SHOP MANUAL. Sprite - Barracuda. 125cc 200cc 250cc FOUR AND FIVE SPEED

Transcription

1 _... Sprte - Barracuda SHOP MANUAL 125cc 200cc 250cc FOUR AND FVE SPEED COSMOPOLAN MOTORS..NCORPORATED JACK~ONVLLE & MEADOWBROOK ROADS, HATBORO. PA r (215) OS f.

2 t:nulnt: - ::ngle cynaer 4 stroke - uver lledo vaves - oore :J4 rnm. -.:truke ::"l mll. - \..yue dsplacement 123,7cc. - Compresson rato 9,5 to 1 - CV. 16 at R.P.M. - Dstrbuton wth stand3rd cam - ntake open 30 BTDC - ntake close 75 ABCD - Exhaust open 75 BBDC - Exhaust close 30 ATDC - Valve clearance wth hot motor 0.006" - Forced lubrcaton by gear pump 60 L/H Ol capacty 2 qts - Gravty fuel supply 98 to 100 octane - Carburetor UB 22 BS - gnton by alternator flywheel magneto wth external H.T. col - gnton advance 19 - Plus automatc advance of 25 - Pont gap 0.016" - Marell Plug CW 260 L - Champon plug N. 3 - Wth multplate clutch - Costant mesh gear box - Foot shft pedal - Prmary transmsson by helcodal gears - Secondary transmsson by chan 1/2" x 5/16". FRAME. Combnaton of pressed steel and tubular " Double acton hydraulc front fork - Rear swng arm wth adjustable hydraulc shock absorbers. TRES - Prell 2.75 x 18" (rb.) front wheel x 18" (unv.) rear wheel - Expandng type brakes. LGHTNG EQUPMENT - Alternatng current 6V 7 amp equpped wth battery to ensure steady supply of current to lghts and horn - Large 130 mm. headlght - Headlght: 6\1 25/25 S. B. OVERALL DMENSONS - Length 76.44" - Wdth 27" - Heght 36.64" Weght 229 bs. (DRY) - Fuel tank capacty 3,5 gallons - Reserve.05 gallons. Maxmum speed 7~ MPH - Fuel consumpton 90 MPG. MOTORCYCLE 200cc. (Techncal data dfferent from 125cc.) ENGNE. Bore 66,5 mm. - Stroke 57 mm. - Cylnder dsplacement 197,9cc. - Compresson rato 8,8 to 1 - CV. 19,5 at R.P.M. -Carburetor UB 22 B5 - gnton advance 9" 30' - Plus automatc advance of 29" wth flywheel magneto ADP 791 AN.. (Note: wth flywheel magneto ADP 54/2ANB gnton advance 17' - plus automatc advance of 25"). TRES - Prell 3.00 x 18" rb. front whee! x 18" unv. rear wheel. OVERALL DMENSONS. Weght 231 bs. (DRY) - Maxmum speed 90 MPH - Fuel consumpton 85 MPG. MOTORCYCLE 250cc. (Techncal data dfferent -from-1-25cc.) ENGNE. Bore 74 mm - Stroke 57 mm - Cylnder dsplacement 245.1cc. - Compresskn rato 8,5 to 1 - CV. 24 at R.P.M. - Carburetor US 24 B5 2 - gnton advance 9'" 30' - Plus automatc advance of 29 wth flywheel magneto ADP 79/AN and ADP 78/2ANB. TRES. Prell 3.00 x 18" unv. front wheel x 18" unv. rear wheel.. OVERALL DMENSONS. Weght 232 bs. (DRY) - Maxmum speed 95 MPH - Fuel cons'jmpton 80 MPG. 2

3 , 2: \ \., \ \ 2B 1 Front fork 14 Petcock 27 Rear foot rest 2 Front fender 15 Tool box 28 Stand : Headlamp 16 Strap 29 Kckstart 4 Swtch key 17 Seat 30 Foot rest.),. Clutch lever 18 Rear lght 31 Brake pedal Dmmer swtch 19 Rear fender 32 Ol dran plug ' Damper 20 Shock absorber 33 Clutch adjuster B Handlebar 21 Chan guard 34 Frame 9 Front brake lever 22 Rear wheel 35 Horn 10 Throttle control 23 Rear hub 36 Front wheel l Gas cap 24 eh 37 Front hub 1:1 Carburetor 25 Chan adjuster 1 :3 Gastank 26 Rear fork 3

4 Specal tools are made n order to facltate dsassembly and reassembly operatons, and used wth metrc wrenches, wll enable you to perform all necessary operatons. A B~ ' ~~ ~ ~ T~ A Thread protectng bushngs B Pston pn shaft extractor -l C Pston extractor.j o Countershaft sprocket holder E Countershaft sprocket wrench F Engne pnon holder G Engne pnon puller H Engne pnon puller Flywheel magn~to holder L Flywheel magneto extractor M Clutch hub holder 138&139/MB 144/nB 141/HB 140/HB 13 11MB 1431MB 146/HB 13 21MB 1371MB 1301MB N Clutch sprng tool o Unversal puller P Cam follower bushng extractor Q Crankshaft spacer R Kch starter sprng holder S 5mm Allen wrench T Shftng drum puller U Cam gear extractor V Engne support 3 SHB 133/HB 134/HB G MB G / /HB 1451MB 4

5 Before performng any operaton, t s advsable to thoroughly clean the machne, n order to prevent any dust partcles from accumulatng on engne components. "' 1 ) Remove engne ol, usng 27mm wrench to unscrew ol plug. Then remove ol flter assembly. 2) Loosen carburetor clamp wth 8mm wrench and pull out carburetor after ar fìlter has been removed. -:3) Remove electrc wres from juncton box. 4) Unscrew fuel lnes wth 12mm wrench. 5) Pull out engne breather tube. 6) Loosen clutch cable clamp and pullout cable. 7) Pullout the spark plug cap. 8) Remove wth plers, master lnk clp, master lnk and chan. 9) Unscrew foot peg bolts wth 17mm wrench. Remove knurled nut of brake rod. 10) Remove exhaust ppe and muffer. 11) Unscrew lower engne stud nut usng 17mm wrench - press out stud. 12) Remove upper engne studs nuts wth. 14mm wrench, also studs and engne from frame. To reassemble, reverse above nstructons. 5

6 " -" Engne vew flywheel magneto sde ~-- Engne yew clutch s.de NOTE: Due to the unque characterstcs of the engne, most of the operatons shown n ths book can be made wth the engne on the frame. Only f the crankcase must be splt, wll engne have to be removed. By removng the left hand cover, the flywheel magneto, clutch adjuster and countershaft sprocket are accessble. By removng the rght hand cover, the clutch, preselector components and cam dstrbuton gears are vsble. These are operated n ol bath, therefore, ths cover must be perfectly sealed. The cylnder head, rocker arm and cylnder are removable from the front sde. 6

7 uu..vyc; \JYVVCC (la~'tau ~U~J Wltrt tool Sf removng the three fastenng screws. Remove the flywheel magneto nut, usng 19mm wrench, holdng at the same tme, the flywheel wth tool. Lock the flywheel puller L n poston and wth 22mm wrench, loosen the flywheel from crankshaft. Tap on the puller bolt slghtly wth a hammer f the flywheel s hard to remove. -;: Before removng the backng plate, t s advsable to made a reference mark on the crankcase n order to facltate the reassembly operaton. 7

8 Remove clutch lever support screws usng tool S. Wth screw drver, unscrew flywheel protecton cover fastenng screws. Holdng kck starter sprng wth tool R, remove wth screw drver the sprng fastenng screw. To remove countershaft sprocket t s necessary to: ) Lft up the safety washer loop. 2) nstall the specal tool D. 3) Remove the nut wth specal wrench E, holdng at the same tme the countershaft sprocket wth tool D. 2 ~ 3 8

9 W th lomm socket wrench, remove the 4 rocker cover fastenng screws. Pull out cover and alumnum gasket. Before removng wth 12mm socket wrench: the four cylnder head nuts, be certan that the pston s n compresson stroke poston. Pull out the rocker arm support carefully n order. not to damage the threads of the cylnder studs. Pull out the cylnder head, gasket, cylnder and base gaskets. 9

10 Remove wth plyers the two pston pn crclps. nsert the pn B n the tool C. nstall the tool C on the pston. (t s advsable to slghtly heat the pston before removng the pn). Turn the spndle untl the pston pn s removed from the connectng rod. NOTE: t s not necessary to remove the pston rngs, to remove the pston. 10

11 After the shftng lever has been removed, unscrew the 10 Allen screws wth the tcol S. Tappng slghtly wth plastc hammer, pullout cover. ~, o#~" Dsmantlng of the clutch Wth the specal curved tool N, dsconnect the fve clutch sprngs. ~.. "-:. ~~~:;~:K.~;"'.:...: Remove the clutch plates and the short clutch rod. Lft up the loop of the safety washer (bent over the nut)

12 Holdng the clutch drum wth specal tool M, unscrew the lockng nut usng 17mm wrench. Then pullout the clutch drum, thrust washer, clutch crown and second thrust washer. Pullout the preselector shaft. Holdng wth specal tool F, the engne pnon gear, remove the cam gear and engne pnon gear lockng nuts. Wth specal puller G, remove the el1~ne pnon gear. NOTE: f the specal puller G can not be use, use puller H. Usng extractor 0, pull.out the cam gear. NOTE: Use specal puller U wth gear havng two threaded holes. 12

13 After the nut of the selector drum has been removed, usng 11 mm socket wrench, pullout drum wth specal tool T. Extract the Woodruff keys of the engne pnon gear, cam shaft and desmodromîc shaft. To remove the Woodruff key, t s ùdvsable to use a small pn n order to rotate t. To nstall Woodruff key, hold wth plers and tap slghtly. How to splt the crankcase: Remove the four ol pump bolts wth 10mm wrench. Use 11 mm wrench to unscrew crankcase stud nut from one sde, then pull out the stud. Unscrew and remove the Allen bolts, usng tool S. The screws are ndcated on sketch on page Wth a pn, press out the crankcase centerng bushng. 1 3.

14 14.

15 1 5.

16 nstall the protectng bushng A tghtly on the crankshaft. t s advsable to slghtly heat the crankcase before proceedng to splt t. (140 F. H.) Tap slghtly wth plastc hammer on prmary shaft and crankshaft untl the rght hand crankcase s separated from the other half. Remove all the components and clean thoroughly. To dsassemble the crankshaft from the left hand sde crankcase, nstall tghtly the coarse threads protectng bu~hng and proceed as per above nstructons. ~. 0 ~-,ì --. ß'n ~, )th \~ ~~'\ ~~~ J$ Heat the crankcase at approxmately 1401 to 1800 Fahrenhet before removng bearng from t. To remove the camshaft and fnal gear drve bearngs from left hand c.rankcase (flywheel magneto sde), dsmantl.: the two bearng covers and press out. To replace the cam follower buslngs, use specal extractor P as ndcated,n the fgure alongsde. 16.

17 the seeger rngs and other components. NOTE: The two half crankcase are joned wthout gaskets, therefore, any mperfectons of the conract faces must be corrected. r-.-.. " -..j1)-~.-\/7~ --7\ Ì7 V\. ~,'0\ ". 10, \ j '\'" ~o\ ~\~~\. \ /~,~,~ fí \ r. ~, :' \,'="'\\ \\'to '. \ \ \\~4~~' \ \\ /1 l)~&\ \,0 ). \\ \LL-,. / /'~ ' \" mr,. \.,-".Y, p \oll~ \\7J'- \~,-. "" ~ \\ L-. ~ \ '.:" J -;l~~-~~ -; ~~~ ~~ -.-.\ 9\ (~0., ~~ì~~. ( \e \,\ /'~~M~=\., ('-J,R., ~.\\ =-' ~,.. \v/:c~'~~\~~~\\\ ~ / 7 / ~.U- -:~ \NJ( :. \ " ', ~~' / /'--'j \~j./ 1 ~-=~, ~~. ~.., \,.' \ t:~~"--/./ Lst of seeger assembled on 5 speed engne crankcases Left hand half crankcase, (Flywheel magneto sde). No. 2 seeger rngs type 47 J assembled nto the man bearng seat. No. 1 seeger rng type 47J must be nstalled after the large bearng s assembled. Rght hand crankcase (clutch sde). No. 2 seeger rngs type 47 J assembled nto the man bearng seat. No. 1 seeger rng type 40J assembled nto the camshaft bearng seat. No. 1 seeger rng type 40JV assembled nto the prmary shaft bearng seat. No. 1 seeger rng type K assembled nto the secondary shaft bearng seat. NOTE: Ths seeger most be nstalled (after the crankcase are joned). Lst of seeer rngs assembled on 4 speed engne crankcases Left hand half crankase (Flywheel magneto sde) No.1 seeger type 47J assembled on the man bearng seat. Rght hand half crankcase (clutch sde) FOR 200cc and 250 ce. No. 1 seeger rng type 47 J assembled nto the man bearng seat. Rght hand half crankcase (clutch sde) FOR 125ec. NO.2 seeger rng type 47J assembled nto the man bearng seat. NOTE: All the other seeger rngs are nterchangeable. After all the seeger rngs are nstalled nto the half crankcases and before the nstallaton of all the bearngs, t s necessary to heat the crankcase at approxmately 1400 to 1800 Fahrenhet. 1 7

18 t ~....' r! " - ::"-"."..,~ ":~~7~'..~~.,.~.,,;;~, : --;-."N.. '~""c;,íc'~. Lst of bearngs nstalled nto left hand crankcase (5 speed engne). 1 Bearng for crankshaft (nner sde ). 1 Bearng 20x47x20,6 (double race) for crankshaft (external sd~). 1 Bearng 25x52x12 for prmary shaft nstallaton from the external sde of crankcase. The bearng must be even wth crankcase face externally_ 1 Bearng 12x32xl0 for camshaft. 1 Steel bushng for secondary shaft needle cage nstalled nternally. 1 Cam follower bushng. nstall the seeger rngs J 47 from the external sde. Then nstall the ol seal 20x47x8. nstall ol rng nto the kck starter shaft hole. :r- \' \"':. 1 8

19 1 Bearng for crankshaft nstalled externally (20x47x20,6 wth double races). 1 Ol seal 20x30x7. nstall the crankshaft ol seal nto the threaded r ng (20x30x7). Assemble gasket and rng on the external sde of crankcase. The ol seal and plate of the fìnal gear drve are assembled on the external sde of crankcase. --, The specal supportng screw of the dust protectng plate must be nstalled on the upper sde of the engne (see pcture alongsde). nstall the cam shaft bearng cover wth the respectve gasket and lock the three screws tghtly. nstall the fìnal drve gear (nternally) and from the external sde, press n the countershaft sprocket spacer. Assemble the countershaft sprocket. 19

20 !. "~.' :~:':~::;~-~::.~t! ~:~::::~.::?~. -'-'~:~ nstall th the fnal ~,two clutch rod rve gear. ol seals nte. Assembl.e specal safety washer. j 1 Use spe ca. to countershaft 0 s D and E Bend safty washer sprocket 0 v-r '" nut. nut (F;o -LB f- lock 65). the ace. - ~ ~ 20

21 nally t: UX4/X:LU,ó C1ouole race). NOTE: For 125cc. (1 Bearng 20x47x14 sngle race). 1 Bearng for crankshaft - assemble nternally 25x47x14. ~- 1 Bearng for cam shaft 17x40x14. 1 Bearng for prmary shaft 17x40x14. 1 Steel bushng for needle cage of secondary shaft-assemble nternally. 1 Brass bushng for kck starter shaftassemble nternally. 1 Brass bushng for desmodromc shaftassemble nternally. 1 Cam follower bushng. 1 Brass bushrng for preselector shaft assemble externally. 1 Kck starter lever stop plate. 1 Ol tube and seal rubber rng. 1 Lower crankcase centerng bushng. 1 Breather tube. lst of bearngs nstalled on rght hand half crankcase. (4 speed engne). ". "' \1. f\\ ry, N,..~ --~',.J'. ''; '--;' For 125cc - 1 Bearng for crankshaftassemble externally 20x47x14. 1 Bearng for crankshaft-assemble nternally 25x47x14. For cc - 1 Bearng for crankshaftassemble nternally 25x47x14. 1 Spacer externally. 1 Bearng for crankshaft assemble externally 20x47x20,6 double race. All the other parts bearng and bushng reman unchal1ed- as per 5 speed. ') 11 Mane bearng assembly 5 speed engne. 2'1

22 A.. ø...: CRANKSHAFT ASSEMBLY TECNCAL DATA AND CONTROLLNG ECCENTRCTY A radal play c:onnec:tng rod B connectng rod sde play STD. 0,010 -; 0, " -; " STD. 0,100 -; 0, " -; " Max allow. Lmt 0, " Max allow. Lmt 0, " C pston pn play D.E 20 mm. = (0.787") STD. 0,015 -; 0, '" -; ".- Max allow. Lmt 0, " at Maxmum the pont excentrcty D-E ndcated admssble, n the measured fgure ( ") 22

23 w.~f~-~~l~f ( CD"" 0 6' '" 0 Gl _"n ~" ~J U J~ - =1(*~~~~ =.l~~ ~-:Mr~......==~~U1 =::-:~~ Gear box rato For S0cc.. Ençne gear box rato = 3 tol nternal bear box rato 1st nd rd th th For 125cc. Countershaft sprocket = 15 T Reôr wheel sprocket = 44 T Fnal rato 1st nd rd th th For cc. Countershaft sprocket = 17 T Rear wheel sprocket = 41 T Fnal rato 1 st nd rd th th

24 ~' :1 ~,.l? aò~ ~J.~\ _.,-' ' ~~L. ~1J' ~ ~~o~. ~h,~~ : _ '- CE~J~~Gr"J'~. r 1~~m~fÌk ~ -c r&l~ 'r.,~)\0j~ ~"' '... :~~ ~.: ~. '~'o)., ~.~, ~""-Z" ~ ~ ~:t:,: 00-~. '/:!::' ~"d _ G=- --:;' :'\'?:,-~,',a-', ~~~ &~,._ ~. ~~d:. :. :..~,.,~;.; ''-...j\:~..~ r' /)~. "\~''Ý!.O/d~/ n ; ;-). /.., j, '.'. ~T-~'\~lJ~~! --. '----', ~..~ J:)!... ~~,:jr-. 'l.! "~~y /' -..z...~"r ~:' / ~..~-~((- ~ ( ~4r:l 'l!.tl-.~. CD 0:: ::~ -:~ ~ ~~u o 1 -_...~T~ Gear box rato For S0cc. Engne gear box rato = tal For 125cc. nternal gear box rato' 1 st nd rd th Countershaft sprocket = 15 T Rear wheel sprocket = 44 T Fnal rato 1 st nd rd th For 200-2S0cc. nternal gear box rato 1st nd rd th Countershaft sprocket = 17 T Rear wheel sprocket = 41 T Fnal rato 1st nd rd th r r

25 Heat the crankcase at approxmately 1400 to 1800 Fahrenhet before proceedng wth the nstallaton of the varous groups. nsert the adjustable specal spacer Q n between the two half crankshafts before assemblng ths group. nsert n the fìnal gear drve the followng: Frst needle cage Spacer Second needle cage nsert the needle cage nto the steel bushng of the secondary shaft. nsert the gear box assembly nto the proper seats. NOTE: For the 4 speed gear box - proceed as per above nstructons. 25

26 nto respectve seat of the crë~nkcase. Protect the end of the shaft wth ù layer of scotch tape. NOTE: Before proceedng to jon the rght hand crankcase, be sure that the ratchet s facng towards the lower part of crankcase as shown n the pcture. Clean thoroughly the ol passages of the cam follower and nsert nto the bushng nsert cam. taportj.n NOE On all engnes for Sprtes and Barracudas, the cam followers together wth the ol passage tubes, play an mportant part for the lubrcaton of the valves and rocker arms (see next page) the' ol s forced through the cam followers and push rod. Ths prevents nose and wear to the parts subject to constant poundng force. o 26

27 .:-_..-. _..._.....'1 \.11.. JUlf "-101'''- cases contact faces, and assemble the half case, beng careful that all the shafts are algned wth the respectve seats and all the components are n the proper place. NOTE The cam follower shoulder must be aganst the bushng and the cam ramps must face toward the back of the engne. J! When all the shafts are partally nserted nto the seats, tap slghtly and evenly the half crankcase and completely close. nsert and tghten evenly (crosswse) ar the screws as shown n Fg. on page Assemble the needle cage nto the steel bushng of the secondary shaft and nstall the seeger rng.._-;," ~~. ~ ~'...,-. ~..d. " "~'~::;-"":'-:~l:';;;'''''' 27 Remove the adj ustable spacer Q from the crankshaft. Free all the shafts tappng slghtly on the ends wth a plastc hammer.

28 (\cê ( (-- ï: ) 0 (l '\! f \ \~J (((() \ \~ß?U~\( 0)) On the rght hand cover nstall th~ gear stop lever sprng, lever and seeger. Assemble Woodruff key and shftng drum nut and tghten frmly wth 11 rnm socket wrench. l! ì! _..~~' -tr-"=., J Y _... t;h ø...f ~:)J \ -,'.yr,., '--~",.:C ~\/. ~-'~t-:'-'-~:'~~~l nsert the ol pump rubber rng nto the ol pump seat and slde t nto the cr::nk case from the bottom. NOTE: Algn the reference hole wth the pn of the crankcase. r! Use gasket cement on the ol pump gasket 'nd the four screws. -, Assemble the preselector shaft 3nd thrust washer. 28

29 second Trust washer..,. ';.-.. "' " Before assemblng the clutch hub, be certan that all the clutch sprng hooks are all facng the center and at the same heght. NOTE: t s mportant that the clutch sprngs are even wth the dutch hub face. Slde on the prmary shaft the clutch hub. nstall the safety washer and lock the nut at ft. lb. Bend the loop of the safety washer over the lockng nut. 29

30 f G).~. " ",,. j ~ \~ \ ~(\ l ft~ \~~. \~? Exploded vew of the clutch assembly for 12Scc (4) four and (5) fve spe engnes..1.. '. ".- " ~ lq)1.: '.

31 :~ (. ~,-. '. 'd'. "" -.".,'.'.,.-.,.,-,.~:'t.~,~ tzl ".. nsert the clutch dscs n the proper sequence as shown on page 30,,:~,L -."..'.'.._,.._..-..., ~',." -f;.:'..~...,..._...._=-...~-:~.._- nstall the 3/16" ball and the short clutch rod..,_.. Assemble the pressure clutch dsc wth the slots correspondng to the hooks of the clutch sprng. Set the clutch sprng retaner rng on the clutch pressure dsc and attach the sprng usng specal tool N. NOTE: The slot of the clutch sprng retaner rng must be placed n the center of two slots of the clutch pressure dsc. 31

32 ( nstall the Woodruff keys an:: assemble the two gears, matchng the tmng marks. ----~). ;';vç, Ca tmg tlutrh ttl,~ The prmary transmsson s composed of three helcodal gears of hgh precson whch are accurately matched by the man. ufacturer. The tmng of the engne pnon gear wth the cam gear determnes the dstrbuton of the strokes, whle the reference mark of the clutch crown s to set the gear n the same poston, to avod any gear nose. Procedure of dstrbuton tmng. nstall engne pnon gear. Match mark (dot) of engne pnon gear wth the dots of clutch crown. Rotate crankshaft clockwse untl the Woodruff key slot reaches 4 o'clock poston. Turn cam shaft untl the key reaches about 3 o'clock poston, Match the dot of engne pnon gear wth two dots of C2m gear..'",. /.;~;.. r?:;l;.::~;' NOTE: When nstallng the cam gear, be certan that Woodruff key matches the key slot of the gear. nstall the gears nuts and tghten at ft. lb. usng the specal tool F. To hold pnon gear. Assemble the lockng nut 2nd tghten at ft. lb. nstall the 4 cylnder head studs usng a nut 2nd lock nut. 32

33 t-):.. 04'.'::SOCc. ~..-.,, ct. Pston wth ndcatve measurement for 2ach model. 15 CYLNDER-PSTON TECNCAL DATA ~yon! P 1'., 125 ce. assembly (') j ay at.mt! Cylnder Pston Gradng Mn. Max. or...ar 54 (2,1259") 54 (2.1259") Selecton: Selecton: \ 0 A \ -0,030 ( " ) A 1+0,010 ( " ) ì New ( ") B +0,010! ( " ) \ ( " ) B í + 0,020 ( " ) -0,030 ( ") 0,030 0,050 0,120 L ) ( " ) \-0,010 (,000393") C +0,0311 ( ") -0,020 (,000787") J oversze 54,2 (2.1338" ) 54,2 (2. 338") 2nd oversze 54,4 (2,1417") 54,4 ( ") rd oversze 54,6 (2.1496") 54,6 ( ") 200 cc. Gradng Cylnder S~ecton : Selectc : c Pston ( " ) (001968") ( ' ) As per STD! As per STD Pa y on assembly (.) Mn, Max. 66,S :2.6181" ) 66,5 (2.6181" )! \ ( ")! A ( " ) A ì -0,045 ( ") ì +0,010 New ( ") ) +0,010 B \ -0,025 ( '') B +0,020 ( ") --,035 ( ") A s per STC Play at lmt, of "'.ar ,: 50 \ ( ") \ -0,015 ( " ) (,001278") ( " ) ( " ) C ; + 0,030 (,001181") C í --,025 ( ") 11 st oversze 66,7 (2.6259" 66,7 (2.6259" ) 2nd oversze 66,9 (2.6338" ) 66,9 (2.6336" ) As per As per - sm STD STO ; As per j3rd oversze 67,1 (2,6417" ) 67,1 (2.6417" ) '--" ce. Gradng Cylnder Pston Play On assembly (* ) Mn. Max, of wear -! Play at lmt 74 (2.9133") 74 (2.9133" ) Selecton: Selecton: New A \ -0,045 ( ") ~ +~,010 ( ") A ( " ) 0,045 0,065 0,150, 1st oversze ) +0,010 ( ") \ ( ") ( ") B / +0,020 (.0007B 7" ) ß -0,045 ( " ) 74,2 (2.9212") 74.2 (2.9212") 74,4 74,4 (2.9291") í,002559") ( _005905" ) As per.2nd oversze (2.9291") 13rd oversze 74,6 (2.9370" ) STD As per! :;TD STO 74.6 (2.9370" ) NOTE; On the cylnder the selecton letters A-B-C are stamped On the Upper Face. The selecton letters A-B-C of the pston are stamped on the pston top. 33 As per

34 ~,. ; Assemble the ol rng and pston rng n the sequence as shown n Fg. ) Assembly of the pston Before assembly, check for wear (see techncal date). nstall the pston rngs on pston. nstall the pston pn nto the pston hub and slde t nto the specal tool C.., Lft the connectng rod and at the same tme, slde the specal tool through the cylnder studs untl the pston pn s n algnment wth the connectng rod bushng. nsert the gudng pn B at the opposte end of the pston pn. 34

35 Turnng the spndle of the tool, drve n the pston pn untl t s level wth the crclp groove. t s advsable to heat the pston at Fahrenhet before the nstallaton of the pston pn. ~;~ Use needle nose pler$ to nstall crclps.,. nstall one thn paper gasket, specal alloy gasket and a second thn paper gasket before assemblng the cylnder. Lubrcate the pston and cylnder wall. Assemble cylnder whle pressng the rngs wth fngers n order to facltate th:= nstallaton. 35

36 ,. YCUYl; :l:cl. l-fc::::. U::rn:rt;nc.c (U- t:andu~.ntêlu= 125 cc, ntake \ Mn, 0,35 ( ") Max. 0,40 ( ") cc. ntake \ Mn. 0,30 (,0 1811") Max, 0,35 ( ") B Valve gude press. nterference for exhaust-ntaka \ Mn, 0,03 ( ") ec. nta"'. Ma_, 0,05 ( ") C Play between valve and valve gude ntake M:n Om ( " ) Max ( " ) STD. 125 ee. Exhaust Mn, 0,02 ( ") Max, ( ") Max. allow lmts 0,1 ( ") STD cc. Mn ( " ) Max. allow lmts ntake-exhaust Max. 0,045 (,001771") 0,1 ( ") D Valve seat wdth STD ce. ntak.-exnjust 2.1 (,082677") Max.Hcwa!:le lmt 3,2 ( ") Outer valve sprng STD. nner valve sprng STD. ~~ FREE LENGTH ") FREE LENGTH ") VALVE CLOSED ") kg.14(1b.31l VALVE CLOSED 27, ") kg.26,2(1b.5s1,. VALVE OPEN 19, ") kg. 25,5 lb.56) VALVE OPEN "1.. kg.43,8(1b.98) Max. allowable lmt (pressure loss.) 25 % N of the standard pressure. 36

37 _.. -. _ _ See techncal data on page 36 To nstall the valve seat, t s necessary to pre-heat the cylnder head at 380' Fahrenhet and press n th:: valve scat usna specal tool. T:: remove and nstall the valve gude, pre-heat the cvlnder head at 220' Fahrenhet. Hold the cylnder head n the vse and usng the specal 45 valva seat cutter, make a 0.60" wde rng, for the perfect couplng wth the valve. ~ ~1 Procc~d to lap the valve se:!t wth valve, usng fne grndng compound. 'Nash thoro~ghy the cylnder head, and wth the specal tool, or wth nut and CO'Jter lock nut, nstall the ntake manfold and exhaust.ppe studs. nstûll the ntake manfold gaskets n seque;ce as shown n the pcture alongsde. Assemble the manfold (facng the back of the engn::) and wth 10mm wrench, lock tr.e two nuts.

38 -...,..,_, "!! To nstall valve and valve sprng, t s neressûry to use the valve sprng compressor. nstall the valve sprngs and upper sprng nlate. Compress the valve sprng wth tool untl you ûre able to nsert the valve keepers. : j For valve sprng tec:ncal data see page l r

39 Assemble the specal rubber gasket. Slde the cylnder head n proper poston. n~en the valve push rods n proper places. NOTE: The poston of the ntake pusn rod (long push rod), s to the rght, facng the front of the engne, whle the short push rod (exhaust) s to the left. ~ ~ '1= ~ th_ NOTE: The top rocker arm (ntake) has an ol passage hole, therefore, before the nstallaton, be certan that ths openng s free of any obstructon...,.).. - _... ~ ~: -- nstall the rocker arm support. 39

40 -~ VEW OF THE (AM SHAFT - VALVE TRAN \Q ~ ~t0': ~. ~ --,~ Tghten the 4 cylnder. head lockng nuts evenly crosswse at ft. lb. Turn engne untl the pston reaches the T. D. C. poston (compresson stroke).. Wth Hot engne ntake.005" Exhaust.OOS" Wth cold engne ntake valve.006" Exhau~t valve.006" nstall the rocker arm cover aunnum gasket and assemble the rocker box cover. nstall n sequence - alumnum washer, steel flat washer :'nd tghten the A nut!; at 7-8 ft. lb. NOTE: Protect all the openngs of the engne n order to prevent any dust partcles from enterng. 40

41 -- _.. _.. --~... -_..._:;. NOTE: Maxmum attenton must be gven to the ol seal and ol openng of the cover, as ths carres the ol t-,) the connectng red. nsert the ol retanng rng n the proper seat on rght hand half crankcase. nsert the cover centerng bushng. Spread the gasket cement on' the cover contact face and assemble, tghtenng the screw crosswse, as shown on page COMPONENT ASSEMBLE ON LEFT HAND SlOE (flywheel magneto) Assemble the kck starter sprng usng the specal tool R. nstall the long clutch rod, wth the flat sde facng nsde. 41

42 l 1, L.. rr! nstall the rubber gromet on dust cover and assemble. (t s advsable to nstall the rear chan on the countershaft sprocket before assemblng the dust cover)., l L 1 j 1 nstall the clutch support lever complete wth respectve roller. r ~ Before lockng the two screws, algn the center of the roller wth the clutch push rod. ~ nsert the electrcal wre through the rubber rng and slde the back of plate n poston, algnng the two marks made durng the dsassembly operaton. Lock the backng plate wth the 3 screws as ndcated on page 7 42

43 nse"t the Woodruff key on the crankshaft and nstall the flywheel magneto nut. Assemble flywheel, washer nut and tghten slghtly. \~,h\ \~- -:- (~' da 20 TO TME GNTON PROCEED AS FOLLOWS: Turn the flywheel untl the mark 0 stamped on the permeter of the flywheel magneto, matches wth the mark 0 stamped on the crankcase. Adjust pont at. 016",, Connect the tmng lght to the wre of the flywheel magneto (tmng lght bulb off). Turn flywheel magneto slowly counterclockwse untl the tmng lght goes on. At ths poston the flywheel magneto mark A (marked on the permeter of flywheel) must concde wth the mark 0 of the crankcase. To retard gnton, turn the backng plate clockwse. To advance gnton, turn the backng plate counterclockwse. For ths operaton t s necessary to remove the flywheel and loosen the 3 backng plate lockng screws. Ths procedure must be repeated untl the specfed tmng s reached. MPORTANT. Tghten the flywheel magneto nut at ft. lb. Holdng the flywheel wth tool. nstall the cover center bushng and frmly tghten wth the 3 screws of the COver. 43

44 ~ r " ",. _ ~_.:,,-;_, 1' 1!.. " 1,., '/. 7 ;. ',.,_, lo 2JM ~.u SC 6. 1t UG 'l D.D "/r 1f'M.! í : Length of spark n relaton of engne R.P.M. (for all engnes). j! 1 L ì j j " : ~,,, c '...!.,, ì -, :m ' : f ; : ',. --. ' y, -!. ;-- : 1_-1 r-t-l --~ ~... t~-! ~.t-~ , "" ì,!,,!,~!...m.!!,, í ì 0,' ;!!,/;,, C.".' ~,././,! '~:.!.: ~'!!~+-+tt~: r-r- L" /:: ~::, A' ;:t~.. ~f.., ' ' 1 ' :.! ~; " ~ 4.o ~.. 'X LO lk looo 9/1' R.flM.... "- ~_~~.. Voltage n relaton of engne R.P.M. measured at the bulb termnal (for all eng nes ). Chargng rate n relatk: of Engn'3 R.P.M. (Battery SAFA 3V2.8.!h) (For all engnes). j 22 Ol FLTER ASSEMBLY, Thoroughly clean the nner and outer ol fl ters. 1 j ì POMPA ouo Ol pulp FL TAO NTERNO.11ut-r flter.,,~':/ (~'('(1 MOLLA \J Sl)rjn~ TAFPO, SCARCO OLO Ol dran lljl~ nsert the outer ol flter matchng the two pns wt!; the two holes located n the ol pump. nstall the nner ol fìlter, sprng, gasket and ol plug and tghten frmly, usng 27 mm wrench. 44 t, / 1

45 /ßr., TUNNG SPECFCATON (engne 4 and 5 speed) :~ g C ~ ~ ~ 125cc. 200cc. 250cc. CARBURETOR DELlORTO UB 22 BS UB 22 BS UB 24 BS 2 1 ) Slde n. 60 n. 70 n. 80 2) Needle E 10 2 Notch E 11 2 Notch E 11 2 Notch 3 ) Needle jet 260 B 260 B 260 A 4 ) dle jet ) Man jet ) Float bowl gr. 7,5 gr. 7,5 gr. 7,5 7) Plot ar dle screw llh turn open 1lh turn open V2 turn open 8 ) Ar cleaner F 35/1 F 20 F 20 NOTE: Wth Carburetor 125cc. wth ar horn A 200cc. wth ar horn A 250cc. wth ar horn B 45 usng ar horn only the man jet must be changed. man jet 95 man jet 105 man jet 108

46 n the frst step (dle system adjustment wth throttle open from 0 to 1/8 - Secton A ot sketch. The proper settng of the ar screw s 1 turn from locked poston. f n order to obtan proper runnng of the engne, the ar screw must be set more or less than the above nstructons. A larger or smaller dle jet may be requred. Bear n mnd that when closng the ar adjustng screw, the fuel and ar mxture s rcher, and leaner when t s opened. n the second step (Throttle valve correspondng wth secton B of sketch - from 1/8 to 1/4 openng). After a satsfactory dle adjustment s obtaned, select the proper throttle valve and proceed as follows. 1) Open the throttle gradually correspondng to specfcatons of secton B of the sketch. f the engne s runng normal, the cutaway of the throttle valve s correct. 2) the engne gves sgns of fallng n R.P.M. or backfrng, t means that the fuel and ar mxture s too lean and t s necessary to replace the throttle valve wth a lower cutaway (lower number). 3) f the engne s emttng black smoke from the exhaust ppe or s runnng rregularly, t means that the mxture s too rch and t s necessary to replace the throttle valve wth one hgher cutaway (hgher number). n the 3rd step correspondng to throttle valve openng from 1/4 to 3/8 - secton C of the sketch. Durng ths adjustment, the poston of the jet needle must be checked. f the carburaton seems to be lean, the needle poston must be rased. f the carburaton seems too rch, the needle poston must be lowered. The needle s equpped wth 5 grooves and the average poston of the needle s at the thrd groove, begnnng from the top groove. The 4th step corresponds to the throttle valve openng from 3/4 to fully open poston. Secton C of the sketch. 1) 1) f, when runnng the engne, black smoke s emtted from the exhaust ppe wth mssng' explosons and f closng the ar mxture pston (choke) ncreases the abnormalty, a smaller man jet must be nstalled. Repeat test untl the correct sze s selected. 2) f when runnng the engne at full open throttle, t wll not reach the proper R.P.M. or backfrng and closng the ar mxture pston (choke) the engne ncreases n performance, ths ndcates that the mxture s too lean. t s necessary to nstall a larger sze jet. Repeat test untl the correct sze s selected. NOTE: Ths test must be made wth the ar mxture pston n open poston. t s advsable to select the man jet whch wl gve the best performance, but keepng the engne at normal temperature. Provng dagram of the dfferent runnng phases. EXACT MAN JET - normal engne temperature SMALL MAN JET - hgher engne temperature LARGE MAN JET - lower engne temperature Throttle 3/.4 to fully opened Man et adustment Throttle from 1/4 to 3/4 opened Jet needle adjustment. --Throttle from 1/8 to 1/4:;; Adjustment for choosng the su- table throttle cutaway. Throttle from 0 to 1/8 opned ~dle system adjustment. 46

47 '11 ', '\J ( '~~)// (' ~ t \~! t 1'1 1,~' "JJ..p ~?'~ ~p - Vew of preselector assembly Ol pump,.r. tnì ~. ~ ' \"., +_..". ì ~L"è ~._, J: ØJ~ L. W3\0:- ~, ~"".":-' l\ ' Vew of kckstarter assembly 24 DSMANTLNG AND REASSEMBLNG OF VAROUS FRAME COMPONENTS Havng to dsassemble the complete machne, t s advsable to dsmantle the front part Arst. The machne can be dvded n varous groups dependng upon the functon. FRAME - ncludes the skeleton of the machne, front and rear suspensons and handlebar, Wheels and brakes, fuel tank, fenders, tool boxes and chan guard compose the BODY, ELECTRCAL SYSTEM: Head lght, tal lght, battery, horn and stop lght swtch, 47

48 r.! r! ; Dsconnect the speedometer cable from speedometer drve and the front brake cable. Usng 22 mm wrench, remove the wheel axle nut. Remove the cotter pn from the dampener rod and unscrew the knob. í,!,. í Remove the axle lockng wth 11 mm wrench and pull out the axle and remove the wheel from the fork..~~.. Pull out the 'Unt from the top, beng careful not to drop the lower components. í ì Unscrew wth 10 mm wrench, the 6 fender fastenng bolts and slde the fender through the top to remove t. j Dsmantle the handlebar clamp usng 10mm wrench to remove the 3 screws and remove the handlebar. 48

49 Loosen specal lockng bolt wth 10mm wrench. Remove the two fork tubes bolts (14mm wrench)....:..,,~..,. "..."...L Remove top fork bracket. 49 Remove the two head lght bolts wth 14mm wrench.

50 r, f Unscrew the threaded steerng cone, usng the specal wrench. Slde out the fork, from the bottom. ~ Pullout the front bolt to remove the fuel tank. Dsconnect the fuel lnes and unlock the plate wth sprng, located n between the seat and the fuel tank. Then usng a 14 mm. wrench remove the front bolt and the two rear bolts of the seat. 50

51 Before removng the tool boxes. t s necessary to dsmantle the chan guard, n order to enable you to unscrew the lower tool box fastenng bolt. ~ Pull out the battery The same bolt also fastens the rear fender. THE ELECTRCAL Remove the tal lght wres from connector. Dsconnect the electrcal wres from respectve battery termnals. Dsconnect the stop swtch wres. Unscrew the battery strap bolt. Remove the horn wres. 51

52 ~. Unscrew the rear brake rod knúrled nut and pull out rod from the npple. t ear swng arm Remove the nut of the swng arm shaft usr.g 22mm wrench. "" Remove master lnk chan and loosen the axle nuts wth 22mm wrench. Wth the same wrench, unscrew the shaft... Pullout the wheel tltng the motorcycle to one sde. 1.~7~~ Remove the rear fender bolt and pullout fender. Usng 14mm rench, unscrew the brake lever bolt. Remove the brake lever and shaft. Remove the foot pegs usng 17mm wrench. Remove the stand usng 19 mm. wrench. 52

53 ~~~./ J /:~~~'~' /~! ".:,.:~",._,':~,. =-,\ X-?:"~:;~~~ ~".k-,~,.,,:'_.'-":"'-'~.'".." ~..""'. n,...-..,...,'--, " W -'~..~d Before procedng wth the assembly of the machne, t s necessary to prepare the varous parts. Start wth pressng the two steerng caps nto the frame. f nstall the center stand. ~ ~ Assembly of the rear swng arm Clean thoroughly the swng arm bushngs and the passage holes of the shaft on the frame. Control the algnment of the shaft and thoroughly clean the grease passages. Lubrcate the shaft and swng arm bushng wth grease. nsert the shaft after algnng the swng arm wth the frame and thrust washers. Tgnten the shaft untl ts shoulder s touchng aganst the swng arm. nstall the lockng nut on the other sde and tghten at 60 ft. lb. NOTE: The swng arm s properly adjusted when slght frcton of the swng arm aganst the thrust washers s obtaned. 53

54 advanced type and the sprng tenson can be adjusted, turnng the lower rng wth the specal tool. Use SAE 20 o. G. 65 (oz. 2,3) for each shock absorber. 3 way - Adjustable shock absorber. Techncal data,. 1 = Kg. 14 (lb. 31) 2 == Kg. 34 (lb. 75) 3 = Kg. 54 (lb. 119) nsert the two half rubber rngs and steel bushngs at each openng of the shock absorber and slde t on the respectve shafts. Tghten at 25 ft. lb., usng 17mm wrench. 54

55 nsert n poston the rear fender and fasten t wth bolts as shown n the fgure ùlongsde. nstall the rear wheel as shown n the fgure. NOTE: The anchor slot of the brake plate must be matched wth the plate whch protrudes from the rght hand sde of the swng arm. ~ Vew of rear hub 55

56 ,.~ After the rear wheel has been nstalled, ;ssemble the brake lever unt n sequence, os shown n fgure alongsde. nstall foot peg. 31 ASSEMBLY OF THE FRONT FORK nstall the 24,3/16 ball bearngs wth heavy grease on each steerng cap. Slde the fork n poston and screw on the threaded steerng cone. Assemble the top fork brocket and the two fork tubes bol ts. nstall and lock the steerng nut. Tghten specal pnchng bolt. Adjust the steerng mechansm by tghtenng the threaded steerng cone untl the ;teerng s free, but wthout play. 56

57 nyaraullc snack aosorber. To dran ol from telescopc tube, remove the 5mm screw wth screw drver located 2t the bottom of the wheel support tube. Refll wth SAE 20 ol from the top, after,-:c. :-olt hùs been removed Cl L!, :!!, ' ; :1. ~ ;1 e, Gì--.: ~!; :1. ~ ;1 : ; 9 ( :!!.1 ll '. \ Ô \' '. ",. :' MPORTANT NOTE To remove the hydraulc tube Turn clockwse the plug (key n 14 mm.) to reassemble, reverse the operaton. To remove fork tube from fork Dsmantle the top bracket bolt. Loosen the lower bracket bolt then pull tube out from the bottom. 57

58 nstall the front fender, Jackng the bolts wth lomm wrench. nsert the front wheel beng careful to match the slot of the anchor plate wth the protrudng plate of the wheel support... Vew of front hub 58

59 NOTE: After the nstallaton of the front wheel, shake t vgorously up and down before tghtenng the axle lockng bolt. nstall the head lght. A HEAD LGHT B DMMER SWTCH C RECTFER 50V-14A o MPEDENCE E BULB 6V-15W F TAL LGHT G TAL LGHT BULS 6V-3/SW H Cor~NECToa BASE GNmON SWTCH L SWTCH FUE 10 A FUSE 15 A SPARK PLUG H. TSON COL FLYWEL MAGNETO 2S-5W BAT" HORN 6V-25W STOP LGHT SWTCH..., \ 33 WRNG DAGRAM. FOR 3 WRE FLYWHEEL MAGNETO. '- 59

60 nstallaton of hgh tenson col. Lock the two bolts frmly. nstall horn usng 14mm wrench to lock the bolt. Hold the wrng harness n poston, usng the specal steel strap. 34 BATTERY nsert battery and attach the as.on Pg. 62 wre 60

61 -, 8. Dsconnect battery, remove the ld cnd dsconnect w res. c. Specfcatons: mak~ safa 3 V 2 capacty 8 AH. f~~ Í M ~l (( \'-. //? \ ~9.d "WOQ ',~ =-G ~.. D. Note poston of battery and cables before removng. Remove battery from the machne. Make sure that cables (wres) are not reversed when replacng the battery. E. Unscrew caps. F. Fll wth pure sulphurc acd used for storage battery, havng a specfc gravty of 1275 at 60 degrees F. Ths operaton s very mportant and, therefore, t s recommended that the specfc weght be checked very carefully. Fll battery to approxmately 3/4" above plates. G. Let the battery rest for about two hours, then brng back to the requred leve by addng as much sulphurc acd as necessary. Then charge at 3/4 amp rate for eght to ten hou rs. 1-. Once all the above operatons have been completed, the battery s ready to be placed n poston. Every month, check the battery level whch should always be about 3/4 of an nch above plate.. mportant: only add chemcaly pure dstlled water and not sulphurc acd to brng level back to the requred poston. J. Mount battery and lock contaner. ) ~.. l;.,/' ;..t~..d / nstall th3 stop lght swtch and attach the sprng to the brake lever. Be careful that the stop lght swtch s not touchng the rear wheel tre. Attach the tal lght wre as shown n the fgure along sde. 61

62 lldr ~.! '"- nstall the reflector unt, lockng the screw frmly. 36 HANDLEBAR ASSEMBLY Lay the handlebar on the top fork bracket. nsert the bracket and tghten the 3 bolts frmly, after the desred poston of handlebar s set. nstall the dmmer swtch. o nstall the felt under fuel tank and slde the tank as shown n the pcture alongsde. nstall the front bolts and attach the hook to the tank. nstall the seat and front bolt. Algn the slots of the two rear seat brackets wth the rear fender bolts. Press the seat down and lock frmly wth 14mm wrench. 62

63 V L1lC: eg YY'Jt:c '-OJ, PU'-\.n:: c: DUVY.. Remove the motorcycle from the stand. St on bke and adyust the chan utl ths has at least 5/16" to 1/2" slock, movng the wheel backward of foward turnng the chan tenson nuts. After ths operaton chech algnment of wheels. front brake cable = Attach the throttle, clutch and brake cable ~ Attach throttle cable. 63

64 35. ' 1\ 1_l. "" PR- YELLOW ~ ~~ OJ ' \ _'\ GRAY BLUE WHTE BLAC le LAAD --- BLACC/BL-E RED- /' / /..) /~ AU ;$...':_.". ~ _"_ "" ~? '. \ fes':25t~_-!J"\\HOR BLACK, f S~_,, 6v'8ah ( 0 Æ,,~/;; \,/ "-, ";J\ 0. \ ~,,) / ~". ",., \,'" P -- (", / íí "! '\V-25w /7 'j ", \! \\ \...., '~'- \~--,/,,) \ ~, '. rr ~. j /, S,6) ;:~~"' ~., '_ -:a) \, ~, \~ '. \ " ~,/,\,,- ) ~l 1-- \ \ ' :, L '- '. -- : ~ - 0 ~ -, 2L-l ).JJ-)) '. \ \ "~'0 ~ \'\ \/ ). \. / - \ ~'~J "' '1 //~--\ -)l: ~',=, ;"!,c'-~~. ""7 / J (C '_o~~\.í,..~ )' ~v);, y "t': ~ '\ l / ~~:-" \ \~_ ~\ /J/)l_,--! ~ ~... G r-~ \ ~"'~ \~/ V, _ '.. ". /. "---- -,.. ~/ /