TA8LE Of CONr ENTS

DE:S IGtlAT ION

Techn ical Spec l fl Clt to~
T001s (sPec 'al s ~ lce )
Use of the Stro ke Ll~ l te r
[ n gine ~va l
Refi tti ng t he [ nqi ne on the frao@'
Di u ssellbllng t he hg t llP
Pl s t on C, llr'lder H.l t dl lng
UIlll\i1 U on o f tlle ty!inller llead , nd t)'l hl<ler

Re,ss_ lI ng the Engi ne

Dearbollil lng the En,lne
"llsIo 1 ns Dec:, rtoorI ll ln, llef l t t l n.g the El"~ lIs t
Tes tf"\l Ignit ion TI., I",
Rewvl nll And Rtf i ttill9 t ile f l )'W~E'E' 1 Hlqne lo
Adjllst i pg th e Ignit ion PoinU a nd f!Jni thm TiJlli ng
.,vlftg .~ d Iletltt l l19 tile C.rtlilrelor
D1n$$~l, ...d ANn_l, of ~retor
~$cript i on and DpeAt ion of ne l'KIIlnu.nc Varf' t or

V. r1ator Ic..~oi@ n tl p.rts )

llew:! wi n, t tle ' ~ 1r1a tor

ttluuenl, and h l$S4'riIly o f Va r 1lt ol"
Adjustl nli and ltefi tt lng t ile V.M. tor
~vtng Refi tt l n g - o; s, S$ ~ 11 ~ Rr ' ~ I e. bl i nv th e Cl ut ~
IlietIovhg ." d Re f lttl n9 Or1 Yefl !"ull"
~v h9 trl d Rle f ittln, 0 8 C~nk'}e4r . 1leplac in, Crant"... r
8usMngs
~1ac i .g Oppe r En9in t Nountt nCj flexi~le ~~ i n ~
Replaei na cabl es
Replaei llt the r,.....
~I~

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

RefItU "9 t!le II.IIt Fort As I _ l,. Rerr'O'rillq ... ltCIlll!f -j tt h llJ
tt-e fort ~ I e te
Rrpllebg Fort. I.4Mngs and SprinllS
Itso.,lng the lIrIfIdlelMrs
~v l", tile Ste ui ", Ile, d
llIefi tt lntil the St e.r h g lINd
ReMov1n9 ...nd Re fi t t i ng the f ron t and Re. r H~~l ,
$lepl .dng UIe Bnt. Shoes
JlNlnoill'jl the ~ nter Sh nlf. tile s..ddl. , Rtplicl _o t~
Ped,a l Ole i n ",,4 t he [ IIt1n. Drive Ch in
1ll!pl . e1ll9 the r"".t Wlleel Adju, t lltent ~s , CUPS , (lnd
Jol ts
,,'
ItepJ. c ift g Al! l r IIlH l 5.111 Ile ar h 'ls
Check WlHl Al lgnw:nt
RNovl . g anlf Rd 1tt i llll (tie f ront and nea r rt:Oder<s
Renovj ng ... ~ d Rlf l tt lrl9 ue Shock A~ l or t>e rs ~nd t lte
Sw i ng Am
Troubl'J Shoot 1 n ~ Gu ide
Wi ri ng Olagr... 6 Vol t
lti rl ~ q Oh gram 12 ~olt

PAGES

,
I

e.s

10 . 11

12, 13

"

I S , 16

11,11 .rs.zc ,21 , 22

""'"
re.,.,
30,31

26,21

12, 33

34."
"")8,39

40,4 1,1.2

41 .1.4

45.16

H ,U

" ,so

51.st ,5]

5-4 ,55

Sfi,n ,58

S9 ,60

""

."
es

66
66
69 , 10

ll ,n
73, 14

"

16,n

78, 19
ao ,IlI ,llZ .83 ,8 4

es

'"

ALPHABET ICAL INDEX

DES IGHATlCNt
Brol kes ( replolcl lHJ tile brake s hoes)
Cabl es ( replolc l ng)
Colrlluretor (re-:ov i llg olnd refittill9 )
Col rbureto r (s t ripp ing olnd reolss e.bl inQ)
Center SU nd (re-ov l ng)
Cha ins ( replaci ng)
Cl utc h (re-ovlnq. refitti ng . repla cinq . reolsse.bllnq )
Cr oln kgeol r (rernovi llg. refittinq . replaci ng c rolnkqear
b1l5hing5 )
Cy li nder He ol d Cyli nde r (exol minati on )
Engi ne ( remo vi ng)
Engin e ( refl t ti llq)
Ellgi ne (dh .S5 ed>li llj '
( llgi ne {re .ssentl li ng
Engi ne ( decolrbolli zing )
( Xhol llst (reMOvi ng . dec a rboni zi no , olnd refitt inQ)
Fron t olnd Ru r Fenders ( relIlOvlng and ref itt ing )
Fl nible BlISh in~ ( repl ol<:i ng)
Flywlleel Ma9'M!to (re-:aving olnd refittl/IQ )
For k (remvi ng t he
In f ort as se-Clly )
Fork {re f i t t i ng the
In f ork asse-b l y . reMOvi ng . nd
re fitt i ng the fo rt c~lete}
Fork ( ~l olci ng bvs hl~ and sp ri ngs)
Fra..:! (replacing )
Freew~1 ( replac illg)
Kalldleba rs (reIIOvi nQ)
Ign l ti Oll (c hecking tilli ng )
Ignition (adj U5 t1 ng the igniti on poillt5 ol nd t i. i ng )
Matching ( pl s t oll-cyli nder )
Dri ven Pull ey ( removi ng olnd ref itt illq)
Sa ddl e ( rep, aci nl)
Shock Absorbers relllOv'n<J and r ef i tt i no)
Steeri llC) He ad (removi ng)
St l!l!r i ng Head ( r efit ting)
St r oke Llmltl! r (use )
Techni cal Speci f lC. t i ons
Tool s (s pec l . l service)
Trouble Shoot i nq Guide
Var h to r ( de5c r l ptl on and oper.ci on)
Var la tor (COflIlIOIIl'nt s parts )
Var la to r ( re-ovi ng)
Ya rla tor ( dis. sse-b l i ng and reas se.bl l"9 )
Vol ri .tor ( adj us t i nq and ref itt i ng)
Fron t and Rear Wheels ( reMOvi ng . nd refitt ing)
Fron t ~h ( rep l ac i ng oldjllStIleftt cones . CUPS . and bolts)
Reol r Wheel ( rep l.ci ng ball ~a rings)
Whee ls ( cbeck alig~nt)
Wi ring Dlag r 6 Volt
Wi ring Diag r a. 12 Vo l t

."'"
S4 .55

32 . 33

".35

"

69.10

45. 46
49,50
15 , 16

'.'

10 . 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

"

"

26 .27
JO . 31
U

41.48

"

78.79

64
65
7
1

e-s

80 .81.82 . !l3.84

"31

38.39
40 .41.42
4].
66 .67

11. n
73.7'

."
es

TECH N IC l\l

$ PEC IF IC I\ T IO NS
M8 TOBECAN E
4 _ S ER I ES

DI ME NS IO NS

Ove rall
Overall
Overall
Weight

l engt h (i nches)
Wi dth (inches)
Height (inches)
(pounds)

/10TOBECAN E
58;O~OA~iR IES Z
SER IES

66. 19
24.82

69 .34
24. 82
39. 79
103 l bs .

3'1.00
90 l bs .

63. 40
24. 82
38.80
88 l bs .

FRAME

Type : Pressed Steel

Suspension; Telescopic Fr ont For k
Re ar Suspe nsion .
Shock abso rb e rs
Brakes: Fron t and Bear DrLlll
Tires: Pressu re Front 21 p .s.1.
Pressu re Rear 26 e.s.t.
Fuel Capaci ty: (U.S. Gallon)
Fue l Mixture : 4 oz. of high
qual i ty 2cyc l e
011 per ga ll on
of gaso line
Mil e s Per Gallon :

YES

"s

NO

VS

.8

143

143

143

ENGI NE

Type: Si ngle cyl inde r , ai r- COO l ed , z-cyc t e

Bore and St ro ke: 1.53 X 1.64 Inche s
Comp re s s i on Ba tio: 7. 8 :1
Ca rbure tor; Gurt ne r
En9i ne Displace ~nt ; 49cc
19nition: Flywheel Ma gne t o
EI ECTR IC Al

Prio r t o January 1, 1978 : 6 volt

After J anuary 1. 1978 ; 12 volt
VEH! Cl E I DE Nll E I CAll ON NUMBERS

[ n9ine: I den t if i cati on pl at e on engine cyl in de r head

Frame: Identif i cat i on pla te on front of f r ame

Ma ximum Speed:

20. 25 , and 30 MPH

.0 1

SPEC I AL SERV ICE TOOLS

PART NO. 100001

CI RClI P PLIERS

PART NO. 100002

CI RC lI p PLIER S

PART NO.

100005

FLYWH EEL WREN CH

I
PART NO. l ll'XlO6
BUSHI NG EXT RACTOR

PAR T NO.

100003

GREASE F IT TI NG WRENCH

PA RT NO. 100004
STRO KE lIl1lTER

."

PAR T NO . 100007
HA GN ETI C E X TR AC TO~

SPECIAL SERVICE TOOLS

=~

!~:

~..

'"'(1\

wsA1

PART NO. 100008

PISTO N PI N TOOL

PART NO, 100009

PEDAL BUSHING TOOL

PART NO. 100010

CRA NKCASE SEAL TOOL

PART NO. 100011

CRA NKSHAFT BEAR ING PULLER

. 03

SPECIAL SERVICE TOOLS

PART NO,

10001 2

FORK TOOL
PART NO. 100016
__.PRESS -

PART NO ,

STEERI NG HEAD RACES

100013

. TIM ING TOOL

PART NO. 100017

THICK NESS GAUGE - METR I C

PART NO,

1000 \ 4

TUBE

PART NO, 1000\5

PART NO, 1001)18

120x30MM

SPOKE WRENCH -

BLADE

""

18

SPECIAL SERV ICE TOOLS

PART NO. 100019

FORK PIVOT WRENCH
PART NO. 100023
SQUARE DR IVE

~
,I

.'

PART NO. lOGON

FLEX IBLOC EXTRACTOR AND
INSTALLING TOOL

PART NO, 1000ZO

CLUTCH PULLER

PART NO. lOOOl5

PISTON PIN EXTRACTOR

PART NO. 100021

CAM PULLER

PART NO. l OOOlZ

FREE WHEEL WREN CH

. 05

SPECIAL SERVICE TOOLS

PART NO. !OOOZ8

GREASE GUN

PART NO. 1000"9

SPARK PLUG WR ENC H

PART NO. 1000.,6

VARIATOR HOLDER

_ ~~

iWlT .NO. 100031

TI MI NG LI GHT

PAR T NO. IOOOZ1

VARI ATOR WREN CH

. 06

PART NO. COIl.,9

fORK WRENCH

USE OF -THE STROKE LIM ITER

I MPORTA N T

For all types of en~ines to be se r viced, the use of the stro ke

limiter , No. 100004, is requ i red i n lllCls t disass embl y and reassembl i ng operations.
This tool is designed t o lock cra nksltaf t revol ut i on at mid -s t roke
and offe rs tlte adva nt aqe o f leav ing both Itands f ree t o pe r f onn
the ope rat ions requi red.
DO NOT USE THE STROKE LIM ITER ON ENGI NES FITTED WITH FLAT- TOPPED
PISTONS.

Afte r Itavi ng s crewe d t he limiter into t he wltole tltreaded l e ngth

of t he s pa rk plug Itole , br ing t lte pis ton t o res t against It
gently.

R07

ENGINE REMOVAL
Remove both side covers (screwd river).
Disconnect t he suppressor cap.
Free t he ceccecresscr cable nipp le using a sc re wdriver (fig . 1) a nd
disco nnect t he cable.
lOl)sen the nut securing t he carbureto r
the ca rbu~to r .

cJa~

(llimI socke t) and remove

Disconnect t he wires 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.
Disconnect t he grey wire at th e ignition coll and slide it 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).

F.._ 1

ENGI NE REMOVAL
CO NT'O .
Loos en the lowe r engine mounting nut dnd wit hdraw t he bolt (l0rrrn open
wre nch and socket) .
Loosen the se lf- loc ki ng nut of the upper engine moun t (1m wrench) .
Drive out t he upper engi ne mounti ng u le only as fa r as t he f irst
spacer (f ig. 3) .
Be fore renJ ving t he engi ne , ca refull y no te th e l oca t i ons of th e upper
engine mo unt s pace rs .
Tilt th e engine and remove it (f i g . 4) .

f;';'.

'"

REF ITTING THE ENGINE ON THE FRAME

! nSll@c t tile upll@r en9'tne .untl nq fl ex i b le bushi nas . nd I nsuld lon ring
for good conditi on ( fig. I ) .
Fit t ill! engine throu9h upper . untt nq bo lt (oll@ ,-, te n

for

~v.l) .

Check tha t sp.cers . ~ cor~ct l 1 lined up and IloI ke s ure t o i nse r t t he

e1e ring of the 9ro und I u d bet ween t he sp ace r .nd C1li nder he.d
( R. H. , f ig 2) .

Tt911ten but do not loc k upper en9ine lOunti ng nut.

Ins er t the SCl'@Of in t o till! l oooe r en9i ne _ unt i n9 brl cke ts .nd Into t he
s pace r- which is fit In with t he tens i on Sprin9s ( f i g. 3) .

o
.... 2

f .._ 3

RO 10

REFI TTING THE ENGIN E ON THE FRAME

CO NT'n ,
Tigh ten and lock lowe r engine lOOun t1 n9 nut (lOIml wrench).
Refit the ca rbureto r all t he way onto t he i nl e t pipe dnd loc k t he
ca rbure t or secur ing clamp nut (llmn soc ket ).
Reconnect t he eecoreresscr cable {screwcr-tver }.
Re connect t he wi res t o t he spade connections behi nd t he fl ywhee l magneto stator pla t e [pas s t hem t h ro u ~ h t he guide s pr i ng . if equipped)
(f i g. 4).
Slide the grey wi re through the suppo rt brac ket on the f rame and reconnect i t t o t he ign it ion coil (st raig ht ~ema l e t e rmina l ) .
Lock t he upper engine mo unti ng nut (while hol din g the othe r end of
the bolt - 12nTn wren ch ) a fte r havi ng i ns t all e d t he bel t (f ig. 5).
NOTE : Make ce rta in to lock upper engine mounting nut a ft er having in s t all ed the belt. Then the engine is i n a medium swinglnq position ,
which will preve nt the f lex i ble bus hings f rom susta in i ng damage.
Refit the s uppre s sor .
Refit both si de covers .

ij
RO II

DISASSEMBL ING THE ENGINE

Engi ne r emo ved .
Remove the exhaus t usi ng 10"", ~ nd ll"'" soc kets to loosen exha us t c lamp
and a 32"", open wrench t o l oosen t he nut connect i ng t he e xhaus t t o th e
cy l i nde r.
Set the enct ne i n a vi ce by I nser t i no a space r be t ween t he lowe r enatne
mo unt pl a t es so t hat t he as semb l y may be f i rm l y c lamped (f io. 2) .
Remove belt cover usf nq a s cr ewdr i ve r for var -t e te r eee tn es or a 101m1
soc ket fo r Dimoby cl utc h engi nes .
Remov e t he flyw heel mag ne t o (See page 28) .
Remo ve t he va r iator or the c l utc h ass embly accordi nq to t he t ype of
mach i ne se r vi ced ( See pages 38 and 43) .
Progre s s i vely l oosen t he cyl i nder head nuts at opposite corner s .
Remo ve t he cyli nder head and t he qa sket ( Hlmn socket ) .
Remo ve the cyli nde r and cy l i nder ba se gas ket.
NOTE: Afte r Jul y , 1975 , our en9ine s are f it ted with pis tons havinq LE VELLE O
UP RINGS WH I CH COVER THE LOCAT IN G PINS ( fig. 1).
Wit hdra w t he piston ri ngs .
St uf f a r a9 i nto t he c r ankca se mout h and r emo ve t h" wri st pi n clips usinc
fl at nose pll ers ( f i g. 2 ).
Dr iv e out t he pi s ton pi n lIsi nq t he pi n ex t r act or tool, 100025 , ( f ig , 3) .

Ol d-s ty l e
Pis ton
.~=t
Fi g. I

New- style
Piston

'i

RO 12

fi g . 2

DI SASSEMBLING THE ENG INE

CONT'D .
W\t lldril., the nee dl e ca ge f ro. t he con rod s-. II end .
l oosen illl c rilnku se reU in ill9 nuts .
~-.e

t he c rilnkcase f ro. t he ylce .

Re.Jye t he c rankca se reta1 nl1l9 bolts alld l ower ~i ne -oun tillCl s tllds
(not e the pos it ion of t he studs alld of t he br ilcket fo r the be l t lIUa r4) .
To prewetlt the crilnkshft JourM l f~ o~ rheil tin~ i llse rt t he blade .
100015 . 011 i t. Repeat t he opera tloll fo r t he o the r joorna l.
Hut ., Uh a propa ne t orch t he crankcue half filcing t he c1u t ctl s ide
ilround the outs ide of the cranks tl..ft bu r i ng (be g in wi t h t his s i de be cause it Is t hen easy t o n par. t e c r..nkcase s he lls ) ( fig. 41 .
The creeeeese ha lf will dro p ilway on n s own ( fig. 4 ).
Re pe..t t he ope ra t ion for the ot her c r..nkc.. se h..lf ( f 1g . 4) .
Whil e ~he c rd" k"d~ e hilhe s e re hot . r"may" t he oil se~ h with iI s crewdriver u pping f rom th e outs i de t o th e I nsi de of t he c ra n ~cu e ha lf.

h t ract the cran ksha f t bear1ngs us i n~ th e cra nks ha f t bea ri no pull er,
100011 ( f ig . 5).
Not e the ilr rangeme nt o f s hllllS beh1nd t he c ranks ha ft suppor t be. r 1nn 1f
t he cra nksha ft Is so f itte d.

Fi g. 5

fig. 4

RO 13

PISTO N CYLI NDER MATCHING

The spoo re poort n" ' n l isted bl!low
conce rn pis t ons fi tted with l n e ll !'d- up ri ngs t hn . re _ nt ed
In li eu of fo..- r pistOflS Ise rtes 168$3 t o 168591.

12273

------- ---- - - - - - - . . .

21274 _._ _. __ . _ __

loA

- - - - - - - - - - - - ------

21276 _ _. _. ________ _

222 71 ----------- - - - ----- - - - . . . .

22218 ----------. - - - - _ _

22275

22219

., ,,

II

__

22280 - - - - -- - -------- - -....

22281

II

22435 --- - - - - - - --- -- - -

_ _ __

EXAM INAT ION OF THE CYLI NDER HEAD AND CYLINDER

b ami nation of tile Cy l i nder Head :
Clleck tllat th e cy li nder head bottom base i s fla t ( qr i nd I t with <1 su r face pla t e i f necessa ry ) .
Refit the spa rk plug <1nd check t he deco-pressor va lve for l eakage by
pouring fuel i n the c~st i on ckaoober (fiq. 1) .
E ~cep t

in

ca~

of abs olu te

ne~ss lty .

the

dec~ressor val ~

s houl d not

be n!'IIOved f roll t he cy li nder Ilead a s se-bl y.

In case of le<1k age and i f th e valve i s not wo rn ou t . tap the va lve head
gent l y t o seat .
Eum i n4tion of the Cy linde r :
Hak e su re t hat the cyl imle r ....11 h ne ither s cuffed not scored (l <1 ck of
chno-Iu- pl at ed s ur f ace).
Meuure the piston e t ee renee (dif f e rence between t he . i ni _ cy li nde r
bore and t he lIIoI ~l_ piston d iamete r) . t he pis ton r inq end gap ( f i g . 2 )
and t he cl earance between r ing and groove .

....

...'
RO 15

EXAM INAT ION OF THE CYLI NDER HEAD AND CYL I NDER
CO NT'D.
- If i nsta lling a new p iston , refer to t he matching lis t on page 14.

CLE ARANCES IN 1'0'1

STANDARD

Pis ton Clea rance

(sldrt}

R1 ng end gap

top ri ng
seco nd ring

Ring groov e
Side gap

top ri ng
second ring

0 .DD5 to 0 . 010

0 .10
0.10

0 .03

MAXI MUM
0.050

0 .10

0 .40

to 0.060

0.15

Fit the small end need le cage and insert t he wr i s t pin in it (fiq. 3).
Th e pin should t urn freely wi t hout ve r tt ea t play .

c>

F";I. J

RO 16

REASSEKBL ING THE ENG INE

NEYER IItSTAL L LlSED GAS KETS ; A1.lIAY S lISE MEW ONES

Whtn f it ting a _ enll i ne cr ankcas e or a _

ShOl.l l d be adj usted.

c ra nhhfft, tile s ide ph y

SIll[ PLAY ADJUSTINT :

To er te ct th is operation . you need two dUllll)' bearlnlls t hat you u n lUke

yourself.
use emery cl oth on the inne r and oute r races of t wo new bea ri ngs {dia...
16 x 42 x 13 - No . 16906} until the bearing s can ro tate f ree ly on t he
cr anksha f t j OUrmNS and the crankcase s he ll hous ings , This oper a ti on
mus t be done wi t hout crankca se s ea ls:
Place the dlJlllll}' bearlnlls on th e c ranksha f t tape red ends .
Place th is usedll y into t he cran kcue .
FH t he c rankcu e p,fipe r gas ket .
NOTE : FrGlI Janua ry I, 1916 , the paper yu ke l ~ . II"9 I t>t! o:.unkuse h.olvu
has been subs t i t uted by a spec ial se.l ln~ ca.pou nd. Ki!'Yer t hel ess . when
u nic in'll an en 'll1ne, we rec_nd c l un in 'll tho roughly tile lUti ng su rfacl!!S
and fitti n'll a p,fipe r 9IS ket.
Pla ce th is as u-b l y In a vice (oYe r lower l uqs and cr ankcase upper sc..-s ) .
ltoll9"' h assu s the

txlstl~

side play with a depth ullpe r 'lla ullE' .

Disjo i nt cr ankcase ha lves and place washers between the two cra nksha ft
bal ance wel'llhts and beari ngs i n orde r to balance t he con -rod be tween t he
shel ls .
' SI DE PLAY

I /I OMM

RO 11

REASSE MBL ING THE ENG INE

CONT 'D .
ClWlKSHAFT FI NAL ASSE MBLY'

Ins e rt a stee l blade (le ngth - 120 X 30 X 7rrJ1l - No. 100005) between
c ran kshaft balance we i ght s (fi g . 1) .
Ins t a l l the as selllbly (without squeezing) i n the j aws of a vi ce opened
at a pp ro ~ i mate1y 75.... ( fig . 1).
If shims we re f itted to t he end of crankshaf t refit them.
I ns t a l l the bea r ing on cra nkshaft j our na l .
NOTE THE DIRECTION in whi ch the bearings are facinq . The rou nded Chamfe red
side must f ace t he crankshaft balance we ight ( fig . -2 ).
Dri ve t he bea ring hOOl(> agai nst the count e r.le i ght with a tube (di am.
18 X 22 X ISOnm - No. 100014. f ig . 1) .
Procee d li kewise fo r the other cra nKshaft end.

fiv. 2

"'"

REASSEMBL ING THE ENGINE

CONT ' D.

REASSU'I3l.. 1NG 1M( CRAIIKCASE :

Oil t lw cranksh. f t

t.~ ~d

ends , tlw bloari nqs. and tile beari nC) C' QU.

HeH mode r~ tel y t ile s "e ll ( facing tile

bea ri ng hous i nq unt il s moke appea rs .

flywh~l

II1(I gne to ) artly nd the

Fi t a new oi l seal wi t h tile c rankca s" suI f i tt inQ t ool , No. 100010 ,
f i9 . 3.
NOTE :

Sea ls ..s t be f ltt"d with t he s prinq and lips fK 1ft9-oa blards .

V"ry Quldly fit t ilt' c r. nksha f t n sf'lllbly ( fl ywhef'1 ..one t o s ide ) In

t he cr . nkca s" 1I.1f ; tilt' be. ring ..il l loc.te itSf'1f co r .-ect ly.

Fi t t he oiled p,lPf' r C)as ket t o til@' crankcaSf' IIoJIf (see NOTE 011 p,l"" 11) .
RePf'.t the OPf' ra tiOll fo r the ot he r cr . nkus" h. l f.
TlgHen but do not lock tlw two UpPf'r s c rews . f ter havi nQ lII)unted t he
l uq fo r secyring til e belt cove r (v.rhtor engi nes ) ( fi~ . 4 ) .
Ch mp (mocle r H e l y) t he e ng i ne i n. vice

over t he cra ntc . se l owe r bosses .

Ma k" s ure t he cylinde r-c r . nkcas e IIIoltln g su rfaces are comp le t e l y f ree
f r'OOl distor t i on ; If nece ss.ry , t . p on t ile upper p.rt of a s t ud (n selllbli flC) cyli nde r . nd cy li nder hea d ) witll .. lI et.
1 ri. t he paper C)as ket with a s cr'Pf' r.

NOTE : As fa r as v.rlator ,,"q ines .~ cOllce ~ . we .-ec_ nd the positlonlno

of t ile belt cover tJPge r ...mtl "9 l Ull before l ockinq t ile c r,)nkcas e 1I. 1f lJl)pe r
-oun tlng sc rew. The t op of th is .untln9 l uq will rest .q.ins t t he cyli nde r ' s
lowest r.dl.t lon f in s ( fiC). 4 ) .

flo . ..

f i q. 3

RO 19

REASSE MBLING THE ENGI NE

CO NT'O ,
- .lock

t~e

two upper mounting screws .

Fit th e l owe r engine mount ing brac kets and the dual lu g secur i ng
belt cove r ( va rl ator engines) .

t~e

Fit and l ock t he cranh:ase moun tin g nut s (nuts on flywheel magneto
s i de) wi th a lOmm wrenc ~.
Pla ce a s~ace r between the lower engine mo unt ing brackets to hold the
engi ne firmly i n the vice (f ig . 5).
Rota t e th e c ranksha ft. If i t ' d~ot reta t e f ree ly , s li ghtly ta p on
the cr ankcase Shell (c l utch side and va r ia to r s ide ) with an a luminum
ma llet to position th e bearing.
REASSE MBti NG THE PISTON:

Sme ar the needle cage with oil and i nse rt it i n con- rod sma ll end .
Posi t i on t he pi s t on over the con- rod in such a way t hat th e ring groove
pegs fa ce t he e~haust por t.
Inse r t t he dunmy wr is t pin wh ich comes wit h Tool No . 100008 t o alliqn
ass eooly (fi g. 6) .

t~e

Fi g . 6

Fi ll. 5

RO 20

REASSEMBLING THE ENGINE

CONT' D.
f it t ilt

~plaWllt

wrht pin II1lnq piston pin anftllb ler No. 100008.

Hea t (-:lde ra t e l)') thl! piston ~ ( torch) until s-:lke aPlll!ars . (This
is not I'Il!Cl!ssary fo r a . - wris t pi n tha t is an e n y s li di ng fit .)
Inse rt the n s_Ier ti p i nto t hl! wrist pin (fig. 7) .
Push he.(' wh i le p~ssing a ga inst the oppos ite s ide of tile pis ton to
prevent unnecessary pr ess ure on t he bi ge nd beari ng . The nseftJl e r
stop wil l cor rec t l y posit ion 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 s t on
pin clips i ns ta ll ed. The cyli nde r will s lide down as th e t empe ratu rl!
e vens out. This oper at i on pre vent s pi ston di s t ort 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 , chec k coo- rod alignIIII"nt.
OIEClWtG ROD

AL I~ NT:

secere t~ cy li nder with two wa shers and two opposltl! c)' l l nd!!r lIl!ad
nuts . Bring till' pis ton to T.D.C.
Sli d!! In a tapered 0.01"
holes ) and cy l inder.

tee te r gauge eeween t hl! piston (I t pin

If the g.lIgt! s li dl!s f rel!ly t hrough one si de and not t hro ugh <h. ot hl!r .
the rod pro'tl!S to be out of allgllll'll!n t . Re.lYl! tiM! cyl1ndl!r ..d
eeee with s t r a lghtl!ni ng.

,ro-

f i g. 1

e
[ffi / M

RO 21

REASS EMBL I NG TH E ENG I NE

CON T'D .

STRA IGHTENING CONNECTING ROD:

CI .-p the crallkcue III the etce alld III$er t a b.Jr t hrou<JlI pluon pi ll U
$hown III fI<;Iu'-' <;I .

To U rd <;llltell tile rod . awly force t o the ba r .

Che ck rnd allgnllll!lIt and U ra l glltell alla l n unt il tile phton t s cor rectl y
cen t e red In t ill' cy li nde r.
Fit

wr h t pi ll lo ck ri n<;ls USi n<l fl at nos e pl ier$ .

Slnea r t he piUon ri n<;lS with o j 1 and fit t llee on the phton.

RASSMBLI NG CYLI NDER CYL INDE R HEAD :
Bri ll<;l the ph ton t o T. D.C. and -. ke ce rtai n t ha t the pinon rln<;lS seat
f i ...l1y i n <;Iroo"es .
Fi t the oOed '}Isket on the b.Jse of the cyli nder .
Place the cyli llder on the ..unt inq UU(h, . s.-a r Ultbo.-. wi th 011 and
lower eellt Iy .

Fit t he cyli llder head IIolkin<;l sure it$ bo UOIl bu e h

Fit wn he n

0 11

c le an .

t he $1\l<Is and t i 911ten prngrl'$sively t he nuts at oPl'Osite

ee-ee-s t o s ft . 1M.
I ns t al l the "arla t or Or cl utch (See page 43 ).

Fi g. ')

RO 22

pe rf~t1y

DECARBONI ZING THE ENGINE

loose n but do not

~-..e

cy li nde r head nuts.

loos en t he upper engine mount i ng nut .

Drive out t he upper engi ne mountln q

a~le

Til t thl' engi ne and r ('lll(lve i t f r OlII t he

as far a t he f irst spacer only .

a ~l e .

Disconnec t t he wire s at t hl' te nlll n. 1s behi nd t he fl ywhl'l' l maqll(' to s ta tor

plate and s lide t hem t hro ugh t he gu ide s pri ng.
PlaCE' b loct ul'lde r t he en9ill(' t o pre -..ent t he 100000 r - . .ti n9 fl e _l bl e Mil.
i ng f~ bei nc; da-.oged.
Re-J~

t he cylinder he.d nuts us i nc; 100- soct e t.

RHo:lve the cy li nder head and t he 9oIket.

:tEVER USE HAADENED TOOLS THAT Will SCRATOI

DR NICK THE COIBIIS TI O/'l OW'SER AND PI STON

""" .

Bri ng pis ton to LD.t.

Scr ape t h", ca r bon d",po $it$ fr'Olll the exhaut port ( fiq . 1).
Al ways f it a new cyli nde r , head , and exhaus t gas ket.
REASSEMBl i NG AN D R[l NSTALli NG THE EN GI NE:
SH pages 8 . 9 . I S. 16, ea .

...

RO 21

REMOV ING. OECARBONIZI NG. RE FITTING THE EXHAUST

REMOVING THE EXHAUST PIPE {Bl underbuss type fig_ I }
loosen the nut 110- and 11... wrenches) and 1'NlIW' the e~ ha us t c1aoop
nut , but do ee t 1'NlIW' the s~cer be tween the enlli ne -:)u ntl nllS ( f lq . 2 ).
loosen t he nut (32Jml wrench ) threaded i nto the cylinde r and reeo ve t he
uh aust comp le tely ( fig. 3).
DE CARBON IZING;

loos en t he locknut and the nut securing t he exhaust

un

ti p.

RemD ft the baffle pl ate and the ta ll cap.

Clea n out t he holes In tile inne r baffl e plate and tall pi pes ( f lq. 4) .
Sc rape out the uhaust pipe ent ry .

- ----,

~i

,I

'--- ---~------ _.-

RO 24

.... '

.... ,

.... '

.....

REMOV I NG, DECARBONIZING, REF ITT ING THE EXHAUST

CONT ' D,
REMOVI NG THE EXHAUST PIPE (Oval ty pe wi t h cros se d chamt>ers , Ftq , 5)
Remo ve the t wo bolts on t he exhaus t clamp us i ng a 10rml soc ket. .

Loosen t he nut connecti ng the exha ust tc t he cyl tnce r (3 20m wre nch ) and
remove t he e xhaust completel y.
DECA RBONI ZING:
Loosen the nut en the clamp securi ng t he muff l er t o t he pipe ( 10rml wrench ) .

eeeove the muff ler.

Insert a t r i angula r scraper t hro u<jh t he hol e and sc rape all car bon depcs l ts
f ro m ar ound t he edges as shown i n f i gure 6.
Insert a steel cable {diem. 711111 - l engt h :
c l e an it out.

250lTJn)

in to t he tal l pi pe and

Lastly , s hake t he exhaus t vertica ll y to r emove deposits f rom t he ent ry

hole.
RE FITTING:
Reverse the procedu re and f i t a new se al i ng was her in th e exhaust por t of
t he cyli nder .
- - -- --:
,'-~
.
,
I~ ~

:-

:~
.I '"
!
"

~,

I
I

.,,\-~ fI\':dJ" :
,
_

_ _ _ -.J

~
-

I nse r t a s t ee l
cabl e (diam . 711111)
i nt o the t a ll pipe .

scra;<lll:arbon deposits with

a sc raper .
f ig. 6

Fig. 5

RO 25

TESTI NG IGNITION TIMING

(WITHOUT REMOV I NG THE ROTOR)
- Remove ri ght hand si de cove r.
- Dis connec t th e grey wi re f rom t he igni t io n coil (fig. I).
- At tach one probe from the ohm me te r to t he grey wire (f ig. 4)
- At t ach t he ot her ohm me t e r lead to a 9round poi nt .
head ) (fig. 4)

(hamp le:

Cylinder

- Dis connec t t he blac k wi re (l ig hti ng sys tem) f rom t he s trai nht female
6. 35lTJ11 t e"" in al at the stato r pla te.
- Remove the r adi o s uppressor and spark plu q.
1.

Scre " i n t he t imin g t ool (No . lOOOlJ) i n place of spark pl uq (fiq. 2).

2.

Bring pis t on t o T.O.C by ro t at i ng the rot or i n t he nonnal runni ng direc t i on.

f~.

NOTE:

When test i ng and re se tti ng t he

Ignition timi n9 on t he machine
with a 12 volt lighti ng system
(ma nufac tured after J anuary I,
1978), a t i min g light te s t e r ,
Part No. 100031, mus t be used.
An ohm mete r w.i ll not reqister
an accurate re~din9 .
f~.

RO 26

TESTING IGNITI ON TIMING

(WITHOUT REMOVING THE ROTOR )
CONT'D .
3.

Tum the ti . i llg tool untll the top edge of t he too l is . lIgned
. Ith the lowr ~ of the blue stripe (fig . 3) .

4.

Ra t . t e the rotor cloctwise _

full revol utl oll . 1Id IS the blue
st r i pe j~ t begill$ to .ppe.r. the ot. ~ ter should dl!f le<; t t o
0<0 . Poi llU j ~ t beglll to eeee. I f . t l. l ng lite /teste r is
und o the li ght . i1 1 go - OM- (fier. 4) . (See eete , P' 'll! l6 .)

",

RO l7

REMOV I NG AND RE F IT TI NG H IE FLYWH EE'- MAGN ETO

REWJVAL:

Remove the right hand side cover.

Remove the fl ywheel magneto cover.

Remove t he r adio supp ressor and sp ark pl uq. Disconnec t the wires fl'(lJl'l
t he t ermi na ls behind t he fl ywhee l magne to stator ph te and t he grey wire
fJ"Qlll the i gniti on coi l.
- At ta ch t he flywheel wr ench to t he rot or (Tool No . 10(1005).
- Loosen t he r ot or nut (left hand th re ad) usi ng t he squar e drive wre nch.
100023, ( f1g . 1) .

- Remove t he rotor.

\(
F1g. 1

""

REMOV ING AND REF ITTING THE FLYWHEEL MAGNETO

CONT' O.

Sc ~ t~

Cill

pul1 ~r.

110. 10002 1. OIlto

Slow ly s c ~ In t he eeeeee s c"", Of t he

cr ant Slla ft ~nd ( f i g. 2) .

th ~

ea .

pull~r

a nd pull t he u- off t he

~~ th~ stator pl at~ ~lf retai ni ng nuts (a. wrencll) and re-ove the

conica l spr ing wa sher5 (f ig . 2).

~W!

t !lf s t ilto r

p l at~ . the

p<!Pt r

gas k~ t

a nd the rubber

gas t~ t

( f i g.

n.

RE FITTING:
- Fit th paper gas tet and rllbtwr

Aft~ r

studs .

gast~ t .

test i ng or ate te e p h t~ re phce-en t . position the sta tor on t he two

Ori W! fully 110ft! OIl cra ntcase .

Fit tile four conica l s pr i ng wnller5 and tile two se lf ret.ining nuts .

Screw on gradua ll y and loct tile self re ta i n ing nuts (8nJn wrencll) ( f iq. 2) .
Adjus t ig nition t imi ng and breaker poi nt gap as des cr ibed on t he following page .

Fi g. 2

Fig . )

110"

ADJ USTI NG THE CONTACT BREAKfR AN D IGN[TION TIM ING

AOJUST11E111 Of THE 8llAKIR POIIlT GAP :

ItlIIPO
obt a i n

i1y ins t.ll [h@ t on t ..ankstwft f'fld and nHat~ it Qf'fl tly to
1_ g.ap betW!'etl tonta tt poh.ts {f ier. I I .

Adjust the g.p ..ith tile reete .. gall')e (110. 100017. fi g . 21 t o bet","",

35/100- . i ni _ .nd 40/100- .... t_.

If NECESSARY PROCEED AS FOLLOWS :

Loosen

tee

retdnin9 Strew o f the fixed .... lIsinQ a st rewd..ive.. {fig , ll ,

Pivot tlle b",.b.. ass_ Iy t e .djlls t t o the sPetifiM <I.p (f tq . 2).

Tlqhten the
( lied tile

f i ~ed

lIIoJ ~i_

. ... ",Ulnln9

St"""

poi nt q. P d t e .. t i qhten i nQ t he fixed a nll ..e tain i ng

screw,

SETTI NG TilE IGN[TlON TIMING:

Remove sp a..k pl ug .nd Ins tel l t imin g t ool.
8"; ner t he pi ston to top de. d ce nt e r ,
Tum t he tim i nq t ool unt il th e t op edqe of t he body o f the tool is a llon ed
with t he l owe.. e dge of the bl ue stripe.
Ro ta te tile ener ine count e rcloc kwise ( vi l'W'e d f reon
t he blue s t ripe jus t clluppeus .

th~

lIIIoneto s ide) unt il

Disconnec t t he g....y ..i re f..-c. t he H, I . co l i . and . U.ch one probe froll

t he ~ mete .. to the g....y .. ire ,

f",. :

RO 30

" ,

ADJUSTING THE CONTACT BREAKER AND I GNITI ON TIH IHG

CONT ' D.
IIf'ORTANT:

SH' No te . Page 26 .

Atttch t ile otller or.

Ohconn~ct
P 1ac~ th ~

IIlI!t~ r

pro b@ t o ground h ot t he c)'l l nde r head }.

tile bl ac k wi re f .-c. t he sta to r IIla t~ pluq (on t he -a9n~to l .

c r anks h4ft and rota t~ I t sl owl)'

until the ohm meter needle
defle cts f ro m 0 to In f1 nit)' oo . Tha t is whe r e th e poi nts have opene d.
If a t im1ng l ite/ t ester is used , the l 1111lt wi ll no "ON".
tilll ing cam

1 00s~1 )'

th~

on

etcee-t se ( vie wed from th e magneto

s id~)

--STOP - T.p t he t l. lng c. . onto t he c r.ntsr.a f t wit hout rotati_ it . ny furthe r

lf1g.

n.

I nsta ll t ile ro to r .
t orq ue .

tlgh Utl ro to r nut ( l ~ fth. n d t hre-ad) t o J.4 ft . /l bs . of

Reeheck tI. i n9 by rot. tl ng th~ f l )'Whee l <:l oc:kw is~ ( v l ~d f~ t he -aqn~ to

si de) . As t he blue ..r k il@q i ns t o appear. t he points s houl d beoln to open.
The 0"- _ t e r s houl d j ust bellin t o IIO ve f N)lll ~~ ro to I nfln ity oO
If
ti min g lite/ test~ r is use d . the lig ht will 110 - ON- . see 1I0te . lIaoe 26 ,
Timinq Spec :

2Tm1 BT OC; Poi nt Gap :

.]5 t o . 4Ormt; Spar k Pluq 1;. 0 :

. 41)nm

f oo J

RO 31

REMOV ING AND RE INSTALLING THE CARBUR ETOR

REtCYAL :
~Ye

t he s ide CO""" .

CloS!! t he fuel h p and dfs COllnl'( t t l>e f ue l pi pe

rote.l"" t he f il ter box

f~

f~

t he u rbu re tor.

t he urbu re tor.

teesee the cuburetor c l..-p bol t (a- nut drive r ) .

~Ye

t he urbu re tor

tecsee t l>e
~W'

f~

t he l nl d

pi pe.

clla~ r co ~r sc ~ ( $C ~r h~ r).

t he carbu retor {f ig . II .

REI NSTAlLI NG ONMACHINE:

Hel ke su -e t he phsti c bIlslll nq on the fnl e t pi pe is in oood condition.
If so ~u i ppe d.
Molk e s ll r~ t he nut s se cllring t he I n l ~ t pip~ to th~ cytt nce r are tig htened
t o the cor rect t orq ue (7 f t. lbs . ) IIs lllQ a t orq ue wrench and 10"," socket .
If the i nl et pi pe 'IdS removed , make s ure t hat t he ma ti ng SlI r fac es are
c l ean. Fit a new gas ke t.
Inse rt the th r(lttl~ s li de (I'IO te the position o f the gllid l ng pin ) and the
choke s li de.

RO n

.I

REMOV ING AND REINSTALLING THE CARBURETOR

CONT'D .
- Fi t

t~

challlbe.. cap and t igh ttn ( sc rewd ri ver) the sc rew secu..i n" it.

- Make ce..tain that the thrott '~ s lldt ope..ates freely and full y open s
~n thrott le g..ip is fully opened .
If neCeSHT")'. sc rew the adjust -

..nt s crew on the ch..oe.. cap to keep an accu ..ate i dle.

Ftt the ca ..bureto.. to t he in le t pipe and pus h f ull y homt.
Pos i t ion the ca rb ure t o.. body ve..tically .
Tighten

ca~reto ..

( l u n t he f ilte ..

retain ing

s c~n

c l~ (~

nut d..ive..) .

and f i t t ile filte .. plastic box.

Conne ct t he f ue l pipe .
Fi nal i dl e adj us tment ca n be IIIolde with t he e net ee ..unntne by sc rewin'l
0" unscrewing the idl e adjustlnent sc rew on t he l e ft of the ca ..bu..e t c ...
fit the si de covers.

RO 33

DISASSEMBL ING AND REASSEMBLING THE CARBURETOR

DISASS("lll1If(; THE CARBURETOR ;
~~

the float bow l cove r using a IOmm wrench .

Chec k the pape r gaske t and tile 0" rinll .

l oose n t he s crew (us i nq a small Phi li ps head sc rewdrive r ) or t he pluti c
cap ( fi g. 1 and 2).
Clea r thls pipe if neces sary wit h an ai r s t re all.
Fit the screw or plasti c cap.
Check t he f1o.Jt f or l)OOd condi tion.
~ve the fue l j e t ( a.. wnench or
with an air streall (f ill . 3).

sc ~ri Ye rJ

and c l ea r i t 1f necess a ry

Un sc rew (s crewdr i ve r) th@ diffuser holde r. If t ile di f f use r cannot be

easily relQved. s light l y push on the di ffuser end I n the . hi n" ch...t>er.
Clea r the dif f user with a hi gh pressure a i r li ne.
NOTE : Some cubure tors are not equi pped with a di ffuse r holde r . These
carbureto rs do not have a remo veabl e di ff use r . Do not try t o remove the
diffuu r froPl t his t ype of carburetor. Si mpl y leave Ins tall ed and clea r
with an a ir s t ream.

..i

g
'. '

f ,O l

RO 34

Di ffuse r
Di ffuser Holder
Fuel Je t

..

'

DISASSEMBL ING AND REASSEMBLING THE CARBURETOR

CONT'D .
- Clun t~ fue l filte r ,
{fig. fl .

t~

filler bowl, and

t~

carbure tor fl oat bow l

Unsc rew the plug sc rew ( Phi l i ps head screwdrive r) and if ~essary , c lea n
wlth an air u rea. ( fi g. 5) . (This s c rew gives you acce ss t o t he idl e
circuit. )
- Re install

t~

pluq sc.....

RrASSOIlLlNG THt: CARBURETOR:

rit the dfffu~r ."ki l'lg s ure tha t the d iffuse r flattened side coi ncides
with the ca rOu re tor or bulllin fl a t luq h c~ri ~r ) .
Locate the diffuser fully '-'e .
n t the diffuser :-'olde r hc rewdrher) and t he j et (8rmI wrench ) .

rl oat Bowl

...
"'''

DESCRIPTIO N AND OPER AT ION OF THE "MOBYMATIC" VA RIATOR

DESCR IPTION:
li ke all !'klbylettes . t he 'Iobyma t l c has a primary rubber belt dri ve whi ch
provi des the well -known srmothness and fl e xi bil ity , and a s econda ry cha in
dri ve.
But t he Mobymati c pr imary drive i s s pec i a l. The drive pulley locked on
the engine is a s pe cia l collaps ible one. whose che ek spacing is variable
under t he i nfl uence Of centrHu~ally moved balls pushin~ on t he chee k
side 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 ti o f rom 18. 7: 1 to 11.8 : 1. The engine t i lts around its uppe r
attachmen t axi s . A s pr i ng tends to push t he eng ine fo .....ar d. thu s ensuri ng bel t t ension .

OPERATION:
On s ta rti ng, .tlle engine revo lves s l owl y as soon as it engages . The springs
Whi ch push the engine fOn/ard compel the belt to rest on t he sma lles t drlvepulley diameter . The reduction ratio is at its hi ghe s t , we are i n l ow gear.
As soon as engine s peed increases, the balls push t he movable cheek, txus dec reasi ng the reduct ion ratio. which means that for a gi ven e ngin e .r pm, the
speed of the machine is i ncreas ed. If the Mobyl ette is on a fl at road, the
be lt goes on i ncr eni ng to la r~er and larger drive pull ey diame ters until top
speed is reached . If t he Mobyl ette enqaces an up-grade . t he speed of both
ma chine and en gin e tend to decrease. The ball s e xert less push on t he mov ab l e chee k which then tends to move away f rom the fixed one. the reby decreasing t he belt wi ndi ng diamete r. As this change of speed is conti nuous. the
modifica t ion in reduction ratio, al though fast . occu rs ~ radu a ll y and smoothly .
The Mobymat ic res ponds to all road conditio ns.

. '

"" .'

Ce nt r i f uga1
Cl utch

RO 36

Cen tr i f ugal
Clutc h

Ope rat i ng dia gram of the vari a t or

VARIATOR COMPONENT PARTS

."

"

,
\

\
\

,,

!
\

,
\
\
\-

RO 17

REMOV ING THE VARIATOR

aeeove t he le f t hand side cover .

R_ve tM v. rhto r cove r (usi ng a screwdr ive r ) ; re-Q ve t he belt.

Unscrew .nd

~ve

the s part pl"'i!.

Fit the st ro ke Ii _He r (100004) as s hown i n fi gure IRota t e t he engine count e rc locblse (h cinq t he varia tor) and bri na the
pis ton t o rest on t ile lim ite r .
Gently loosen tile var l. tor d...... locknut

0_ soc ke t. f ig . II .

Unscrew t he qrea se ni pple us ing t he _

nut driver ( fig. 21

...
... '

RO 38

REMOVI NG THE VARIATOR

CON T'O.

NOTE :

REPLACING TIC( GREASE Ni PPlE

s t ece Otctdlt r IS, 1976, tilt cren ksh, f t . nd 9reut n i ppl t thre.c1s hUt
slli ftt d f~ 4 I 7S t o S I SO.
Ro t dt t ilt tn9 i nt in , c1ock... tse di rec ti on ( flcl ng tilt .rl.tor ) .nd
bri n9 t ilt piston t o rest on tilt Ii.iter .
(it t ilt varhtor pullt r (100020 . 14 I l OCI ) .nd qr. du. lly sc rew to tilt
hub of tht vari. t or
T1 9htt n the ce nt e r- bol t of tIM! puller "" tl1
t ilt dr... is fret (lhn soc te t , fl o . 3).

d.......

Withdr.w tilt tnte..... l rl n9 {dosi "ll pli trs .

- Withdr.... t he shi.s ("'1ne ti c extr. c tor .

1 oo 1}

1 oo 7)

{fig. 4} .

(flq . S).

With draw the ex t erne t rinD (ope ni nq pll trs , 1 oo2 ) ( fi q, 6 ) .

Varil to r asseri:ll y is now fret f or r t<l'lOval.

... ,

. ..

....

"

RO 39

DISASSEMBLING AND REASSEMBLING THE VARIATOR

OISASSEKaL IIIl>:

I"s u ll

th@

dis..nt ll ng t ool, Ito. 100026. In t he J.WS Of. vic!! (fiq . I) .

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 relllOve the f bed c hee k usino Tool Mo. 100027 ( f i q. 31.
RelllD ve t he s 11 dl" q chee k , the b,,11 qui de , ""d t he bill Is .
Loos!!n .nd reecve ue f eece t ers...k screws holdln q till! dr.... to the hub
l,I5i"g s c rewdr h !!r or an IlIpI;c t screwdrh!! r (fill. f l .
Re.lve tile dr.... asse-b l)' .Ith till! flywe ights .nd sp d nq . ash!!" .
Re.lve t he flywei9hts by sl1 di ng t helo vert ica lly " l ong the i r pivot.

' J

-1.-

"

~-

\;.

rt : .;>~

C/,~"
:---

'. ,
,

.,

".,
.'

0;' \ -:.:.

I .. .

t-

,,

,,

'. ,3
RO 40

'

.-

>

DI SASSEMBLI NG AND RE ASSEMBL ING THE VAR IATOR

CO NT ' D,

REASSEMBLING:

Insta ll t he u rl Uo r nub on t he di sma nt linn too l . No. 100026 (fio. I ) .

Insta ll t he flywe i ght s connec t ed by two spri nqS onto t he pi vots.
f ul l y fitted in, t hey s hould s pread out f ree ly ( fi 'l . SI .

When

Prev ious ve - te tc-s are fitted with flywein nts dri lle d wi t h f our
2"", notes for hookino return s p r i n ~s. You may hook the sp- mcs in the
holes nea res t to eac n ot he r. Thi s will decreas e sprin'ls t ens ion a nd
allow bette r sta r ti ng at l owe r speeds.

NOH :

Fit t he two sprinq wa she rs on the pivo t s Ltc prev ent flywe i qht side
p lay, f iq . 5) .
Fit t he varia to r bel l onto the hub/ flyweiohts as semb ly ( f iQ . S).

IN THE CAS E OF NEW VARIAT ORS:

Cle an the t hread and put some tOCT Il E and fit t he four count ers unk
s crews.
Ti ghten progre ss ive ly and lac k t he se-e.. s by mea ns of a hea vy screwdriver.
IN TIlE CASE OF OtD VAR IATORS :

Fi t f aur new count er s unk s crews and t i ohte n prao ress i ve ly.

By me ans of

a heavy sc rewdr iver , lac k tile screws .

Punch lock the ccunte es onk screws i n the notch provided f a r this pur pose
(fiC!. 6 ).

F iq . 5

Fio . 6

eo ' \

DI SASSEMBLING AND REASSEMB LING THE VARIATOR

CONT 'O .

h k~ th~ slid inCl ch~ k ( t h@ hub t llm~d " pw.l n:!s ).

and i nst rt t M b.1lh i n t ht r~ussn {f i g . 11.

~ft

InH a 11 t h@u ll U /lle

t ile wa rj Uo r m..b fl"Oll t he suppor t t oo l and fit tee scl"@Wd

~ h !"d

(~t .

fi t
NOTE :

th~

assedll y on t ile suppo r t t oo l {llo. 100026 1.

Var l ators fo r Vt>tlt s (_I na ' wid th * 111_ ) are fi tt~d with thfo
r in g and t hfo wa s htr pla(pd be fore t ht f i ~ ~d c~k .

~t a i n ln ~

Insta ll t hoP
Ti qht t n

th~

' i ~~ d ch~~ t

(R. H. t hread ) and l ock i t .i t h Tool '60. 1000l7.

lo d n" t (l. H.

th r~a d )

with a 35nn

f iq . 1

eo

41

bo ~

wrenc h.

ADJUSTI NG AND RE FITTING THE VARIATOR

Ma ~ e

s ure that the small r in g qraa ve (an the c rank sh aft t apered end) is
in aood cond i t ion ( f i o . n.

Clean tharounhly and remo ve

(wi re bru sh ).

~11

grease f rom t he

c ra n h h ~ ft

threade d end

Ins e rt the caged needle beartnq in to t he varte tor- hub.

Place a O.8mu sh im on the needle ca-re.
Fit the small ret a i ni n~ r i nn on top cr the shi m ( fi 5. 2 ) .
Ins ert the o th er O.8nm shims and t he otter r inq (cl osinq pl iers) (fiq. 3) .
Sl OE PLAY ADJUSTMENT :
MAX IMU M SlOE PL AY:

O. lMM

The shi ms and reta in ing rinqS should have a side pla y (s l iqht a l l owance ) .
If t he re is too much s i de pl ay, perform an adjus t-rent usi ng O. l m s hims
( fi g. J).

F;g. I

FOG 3

RO 43

ADJUST ING AND RE FITTING THE VAR IATOR

CONT'D.
c-eese .ooerite l)' t he i nner p, r t of the hub ( c' tIPd ndl e bu r l nq) .
The v,d itor ca n _
Ori~

the va r i ,tor

he rei nsUllt<t (f iQ.

full)' ~ .

41.

It will Icc a te i tse lf in the r lq+, t pos I-

t i on.
The use-b l)' will rou te f retl)' without p1l)' if t he si de pl.)' h.s bt'tn
, dj usted as des cribed ,bove .
Br ing t he piston tQ rest on the stro ke I i. iter , nd fit t he var h t or
dr um ( ~t f orget the o- r i nQ on the d~ hub) .
Tight en t he nut to 22 ft . l bs. {torque wrench } .fte r h. vi no ,pPcl1ed .
si ngle drop of t OC TIH (fig . S).
Fit t he qreese ni pple (6m nut dr i ver ) refer t o 1I0TL P. 'It 39.
geecve t he st roke l i mit e r , f tl t he spark pl uq and ra dio Suppressor .
Fit t he be lt , t he var i H or cover , and s r ue co ver.

RO 44

RE MOVI NG - RE FITTING - DISASSEMBL I NG - REASSE MBL ING THE CLUTCH

REMOVI NG THE CLUTCH;
Do not remove the be lt guard.

Slip t he drive belt off f rom t he pedal s haft

pull ey .
Re fer to page 38 (s ame procedure as f or the ver -i ato r }.

DI SASSEMBLINGTHE CLUTCH:
- Remove the caged needle bearing .
. Moderately cl amp the pulley cn.tne c l ut ch i n a vi ce fi tte d with copper j aws.
Loosen and remove the t wo counters unk screws {impac k sc rewdr ive r } (fig. l Al .
Remove t he count er flange (fi g . lB).
Remove t he two s pr i ng washe rs .
- Remove t he flyweig hts by slidinQ t hem vertical1y alon o their pi vot (c are fu lly
not e flywei ght s posit ion. f ig. Ie ).

Dj ,.." ct ion of Rota tio n

r ; Q. I

RO 45

REMOVING - REFITTING - DISASS EMBLING - REASSEMBLING THE CLUTCH

REASSEMBLI NG THE CtuTCH :

FI t bot h flywei ghts (connect ed with two springs) on t he mCllmtinq pil lars
(fig. IC).
Place bot h sp ri ng was he rs on t he moun ting pi ll ars.
Place t he count er fl ange on the was hers (fi g. 1B) .
Secu l'@ Ole counte r fla nge wit h two new countersun k

SCI'@WS

( f ig.

1A) .

After f i na l t ight en i ng . punch loc k both sc rews i n the notches prov ided
for t hi s purpose ( f ig. I A) .
SIDE PLAY ADJUSTMENT AN D REFITTI NG THE CLUTCH:

Re fe r t o pages 43 and 44 (same orocedure as f or variHor) .

Fit t he belt on clu t ch pulley.

- _/
Di re c ti on o f not atto n
RD 46

fio . 1

REMOVING AN D REFITTINr. THE DR IVEN PULLEY

ROOVAl. ;
Jleftlve the LH. st ee cover us i"9 a sc rewd ri ve r .
It is unnecnsal')' to ~ve the drive cha i n . but if you neell to ", pla ct!' it.
m e "-.<I s tt!' r" lin k.

~ve

In tht!' cne o f a nriator e ngillt!' . re-:lve the beo l t cove r (sc rewdr i ver).
~ve

t he ped. l pin nut ( 11_ wrench ) and dri ve out t he loll . cra nk co tte r

pin.
"",,,ve the peda l c r ank with the p@da l attached .
Slip the dri ve belt off f.-u. the pull ey groove .
lIsi ng a mu it i lock pliers

1't!'1O)'It!'

t he dun c.p ( fi Q. 11.

Remove t he I't!'U ining r i ng (open i ng pll t!' rs . No. 100002 ) .nd the thrust
wn her ( f ig . 2).
Turn the engi ne

eng.qe~nt

leve r t o V Ie nqt ne dis engaged).

The pulley as se mbly can now be pulled off the shaft.

Ro t at e t he pull ey and pull on I t .

Ho ld t he dual sprocke t.

Remove the pul ley.

L itt t he ch. i n off the T1! ar s pro cke t wh11 e ro U tin g tht!' wtle-el and remove t he
dual sproc ket .

f",

~o

47

RE MOVI NG AND REF ITTING THE DRIVE N PULLEY

CO NT'D .
RU ITTI NG:
Fit t he dual sp rocket on the pedal s ha ft (smaller teet h facing the frame ) .
Fit t he chain on t he dual sprocket mak i nq sure that the "mas t er" lin k clip
is fac ing the correct way . The cl osed end of the sp rlnq clip mus t fac e
the direction of Chain travel { ff q . J).
Fi t t he chain on the rea r whee l sp roc ket.
Place the pull ey (engi ne enna!jell'ent lever set to V) on the pedal Shaft.
Cen te r t he dual sproc ket manua lly and fit it on pulley hub.
Press on t he pulley t o dr ive the sproc ke t fully home.
Fit t he t hrus t waS her and th e ret aini ng ri ng (openinq pli e rs No. 100002).
Fit t he dust cap ( repl ace it If I t was damaged durinq dismounting).
Fit t he belt , t he cover (if var ia to r engi ne) and si de cover.
Make certain t he chain Is correct ly t ens ioned (this operation mus t be done
wit h a rider on the mac hi ne).
The adj ustin g of the chain is carr i ed out by mea ns of t he chain adjuste rs
s itua ted a t th e end of t he swi ng ann . Do n' t f oroe t to l oosen the whee l
axle nuts (&rm wrench ) ( fig . 4) .

f ....

F'll . '

RO 48

REMOVI NG AND REF ITT ING THE CRANKGEAR

REP LAC ING CRANKGEAR BUS HINGS
R(llIYING l H[ CRAN KG All :
~w

thop driw!'n pull.y (l"I!'f.r to 1N9I!' U ).

~w tht' t? t ai ni nq rinq (OPf"'i no plt.rs. 110 . 100002 ) .nd thrust wnhopr

{fiq . II.
~w
~ l ..s.

t"'" R. H. si d!' cow r.

thE> ell. i n tens lOftl!'r (fiq . 2 ) .

Slip t hi!' PI!'.s.l e"'i n oft

or ......w I t

if it is dUl!' f or l"I!'jl l,,_nt.

~we

the ( ra ntqeu witll the R.H. c r.n t . nd t hrust .nheM. ( di u n Mlb l e

t hop vant if t he crankqu r is due fo r rep lac_nt : II"'" wrench ) .

ADJUSTI NG TflE CRAN U l LE Sl OE 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 in qs .
f it t ile ri nq and t hrust was her (f io. I).
The Sha H s hould ha.e almost O. I!TYII sid!' play.
I f nece ssary, perfo .... a co r rect adjuStml!'nt by us inq s hilOS (No. 14863 ,
0. 1... ; No . 1486S, O.)rn) .

"

"

,
00

~9

REMOVI NG AN D REF ITTING THE CRA NKGEAP.

REP LACING C PAN KGE A~ BU SH I Nr,~
CONT 'D .
REFi n iNG THE CIWlKGEAR;

like u rt' in positioning t ilt! "..uer" link in t hf' ee r -ec t ...y h l!'t!
REPlACING CRAl(KGEAR BUSHINGS :

Fte-ovot t he driven pull ey ( rt'fer t o

Il.~

411 .

RelllO vot the cr . nkge. r (see pl"t!ceed i ng 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 tile r fllloli ni nq bus hi ng out with t ile 2Dnn H eel t ube .
rit new bushin gs by usi nQ Tool No . 100009 ( fio . 41.
Inse r t t he crank axle i n t he bush in \ls. The u le shou ld t"rn frt'ely
without phy (if nece sury us e. 16Irm re allll'r on the buslli n<l\ l .
Fit the cr ankgea r . nd t he pulley (see ebeve and paqe 41J ) .

... '

. ..

Il.~

4ft).

REPLACING UPP ER ENGINE MOU NT ING FLE XIBLE BUSHI NGS (MODELS ~ AND 50)
TOOL NO,

l0002~

IS ABSOL UTELY NECESSARY TO EFFECT THESE OPERAT IONS

Remove bot h si de cove rs us ing a sc rewd rive r.

Remo ve t he belt f rom t he pull ey groo ve.
loosen the uppe r e ngi ne moun t inq nut (12 and IJll1II wrenche s ).
Drive out t he upper engi ne mo unting axl e whi le hol ding the ene tne .
le t t he engi ne Jean downwards but pl ace a bloc k under it for su pport.
For remova l or i ns t a ll a t i on operations , the fle xible bus htnos must be
remove d Or ins tal led from insi de to outside .
RH~V I NG

THE FLEX IBLE BUSHi NG:

- Pos it ion the tool in alignme nt ( fig. I). Ho ld t he nut with a 170m wre nch
and s crew in pull er ' s sc rew by usi ng a 120m wrench.

POSIT IONING THE FLEXI BLE BUSHING:

Insert the sto p was he r ( t his wi ll loc a te the bushing co r re ct l y in the f rame )
as shown on f i g. 2.
Position the fle xible bushing (chamfe re d end) on the sc rew and proc eed as
whe n remov i n'1 t he flexible bus hi ng.
Re pl ac e if nece s sary t he l eft fle xi bl e bush in su lation ring .
fit the upper e ngine mo unti ng ax le , t ighten the nut with out l oc ki ng it
(refer to the NOTE on page 11 1.

I!.O 51

REPLACI NG UPPER ENGINE MOUNT ING FLEXIBLE BUSHINGS

(~DEL

]>

NOT[: All service ecerett ees ~9ar4in9 the en91ne and the fr_ Indicat.M
th rou9hOut our JlPAIIl OPERATIONS a~ valid fo r ~~d ty~ -1- .
1001. 110 . 100024 IS A8SOlllTHY IIECESS.lIl' TO EffE CT TH IS OPtRATlON

Slip thl! belt off fn:. t he pulley orooVE' .

l oosen tlf@ nut (IOrrrn soc ket) on t ile 10000r enai ne ..aunU no

SC~

and remove I t.

l oose n th e two nuts {I 3nm socke t) on the upper ena ine mounti nq.
Remove the en91ne and le t i t de t ach f rom the f ra ne.
placin g a blOCk under I t.

Suppor t the enoine by

Fo r I"@llI)vl ng or fit tlnq ope rations. t he flexi bl e, btlshes will be removed or

fi tted f r{lnt f ront t o re er- of U.e ..achlne ( flq. 1 and flq. 2) .

f l q. I _ loca t ion o f par t s for bushina remova l

REPLACI NG UPP ER ENG I NE MOUNT ING FLEXIBLE BUSHI NGS (MODEL

cONT 'n ,

7)

REMO VING THE FLEXI BLE BUSHI NG:

- Ali gn the too l ~ S Shown in f i g . 1, and hold the nut. with a 17"", wrench
~n d s c rew i n the too I ' s screw us i ng a 12"", wrench .
FITT ING THE FL EX IBLE BUSHI NG :
Re verse the body of the too l and in se rt t he screw i n it .
f it t he fle xi bl e bushi ng (chamfered s i de ) on t he s crew, pile up t he two
of t he too l as i ndi cated (f ig . 2) and sc rew t he nut unt il t he
wide r w~ sher rests a g~inst the f l exi bl e bush inq hous i nq we l ded t o the
w~ s he rs
fr~rre .

fi g . I - Locati on of part s f or bushinq ren>:)v a l

Fig . 2 - toee ttce of

p~rts

for buShi nQ 'i ns teTla t inn

RO SJ

RE PLAC ING CABLES

FRONT OR REAR BIU.K[ t ABU:

Lee sen t he cable e nd usi lHj a ~ open _

t hrough the brake l eve r (f ig . 2) .

ch and s l ide t he i nner .. I re out

Tigh t en t he bra ke adj uste r at t he handqri p f ully ( Hi) .

31.

Grene the new i nne r wi re and fee d It t hrouq h the le ver ancho r pi n , the
adj uste r and out e rc nl n9.
Whe n rep la c ini) the re ar brake inne r wire , IIol ke su re t hilt the fe r ru le is positione d cor rec tly.
ADJUSTMENT:

rig.

Ho l d the ca ble '11th pli e rs ( ri ght hand ) , Pus h On t he cable a r lp with a

seco nd pa ir of pliers . Pi nch t he Inner wi re at t he poi nt where the cam
lever t ouches . Releas e t he end of the cable and t1qhte n Ub le qr i p s crew
( fig,

21.

If ne~ssa ry , adjus t the brak es us i nq t he adj llS t e rs 011 the leverli ( f lC!. 3) .

merrne

CA8l.. E:

Re-ove t he R.H. enqlne cover and t il t the u rbu re t or ( to the le ft s i de ) by

loos~ lni) theu rbu re to rcl.-p(a- nut driver) .
RMove the sc rew on the . h_
i nq cha. r cover . Re.:lW' the cover c...,lete .. I th the t hrottl e s li de and
choke s li de (sc rewd ri ve r) .
l oos e n t he cable l ock f nll' t he Ulrottl e twts t gr ip (~ open wrench) .
out t he Inner wi re .

Pull

Reassemble i n reverse seque nce and qren e the new inner wire be fo re s lid in'!
H into the oute rc nl nq .
Fit t he ca r bure tor and ti ghten t he c lamp.
Ma ke t he fiM I adj ustment on the sc rew located on t he _h ino chambe r co ve r
iIIld lI\II ke ce r tilin the thrott le sli de wo r ks free ly .

....
RO S4

. .'
f ;g, J

REPLAC ING CABLES

CONT' O.

CNOl[ CA6L :
foll ow the procedure IS dl'scribed for tile t hro tt l e inner wi re .
Slacken t he nut at t he chOke l e ver (&mI ope n wrench ) and pull the i nne r
wi re out f rom t he bottom of t he choke slide .
Reverse t he procedure t o re assemb le a fte r havinq lUbr i cate d t he repla ce me nt i nner win! and feed it up t hrouqh t he c hoke s lide .
Adj ust the t ens ion at the choke leve r adjl,lSte r (a SIllolJ1 a.-:)unt of free
lD_nt is requ ired and should not e .cee d \~ . f ig. 4 ) .
DECOlf>ftSSOR CABLE:
l oo s ~

t he caete end .,s in9 a 6no open end wrench .

Remove the radi o S" llP reS50r and depr es s the dec o-pnessor spr i no us i nq a
sc rewd rl ~ r and relDve t he fe rrule f,.,. its hol der .
Pull out the in ner ..i re from the oute rca sing.
Grea se t he new i nner wire and reroute it t hrouoh t he ou tercas i ng and i nto
t he s hou ldered f e r r ule . Reverse di u u emblinq procedure.
Adj llS t the ca bl e tension at the detOqlreno r adjuster on t he twist qr lp
(a s... l1 ~n t of free eoveeen t is rt'q\lired and s houl d not e xceed \~ . t t e . 5).

f i C). 4

f ig. 5

RO 55

REPLACI NG THE FRAME

~ W!

bot h s ide covt'n.

~ vt'

t ilt radi o SuPJI res sor . nd di$ C(ltlM't t t ilt dttooopres si on eee te.

Jlea) ve t he l. H. bla ck pl astit

cov~ r

(fIg . I) .

Re!nDve t h~ strew 011 t he .. I xing ch.llbe r cover , .nd t he cove r cooop le t e with
th rott le sli de and choke sl i 6l! f rom the t arb ureto r .
Remove t he out e rtu i ng
wrench . fi g. 2) .

re ta ine r

tog~t h ~r

wit h th e ig ni tion coil (Brrrn

Dis connec t the reer br ake i nner wire . eeecve the sc t eer-tes s
t he oute rca sln g s houl dered end.
Di sconnect t ilt fo ur -way connec to r. t h~ wires
and zene r d iode s t ra ight te Tll ina ls .
Re.;l't'e

t he

Dl! yt h all

R .H .

blat t phsti t

~ l ~( t rlt

oU15 i d~

"

te ees ,
~ l.

"
RD 56

.nd

the fl ywheel .... gne to .

(Oft l"$ .

Set t he ..thi ne on a 11ft benth and clUICI t he rear

n lppl ~

REP LACI NG.THE

CONT' n ,

Unsc~ and
bar . I T ~ls

US e

wrenc~

~ve

the

Unscrew.nd

FR~

on~ of th~ U c l.-ps on the ~andl e

-.achi~ i s f it te d wit~ t.1I " U ct.mps .

ne-ove t he nuts se cu ri ng
is not req uired If the

Ito. 1129 to r@lIIOve the top s t ee ri ng locknut ) .

s ~ rra t~d

reIIIO'I't

.a..,tl ng bloc h .
the stffrl"9 locknut (:n- wrench ) .nd the washer .

...-fla tten the loc k pt.te and I"f1IIOve the botto- pivo t sc~ ( ~wrench) .
Re.l 'l't the front wheel assedl ly. fork . h.ndleb,)n. and cOntrols .

fte.n)ve the s tl.'l.' rl"'l he.d se t ( refl.' r t o P'lJI.' 64

Rl.'IIIOvl.' the belt cc ve r .

utsccn nec t t re f ue l pIpe , and reecve t he I.'n 9ine as serrbly wit h t he carb ure t or (refe r to pagl.' e).
Remove the dr iven pull ey ,

47 - sol.

t~ e c ra n~ g e a r ,

and the chai ns Ire fe r- to paqeS

Remove t~ e loading s pr i nqs and the s top bracket (ll)rrn wrench , fig . 3) .

RO 51

REPLAC ING YHE FRAME

CONy 'D.

....... ,,,

u.. u ddl t and tile c h .. around

...

._~

~~

_~

Remove

'"
".
".

fue l cap . decals .

ch~

t~

fr_

sut pilla r (1 3M wreno:h l .

s t rip and too l box ce vees,

Ze nt r diode (to- wrench ). if equi pped.

s hock absorbe r upper mount i no bol t s (13mm wrtnch l .
se lf -locki ng nut (I7rrrn wre nch) and dr ive out swing arm s haft .

Remo ve t he swi ng arm compl e te wi th s hock abso r bers and th e rear wh ee l ( fiq .

41,.

Remo ve the rear f ender wi th wi rin g and l uqgage ra ck l owe r s uppor t br acke t s
( re f e r t o page 15 ) .
geecve t he l uggage Cir r; e r r ack and l uqqage rack upper suppo rt brackets (lIN
wrench and Philips sc rewdr ive r) .

Re-ove t ile f~ l tap 114. . open _

good Con d lt lon (f Ig. 5 ) .

ch i .

Ma k" sure the rubbt' r s u i is i n

~ve

the plast i c s t r ips f ro- rea r f r _ a..-s and the g.--t f n:- t he l _ r
p;lr t of t he f r _ .

Remve the cente r s ta nd ( re f e r to p;lge 69) .

REFi niNG THE FRN'[ :

_ Re ve rs e t he procedure .
bus hi ngs (Page 51).

fi t nelO c rankqear bush i n"s ( Page 50 ) and new f lexib le

Do IIOt f or get t o stamp the f r arne number on th e nelO frame i n t he same loca t tDn as the ol d f rame .

NOTE:

fi g. 4
RO 58

rlq . 5

RE~VING

THE MA IN FORK ASSEMBLY

Foran OjM! l"I tions on t he f ron t fori: . f uten the rear wheel ( t ile front wne-e l
..ill 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

t~

s eeo ve the

U c lamps comp le t e with wedges .

headla~

let the handl ebar hang down .

assent> ly and dis connect t he wires from the s ealed beam.

Disconnect the .. i res at the headlamp s.. itch .

Dis connect the .. ires fl'Oll t he hom , dis connect the s peecloRter control fl'Oll
spee~te r drive unit and the-f ront brake control .
Re.l~

the

tM outercnlng fe r ru l e (I o- wrench) and f ree the brake cable fl'Oll

brac h t.

f~der

Re.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 lot ted screwdr iver, Ko. 100012 . fi g. 2)

..,
RO 59

REMOV ING THE MAI N FORK ASSEMBLY

CO NT' D,
Remo ve the fron t whee l with the for k pl unQe l'"S .
Remove the top steeri ng loc k nut and washe r j321ml wrench. fi g . 3).
Flatt en t he loc k pla t e and rel1lQve t he bottom f or k s t em reh i nin9 bolt
(wN'! ncll. No . 100019. fig. 4 ) .
PN'!SS aga in st t he fo rk pi vot and lowe r fo r k ple t e wit h a screwdri ver t o
f r ee t he pegs (fig. 5) .

Pull on the rna in fork as senbly to f N'! e the l ower fork plate and l if t to
free the uppe r part.
Rel1lQ ve the lleadJamp and the horn (lOnTll wrench ) and f it them t o t he new
ma i n fo r k as sembly . ( Do not f orge t t he gro und l ea ds on t he head'l aep
lower moun t i ng s crew.)

t>J

;;~,

F" .5

RO 60

REfI TTI NG THE MAI N f ORK ASSEMBLY

REMOVING ANO REF ITTING THE FOR K COMPLETE
_ Reverse dismantli ng procedure .
Ma~e

su re th at the lo we r pla te pegs are posi t ioned i n t he s l ots of t he

fork pivot.
If necessa r y , replace fo r~ bush in qs and sp ace r s (refer t o pane 62 ) .

Al ways f it a new lad

pla te on t he oottom pi vot sc rew.

RE1'IO VING ANO REFITT I NG THE FORK COMPLET E:

IlelllO ve t he f ro nt wheel ( re f er to page 66 ) and the fe nde r (ref e r t o
page 76) .
Yo u need not remove the fork ca ps re ta i ner nut s ( fig . I) .
Follow t he i nst ructions gi ven f or t he ma i n f or k as semb ly remova l and
refitt i ng.

f i 'l . I

., ,,

REPLACI NG FOR K BUS HI NGS AND SPR I NG S

Di sconnect t he spee do.-ete r cable .
Disconnect t he front bra ke cont rol cable.
Remo ve the oute rcasi ng s houl de r ed en d of th e fron t br ake cable and f r ee t he
cable f rom fender s uooc - t .
Remove t he fo r k cap reta i ner nut s (s lo tte d sCN'wdrl ver, No. 100012).
Remo ve th e whee l compl ete wit h f orI< plunqe r-s and spr i nqs .
Remo ve the dampe rs .
Remo ve the forI< seal s (f ig . 1) .
Ext ract t he bushings and s l ee ves with th e 2-ja w pull er, No . 100006 ( fiq. 2).

Inse r t a new set of bushings and slee ves i n each for k t ube .
Ma ke su re the bottom fork sea ls are i n good condit ion:
t hem (fig . 3).
Fit new fork

spring~

or ne....ts e r e pl ace

if the old ones were br oken.

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

Coat t he sp ri ngs with qr ease and fit the whee l wit h plu nqe rs back into th e
the for k s hell .
Fit the rubbe r washe rs , cups , and tiq ht en t he uoper nuts (s lotted screwd r iv er ,
No . 10(01 2).
NOTE : Make sure t he t op struts of t he fo r k pl unqer s a N' l in ed 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 ) .

\,

F". ,
F;g, S

RO 62

RE MOVING THE HAN DLEBARS

Slacken the loc knut unde r the twist gri p and remove the sc rew ( &mI wrench
an d s crewdr j ve r , fi g . I ).
Remove t he twi s t gri p s lee ve.
Free t he t hrottl e and decompressor cont rols from the retai ning bra cke t on
the for k 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) .
Ins er t a sc rewdri ver blade bet ween t he rubbe r grip and handle bar t ube
(fi g . 3) .
Tilt the machine s l i ght l y and inject some oil drops i n th e space opene d
by t he s crewd ri ve r (fi g. 3).
Remo ve the rubbe r gri p (f iq . 3) .
SlaCken t he sc rew se cur i ng tile left hand gr ip body.
Remove t he four nuts under t he handlebar "U" clamps .
Remo ve th e l eft hand gri p body .
Remo ve t he handleba rs.

Mg. I

F.." 2

RO 63

REMOVI NG THE STEERING HEAD ASSEMBLY

RE PllVAl:
~W! one U c1..-p 110.. w",nth ) .
This is not n""u n O')' fo r t. ll U
t 14""s . Re-I)vl' tM t op stl'l'riM l o<:k nut us ing Wrench No . 12211 (fig . t) .
Sl at kl'n thl' nuts sl'c ur t ng tM othl'r U clamp and re-oYl' the wedge unoer
t hl' .U" t lalllP alread)' r"'ll~d (fi,l. I ).

Fla ttl'n tile l o<:k ph t l' and re-on t ile lower pivot Strew (l1""'th No . 100019) .
~ ve

the f ort with tile whl'l'1 without discoMl!l;tl nq an)' wires .

l et t his .sseoobly h. n9 t o ont sidt and inse r t a sc rewdrlvt r o r a h. rdwood

block through tht spo ktS to l ot. t ile ~l (fi9. 2).
Hold the steering he. d steoo w1th inte rlocki ng joint plit rs . "d s hc kt" t he
uppe r stter tng cone.
Iltlaove the stteri"9 htad steoo, eauec t the s t l!'l! ri nl) hea d stte l ba l h . and
pul l out t ht upper and l ower Cup1 b)' lISi"g a t up pull e r ( f i g. 3) .

",

RO 64

REFITTING THE STEER I NG HEAD ASSEMBLY

Insert the bott om and top cups into t he f rame stee ri nq tube ( f it t i ng
tool, No . 100016, f ig. I ) .
Pack the top cup and pivot stem cone wit h gre ase to ma ke ball f itt i ng
easier.
Place the ba II s (26 ba115) on t he pi vet stem cone and i nsert it i n th e
frame stee ring t ube .
Fi t t he ot her 26 be lIs in the top cup.
, ,:rew in t he top cone . Hold the pi vot ste m wi th tnte r-Iccktnc joi nt
pliers and s tra ighten t he cone wit h t he hand ( fi g. 2 ).
Fit t he as s emb ly (wheel, fork, and handl eba r ) .
Fit t he "U" c lamp and wedge .
Ti ghten t he f our "U" ct amps nuts (IOPm wrench).
Make s ure t here is no up and down play in t he steer inQ head races .

' '" , I

RO 65

RE MOVING AND REF ITT ING THE FRO NT AND REAR WHEELS
REI'O VI NG THE REAR WHHl:

Place the machi ne on the ce nter stand and l oosen the rear whee l axle nuts .
loosen atnos t. full y the left h<1 nd a xte nut to remove the chain <1djuster
bolt . Lift th e drive chaf n off t he rea r whee l sprocke t (fig. l).
Push t he Chain te nsto ne- up into the lOcked position and lift t he p':'d<1lli ng chai n off t he freewheel (fiq. 2).
Push t h.:. cam leve r fONard to reteese the rear bre ke ceble (fiq. 1).
Remo ve the wh .:. .:. I.
Remove the bra ke <1sselT"bly and insp.:.ct t n.:. brak.:. s hoes.
REFITTI NG THE REAR WHEEL:

Reverse the procedure.

M<tke sure the Slo t in the brake backi ng pIa te fits over the lug weld.:.d
on t he swing <1 nn (fig. 3) .
App ly the bra k.:. and tighten t he rea r whee l axte nuts. (This will cente r
the bra ke shoes.)

\
o

fOg. 1

RO 66

RE ~ V IN G

AND REFITT ING THE f RONT ANO REAR

CONT'O .

~EELS

REIt)VI NG TIfE fIWNT WHE El :

Rep lace I bl ock uncle r th e engi ne or, if the ma chi 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 off t he gro und.
Disco nnect the s peedome ter cable and retease the fron t brake cabl e f rom the
f ront bra ke Inn ( fig. 4 ) .
Slacken the ule nuts sufficien tl y en(luqh to

f~e

the flat wn he rs ( f i <;l. 5) .

Pull the ....ee 1 dOWI and out o f t/le f ort.

~ve

t he br.ke pll te I nd i nspec t t he bra ke shoes .

Clea n the dO'. . if neceSS"' I')'.

REfiTT ING THE fRONT WHEEL :

Re verse remo va l proce dure.
Mil ke s ure t he l ug on t he brake backi ng pla t e fi u
( r i ght hand ) fig . 6 .

i nto t he f ork s lot

App ly the bra ke and t ight en the f ront whee l s pi ndle nut s.
ce nte r the brake shoes .)

(This will

,..

f ;g. I

Ill) 67

REPLAC ING THE BRAKE SHOES

(FRO NT OR REAR)
REMOVI NG THE BRAKE SHOES:
Remo ve t he whee l f rom the chassis ( re fe r to paqe 66).

Remo ve t ile bra ke back i ng pla te from t he wheel hub ,

Clamp t ile br a ke pla t e In a vi ce and i nspe ct t he
ing t hem from the brake backinq pla te.

br ~ k e

shoes before remo v-

Ins e r t a screwdriver betwee n t he bra ke backing plate and one brake s eee
and pr~ss aga i nst it t o re move t he shoe ( fi g. I) . Lif t th e ot he r shoe
off the bac king pl at e assem bl y.
NOTE: Be care f ul not to bend t ile backing
shoe s .

~ late

when r emov in g t he br ake

RE FITTING THE BRA KE SHOES:

Assemble tile new bra ke shoes wit h the return s pr i n9S.

Force the shoes apart holdi ng t hem i n a "V" formation (fi q . 2).
Press downwards on t he bra ke s hoe to posit i on it cor rectly.
Coat t he bra ke pivot cam with a li ght f il m of gre as e ( flq. 3) .
The i nner surfaces of t he brake drums must be kept free f rom oily s ubs t ances .

Fi g . 1

Fi ll. 2

eo sa
Fi g . 3

REMOV! N(, THE CE NTER STAND. THE SADDLE

REPLACING TH E PEDALL I NG CHAI N AND THE DRIVE CHAI N
REI"IJV ING THE CE NTER STANO:
cr~nkg~ar pull~y

Using multi- l ock pl i e r-s , grip txe

(See paqe 47) .
R~mo ve

the

Tilt the

ret ~ ;ni n9

mach i n~

r i ng usinq

th~

dust cap

~nd

remove it .

open inq pl iers No. 100002. (See pace 47 ) .

(pulley opposite s ide ) .

Se t the cente r st and s pri ng by pas sing

bow of the sp ri ng ( fig. I).

pi ece of st ri ng t hro ugh

th ~

lower

Remo ve th e s pr i ng (fig . I) .
R~mo ve t he nut s ec uri ng the center s t and bolt (1311111 SOC ket and 1411111 open end
wren ch ) .

Slig htly Pull th e pulley upwards an d remove t he bolt (flq . l) .

aeneve t he ot he r bolt and

r~mo ve

t he cen ter s t and .

REFI TT ING THE CENTE R STANO:

- Reverse t he procedure.

- If nec ess a ry, rep lace t he dust cap on the cr ankgear pull ey.
RE I1JVI NG THE SADDLE:
l oosen the s addl e cl amp (1311111 socket )
Lif t t he saddle upward s and remove it.
REFITTI NG THE SADDLE:
- Re ve r se t he pr acedure ,
NOTE : wtl~n r e fitti ng a saddfe ,
th e seat post when sat upon.

ma k~

s ure t hat i t does not come t o rest on

REPLACI NG THE PEDAL CHAlN:

- Push t he ch ai n tensioner up into t he l ock ed posit i on.

F". l

RO 69

REMOV ING THE CENTER STA ND. THE SADDLE

RE PLACING THE PEDALL ING CHA IN AND THE DR IVE CHAIN
CONT'O ,
RelKJ w<! t IM> joi nt cli p (flit nos<! pli<!~
ch. in joint cli ps (f i '] . land 3) .

).

TlM> re.re t "O ty p<!s o f pedal

Conll<!c t the nl!W cll<li n with the cha in joint of t he old cha in . nd pull it
.u'Ound tile freewtlee l until t he new ch. i n end is brouqht out.
Fi t th e joi nt c lip ( fl a t nose plie rs ) ( fi q. 4).
Re l ease the cha i n te nstone r t o brino it back into PQsit io n .

REPLACI NG THE DRIVE CHAI N:

Loosen t he rear axl e wheel nuts ; :<9rm wr.ench ) and unsc re w t he adj uste r
bolts a fe w turns (8rrJn wren ch ) .
nescve the N ste r l i nk clip ( flit nose pller-s ).
COnnec t the new chai n with t he ch.i n li nk of t he old cha in .nd pull it
<l rou nd t he sprocket unt il lhl<! nf!'W chai n I<!nd is brou<lht out.
Fit thl<! li nk c li p ( fl a t nose pli<!r-s) (fig. 4) .
Cl<!nter the wll1 (IS I I1 ~ t r<l ted on P<l<le 75) and <ldj~ t t he clLa i n tens i on
by '''!!Ins o f Idj~ t<! r bolts (one -.st t .k<! into account the r1dE-r 's wei<lht l .
Lock t IM> . xll<! nuts (I~ wl"l!'ftCh ) .
The wheel should t um freely with no T'Ol.Iqhll<!sS or t iqllt sPOts (. r row - 1(111 ,
f i g. 5) .

... ,

R0 70

... ,

REPLAC ING THE FRONT WHEEL ADJUSTMENT CONE S, CUPS, AND BALLS
Re-ove

t~

fl"Ollt whee l and t he front br"ke phte ( re fe r t o paqe 611 .

Re-o ve t he ule nut on the ot he r s ide of the wheel (IS- wrench ) . t ooe ttttr
with t he washe rs "nd sPff~te r dr ive unit (fig . I) .
~ff

the sP<Jcer ind t he fo.1ll was her .

Re-off the cone lock nut

( f i g. l) .
Rewove t be

i ~l e

(t~

wrench) i nd keye d wisher .

Re-ove t he cone

nut.

Rewove Ute two a ll deflpctors us l no , SCrewdrive r i nd t ak e care no t t o

drop tM b.llls . d i _ter 5.S- III b.ll ls 01\ each si de , flq. 3) .
~ve

t he bear i ll9 cups us ing " dr i ft punch "nd

..

h~r

'

' .... J

RO 71

RE PLAC I NG THE FRONT WH EEL ADJ USTME NT CONES . CUPS. AN D BALLS

CONT' D.
Inst. ll t he new hub be. rint cuPS us i nq TOOl Ito. 100014 (tubP ) . nd h _ r
(f it. 4).
II.Ike s ure the u l e is Pl'rfl' ctiy t l"Ul' . If it i s not . lit F?P I' ce-l'fl t

_.

Screw in t he new cone on .I_ st

so.-

f n:- t ne u ll' e nd.

fit t he kl'yed " U her .nd t he cone lock nut {1;o.. .......1tC1l }.

r till' CUJls .. i tll qreu l' , fit t ill' b.lls on t he br. te d,-". si de .nd f it
the o i l de f lec to r.
Inse r t t he 'lI e in thl' nut , f it the othl' r b. lIs and fh the othe r oil defl e ctor ( f i q. 5).
Screw i n till' cone lock nut , nd keyed ..uhe r . The ....ee t s houl d tur n free ly
..ithout ph y.
f it t he 1000 m .. Uber ( rephce i t if necessary ) , t he sp ace r. t ill' SPl'eOOml' t l' r
drf ve uni t , t he ..aSher and t he nut ..it hout locki nq i t.
fit the wheel (refe r to page 67) .
Ti ght en t he ax le nut On t he bra kl' sl dl'.
Connec t t he speedometer contro l On t he SjleedoJlll! t e r dri ve unit and ti qht l' n
t he nut (l8lml wrench ).
Lock till' a xle nuts whil e apply i ng t he brakes .

...

f ... 1

RO

RE PLACI NG REA R WHEEL BALL BEARI NGS

Remo ve the re~r whee l ~n d pull out the rea r brake ~ s semb ly (re fe r t o p~ ge 66) .
Remo ve t he axle by t apping with a ma llet (fig. I).
Remo ve t he s ta r was he r, the s houl de red s pace r , and th... s pac... r ( freewhee l s ide ) .
Rl.'fIlOv", t he bea r ing locknut with punch and ha_ r ( f i g . 2) .
Rfomo ve t he dus t cap on th e freewh...el si de with a sc rewdri ve r.
Ins... r t ~ dr if t punCh and kn ock out th... bear in q (d iame t ... r 3Omn) on drUlli s i d...
( f ig . 3) .
seecve th e beari ng s pace r and pull out t h... ot her b...u ing {diame t ... r 26nm} ust ne
~ stee l t ube . di ameter 23....
R...mo ve the wheel nut and locknut t ha t relllol ;ned on t he ax l e (I 7nm wren ch ) .
Make su re t he axle is true. (Fit a re pl acement one i f it i s noLl
Dr i ve home t he new bea r l nq ( di ameter 3Dnn) on bra ke s ide us lnq a s t ee l t ube
(d i ameter 28m11 {fi g . 4}.
IMPORTANT MOH: Ins ert t he bear ing ve rti cally t o [lre vent the threa ds f ron be inQ
damage d ( fi g. 4).

F~_ '

~g. 2

F~ .

RQ 7l

REPLACI NG REAR WHEEL BALL BEARINGS

CONT 'D .
REPLAC ING THE FREEWHEEL
Fit tIM! be..-inq l ocknut and punth loct I t 12 opposl t " punch ..rt.s
ct ee..f"re-nc" l (fI ll I) .

Oft

thrn d

Ins ut the- beoarlnq sp au r i nto t he- hub and i nu r t 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 o f the bea ri ngs and t h" spa c"r a re ali "ned .
- f it the dus t cap .

REfitTi NG THE AXL( AND THE REAR BRAKE PLATE ASSEMBL,, :

Revers e dis l\il nt I i n9 procedure-.

fit t he ..... aT" wIIe"l lrefe r to paOJe 66) .

REPLAC ING THE fRHW EL :

1lewJ-.e the- rear wh1 (re-fer to

~qe

661 .

Re-:l-.e the- freewhe,,1 us illlJ Tool Mo. 100022 l fi q. 2) .

Re~rs"

the- proc"dure- t o f it theo """ freewheel.

"< '

RO 74

a
o

m
n

m
n

' ;

,.

' " >" n,,

R~

,n

.>

-- -
,=-a-sR ' , I, I,
-- - o.

..=
----- -
-,- -
--:

> .

>

>

"z

>

"
10

> 0

m
m

>

,. ,

>

.0 0
, 0,
>

,mzm

'"

>

RO 7S

REMOVING AND REFITT ING THE FRONT AND REAR FENDERS

REKlY IItG THE f RONT FE NDER :
- R80V't tilt front

~l (~ fer

t o PfI11e (1).

R80ve tilt fe nde r 5tay f h l ll9 bolts ,net f ender br,cket bol ts (10.. _
fig. 1) .

ch .

Remove t he fendtr.
REFITT ING THE ntONT FENDER :

- geve rse t he
REIil VI NG

rat

p roc e dy ~.

REAR FE NDE R:

This remov, l " 1 be e ffec t ed wt thollt ~mov t nq the r e,r whee l (a<:cordinll to
the cne) .
Re-ove both side cove rs (s crewd rive r) .
Ile-:lve t ilt shoc k 'MO rtle rs lIpper IIIOl/Il tl n'l bol ts (Il_ wrenc h . fi g . 2 ) .

'- '
RO 16

RE MOVING AN D REFI TTING THE FRONT AN D REAR FENDERS

CONT' D.
~l!

""I r

f~ r

I_

r _

l ing bol ts (Ie- ..""nch . f lq . 3) .

RenJ ~r ue bol ts ncur ift9 t he lugg.lqr Cir r ie r rid

In d ..""nch. fig . 4) .
Re.l~

t o rte f ender (10m '5.octe t

the re ar moun ti ng '5. Crew'5. (Phil ip$ head ) o f t he l ugqaqe rl ct ( f i g . 4 ) .

RI'IIOYC bot h t ool 00 .

co ~ r n; .

Fl a tten the an t tvlb rat ion brac kets t nside the rende r- ,
Di'5.connec t t he r u r wirin g harn l"5.S (lIIU lt i -connec t or Bloc k) a t the l owe r pa r t
of thl' f rame .
Ren.:lYl! t hl' fen der with wiring .

RHITTI NG THE RE Ali FENIlR :

fi t on t ee new fender . the ~rU le ft

~l! n;l'

thr

rtftI~al

(lI'l

t hl' o ld fl'n dtr :

(wi r l nq . s uppor t s ) .

procl'd,,", .

110 77

REMOV ING AND RE FITTING THE SHOCK ABSORBERS AN D THE SWI NG ARM
RH'i)VING THE SHOn ABSORBERS'
Remo ve the locknut on t he shock abs orber lower moun t ing bolt (I3Irm open
..rench, f 1g. l) .
Remo ve t he lowe r mo unti ng bolts (l3nm wrench . fi g. 2).
Co ll ect the loc knuts . space rs . and ..esne rs .
The ..heel and swi ng a rm as se mbly are now f r ee t o drop down .
Remo ve the uppe r bolt as sembl ie s (I31rm wrench . f iC! . 2).
Remo ve the shock absor be rs .

REFITT ING THE SHOCKABSORBERS:

Re verse the above procedure but sc rew in t he rioh t hand lc..er- bol t loc knut
before sc rewing the bolt in fully . W
l1e n t he bolt is sc re wed home. the di s tan ce between the bolt and th e freewhee l prevents locknut f Htino.

F;" ,

f if!_ 2

RO 1B

RE MOV ING AND REF ITTING THE SHOC K ABSORBERS AND THE SWI NG ARM
CONT'D .
RE MOVI NG THE SWI NG ARM:
Remove
Remove
Rem ve
eeecve
Remo ve
Remove

the
the
t he
t he
the
the

rea r wheel ( re f e r to paQe 66 ) .

sho ck absorber lower eo untt nc bolts ( flQ . 2).
driven pull ey ( re fe r to page 47 ) ,
cha i n tens ione r (&rm socke t).
swi ng ann pivot sha ft and nut (17nm wre nch, fi g . 3 and 4 ) .
s w; nq ann ,

REF ITTING THE SWI NG AR~;

Pos it ion the swing ann and i nse rt t he pi vot bolt.
Screw i n the nut withou t l ocking it .
Fi t t he chain tens ion er (&rm wrench ) .
Fi t t he chains (bicyc le and engine) th rou'l h the swing arm.
Fit the shock absortler l ower mo unt i ng bolts wit h lock nuts (13ll'm wrench ) .
Lock the nut securing t he swing a rm pi vot s haf t ( 17nm wrench) .
f it t he dri ven pull ey (re fe r t o page 48) .
Fi t the rea r wheel (refe r to page 66 ) .

<,

,
""
"

~,

F;g, 3

RO 79

HOTOBECANE TROUBLE SHOOT ING GUIDE

TIM! follow in g guide i des igned to I"Pduce tIM! _ nt o f tilllP s~t troubl e
shooting. s e .....i ce problPII . When l"P.dl ng t hrough thP t roub l e shoo ting guide.
s _ of the steps will be ~ fel"Pnl:ed with t h@ s)"ltJol (6VI. This I'Oti tlon I"Pfel'"S t o Nchines Nnu f.c tu~d by Kot obeurot prior to J.nUiry 1. 1918 nd
"Mch .~ ~uipppd "i th. s h '( 6) 0f01t llqh ti nq syHPII . Subspquently ,.11
Hotobeune Ito~ds N nuhc t ul"P d for thP lhi ted Sti tes .Her J.nUiry t . 1918 ,
.re pqulpptd with. IZ vol t li ght ing sys tPil .
H[lPf Ul. HIIlTS;

1.

Wlltn troub le shoo t i ng e lec t ri c.1 c~nts.

. nd Pls iest _thod Is s ubs ti t uti on .

t~

qu ickest

Al Kak e s ure t h.t t ilt p.lr t bPinq us ed in t h@ s ubsti .

t ut l on Is k _ t o bP good .
8)

Wl\tn a part s Subst itut ion Is lIIoI lie and th@ probl Pil
is not s olv ed. leave tttf newly subs tituted part
in the s yH e.. until th e prob l N is found . Th en,
l>dck tra ck one C()OIlponent at a time . This lIle t hod
"ill enab le you to mo re effective ly troubl e Shoot
a ma ch lM whi ch lIIoly have multipl e problems .

ENGINE
I . ENGI NE WIl l NOT START
A~ l

-'-0)

II .

Check for spa r k at spark pl ug.

Chetk for flow restrict i ons In the f uel systl'll.
Check engine co-p ression by t urn i ng the cl utCh drUII by h.nd
with t he spark plug i ns ti ll ed.
Check t o U!e. if t ilt enqine s top switch is in the " ru n" pos 1
t i on.

NO SPAR';
A}
I)
C)
0)
E)

fau lty Sp.ln plug

f . ulty r.di o suppressor (sp,a rk plug cover)
f.u l ty high t enSi on ca l l
ffulty i gni ti on points .nd condenser
Ignition points not OPenIng
Gro undi ng wi re inside tilt Narot to
GI ....gneto wiring h. rTlPSS burnt or broken ~h i nd t he engine
H) Poor Ngne ti $ll pruent in ro to r
I) F.ulty exciter ca ll Ins ide N qr>P to
J) 8lack " i re f rQIII "'9"e t o broken or disconnected " {6Vl

RO W

MOTOBECANE TROUBLE SHOOTI NG GU IDE

ENG I NE, CO NT'D .
Il l.

GOO D IGNITION SPARK, BUT THE ENG INE Wi l l NOT START

A)
B)

C)

OJ
El
F)

IV .

llecompre~ ~ion y~ 1ve c~ b l e adjusted too t i qht

Restriction of f ue l flow (Ex. fue l t ap, fue l t~ nk, f uel li ne ,

c~ rbu re to r)
F ~ u lty he~d

gas ket
Igni t i on t imi ng incorrec tl y se t
Faulty inlet pipe gas ke t
Exhaust port and exhdus t pipe c l 09ge d

ENGI NE RUNS , BUT HAS A HIGH SPEE D MI SS

Faulty or wor n spark p1u!l
Improper ignition ti ming
Cl Faulty r~d i o suppre~~or
0) Faulty high te ns ion co il
E) Faulty or wor n i gnit i on poi nts a nd conde n~er
F) Fau lty hedd gas ket
G) Ile c~re s . i on v~ Jye u ble ~dj usted t oo ti ght l y
Hl Air t eak betwee n i nl e t pi pe and cyl i nde r
I} [xhau~t sy~tem c l ogged
A)

OJ

V.

EN GIN E RU NS , BUT HAS l OWSPEED HISS

A) Imp roper spark pl ug
B) Improper i gni tion t i mi ng
cl Fdulty or wor n out i gnit i on poi nts ~n d condense r
0) Faul ty r adt o s uppres sor (spu k p1 uCl cover)
E) Magne t o r otor rub bi ng on I nter nal co ils

VI .

ENGINE POPS AN D BAC KF I RES WHEN

T R~ I NG

TO START

A) Igni t i on ti ming imprope rly set

B) De compression cabte adjust ed t oo t i ght
C) F~ u lty cylinder head Qa sket
0) Faulty ign i tion poi n t~ or conde nse r
VII .

DI FF ICULT TO START WHEN COl D

Al

BJ

VIII .

Car bureto r choke v~1ve not f unc t i oni ng s uff i ciently

Impr oper ignitio n t i mi ng

DI FFI CULT TO START WH EN WARM

A)
~I
~

D)

Imprope r ignit ion t i mi ng

Worn out ~p~rk plug
E x h a u ~ t s ystem clog ged
Faul t y ign i ti on point~ and condens e r

RO 81

MOTOBECA NE TROUBLE SHOOT I NG GUI DE

ENGINE. CO NT'C.
IX .

EXCESS IVE FUEL CONSUMP TION

A)
B)
C)
0)
X.

ENGINE HAS NO POWER

A)
B)
C)
0)
[)
f)

G)
H)

XI.

Improper igni ti on tim i ng

Clogged exhaus t port or pi pe
Decompression cab l e adj~ s ted too t ight
Fuel res tri ct i on
Wo r n out p iston ri ngs or engine s ea ls
Enginll part i a l ly s eized
Moplld chai ns a dj ~s ted t oo tig ht
Br akes a dj ~stlld too tig ht

THE EN(;INE
A)
B)
cj
oj
[)
F)

XII.

Engi ne is not bro ken in (600 mil es)

Carb ~re to r choke valve par ti ally opened at all ti mes
Ca rb~ re tor flooding (s ticky floa t)
Leakage in file I li ne

vtu RUN

ONLY IF THE CHOKE IS USE[)

Clogglld f ~el j e t i n ce reure tc r

C10gqed fuel 1i nll
Cl ogged f~e l fil t er i n ee r bureecr or gas ta nk
Clogged fi lte r cap vent M1e
Loose or crack ed i nle t pipe and gas ket
Loose ca r bure t or

ENGlNE WILL RUN BUT WON'T I OLE

A) Id le ct r cut t I n ca rbu re t or cloqged

__ . 8) Thrott le s li de h ci ng wrong di r ect i on i n ca rb~ re to r
.,- ' .c}_~ ld le-sC n'W . not a dj ~ s te d correctly
01 Air leak at ca r bure t or or i nl et pipe mo~n ts

XII I.

ENGINE SEiZEO OR STARTS KN llCK IN(;

A) I n s ~ ff i c i en t oil i n f ue l mi x t ~ re
Bj Co nnec ti ng rod looseness on cra nks ha f t
C) Loose IIIiIgne t in flywhllel
0) r ee se fl ywheel jaomed on stator plate
[) Piston se i zed t o cylinde r

RO 82

POOR EHr. INE PERFORMANCE

Very often poor engi ll@ pe rfo ....nee lI<1Iy not ee .-ela ted to the en~i ne Itsel f ,
but t o coe or seyera l f requent1)l unsus pec ted seconda ry ca uses .
III Such a case , we s uggest th e

fo ll ow j n ~ :

I.

Check that t he decomp.-enor control is not or has II0t bEoen ove radjus t e d
which mi'lht dall<1l qe t he va h e alld entail COlllPren i oo l oss (this is a f.-e '1uent ca use ).

1.

CIleck t hat tile th rott l e slide OPMS fully . Quite often the contro l is
badly adjusted . nd tile entine is st.~d e ven .t full thro t t le posl ti oo.

3.

Check that the.-e is no br. Unq action due to ch. ins be lnQ too t iqht. In
t his respect , on f't)byle ttes fitte1f wit h a swillg . .. ",ar s uspe nsion . tens ion adjus tJllent IllUS t be pe r fonled i n t he rvnn ino pos ition , t he IIla chille
loaded with a rider we ighin g about 165 l bs.

4.

Ched

5.

Ma ke su.-e the belt is co rrect 1)l ali gned .

6.

M.l ke su re the bra kes .re not adjusted too tiqhtl y .

7.

Check t h.t t he f uel ca p nnt hole is not c1oq<led

poor f ue l supp1)l.

8.

Ched tha t the Spu k plu", is i n accorda nce wit h the ....nufa ctu.-er s specif icat ions .

g.

Check t hat t he exhaust is neither pa r thlly bl ocked liar blocked.

th is is t he case , cle an out t he co~ le te e xh aus t sys t em.

10.

varh tor oper ation.

II

th is ..y bri n9 abCIut

If

Very hopo r Un t ee te r- Quite of le n poor enq ine perfomlolnce !My be c aus ed

by ove r tighteni ng the cyli nde r head nut s and the 'e~) di ~~ ~ the cyl i nder . (Cyli nder head nut t orque is 9 t es , f t.)

LIGHT ING CI RCU IT

r. ...0 U GHTS AT All

A) Fau l ty zene r diode *( 6V)
S) Faulty head la ~ swit ch
C) Faulty 1I 9M ing co il or co il ground
DJ M.l gneto harness burnt or qro undi no behind engine
[J Wi r i ng haMll"SS connecto r bl ock discon'le(:ted behind carbu.-etor
F) h,,' ro per wi ", eeeeecr tees
GJ

Bl own bul bs

RO 63

MO TOHECAN E

T~OUBLE

SHOOTI Nr. GUI DE

LI GHTI NG CIRCUIT . CO NT'D

II.

NO

A)
B)

C)
H I.

BR ~I(

l [GHTS

Faulty br. k. li5ht d lol t ch

Faul ty 9round at "'al" fendel"
Faulty ~ toll l it)ht co il or 9T'Ound ( If equl pPi1d wllh 12'1 sys t<!Ol1)

DIM LIGHTS AN D KG NCIIN liNEN 1t(A.OLAIlP S:.IITCIt I S OM

Faulty l ene r diode ' ( 6'1 )

r'ulty l i 9htl r.9 co il
C) r au l ty brOOM .. ire or cOII",2(: tI0'l
0) I ncor rec t bulbs
A)

B)

I V.

nCfSS!YE LIGHT ct,uSI NC lJlKl'

A}

B}

v.

BUR~ OUT

Faul ty lenel" t iode (6'1 )

Incor N;: ct bults

NO 1I0RN

AI F' ul ty l ene r diode (6'1 )

'I

C
D)
VI.

WH(1f LIGHT S

', j
'o j

P.D 84

F'u lty horll uni t

Fl ulty ~o rll s.H~ h
Faulty horn w l l'"1.'~ or ccne ect tcns

Fdul ty
Faulty
Faulty
Faulty

A~ f

TURN O ON . THE ENG INE STAllS (6Y)

ee ner diode ' ( 6'1 )

hud llll'p $w!tl:h (6'1)
ereee ll ~t s lwt l: ~e s 0{6V)
blaC.k wire or connecti on I n lftI'lneto

h~ nteSS

( 6'1 )

R.H . STOP LIGHT SWITCH

~ MOTOBECANE WIRING DIAGRAM

YELLOW

12 VOLT SYS TE~1

(MACH INES M
ANUFACTURED AFTER JANUARY1, 1978)

-- - -I
I

BLACK

0......

z
3:
o

<5

0:

'"

>

REARUGHT

WH ITE
VIOLET

15
...J
...J

>-

BROWN
IO l ET

WHITE
GREY

0-

......
o

...J

>

GREY

:u
I

ro\/lIllDS
; pr\~ K

PLUG

SP EEDOMETER
..J

LITE

I ~I I ~

I-!

:I:

YELLO\,

-"-,

FLYWH EEL MAGNETO

VIOLET

HORN AND ENGI NE

KILL SI-i!TCH

L.H . STOP LIGHT SWITCH

lD

00

0::

RIGKT-HAHD
STOP CDNTACTOfl

TOWARDS SPA1KltG PLUG

'Z':::(,i--'

t:

- ", \

~(lJ

GREY

HORN I ';

-,

}i

H:(~L

...Q--,-;~

- - _....

=\

FLYWHEEL MAGNETO

BROWN
aLA'

GREY
I

8l-UE

SPEalOMETER ~
-'
UTE
'"

..

~-

~Il:j
~

. :s'"

III ild~
4CHANNB. CONNECTOR

"

REO

[i

BLUE
GIlEEN
B

DLAMP

'"j
Ii

'"

1//
"--~

HOflNCONTACTOR AND
ENta.lECUT-OUT SWITCH

(;;
0:

<II

0-

I
~I i
'"

II

1::1
ill!.

Ci

ZENER [)jOE

~~
~_.-

MOTOBECANE WIRING DIAGRAM

6 Volt - Pre 1978

REARUGHT