Microsoft Word - Zundapp Service Manual.doc
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1. CS HESE Servicing Manual for Two Stroke Engines up to 100 cc Issued February 1966 d Subjekt to alterations ZUNDAPP WERKE GMBH MUNCHEN DN 8 M nchen 8 Anzinger Stra e 1 3 _ Printed in Germany ZS o FOREWORD Advances in the design of motorised two wheelers during the last few years particularly for the lower cubic capacities have greatly stepped up engine output as well as riding comfort ZUNDAPP machines in particular have led the way and gained an enviable reputation for good engineering design and solid construction Each new ZUNDAPP model will always make its contribution to wards justifying our excellent reputation so as to maintain and increase the popularity of ZUNDAPP machines One of the most important factors in ensuring our continuing success is a first class after sales service That is why we are anxious to acquaint all our distributors and appointed service stations with the latest developments Throughout the winter months our ZUNDAPP training centres are holding courses for service mechanics This manual is designed to save students at these courses the time wasting trouble of taking copious notes and to be a permanent record which they can consult at any time to refresh their memory The descriptions of dismantling and assembly operations have been compiled with clarity and simplicity in view and are accom panied by numerous illustrations We trust that every distributor who has2. n Measuring Main Drive Shaft Position o Mounting Chiche p Setting Clutch Tongue and Clutch zs pm E p q Taking off and Mounting Gear Change Spindle d Mounting Clutch Bell Cover s Setting Pedal Gear Change Spindle t Mounting Cover over Clutch and Gear Selector Assembly Connector Cal u Mounting Ignition System v Setting Ignition Timing w Taking off and Mounting Kickstarter Spring and Sleeve voter sepals UM yee E x Mounting Fan Left Casing Cover with Kickstarter and Fan Gasing a ae eh ur ar Special Service Tools Bing Carburettors Troubles and their Causes Technical Data er cele ints 30 34 35 35 36 38 41 48 49 Introductory Notes The comprehensive text of this extensively illustrated manual on engine dismantling and assembly applies with appropriate modifications to all models with manual or pedal gear change and kickstarter Where the assembly sequence differs in a few respects or where different tools are needed special reference is made to the changes in the relevant chapters The manual covers the following engine models Type Model Description Starting System Gear Change No of Gears System 267 Scooter R 50 Kickstarter Manual 3 267 Super Combinette Kickstarter Manual 3 267 Sport Combinette Kickstarter Pedal 3 276 Scooter RS 50 Kickstarter Manual 4 276 KS 50 Supe
3. 1 1 mm Standard washer on drive shaft 05mm Remainder flywheel magneto shaft 0 6 mm On engines of type 281 the standard washer is 0 2 mm thick Fitting Crankshaft into Right Casing Heat up inner race of ball bearing with a hot mandrel then fit crank shaft fig 43 Fit sealing ring for crankshaft drive shaft using special assembly sleeve MV 6 339 to prevent damage to the sealing lips by the drive shaft thread Drive sealing ring home with light taps of hollow punch MV 6 347 fig 44 Fig 41 Fig 42 Fig 43 Fig 4 Fig 45 Fig 46 d For engines of type 281 use assembly sleeve SK A 217 first expanding the bore to 13 5 mm Fit two 5 mm steel balls with a little grease into the ball seats of the drive shaft crankshaft then slide on the primary drive gear Finally secure assembly with locking wash er and hexagon nut fig 45 Remember to secure the nut On engines type 281 stick 19 rollers 5x 3 5 dia with a gene rous grease coating into the bear ing race of the right casing then slide spacer ring 281 05 110 on to the roller assembly fig 46 Measuring Axial Play of Selector Shaft Place gauging bar or the yoke over the right hand casing so that you can measure with the depth scale right to the stop face for the selector shaft inside the casing Note the value measured remem bering to allow for the thickness of the scale bar fig 47 Place the bar
4. turn the dome back by half the num ber of quarter turns counted and fix it to the casing with the screws provided fig 89 Mounting Cover over Clutch and Gear Selector Assembly Connector Cap Fit the cover and secure with the two countersunk fillister head screws M 5x15 fig 90 Mounting Ignition System Fit baseplate and run down screws M 4x15 lightly only since these have to be slackened again when setting the ignition Then slide cable with rubber grom met into the opening provided on the casing remembering the igni tion cable clip Fit Woodruff key into its slot on the crankshaft then slide on the flywheel magneto Note Take care not to push the key out of its slot again Run down fixing nut and firmly tighten it with socket key holding the flywheel in position with service tool SK A 251 On engines of type 281 the baseplate is fixed with 3 screws fig 91 34 d Setting Ignition Timing Set contact breaker gap to 0 35 0 45 mm then with a dial gauge or similar instrument determine top dead centre Next turn flywheel magneto back in opposite direction to engine ro tation until piston has reached the position matching the specified ignition point Check the setting with a standard ignition tester or control lamp It is advisable to carry out a second check of the timing after baseplate screws have been tightened fig 92 For specified ignition timing see technical data
5. Cross section 16 16 16 16 18 16 Main Jet 70 7 70 o 8 70 Needle Jet 220 220 220 27 217 220 Needle setting stop from top 3 3 3 3 3 3 Idling Jet Air Adjuster Screw S Electrical Systom Bosch Bosch Bosch Bosch Bosch Bosch KK 6V 23W 6V23W ENW AH 6V 23W Ignition timing before TDC 18 mm ta mm 1 8 mm 18 mm 18 mm 18 mm Contact Brecker Gop 0335 045 0 35 045 0 35 045 035 045 035 045 0 35 045 vc KS50Super KS50Super KS50Super pm Scooter R50 Scooter RS 50 04 515 002 515 061 515 061 514 320 561 003 561 004 06 032 276 002 276 026 276 026 281 320 267 020 276010 276 44 a 50 499 499 E DI 499 39 418 39418 mus 50 50 39 41 8 39 418 85 1 9 9 9 9 EN 42 46 48 82 26 46 o 7200 6900 7500 6340 4500 7000 roke stroke 2stroke stroke 2 stroke 2 stroke 2 stroke a SAE 80 SAE 80 SAE 80 SAE 80 SAE 80 SAE 80 350 450 30 350 5 125 1 25 1 25 125 rokeoilor 2strokeoilor 2strokeoilor 2strokeoilor 2strokeoilor stroke ger 2 stroke oil or E40 SAE 40 SAE 40 SAE 40 SAE 40 SAE 40 SAE 40 ine oil engine oil engine oil engine oil engine oil engine oil engine oil 231 261 261 271 231 251 760 117 61 117164 11778 van 1116 63 117162 17 1 7 2 16 7 82 a4 82 100 68 70 224 224 215A 264 220 215A 2 3 2 3 3 2 2 a 5 35 WEI Bosch Bosch Bosch Bosch Bosch Bosch BW DH SON DEM DK 6W8 5W 6 V 29 5W mm 18mm 11 mm 1 mm 1820 mm 18 mm 11 mm 045 035 045 035 045 035 045 035 045 035 045 035 045 005 5 Technical D
6. connec tor fig 1 Take off gear change pedal With the 14 mm open ended spanner or socket spanner slacken hexagon nut Remove serrated washer draw pe dal and spacer ring from gear change spindle fig 2 Not applicable to en gines with manual gear change Take off fan casing cap first remoy ing two cylindrical screws M 5x 15 fig 3 Remove 3 cylindrical screws M6x 45 from the left side of the fan casing then take casing off fig 4 2 befir A b Taking off Casing Cover left and Kickstarter Assembly With a 10 mm socket key take off 2 hexagon screws M 6x35 then remove left hand casing cover complete with kickstarter kickstart er spring and cover plate which also acts as the kickstarter stop fig 5 On air cooled engines slacken 2 cylindrical screws M 6x 45 instead of the hexagon screws men tioned above Take the 4 cylindrical screws M 5x20 off the flywheel magneto then remove fan d Dismantling Ignition System Holding the flywheel firmly with ser vice tool SK A 251 take off the wheel nut with the 14 mm socket spanner fig 7 Fit press off bolt SK A 263 to wheel hold assembly firmly in position with tool SK A 251 and press wheel off the magneto spindle on the crankshaft Remember the key which secures the wheel to the crankshaft fig 8 Fig 5 Fig 6 Fig 7 Fig 8 Fig 9 Fig 10 Fig 11 Fig 12 d If the work described in
7. consisting of main jet mixing chamber insert or fixed atomiser and needle jet The exchangeable main jet sits in the nozzle block screwed from below or from the side on inclined jet carburettor designs into the carburettor housing On carburettors with fixed atomisers the main jet is screwed to the lower end of the needle jet As the main jet system comes into action the fuel flows via the main jet to the needle jet The outlet bore of the needle jet is located in the mixing chamber where the preliminary mixing of fuel and air takes place Here little fuel air bubbles form which are then mixed with the main air flow stream and drawn into the engine combustion chamber A tapered needle fixed to the throttle slide controls the available needle jet cross section Operation of the throttle slide drives the needle further into the jet thus narrowing the free cross section between needle jet bore and needle or vice versa draws the needle further out and thus increases the cross section The needle shank has several grooves so that the needle can be re set in relation to the throttle slide If the setting is altered so as to drive the needle deeper into the bore the engine is supplied with a leaner mixture If the needle is set higher on the throttle slide the available flow cross section increases and consequently the mixture becomes richer The needle setting will only influence fuel consumption un der throttle control With the throt
8. one half of the way to a clearly perceptible stop Once the engine has come to life leave the throttle in this intermediate position until the engine has run itself warm Then open throttle all the way and this will also raise the starter slide to its end position where it engages If on starting you inadver tently pull out the throttle too far so that it overrides the stop and takes the starter slide with it so that the knob jumps back again press the starter knob once more Starter Jet Carburettors see carburettor for KS 100 On these designs a cylindrical starter jet housing is arranged next to the main hous ing whose piston is operated by Bowden cable In its top position the piston un covers the port which admits starting air from the filter socket and the starting fuel mixture port leading to the carburettor intake socket Fuel enters from below through the starter jet into this housing which generally also has a storage chamber When the engine is started from cold the piston is raised while the throttle slide remains closed The fuel is first drawn from the storage chamber and when this is empty through the starter jet It is then mixed with the starting intake air to produce at first a very rich mixture which becomes gradually leaner as it flows directly into the intake socket of the carburettor and from there to the engine Once the engine has run itself warm shut off the starter piston 44 Carburettor for Engines 26
9. setscrew until selector fork b can be swung away and selector c can be taken out fig 36 16 2 Engine Assembly Before assembling the engine first clean all parts thoroughly remove the sealing compound from casing rim surfaces and check that all parts and sealing faces are in perfect condition Replace defective or damaged parts with Original ZUNDAPP Spare Parts Gaskets and sealing rings must always be replaced by new ones Make sure that all parts such as spindles shafts and bearings are pressed home all the way to the stop in their locating bores seats etc To fit a ball bearing always heat its housing to ap prox 85 C Coat the sliding and stop faces of all moving parts with a generous film of oil using only the grade and type speci fied by us gt Clean all metal filings off the magnetic plug in the right hand casing 17 Fig 37 Fig 38 Fig 39 Fig 40 a Setting Steel Ball Selector on engines with manual gear change On engines with manual gear change set the steel ball selector with the setscrew so that the spheri cal part sits exactly in the centre of the selector shaft bore correspond ing to the highest gear 3rd or 4th Use setting gauge SK A 232 3 speed a to carry out the adjustment fitt ing it into the bearing bush of the right hand casing in place of the selector shaft and securing it with locking washer SK A 233 b Now press the inner face of the sele
10. special ser vice tool SK A 234 as shown on fig 16 and insert thrust plate be tween clamping bolt of the tool and the clutch springs Press clutch springs together and you can then fit and tighten the 5 or 10 nuts M5 Take off the service tool fit thrust pin with the required packing washers fo the thrust plate fig 74 29 Fig 73 Fig 74 p Setting Clutch Tongue and Clutch To obtain the largest possible re setting range the clutch tongue must be set to the mushroom shaped thrust pad To do this first coat the pad with chalk then fit the clutch bell cover and operate the clutch lever on the housing Take the bell cover off again check whether the thrust pad contacts the tongue roughly at the centre If it does not re set with the setscrew for the thrust plate on the bell cover then secure the new setting Next check the clutch lever play at the housing In its rest position it should be possible to move the lever by hand about 2 3 mm in its bear ing at the clutch tongue If the play is too large or too small correct by fitting or removing the appropriate number of washers under the thrust pad fig 75 The following notes up to fig 85 apply only to engines with pedal gear change q Taking off and Mounting Pedal Gear Change Spindle The assembly is shown in fig 76 Inside the pawl mount C are the 4 two gear change pawls D with spring Selector drum B engages over the pawls a
11. with hollow punch MV 6 734 noting that chamfered side of ring must face casing fig 61 25 Fig 60 Fig 61 Fig 62 Fig 63 Fig 64 k Inspecting Connecting Rod Fit gauging ring SK A 125 needle bearing and gudgeon pin into con necting rod Turn crankshaft down until gudgeon pin lies against gaug ing ring Check that it contacts flush on both sides fig 62 Gauge in turned over position and compare results Adjust connecting rod as shown in fig 64 On engines of type 281 place two gauging bars SK A 161 on both sides of the connecting rod on the casing face accommodating the cylinder base gasket Turn the crankshaft until the piston rod edge lies ag inst the bars Then repeat the gauging in the opposite position Adjust the connecting rod as shown in fig 63 Carry out final connecting rod sett ing with the setting bar MV 6 116 fig 64 Assembling Piston and Cylinder Fit the piston the mark Auslass xhaust port must face towards the exhaust Introduce gudgeon pin with service tool SK A 163 fit crankshaft cover then fit retaining rings Position cylinder base gasket but without sealing compound fig 65 On engines of type 281 use tool SK A 272 to fit the gudgeon pin 26 RH Fit piston ring and support piston with a special fork tool made in your workshop fig 66 Fit cylinder introduce piston care fully and gently into cylinder to prevent fract
12. 6V2525W 6V25NSW 6VN5W SV 25 25 W DE ovis Ww SVAW DREEM VIEW 6vaw DEM 2 VIEW KK vis W RK VIEW au DNH S 2 5 DRAN 3 Bell Buzzer Buzzer Buzzer Horn 17W Sei Buzzer 1 2470 1 3 436 13636 13636 1 3 636 1 2 466 1 3436 11 476 1 2058 1 2058 1 2 058 11476 12058 1 0 962 1 1 363 WE BE WEN 1 0 961 WE 121 080 121 080 1 1 080 E 1 1 080 1 369 1 354 1354 1 354 1 2600 1 2649 1 26 84 1 21 1 20 1201 1 20 1 1475 11597 11519 11445 1132 1132 1132 1977 1 10 41 1 10 06 12105 1105 1 105 1774 12 97 1433 1 433 1433 1 433 1 2785 1 433 1433 late Multiplote Multi plate Molti plote Multi plote Multi plote Mulliplate Multi plate iType OilbethType Cilbeth Type OilbathType Oilbath Type OilbathType OilbalhType Oilbath Type
13. 7 276 R 50 RS 50 a Carburettor housing b Cover plate d Hose union with sealing ring d Adjuster screw with spring e Collared screw with spring f Starter shutter g Float h Float cap i Pin k Float needle I Slide spring m Throttle slide n Needle jet o Main jet p Washer lt q Jet needle with locating plate Carburettors for Engines 267 276 KS 50 Super Sport Combinette and Super Combinette 433 a Carburettor housing b Starter slide d Cover plate d Throttle slide e Slide spring D Washer g Jehneedle with locating plate h End plug with sealing ring i Needle jet k Main jet 1 Adjuster screw with spring m Float with float needle n Float housing cover Carburettors for Engines 281 KS 100 a Cover plug b Float housing cover d Carburettor housing d Float with float needle e Slide spring f Throttle slide g Jet needle h Adjuster screw with spring i End plug with sealing ring k Needle jet I Main jet m Screw with sealing ring n Starter piston o Spring p Adjuster screw with nut a Air control screw with spring r Screw with sealing ring s Idling jet Troubles and their Causes 1 Engine will not start Cause Fuel tap not opened star ter aid not operated when starting from cold Jets clogged Carburettor flooded engine drowned Ignition not switched on Spark plug defec tive spark too weak Spark elec trode gap on p
14. Eege AA mrd i Frisbee koks Fig 51 Fig 53 Then measure from the same point to the stop collar of selector shaft fig 51 The distance must not be larger than the value obtained to fig 50 Cor rect any backlash in gears by fitting packing washers between Ist and 2nd speed gear play must be eli minated to 0 fig 52 Note The balls for the selector gears should be coated with oil not with grease to stick them into posi tion Before fitting selector shaft check that stop pins of selector shaft are correctly mounted com plete with their annular springs Measuring Starter Spindle Check distance of opposing teeth between driver and kickstarter gear on kickstarter spindle This should not exceed 0 8 mm If it does fit packing washers between shap ring and driver A washer of I mm is fitted to the short shaft stub as standard fig 53 With gauging bar and depth gauge measure distance between contact face of right casing and stop collar for stdrter spindle fig 54 Note down the reading 22 On the left casing measure the same distance with the same instru ments fig 55 Next measure distance between the two stop faces on the starter spindle fig 56 then make up the difference from the sum of the two measure ments just described by fitting pack ing washers until only a play of maximum 0 3 mm remains Assembling Engine Block Fit selector shaft and kickstarter spindle togethe
15. are not to loose the two 5 mm balls underneath the gear fig 23 If the drive gear cannot be pulled off by hand use a standard two arm puller tool fig 24 13 Fig 21 Fig 22 Fig 23 Fig 24 Fig 25 Fig 26 Fig 27 Fig 28 Take the remaining screws from left hand casing 2 in magneto section M6x35 a and 1 under starter spindle M amp x 65 b fig 25 On the right hand side take one screw M 6x 50 off the base of the cylinder fig 26 Engines 267 and 276 Fit service clamp SK A 234 by 2stud bolts M8 SK A 246 and I locating bolt SK A 123 on the left hand side above the magneto spindle fig 27 For engines 281 make your own press off fixture and secure it with three 8 mm screws SK A 246 to the left hand casing above the magneto spindle The diameter should be 6 in 150 mm thickness 7 mm bore 9 mm to take the 8 mm bolts see special tools fig 28 k Take the gearbox block from its mounting frame and place it right hand side facing down on two wooden blocks Turn the press off bolt and at the same time press on selector and starter shafts to prize the two gearbox halves apart Then carefully lift off the top half left fig 29 Before taking out the various shafts note the position and number of washers and spacer rings fitted as well as the correct meshing position of gears and mark these with a reference line for preference Careful attentio
16. ata Mee Super Co Super Co Super Co Sport Co Sport Co Sport Co 433 002 433 004 138022 515 003 515 004 515 041 Engine Model 267 003 267 004 287 091 267 001 267 002 267 032 Spark Plug Wa25T1 WsT1 w23T1 W225T1 wn wan Sau 254u2 25142 225142 225402 225142 Spark Gap 05 05 04 05 os 04 Headlight Bulb DEN KE evs W 6Vn5W DIE 6VASW Rear Light Bulb 6VAW 6ViaW DKG 6VISW o vw VW Brake Light Bulb DN DNH VIEW D D 6VEW Flashing Direction Indicotors 3 og A Signal Bell Bell Bell Bell Bell Bell Gear Ratios 1st Gear 12 470 1 2470 1 2470 1 2470 1 2470 1 2470 And Gear 11476 11476 11476 1 1476 Naar 111 476 3rd Gear 1 0 962 1 0962 1 0962 110962 1 0962 1 0962 4th Gear E 1st Goar 1 369 1369 1 369 EH 1359 2nd Gear 1 22 1221 1221 1221 121 1 22 3rd Geor 11445 1 1445 1 1445 1114 45 1 14 45 11445 4th Gear Primary Reduction 1 433 1 433 1 488 1 433 1433 1 43 Clutch Muliplate Multi plote Multi plate Multi plate plate Muli plate Oilbeth Type Oilbath Type OilbathType OilbathType OilbathType Oilbuih Type Sport Co KSS50Super KS50Super KS50Super KS 100 ScooterR50 Scooter RS 50 515 041 515 002 515 061 515 061 514 320 561 003 561 004 06 267 032 276 002 276 026 276 026 281 320 267 020 276 010 276 44 1 w25T1 W260T1 w ert W260T1 W260T1 W225T1 W260T1 12 M542 260 14 u2 2014 u2 260114 u2 260 14 u2 E 260142 24 05 64 de OA 815 04 04 7 6VASW 6V2525W 6 V2525W
17. bove the drum sits pawl deflector A with return spring The whole assembly is held by snap ring F In case of damage to the selector spindle we supply the complete assembly for replace ment but the return spring is avail able as a separate repair part fig 76 EEE 3 The selector spindle comprises the following separate parts A Pawl deflector B Selector drum C Pedal selector spindle D Selector pawl E Return spring F Snap ring G Spring H Oval head rivet I Compression spring J Stop pin fig 77 Clamp pedal selector spindle by the thread for the selector drum into a vice between a pair of soft metal pads then remove top snap ring fig 78 Span the selector drum with your hands from underneath so that as you lift it off together with the pawl deflector you will prevent the pawls from dropping out under spfing pressure fig 79 Fit selector pawls and pawl springs into the groove on the selector spindle Note that the large side faces on the tapered pawls should face the cylindrical pin in the pawl mount on the spindle fig 80 31 Fig 78 Fig 81 Fig 82 Fit the selector drum on to the pedal selector spindle pressing the pawls inwards as you do so The collar with the recesses acting as internal stops must face the cylindrical pin on the spindle Tilt the drum at a slight angle to make it easier to fit fig 81 To fit the return spring to the pawl defle
18. change you can now draw out the steel ball selector through one of the openings in the clutch On engines with ma nual gear change the steelball selector assembly can only be taken off after the engine has been completely dismantled Taking off Chain Sprocket Bend open the locking tab washer and with an open ended spanner take off the hexagon nut if necess ary use a two arm puller tool fig 19 Taking off Cylinder and Piston Take off cylinder head and cylinder Remove the 4 nuts M7 with the 11 mm socket key take off the washers underneath then lift away cylinder head head gasket cylinder and base gasket take off piston rings fig 20 per i On engines type 281 no head gasket is fitted as from engine No 4600937 Press off crank casing then with pointed nosed pliers draw off the retaining ring for the gudgeon pin do not use a screw driver fig 21 Fit gudgeon pin press off tool SK A 64 and press off the gudgeon pin fig 22 For engines of type 281 use press off tool SK A 268 Note Remove gudgeon pin needle bear ing from connecting rod and put it away well protected from dust and dirt Taking off Crank Casing To take the main clutch drive gear off the crankshaft first bend up the locking tab washers Hold assembly steady with the 11 mm spanner applied to the crankshaft flats then with the 19 mm spanner toke off the hexagon nut and pull off the wheel Note Take c
19. ctor insert it with its top stop into the lower recess and with the bottom stop into the top recess of the pawl deflector The spring should be unloaded It is advisable to ease the spring into position with a pair of flat pliers to ensure that the stops enter the recesses far enough To turn the spring use only a screw driver pliers or similar tool To make the fitting easier you can use a second screw driver to press the spring against the recesses in the pawl deflector as you coil and ease it into position fig 82 Next fit the pawl deflector com plete with return spring to the pedal gear selector spindle Note that the cylindrical pin in the pawl mount must be fitted through both arms of the return spring To check correct assembly fit assembly pin SK A 213 into the recess of the pawl deflector when you should be able to move the deflector to both sides under spring loading fig 83 Fit the snap ring into the groove on the spindle then turn the pawl de flector to expose the bore into which oval head rivet H compres sion spring I and stop J are fitted Having fitted these parts in the se quence listed turn the deflector again until the stop engages in the recesses providing the internal stops for the selector drum To mount the pedal selector spindle set the transmission to 2nd gear fig 84 Fit selector slide and pedal gear change spindle Note that the taper groove on the selector drum e
20. ctor at the selector lever guide against the end of the setting gauge Turn in threaded pin c un til all play in stop bracket d and thereby in the selector is reliably eliminated Tighten locknut and se cure setting with the tab washer Slacken nut on gauge and take gauge off On 4speed manual gear change engines first fit a bush of 11 5 mm length 14 mm o d and 12 mm i d made in your own workshop then fit gauge SK A 232 figs 37 and 38 D Measuring Axial Play of Crankshaft Permissible play is 0 1 mm To mea sure it you need a gauging bar and a caliper gauge with depth scale Measure from the contact face of the right hand casing to the inner ball bearing race fig 39 Then cagry out the same check on the left hand casing and add the two values obtained fig 40 r 18 d Prepare crankshaft for gauging Fit a washer with 2 mm bevel on to the crankshaft drive shaft bevel facing crank web Fit a washer with 2 mm bevel on to the flywheel magneto shaft bevel facing crank web fig 41 Now measure crankshaft over both webs including special bevelled washers fig 42 then deduct the value obtained from the sum ob tained by the two gauging oper ations shown in fig 39 and 40 Fit packing washers to eliminate all but the permissible play of 0 1 mm as shown in the following example Example Left casing 18 4 mm Right casing 24 5 mm 42 9 mm Crankshaft 41 7mm 1 2mm Axial play OI ms
21. eath starter spindle fig 13 Operate the clutch lever to press off the clutch housing cover Located inside the clutch housing cover are I Clutch spindle with lever Clutch dog 2 leaf springs for clutch dog Ball headed threaded pin for re setting clutch dog _ Bush for starter spindle Gearbox oil level checking screw Guide pin for selector slide pedal gear change engines only On engines of type 276 and 281 the third crankshaft bearing is needle bush 277 01 135 engine 267 has no third crankshaft bearing fig 14 e Taking off Pedal Gear Change Spindle and Selector Slide Take off pedal gear change spindle and selector slide fig 15 Only on engines with pe dal gear change f Dismantling Clutch Fit service tool SK A 235 to clutch with 2 studbolts SK A 237 and 1 stud SK A 265 Take off 5 or 10 nuts M 4 with the 7 mm socket key l Slacken the clamping bolt and clutch thrust plate springs and spring bushes can now be taken off On engines of type 267 fit the clamp with 3 studs SK A 237 fig 16 Fig 13 Fig 14 Fig 15 Fig 16 g D d Fit hold down tool SK A 279 to clutch thrust plate then release clutch nutwith the socket ke fig 17 Take off clutch complete with hub and the packing washers behind the hub fig 18 The clutch gear remains inside the right hand casing held by a snap ring on the inside gear box On engines with pedal gear
22. it slacken the connector nut and take off float cap On carburettors with side mounted float housing slaken the two screws on the cover take off the cover then take float from housing The float should drop by its own weight from its suspension on to the bottom of the float cap so that it can readily be lifted out The float needl can then be removed after taking off the spring loaded retaining clip On some versions the float lies loosely in the cap The forked part which prevents the float needle from dropping out can be taken off after its fixing pin has been drawn off Do not bend the fork piece and check that it lies horizontally in its top position Never use a sharp hard tool to clean the needle seat or the jet bores but merely rinse them out carefully then blow them out to remove all liquid Do not tighten the locknut too hard but run it down by hand only Use only the original sealing rings for the float cap seal Take care not to bend the float sealing edge otherwise the float may become displaced up or down and no longer seal off the float needle This would lead either to fuel leaks or to a partial or total fuel blockage Use only absolutely clean fuel and fill it through a filter into the tank to prevent trouble with the feed system Before fitting the fuel hose first allow a little fuel to run through it to drive out all the air and prevent the formation of bubbles and an airlock in the system Special Hints 1 The carburet
23. lug too large spark plug short circuited gap clogged by dirt water or oil 2 Engine chokes back on starting Cause Ignition timing set too early 3 Engine starts badly Cause Mixture too lean operate starting aid Idling jet clogged Spark plug dirty or oily spark gap too large or too small weak spark Water in fuel 4 Engine starts but stops again after short run Cause Carburettor empty because fuel tap remained closed 5 Engine starts but stops on throttling up Cause Main jet or fuel line clogged engine still too cold carburettor badly adjusted 6 Engine starts but carburettor spits back on throttling up coughs and sneezes Cause engine very cold fuel mix ture too lean Jet too small or clog ged Carburettor badly adjusted poor transitions Too many late firings Suction intake line leaks or air enters at carburettor union Engine starts but runs irregularly and splutters on throttling up Cause Mixture too rich fit smaller jets alter needle setting of throttle slide Air filter dirty Float over flows Ignition cuts out Spark plug oily or coked up Starter piston not completely closed high fuel con sumption Engine runs properly but exhaust backfires Cause Ignition cuts out Mixture too lean Engine knocks or pinks Cause Too many early firings fuel is not of anti knock grade Exces sive compression Glowing coke de posits or parts of overhea
24. n to correct fit be fore starting to dismantle may save you considerable gauging and sett ing work when the engine is re assembled Take out shafts in this sequence 1 Gear selector shaft with selector gears and steel ball assembly 2 Starter shaft 3 Main drive shaft 4 Crankshaft 9 30 For engines with manual gear selection the steel ball selector remains in the selector fork on the right hand casing Carefully inspect all shafts and gears for traces of wear and pro per alignment as soon as you have taken them off fig 31 Taking off Bearings Bushes and Clutch Gear On engines of type 281 the 19 rollers 5x35 dia can be taken out after removing spacer ring 281 05 110 fig 32 15 Fig 29 Fig 30 Fig 31 Fig 32 Hi ih Ing APR Zaun The clutch gear can only be pressed off after taking the circlip in the casing behind the ball bearing from its seat with a pair of pointed pliers If clutch gear and both ball bear ings are in perfect condition they need not be taken off fig 33 If necessary pull the ball bearing _ from the clutch gear with a stand ard bearing puller tool fig 34 Casings should be warmed first for easy withdrawal of ball bearings and bushes Or use the puller tool to remove them fig 35 Taking off Steel Ball Selector on engines with manual gear change Bend up the tab of the washer se curing the locknut of setscrew a Slacken nut turn
25. ng for driver 60 s SK A125 Ring gauge 62 t SK A 163 Mandrel 65 u SK A 275 Mandrel 100 cc 65 v MV 6 339 Assembly sleeve 44 w MV 6 347 Hollow punch 34 98 x MV 6 961 Hollow punch 61 y MV 6 734 Hollow punch DI z MV 6 960 Mounting sleeve ai al MV 6 115 Aligning bar 64 bl MV 6 1563 Sleeve 98 cl to be made in Press off plate 28 sketch on p 39 own workshop g di to be made in Ring for selector shaft 60 sketch on p 40 own workshop el to be made in Spacer sleeve 37 38 sketch on p 40 own workshop Press off Plate Thrust bolt Hexagon nut welded on Steel grade 37 K Cylindrical pin Pressure pad e anca ue aud Ring for Selector Shaft kel 31 36 Spacer Sleeve l 11 4 BING Carburettors Operation The carburettor is designed to supply the engine with the correctly proportioned and thoroughly mixed fuel air mixture to match any load The mixture is prepared in one idling and one main jet system The idling jet system supplies the engine at the lower speed stages It consists of the idling fuel jet the idling air jet and the air adjuster screw If the air inlet is partially throttled with the adjuster screw the idling mixture becomes richer if more air is admitted the mixture becomes leaner Carburetors on small engines have no separate idling jet system instead the needle jet system provides the mixtures at all stages As engine speed increases the main jet system comes into action
26. nga ges with the mating piece on the selector slide while the recess on the pawl deflector engages over the pin on the right hand casing Oil all moving parts fig 85 d Mounting Clutch Bell Cover Insert two press fit bushes into the right casing coat the joint faces with sealing compound then fit clutch bell housing cover Introduce one bolt M 6x 45 from the right under the pedal gear change spindle and run it down firmly fig 86 On the left hand side fit the follow ing screws 267 276 281 A M6x120 M6x120 M6x120 B M6x120 M6x120 M6x120 O M6x98 M6x120 M6x120 D M6x120 M6x120 M6x120 E M6x98 M6x98 M6x98 F M6x98 M6x98 M6x98 Gr M6x92 M6x92 M6x92 H M6x98 M6x98 M6x98 1 M6x98 M6x98 M6x98 M 6x98 Screw with cable clip to be fitted only after base plate has been mounted al Only fitted to engines of type 281 where ir ie located between I and G We 87 Fig 84 Fig 85 Fig 87 Fig 88 Fig 89 Fig 90 Fig 91 Setting Pedal Gear Change Spindle The spindle must be fitted with slight play Press it lightly to the left seen in direction of travel all the way to the stop Screw on the setting dome running it down until it lightly contacts the face of the casing but without al tering the axial location of the spindle fig 88 Now draw the spindle to the right and turn the setting dome further all the way against the casing counting the quarter turns as you go Then
27. not yet had the opportunity to attend a training course will find the manual a useful aid and reference book Reproduction in whole or in parts prohibited except by prior authorisation Table of Contents Introductaryg Notes ang A ware Mera Gi EEN 1 Dismantling Engine a Taking off Gear Change Pedal and Fan Casing b Taking off Casing Cover left and Kickstarter Ehe fae NE SC c Dismantling Ignition System d Taking off Clutch Cover Cover for Clutch and Gear Change Setting Controls Taking off Pedal Gear Change Spindle and Selector ARE ee ee Er en PERL EE EE ee g Taking off Chain Sprocket h Taking off Cylinder and Piston i Taking off Crank Casing 2 eee k Taking off Bearings Bushes and Clutch Gear I Taking off Steel Ball Selector on engines with manual gear hunge e Engine Assembly a Setting Steel Ball Selector on engines with manual gear ange aula Ee b Measuring Axial Play of Crankshaft d Fitting Crankshaft into Right Casing d Measuring Axial Play of Selector Shaft e Measuring Selector Gears f Measuring Starter Spindle SH g Assembling Engine Blok h Fitting Selector Shaft to Bearing on Left Casing i Mounting Sealing Rings 1 erre k Inspecting Connecting Bed I Assembling Piston and Cylinder m Mounting Chain Sprocket
28. o that the spring cannot shift out of position as the two casing halves are fitted toge ther fig 58 Bolt casing halves together on the left with 2 bolts M 6 x 35 at the fly wheel magneto side a and below the starter spindle b fig 59 On the right hand fit 1 bolt M 6x50 at the cylinder base shown by arrow on fig 26 Fig 59 24 h Fitting Selector Shaft to Bearing on Left Casing Fit 1 ring made in your shop of the following dimensions Height 6mm Outer dia 36 mm Inner dia 31 mm on to selector shaft flush against the casing Fit chain gear and tigh ten gear nut to shift shaft upwards bringing its collar all the way against the inner race of the ball bearing Take off nut chain gear and ring again fig 60 On engines of type 267 use spacer ring SK A 138 for driver in place of the ring just mentioned Having fitted the ring fit and run down chain gear nut only Check that all shafts move smoothly Mounting Sealing Rings Fit engine into service fixture SK A 126 and clamp the whole assembly into the vice Fit sealing ring to left casing fit sealing ring for crankshaft with punch MV 6 961 Fit sealing ring for selector shaft with assembly socket sleeve SK A 217 and drive it home by tapping with punch MV 6 734 On engines of type 267 manual and pedal gear change use socket sleeve MV 6 960 together with punch MV 6 961 Fit sealing ring for kickstarter spindle
29. ollowing engines Type 267 up to No 3484 123 Type 276 up to No 4045 406 Type 281 up to No 4600 606 Fit retaining lining and outer steel plates then fit cover plate To align bores for the spring sleeves correct ly the clutch shifter hub is marked with a reference line and all plates with internal splines have a special aligning bore Make sure that all these bores are accurately aligned on the line mark fig 72 Having fitted the cover plate run down the nut and tighten it firmly holding the assembly steady with tool SK A 279 IRA ON EE Clutches with 4 plates fig 73 are fitted to Type 267 as from No 3484124 Type 276 as from No 4045407 Type 281 as from No 4600607 All scooter engines are fitted with 4plate clutches Assemble as foll ows Fit retaining plates lining and outer steel plates then fit cover plate Here again the clutch hub has a reference line and all plates an aligning bore Underneath the reference bore on the cover plate an arrow is addi tionally marked which must be in line with the mark on the hub Also note that the dished side of the upper steel plate must face the gearbox Having placed the fourth plate in position fit the cover plate so that the dished side faces the gearbox Having fitted the cover plate run down the nut hold the assembly tightly with tool SK A 279 and tigh ten nut firmly fig 73 Next insert the spring sleeves com plete with springs fit
30. on the contact face of the left casing and measure distance to the ball bearing inner race stop face for selector shaft fig 48 Add the value read off to the one already noted 20 e Note Remember to allow for thick ness of bar Now measure selector shaft bet ween the two stop faces fig 49 This value will always be smaller than the sum of the two obtained to fig 47 and 48 Fit washers on the shaft between ball bearing and speedometer drive until only a play of 0 1 mm remains for swinging fork machines Example Measurement obtained to fig 47 22 7 mm Measurement obtained to fig 48 349mm Sum 57 6 mm Dimensions fig 37 56 9 mm 0 7 mm Axial play OI mm Packing washers required 0 6 mm For engines of machines with telescopic fork a spacer bush is fitted to the collar of the selector shaft since the speedome ter drive is taken from the front hub Measuring Selector Gears Fit the selector shaft with the num ber of packing washers calculated into the left casing then fit selector gears in sequence in such a way that the larger collar faces down i e towards the larger gear Gears are correctly fitted if only onb oil groove lies between each two gears and the arrow at the side points to the next larger gear Next with the depth gauge mea sure distance from end face of selector shaft to stop face of selec tor gear fig 50 21 Fig 49 Fig 50 a scha
31. parate idling speed system work as follows The dir adjuster screw controls the ratio of the fuel air mixture supplied by the idling speed system By turning the adjuster clockwise the mixture becomes richer by turning anti clockwise it becomes leaner The setting is correct when the engine ticks over quietly and evenly As soon as it does do not alter the air adjuster setting again since this also governs the lower and medium speed range so that any further ad justment might increase fuel consumption When the throttle is slowly opened out the engine should steadily rev up It should neither splutter nor should the speed drop back again at any throttle setting If the engine splutters or speed rises in surges or if black fumes escape from the exhaust silencer the mixture has been made too rich If the engine coughs or cuts out for brief moments if a blue flame blows back from the carburettor or if the engine is difficult to start the mixture has been set too lean Driving Speed Range In order to determine the most suitable main jet for a carburettor first take the machine on a straight level road and find out its maximum speed by the speedometer or with a stop watch Generally the main jet which will produce the highest speed on a level road will be the most suitable for any machine But If on long continuous runs at full throttle the engine starts knocking due to overheating select the next larger jet size In the medium speed
32. r Kickstarter Pedal 4 276 Scooter RS 50 Kickstarter Pedal 4 281 Motorcycle KS 100 Kickstarter Pedal 4 The instructions take account of all modifications introduced on engines supplied as from 1965 Complete dismantling of an engine is only called for in cases of damage to the gear box crank drive kickstarter assembly except for kickstarter spring or the manual gear change assembly Ss Defects of the gear selector mechanism steel ball selector mechanism for pedal change engines clutch crankshaft drive gear of engines with either manual or pedal gear change can be remedied after taking off the clutch housing cover Con sequently the engine need not be taken off the frame But in all these cases the gearbox oil must be drained off through the drain plug in the bottom of the housing This is preferably done while the engine is still warm Gear change pedal kickstarter pedal with return spring chain sprocket flywheel magneto wheel and baseplate cylinder with piston cylinder head and fan assembly can all be taken off and fitted without dismantling the engine Here of course the oil need not be drained from the gearbox For air cooled engines consult the assembly instructions on model KS 100 and dis regard all references to the fan system Fig 1 Fig 2 Fig 3 Fig 4 1 Dismanting Engines a Taking off Gear Change Pedal and Fan Casing Fit engine into service fixture SK A 1926 draw off spark plug
33. r with the packing washers determined by gauging and the main gearbox drive shaft with a standard 1 mm washer into the left casing Set brake spring so that when the two casing halves are fitted together the stop pin in the right casing can be introduced into the spring Locating stop on starter spindle must face bore mark ed x on housing fig 57 Theassemblynotesonthe locating stop of the star ter spindle apply only up to the engine numbers listed below Typ 267 Nr 3525493 Typ 267 R50 Nr 8000639 Typ 276 KS 50 Super Nr 4056928 Typ 281 KS 100 Nr 4601353 DH As from the succeeding engine num bers of the types listed and on all RS 50 models right from the start the kickstarter stop has been trans ferred to the outside and is now located in the left casing cover Consequently the assembly notes accompanying figs 93 95 apply 23 Fig 55 Fig 56 Fig 57 Gi m Eege Be Press clutch gear if earlier taken off into right casing then secure it from inside with the snap ring see fig 33 the pre assembled right casing is shown in figs 24 and 26 Mount two press fit bushes coat casing contact faces with com pound such as Teroson Atmosit oil shafts and bearings then carefully fit both casings together taking care to position the brake spring correctly It is advisable to lift the starter spindle up from underneath until the stop pin engages with the brake spring s
34. range carry out fine settings between two needle jet sizes by means of the needle By setting the needle higher the mixture will become richer and vice versa Note that needle position only affects the mixture ratio in the lower and medium speed ranges not for driving at full throttle If the carburettor is correctly set the ins tator of the spark plug will show an even brown combustion coating A spark plug coated with black coking residues or wet to the touch is a sure sign that the mixture is too rich a white insulator shows that it is too lean Always remember that only correct carburettor setting guarantees maximum running economy 43 Starter Systems To start a cold engine needs a specially enriched fuel mixture To supply this many carburettors have a separate starting system Starter Air Shutter see carburettor for R 50 and RS 50 On some carburettor types the starting aid consists of a pivoted shutter in the filter chamber operated by Bowden cable When the starter knob is pulled the shutter substantially narrows the carburettor cross section so that the mixture will become rich enough to start a cold engine Starter Air Slide see carburettors for KS 50 Super Sport Combinette and Super Com binette 433 With these designs the engine is started from cold as follows Close throttle slide all the way and with the pressure pin and knob press the starter slide down As you start pull out throttle about one third to
35. ted spark plug produce faulty ignition Main jet too small Engine does not pull or does not give full performance Cause Mixture too lean or too rich Too few early firings Exhaust clog ged Piston leaks Intake or exhaust ports clogged by coking deposits Air filter dirty Brakes drag Fric tion losses in transmission compo nents Float overflows Cause Foreign body carried in fuel to float needle seat and obstructs needle operation Float leaks Float needle jumped out of float spring or was wrongly mounted 5 Technical Data E Super Co Super Co Super Co Sport Co Sport Co Sport Co 433 002 433 004 433 022 515 003 515 004 515 041 Engine Model 267 003 267 004 267 031 267 001 20702 267 092 Cubic Capacity 50 50 499 50 50 499 Bore Stroke 39418 8 3918 39 418 39 418 39 418 Compression 851 EEN 851 85 1 85 1 85 1 Capacity h p 26 26 26 26 26 26 RPM 4500 4600 4830 4550 4600 4850 Mode of Operation 2 stroke stroke 2 stroke 2 stroke 2 stroke 2stroke Gearbox Oil SAE 80 SAESD SAE80 Sara SAE BO SAE 80 Gearbox capacity ce 350 350 350 350 350 350 Petroil mixtur 1 25 1 25 1 25 1 25 1 25 Oil grade for petroil mixture SAE 40 SAE 40 2strokecilor 2 trokeoilor 2 strokeoilor 2 stroke oil or 2strokeoilor 2stroke oilor SAE 40 SAE 40 SAE 40 SAE 40 EE engine oil engine oil engine oil engine oil engine oil engine oil per 100 km 161 161 161 161 161 161 Carburetior Model Code 116 60 1116 60 116 60 176 60 111660 16 60
36. the follow ing passages is confined to a re pair of clutch and pedal gear change system the baseplate can remain on the left casing If the en gine must be completely dismantled take the plate off now first remov ing the 2 cylindrical screws M 4 x 15 and the casing screws M 6x92 complete with cable clip fig 9 On engine model 281 the baseplate is fixed with three screws M4x15 Taking off Clutch Cover Cover for Clutch and Gear Change Setting Controls Take the following screws off the left hand casing cover 267 276 281 a M6x92 M6x92 M6x92 H M6x98 M6x98 M6x98 d M6x98 M6x120 M x 120 d M6x120 M6x120 M6x120 d M6x120 M6x120 M6x120 f M6x120 M6x120 M6x120 ad M6x98 M6x98 M6x98 h M6x98 M6x98 M6x98 i M6x98 M6x98 M6x98 with cable clip fig 9 Three screws remain on the casing 2 at the magneto and 1 below the starter spindle fig 10 On engines type 281 ad ditionally take off 1 screw M 6x98 above screw i Remove connector cover closing off the clutch re setting and gear change setting controls for pedal gear change engines The cover is fixed with two countersunk fillister head screws M 5x 15 to the right hand casing cover fig 11 On engines with manual gear change the setting dome for adjusting the gear change as sembly is not provided Slacken 2 fixing screws M 6 x 12 on the setting dome fig 12 10 Take off setting dome remove cy lindrical screw M 6 x 45 undern
37. tle fully open fuel consumption is exclusively governed by the main jet Fitting Carburettor Carburettors must be mounted with special care They must be positioned accurately vertical and fitted flush and precisely on their connecting socket The slots of the clamping connecting fitting must on no account admit secondary intake air other wise a steady quiet idling speed cannot be set Where connecting flanges are pro vided use only gaskets in perfect condition and tighten nuts evenly Fix Bowden cable sleeves without any sharp bend or kinks Check that throttle slide opens and cioses all the way as you operate either lever or twist grip On carburettors with starter jets the Bowden cable hooked to the starter piston should have a little play to ensure that the piston provides a reliable seal 4 Carburettor Maintenance From time to time the carburettor should be rinsed out with petrol and thoroughly cleaned While this is done check that all parts are in perfect condition Replace worn float needles needle jets and jet needles as well as throttle slides since these govern engine performance and fuel consumption On carburetors with separate starter jet assembly test that starter piston has tight seal The air filter should also be rinsed at regular intervals in either kerosene or petrol After cleaning coat the filter mesh with oil Where a screwed hose union is fitted take this off draw out the filter element and clean
38. tor is one of the most delicate parts of the engine Handle all parts with great care run down all threaded connections lightly never use force to fit any parts of the float into position 2 Do not use hard sharp tools to clean the jets On no account enlarge nozzle bores with a reamer or by any other means 3 Fit only Original BING spore parts to ensure troublefree operation and a long service life 4 Ifall your spare part orders quote part No accurately and in full If the num ber is not known quote the carburettor type code stamped into the casing or send old part as a sample 5 BING carburetors will give excellent service at all times provided standard good quality branded fuels are used carburettors are kept clean and only Original BING spare parts are fitted 42 Carburettor Setting Manufacturers of carburettors work out the most suitable design and select the jet sizes in close collaboration with the engine makers They also specify the setting which tests have shown to give best performance and maximum economy It is there fore inadvisable to depart from their specifications Idling Idling speed should always be set or regulated while the engine is warm With the adjuster screw close the throttle slide until the engine just ticks over slowly and steadily On carburettors without separate idling speed system the needle jet as sembly supplies the amount of fuel required for idling speed Carburettors with se
39. ure of piston ring Note The locating pin in the piston ring groove must sit inside the ring joint Fit cylinder head gasket and cylinder head Fit 4 packing wash ers then tighten the 4 nuts M7 with 11 mm socket wrench working always on diagonally opposite nuts in turn torque 10 6 Ib ft 1 5 mkg see fig 67 Engines of type 267 276 without fan and 281 have two piston rings m Mounting Chain Sprocket Fit the sprocket and secure with washer and hexagon nut use the chain assembly tool to hold as sembly firmly in place Secure nut with tab washer fig 68 n Measuring Main Drive Shaft Position Fit the clutch hub cover plate and clutch nut With a wooden spatula or other tool shift the cover plate to the top position then with the depth gauge inserted through the marking bore measure distance to the clutch gear it should be 22 5 mm fig 69 27 Fig 66 Fig 67 Fig 68 Fig 69 Fig 70 Fig 72 Take the tool away from the cover plate and press main drive shaft down all the way to the stop then measure distance again it should be 21 8 mm Example 225 mm 21 8 mm 0 7 mm The values and final clearance list ed are only given as examples fig 70 To obtain the required axial play of 0 1 mm fit 0 6 mm packing washers between ball bearing in clutch gear and clutch shifter hub fig 71 Mounting Clutch The clutch shown in fig 72 is fitted to the f
40. w Taking off and Mounting Kickstarter Spring and Sleeve Take off snap ring lift cover plate on one side at the stop nose Gripp ing the kickstarter pedal lever firm ly you can now release the kick starter spring from load fig 93 Take off lever coniplete with sleeve and sealing ring from below lift cover plate with stop up and off The kickstarter spring can now be replaced fig 94 i 35 Fig 92 Fig 93 Fig 94 x Assembly of Kickstarter If the left hand casing cover had been completely dismantled first fit starter spring in such a way that seen towards the inside of the cover the spring can be tensioned anti clockwise Grease the spring well Then introduce the small stop nose of the cover plate into the inner spring loop and fit the sleeve kick starter pedal lever facing up through the plate from the other side remember checkplate between casing gover and sleeve Hold the casing cover with one hand then pre tension kickstarter spring by turning kickstarter pedal lever through about 1 revolution until the stop nose lies just in front of the top stop on the casing Finally fit the snap ring fig 95 Mounting Fan Left Casing Cover with Kickstarter and Fan Casing Fit and bolt fan to flywheel magne to with 4 cylindrical screws M5 x 20 fig 96 The following can only be carried out after engine has been fitted into frame Fit casing cover on left and bolt down with two he
41. xagon bolts M 6 x 35 fig 97 On air cooled engines fit 2 cylindrical bolts M6x45 Fit sealing ring of pedal gear change spindle into sleeve of kick starter using sleeve MV 6 1563 and hollow punch MV 6 347 fig 98 36 Mount fan casing bolting it to the left casing cover with 3 cylindrical screws M 6 x 45 fig 99 Bolt on fan cap with 2 cylindrical screws M5x 14 Note Check that the 2 rubber buffers are fitted inside the fan cap fig 100 Fit gear change pedal in this se quence 1 Bush spacer ring Lever with pedal Serrated washer Hexagon nut Plastic pedal cover sleeve fig 101 Refill gearbox with oil see technical data 37 Fig 100 Fig 101 3 Special Service Tools Illustr Order No Description For use see fig No a SK A 126 Engine clamping fixture 1 28 61 96 b SK A 251 Flywheel magneto key 7 8 91 c SK A 263 Press off bolt 8 d SK A 234 Clamp 16 27 74 e SK A237 Studs 7 f SK A 265 Clamping stud 8 long 16 74 SK A 279 Assembl key 17 73 R SK A 64 Press off tool for gudgeon pin 22 i SK A 268 Press off tool for gudgeon pin 75and 100cc 22 k SK A 246 Stud 27 28 29 I SK A 213 Supporting pin 27 29 83 m SK A 232 Setting sleeve 3 speed engines 37 38 n SK A 233 Clamping snap ring 37 38 o SKAI Gauging bar 39 40 63 p SK A 206 Gauging yoke ip place of SK A 161 39 40 63 q SK A217 Assembly socket sleeve for selector shaft 44 61 r SKA138 Spacer ri
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