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Motobecane Cady Maintenance Manual

1. HORN i TIMING FUEL CONSUMPTION PLUGS PLUGS 1 PLUGS 1 PLUGS t PLUGS SERVICE MANUAL TECHNICAL DATA 2 Cycle Ml 1H P at 3000 R P M M3 1 5 at 4500 R P M 49 9 hore 39 Stroke 41 8 mm 8 te 1 Gas Petrol and oll mixture Flywheel magneto Plug 015 Points Gap 012 to 014 Gravity feed fixed jet manual choke Dimaoby double sutomatic Drum 70 mm dia Cantilever Direct D C Flywheel Magneto generated 16 x 2 Moped Cushion type 16 x 2 with Schrader valve Tube pressures Front 22 lbs Rear 26 lbs average rider Capacity 614 Gallons Electric 1 2 before T D C 100 ro 120 HPGe MARCHAL GT 35 BOSCH 436 A c A3OZ MOTOCRAFT AE 32 CHAMPION LAHA Page 57 Cacly SERVICE MANUAL MOTOR FAULT FINDING In this section we will deal with finding faults when the motor willl not start or run correctly or constantly Motor faults can be broken down into two basic sections and these are FUEL PROBLEMS and IGNITION FROBLEMS Both of these problems can be dealt with systematically and for the most part will be found externally Before pulling the motor apart to find a problem follow the instructions in this section and by a process of elimination you will most likely find the fault without too much trouble From the outset it is necessary to determine whether the problem FUEL or IGNITION and the best way to check this is to proceed as follows M
2. Hodels with rear suspension NO SPECIAL TOOLS REQUIRED REMOVAL 1 Remove both chain covers 2 Remove rear wheel see page 28 3 Remove pulley converter see page 22 4 Remove 80211 engine sprocket and right hand chaln wheel with axle see page 24 5 Remove the lower shock absorber bolts A Fig 41 1 both sides 6 Remove the 2 chain tensioner retaining bolta B Fig 41 1 and the chain tensioner pulley bolt 7 REFITTING 9 and pulley wheel C Fig 41 1 and the chain tensioner now free to be removed from the pedalling chain Remove the rear fork pivot bolt and nut D Fig 41 2 and pull the rear fork out of the frame Replacement rear forks are fitted with pivot bushes and resdy to be installed To install the rear fork reverse the above operations making sure to grease the pivot bolt Dp Fig 81 2 with general purpose grease and securely tighten rhe nut Make sure the pedalling chain and motor chain inside the shock absorbers before refitting the lower shock absorber bolts 10 The rear fork bushes are replaceable but this should not be attempted unless a press 19 avallable Fig i 41 Page 41 Cacly SERVICE MANUAL REMOVAL AND REFITTING OF SHOCK ABSORBERS WO SPECIAL TOOLS REQUIRED The Rear Shock Absorbers These are a factory assembled unit and not designed for repair and should be replaced as 1 assembly or in pairs If replacing one shock absorber only it will be nece
3. If replacing only the inner wire feed through the mixing chamber and plastic cable guide Lf used and through the outer casing leaving enough wire to replace the spring and the throttle slide Now push the inner wire up to the point where the spring is held between the cap and throttle slide Before installing the throttle slide E Fig 35 2 and choke slide L Fig 35 2 into the mixing chamber line up the slot Fig 35 3 in the throttle slide with the small guide pin I Fig 35 3 inside the mixing chamber the cutaway portion on the bottom of the throttle slide facing the air filter When lined up properly push the throttle and choke slides into the mixing chamber see Fig 35 3 Correctly Lined up they will slide in easily press down the compressing the springs anm replace the screw D Fig 35 1 At the twist grip end you can now feed the inner wire through the adjuster and into the retainer with the square headed bolt C Fig 35 1 page 35 Pull up the slack on the Inner wire and tighten the square headed retainer bolt Before refitting the carburettor to the intake pipe operate the twist grip a few times to ensure the throttle working freely Refit the carburettor and make final adjustments as described on page 32 To replace the complete cable follow the instructions 1 to 4 on page 35 and then separate the new inner wire from its outer casing Before removing the old outer casing observe
4. This Service Manual has been specially prepared for the use of our Cady Servicing Agents some areas it may appear that we have been too explicit but we have taken into account that Eherea may be many consumers who wish to have such a manual The techniques recommended in this manual are those which we employ and teach in training COUFSPE NOTE the Warranty Wen an operation is described as Left Hand Side or Right Hand Side this determined as when the rider is seated on the machine the normal manner USEFUL METRIC CONVERSIONS 1 om millimetre 140394 inch 1 IMPERIAL GALLON 1 em centimetre 4 394 inch 1 U S GALLON 2 54 1 000 inch 1 IMPERIAL GALLON 1 U S GALLON To the consumer and the servicing dealer It is expressly understood that under the terms of the Cady Warranty any damage caused ro any part or parts of the Cady motor or machina by usa of tools other than SPECIAL TOOLS as listed in this SERVICE MANUAL Will not be covered by 4 546 litres 3 785 litres 160 fl ors 128 fl ozs Basic Tool Requirement Belt Belt replacement Belt tension Breakers Brake adjustment Brake cables Bottom bracket Clutch Removal Clutch Servicing Ciuteh Refitring Contact Breakers Cylinder head removal Cylinder head refitring Cylinder removal Cylinder refitting Cylinder Piston Matching Carbon Chains Care and Replacement Chal
5. Lightly lubricate the replacement wire and feed it up through the choke slide and the outer casing until it appears st the lever end Screw the adjuster all the way into the lever bracket Fass the wire through the adjuster and into the pinch bolt on the choke lever pull gently on the wire to take up any slack and tighten the pinch bolt Adjust described above items 2 to 5 If is necessary to replace the outer casing remove the inner wire first and install the outer casing following the same toute the old one Then install the inner wire as described above items 7 to 10 and pull it out from the bottom Fig 33 1 Cacly SERVICE MANUAL 22955508 caste ADJUSTMENT amp REPLACEMENT Page H NO SPECIAL TOOLS REQUIRED The decompressor cable is found on the Right Hand lever bracket end it is important that it is never over adjusted Ad jus tment 1 small amount of free movement of the decompressor lever Ls required and this should not exceed 1 4 of movement at the lewer end 2 To adjust first unlock the lock nut on the adjuster and unscrew the adjuster until the required free play is achieved on the lever 3 Cheek to make sure the decompressor moves freely up and down 4 If everything is in order tighten the locknut amd double check the free movement 5 If the decompressor sticks in the down position when operating the lever check the cable for damage and or rust To do this the adju
6. Remove the handlebar assembly complete with stem and control levers by unscrewing the bolt A Fig 43 1 approx 1 4 and tapping it down to Teleasa the expander plug located inside the fork column at base of the stem Lift out the handlebar assembly and let it hang to one side 2 Remove the front wheel see page 27 and support the machine with a block under the muffler 31 Remove the mudguard attached by 2 bolts and nuts at fork crown and 2 stay eye bolts just above fork ends 4 Slacken the pinch bolt nut B Fig 43 2 and pull our the brake wire Remove the head fittings C amp D Fig 43 2 then the lamp bracket with head lamp and horn and let it hang to one side then the washer and the screwed race E Fig 43 3 Hold the forks while unscrewing the screwed race and when fork is free can bs pulled down and out nf the frame The loose ball bearings 5 32 wlll fall out from the bottom frame cup G Fig 43 3 and can be removed from the tap cup F Fig 43 3 These should be replaced 24 balls to each cup when servicing the forks 6 If fitting a new fork the fixed cone Fig 43 3 be removed by driving Lt upwards from underneath using a hammer and punch and than refirted onto the new fork Drive it on using a brass or copper punch so as not to damage the bearing surface 7 Before refitting the forka check the bearing surfaces of the parts E H F amp G Fig 43 3 These parts should a11 have
7. before in amp pecting the magneto The things to look for when double checking are 8 1 The plug being grounded properly B 2 The plug lead properly connected to the plug cap and coll 8 3 feed wire properly connected also check the cover of the wire from the Coil to the magneto plate for damage or fractures and possible shorts If still no spark it will be necessary to inspect the magneto as follows 9 1 Remove the double clutch see page 9 2 Remove the flywheel see page 11 9 3 With the magneto exposed check for the following possible problems 9 4 The points are opening and closing by rotating the engine check points gap see page 12 9 5 Check for sticking contact breaker points or moving breaker arm stiff remove and clean ani lubricate shaft with a smear of graphite o11 9 6 Check 11 the wires for chafing and possible shorting to ground and rubbing on the flywheel 9 7 Check the points for burning and clean or replace as necessary 9 Remove and replace the condenser 8 9 Check for oil seepage from the crankshaft denotes oil seal damaged Cleaning the oil from points and magneto will effect a temporary repair but not eliminate the problem 9 10 Check the flywheel for damage possible loose magnets 9 11 Check for demsgnetized flywheel VERY RARE by replacing with a new one 9 12 Check Coll by replacing with new one NOT COMMON RESISTANCE
8. nuts A Fig 25 1 and lock the quick release lever Note MODELS WITH OR WITHOUT REAR SUSPENSION Make sure the chain tensioner is properly aligned by rotsting the pedals backwards Lf there any roughness due to the arm being bent or twisted minor adjustments be made by gently bending and straightening the tensioner arm to correct the alignment Page 25 Fig 25 2 NO SPECIAL TOOLS REQUIRED Ceca SERV ICE MAN UAL CHAIN ADJUSTMENT NO SPECIAL TDOLS REQUIRED MODELS WITH REAR SUSPENSION machine on it s stand 1 The pedalling chain on these models has spring loaded tensioner and chain tension is constantly maintained The tensioner can be lifted and locked in the UP position and released by pressing the catch D Fig 26 2 inwards Meter Chain 2 The adjusting of the motor thain on models with the rear shock absorbers depressed to this done the chain tension will be too with rear suspension should be carried out the position of an average rider Unless tight when a rider sits on the machine 51 the axle nuts Fig 26 1 and the lock nuts B Fig 26 1 on the chain sdjusters D Fig 26 1 and push the rear wheel backwards by screwing in the chain adjusters equally on both sides until the correct tension is achieved as described on page 21 nuts A and adjuster lock nuts Tighten axie Fig 26 1 Carclyy SERVICE MANUAL 9e ron s errime FRONT WHEELS NO SPECIAL TOOLS REQUIR
9. 5 can be removed by unscrewing them usually by hand from the fork tube after removing the fork gator E Fig 46 5 3 Inside each fork tube 1s a set of bushes and sleeves see H Fig 46 4 These can be removed and replaced if worn but this seldom necessary REASSEMBLE 4 Reverse the above proceedure replacing the bushes and sleeves order as illustrated ard coating the springs with graphited grease 5 The springs should always be replaced in pairs so fork ends are equalized in length NEVER mix old and new springs 6 Make sure the fork blades are fitted to the correct side The main difference 1s the fork blade has a Blot the fork end to retain the brake plate sees Fig 46 5 FRONT FORK SERVICING hit Fig 46 3 SPECIAL TOOLS REQUIRED Carcly SERVICE MANUAL torro norauarroy aw anon NO SPECIAL TOOLS REQUIRED If a fork lock has to be installed or removed follow the instructions below lock assembly consists of 5 pieces and they are installed the order as listed A split washer spring The principle is to lock the steering 50 C the brass lock the machine cannot be driven or wheeled away D two keys E a wire clip Wote The lock housing ls located on the left side at the rear of the steering head just above the fuel tank 13 29 3 4 5 8 7 7 Place the aplit washer over the tongue of the brass lock partially inse
10. TEST FIGURES COILS FEED COIL 19949 or 21994 LIGHTING COIL 19948 21995 SUPPRESSOR 20451 4000 OHMS in plug cap CONDENSER 19067 0 15 Continued on next page Page 55 Cacly SERVICE MANUAL MOTOR FAULT FINDING CHECKING FUEL PROBLEMS Always remember that the fuel which reaches the cylinder a combination of Gas Petrol and 011 and Air and if this mixture is upset by any means the motor will not perform correctly Any fuel problema will involve The Fuel Tank Fuel Tap The Carburettor ami ultimately the motor A number of possible problems are described on pages 37 38 and 39 and it is worth reviewing this section before proceeding with the following NOTE The carburettor is of the gravity feed type ani the mixture is constant as there 1s no provision for a LEAN or RICH mixture and the fuel is metered by a replacesble jet The gas petrol and oil mixture a ratio of 25 parts gms petrol to 1 part 011 when using regular TWO CYCLE or 2 STROKE oils of top grade mixture of 40 parts gas petrol to 1 part oil can be used if ESSO ULTRA MARINE OIL is aval lable Any Regular gas petrol is satisfactory or Premlum fuels may be used Non leaded gas petrol is also acceptable 25 to 1 RATIO 47 6 4 ozs 011 to 1 IMPERIAL GALLON GAS PETROL 40 to 1 RATIO 2 51 4 ozs 011 to 1 10 Make sure there is fuel in the tank see pages 37 38 39 11 sure t
11. With a simple low voltage 1 5V to continuity tester attsch one lesd to the HIGH TENSION FEED wire Grey wire at bottom of Coll snd the other to the cylinder fins See Fig 14 1 8 Rotate the motor clockwise till the YELLOW mark disappears and than slowly rotate the motor anti clockwlee 5 While rotating anti clockwise observe the light bulb and you will notice a flicker the light This occurs at the moment the contact breakers open and the top of the YELLOW mark should just be visible at the shoulder of timing gauge 6 If the flicker the light and the YELLOW mark do not coincide as described it will be necessary to re time the ignition see page 13 The timing of the ignition is 1 2 mme BC which is equivalent to 3 4 of rotation on the outside diameter of the flywheel Page 14 Fig l 1 Ceca SERVICE MANUAL ees Bean AND CYLINDER REMOVAL HOTE This be done with motor in frame 1 2 3 4 5 Page 15 but can be better accomplished if motor is removed See page Remove motor from frame and remove exhaust assembly as described on pages 6 amp 18 Clamp motor in bench vise using the lower motor mounting bracket See illustration below Cylinder head can be removed hy unscrewing the four cylinder head bolts using a 5mm hex ALLEN type key To remove the cylinder use a 5 mm Hex Allen type key and unscrew the four cylinder bolts sunk into lower part of coolin
12. diagram Fig 34 2 If bent or worn replace it with new one Shake the float to determine if there is any fuel inside and if so replace it Check the gasket G Fig 38 1 on the float bowl cover and replace Lf necessary If the needle is worn the needle seat the float bowl cover wlll alse be worn and it also should be replaced along with the float The other things to check if there is a fuel leak is The fuel tap is tight Fig 38 2 b The fuel iine is not cracked or split Before replacing the float and float chamber cover inspect the inside of the float bowl and clean Lt out thoroughly There could be gummed oil and grit inside or water or corrosion caused by moisture AIR FILTERS 153 Page 38 There tine wire mesh screens in the alr filter Fig 38 1 whieh should be cleaned this is easily done by removing the alr filter cover and removing the two screws on the end cap of the Bir filter giving access to the screens Wash these clean with a suitable solvent Continued on Page 39 Cacly SERVICE MANUAL cassunerron service continues THROTTLE amp CHOKE SLIDE 16 If the throttle or choke are sticking follow the instructions on page 33 for choke pages 35 and 36 for throttle and inspect for Corrosion caused by moisture b Damage to throttle slide and or choke slide Frayed throttle or choke wires d Throttle or choke wires stiff in outer casing To correct the above problem
13. the fixed pin A Fig 30 1 then push the shoes off the brake arm cam B Fig 30 1 with the springs C Fig 30 1 still attached 4 Smear a litrle all purpose grease on the fixed pin A Fig 30 1 and a few drops of oil where the brake shoe cam passes through n 40 the plate Make sure the brake operates freely when you Pg 39 1 have the brake shoes off 5 install new brake shoes reversa the above operation using new springs vith new shoes Attach the springs to the shoes first NOTE Front brake on models without front suspension If it is found necessary to remove either side of this cantilever type brake from the fork blades is best to use an impact type tool with socket to loosen the bolt D Fig 30 2 This bolt is securely tightened at the factory and being thin one could easily strip the corners off the hexagon head with a ring or apen wrench brake shoes with pads can be adjusted or replaced by slackening i the eye bolt nut E Fig 30 2 Fig 30 2 Page 30 Carchy SERVICE MANUAL ss sees NO SPECIAL TOOLS REQUIRED The servicing of hubs relates to the axles and bearings Brake service will be found on page 30 and the same principles apply whether the machine is with nr without suspension axle set consists of a number of washers and spacers and locknuts and cones When stripping a hub its axle the order in which the parts are assembled should be carefully noted 1 Remov
14. the right hand crank for normal servicing of the axle 5 To refit the chailnwheel and axle reverse the proceedure above making sure the circlip and washer G sre in place and lightly grease the axle with a general purpose grease It is also s good idea to apply a grease gun to the grease nipple at the end of the axle and force some grease through to make sure the grease channel is not blocked before assembling 6 Before refitting the needle bearing C and the small engine sprocket B clean them thoroughly and coat them with general purpose grease Page 24 Ceca SERVICE MANUAL 222 venmesr MODELS WITHOUT REAR SUSPENSION Machine on it s stand PEDALLING CHAIN The engine drive chain and pedalling chain can be adjusted independently or together at the same time I Slacken the 2 nuts A Fig 25 1 on the chain tensloner press down on the tensloner arm setting the tension as described on page 21 Tighten the tensioner nuts Motor Chain 2 35 A 5 6 Release the quick release lever on the frame under the saddle Slacken the 2 nuts the chain tensioner item 1 above Slacken the 2 nuts one each side at the base of the frame stays C Fig 25 2 Pull the rear wheel backwards until the engine chain ts tensioned as described on page 21 sure the wheel is properly centered in the frame and tighten the frame stay nuts C Fig 25 2 Set rhe pedal chain tension and tighten the tensioner
15. the space either side of the tire at the inside of the forks The space should be equal on both sides Page JBA Cacly SERVICE MANUAL im ausis NOTE ALL BRAKES NO SPECIAL TOOLS REQUIRED The basic adjustment of the brakes done at the handlebar brake lever position This adjustment will take up any slack in the brake cables during the bedding down of the brakes and initial stretch nf the brake cables Brake adjustment machine on its stand Engine engagement lever to motor disengaged position Fig 22 1 Page 22 1 Slacken the locknut A Fig 29 1 on the respective brake lever 2 Spin the wheel being adjusted and screw out the adjuster B Fig 29 1 until the brake begins to engage the wheel Squeeze the brake lever once or twice spin the wheel agsin readjust Lf necessary and screw up the locknut A Fig 29 1 When squeezing the brake lever there should be approximately 1 2 of free mowe ment before braking takes effect Front Brake models without suspension 3 Additionsl adjustment is provided on the brake at point C Fig 29 2 amp Screw in the adjuster B Fig 29 1 on the lever 5 Slacken off the nut D Fig 29 2 squeeze together the brake shoes against the wheel rim and pull the brake inner wire downwards holding with pliers and twisting at the same time 6 Hold the wirs in this position and tighten nut D Fig 29 2 73 Hake fine adjustment as described in ltem 2 abovess
16. transferred to the new head or engine Ceca SERVICE MANUAL Regular Lubrication is necessary wherever there are moving parts that come in contact with each other following is a guide only and should be adjusted depending on conditions and usage The major lubrication points are as follows 1 Brake lever pivot bolts S A 30 oll frequency Every month or Every 600 miles 1000 KM 2 All cables i SI TE XL 5 3 Decompressor lever oou UM en Choke lever x 5 Throttle cable 9 us 8 Pedals m AEn 7 Brake arm and cable nipples F and H c B Brake pivot bolts cantilever brake gt ros 9 Kickstand pivot bolts a 10 Freewheel W Under extreme operating conditions lubricate more frequently as required MILES KM 11 Pulley shaft Multi Purpose Grease Every 1250 2000 12 Telescopic forks 600 1000 13 Hub bearings 3700 6000 14 Clutch bearings a 1250 2000 15 Chains or Special Chain lube monthly or 9 x 16 Steering head bearings M Every 3700 6000 17 Bottom bracket axle n 3700 6000 Under extreme operating conditions the parts requiring grease should be cleaned and greased more regularly Page 52 Cacly ENGINE CAPACITY COMPRESSION LUBRICATION s IGNITION CARBURATION CLUTCH BRAKES t LIGHTING TIRES TUBES 1 FUEL
17. use a new head gasket NOTE Cacly SERVICE MANUAL CABLE REPLACEMENT THROTTLE SPECIAL TOOLS REQUIRED a Quite often Lt 1 possible to replace only the inner wire rather than the complete assembly but thie should only be done if the outer casing is good condition aress most subject to damage are the exposed sections of the cable between the control the frame Thrattle 13 Slacken tbe locknut A Flg 35 1 on the cable adjuster B Fig 35 1 and screw the adjuster into the twist grip bracket as far possible Unscrew the square headed cable retaining bolt C Fig 35 1 pull out throttle cable Remove the carburettor from the intake pipe by slackening the clamp E Fig 35 2 and remove the screw D Fig 15 2 on the mixing chamber cover TF Fig 35 2 and the cover complets with the throttle slide and spring and choke slide and spring see Fig 35 3 Push the throttle inner wire down so you can pull Le right out of the throttle slide and throttle slide spring Some carburettore have a plastic cable guilde on the mixing chamber cap this will become free when the inner wire is removed so place it aside until installing the new inner wire or complete cable See G Figs 35 2 Fig 35 2 Fig 15 1 Continued on next page Page 35 Cacly SERVICE MANUAL neenacenenr mROTTLE Continued see Page 35 for Fig 35 1 2 and 3 5 amp 7 8 9 10 11 12 Page 36
18. 1 The life of a chain depends entirely on the care and attention it E receives and 1f properly cleaned lubricated and tensioned it will 2 M perform ite function for many years MS 1 2 new chain takes little time to run in and during this time will need adjusting Regular care and attention is required for exposed Fig 21 1 ee eal chains as used on the Cady Correct adjustment is determined by the degree of up and down movement deflection of each chain at a point midway between the sprockets see Fig 21 1 maximum deflection 1 2 and the best operating tension is a deflection of 1 4 minimum to 1 2 maximum See special adjustment for machines with rear suspension on page 26 items B and 9 3 chain that 18 too loose may not only jump the sprockets but will whip sideways causing excessive sprocket wear stretched chain 1s acutslly s worn chain and showld be replaced before it wesrs the sprockets 4 The pedalling chains on the Cady s are provided with chain tensioners MODELS WITH rear suspension have spring losded tensioner which the tansion constant MODELS WITHOUT rear suspension have an adjustable tensioner which will require occasional adjustment See page 25 1 21 3 5 To decermine when a chain needs replacing measure 23 pitches 2 ses Fig 21 2 This would be 11 1 2 on a new chain and if this more than 11 3 4 replace the chain 6 Make sure when fit
19. 11 4 To remowe stator plate E Fig 11 2 simply remove the three Allen type screws using 4 mm hex key zee F Fig 11 2 Fig 11 4 Carcly SERVICE MANUAL 45 gaon ram 1 2 3 4 NO SPECIAL TOOLS REQUIRED STATOR PLATE Beplace the stator plate by reversing proceedure 4 on page 11 making sure wire and lighting terminal in 1 o clock position D Fig 12 1 and lining up the 3 holes for the Allen type screws See Location E Fig 12 1 Use Locktite Blue Locking Cement on the mounting screws CONTACT BREAKER SETTING Place magneto cam C Fig 12 2 gently onto shaft and rotate to obtain maximum breaker gap At this point adjust the point gap to 3 10 mm 012 as follows Loosen contact breaker securing screw A Fig 12 1 and turn concentric cam B Fig 12 1 to set points to 012 using feeler gauge Note Turning the cam B anti clockwise opens the gap and clockwise closes the gap Tighten locking screw A securely and double check points gap is still 012 and has not changed Final fitting of flywheel and magneto cam is described on page 13 Page 12 Cacly Page 13 1 2 3 4 5 6 7 8 9 10 Having set the contact breskers page 12 proceed as follows SERVICE MANUAL FLYWHEEL REFITTING AND TIMING THE IGNITION SPECIAL TOOLS REQUIRED TIMING GAUGE 1470 FLYWHEEL VISE 1291 Remove the spark plug and screw in the timing gau
20. ED Models without front suspension machine on its stand 1 Slacken the axle nuts A Fig 27 1 Raise the wheel off the ground and pull the wheel down and out of the forks Reverse the proceedure to refit the wheel Models with front suspension machine on its stand 21 Push the brake arm A 27 7 and release the cable nipple BR Fig 27 2 and cable from the brake arm 3 Slacken rhe axle nuts and washers C Fig 27 2 Raise the wheel off the ground and pull the wheel down and out of the forks Reverse the proceedure to refit the wheel making sure the lug D Fig 27 2 on the brake plate is engaged in the slot E Fig 27 2 on the R d Fork end 8 Make sure the ferrule on the cable outer casing is properiy installed in the cable stop located inside the fork end at point Fig 27 2 Page 27 Cacly SERVICE MANUAL seen c SPECIAL TOOLS REQUIRED REAR WHEELS MODELS WITH REAR SUSPENSION machine on its stand 1 Push the brake arm A Fig 28 1 forward and release the cable nipple B Fig 28 1 with cable rom brake arm 2 Slacken the axle nuts C Pig 28 1 and the chain adjuster belts D Fig 28 1 and push the wheel forward 3 Push the chain tensioner up into the locked position E Fig 28 2 4 Lift both chains off the rear wheel sprockets and pull the wheel to rhe rear and out of the frame slots 5 To replace the wheel reverse the proceedure making sure the slot in the brake plate fi
21. EL VISE 1470 5 15141 TIMING CLUTCH PULLER GAUGE c 98952 PEDAL WRENCH SPECIAL TOOLS MAGNETO CAM PULLER PISTON PIN TOOL E ias CAM FIXING TOOL FREEWHEEL REMOVER Page 4 Page 5 Ceca SERVICE MANUAL OBSOLETE ENGINES A WORD WARNING MR DEALER OVER THE PAST FEW YEARS A CERTAIN NUMBER OP MOPEDS iAUTOCYCLESI HAVE ENTERED CANADA USING BASICALLY THE SAME ENGINE IS PRESENTLY USED ON THE CADY MOPEDS IT CONCEIVABLE THAT YOU WILL RECEIVE SOME EBUUTRIES FOR PARTS FOR THESE FORERUNNERS AND WHEREAS QUITE A CADY PARTS WILL BE INTERCHANGEABLE THERE WILL BE OTHERS THAT ARE NOT VARIOUS MODIFICATIONS AND IMPROVEMENTS HAVE BEEN MADE OVER THE PAST FEW YEARS WHICH HAVE PUT CERTAIN PARTS OF THESE OLDER MACHINES INTO THE CATEGORY OBSOLETE THE SAME TIME WHILST YOU MAY NOT BE ASCE TO REPLACE AN EARLIER PART IT MAY BE POSSIBLE TO REPLACE THAT PART WHEN INCLUDED IN SUB ASSEMBLY WHEREVER SUCH INSTANCES ARISE PLEASE CHECK OUT THE PART THOROUGHLY AND WHEN IM DOUBT PASS YOUR INQUIRY THROUGH HOME OFFICE WHERE EVERY ATTENTION WILL BE GIVEN TO PROCURE THE NECESSARY PARTS Carchy SERVICE MANUAL smova s NO SPECIAL TOOLS REQUIRED NOTE For many service operations is not necessary to remove the complete motor Such operations as Minor decarbonizing Checking the timing Clutch removal Ignition checking etc can be carried out with the engine in pla
22. Front Brake models with front suspension B Additional adjustment provided on this brake at point E Fig 29 3 8 Screw the adjuster Fig 29 1 on the lever 10 Slacken the square headed bolt on the cable nipple P Fig 29 3 11 Push up on brake arm G Fig 29 3 and slide nipple up as far as possible and tighten the bolt on the cable nipple Fig 29 1 12 Make fine adjustment described in item 2 above Page 29 Cacly SERVICE MANUAL gt amp CABLE REPLACEMENT Replacement of cables NO SPECIAL TOOLS REQUIRED A brake cable should be replaced when the brake lever becomes sluggish or stiff to operate This is usually caused by DAMAGE HIST CORRISTION a FRAYED Inner Wire If you are replacing only the inner wire on a brake make sure it Ls lubricated first and follow the sdjusteent directions on page 29 after you have installed the new wire If you are replacing complete cable first check the routing of the cable you ars going to replace and install the new cable in exactly the route and follow the adjustment directions on page 29 Replacement of drum brake linings Remove the wheels as per directions on page 27 amp 28 2BA 1 HBemove the axle nuts and washer and spacer from the brake plate side of the axle 2 Remove the brake plate and clamp it in the visa See Fig 30 1 3 Mith a screw driver lever the brake shoes up and off
23. G OTHER POSSIBLE MOTOR PROBLEMS Having checked the IGNITION and FUEL and 1f the motor still does not run properly check the following list for the most likely cause of the problem Foor Motor Performance 20 Check fuel mixture 21 Check spark plug 22 Check colour of spark it should be blue if it is orange check the points for burning gap or dirt Lf still orange replace the condenser 23 Check the timing see page 13 and 14 24 Double check for carbon build up see page 18 25 Check drive belt for tension see page B 26 Check chain tension ses page 21 27 Check tire pressures could be too low 28 Check the brakes are not over adjusted If motor runs in reverse the timing needs adjusting see pages 13 and 14 This usually caused by the magneto cam improperly installed during after service 29 Check that the crankshaft is not bent this can be visually checked by turning the motor over end observing the double clutch and flywheel If bent the crankcase assembly will to be replaced Remember the crankshaft controls the magneto cam and if bent it is not possible ta obtain correct ignition 30 Check for worn crankcase bearings side play on the crankshaft 31 Check for cylinder and piston ring wear Noisy Motor 32 Check for cylinder and piston and piston ring wear 33 Check connecting rod bearings for wear both the big end and small end 34 Check for loose muffler 35 Check for loos
24. OTOR DOES NOT START er HARD TO START 1 Remove the plug lead and cap from the spark plug remove the spark plug and inspect it If the plug is wet the problem is most likely IGNITION If the plug is dry the problem is most likely FUEL CHECKTNG IGNITION PROBLEMS The external parts to check the following order are The Spsrk Plug B The Spark Plug Cap C The H T Plug Lead D The Coil E The Magneto The Feed Wire CHECKING FOR SPARK 1 Remove the spark plug from the motor attach it to the plug cap and lay it on the cylinder head fins grounded 2 Rotate the motor by turning the pedals and check for a spark at the plug 3 If no spark replace the spark plug and check again 4 If still no spark replace the plug cap which contains an interference supressor and check for spark again Continued on rext page 3 3 Carcly SERVICE MANUAL o ss rror If still nn spark replace the plug lead and check again The plug lead has long and a short connecting end and the long end fits into the Coil and the short and into the plug cap If still nn spark remove the coll Attach new coil to the H T plug lead and attach the feed wire from the magneto to the coll Place the Coil on the cylinder head fins so one of the mounting screws is wedged in the fins grounded and check again for spark If still no spark double check the proceedure items 1 through 6
25. TABLE FOR BEACH ADIUSTABLE FOR NON ADIUSTABLE HEIGHT ONLY Page 48 NOTE NOTE REMOVAL REFITTING Cearcly SERVICE MANUAL sacer asses NO SPECIAL TOOLS REQUIRED service the bottom bracket it wlll be necessary to complete the operations on page 22 and 24 first As you willl see by the illustration on this page the bottom bracket bushes are removable and replaceable It is very seldom necessary to replace these bushes and generally the only Service conaiata of cleaning and greasing To remove the bushes drive them out using a hammer and punch Tn refit the bushes first start the bushes the bracket housing by partially tapping them in using hardwood block Complete installation can be done by passing large bolt through the bushes placing a washer against the outside of each bush first then fitting nut to the bolt and tighten up on the nut while gripping the bolt head Alternatively the bushes be pressed in using a bench presa or bench vise Fig 49 1 Page 49 Ceca SERVICE MANUAL merw moval ano neritic SPECIAL TOOLS REQUIRED FREEWHEEL REMOVER 17650 The freewheel should be lubricated from time to time to keep it running free and to prevent corrosion The best way to do this is to rotate the cranks backwards and at the same time apply a few drops of SAE 30 oll to the edge of the freewheel at the point A Fig 50 1 where the moving outer rim of the freewheel revolv
26. age 31 Ceca SERVICE MANUAL NOTE Machine on its kiokstand It important to allow 1 16 to 1 8 of play in the throttle cable to allow for any pull on the cable when the steering is rotated 1 2 3 5 8 7 Start the motor allow time for warm up and rotate the throttle noting the amount Jf rotation required before the engine speed picks up With throttle closed unscrew the idle adjusting screw Fig 32 1 until the engine speed is at its lowest and then slowly screw it in until the engine speed just begins to increase At the lever end slacken the lock nut Fig 32 2 and with throttle closed screw out the adjuster BR Fig 32 2 until the engine speed increases screw the adjuster back in two full turns and tighten the lock nut Fig 32 2 You should now have the necessary amount of free rotation on the twist grip before the engine speed increases and remove the possibility of any increase in engine speed when the steering is rotated to this point we have assumed that the throttle wire and casing are good condition so it is advisable to open and close the throttle a few times and make sure everything is in order If tha adjuster has to be screwed out to its full extent refer to page 36 item 7 for instructions of additional adjustment at the twist grip Should the engine speed not slow down to an idle after operating the twist grip check the throttie cable for damage ond re
27. and protect the crankcase by wrapping a clean cloth around the connecting rod to stop any carbon falling inte the crankcase 12 Remove the piston rings and scrape out any carbon in the piston ring grooves a broken piston ring a goo scraper and clean the piston head 13 Reverse the proceedure to reaseemble using new gaskets where necessary and new piston rings if required See page 19 for Piston Ring fitting and page 20 for Cylinder and Cylinder Head refitting Page 18 Cacly SERVICE MANUAL PISTON RING FITTING PISTON TO CYLINDER MATCHING NO SPECIAL TOOLS REQUIRED Tha fitting of piston rings is very simple just follow the notes below Fig 19 1 Page 19 NOTE A There are piston ring anti turning atops in the pieton ring grooves of the piston make sure the rings are the right way to match the stops in the piston See Fig 19 1 NOTE B Although there are pistons manufactured to match up with specific cylinders the rings are all one sire and fit ali pistons NO GCAPPINGC IS REQUIRED NOTE C Wher replacing piston rings on a used piston make sure the piston ring grooves are free of carbon simple method of cleaning the grooves is to snap an old piston ring and with piece about 1 long and squared off at the end on a grind stone carefully scrape the carbon from the grooves being careful not to remove any metal FITTING To refit the rings simply spread each ring spart just enough to pass ove
28. at side out Hold the flywheel with tool 1291 and tighten the flywheel nut see Fig 11 1 Page 11 See Page 14 for timing check Ceca SERVICE MANUAL mrc aie amp merear SPECIAL TOOL REQUIRED Timing gsuge 1470 Flywheel vise 5 1291 Having complete the operations on page 13 proceed as follows INTERNAL With timing gauge installed flywheel removed 1 Ratate the motor clockwise till the shaft of the timing gevge only protrudes approx 1 2 2 the contact breaker points and place a thin leaf of psper between the contact beads cigsrette paper ideal or a feeler gauge of not more than 002 3 Potete the motor slowly anti clockwise gently pulling on the paper until it pulls out from between the contact beads and stop the rotation there At this moment the breaker points start to open and th s is the exact point of ignition and the top of the yellow mark on the stem of the timing gauge should just be visible and line with the shoulder of the timing gauge 5 Replace the flywheel as described section 9 10 page 13 EXTERNAL With motor on bench on machine fully assembled 1 Remove spark plug and screw the timing gauge 1470 finger tight 2 Rotate the motor until the stem of timing gauge is fully extended unscrew the timing gauge the bottom of the YELLOW mark is level with the shoulder of timing gauge see Fig 14 1 Yellow Timing Mark 3
29. ce If the machine is elevated to bench level by whatever means sults you best most servicing and repair Joba can be carried out efficiently and successfully REMOVAL 1 Remove both chain covers LH amp sides 2 Loosen upper engine mounting bolt A Fig 6 1 but do not remove 33 Loosen and remove lower engine mounting bolt B Fig 6 1 Slip drive belt off large pulley 5 Release decompressor cable by screwing in cable adjuster lever Now press down on decompressor C Fig 6 1 release outer casing from top of decompressor and inner wire nipple from bracket at base of decompressor 6 Remove lighting wire from magneto stator plate D Fig Page 12 and spark plug cap from spark plug 7 Remove carburettor by slackening screw D Fig 6 1 gently rotate carburettor left and right to remove front intake pipe The carburettor can now hang freely B The motor can now be removed by holding it firmly while removing the upper engine bolt A Fig 6 1 REFITTIEG 9 Reverse the operation when refitting the motor making sure the carburettor pushed all the way onto the intake pipe 10 Readjust the decompressor cable allowing a little slack in the cable See page 34 Decompressor Adjustment Page Carcly SERVICE MANUAL 5 25 Page 7 The correct tensioning of the drive belt 18 important A tight belt will cut down performance as also will contribute to belt wear Any excess tensi
30. ch piston ring being compressed one at a time as the cylinder is installed slight rotation of the cylinder both left and right will help 4 Rotate crankshaft so piston is at T D C position compress the piston rings with your fingers make sure they are lined up properly on the stops in the piston ring grooves and place the cylinder over the piston exhaust and intake ports to the front Gently push down until it mates with the crankcase Double check that the cylinder base gasket is in correct position and that the cylinder and cylinder base bolt holes are lined up If you have to rotate the cylinder to line up the holes double check the crank case gasket again 5 Place the copper washers over the crankcase Allen type hex screws and drop into their respective holes through the cylinder fins and tighten securely with 5mm Allen type key 6 Rotate the crankshaft few times and make sure everything is correctly assembled then lightly grease the cylinder head gasket both sides place it on the cylinder head lining tp the holes correctly 7 Line up cylinder head on the cylinder and screw the cylinder head bolts in place tighten securely with 5 mm Allen type key Carclyy SERVICE MANUAL cams ca c senacewer NO SPECIAL TOOLS The Cady uses two sizes of chains and the lengtha differ according to the model NOTE The pedalling chain is size 1 2 x 1 8 NOTE B The motor chain is 1 2 x 3 16 haavy duty type
31. d centrally between the fork legs This is reached from the back of and ftom underneath the headlamp and straightened out by levering with screwdriver Let the headlamp hang to one side Remove the fork stem retaining bolt D Fig 44 3 by first bending back the tsp of the lock washer E Fig 44 3 then remove the head lock nut and its washer See B5 Fig 45 1 on page 45 Fig a 44 Continued on next page SERVICE MANUAL mor ror movan REMOVAL continued 6 The fork assembly can now be removed see Fig 45 2 using a hardwood block and a hammer This will spring the lower plate off tne bottom of fork stem and by pulling the fork assembly forward and up it will lift off the threaded upper part of the fork stem Fig 45 2 7 fork stem H Fig 45 1 can now ba removed by unscrewing the screwed race I Fig 45 1 The loose ball bearings 5 32 will fall out of the bottom frame cup L Fig 45 1 and be removed from the top frame cup Fig 45 1 These should be replaced 24 balls to each cup when servicing the forks REFTTTING A Before refitting the forks check the bearing surfaces of tha parts J K L M see Fig 45 1 These parts should all have smooth bearing surfaces and if worn be replaced The frame cups and L Fig 45 1 be removed using a punch and hammer when refitting them use a hardwood block Note Before refitting the fork
32. d with wrench on the nut with pressure applied strike the head of the cotter and take up the slack on the nut at the same time Repeat this a few times until you feel the pin is far ms it will go and the nut is tight NEVER use excessive force when tightening the nut as this will weaken or strip the threads NEVER drive the pin with excess hammering ALWAYS take up the slack on the cotter pin nut at the same time as you strike the cotter pin head 4 When fitting the crank arm follow the same proceedure as in 3 above crank arms Left or Right must face to the rear when installing crank cotter pins and the is inserted from below and the nut screwed on from above Fig 43 1 Page 23 Cacly SERVICE MANUAL gt sprocket CHATNWHEEL REMOVAL NO SPECIAL TOOLS REQUIRED NOTE 11 parts indicated by letters refar to Fig 24 1 1 Remove pulley converter as described on page 22 ltem 1 to 4 2 Slacken the rear wheel as described on page 28 and lift chain off the large sprocket and the small engine sprocket and remove the washer it may have remained stuck grease to the pulley converter and the small engine sprocket B with its needle bearings C and washer 3 Remove the circlip E and the chainwheel with axle la now free to be removed from the right hand side of the frame after you have slipped the chain off the chainwheel 4 It is not necessary to remove
33. e engine mounting bolts 36 Check for main bearing wear 37 Check for clutch bearing wear and possible damage from impact and also for bent crankshaft 38 Check for broken mounting bracket UNCOMMON Page 57
34. e the wheel and if a drum brake is fitted remove the brake plate See pages 27 2 30 2 Once the brake plate is removed you can proceed with whatever wheel is involved in the same manner 3 Grip the lock nut on the side opposite the brake drum in the vise and with suitable tools remove the lock nut from against the cone on the exposed side and then remove the cone 4 The wheel can now be lifted off the axle the ball bearings will drop out 5 Wash off the hub and the bearings and cones with a suitable solvent and wipe ry with a clean rag Inspect the cups in the hub for any rough spots also the ball bearings and cones and replace as necessary 6 Pack the bearing cups in the hub with general purpose grease and place the ball bearings in the grease in each cup 7T HBassemble by reversing the stripping procedure HOTE 1 It is always advisable to replace the ball bearings with new ones when servicing a hub HOTE 2 If you are not sure how many bearings should go in the hub the best rule to follow is fill the cup to create full circle of balls and then remove ane B The final setting of the cone should be done with the wheel in the vise see item 3 above sn that very slight amount of play be felt at the rim and with the wheel removed from the vise the axle should rotate smoothly between the fingers WHEEL BEARING SIZE CHART MODEL FRONT REAR M1 PR 1 4 3 16 Mi FRTS 7 32 3 16 H3 PRETS 7 32 3 16 P
35. es over the fixed body of the freewheel If the freewheel La worn not engaging when pedalling it will have to be replaced REMOVAL 1 Remove the rear wheel as described on page 28 and 2B 2 Remove the axle nuts and washer and cone lock nut from right hand side of the axle 3 Place the freewheel removal tool in the bench vise 4 Place the wheel over the freewheel removal tool the axie fits into the tool and the lugs on the tool engage in the grooves in the freewheel body See B Fig 50 1 5 Hold the wheel firmly pressing downwards to keep the tool engaged in the freewheel and turn the wheel anti Clockwise and unscrew the freewheel from the wheel hub 6 Lightly lubricate the threads the hub and screw the new freewheel on as far as possible by hand 7 The freewheel will autocatically tighten itself Fig 50 1 on the hub after the wheel is installed in the machine Ii and has been pedalled Refir the rear wheel as described on page 28 and 284 Page 50 Cacy SERVICE MANUAL Ecm rae senm summers NOTE i Every Cady has an Engine and s Frame serial number These are located A The Engine serial number is the left hand side of the cylinder head sas Fig 51 1 Ah The Frame serial number stamped on tha left hand side of the frame ses Fig 51 2 If a cylinder head or complete engine has to be replaced the engine serial number plats must be
36. etric thread 14mm and it is important that the correct replacements used NOTE B pair of pedals consists of one Right hand and one Left hand The Right hand pedal 12 2 3 4 Page 40 can be identified letter E or D stamped on the threaded end or shoulder of the pedal spindle The thread is right hand and is screwed into the pedal crank clockwise and fits on the right hand side of the machine Tha Left hand pedal can be identified by the letter L or stamped on the threaded end or shoulder of the pedal shaft The thread is left hand and is screwed into the pedal crank anticlockwise To remove the pedals use a pedal wrench approx 13 long to achieve sufficient leverage Fit the wrench over the flats on the end of the pedal spindle and unscrew turning the wrench anticlockwisa for the Right hand pedal ani clockwise for the Left hand pedal To replace the pedals always start the threads using your fingers making sure the pedal spindle threads are lined up correctly with the pedal crank threads This will eliminate cross threading Screw the pedal spindles s11 the way and tighten securely with the pedal wrench If a long pedal wrench is not available use a suitable open ended wrench and a length of pipe to extend the length and obtain the necessary leverage to either remove or replace the pedals PEDAL WRENCH Cacly SERVICE MANUAL sean amp nerrrrinc amp stock ansonners
37. follows The SECONDARY clutch Fig 10 1 This 1s very simple mechanism and the things to check for are damage to the drum and wear on the clutch linings The clutch linings can be replaced but generally 1 is best to replace the complete drum If replacing the linings smooth off the rivet heads inside the drum after rivetting The PRIMARY clutch Fig 10 2 incorporates a needle bearing and this requires inspection from rime to time The clutch drum should be checked for damage and the clutch linings for wear To 1 2 35 4 5 6 7 1 2 remove the needle bearing Remove the circlip E internal pliers The flat washer D larger than The splined washer The flat washer B smaller than D j The needle bearing Inspect the inner bearing surface of the clutch drum for wear and or corrosion pit marks Fig 10 2 To reassemble reverse the proceedure above making sure the bearing surfaces and the bearing sre absolutely clean and then greased wlth a general purpose grease remove the clutch shoes File off the swaged end of the pivot pins I Fig 10 2 and remove the plain washer and wave washer L and then the clutch shoes with lining and unhook the springs Reverse the proceedure torefit the clutch shoes Lubricate the pivot pins first with smear of general purpose grease Swage the ends of the pivot pins to securely hold the clutch shoes in place T
38. g Fins be careful not to lose copper washers used on cylinder bolts as they may be left behind when you remove bolts The cylinder can be pulled up and off the piston quite sasily There will be metalized head gasket and paper cylinder base gasket exposed during this operation These should be discarded and replaced with new ones z Ai Emo NO SPECIAL TOOLS REQUIRED Carcly SERVICE MANUAL see SPECIAL TOOLS RE Piston Pin Tool 1434 with dummy piston REMOVAL Having removed the cyclinder head and cylinder proceed as follows 1 Clamp the crankcase in the vise 2 Remove piston pin clips use needle nose pliers and piston rings 3 Heat piston with blowtorch directed onto top of piston to about 212 100 C see Fig 15 1 and with the dummy piston pin placed over the piston pin tool 1434 insert the end of the tool into the piston pin and apply gently pressure as the correct heat is reached the applied pressure will push the pin out 5 Fig 16 1 Place tha piston on the bench and place the cylinder over the piston At first the cylinder will not drop over the piston but as the piston cools down the cylinder will slowly slide down F over the piston This does two things 1 It allows the piston to cool evenly and 2 Iliiminates any distortion Page 16 Carcly SERVICE MANUAL 27 wer REFITTING SPECIAL TOOLS REQUIRED Piston Pin Tool 1434 with dum
39. ge 1470 finger tight Fle 13 1 Rotate the motor clockwise until piston is at T D c The stem of timing gauge fully extended Unscrew the timing gauge slowly until the shoulder nf the tnol reaches the bottom of the YELLOW mark on the stem See B Fig 13 1 Turn the motor clockwise until the yellow mark disappears about 1 4 below the shoulder of the gauge and then rotate the motor very slowly anti clockwise until the TELLOW mark just becomes visible DO NOT rotate the motor again until you do the timing check see page 14 Place the magneto cam over the crankshaft onto the tapered section rotate the cam anti clockwise and stop as soon as a resistance felt This is when the high point of the cam comes in contact with the plastic pad on the moving breaker arm Using steel tube 23 32 1 4 x 7 8 o d x 6 tighten the cam onto the crankshaft by lightly tapping with a hammer Final tightening will be made when the flywheel 1s installed See Fig 13 2 Before you refit the flywheel double check the timing in case the cam slipped when being tapped into position Place the flywheel over the crankshaft and onto the cam making sure the two studs inside the flywheal are lined up and engage the corresponding holes in the cam The flywheel can be rotated either direction to line up the studs with the holes Hold the flywheel in place place rhe washer over the cam shoulder and screw the flywheel nut on finger tight Fl
40. he double clutch can be adjusted to allow for starting at a lower speed This is achieved by hooking the springs in the holes nearest to each other See M Fig 10 2 install the Double automatic clutch 1 2 Fush assembled clutch drum T Fig 10 2 on the crankshaft aligning splined washer C with crankshaft splines allowing the clutch to slide all the way on Place clutch drum G Fig 10 1 on splines on the shaft push on far as possible and finally install clutch nut and tlghten Hold the flywheel with tool 1291 to securely tighten the clutch nut See Fig 9 1 page 5 Carcly SERVICE MANUAL ro FLYWHEEL AND STATOR PLATE REMOVAL SPECIAL TOOLS REQUIRED 13 2 3 amp Flywheel Holder 129 Magnero Cam Puller 1390 After removing the clutch see page 9 proceed as followsi Disconnect the ignition wire small wire with spade terminal from the coil under the fual tank and the lighring wire at Stator plate also spade terminal and L Fig 11 2 Tighten universal wheel vice 01291 onto flywheel see A Fig 11 1 and remove flywheel nut and washer Fig 11 2 thread using long wrench B 11 flywheel is now free to be removed magnets will cause some rasistance Using mapneto cam puller 1390 C Fig 11 4 remove cam Fig 11 2 from shaft by screwing puller C on cam hold the puller with a wrench and screw in centre bolt p Fig
41. here is fuel reaching the carburettor see pages 37 38 39 12 If the motor has had considerable use and is hard to start or idles poorly check for carton build up the exhaust port ami exhaust pipe and check the muffler is not blocked See page 18 13 If there excessive carbon check the fuel mixture is correct Drain the tank and pour in about a pint of fuel you know is the proper mixture and rum the motor 14 Check that the carburettor ts fitted right onto the intake pipe and the intake pipe is tight on tha cylinder at the manifold 15 Check the manifold gasket replace if necessary If the intake pipe is loose or the gasket damaged the motor will draw in extra air and upset the mixture 18 Check the fuel filters and jet for clogging see pages 37 38 39 17 Check that the cylinder Ls tight and cylinder base gasket not damaged the motor will draw in excess air at this point also as wall as lose its crankcase compression 18 Check that the cylinder head is tight and the head gasket good condition Generally if there is a problem in this ares you can hear the pressure escaping 19 Check the joining of the two crankcase halves for any leaks of fuel and if necessary tighten the crankcase bolts 7 Allen type hex bolts If the crankcase gasket is damaged it will be necessary to strip the engine to replace It is very rare that this occurs Page 55 Continued on next page Ceca SERVICE MANUAL MOTOR FAULT FINDIN
42. l shaft 5 Remove the two piece needle bearing D inspect the pulley hub F and bearings for wear and corrosion Make sure the bearings are well greased with general purpose grease 6 Check the motor engagement lever and ensure the rivet is secure and the engaging dog 7 not worn If the rivet is loose it can be peined over at point If the engaging lever worn drill out the rivet at point 5 15 drill mo washer L free then punch out the rivet Replace the required parts and securely pein over the rivet at point Fig 22 1 Fig 11 2 PULLEY CONVERTER REFITTIING amp SERVICING Cacly SERVICE MANUAL AND DRIVE SELECTOR LEVER NOTE ALL PARTS INDICATED BY LETTERS REFER TO FIG 23 2 NO SPECIAL TOOLS REQUIRED 1l The selector lever M can be replaced by drilling out the rivet from back of pulley and removing the screw P When replacing the screw P apply Locktlte Blue to the threada first 2 Reverse the proceedures 1 to 5 on page 22 to re assemble and refit the pulley converter 3 When replacing the crank cotter pin rotate the pedal axle so the cutaway section faces to the rear place the crank arm over the axle with it also facing the rear see Figs 23 1 Insert the cotter pin from the bottom with the fiat portion lined up with the cutaway portion on the axle put on the washer and nut and tap into place and tighten nut rotate the axle so the crank is vertical an
43. my piston pin With crankcase held in the vise 1 3 43 5 6 7 8 Page 17 sure the piston is facing the correct way small hole A Fig 17 1 faces to the rear of the motor Insert the small end needle bearing into the connecting rod position the piston over the connecting rod and insert the dummy piston pin into the needle bearing to secure the piston its correct place Have the tool 1434 ready with the piston pin placed over the piston pin tool right up ro the shoulder B Fig 17 1 If possible keep the piston pin chilled for easier replacement Heat the piston as directed on page 16 and when heated sufficiently place the exposed end of the piston pin tool into the dummy pin and push the piston pin tool with the piston into the piston one movement far as the shoulder Fig 17 1 will allow The dummy pin is pushed out and the piston pin now properly centred With the piston rotated to the T D C position place the cylinder over the piston and allow it to cool in the same manner as described on page 15 Remove the cylinder and replace the piston pin clips and piston rings See page 19 for correct positioning of piston rings Lightly lubricate the piston pin needle bearing with SAE 30 011 or a good grade Two Stroke 011 and make sure the piston moves laterally and freely on the piston pin Carcly SERVICE MANUAL ezme SPECIAL TOOLS RE NOTE Carbo
44. n build up is common to most two cycle engines and is the moat likely cause of poor performance The removal of carbon from the Cady engine is a simple operation and should be performed regularly MINOR DECARBOMIZINC Motor the frame 1 Remove the 2 exhaust flange nuts and washers Fig 18 1 2 Remove the muffler clamp bolt and nut VB Fig 18 1 3 The suffler now free to work on on the bench Pull the exhaust pipe out of the muffler and remove any carbon and clean thoroughly Discard the two gaskets one each side of the exhauat pipe flange and replace with new ones when re assembhling 5 Remove the bolt E Fig 18 1 at end of muffler and then remove rhe end cap F Fig 18 1 and clean out the tall pipe 6 Remove the baffle plate O Fig 18 l and clean the holes in it 7 Clean the bole H Fig 18 1 the inner fixed baffle plate B Inspecr the exhaust port in the cylinder and clean thoroughly may be necessary to Scrape the carbon out be careful not to damage the piston final cleaning can be done with a battery terminal wire brush 9 Reverse the proceedure to re assemble MAJOR DECABBONIZING Motor in bench vise Carry out the same proceedure for a MINOR DECARBONIZING and also 10 Remove the cylinder head and cylinder see page 15 and remove the carbon from the cylinder head 11 Before cleaning the piston head and piston ring grooves rotate the motor the piston is at
45. ns adjustment 25 Chain tensioner 45 Cranks pins Cotter pins Chailnwheel 10 12 15 20 15 19 18 21 26 26 23 23 24 Vern Toetie Carcly SERVICE MANUAL INDEX Cables brake Cables throttle Cables choke Cables decompressor Choke cabie Carburettor service 37 Convertor Crank axle Drive belt Drive belt replacement Drive belt tension Double clutch removal Double clutch servicing Double clutch refitting Decarbonizing Drive selector Drum brakes Decompressor Decompressor cable Engine removal Engine refirting Engine timing Englne sprocket Engine number PAGE 32 3B zz2 33 34 33 39 49 10 10 1 23 BES 13 24 51 Page 2 Ceca SERVICE MANUAL nex PAGE Exhaust pipe 18 Motor removal Motor refitting Foreword 1 Magneto removal 11 Flywheel 1 11 Magneto refitting 12 Flywheel refitting 13 Magneto cam 11 Front wheels 27 Magne to plate removal 11 Front brakes 29 4 Magneto plate refitting 12 1 1 FERE Motor timing 13 Fnrks f t 43 44 45 eem ERT Mixture fuel 55 E m j Forks servicing 46 Muffler 18 Fork lock Freewheel 50 Obsolete engines 5 Float 38 Fault finding 54 55 56 57 Pointa setting gap 2 Frane nusbar 51 Piston removal 16 Piston refitting 17 Gas cable adjustment 32 Piston rings fitting 18 Gas cable re
46. on from a tight belt will also add ta bearings Most failures in belts can be contributed ro 1 Using a non original drive belt thie the most 2 Too much or too llttle tension 3 warped pulley damaged deformed or dented pulley groove 5 Improper alignment of the belt due to twisted frame or motor or bent pedal crank shaft NO SPECIAL TOOLS REQUIRED to the performance of the motor a slack belt and both condi tions the wear of the crankshaft common The tension on the drive belt should be set as described on page B to allow for a deflection of the belt of approx 1 4 ro 3 8 saa Fig 7 1 You might into situation where the engine mulsates when being drive and this is vary often condition caused by the belt being worn narrow in one area due to excessive revving of the motor with the machine stationery good example revving the motor for a quick get a way at stop lights Always check that the belt does mot have any narruw worn areas and ia not showing signs f cracking and separation Properly cared for the drive belt will be the least of your problems When in doubt always replace the belt with am original equipment belt This hes been Specifically developed for Cady mopeds for long life See next page for Belt Replacement am Adjusting i SERVICE MANUAL DRIVE BELT REPLACEMENT amp TENSION NO SPECIAL TOOLS REQUIRED 1 Remove L H Chain Cove
47. place if necessary see pages 35 and 36 and check that the throttle slide is not sticking see pages 37 38 39 Also check that the idle adjusting screw Fig 32 1 La not screwed in too far THROTTLE CABLE ADJUSTMENT NO SPECIAL TOOLS REQUIRED Ceci SERVICE MANUAL croz cam anrusmenr amp REPLACEMENT A The choke cable adjustment ia simple and seldom 2 3 4 8 6 7 9 10 11 required but like the throttle cable it is important to maintain it correctly and operating freely for correct engine performance The choke lever is found on the left hand lever bracket A Fig 33 1 SPECIAL TOOLS REDUIRED A small amount of free movement of the choke lever la required and this should not exceed 1 4 at the lever end To adjust first unlock the lock nut B on the adjuster C and adjust until the required free play is achisved on the lever A Fig 33 1 Check to make sure that the choke moves freely up and down If everything is in order tighten the lock nut and double check the free movement If the choke slide sticks or is stiff to operate Lt may be necessary to replace the choke cable due to damage or rust or the choke slide could be corroded or damaged See pages 37 38 39 for Carburettor Service To replace the choke inner wire slacken the nut D 13 1 st the lever remove the carburettor from the intake nipe and push the inner wire down of the choke slide
48. placement 35 36 Piston Cylinder matching 19 Pulley removal 22 ubs 1 Hubs servicing 32 Halley ferviciuk 22 Handlebars adjust 48 Fulley refitting 23 Ignition timing 13 Patala Ignition checking 14 Prage Pedal axle 47 Locks Lubrication 52 Page 2 Carcly SERVICE MANUAL PAGE Rings piston Rear wheels Rear forks Special tools Stator plate removal Stator plate refitting Shock absorbers Serial numbers Tools basic Tools special Timing Throttle cable adjustment Throttle cable replacement Technical data Tank capacity Telescopic forks Trouble shooting Use of special tools y Belt Wheels front Wheels rear 18 2H 284A 41 11 12 42 51 44 45 45 54 55 56 57 INDEX Page 2H Page J Ceca DESCRIPTION GREASE GUN WITH MINIATURE NOZZLE PLUG WRENCH 14 mm l0 SCREWDRIVER FLAT BLADE 82 PHILLIPS SCREWDRIVER OPEN WRENCHES me THROUGH l mm and 16am METRIC NUT DRIVERS 5mm THROUGH BATTERY TERMINAL BRUSH 7 PLIERS LONG NOSED PLIERS 12 ADJUSTABLE WRERCH BASIC TOOL DESCRIPTION FEELER GAUGES CIRCLIP PLIERS INT PLIERS EXT BLOW TORCH Amm HEX KEY LONG TYPE BEST Sem HEX KEY LONG TYPE BEST METRIC WRENCHES AND DR SOCKETS 8 10 11 12 13 17 MULTI LOCK PLIERS DOUBLE ENDED PEDAL WRENCH HAMMER BALL PEIN w FLYWHE
49. r 2 Loosen upper motor mounting bolt A Fig 8 1 3 Loosen lower motor mounting bolt B Fig 8 1 on some machines loosen algo the belt adjusters E Figs 8 3 The motor can now be plvotted to the rear on the upper mounting bolt slackening the drive belt Slip the drive belt off from the bottom of the large pulley D Fig 8 2 and rotate the pulley anti clockwise until the belt is free of tha pulley You can now force the belt from under the plastic cover and off the clutch without removing the plastic cover C Fig 8 2 53 To replace the drive belt reverse the above proceedure and tension the belt correctly as follows 6 On machines without belt tensioning adjusters pivott the motor to the front until any belt slack is taken up and then tighten the lower motor mounting bolt first and then the upper motor mounting bolt 7 machines with belt tensioning ad justere adjust both equally See E Fig 8 3 for location Make sure you can depress the drive belt 1 4 to 2 8 before locking the adjusters and tightening the engine mounting bolts See Fig 7 1 page 7 for checking belt tension Pape Cacly SERVICE MANUAL xtc anova NOTE This operation be performed with the motor on the machine or on the bench vise If clamped in a vise do not overtighten and make sure the lower motor mounting bracket is at right angles to the vise jaws Fibre pads should be used in the vise ja
50. r the piston it is best when servicing a motor to always fit new piston rings Piston to Cylinder Matching See Fig 19 2 NOTE D Cylinders are always supplied with matching pistons E It 1f is necessary to replace piston only first identify the cylinder by the letter stamped on the top face of the cylinder and order the part number according to the chart below EXAMPLE cylinder marked F or O use cylinder part number 19187 PISTON CHART Wee Part 19199 H J Use part 19188 Bc 19185 18189 DE 191985 19190 T 193187 OP 19103 lt 1 SERVICE MANUAL eer comer HO SPECIAL TOOLS REQUIRED Crankease held in vise NOTE Use new gaskets when carrying out this operation 1 Make sure the cylinder and cylinder head are perfectly clean especially the contact area between the crankcase and cylinder and cylinder top and head Make sure the two halves of the crankcase are lined up and form flat surface so a proper joint can be made with the cylinder 2 Lightly coat both sides of cylinder base gasket with general purpose grease and place it on the crank case making sure 1t is correct way round 3 With piston assembled lightly lubricate the piston and piston rings with SAE 30 oll or good grade Two Stroke oil NOTE The cylinder bore 1s chamfered at the base to allow easy entry of the piston rings when compressed with the fingers Ea
51. replace it with a new one 6 Make sure the gaskets on both the fuel tap and carbur ttor intake good condition replace if necessary 7 With the filters and fuel iine back position remove the jer D Fig 37 3 push the fuel tap down CON and fuel should run out of the carburettor This determines that fuel is reaching the float bowl E Fig 37 3 Replace the jet after cleaning thoroughly Continued on Pages 38 amp 39 Page 37 IHE Cacly SERVICE MANUAL CARBURETTOR SERVICE Continued FLOAT 8 9 10 11 12 135 14 The float bowl contains a cylindrical float which incorporates s needle through its center the float bowl fills with fuel the float rises and at the correct fuel level the needle seats into the inlet valve and cuts off the supply of fuel If a situation of fuel flooding occurs it could be due to the needle not seating correctly for the followlng reasons The needle seat has some foreign matter in it Grit gum of 1 b The float needle 15 bent uncommon or worn common after long use c The float has a leak and fuel has entered and made it heavy uncommon Io check any of the situations or C remove the two screws E Fig 38 1 and remove the float bowl cover J and lift out the float Check the needle seat for any foreign matter or gum and clean it thoroughiy Check the needle and make sure it is not bent or worn see
52. rt the lock into the housing and compress the split ring so it enters the housing insert a key into the lock and turn it anti clockwise and push the lock as far as possible This will place the split washer into its position inside the housing With the key still inserted and turned to the left anti clockwise remove the brass lock and place the amp pring over the tongue and still with the key turned to the left insert the lock with the spring in place into the housing as far as it will go Release the key so it turns back to its vertical posirion and it is installed To secure it in place with rhe wire clip The two short ends of the clip fit into the holes one either side provided in the top of the lock housing and the closed end of the clip is snapped down over the front of rhe housing To lock the forks turn the key to the left anti clockwise pressing the brass lock inwards at the same time and rotate the forks to right turn position and move slightly to left and right while still applying inward pressure to the lock At the correct position the lock will move little further as the rongue fits into lta slot in the fork stem The key can now be removed by turning it clockwise to vertical position To unlock the fork insert the key ami turn it to the left anticlockwise spring will push the lock out and the key can be removed by turning it to the right clockwise may be necessary to wiggle the s
53. s a Clean the throttle and choke slides thoroughly also the inside of carbursttor mixing chamber insert each of these individually into their respective position to make sure they operate freely This can be done without removing the slides from the inner wires b Damage to the throttle slide and choke slide is umuslly in the form of a burr It may be possible to remove this using fine wet and dry rubbing down paper After removing the burr check each slide in its respective position and make sure they operate freely If doubt or Lf damaged too much replace the part c amp d Replace any frayed wires and or outer casings see page 33 for Choke Cable or 17 18 pages 35 and 36 for Throttle Cable After servicing a carburettor and before installing on the engine double check that the throttle and choke slides operate freely and set the idle screw The best way to do this is to unscrew the idle screw to allow the throttle slide to be its lowest position then screw the idle screw in slowly until the throttle slide begins to rise This can be observed by looking into the carburettor air intake with the sir fliter removed Ses slao page 32 for idle adjustment Final idle adjustment can be made after the carburettor is assembled on the engine and with tha engine running Page 19 Cacly SERVICE MANUAL PEDAL REMOVAL AND REPLACEMENT NO SPECIAL TOOLS REQUIRED NOTE At The pedals as used on Cady mopeds use a m
54. s reversing the removal proceedure pack the top and bottom frame cups KE and L Fig 45 1 with general purpose grease and place the ball bearings the grease Note C fork assembly has to be sprung back onto the fork stem after the stem has been installed and the screwed race adjusted so the stem rotates freely and there is no up and down play Note D Rotate the fork stem so the chamfered edge of the fixed cone at the bottom of the fork stem faces the front of the machine and the two lugs in the hole in the lower plate in line with the corresponding grooves at the base of the fork stem i o Fig 45 1 I Page 45 uma Carcly SERVICE MANUAL MODELS WITH FRONT SUSPENSION Note most instances the forks can be serviced on the machina do this remove the front wheel see page 26 and the front mudguard see page 44 If it is necessary to remove the complete fork refer to pages 44 and 45 any event the following instructions apply DISASSEMBLE 1 Either fork blade or B Fig 46 1 can be removed by unscrewing the slotted nut metal cover and rubber washer Fig 46 2 which allows the complete fork blade or B with spring C Fig 46 3 and upper spring retainer Fig 46 1 to be completely removed from the fork tube This assembly can be separated simply by unscrewing the fork blade or the upper spring retainer from the spring 2 The fork blade seals D Fig 46
55. smooth bearing surfaces and if worn be replaced The frame cups F G G can be removed using punch and hammer when refitting them use a hardwood block Fig 43 2 H REFITTING B Before refitting the forks reversing the above proceedure pack Ehe top and bottom frame cup F amp Fig 41 1 with 1 purpose grease and place the ball bearings the grease Page 43 il Cacly SERVICE MANUAL FRONT FORK REMOVAL AND REFITTING Models with front suspension Machine on stand NO SPECIAL TOOLS REQUIRED REMOVAL Note If removing only to service the head fittings the front wheel and mudguard can remain 1 2 3 4 5 Page 44 in the forks Remoye the handlebar assembly complete with control levers by removing the nuts from the handlebsr U bolts see A Fig 44 1 and on some models remove the bolt that locks the handlebars it in front of and between the two U bolts Remove the front wheel see page 27 and support the machine with a block under the muffler Remove the mudguard by removing the stay fixing bolts C Fig 44 2 Disconnect the horn wires and the ground wire located at the back of the headlamp mounting plate F Fig 44 3 then remove the two bolts one on each side left and right of the headlamp mounting plate see GC Fig 44 3 Before you can remove the head lamp completely you will have to straighten out s metal tab that secures the headlamp body to the fork top plate locate
56. ssary to remove both shock absorbers from the machine and check the new one for length against the one to be retmined If there 1 2 of more difference when extended replace both shock absorbers This will ensure equal compression of the shock absorbers while riding as well as correct suspension Removal NOTE rear shock absorbers retained by bolts and nuts at the top and bottom of each unit See Fig 42 1 A and B The lower bolt assembly B threaded into the rear forks and locked with a lock nut The upper bolt assembly passes through hole in the frame bracket C and is locked with its nut at point A Fig 42 1 1 Remove the from inside the rear fork then unscraw the belt B making a note of the order of washers and spacer 2 the bolt A and nut from the upper frame bracket 1 Hemove the shock absorber Refitting 8 Reverse the above proceedure the spacer goes between the frame and shock absorber on the lower mounting bolta 5 Make sure the lower bolt is securely tightened into the rear forks and the nut locked up tight Also the upper nut and bolt are securely tightened Fig 42 1 Page 42 SE RVICE MAN UAL FRONT FORK REMOVAL AND Models without front suspension Machine on its stand NO SPECIAL TOOLS RE UIRED REMOVAL Note removing only to service the head fittings the front wheel and mudguard can remain in the forks 1
57. ster at the lever all the way in and remove the cable at the decompressor and check that the cable operates freely If necessary replace it see items 7 to 10 below 6 If the cable operates freely press down and release the decompressor a few times with your thumb and Lf it sticks replace it see tems 11 to 14 below Cable Replacement 7 Remove the old cable by first slackening the pinch bolt on the lever amd pulling the inner wire out then remove the nipple from its holder at the cylinder head then the complete cable Note the shouldered ferrule position in the top plate on the decomprassor B Re route the new cable through the plastic casing and reverse the proceedure in item 7 above making sure the shouldered ferrule is properly fitted into the top plate on the decompressor 9 Before feeding the inner wire into the lever pinch bolt screw the cable adjuster on the lever bracket out about 1 4 then take up the slack on the inner wire and tighten the pinch bolt 10 Make final adjustment as described above items 1 2 amp 3 Decompressor replacement 11 Remove the cable disconnect the plug lead 12 Remove the upper engine mounting bolt four Allen type cylinder head bolts and the cylinder head 13 Remove the decompressor valve using s wrench on the haxagon nut on top of the valve stem and a Screw driver at the base of the valve stem insids the cylinder head 14 Install the new decompressor reversing the above proceedure and
58. teering slightly ro remove any pressure From the rongue of the lock when unlocking To completely remove a lock from the frame reverse the installation proceedure Page 47 Carcly SERVICE MANUAL sus MODELS WITHOUT FRONT SUSPENSION SECTA See handlebars on these machines can be adjusted for height only To adjust the height on these see page 43 item 1 slacken the stem bolt as described and set the handlebar height to required position Tighten the bolt securely after setting the handlebars and make sure they are correctly centred in relation to the front wheel MODELS WITH FRONT SUSPENSION Only the handlebars on those machines that are NOT fitted with locking plate and belt between the U bolts can be adjusted The adjustment available on handlebars without a locking bolt is for reach and this is achieved by twisting the handlebars in the U bolts after slackening the U bolt nuts see Fig 44 1 page 44 After changing the handlebar position it may be necessary to also change the levers for a more comfortsble grip position The levers can be rotated to any desired position by slackening the slotted screw that passes through the choke lever on the left hand side and the decompressor lever on the right hand side sure you tighten the U bolt nuts the lever slotted screws securely after making adjustments Illustrated below are the types of handlebars ADJUS
59. the route it follows and then replace with the new one To complete the operation once the new outer casing installed follow the instructions 5 through 9 above Cacly SERVICE MANUAL CARBURETTOR SERVICE NO SPECIAL TOOLS REQUIRED NOTE The Cady carburettor is a very simple carburettor and is a gravity feed type NOTE B In the event of carburstion problem and before deciding that it necessary to remove the carburettor first check that there fuel flowing from the fuel tank to the carburettor TO CHECK FOR FUEL FLOW 1 sure there is fuel in the fuel tank and with fuel tap up OFF remove the fuel line from the fuel tsp push the fuel tap down 09 and make sure the fuel is flowing If the fuel is flowing pull the fuel tap up OFF and refit the fuel line Repeat the processes at the carburettor to ensure the fuel flowing 2j There two filters which should be checked One is situated on the fuel tap retaining bolt A Fig 37 1 The other on the carburettor at the float bowl cover B Fig 38 2 If there is lack of fuel to the carburettor the filters could be blocked the fuel line clogged FIEL FILTERS 3 To check the fuel tank filter remove the fuel tap retaining bolt A Fig 37 1 and check and clean the filter screen 8 To check the carburettor Filter remove the slotted end cap C Fig 37 2 pull out the filter check and clean it 5 If either filter is damaged
60. ting a new chain that the connecting link is the correct way round closed end of the spring clip facing the direction of ohain travel See Fig 21 3 7 Illustrations Fig 21 4 and 21 5 show the removal of rivets and fitting of the spring clip on s master link Fig 21 5 Page 2 Coda SERVICE MANUAL ruter converter renovar ano SERVICING NOTE ALL PARTS INDICATED BY LETTER REFER TO FIG 22 2 NO SPECIAL TOOLS REQUIRED The pulley converter is used to engage disengage the motor and this achieved by turning the drive selector lever Fig 22 1 anticlockwise to the y position to disengage the motor clockwise to the M position to engage the motor There may be some resistance felt in turning the lever to the engaged position and this is easily overcome by rolling the machine backwards allowing the mechanism to fully engege The pulley converter requires very litrla service and tha removal and refitting quite simples Most service problems are due to damage and or lack of lubrication service proceed as follows 1 Remove the drive belt described on page 8 2 Remove the L H Chain cover and the L H Crank cotter pin and pedal crank with pedal Hold solid steel object against the crank when striking the pin to remove it 3 Using multi lock pliers grip the dust cap A and remove with a twist and pull action Remove the cirelip B and washer C and amlide the pulley converter off the pada
61. ts over the lug on the inside of the rear fork just forward and slightly below the bolt at the bottom of the shock absorber See location indicated by Jf on Fig 28 1 REFITTIING Beverse the proceedure 6 The washers on the axle go to the outside of the rear fork followed by the axle nuts 7 Before tightening the axle nuts adjust the motor chain as described on page 21 and 26 and check the pedal chain tensioner Tighten the axle nuts securely and adjust the brakes Page 28 Coca SERVICE MANUAL exer MO SPECIAL TOOLS BEQUIRED MODELS WITHOUT REAR SUSPENSION REMOVAL 1 Posh tha brake arm A Fig 2HA l forward and release the cable nipple and cable B Fig 2 1 from the brake arm Slacken the axle nuts C Fig 2BA 1 Raise the frame and pull the wheel downwards and out of the frame slots 1 Slacken the pedal chain tensioner nuts and bolts lift both chains off the rear wheel amp prockets and remove the rear wheel REFITTING Reverse the procedure 3 The washers on the axle go to the outside of the rear fork followed by the axle nuts Tignten the axle nuts securely and set the chain tension as described on page 21 and 25 and adjust the brake 4 Hake sure the slot in the brake plate D Fig 28A 2 fits over the lug on the inside of the frame stay at the point indicated by Fig 284 1 NOTE When refitting rear wheels make sure the wheel is properly centred hy checking
62. ws 1 Remove plastic cover A Fig 9 2 using thin bladed screwdriver between edge of stator plate and plastic cover B Fig 9 2 it is a snap on fit and will off by gently prying at 3 or 4 points around the edge 2 Tighten universal wheel vice 1291 CU Figs 9 1 on flywheel D Fig 9 1 3 Remove clutch drum nut E Fig 9 2 thread 4 Serew clutch puller 15141 into hub of drum see Fig 9 1 keeping a firm grip on tool 1291 and progressively tighten centre screw G Fig 9 1 thread The clutch drum Fig 9 2 which ia splined to the crank shaft will now pull off easily pulled off the shaft off easily ensure t ia not bent needed Page 9 SPECIAL TOOLS REQUIRED rder of use 1 Flywheel holder 1291 1 Clutch Fuller 15141 5 The clutch hub assembly J Fig 9 1 now be It may be necessary to turn the clutch hub a little left or right to line up the grooves the clutch hub with the grooves on the crankshaft before it will pull 6 Never force the clutch drums off with levers The clutch is a two piece unit and unless severely damaged it will be easily removed without force 7 If severely damaged inspect the crankshaft and 8 To refit the clutches reverse the above proceedure making sure to line up the splined washer no force Ceca SERVICE MANUAL sves sErTTTING NO SPECIAL TOOLS REQUIRED With the double clutch removed proceed as

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