re fe r t o page

15 ) .

geecve t he l uggage Cir r; e r r ack and l uqqage rack upper suppo rt brackets l IN

wrench and Philips sc rewdr ive r .

Re-ove t ile tap

114

open _ ch i . Ma

k

sure the rubbt r su i

is

i n

good

Cond

lt

lon

f

Ig.

5 ) .

the plast i c s t r ips f ro- rea r fr_ a..-s and th e g t f

n:-

t he l r

p;lr t of t he f r_ .

Remve th e

cente r s tand (re fe r

to

p;lge

69

.

REFin

NG

THE F

RN [

:

_ Reve rs e t he procedure .

fi

t nelO c rankqear bushi n s (Page ) and

new

f

le

xib le

bushings (Page 5

1 .

NOTE:

Do

II

Ot forg

et

t o s ta

mp

the f r arne number on th e n

elO fr

a

me

i n t he same loca



~ V TH E MA

IN

FORK

ASSEMB LY

Foran OjM l I tions on t he f ron t fori: . f

u t

en the rear wheel t ile fron t

wne-e

l

..

i l l

cl

ea r tile ground) ..i

th

a c hlllP s

l . i

h r

to

that

sl\oMn

i n f i g .

I

I @n::lve t he f our nuts and ..nhers unde r the handl eba r ·U· chq S

(100m

wrench) .

Remove ~ ·U· c lamps

comp

l e t e w

i t

h wedges . le t the handlebar hang down .

s eeove the

h e a d l a

ass

ent>

ly and disconn

ect

t he wires

fr

om the sealed beam.

Disconnect the .. i res at the head

la

mp s.. itch .

D

is

con

nect

the

..

ires

fl Oll t he h

om

, d

is

conne

ct

the

s peecloR

te

r con

tro

l fl Oll

s p e e ~ t e drive unit and

the

f

ront brake control .

R e l ~ tM ou

tercnlng

fe r r u l e

I

wrench) and f ree the brake cable fl Oll

t

f ~ d e

r

br

ac h t .

R e I ~ t M upper nuts t oqether ..

ith

t he f

ort

caps and rubb@r wasMn f l Oll tile

upper end

of

the fort s lo t

te

d screwdr

iver, Ko.

100012 .

fi

g. 2) •



REMOV

ING

TH

E

MAI

N FORK ASS

EM

BLY

CO NT

D,

Remo

ve

the

fron

t whee l with the

for

k pl unQe

l' S

.

Remove the top

s tee r

i ng lock nut and washe r j321ml wrench.

fi

g. 3 .

Flatt en t he lock pla t e and rel l ve t he bottom for k st em reh inin9 bol t

w

N'

ncll.

No

. 100019. fig. 4) .

P

N SS

again

s t

t he fo rk pi vot and lowe r for k ple t e w

i t

h a screw

dri

ver t o

r

t he pegs fig. 5) .

Pull on

th

e rna in

fo r

k assenbly

to

f N' e the l ower

for

k plate and l i f t

to

free the upper part.

Re l l ve the lleadJamp and the horn lOnTll wrench) and f i t th em t o t he new

mai n for k as sembly.

Do

not forget t he ground l ea ds on t he head 'l aep

lower moun t i ng screw.

t

>J



REfI TTING THE

MAI

N f

ORK

AS

SEM

BLY

REMOVING ANO R F ITTING THE F

OR

K

CO

MP

L T

_ Reverse dismantli ng procedure .

su re th at the lowe r pla te pegs

ar

e posi t

io

ned in t he s l ots of t he

fork p

ivot

If necessary , replace bushin qs and space r s r ef

er

t o

p ne

62 ) .

l

ways f i t a n

ew

lad p

la te

on t he

oottom

pi

vot

sc rew.

RE

IO

VI

NG

ANO

R FITT

ING THE FORK COMP

L T

E:

IlelllO

ve t he f ront whe

el

re

f

er to

page

66 )

and the fe nder

re

fe r t o

page

7 .

Yo u need

not

r

emove

the fo rk caps re ta i ner nut s fig .

Follow t he i nst ruc

t io

ns gi ven for t he ma i n for k assemb

ly

remova l and

refi t t ing.



REP

L CI

NG FORK USHINGS ND SPR ING S

Di

sconnect t he speedo.-ete r cab

le

.

Disconnect t he

front

b

ra

ke

co

nt

rol c

able.

R

emo

ve the oute

rcasi

ng shoul de red end of th e fron t brake cable and f ree t he

cable f rom fe

nder

suooc- t .

Remove t he fo rk cap reta iner nut s (s lo tte d sCNwdr l ver No. 100012).

Remove the whee l compl ete wi t h fo rI plunqe r-s and spr i nqs .

Remo

ve the da

mp

e rs .

Remo

ve the fo

rI seal

s f ig . 1) .

E

xt ract

t he b

ushings

and s lee ves w

ith

the

2-ja

w pu

ll

er, No. 100006 (

fiq.

2 .

Inse r t a new

set

of bush ings and sleeves i n each

for

k t ube .

Ma

ke su re the

botto

m fork

sea

ls a

re

i n good cond

i t

ion: orne....ts e repl ac e

t hem fig . 3 .

Fit new fork s p r n ~ i f the old ones were broken.

Fit t he dampers and t he fo r sea ls on t he pl unqe rs .

Coat t he sp ri ngs w

i t

h qrease and i t the

wh

ee l w

i t

h plunqers back

into

the

the

for

k s

hell

.

F

i t

the rubbe r washers , cups , and

tiq

ht en t he u

oper

nu

ts

(s

lotted

scre

wd

r iv er ,

No . 10(01

2 .

NO

T

: Mke su re t he t op

s trut

s

of

t he fo rk pl unqers aN l ined up

wit

h the for k

hous inq

before

ti

ghtening

down

on

t he Slo t te d nut wi t h Tool No. 100012 fi g. 4

and

5 ) .



REMOVING THE H N DLE RS

Slacken the locknut under the twist g

ri

p and remo ve the sc rew mI wrench

and screwdr j ve r , fi g . I ).

Remove t he twi s t g

ri

p s leeve.

Free t he t hrottl e and decompressor cont rols from the r

etai

ning bracke t on

the fork upper pl a te fi g.

2 .

Sla cken th e sc rew securi ng the twi s t grip body to t he handlebars f I9 . 1) .

Inser t a sc rewd

r i

ver blade between t he rubber g

rip

and hand lebar t ube

fi

g . 3) .

Tilt the machine s l i ght ly and

inject

some

oil

drops i n th e space opened

by t he screwdri ve r fi g. 3 .

Remove the rubbe r gri p f iq . 3) .

SlaCken t he sc rew se cur i ng

tile left

hand gr ip body.

Re

mov

e t he

four

nuts under t he handlebar

U

clamps .

Remove th e l eft hand gri p body.

Re

mo

ve t he handlebar

s .



REMOVI NG THE STEERING HEAD ASSEMB

LY

RE PllVAl:

~

one

·U·

c1..-p

110..

w

,nth

) . Th

is

is

n

ot

n

u n

O )

fo r

t .

l l

·U·

t

14

s . Re-I)vl

tM

t op

stl'l 'riM

lo< k

nut

us ing Wrench No . 122 (fig .

t )

.

Sl at kl n

thl'

nuts sl cur tng tM othl'r · U· clamp and re oYl

the

wedge unoer

t hl

.U

t

lalllP

alread) r l l ~ d f i l

.

I ).

Fla

t t

l n tile l o< k ph t l and re -on t ile lower pivot Strew (l1 t h

No

. 100019) .

the f

ort

w

ith

tile whl l 1 without discoMl l;tl nq an)

wires

.

l e t t his .sseoobly

h.

n9 t o ont sidt and inse r t a sc rewdr lvt r o r a

h.

rdwood

block thro

ugh

th t

spoktS to lot. t ile (fi9. 2).

Hold

the

steering he.

d steoow1th

inte rloc

king

joi

nt

pli t

rs

.

d

s

hc

kt

t he

upper s t ter tng cone .

Iltlaove th e

st ter i

9 htad steoo, eauec t th e s t

l l

ri nl) head s t

te

l ba l h . and

pul l out tht upper and lower Cup b) lISi g a t up pu

l l

e r ( f i g. 3) .



REFITTI

NG

THE

ST

E

ER

I

NG

HE

D

ASS

E

M LY

Insert the

bott

om and top cups into t he f rame

t

ee ri nq tube f tt i ng

tool

No. 100016, f ig. I ) .

Pack

the

top cup and pivot stem cone w

t

h gre

ase

to

ma

ke ba

ll

f t ti ng

easier.

Place

the ba II s 26 ba115) on

t

pi vet stem cone and insert

t

i n th e

frame stee rin g t ube .

Fi t t he

ot r

26 be

lIs

in the top cup.

, ,:

re

w in t he top cone . Hold the pi vot

ste

m

wi

th

tnte r-Iccktnc joi nt

pl iers and s tra

ighten t

cone w

t

h t he hand

fi

g. 2

.

Fit t he assemb ly wheel fo rk, and handlebar) .

Fit t he U c lamp and wedge.

Tighten t he four

U

ct amps n

ut s IOPm

wrench

.

Make su

re

t

here

is

no up and do

wn

p

lay

in

t he

steer

inQ head races .



RE

MO

V

ING

A

ND

REF ITT I

NG

THE FRO

NT

A

ND REAR

WHEELS

REI OVI NG THE REAR WHHl:

Place the

mac

hi ne on the center stand and l oosen the rear whee l axle nuts .

loosen atnos

full

y the

left

h nd axte nut to remove the chain <1djuster

bol t .

Lif

t th e drive chaf n off t he rea r wheel sprocke t fig. l .

Push t he Chain

te nstone-

up

into

the lOcked

position

and l t t he

p : d<1l-

l i ng chain off t he

free

wheel

fiq.

2 .

Push t h

cam

leve r fONard to reteese the

rear

bre ke ceble fiq.

1 .

Remo

ve the

wh

I.

R

emove

the

bra

ke

<1sselT bly

and insp.:.ct t

n

bra

k

shoes.

REFITTI NG THE REAR

WHEEL:

Reve

rs e

the procedure.

M<tke sure

th

e Slo t in the brake

on t he sw

ing

nn

fig.

3 .

App ly the bra

k

and tighten t he

the brake shoes.

\

o

backi ng pIa

te fits

over the lug weld.:.d

rea r whee l axte

nuts.

T

his

will cente r



~ AND REF ITT IN G TH E f RONT ANO REAR ~ S

CONT O .

REIt)VI

N

TIfE

fIW

NT

WH

El :

Rep l ace I block uncle r th e engi ne

or,

the machi ne is f itted t o a work

bench, ch mp the rea r whee l so

that

th e f ront wheel Is well o

ff

t he ground.

Disco nn

ect

th e s pe

edome

t

er

cable and retease the fron t

br

ake ca ble f rom the

f

ront

bra ke

Inn

fig.

4 ) .

Slacken the u l nuts sufficien t ly en luqh to ~ the flat wn he rs f i

< l

5) .

Pull

the ee d W and

out

o f t/le fort

~ t he br.ke

pll te

I nd i nspec t t he

bra

ke shoes .

Cl ea n the dO neceSS I ) .

REfiTT

I

N

THE fRONT WHEEL

:

Re verse re

mo

va l proce du

re.

Mil

ke s ure t he l ug on t he brake backi ng pla t e

fi

u i nto t he f ork s l ot

r i ght hand ) fig . 6 .

App

ly the

bra

ke and t ighten the f ront whee l s pi

ndle

nut

s. This

wi l l

ce nte r the brake

shoes .



REPL CING

THE

BR KE SHOES

FRONT OR RE R

RE

MO

VING

THE

BR KE

SHOES:

mo

t he whee l f rom the chassis re fer to paqe 6

6

Remo ve t ile brake back ing pla te from t he wheel

hub

Clamp t ile brake pla t e In a vi ce and i nspect t he shoes before remo v-

ing t hem from the brake backinq p

la

te.

Inse r t a

scre

wdriver

be t

wee n t he bra ke backing

plate

and one brake

seee

and agains t

i t

t o remove t he shoe fi g. Li f t the ot he r shoe

off the

backing pl a t e assembly.

NOTE: Be care ful not to bend t ile backing when remov ing t he brake

shoes .

RE FITTING THE BR KE SHOES:

Assemble tile new bra ke shoes w

i t

h

the

return s pr i n9S.

or e the shoes apart holdi ng t hem i n a

V

formation fi q .

2 .

Press downw

ards

on t he brake shoe to

posit

ion i t cor rectly.

Coat t he

bra

ke pivot camwith a li ght f

il

m of gre ase flq. 3) .

The i nner surfaces of t he brake drums must be kept free f rom oily sub-

s t ances .



REMOV N , THE CE NTER STAND. THE

SADDLE

REPLACING THE PEDALLING

CHAI

N AND THE DRIVE

CHAI

N

REI IJV

I

NG THE CE

N

TER ST

A

NO:

Using m

ul t i

lock

pl i

e

s

grip

txe

c r ~ n k g ~ a r p u l l ~ y

dust

cap remove

i t

.

See paqe 4

7

.

R ~ m o

the r i ng

usin

q open inq pl iers No. 100002. See pace 47 .

T

i l t

the pulley opposite s ide .

Se t the cente r

s t

and s p

r i

ng by pas sing pi ece

of s t ri

ng t hrough lower

bow

of th e

sp

ri

ng fig.

I .

Remove th e s pring fig . I .

R ~ m o

t he nut s

ec

u

ri

ng

the ce

n

ter

s tand

bolt

1311111

SOC

ket

and 1

open end

wrench .

S

l ig htly

Pull th e pulley upw

ar

ds and remove t he bol t

flq

. l .

aeneve t he ot he r bol t and t he cen t r s tand .

REFI TT ING T

HE

CEN

TE

R STANO:

- Reverse t he procedu

re.

f

nec e

ss

a r

y,

rep

lac

e t he

dust

cap on th e cr ankgear

pull

e

y.

RE I1J

VING THE SADDLE:

• l oo

se

n the s addl e cl a

mp 1311111

sock

t

•

•

Lif

t t he sad

dle upward

s and remove

i t

REFITTI NG

THE SADDLE:

- Rever

se

t he pracedu

re

,

N

OTE

:

w t l ~ n

r e

f i t t i

ng a

saddfe

, sure t h

at

i t do

es not come

to

rest

on

the seat po

s t

when sat upon.

REPLACI NG THE PEDAL CHAlN:

- Push t he chai n

tensioner

up into t he l ocked posit ion.



REM OV ING

THE

CEN

TER STA ND.

TH

E SAD

DLE

RE P

LA

CING THE PEDA

LL

ING

CHA

IN AND

THE

DR IVE CHAIN

CONT'O,

RelKJ

w< t

IM>

joi nt clip

f l i t

no

s<

p l i ~ TM> r e . r e t O ty p< s o f pedal

ch. in jo int cli ps fi']. land 3) .

Con ll< c t the nl W c ll<li n with the cha in

joint

of t he old cha in . nd pul l

.u'Ound tile freewtlee l

until

t he new ch. i n end

is bro

uqht o

ut.

Fi t the jo i nt c lip ( fl a t nose plie rs ) ( fi q. 4

).

Release the chain tenstoner t o brino back

into

PQs i t ion.

REPLACING THE DR IVE CHAIN:

Loosen t he rear axle wheel nuts ; :<9rm wr.ench) and unsc rew t he adj uste r

bolts a few

tur

ns (8rrJn wren ch) .

nescve

the

N

ste

r l i nk

clip

(f l i t nose

pller-s ).

CO

nnect the new chain wi th t he ch. i n l ink of t he old cha in .nd pull i t

<l round t he sprocket unt

il

lhl<

nf W

chai n

I< nd

i s brou<lht out.

F

i t thl<

l i nk c l i p ( fl a t nose pli< r-s)

fig

. 4) .

Cl<

n

te

r

the

wll«1

I

S

~

on

P<l<le

7

5)

and

l d j ~

t he c

lLa

i n

ten

s ion

by ''' Ins o f

j ~ bolts

(one

.s t

t .k<

into

account

the

r1dE-r s wei<lhtl .

Lock t

IM>

. x ll<

nuts

~ wl l 'ftCh ) .

The wheel should t um

freely

with

no T'Ol.Iqhll< sS or t iqllt sPOts .r row - 1

111

,

f ig. 5) .

@



REPL C ING THE FRONT W EEL ADJUSTM

EN

T CONES,

CUPS

A

ND

LLS

Re-ove

fl Ollt

whee l and t he front b

r ke

p

h te

( re fe r to

paqe

611 .

Re-o ve t he

u le

nut on

the

other s

ide

of

the

wheel

IS -

wrench ) . t ooe

ttttr

with t he washe

rs nd s f f ~

dr

ive

un

i t

f ig . I

~

the

sP<Jc

er ind

t he fo.1ll w

asher

.

Re-of f

the

cone lock nut

t ~

wrench) i nd keyed

wisher

. Re-ove t he cone

( f i g

Rewove t be nut .

Rewove Ute two a l l deflpctors us l no , SCrewdrive r i nd t ake care not t o

d

rop

tM b.ll ls . d i

t r

5 .S III b.ll ls

01\

each si de , flq 3) .

~ v t he bear i ll9 cups us ing dr i f t punch nd • •



RE

P

LAC

ING T

HE FRO

NT

WHEEL ADJ

US T

ME

NT

CO

NE S. CUP S.

AN

D BA

LLS

CONT D.

Inst. l l t he

new

hub

be.

rint

cuPS us inq

TOO

l

Ito.

100014 (tubP) . nd •

h r

f

i t 4

).

II Ike sure the u l e is Pl rfl ct iy t

l Ul'

. I f t i s not .

l i t

• F?P

I

ce-l fl t

c

rew in t he new cone on I

_

st so fn: t ne u ll end.

t t he kl yed U he r .nd t he cone lock nut

{1;o 1tC

1l}.

r till CUJls ..

i tll

qreu l , i t t ill

b.l ls

on t he

br. te

d,- . si de

.n d

f i t

the oi l deflec

to r.

Inse r t t he lIe in thl nut , f i t the othl r

b. lIs

and

fh

the other oi l

de

fl

ector ( f iq . 5).

Screw i n till cone lock nut , nd keyed ..

uhe

r . The ....ee

t

s houl d tur n

free

ly

..

itho

ut ph

y.

f it t he 1

000

m

. .Uber

(

rephc

e i t

neces

sary

) , t he space r t ill SPl eOOml' t l r

drf ve uni t , t he ..aSher and t he nut ..i t hout locki nq i t

f i t

the wheel

refe

r to page 6

7)

.

Ti ght en t he ax le nut

On

t he bra kl

sl

dl .

Connec t t he speedometer con

tro

l On t he Sjleedo

Jlll

t e r

dr i

ve unit and

t i

qht l n

t he nut

(l8lml

wrench).

Lock till axle nuts wh

il

e apply i ng t he brakes .



RE PLACI NG REA R WHEEL BALL BEARI NGS

R

emo

ve the r e ~ r whee l pull out the

re

a r brake re fe r t o 66 .

Remo ve t he axle by t apping w

ith

a mal let fig.

I

Remo ve t he s ta r washe

r ,

the shoul de red spacer , and

th

spac r freewhee l s ide .

R

fIlOv ,

t he bea r ing locknut w

ith

punch and h a _ r f i g . 2 .

Rfomo ve t he dus t cap on th e freewh el si de with a sc r

ew

d

ri

ve

r.

Ins r t dr if t punCh and knock out th bear in q d ia

me

t r 3Omn on drUlli s i d

f ig . 3 .

seecve th e beari ng space r and pu

l l

o

ut

t h ot her b u ing {diame t r 2

6nm}

ust ne

s tee l t ube . di ameter 23.

R mo ve the wheel nut and locknut t ha t

re

o ;ned on t he axl e I 7nm wren ch .

Mke su

re

t he ax

le

is tr ue. Fit a re plac

eme

nt one i f i s no

l

Dr i ve home t he new bea rlnq di ameter 3Dnn on brake s

id

e us lnq a s tee l t ube

d i ameter

28m1

1 {fi g . 4}.

IMPORTANT MOH: Insert t he be

ar

ing ve r ti cally t o [l

re

vent the threads f ron be inQ

damaged fi g. 4 .



RE

PLA

CING REAR W EEL

BA

LL BEARINGS

CONT D .

REPLAC

IN

G THE

FREEWHEEL

Fit

tIM be..-

inq l ocknut and punth loc t I t 12 opposl t punch rt.s

Oft thr

n d

ct ee f re-n c l (fI ll·

.

Insu t the- beoarlnq sp

u

r into t he hub and inu rt

theo

2 r.di _ t r bearinG

US

i nll a 2

di_t r steoel t ubt .

•

Ma

ke sure- t h t the i nner dh ,ttr of the beari ngs and t h spa c r a

re

ali ned .

f

t

the dus t cap .

REf

t

NG

THE

XL

A

ND

T

HE RE

R

R

KE

PL

TE

ASS

EM

BL :

Revers e d

is l\il

nt I i n9 procedure-.

t

t he aT

wIIe l

lrefe r to

paOJe 66)

.

REPLAC ING THE fRHW EL :

1lewJ-.e

the-

rear

wh«1

(re-

fer to

~ 661 .

Re-:l-.e the-

fre

ewhe,,1 usilllJ Tool

Mo.

100022 l

fi

q. 2) .

e ~ r s the- proc dure- t o f t theo freewheel.



n

,

m

n

z

m

m

m

r

>

r

m

z

,

m

z

a

o

•

•

m

n

;

;

•

,

N

n

>

•

.

•

,

,

•

·

-

>

-

>

=

·

-

•

I

0

>

R

I

, ,

,

• •

,

•

> 0

•

>

, .

,

• •

-

=

•

•

•

•

•

,



REMOVING AND REFITT ING THE FRONT ND RE R FEN DER S

REKlY

IItG THE f

RONT

FE

NDER

:

- R80V t

tilt

front

~

t o

PfI e

1).

R80ve

tilt

fender

5tay

f h l ll9 bo

l ts

net fender br,cket bol

ts 1

_ ch .

fig.

1 .

Remove t he fe

ndtr.

REFITT ING THE ntONT

FEN

DER :

- geve r

se

t he

r o e ~

REIilVI NG rat

RE R

FE

NDE

R:

This

remov

, l

1 be

e

ff

ec t ed wt thollt

th

e re,r

wh

ee l (a<:cordinll

to

th e cne) .

Re-ove both side cove

rs s

crewd rive r) .

Ile-:lve t

il t

shock MOrtle

rs

lIpper

IIIOl Il

t l n l bol

ts I l_

wrench .

fi

g. 2 ) .



RE

MOVING

AN

D REFITTING THE F

RONT AN

D RE

AR

FENDERS

CONT D.

~ ¥ l

I r

I_ r _ l

ing

bol

ts Ie

nch. f lq . 3) .

R e n J

ue bol

ts n

ur ift9 t he lugg.lqr Cir r ie r r id t o rte f

ender

10 m 5.octe t

Ind

..

nc

h. fig

. 4) .

R e l ~ the re ar moun t i ng 5 Crew 5 (Phil ip head ) o f t he l ugqaqe

rl

ct ( f i g .

4

RI IIO YC bot

h t ool

00 .

Fla

t t

en the an t tvlb rat ion brackets t nside the rende r ,

Di

5.c

onnec t t he ru r wi

ri n

g harn l 5.S (lIIU

l t

i

-c

onnec t or Block) a t the l owe r pa r t

of thl f rame .

Ren :lYl

t hl fender with wiring .

RHITTING

THE RE

Ai FENIl£R

:

f i

t on t ee n

ew

fen

der

.

the

~ r

le

t

lI l

t hl o ld fl n

dtr

: (wi r l nq . suppor t s ) .

~ ¥ l

thr

r t f t I ~ procl d .



REMOV ING AND RE FITTING THE SHOCK ABSORBERS AND

THE SWI

NG ARM

R

H i)

VINGTHE SHOn ABSORBERS

Remo

ve the locknut on t he shock abs

orber

lower

moun

t ing b

olt I3Irm

open

..rench , f 1g.

l .

Remo

ve t he l

owe

r

mo

un

ti

ng

bolts

l3nm wrench .

fi

g.

2 .

Co ll ect

the loc knu

ts

. spacers . and ..esners .

The ..heel and s

wi

ng a

rm

assembly are

now

r t o drop d

own

.

Remo

ve the upper bo

assembl ies

I31rm

wrench. f

iC

.

2 .

Remo ve the shock absorbe rs .

REFITT IN THE SHO KA

BS

ORBERS:

Re

ver se the above procedure but sc r ew in t he rioh t hand lc..e

r

bol t loc knut

before sc rewing the bolt in

fully

. W1en t he

bolt

is sc re

wed

home. the di s-

tan ce between the bo

and the freewhee l preven ts locknut fHtino.



RE

MOV

ING AND REF ITTING TH E SH OC K BSORBERS AND THE SWI NG RM

CO NT D .

R

MO

VI

NG

THE S

WI

NG

RM

:

Remove th

e

re

a r wh

eel

re fe r t o p

aQ

e 66 ) .

Remove the sho ck

absorber

lower eo unt t nc bo

l t

s flQ . 2 .

Rem ve t he driven pull ey re fe r to page 47 ) ,

eeecve t he cha i n tens i one r rm socke t .

Remove th e swi ng ann pivot shaft and nut

7nm

wre nch, fi g . 3 and 4 ) .

Remov

e th e s w; nq ann ,

REF ITTI

NG

THE SWI NG

Pos t ion the swing ann and i nse

rt

t he pi vot bo

l t

Screw i n the nut withou t l ocking

.

Fi t t he chain tens ion er rm wrenc h ) .

Fi t t he chains b icyc l e and engine th rou l h

th

e swing arm.

F t the shock abs or tl er l ower mo u

nt

i ng bolt s wit h l ock nuts 13ll m wrench) .

Lock the nut securing t he swing a

rm

pi vot s haf t 17

nm

wre nch) .

f

t he dr i ven pull ey re fe r t o page 48 .

Fi t the rea r whee l refe r

to

page 66 ) .



HOT OBECANE T

ROUBL

E SHOOT ING GU

IDE

TIM

fo

l l

ow ing guide i§ des igned

to I Pduce tIM

_ nt o f tilllP

~ troubl

e

shooting.

s e

.....

i ce problPII .

When

l P.dl ng t hrough thP t roub le shoo

ting

g

uide.

of

the

steps

w

i l l

be

~

f e l P n l : e d

w

i th

t

h@

s) ltJol (6VI . T

his

I'Oti

tlon

I P-

fel S t o

Nchines

n u

t u ~

by Ko t obeurot p

rio

r to

J .

nUiry 1. 1918 • • nd

Mc

h ~ ~ u i p p p i t h . s h ( 6 f t

llqh

ti nq syHPII. Subspquently , .11

Hotobeune t o ~ s

N nu

hc

t u

l P

d

fo r thP

lhi te

d S

t i tes .He r J.nUiry t .

1918,

. re

pqulpptd

with . IZ

vol t

li ght

ing sys tPil .

H[lPfUl. HIIlTS;

1. Wlltn troub

le

shoo t ing e le c t ri c.1 ~

t ~

qu

ickest

. nd

Pl s

iest

_thod

Is s ubs

ti

t u

t i

on .

Al

Kak

e sure t

h.t

t il t p.lr t bP

inq

used

in

t h@ s

ubsti

.

t ut lon

Is

t o bP

good

.

8)

Wl\t

n a pa

r t

s Subst i tut ion Is l o lie and th@

pr

oblPil

is not solv

ed.

le

ave tttf newly

su

bs

t i t

uted

part

in the syH e.. u

ntil

th e problN is found.

Then,

l>dck tra

ck one C()OIlponent at a time . This

lIle

t hod

i l l

enab

le

you to mo

re

effective ly

tro

ubl e Shoot

a

ma

ch

lM

which

lIIoly

have

multipl

e problems .

ENGINE

I . E

NGI

NE

Wl l

NT

STA

RT

Check for spark

at

spark pl ug.

Chetk

for

flow

res tr ic t

ions In

the

f uel sy

s t

l'll.

Che

ck eng

ine

co-pression

by t urn i ng

the

cl

ut

Ch

d

rUII

by h

.nd

w

i th

t he

spar

k p

lug

i ns t i l l ed.

- -0)

Ch

eck t o

U e.

t ilt enqine s top swi

tc

h is in the run pos1·



MOTO ECANE TROUBLE SHOOTING GU IDE

E

NG

INE

CO

NT D .

Il l . GOOD IGNITION SPARK,

UT TH

E ENG INE

Wi

l l NOT START

A)

l l e c o

m p r e ~

ad

justed

too t iqht

B) Res

tr iction

of f uel

flow

(Ex. fue l t a

p

fue l fuel

ne ,

C) gas

ket

OJ Igni t ion t iming

incorrec tl

y se t

Fau ty

in le t

pipe gas ke t

F)

Exh

aust

po

r t

and exhdust

pipe

c l09ged

IV .

ENGI

NE

RUNS

, UT

H S

A HIGH

SPEE

D MI SS

A) Faulty or wor n

spar

k p1u l

OJ Improper ignition t i ming

Cl Faulty s u p p r e ~ ~ o r

Faulty

hig

h tens ion co

il

E)

F

ault

y or wor n i gn t ion poin

ts a nd

F)

Fau

t

y hedd gasket

G)

~

u b

le

d j u s t e d

t oo t i ght ly

Hl Air t eak bet

we

e n i n le t pi pe and cyl i nde r

I}

[ x h a u ~ t

s y ~ t e m c l ogged

V.

EN

GINE

RU

NS ,

UT

HAS l OW

SPEED

HISS

A)

Imp roper spar

k pl ug

B) Improp

er

i gni

tion

t imi ng

cl Fd

ult

y or wor n o

ut

ign

t

i on poi

nts condenser

0) Faul

ty

r adt o

supp

res

sor (spu k

p1

u

l

cove

r

E) Magn

e t o rotor rubbi ng on

Inter nal

co s

VI

. ENGINE

POPS

N

D

B

C KF

IRES

W EN TO START



M

OT

OBE

NE

TROUBLE SHOOT ING

GUI DE

ENG

IN

E.

ONT C.

IX

.

EXCESS

I

VE

FUEL ONSUMPTION

A

Engine

is

not bro ken

in

600 m

i les

B) choke valve par

t i

ally opened at

all t i

mes

C) r e t o r flooding s

tic

ky

flo

a

t

0) Leakage in file I

l i

ne

X. ENGINE

H S

NO PO

WER

A

Improper i gni

t i

on tim i ng

B) Clogged exhaus

t

po

r t

or pi pe

C) Deco mpression cab l e too t i ght

0) Fuel r es tr i ct i on

[ Wo

r n out p iston

ri

ngs or engine s ea

ls

Enginll pa

r t

i a l ly seized

G Moplld chai ns t oo tig ht

H) Br akes too tig ht

X

T

HE

EN ;I

NE

vtu

R

ONLY IF THE C

HOKE

IS

USE[

A) Clogglld j e t i n ce reure

tc

r

B) C10gqed fuel 1i nll

cj

Cl ogged

f il

t er i n ee r buree cr

or

gas

ta

nk

oj Clogged fi

l t

e r cap vent M1e

[

Loose or crack ed i nl e t pipe and gasket

F) Loose ca rbure t

or

XII

ENGl

NE

WLL RUN BUT

WO

N T I OLE

A) Id l e

ct

r cut t I n ca rbure t or cloqged

__ . 8) Thrott

le

s

l i

de h

ci

ng wrong di r e ct i on i n



POO R EHr INE

PERF

OR MANCE

Very o

ft

en poor engi

ll@

perfo

....

nee

lI Iy

not ee .-e

la

ted to the

e n ~ i Itse

l f ,

but t o coe

or

seyera l f requent1)l unsuspec

ted

secondary ca uses.

III Such a case , we sugges t th e

Check th

at

t he

decomp .-eno

r control

is

not

or

has II0t

bEoen

ove

radju

s t ed

which mi lht

dall< l

qe t he vah e alld entail COlllPren i oo l oss

( t

his

is a f.-e

'1uent cause ).

CIleck t hat tile th

ro

t t l e

slide OPMS

fully . Quite o

ft

en the contro l is

badly adjusted . nd tile en tin e is s t ~ even t full thro t t le posl ti oo.

3.

Che

ck that the.-e is no br .Unq a

cti

on due to ch. ins belnQ too t iqh

t

In

t his

re spect

, on f t)byle ttes

f i t te1f

wit h a swillg

,a

r suspension . ten

s ion ad

ju s

tJlle

nt IllUS

t be per fonled in t he rvnn ino pos i t ion, t he IIla chille

loaded with a

rider we

ig

hin

g about 165 l b

s.

4. Ched va

rh to r

oper

ation.

5.

Ma

ke su.-e the

bel t is

co

rrec

t

1)l

ali

gned.

6.

M l

ke su

re

the brakes

.re

not a

dju

st

ed too

tiqhtl

y.

7. Check t h t t he fuel cap

nn t hole is not c oq led th is

y bri n9 a

bCIut

poor f uel supp1)l.

8.

Ched tha t the Spu k plu , is i n accordance wit h

th

e ....nufa

ctu

.-er · s s

peci

f ic

at

ions .

g. Check t

ha t

t he exhaust

is

n

either

par

th l ly

bl ocked liar blocked. If

th

is is t he case ,

cle

an out t he

e

xh

aus t sys t em.

10. Very

hopo

r

Un

t ee te r- Quite of

le

n poor enq

ine

perfomlolnce

My be

caused

by over tightening the cyli nder head nuts and the cyl in



MO

TOHECANE

O

SHOOTINr. GUI

DE

LI GHTI NG CIRCUIT .

CO

NT

D

• •

I I .

NO

l [GHTS

A) Faulty br .k. li5ht d t ch

B) Faul ty 9round at 'al fendel

C) F

ault

y t o l l l it)ht co i l or

9T Oun

d

equl pPi1d wllh 12

1

sys

t< Ol1)

H I. DIMLIGHTS AN D KG NCIIN liNEN 1t(A.OLAIlP S:.IITCIt IS

O

A) Faulty l ener diode ' ( 6

1

)

B) r u l t

y l i 9h

tl

r.

9 co

i l

C) r aulty brOOM ..ire or cOII

,2(:

tI0 l

0) Incor rec t bulbs

IV.

nCfSS YE LI

GH

T ct,uSI

NC lJlKl

A}

Faul ty lenel t iode °(6

1

)

B} Incor N;:ct bu

l t

s

v.

NO

I R

N

AI F

ul ty l ener diode ° (6

1

)

I F u

lty horll uni t

C Fl ulty s

D) Faulty horn

l 1 .

or ccnee

ct

tcns

VI.

W

(1f LI

GHT

S TURN£ O

ON

.

THE

ENG

INE

STAllS · (6Y)

j

Fdul ty eener diode ' (6 1 )

Fau

lty

u

d llll'p

$w

t l:

h

°(6'1)

o

j Fau lty ereee ~ t 0{6V)

F

aulty blaC.k

wire or con

necti

on In lftI'lneto

n t e S S

°(6

1

)



R

H

. S

TOP

LGHT SWITCH

I

I

BL

ACK

YELLOW

MOTOBEC NE WIRING DI GR M

12

VOL

T

MACH

INES MA

UFAC

T

URED

AFTR

JANUAR

Y

1 978

:u

I

I

IOl ET

REARUGHT

§

FLYWH EEL MAGNETO

V

OLET

GREY

BROWN

WHITE

WH ITE

..J

o

o

I-

:I:

z

:

o

'

GREY

>

ro\/lIllDS

PLUG

-

...J

o

>

15

...J

...J

W

>

YELLO\

- -

I

SP EEDOMETER

LITE

VIOLET

HORN AND

ENGI

NE

KLL S

i TCH

L

H

. STOP LIGHT

SWITCH

lD

o



RIGKT-HAHD

STOPCDNTACTOfl

REARUGHT

s

..

'

4CHANNB CONNECTOR

aLA

ROWN

FLYWHEEL MAGNETO

GREY

'

TOWARDS

SPA KltG

PLUG

~ l

H ~ L

=\ I

....

B

LUE

GIlEEN

REO

III

i l d ~

DLAMP

8l-UE

Z ::: ,i-- GREY

, \

I

HORN

I ';

\ } i

. . . Q ; ~

SPEalOMETER

UTE

I

i -

I •

~

w

°

ill .

1

I

I

i

' I

I

Ci

ENER

[ jOE

MOTO EC NE WIRING DI GR M

(;;

0:

<II

OflNCONT CTOR AND

ENta lECUT OUT SWITCH

motobecane repair manual

Documents