Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
TABLE OF CONTENTS
Front Wheel Assembly. . . . . . . . . . . . . . 37
Wheel Axle . . . . . . . . . . . . . . . . . . . . . . . 37
Wheel Bearing Play . . . . . . . . . . . . . . . . 38
Front Brake Mechanism . . . . . . . . . . . . 38
Front Brakes . . . . . . . . . . . . . . . . . . . . . 39
Front Mudguard . . . . . . . . . . . . . . . . . . 40
Mudguard Supports . . . . . . . . . . . . . . . 40
Steering Races. . . . . . . . . . . . . . . . . . . . 41
Front Forks . . . . . . . . . . . . . . . . . . . . . . 42
Kick Stand. . . . . . . . . . . . . . . . . . . . . . . 42
Crank Spindle . . . . . . . . . . . . . . . . . . . . 43
Crank Assembly. . . . . . . . . . . . . . . . . . . 44
Handlebar . . . . . . . . . . . . . . . . . . . . . . . 44
Throttle Twist Grip . . . . . . . . . . . . . . . . 45
Left Handgrip . . . . . . . . . . . . . . . . . . . . 45
Saddle Assembly . . . . . . . . . . . . . . 45-46
Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . 46
Rear Brake Drum . . . . . . . . . . . . . . . . . 46
Brake Shoes . . . . . . . . . . . . . . . . . . . . . 47
Rear Brake . . . . . . . . . . . . . . . . . . . . . . 48
Rear Wheel Bearing. . . . . . . . . . . . . . . . 48
Rear Mudguard . . . . . . . . . . . . . . . . . . . 49
Mudguard Support . . . . . . . . . . . . . . . . 49
Luggage Carrier and Supports . . . . . . 49
Headlamp . . . . . . . . . . . . . . . . . . . . . . . 50
Rear Lamp. . . . . . . . . . . . . . . . . . . . . . . 50
Techical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Principle of Operation of the 2-Cycle Engine . . . 2
Ignition3
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Automatic Compound Clutch . . . . . . . . . . . . . . . 6
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . 7
Engine Repair Operations . . . . . . . . . . . . . . . 8-29
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Guard Rail . . . . . . . . . . . . . . . . . . 9
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stator and Stator Bearing . . . . . . . 12-13
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drive Roller Assembly . . . . . . . . . . . . . . 15
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cylinder Head . . . . . . . . . . . . . . . . . . 18-19
Cylinder . . . . . . . . . . . . . . . . . . . . . . . 20-21
Carburetor . . . . . . . . . . . . . . . . . . . . . . . 22
Crankcase End Cover . . . . . . . . . . . . . . 23
Connecting Rod Assembly . . . . . . . . . . 24
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Supports and Axle . . . . . . . . . . 26
Engine Decarbonizing. . . . . . . . . . . . . . . 27
Decompressor . . . . . . . . . . . . . . . . . . . . 28
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 28
Ignition Timing . . . . . . . . . . . . . . . . . . . . 29
Electrical Connections, Solex 3800 D.O.T. . . . 33
TECHNICAL DATA
Dimensions:
Frame:
Type.................................................Pressed steel
Front brakes ................................Caliper
Rear brakes ..................................Internal expansion
Tire size .........................................1.75 x 19
Tire pressure F/R........................32 psi
Fuel:
Engine:
Electrical System:
Performance:
Identification
Transfer port opens. Descending piston forces fresh mixture through transfer port to combustion
chamber. The incoming fresh mixture helps to push exhaust mixture out. See figure 5
Exhaust port closes. Compressions begins. See figure 6
Exhaust
Port
Inlet
Port
Exhaust
Port
Inlet
Port
Figure 4
Figure 3
Exhaust
Port
Inlet
Port
Figure 5
Exhaust
Port
Inlet
Port
Fuel
Pump
Port
Figure 2
Figure 1
Exhaust
Port
Inlet
Port
Exhaust
Port
Inlet
Port
Figure 6
IGNITION
Flywheel Magneto
Ignition Circuit
The ignition circuit consists of an ignition coil with the primary winding,
contact points to interrupt the primary circuit, a condenser, and a secondary winding.
Operation
As the flywheel magnets rotate past the coil, a current is induced in the
primary winding. The primary winding of the ignition coil sends the current
to the moving contact which, at the closed position, is grounded to the
fixed contact. As the flywheel rotor revolves, the cam opens the points;
the current is no longer grounded and, therefore, must move. The current
moves to the secondary winding of the ignition coil, producing a high tension current which goes to the spark plug lead and ignites the mixture in
the cylinder.
Condenser
CARBURETOR
Principle
The Solex carburetor is supplied with fuel by a crankcase pressure activated fuel pump. Fuel is pumped from the fuel tank through the fuel pump
to the carburetor at which time the fuel needed is metered through the
fuel jet, combined with air. This mixture goes to the cylinder.
The Solex carburetor consists of 13 parts:
1
2
3
4
5
6
7
Operation
8
9
10
11
12
13
Throttle barrel
Cable bracket
Carburetor slide
Slide fixing bolt
Slide spring
Carburetor filter
The fuel is delivered to the carburetor through the fuel supply pipe, at
which time it is filtered (A). The amount of fuel needed is then metered
by the fuel jet (B) into the cylinder, and the surplus fuel delivered by the
pump is returned to the fuel tank through the overflow pipe (C). This principle avoids the need of a float because there is always the proper
amount of fuel at the jet. See figure 7
After the fuel is metered through the fuel jet, it combines with air from
the air jet (D) through the choke assembly (E) to the mixing chamber (F)
and proceeds through the diffuser (G) which vaporizes the fuel mixture.
This vaporized fuel mixture proceeds through the air horn (H), through
the throttle barrel (I) to the inlet pipe, then to the cylinder when the inlet
port is opened (See figures 1 thru 6).
Throttle Barrel
The throttle barrel controls the amount of the vaporized fuel entering
into the cylinder.
When completely opened, it draws more air through the air horn, which in
turn increases the fuel mixture in the diffuser, which in turn causes the
motor to turn faster.
As the throttle barrel closes, the amount of air drawn through the air
horn decreases, which in turn decreases the fuel mixture in the diffuser,
which in turn causes the motor to turn slower.
Idle
The throttle barrel has been modified by the factory to give a proper control when idling. There is a special manufactory control on this modified
barrel indicated by a blue spot on the carburetor body. his modification
is so critical that the company does not wish you making this operation,
but suggest you replace this part if the carburetor does not have this
control mark.
Choke
The choke lever control the amount of air entering through the air jet. By
closing the choke lever, you decrease the amount of air, thereby enriching
the full mixture in the mixing chamber, which in turn creates more combustion in the cylinder; thus, allowing your engine to start more easily
when cold.
4
AIR FILTER
C
F
CARBURETOR BODY
A
A - Fuel Filter
B - Fuel Jet
C - Overflow Pipe
D - Air Jet
E - Choke Assembly
F - Mixer Chamber
G - Diffuser
H - Air Horn
I - Throttle Barrel
Figure 7
Clutch Action
The clutch is a single action, centrifugal clutch that starts the engine as
well as propels the machine.
When stationary, the flyweights (F) due to the action of the springs (S)
press the centrifugal clutch arms (A) and pads (P) against the drive
roller drum (D). When the front wheel begins to revolve, the engine is
turned. See figure 9
Normal Running
When the throttle is opened the speed of the engine increases, forcing
the flyweights further away from each other, thus forcing the centrifugal
clutch arms and pads further against the drive roller drum transmitting
power from the crankshaft to wheel through the drum and the drive
roller. See figure 10
Normal RPM at full speed is 3800 RPM.
Figure 8
When the engine reaches idling speed (1500 RPM), the flyweights move
outwards due to centrifugal force. During this time the centrifugal force
is overridden by the power of the springs. The pressure of the pads on
the drum is reduced by the contraction of the centrifugal clutch arms
allowing the clutch pads to slip while the engine continues to run. Power
is now discontinued from the drive roller drum and drive roller allowing the
engine to idle. See figure 11
Figure 9
Figure 10
Figure 11
Muffler
Removing
1. Loosen, but do not remove, the nut securing the muffler to the mudguard. Loosen the nut securing the exhaust pipe to the right hand engine
support. Use 10mm wrench. Figure 12
2. Pull on the muffler to remove it from the mudguard.
3. Pull the muffler outwards, while pulling down on the exhaust pipe near
the engine support, and free the pipe from the upper section of the
exhaust pipe.
Solex owners are advised to consult their dealer at each 3600 miles for
muffler inspection.
The muffler should be replaced at this interval if restricted at all. When
fitting a new muffler, check that no obstruction enters the exhaust pipe.
Reassembling
Figure 12
1. Loosen the bolt securing the engine guard rail to the fork assembly
(10mm wrench). See figure 13
2. Pull gently on each side of the engine guard rail at the clamp position
and lift the rail forward and over the engine.
Reassembling
Figure 13
Engine
Removing
Reinstalling
10
Rotor
Removing
1. Remove the stroke limiter plug and insert the stroke limiter as
described. Unscrew the stroke limiter slowly while turning the flywheel and
stop as soon as the flyweight just catches the stroke limiter (tool
#200009).
2. Loosen the flywheel cover plate nut and remove the plate and rubber
seal and remove the rotor nut (14mm wrench).
3. Install the flywheel puller nut with the flange of the nut to the rear
(tool #200005).
4. Install the flywheel puller plate on the flywheel and tighten the three
fixing bolts (10mm socket). See figure 14
5. Loosen the flywheel puller nut until a cracking noise is heard (14mm
wrench).
6. Continue to loosen the flywheel puller nut and remove the rotor.
7. Remove the flywheel puller plate and the nut from the rotor (use
10mm wrench).
8. Place the rotor on the workbench with the open side up to prevent
foreign metal objects connecting with the magnets.
Reassembling
Figure 14
11
1. Loosen the two bolts securing the top left horn coil and remove (7mm
wrench).
2. Turn the coil to one side and reinstall the bolts (7mm wrench).
3. Loosen the drive roller cleaning bolt and disconnect the spark plug
lead from the stator plate and wires. See figure 15
4. Loosen the bolt securing the engine engagement lever. Do not remove
(10mm wrench).
5. Loosen the two stator plate fixing bolts and install the stator plate
puller tool on the crankshaft (tool #200004).
NOTE: Remove the stroke limiter but do not replace the stroke limiter
plug.
6. Screw in the stator plate puller wings until each wing fits over the corners of the ignition and lighting coils. Hold wings firmly and screw in the
stator plate puller until stator plate is free of the crankshaft. See figure 15
7. Remove the stator plate puller and the stator.
Figure 15
12
Reassembling Bearing
Reassembling Stator
Figure 16
13
Clutch
Removing
Reassembling
NOTE: The X marked on the clutch arms indicates the outward facing
side of the clutch when mounted. See figure 17
1. Squeeze the flyweights together and insert in the drive roller housing.
2. Install the nut on the crankshaft.
3. Fit the clutch wrench over the nut with the arm of the wrench aligned
with the front side of the engine engagement lever bolt hole. Insert a bolt
through the arm of the wrench into the bolt hole to hold the clutch
wrench firmly (tool #200008).
4. Tighten the crankshaft nut fully.
5. Remove the bolt and clutch wrench (tool #200008)
Figure 17
14
1. With the left index finger, press one side of the oil seal while rocking the
seal on the other side with the right index finger. Gradually withdraw the
oil seal over the thread of the crankshaft and remove.
2. Remove the drive roller nut and washer (tool #200003). See figure 18
3. Remove the drive roller.
Reassembling
1. Lightly grease drive roller between the roller and crankcase flanges.
2. Align the flange of the drive roller with the engine engagement lever
bolt hole and insert a bolt.
3. Fit the washer and drive roller nut and tighten slightly (tool
#200003).
4. Fit the oil seal.
Figure 18
15
Fuel Tank
Removing
1. Disconnect the fuel recirculation pipe from the carburetor. See figure 19
2. Loosen the fuel inlet pipe nut on the fuel pump (10mm wrench).
3. Loosen the fuel tank mounting bolts (10mm wrench).
4. Remove the fuel tank.
5. Loosen the fuel outlet pipe nut.
6. The fuel filter is located at the fuel outlet.
7. To remove the filter, insert a 2-inch, #6 or #8 sheetmetal screw in the
fuel outlet.
8. Screw into the filter and pull.
9. Replace the gas tank filter if fouled.
Reassembling
Figure 19
16
Air Filter
Removing
1. Loosen the air filter cover and remove the air filter unit (10mm wrench).
See figure 20
2. Hold the cover and tap lightly on the protruding lip of the air filter
housing until the cover is free of the housing.
3. Pry the filter ring loose and remove the filter (screwdriver).
Installing
Figure 20
17
Cylinder Head
Removing
1. Disconnect the lead to the spark plug and remove the spark plug lead
(10mm wrench). See figure 21
2. Loosen the spark plug (tool #200003).
3. Loosen the cylinder head bolts and remove the cylinder head (10mm
wrench).
4. Remove the air filter support bracket.
5. Remove the decompressor cylinder head plate.
6. Remove cylinder head spacers.
7. Loosen and remove the brass nut connecting the decompressor valve
assembly.
8. Scrape all carbon deposits from the cylinder head. DO NOT scrape the
decompressor valve seat (scraper).
9. Place a little oil in the decompressor valve port and insert a valve
reamer to clean the port.
Figure 21
18
Reassembling
NOTE: Always fit a new decompressor valve after having reamed the
cylinder head valve seat.
1. Insert the decompression valve in the cylinder head with the slot on the
valve end facing a 1 oclock direction (screwdriver).
2. Place the valve spring on the valve and fit the decompressor valve
brass nut.
3. Tighten the nut also aligning the slot in the nut to the 1 oclock direction (10mm wrench).
4. Hold the decompressor valve and loosen the nut counter clockwise one
complete turn.
NOTE: Always fit a new cylinder head gasket.
5. Fit the gasket, and place the cylinder head in position in the cylinder.
6. Insert the air filter support bracket in the slots on the cylinder head
with the screw hole facing to the front of the motor.
7. Insert the cylinder head spacers.
8. Fit the decompressor cylinder head plat in position and connect the
engine decompressor lever in the slot in the decompressor valve.
9. Insert the cylinder head bolts placing one washer on the top of the
plate on the cylinder head bolt at the decompressor lever.
10. Tighten the cylinder head bolts progressively at opposite corners to
8.5 - 9 ft. lbs. (10mm wrench).
NOTE: Never tighten the cylinder head bolts excessively.
If the decompressor cable has been disconnected, connect and adjust
the decompressor as described (see page 28).
19
SOLEX 19
Cylinder
Removing
Figure 22
20
Reassembling
Figure 23
21
Carburetor
Removing
Reassembling
22
1. Loosen and remove the eight bolts securing the crankcase end cover
(10mm wrench). See figure 24
2. Remove the cover and gasket.
Reassembling
Figure 24
23
Reassembling
Figure 25
24
Fuel Pump
Removing
1. Loosen the four bolts securing the fuel pump housing to the engine
(7mm wrench). See figure 26
2. Remove the fuel pump.
3. If the fuel pump has been removed with the plastic pump seating piece,
pry the seating piece loose and remove the diaphragm.
Reassembling
1. Clean the plastic pump seating and place in position on the crankcase
air port with the concave side facing the fuel pump.
2. Tap the center on to the air port lug.
NOTE: Always fit a new diaphragm after having removed the fuel pump.
3. Check that the plastic fuel pump ball is correctly seated in the fuel
port of the pump.
Figure 26
25
1. Unhook the suspension springs on each support and remove with the
engine mudguard. See figure 27
2. Release the engine pivot pin nut locks.
3. Loosen the engine pivot nuts (14mm wrench).
4. Loosen the front nuts and remove the bolts and spacer (14mm
wrench).
5. Remove the engine support.
6. Loosen the suspension friction plate tension nuts and remove the
springs and guides (10mm wrench).
7. Remove the engine axle.
Reassembling
1. Before tightening the engine axle nuts when reassembling the engine
axle with the crankcase and the engine supports, these parts must be in
the same position as the motor on the front fork against the wheel.
Figure 27
26
Engine Decarbonizing
Removing
Reassembling
NOTE: When reassembling use new gaskets. Check the ignition timing on
the flywheel magneto. Adjust the plug gap to 5/10mm (0.020"). Clean or
change the air filter if necessary. Adjust the throttle control.
Figure 28
27
Decompressor
Adjusting
1. The decompressor valve opens correctly when the travel of the decompressor engine lever is between 1/8 inch and 1/32 inch.
2. Loosen the cable guide nut and adjust the tension on the cable until
correct adjustment is reached (7mm wrench).
Throttle
Adjusting
1. Insert the throttle cable cover end in the upper cable holder on the
throttle arm. See figure 29
2. Loosen the cable pulley nut and wind the cable from left to right over
the pulley and under the washer of the cable pulley nut.
3. Tension the cable.
4. Tighten the cable pulley nut.
5. Start the engine.
6. With the throttle twist grip rolled to the front and the throttle off,
the engine should idle smoothly.
7. If the engine runs too fast, loosen the cable pulley nut and adjust the
position of the cable on the pulley until correct idling speed is reached.
8. The correct engine idle is 1500 rpm.
Figure 29
28
Ignition Timing
Adjusting
29
30
31
32
Powers
a. Headlight switch - brown wire
b. Electric horn - yellow wire
2.
2.
Ignition Coil
2.
3.
4.
2.
3.
33
Possible Causes
Incorrect timing
Check by substitution.
Condenser (R=150)
Check by substitution.
There is an intermittent
spark or no spark
Contact breaker
Defective, replace it
Carbon build-up
Decarbonize.
Fuel pump
34
Symptoms
Possible Causes
Carburetor
Ignition
Crankcase
Spark plug
Stator plate
Timing:
a. check timing;
b. check fixed contact, clean or replace;
c. check moving contact, clean or replace.
Check condenser, substitution.
Check ignition coil, substitution.
Check cut-out switch ground connection.
Carburetor
Fuel pump
Ignition
Compression
Carbonization
35
Symptoms
Possible Causes
Carburetor
Carburetor obstructed:
a. fuel jet, remove and clean;
b. barrel, remove and clean;
c. air filter, clean;
d. fuel filter, replace.
Fuel supply
Ignition
36
Reassembling
Wheel Axle
Removing
Reassembling
1. If the axle is to be replaced, lift the wheel off the axle and secure the
new axle with the hub cone and washer cone counter nut in the vise, then
replace the wheel.
2. If the ball bearings on the opposite side of
the hub are to be replaced, first assemble
one side of the hub and turn the wheel over,
repeating the procedure.
3. Grease the axle and pack the ball
bearing races with grease.
4. Replace
the hub cone, tighten
and release 1/4 turn.
5. Continue to reassemble
in reverse sequence.
Figure 30
37
1. Disconnect the brake cable from the brake bar assembly at the brake
mechanism. See figure 31
2. Loosen the nuts securing the brake mechanism to the forks (14mm
wrench).
3. Loosen the nuts attaching the brake mechanism to the mudguard
(10mm wrench).
4. Remove the brake mechanism and brake shoe blocks (10mm wrench).
Reassembling
Figure 31
38
Front Brakes
Adjusting
1. Minor adjustment to compensate for wear of the brake shoes and play
at the brake levers is carried out at the right handlebar lever. See figure 32
2. Check that the engine engagement lever is pulled to the rear.
3. Unscrew the locking nut and the adjusting nut slightly (10mm wrench).
4. Spin the wheel by hand, adjusting the amount of free play on the brake
lever until the brake shoes take hold and stop the spin, by turning the
adjusting nut and applying the brake lever.
5. The amount of free play at the end of the brake lever should be about
1/2 inch.
6. Tighten the locking nut (10mm wrench).
Additional adjusting
Figure 32
39
Front Mudguard
Removing
Reassemble
Mudguard Supports
Removing
1. Loosen the two lower mudguard support nuts and remove the bolts
(10mm wrench). Remove the splashguard. See figure 33
2. Loosen the nut attaching the horn and mudguard supports to the
engine supports (10mm wrench).
3. Remove the supports.
Reassembling
Figure 31
40
Steering Races
Removing
Reassembling
Figure 33
41
Front Forks
Removing
Reassemble
Kick Stand
Removing
1. Tilt the machine and empty the fuel from the fuel tank into a can.
2. Turn the machine over and support the frame in the recommended
workshop support stand.
3. According to model; drive out the rivets or loosen the nuts and remove
the bolts on each side of the kickstand (14mm wrench.
4. Unhook the spring. See figure 35
5. Lower the kickstand ad lift from the frame.
Reassembling
Figure 35
42
Crank Spindle
Removing
1. Slip the cycle chain from the crank sprocket wheel. See figure 36
2. Remove the wedge nut and tap out the wedge on the sprocket wheel
pedal crank (13mm wrench).
3. Pull on the left hand pedal crank and remove the crank spindle from
the crank assembly with the left pedal crank.
4. To replace the crank spindle, remove the wedge nut and tap out the
wedge on the left pedal crank.
Reassembling
Figure 36
43
Crank Assembly
Removing
Reassembling
Handlebar
Removing
1. Loosen the throttle twist grip collar screw and remove the grip with
cables and wires attached (allen wrench).
2. Remove the left handgrip (page 45).
3. Loosen the left handgrip collar screw and remove with cables and wires
attached (allen wrench).
4. Loosen the handlebar support bracket bolt and remove the handlebar
from the bracket (12mm wrench). See figure 37
Reassembling
Figure 37
44
1. Loosen the throttle twist grip collar screw and remove the grip with
cables and wires attached (allen wrench). See figure 33
2. Pull back the shouldered end of the throttle outer cable cover and
remove the cable from the cable guide.
3. Pry back the rubber twist grip flange and remove the cable end ball.
4. Pull on the rubber grip and remove the grip sleeve or cut the length of
the rubber grip with a razor or knife and remove.
5. Replace parts as necessary.
Reassembling
Left Handgrip
Replacing
1. Cut the length of the handgrip with a razor or knife and remove.
2. To fit a new handgrip, first soak the open end of the grip in gasoline.
3. Tap the grip into position on the handlebar.
Saddle Assembly
Removing
1. Loosen and remove the nut and washer of the support bolt connecting
the luggage carrier to the frame (14mm wrench).
2. Withdraw the support bolt from the opposite side of the machine and
remove the spacers.
3. Loosen the nuts on the upper mounting bolts and remove the washers
and bolts (14mm wrench).
4. Withdraw the saddle and seat post from the frame seat support.
5. Loosen the nut and remove the two washers on the bold securing the
main saddle spring to the seat post (14mm wrench).
6. Withdraw the bolt and remove the third washer from the spring side.
7. Remove the spring from the saddle cradle with a twisting action.
Reassembling
Adjusting
5. To adjust the angle of the saddle, grip the saddle at the front and
rear, press down firmly or lift, either the front or rear until the desired
angle is reached.
6. Tighten the two upper nuts and the nut of the support bolt (14mm
wrench).
Rear Wheel
Removing
Reassembling
Reassembling
46
Brake Shoes
Replacing
Reassembling
Figure 38
47
Rear Brake
Adjusting
1. Minor adjustment to compensate for wear of the brake shoes and play
at the brake lever is carried out at the left handlebar brake lever.
2. Check that the engine engagement lever is pulled to the rear.
3. Unscrew the locking nut and the knurled adjusting nut slightly (10mm
wrench).
4. Spin the wheel, adjusting the amount of free play on the brake lever
until the brake takes hold and stops the spin, by turning the knurled
adjusting nut and applying the brake lever.
5. The amount of free play at the end of the brake lever should be about
1/2 inch.
6. Tighten the locking nut (10mm wrench).
Additional adjusting
Reassembling
48
Rear Mudguard
Removing
Reassembling
Mudguard Support
Removing
Reassembling
Reassembling
Headlamp
Removing
1. Remove the headlamp by pushing down and then pull out that connects
to the lever touching the bulb. See figure 39
2. Disconnect wire.
Reassembling
Figure 39
Rear Lamp
Removing
1. Loosen the screws and remove the lens (phillips screwdriver). See figure 40
2. Remove the gasket.
3. Remove the bulb.
4. Disconnect the wires.
5. Loosen the mounting bolts from the rear of the rear lamp bracket
(10mm wrench).
6. Remove the rear lamp body.
Reassembling
Figure 40
50
CONTROL CABLES
Brake Cables
Replacing
1. Push on the cable pivots at the brake levers and detach the cable end
balls from the brake levers.
Front Brakes:
Rear Brakes:
2. Pull on the cables at the cable end balls and remove the cables from
the outer cable covers.
3. Grease the new cable(s) and slide in and out of the outer covers to
ensure that the entire length of the cable and inside of the outer covers
are well lubricated.
NOTE: Check that the outer cable cover shouldered end is well located in
position.
Reassembling
Throttle Cables
Replacing
Reassembling
51
Decompressor Cable
Replacing
Reassembling
52
TORQUE DIAGRAM
53
TORQUE DIAGRAM
54
TORQUE DIAGRAM
55
TORQUE DIAGRAM
56
TORQUE DIAGRAM
57
TORQUE DIAGRAM
58
59
YELLOW
WHITE
GREEN
RED
BROWN
RED
VIOLET
GREEN
TO SPARK PLUG
BLACK
BLACK
GREY
FLYWHEEL MAGNETO
HEADLAMP
HORN
BLACK
GREEN
RED
RED
RIGHT HAND
STOP CONTACTOR
GREEN
BLACK
GREEN
REAR LAMP
VeloCruz 650 North Main PO Box 540080 North Salt Lake, UT 84054
Ph: 801.593.6783 800.393.7101 Fax: 801.593.6790
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a2
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a3
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a4
Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . a15
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . a6
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a16
Cycle Part I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . a8
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . a19
a1
Ref.#
1
2
3
4
5
6
8
9
Order#
SPM 90837
SPM 90820
SPM 90758
SPM 90759
SPM 91525
SPM 90841
SPM 91263
SPM 90421
10
SPM 90786
11
SPM 90980
12
13
14
15
16
17
18
19
20
21
SPM 93106
SPM 90848
SPM 90859
SPM 90792
SPM 90858
SPM 90821
SPM 90437
SPM 90496
SPM 90016
SPM 90000
23 SPM 90497
24 SPM 90817
25 SPM 90849
26 SPM 90024
27
28
29
30
31
32
33
34
35
36
40
SPM 90867
SPM 91342
SPM 90413
SPM 90414
SPM 90019
SPM 90015
SPM 90415
SPM 90679
SPM 91215
SPM 90073
SPM 91297
ENGINE
41
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
Description
Air filter cover
Air filter base
Air filter
Air filter fixing ring
Internal gear washer M6
Hexahedral screw M6x12
Decompressing lever
Cylinder head fixing screw
M6x45
Space holder for cylinder
head
Air filter house suspension
bridle
Sparking plug
Ignition cable fixing nut M4
Decompressor valve nut
Decompressor valve spring
Decompressor valve
Cylinder head
Cylinder head gasket
Cylinder
Cylinder base gasket
Hexahedral nut M6 for
cylinder fixing
Piston crank rod with
crankpin bush
Piston ring 39, 5x1, 7
Crankpin bush
Space holder ring to
crankshaft
Crankpin nut M10x1
Crankcase with crankshaft
Crankcase cover w/drop bolt
Gasket to crankcase
Washer M6
Stud bolt
Screw M6x20
Screw M6x15
Screw M6x45
Bearing
Piston (simple)
a2
SPM 93200
SPM 90055
SPM 90185
SPM 90568
SPM 91013
SPM 91456
SPM 93059
SPM 93060
SPM 93061
SPM 93062
SPM 93105
CLUTCH
Ref.#
1
2
3
4
5
Order#
SPM91287
SPM90978
SPM90816
SPM90815
SPM90977
Description
Complete friction 0/ 42mm
Clutch
Clutch structure
Clutch spring
Cap washer
6
7
8
9
10
NR
a3
SPM91348
SPM90491
SPM90484
SPM93063
SPM93072
SPM93137
Flat washer
Friction nut
Flywheel cover fixture
Clutch bell
Friction 0/ 42
Friction 0/ 42 (steel)
Ref.#
1
2
3
4
5
5
6
7
8
9
Order#
SPM90845
SPM91400
SPM90074
SPM90772
SPM93117
SPM90571
SPM90802
SPM90833
SPM90832
SPM90421
10
SPM90763
11
SPM91303
12
SPM90775
Description
Flywheel
Stator
Bearing
Spark roll
Lighting roll 2 out
Lighting roll 1 out
Condenser 0,2 mF
Stator insulating facing
Stator contact bolt
Hexahedral head screw
M6x45
Hexahedral head screw
M4x20
Hexahedral head screw
M4x8
Contact breaker
FLYWHEEL
13
14
SPM90971
SPM90970
15
16
17
SPM90969
SPM90972
SPM91014
18
19
20
21
22
NR
NR
NR
NR
SPM90934
SPM90843
SPM91299
SPC91390
SPM90780
SPM93139
SPM93068
SPM93113
SPM93116
a4
Flywheel nut
Caoutchouc gasket for
flywheel
Wadding plaque
Low nut
Contact breaker anvil
hammer (2 pc)
Ignition cable
Cable end for ignition cable
Borne HT
Screw bolt
Placket binding cable
Electric ignition
Flywheel fixing set
Service set
Stator (full)
Ref.#
1
2
3
4
5
6
7
8
9
10
11
Order#
SPM90921
SPM90854
SPM90851
SPM91346
SPM93107
SPM90407
SPM90501
SPM90440
SPM90853
SPM90869
SPM90924
Description
Carburetor
Carburetor fitting strip
Regulating valve with blank
Carburetor fuel filter
Air filter house gasket ring
Air jete
Starter valve lever
Starter valve
Carburetor closing disc
Regulating lever spring
Regulating valve lever
a5
13
14
15
16
17
SPM90920
SPM90183
SPM90932
SPM90023
SPM90434
18
19
NR
NR
SPM90763
SPM91389
SPM93108
SPM93132
Ref.#
1
2
3
4
Order#
SPM90785
SPM90753
SPM90041
SPM90442
EXHAUST SYSTEM
Description
5 SPM90445
Inlet pipe
6 SPM90964
Exhaust pipe
7 SPM90793
Gasket to inlet pipe
NR SPM93138
Carburetor and inlet pipe
gasket ring
a6
Ref.# Order#
3 SPM90792
8 SPM90558
9
SPM90779
10
11
14
15
16
17
SPM90987
SPM90778
SPM90022
SPM90800
SPM90030
SPM90026
a7
Silent block
Nut lockplate
Lockscrew
Collar nut
Nut M6
Screw bolt
Flat washer
Engine lift out lever
Hexahedral nut M8x1
Flat washer 0/ 6,3
Engine support set
Ref.#
1
2
3
Order#
SPC90190
SPC90883
SPC90872
4
5
6
7
8
9
10
11
12
13
SPC90875
SPC90885
SPC90888
SPC90469
SPC90996
SPC91008
SPC90991
SPC90880
SPC90891
SPC90897
14
SPC90540
15
19
20
21, 22
23
24
SPC90894
SPC90528
SPC90534
SPC93067
SPC90453
SPC90850
CYCLE PART 1
Description
49
Framework
50
Saddle support space holder
51
52
Main support (rear fork)
right
53
Main support (rear fork left
55
Seal upholder right
56
Seal upholder left
62
Luggage carrier upholder
Rear mudguard arm
63
Front mudguard
64
Rear mudguard
65
Luggage carrier
NR
Drive chain protective cover
NR
NR
Pedal house cover, leg
holder
NR
Protective plate (engine
NR
cover)
NR
Stank fork
NR
Front mudguard arm right
NR
Front mudguard arm left
Rubber mudguard set
NR
Toolbox
Toolbox sponge
a8
SPC90999
SPC90893
SPC93111
SPC90907
SPC90909
SPC93066
SPC90549
SPC90755
SPC90939
SPC90806
SPC91004
SPC90910
SPC91294
SPC91386
SPC93065
SPC93070
SPC93071
SPC93073
SPC93133
SPC93134
Stand spring
Decoration latch
Pump
Saddle
Saddle cover
Fork bearing
Engine lift out fixing plate
Cable cross leading to
framework
Cable packet front
Support fork pin + bolt
Premounted fork
Saddle spring back
Head of fork
THI-BLOC nut M6
Framework fixings set
Label to framework
Fork fixings set
Tool set
Counterdie SOLEX white
(2 pcs)
Counterdie SOLEX black
(2 pcs)
CYCLE PART 1
a9
Ref.#
29
30
31
32
33
Order#
SPC90056
SPC90000
SPC90019
SPC90903
SPC90936
34 SPC90054
35 SPC90053
36 SPC90409
CYCLE PART II
Description
37
Hexahedral bolt M6x10
38
Nut M6
39
Washer 0/ 6,5
40
Hexahedral bolt M8x1-109
41
42
Flange socket to saddle
upholder
43
Washer 0/ 8,1
44
Hexahedral nut M8x1
45
Hexahedral head screw
47
M10x1-110
48
a10
SPC90901
SPC90473
SPC91235
SPC91236
SPC91900
SPC90076
SPC90968
SPC91209
SPC90077
SPC90551
SPC90803
Ref.#
1
2
3
4
5
6
Order#
SPM90918
SPM91376
SPM90557
SPM90979
SPM91345
SPM90770
a11
Ref.#
1
2
3
Order#
SPC91307
SPC90465
SPC90485
SPC90476
a12
Ref.#
1
2
3
4
5
6
Order#
SPC93085
SPC90423
SPC90508
SPC90513
SPC90514
SPC90512
FRONT BRAKE
Description
7
Front brake
8
Flange brake key mounting
9
Flange brake cover
10
Brake arm right
11
Brake arm left
12
Bridge for brakes
13
a13
SPC90481
SPC92169
SPC90076
SPC93202
SPC90070
SPC91296
SPC90502
Ref.#
1
2
3
4
5
6
7
8
9
10
11
12
Order#
SPM90204
SPM90205
SPM90574
SPM90767
SPM90834
SPM90831
SPM94133
SPC93069
SPC93114
SPC93083
SPC93124
SPC93140
LIGHTING SIGNALS
Description
13 SPM93112
Engine cover
14 SPC93115
Headlight with bulb
15 SPC93079
Bulb 6V-15W-26S
16 SPC93075
Contact button
17 SPC93122
Light switch
18 SPC93127
Headlight switch spring
19 SPM93120
Screw M4x8
20 SPM93126
Light switch kit
NR SPC90569
Rear lamp with stop
NR SPC93123
Rear light
NR SPC93128
Rear light (GB)
NR SPM93077
Rear light (Japan)
a14
Ref.#
1
2
3
4
5
6
7
8
Order#
SPC90190
SPC90192
SPM90193
SPM90199
SPM90194
SPM93085
SPM90197
SPM90196
9
10
SPM93084
SPC93203
HANDLEBARS HILTS
Description
11 SPM93102
Handlebars
12 SPM93086
Stem bow bolt
13 SPM93087
Right (gas) hilt
14 SPM93088
Left hilt
15 SPM93089
Fixation of right arm
16 SPM93090
Rubber hilt right
Cursor to front brake cable
Cursor to gas cable (gas
cursor)
Brake lever right
Plaque for protection of
hands
17
18
19
NR
a15
SPC93091
SPC90206
SPC93136
SPC93141
CABLES
Ref.#
1
2
3
4
Order#
SPC92174
SPC90974
SPC92177
SPM2178
Description
Front brake cable
Rear brake cable
Nut for fixing decompression
Decompressing cable
a16
SPC91371
SPC93092
7
8
SPC91446
SPM93104
Ref.#
1
2
3
6
Order#
SPC90058
SPC91358
SPC90052
SPC93095
a17
Rim
Inner tube
Tire (1,75x19)
Front wheel without tire and
inner tube
Ref.#
1
2
3
4
5
Order#
SPC91395
SPC91405
SPC93098
SPC93100
SPC91359
a18
Protective band
Rim
Inner tube
Tire (1,75x19)
Rear wheel without tire and
inner tube
Ref.#
1
2
3
Order#
SPC93130
SPC93142
SPC93143
ACCESSORIES
Description
5
Saddle bag, black
6
Saddle bag, burgundy
NR
Saddle bag, blue
NR
Ref.#
7
8
9
Order#
SPC93145
SPC93148
SPC93149
Description
Solex T-Shirt
Solex Mock T-Shirt
Solex Fleece Vest
10
11
a19
SPC93145
SPC93146
SPC93147
SPC93148
Solex hat
Speedometer
User guide (French)
User guide (English)
SPC93150
SPC93113