MIMS Machinery Movers mimsriggers.com

MIMS Machinery Movers mimsriggers.com
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fflENE-urPANED
I
RAINHENJ&N@E
I
)
TuNE-UP
OPERATIONS
Ignition Timing
BREAKER POINT
IGNITION
I. Remove the kiCkStarter. Unscrew
the four allen bolts u,hit.h secure the left
side el\gtue cast., and take off the case`
- 2. Remo\.a the spark Plug and, in its
Test llgm properly COnO.clod with I dl.I gauge ln pl.c® In th.
.p.rk plug hot.
clockwise to dccrcasc. the g:lp.
thtJ. COrrl`CL igllitiOn tinting for i.ACh Ill.I.
place' illStall tl ditll gi"lgC.
3. Rot^(a tnt, m\gTletO flywheel until
one or thc. windows is at twelvt, o'clork
alld lht, oth|.I is at ten o'clock.
i. Tu"\ th(I flyw,tlcel slightly in either
dircctiorl "ntil piston Top Dead Centc.r is
indici`tl.a b`. the dial g:\ugl',
lh dial gMlgr iS flOt l\VuilublL. a thil``
china.
Ht.ftT
lt)
uC.C.l""I.ill\ying
l\). l]{.fore rel.ht`cking tha timillg} en
C.hurt.
"re th"I the flywheel nut has been tor(I"a,(I ") th-orrect value (75 ft lbs).
Nott? th:Lt l")St lll\XJt.I.\ firt. 3.0-3.25mtn
I)TL)(.I.
Thl* ill)[}lit` to moLlt.Is \+.ith co"-I.
tiolt:Ll
5.
br``aL\..I
(:()I"ll.ct.I
lit)lllt
tc-st
I FEMSATRONIC.
igllltiullS.
light
or
IGNITION
1`OntiI\tlit.I
I"Lt.r \`.itll u S(`ll` COlll:"LILT(I I)I)`+.l`r -lrCC`
nof|-ln|,tplhc ot)ject (sLIC`t\ :lS ll prllCin owl
I. f\``fllove th+. spark. plug.
I() thl. i#nllio" lx)itlts c.il.c.uit. ()a.. h`u<l ls
be ih`ertl`d tnt() the I)lug I"tll' to filld thl.
highest I)iston posititm. Sl.rl\)a a.l"rk ("I
2. Hunlo`,a. the left lidC' t'ngim` CaS¬`.
a("m``c,tl.cI Jt} th.. bbc.I- wi". A(}lng l'"T\
tt`. p.n..il evl." ".lth th`` tot) thrl.nd ofthl.
3. I.|t :I lliul mug¢ llltO the Sperk Plug
IIOI¢, \«ld I"hte thL. ctlginC "ntil the?
Thl` I)lh(.r i} xro."ldl.a tp tht` ""i"l. J.
Spark plug hull`...\llothl.I "lTk ""lSt lX`
st\o\`,tl ill thl. AC.a(""l»l1)i"& ill"ttr(lti()ll
soribe\I ;\ho\,I. tnt. l'Ll.St I.a-.`lrollClillg tO
th(`.`h..I,.(ril.l\l julICti`)I` I")I tO thl. P()ll`tS.
{)A l'",t.-.`lu.I.A ""xl(.ls, lhl. tirol-I lt..Ill
mllst l"Ill Ll" l`xp`)st.{l end I)I thl` grl`l`ll
\`,ire. ilx:LillSt the (.ntZint. Ci`S..
AH BTDC
mm
Lobilo
lco cc
3.00.3,25
200 cc
";:;.:
3.00.3.25
:;:(.
Mercurio
l`
on
'rhl` t`olltillLIit+
ut
thl`
tl`St
l^)i"I. 'l\ot"t`.
ligrll
l25 cc
3.00
175 cc
3.00-3,25
tht.
lx`
lI).v`.hl.I.I
"r.` lhilt it is "rrectly [rositionod. Zero
+ ,i`h.. rot"I hire a pi" hole in it. The.
2""n I)in should tx. i-L`rted i» lhi3 hall.
clock".lie. 'l-ho I")im` >llouI(I lx.gt" to
iutd th|. rotor turT-I it` a CIOCk`\.i+L` dirce.
open (pud th.. tt\t llgllt "ill gl) a"I) ".hl`ll
ii(.it ifitil! iilc pm ,Ills"a "ith. a"d ",ill slip
" mlo, th\, hol|. ul lhC. len-hand dirm.r Of
the i):*clI I..`t i:lt. I)rt}[".t LliStullC`` ltl`f(lr(.
th(. LILllX.I cull..I.h. I)ill will be uppTOXi.
dlc`ltc(I by. thl. diill ""Iic.\tur or L}). tnt.
Ill.ltt'l` Ill tht. ''9 o`clcek.I I-itiolt.
"ndo"d s"llw.(i !i"(. i" tht` pencil.
7. Nt\l"m. th.. pui"I |.ilp with the. :lp.
'-.. \.\'lth th"otor aligt".{l ub dl-s(`ribed`
thti di"I g"t:.` shoLlld hat.a indiC.atCd a
I)ropriute fl.¢h.I I:"l#l.. Poillt g;lp for ull
models should bc l1.I)l5iII.
tt)lilt pliloll lllO`.t`n.l`nt Or 3.0-3,25tTLTtl6. Yr :IdjLIStmellt iS naC`OSSary, remO\,a
thc. rotor ".ilh lh. special toad and loosen
th|. lllrae Screws \\.hiC`h SCtLlre the statOr
Campela
l75 cc
I}i`t("I buck a"A forth Sl.`.l.rat lifneS tO On-
lht. I.lllHC |luhiS prim.
>llt"lltt
tt)p tll`Lld a"lt" 'l.I"` "llll. Will Lx. "I-
Metfalla
I:;:
(;.
"JAu*C. thou.i ;I IT-imum rl.ildi"X. The
I">tt" i"LO". "I tttPdL`ad center Rock thc.
I,ht`.,
7 Rt.plilce the mtor, but not the rotor
3.00.3.25
i``lt. h?o`,a lhl. 2lnm I)!n ill POSitiOn.
Matador
"';
200 cc
.)
s. ncjt.ltf, tl|tL. rotor ilIld StutOr until
3.co.3.25
th..y are ill the. corrcat timing position, u`
indictltt?cl b). tht` dial g:llLge (3.Ord.25Ilun
Sherpa S
BTl)a).
l25 cc
l75 cc
200 cc
9. H`.mo`le the. rotor a.Lrt'`fully,I aSSur.
:3 ::2
ills th.lt thc, stator don.s not mo`.a, al|d
:
!ightc.Il th.I StalOr St`r-.S Sceural},.
LIT Ref)lnel. thl` rotor alld rotor nut.
TT Scrambler
250 cc
3.85.4.lO
Motaeross Scrambler
i,i
;I
250 cc
8. lr `\djuslmt.Ill iS nl.a"<"ry' rt.lt`O`.a
3.854.10
I Matador
3.85-4. lO
Pursang MH IV
250 cc
2.75.2.95
Spark Plugs
the. ll).``.hI.I.I mlt ulld Ptlll Oll` tllC. Hv`` h|.t.I
w.ith thl..iln.ci"I nullac.() tool \o l'3=.I)lr+
i;I)::`
250 'cc
Tightl.n the nut, ilnd reeheck thl. timimg
us describ|.A
Ctlacklog the pOlnt gop
(or Tool \'o I I-32-ttlr+ for t.l`gtncs \`.itll
tht. I.lrHt. k\prr Shalt).
9, |\) il(ill"I tht) timlllg| h)OSl.n tile
The corrocl gnp for all modc.ls is 0.020
ill. Hc.I.oln"1t.llded Plugs I'or indi\idual
mo`lcls ilre xt`.Oil in th.. I-OllO``.ills Ch.`rt
\otc, th:lt thf. bc.st hetlt range for each
tllrt.`. sl`rl-.v\.a oll the.`t.\tOr disc imd rOl\tt|`
lT\OtOrC.yCltl l"}. \.:lr), uC.a.Ording tO hO\\
the tliic. l-It)(`k\\.i*t` tlt illC`re`l+t-. Or C`O|ltlt|.r.
tht. Ill:ldhim. iS used.
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MIMS Machinery Movers mimsriggers.com
146
_I
6. Press up on the slider and unscrew
the stanchion plug from the damper rod
250 cc
250 cc
250 cc
10.30
10-30
loo cc
80
'30
125cc
80
30
80
30
EI Tigre
::
: ol
100 cc
80
20
l25 cc
I50
20
175 cc
150
20
200 cc
I50
20
200 cc
Sherpa S 5.speed
disassembly. R:for to the I.a+assist. see.
lion for reassembly procgdur(?S.
1966rf7 Lobito
1. Remove the slotted dri\ill Plug near
the bottom of each fork leg.
2. Work the forks up and down to ex-
STEERING HEAD.:i.
To check steering head bearing ¢ofro;
lion, put the bike on its center stand'ot
I60
360 cc
ii,,;
mc.nt should be snlooth, light. and hck
from any binding. check for play;in th;
bearings by grasping the bottom, bf tbp
fork legs and trying to rock ltheri ba'-:
and forth in line with the motorcycle
play can be removed by tighteulnj! thr
steering head main nut. I,'gb,en nomor.
thanl "ecessaly lo remove play:.]I_dkerl.
ing movement remailrs unSdtiSfaCIOny
aftL.r adjustment, the bearings dyOul!br
Bandido Scrambler
pel the oil from the legs..
3. Remove the handlebars and unscrew the two stanchion plugs.
.
4. Add 70ccofSAE 20W or 30Woil to
each fork leg.
5. I.loosen the fork tube Clamp bolts On
the lower triple clamp. Screw the stanchion plugs into the tubes and torque
them to Soft lbs. Tap the top and bottom
of each side of the lower triple clamp
with a mallet to relieve any strain.
6. Torque the clamp balls to l5 ft lbs.
two adjusting screws dt e:lch sNI\g afin
etld in aTl equal amount until the train
has about t4-% in. fro.eplay. Retighten
the ilxle nut and check the play again.
!r:a:I:?ug!l?t%iirinud::Srs:i:ee:i!'hgaemfOvrlekOls.li#£o!ir
250 cc
satisfactorily.
l2. Reassemble in the reveI>3 Order Of
(f total mo+.ement exceeds nbr,.t I;in'.I
the c.hatn mlst be readjusted.
lJOOSen the rear axle nut and I `:"it,
160
175 cc
Refill eat,h slic1.er with 85cc cfSAE
To chl.ck ch(`in nd)`lStDtht, ,.,t!'',thJ
bikcL On its stand and move the ,.,,lifeul
ilnd down at the midway point or
Campera 5.speed
20W or BOW oil. Work the d:lmper rod up
and down until the oil has been sucked
into the cylinder and the unit is working
I
160
Lobito 5-speed
oil.
(
10-30
Matador Mk ll, Mk Ill
using pliers, and push the spring down
and away from the carrier locknut, Put a
wrench on.he locknut and remove the
tarrier with pliers
9. Remove the fork springs and carriers from the slider legs (Campera).
10. Tum the glider legs upside down
and pump the damper rod to exp3l the
ll
160
Motocross Pursang
(sherpa S). Unscrew the spring carric`r,
20
replaced.
360 cc
160)
20
b`lshing
20
by cracked welds.
I 30 or40optional
ENenNE A
" 30 or 50 optional
Service Checks and
ITRAN§MOS§l
I. Remove the wheels periodically ,1nd
Each Leg
check the shoes :lnd drums for excc`ssivcl
CC
wear or glazing. Remove any surface
70
Lobito Trail
100 cc
70
-20
I
85
20
Campera
3. The rear brake is adjusted by turning the adjusting nut on the brake cam
actuating lever.. pedal free-pk`y should be
20**
85
30-50
comes on when the brakes begin to bite.
125cc.
85
20.50
Always maintain.clutch lever free-play
l75 cc
88:
Matador
200 cc
about I in. If the mac.hine is equipped
with lights, make sure that the stoplight
switch is adjusted so that the stoplight
CLUTCH
Sherpa S 4-speed
200 cc
i
1,a.
Plastic RI
penetration.
2. The front brake c,im bc ildjusted at
either end of the brake cable. Adjust the
cable so that actuation occurs after about
85
175 cc
slide.
Ball)a Car
I in. of free-play is tat(en up.
Mercurio
l75cc
Engine Removal:
I. unscrew the plastic cap rr':#
top of the carburetor and pull 6ht tlg
down llcilr th,a rivets Or Show Signs Of Oil
20*
I
.
FOUR SPEED
MODELS ,,
BRAKES
glaze with emer). cloth or fine sandpaper
and replace the linings if they are 'worn
loo cc
periodically. / Thor,`.
swing arm must not be bent or
85
250 cc
Lobito "K"
side.play
should be absolutely no play
MetraIIa
auantily SA| #
..,
The swing a,,n should be cheOk#f;
^diuslmanls
Model
. 1"
SWING ARM..,.,:,j\
EI Montadero
roRK ljEC CAPACITIES
+
FINAL DRIVE-CH- l":l
TT Pursang
(Campsra).
7. Remove the slide,.a from the fork
tubes.
8. Hold the fork spring in a vise
T|.`
i
i;I:-i?
Bultaco
loo:550j-
a..huretor wit.#
Nuts
C.rburetor stfurlng points
2. Unscrew the fuel line banjo.`
screw and rc.move the banjo, I"el_filter.
and washer. tJnscrew the retai"in! qOS
and removp the Carburetor.
// ,.
3. Unscrew the gearbox ant:
case filler plugs. Using a l9 mm
remove th-a dr_ainplug|rom the I,- [tofii-¢
it::aPdd:iubOs!;TeanEd;I.Y:I,2,hT,e3nAg.'aTbhle:as:ice:laa? :i: the pri-rychaincase, catching lefTLl
a suitable container.
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Bultaco
147
6. Turn Bultaco tool l32-Ol5 (or Tool
No, l1-32-Ol5 for engines with the large
taper shaft) completely into the flywheel
center. «Jse a small amount of grease on
the end of the crankshaft and make sure
that the center bolt is screwed all the way
out so that the tool seats fully.) Tighten
the center bolt until the flywheel pulls
free of the crankshaft. Remove the woo.
druff key from the crankshaft.
carburetor Htllding Nut
CI.enk seal cover bolts
Gearbox r\ller plug,
Prtmary Drtve I,tller Plug
Gearbox ¢on) ehd prim.ry c.se (right) filI®r plugs
8. Remove the six bolts which hold the
crankshaft seal cover and remove the
cover and gasket.
9. Bend back the tabs of the lockwasher which holds the countershoft nut
and again, holding the rear brake on, unscrew the nut.
10. OIl early models unscrew the three
countersunk screws which retain the
countershaft seal holder and remove the
holder, gasket, and spacer. On mid-1964
=d,:at,eerl=nag,:'dcsi,nt:ed:ri,regu:=hp±:sro:
case. These later series engines use a
larger countershaft ball-bearing.assem.
bly which has the same pert number as
the main bearings. If this bearing operates roughly or is wom, it should be re.
placed after the crankcases have been
" cranhase dmln plug
i':i,:;RL::a:ev:ft,thheefokj:kit,ae'nt *:serwh=!
split.
"?-decure the left side engine case.
I,5:' Engage First gear in the transmis-
" ston end, while a helper holds the rear
I brck6 on, unscrew the nut which secures
the fl')"/heel to the crankshaft. A magnet
carl be used to remove the two flat wash.
ers'and one lockwasher from the end of
the`Crankshaft.
Pulling the fl]nl/hcol with the sp'eciel tool
Removlng the countorst]Ift nut
Klck<.\.rip.,el iaver and case securing bolts
remove the screv"
7.. Mark the original position of the stator disc in relation to the engine case, as
sl'uwn (for convenience ,when rea§sembling the engine). Pull the wires from the
connector block, and unslcrew the three
screws and remove the stator disc assembly. Pull out all electrical wires lea_ding to
: "##::i ;hueshf#h.=tfn#wa.Tl#ndic.be
the frame through their rubber grommet.
MIMS Machinery Movers mimsriggers.com
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MIMS Machinery Movers mimsriggers.com
160
Bultaco
lO. Early engines have a short clutch
rod and a'clutch mushroom with loose
ball bearings b'etween the clutch rod and
l6. After adjustment. is complete,
safety wire the clutch spring IlutS using I
mm diameter stainless steel wire. Pull
tube into the gearbox filler hole. ReiIIStall
the filler plug with tits rubber gasket.
23. Check the drainplug for tight!1C`S
pressure plate. On this type, first install
the wire through the hole in each fa,
the mushroom. Then align the stud holes
in the pressure plate- with the studs on
taking citre not to tighten or loosen the
nut in the proc,ass. When the wire is
threaded through all the nuts, twist the
ends together.
and pour 250cc of SAE low or 20W oil
into the primary drive case through the
the inner c,lutc.h hub and install the prcssurc, plate.
ll. Latc,I model engines have a long
clutch rod and a pressure plate withaball
bearing thrust cover. Remove the thrust
cover, pack the bearing with high tem-
l7. Collt the Crankcase Side Of the Primar), case gaskc.t lightly with grease and
perature grease, and reinstall the cover.
allen bolts.
Flit the plc.ssure pkltc.. on thc` c.lutc,h as-
l8. Loosen thc, clutc.h lever adjustcr
knob :lt the handlc,bilr. Remove the slot-
sembly, taking c.are not to let the thrust
cover fall off imd the bc.arings fall out
bc,fore the thrust cover contacts the
plac.a it on the c.rankc.age. Install the pri-
mary case and secure it with the seven
c.lutch rod.
ted c,lutch :ldjustment cover cap from the
magneto side case and loosen the locknut. Screw in the slotted clutch rod ad-
l2. The latest engines have the pressure plate thrust cover retained by a
snap-ring. Squirt a fewdrops of lO weight
oil into the thrust c.over cup. Aligm the
tabs and slots and tr), fitting thl. pressure
justment sc.row untll the c,lutch lever ha.s
about 4 mm l'rce-plo),. Check to see if you
can still pull the clutch lc.vcr all the way
to the grip. If not, loosen the setscrew on
the cilbll.-clamping nipple. Move the nip-
plllte to the clutch ilssembly. It has bc.en
fitted properly if' the iiiner clutch hub
ple back toward the end of the cable i|nd
studs are c.entered in their holes in the
pressure plate. If not, remo\,c. the pressure phltc,, rotate it clot.kwise until the
next set of tabs andslots are :lliglled, and
instnll it Again. If the s(uds :\rc, still not
rect adjustm;nL I:ght.zl the Clutch rod
adjusting scre\\. lot.knllt ilnd replace the
sloth.(I cot,er c.ap ln thl. ImlgnetO Cover.
fully Into posltlon ()ll the C.Lutch :lv`eml)l\
fr"l\ Its c.h"n])"lp lll[)I)lt., thi` ChltC.h rO(I
IIIStllll Lhc, sl)rmgc,llps()n thl. "Ill"
CAUTION:.Vet,er I,se A IT`in any a,ISine I.,i[h neoprene clutch plates, "s
the fluid will deteriorate the neoprem..
24. Install a spark plug of the correct
heat range, tightening it sufficientl). to
compress the gasket. Do not overtighten.
Fit the high tension lead onto the plug.
FIVE SPEED MODELS
Disassembly and repair of five-speed
Bultaco engines is similar to the basic
four-speed engine. The, major differencc>`
are;
I. The five-speed engine does not a.mploy cylinder base nuts; instead, the a) l-
inder is spigoted to the cases and held Ill
retighten the, sc.tsc,raw. Adjust the, clutc,h plac.a by the four head nuts on through
rod sc.rev. imide the I-gneto cot,er ag:tin
studs.
and check for full tr.l\.c.I at thc, clutc.h
2. The drive side crankshaft hut h:l`
lever. Whcm \.oll h.l\.a ()btilincd the cortwo main bearings butted againsti=1lC.I
c.enterc.d in the holes, rl.pei`t the procc`s
until ),o\l a.ln push the prc.i`llr(` phte
l3
filler hole.
\\'h(.n|`vl.r \.o\l
relllO\(.
:I (.hltCh Cable
A(lJ\lttm|.lit I)rot.|.dim. mutt I)(. fOllO\\t.(I.
other. The engine sprocket fly\`.heel I
shaped differently and th6 inm.I i\n(
outer chltch hubs are larger and strongcl
3. The shift forks arc o[)Crated b).
shirt drum instead of A c.:lm phlte
i
'rhc. gl.ArS i)nd Slidillg dOg'» ;LIL. :\T
c.lutch hllb `tlldS Pr()tr"(llI1= th-lgh thl`
I:lngl.(I {llfrorentl\. on thc` l"llmhaft <tI1(
pro"llre pht(`. thcu rlt the cllltch sl)rintzs
co"ntl.rshLf.I, bLlt- their Opt."lion ii th
:\l1(I
s.lml..ls m lhc follr-spred engine.
nuts.
Tlghtl`n
(..lch
tl"I
lmtil
the
spring bottom`, thl.n loo-I t`:I(.h n"I follr
Bc,c.¢|u_\c' ()i the silnilariti|.s in LhL. I_|t\.
full turm (,thrf,t. tllrm (m the 250 Sc.I:lm-
i"I(I lL"-SPC't`d (`nginl.!' this "`Cti(m \\ I
trier).
(lt`{1l Onl\. \+'ith the i.uhatiOnS ill
l4
Pllll in thc.(.llltc.h lt.I.t.I on tllc` h:m-
th. li\`
>lx.ltd engmC. Use this s(.ction in c{"\i",
dlc.b.lr :\n(1 tllrIl th(1 mgmt` I".(`r \\ith thl.
Ilo"
With
l_("I-i[)t.l.(I
th(`
prec.{.ding, -i(.c.ti(m
l-
TllOdeh
I:c[l,::.I',rrt,i.',I,,:'r:I;'l'.,'l'!'¥('l:::;,rl,i',i,"rr(.I,I.l',tl:,':I(:
Clutch cable clamp nipple
ls not I):lr:lllc,I with tht. (lrl\(. I)I.\tl.. it \\.ill
wobbl|. \\hill, I()I;\tl]lg
l5
Whlll.
thl. cllltcll
l` \t:lt.i("1:lr\.
()))
l9,
ll1`t,lll
Crate the el"len lcl\|-I s(`\.t.I:ll tim|.+ \`hllt.
dt.I
watching the pro""r|. pl.ltt. ()n¢ `i(lc. of
Rl.I)I.I(,l.
the plate might I)a I)u`h(,(I -I I',lrthcr
than the othc.r sid(I. If ". lc.\l.I tI". I)rt`sure
plate
by
slightl).
ti*htcl"Ill;
tlll.
i"I(I
2(I
li\.
lht. (..ll-lJ\lrt`tur ()n
thl-
Ll"
fl".I
slldt.
"
l'nt.
COMPONENTS
lh.. rt.TIT "uu\tH\[ ll.u\L:(. W.tth lt\ I)I;]CLr.I
()" the h"1``. :""I :lhg" tht. Pint. Wlth iS
-"nt I" Ill(. (.).I-hr \\|"lt. hol(lmg the
i)`t""
ing until the phte is dr:Ld.let.(.I \+.lth thl.
lht` c\lin(Il`r. lil"llr onrc` not to c,I"`-
fric.lion plates \\,hc`n thl. c,l\ItCh le".I l`
thr.:ld
"I
tht.
L)I,I-,
\t.lrt
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wT(.nCh tO tlX,htl.n thl. rlt`g-tlut S(.Curt.Iy.
Il"tall tl" I)olts.lt tl". r{.ilr mo\"1titlg
ll.lngt.. Do not l'orc|. thl. n.'1r mOllnting
llil,ngt. into phet. `gail"I tnt. I-ckt`t or
).ol-"n the-Ilk (`i: (I"""ting lh-\lmder. I"stlT^d' bl`nd tl" ll.Lnge O-nlLrgt`
Ill.for to the ''r.IlgillC' Ramr)\.ill'' st.c.ll(
on four `pce(I modl-l`
I. RelllO\.t. the rurl)|Ir|.tor. Dhltn tl
pri""r'`. all".."rd the gc.'lrbO.\.
2 R;moyc the kickst.\rt lu.c-"ud u
I+cre\\. thc` :`llcn bolts l`rom the I-gr`l`
CitS(I.
I?. UIISCreW tht` magneto fly.``hel.I n
:lnd rc.mo`,a thl. H).I+.he|.I.
1. \lilrL thl. I-gnato bilcking ph
the holes i() thlt th{. bolts cJln bC, tight-
an(I rt.mo\,|- it. P\tll b:lc.k th|` \\ir|`< ,li
ens(I \"lhotlt I)utt"1g il Strain On the CX-
I)\lll the. wirt>s :.nd I"lil the wlrl. c"\m
h:lust \\st{`m.
tor-i ap:\rt.
2l. On
rat.lng
machm<`s,
`.lfot\.\\.irc'
tllc1.Xh:Lust ""g-nllt tO the rr:"ne :low"22
5. Rc.mo`,a the se.Ill cot.t.r art(I ll\ a
k|,I.
6. Bc`nri lxlck th|` lockti|b mld \ln`(.I.
tllh{`_
Safety wire in place in the clutch mlts
REMOVINGTIIE.
+ MAGNETO SIDE. --_
I"I.
I() it"I,Ill tht. l"h."`t i),>t"", ;\IIL'n
cl(Itch spring mlts nearest thc, hiih si(lc. of
the. plate. Rep_6at tnt. tes`tillg :-I :ldJ\"l-
pulled to the hilndlel)ur grlp
Engine `Removal
th(. (.\lin-
C..lrblITt.I()I.
Chec.k the. gc`ilrb()I drainpl\Ig I'ol
tli:htI"```.md POUT.500c.c. of SAP 90 gc,Jr
tht` co\lr\lt.rsh:ll't
nut,
7. Rc,mo+.{. the exh:l|1St S\,Stem
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182
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19. Turn the stilnChiOn tube uPSidC.
lo. coat the inner surfaces of the
steering damper stops with light oil or
liquid detergent so they will slide down
the stanchion tubes easily. Lay the stops
~
dow.n and the valyl. ttlbe assembly Will
fall out. lf the dumper cylinder support
sticks in the bottom of thc, tube' screw the
181
and the handlebars near the front end of
allen bolt back into the bo(tom of the
tube a few turns and tap it with a ham-
the bike.
ll. Insert a stanchion tube from the
bottom of the bottom bracket. Fit a rub-
mer to frecl. the support.
ber stop Ilo the top of the tube and work
¢fio:!omReoTloh`:sttdhnechsino:ip-I:bneg. f'()m the
it down in the tube.
21. Insert a Squall.A Off broomstick
I
into the top of the sianchio" tube and
-
I
I
/
+
push out the rcI"\ining damper COmPOnents.
22. Remove the rubber dllSt glmrd al`d
the smp ring froln the top of thc. slider
leg. pry ou"hc-il sl.als w.ith a blunt
I.
`'
lnstemng the steering head bearing reces
screwdrivc`r, (aki": care not to g(tugl` the
soft walls of the shder leg.
INSPECTION
1. Mcasllre
the.
lc.ngth
of the
fork
springs. If the). arc, lc.`s thaII l7 ll /l6 in
Long, or
Arc,
uneqllal
I"
It.ngth,
___,__------- ---`-Inserting a stanchion tube
they
should b|. rcplac|.a.
2. If volt l"\.c, follnd thilt the spri:TgS
l2. Fit :I hz|ndlebar to the stanchion
were b;ttoming regularl)., -kt. tlp two
tut;e. sc:1Hhe tube in the top bracket by
bumping the,bottom of the tube lightly
\+,ith a rubber mlllet. Install the other
tube ln the same manner.
l3. Tighten the stanchion tube Clamp
bolts on the top brilcket enough to hold
the tube in place while the damper com-
I ln. spacers and flt them bel\`.eon the
top of each spring illlCl the bottom Of the.
stanchion plllg.
3. If the distrib\ltor ri]\g st)rlng \\.ll>hcr
on the valve tube has brokcm or lost its
tension, replace it.
4, Examine the threads or th. all.h
bolt and the threads in the bottom of the.
fork leg where the allen bolts screw ill. If
wom) replace the bolt and the `al`.a
tube.
5. Each time the forks are dlsasscm_
bled, the follow,ing components should
be replaced:
a. Oil seals (4);
b. O-ring (2);
a. Dust guard (2);
d. Oil drain plug washer (2);
e. Stanchion plug o-ring (2);
f. 30mm intemal snap.ring (2);
g. l6mm external snap-ring (2);
h Rubber damper cy,Iinder support
w`J`hcr (2).
6. ri_I ) compensate for normal wear, the
follr
\g components
I)la(.I ,.
should be re.
I-\IICe a year:
i)istributor ring assembly (2);
I-)amper piston (2);
\_alve washer (2);
I I Valve support cylinder (2).
REASSEMBLY
Tl")roughly clean all steering head
:i a"nper coL¥nents before reassem-
_
2. h"tall the upper_ nnd lower outer
shteeae::nI;,Pvc.ear,¥eLra,cnessjfartehle" a::ir:ng
I
Piece of pipe with an outside diameter
:l!s!,ht:y :::l£rgthh=a:?e:nhs:cdke d.ira,:neI::
make sure that the races are going in
straight.
--- - -
i
---- ---.--- --lh_stamng the I,ocking collar
)
3. IllStall the inn|.r rLICe Of the lot+.er
stc.erlng bearing on the steering shaft,
".ith the smaller end up' using a Suitably
sizedrpipe. Before dnving the race into
position, fit the b-'6ttom dust cover to the
shaft `with the dished edge facing up and
the three drain holds facing the Tear Of
the bottom brilcket.
4. Grease the ilmer rat.es of both bearings with wheel bearing grc,ase.
5, Insert thesteering shaft in the stccr-
ponents are installed.
l4. Fit the damping piston on the end
of the valve tube away from the flange.
The recessed end of the piston should
face away from the flange. Butt the piston
against the flange on the valve tube.
ing head from the bottom.
6. Sc,rew the lot,king collar onto the
steering shaft and tighten it until the in.
her race of the upper bpearing is forced
into its outer rat.e. When the collar has
been tightened enough, you will need to
give the bottom bracket a gentle push to
rotate it from lock to lock. Ifyou feel any
roughness or binding while movir ,3 the
bracket, there is probably dirt in the
bearings and they will have to be
removed and cleaned.
7. After adjusting the lot.king collar,
rap the top of the steering shaft with a
hammer (protecting it with a pl-ece of
wood). If the effort required to move the
bottom bracket from side to side remains
the same as it was before, the bearings
are fully seated and properly adjusted. If
the bottom bracket has loosened, readjust the locking collar again.
8. Install the top bracket on the steering shaft.
9. Screw the top nut on the steering
shaft down finger-tight.
Installing the damping components
I,5. Spread the 16mm snap ring just
enough so that it can be slid along the
valve tube into its groove next to the piston.
l6. Put the valve tube r6tainingspring
on the valv'e tube and butt the spring
against the piston.
l7. Put the distributor ring assembly
on the valve tube with the spring washer
facing away from the valve tube retaining spring. Butt the distributor ring assembly against the spring.
l8. Put the valve spacer on the valve
tube. Butt the spacer against the spring
washer.
l9. Put the valve support cylinder on
the valve tube so that the washer fits into
the counterbored end of the cylinder. Assemble the other valve tube assembly in
the same manner.
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FRONT FORKS AND
STEERING
1?65-66 25Occ
Scrambler
DISASSEMBLY
1. IJOOSen the Clamp bolt On the front
brake cable nipple and remove the nipple from the cable. Remove the brake
cable and the spring from the brake arm
on the front wheel. Remove the cable
a outer bearing races remain
from trye forks. Unscrew the drain plug
12. Unscrew the steering head bearing
from each of the fork legs and pump the
locking collar.
oil out.
l3. Hit the top of the steering sl,-nit
2. Prop up the bike so that the front
with a hammer, using a piece of wood to
wheel is off the ground and remove the
two bolts that mount the brake anchor
protect the shaft. This will free the upper
a steering bearing from the shaft and the
strap to the right fork leg.
bottom bracket will fall off.
. i,..
3. Unscrew the front axle nut and then
l4. Lift the inner race of the upper
loosen the two axle clamp nuts. Withsteering head bearing out of the top of
draw the axle and remove the wheel.
ire ste-ei'iag head.
4. Take off the two fender mounting
|5. Ifit is necessary to remove the hotclamps from the slider legs. Slide the
tom steering bearing} clamp the bottom
front fender down the forks to remove it.
bracket upside down in a vise and ham5.Using a 28mm socket, rotate each
mer alternately on the two protruding
stanc.hion plug five turns to loosen it.
6. On early models with steel top and
bracl(ets, loosen the two clamp
7i,bottom
bolts on each bracket.
7. On late nlodels with a forged alloy
top bracket, loosen the four clamp bolts
on eat.h bracket.
8. Loosen the stanchion tubes in th6
\ )Ius,i :oupbbberracieatll:r hu.:::rgtheeac:1uP:ugbo:::fin:
against the top brat.ket. Remove thb
plugs from the stanchion tubes.
9. Remove the top bracket mounting
nut on top of the bracket. IJOOSen the
steering shaft clamp bolt on the top
bracket. Remove the top brat.ket by tap-
ping it upward With a rubber mallet.
lO. Loosen the handlebar I.1Our,till;;
bolts and pull each stanchion tube down-
"j;li
ward out of the top bracket far enough so
that the handlebar can be rc.moved.
ll. Tap eat,h stanchion tube downward through the steering damper stop.
When the tubeis free ofthe stopit can be
removed.
portions oftheaust shield with-a hamme:
and drift.
l6. If you wish to remove the out
I races of the steering bearings' insert
Ftemoving the allen bolt from the bottom of
the fork leg
:,S
drift from the opposite end of the steerl
ing head and drive them out squarely.
Take care in this-; if,'th6y come out at an
a`ngle you can disto.rl the ste:ring head.
l7. To remove the stanchion
from its slider leg} unscrew the allen
from the bottom of the slider leg.
;lidcr and stalrohiOn Can then be Pulled
apart.
NClrFE.. Sometimes the c.omponents ln_
side the leg will rotate with the allen
bolt, and il will not loosen. If this bc'
a.HIS, Perform the fO!1cwing.
a. Drilla I/a in, holeintothedamper
cylinder support inside the slider leg
through the oil drain hole, taking care
not to chew up the hole threads.
b. Pack some grease on the end ofa
thin drift and insert the drift into the
drain plug hole to remove the inetal
emoving the snap+ing from the bottom oI
a stanchion tube
chips. Repeat this as many times as is
necessary to remove all the chips.
a. Insert the drift again and use it to
hold the dainper components in plac'e
while you unscrew the allen bolt.
l8. Remove the fork spring through
the top of the stanchion tube.
.i
The front forks and steering head disassembled
Removing the stanchion tube
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