NOTICE DÉMONTAqEdES of

CycloiVIOTEURS
BB7

AFTER SALES SERVICE

SOCIETY

ANONYMOUS SOCIETY CAPITAL TO.500.000 NC

Beaulieu -VALENTI CNE Y (Doubs)

TELEPHONE: 2.21 MONTBÉLIARD - At 6 VALENTICNEY

ÏÉlÉqRAMMES Cycles VAlENiiqNtyReq. Com. 55 B 45 MoNibéliARdC.CP Dijon 181-41R. P. 420 Doubs

July 1961
 SommcUte

Pages

Characteristics ..................................................................................................................................................... 3
Engine support ...................................................................................................................................................... 4
ordering parts for Tips spare ................................................................................................. 34

REMOVAL:
Engine Removal ................................................................................................................................................... 3
Dismantling the motor .......................................................................................................................................... 4
Dismantling the bolt .............................................................................................................................................. 5
cylinder disassembling .......................................................................................................................................... 5
Removing the decompression valve ..................................................................................................................... 5
Disassembly of decompression ............................................................................................................................ 5
Disassembling the piston ...................................................................................................................................... 6
Removing the flywheel ...................................................................................................................................... 6-7
Removing the right cover ...................................................................................................................................... 7
Disassembling the output gear ............................................................................................................................. 8
Disassembly of the primary transmission ........................................................................................................... 8-9
Opening the engine block .................................................................................................................................... 10
Stripping of the right crankcase ........................................................................................................................... he
Stripping the left casing ........................................................................................................................................ he
Extraction of the crankshaft .................................................................................................................................. he
Extraction of bearings ......................................................................................................................................... 12
Dismantling of the telescopic fork ....................................................................................................................... 25
Disassembly of the rear suspension and pedal.................................................................................... 26
Carburetor Disassembly ................................................................................................................................... 24

ASSEMBLY:
Mounting bearings and seals in the left carier ........................................................................................... 13
Mounting bearings and seal in the right carier ........................................................................................... 14
Preparation of the right crankcase ................................................................................................................. 15-16
Coupling housings ......................................................................................................................................... 16-17
Reassembling the driven gear clutch ............................................................................................................. 17-18
Winding of the output pinion ................................................................................................................................ 18
Reassembling the right cover .............................................................................................................................. 18
Reassembling the piston ..................................................................................................................................... 19
Reassembling the cylinder ................................................................................................................................. 20
Reassembling the decompressor ....................................................................................................................... 20
Refitting the cylinder head ................................................................................................................................... 21
Reassembling the flywheel ................................................................................................................................. 21
Reassembling the motor on the frame ................................................................................................................. 22
Connect the controls ........................................................................................................................................... 23
Reassembly of the telescopic fork ....................................................................................................................... 25
Reassembly of the rear suspension and the pedal .................................................................................... 27

SETTING:
Calibration and adjustment of the flywheel........................................................................................................... 21
Adjusting the tension of driving chain.................................................................................................................... 27
Carburetor adjustment ......................................................................................................................................... 24
Setting the shift command ......................................................................................................................... 23
Lighting (in data) ................................................................................................................................................... 3

Troubleshooting Tips ................................................................................................................................ 28-29-30

special tools ............................................................................................................................................. 31-32-33

2
Bore - stroke 40 mm X 39 mm
Capacity: 49 cm3
Compression ratio: 6 to I
Ignition: flywheel
Spark advance: 3 mm
primary transmission: by crankcase chain
2-stroke engine with precompression in the
Driving the rear wheel: chain crankcase
Consumption: I. 2 400 100 km (average) Tank capacity: 8 liters Sump capacity: 0 liter 200 Approximate Total weight: 48
kg bearing speed: 55 km / h Tire AV: 23 <2 Tire AR: 23 2.25
Lighting :
Bulb 12 volts, 0.5 amps - Lantern arrière.6 volts, amps I - Phare.

ENGINE REMOVAL
TOOLS
Screwdriver - Key 6 - Key 8 - key 12 Key 14 - Key
0.74.

— Remove cowlings left and right

(Fig. 0) (careful! Not to lose the washers
between the cowling and the mounting
brace on the back).
— Disconnect the clutch control to
the engine by removing the cable clamp
(key 6).
— Disconnect the decompression
control by removing the cable clamp (key 6).
— Disconnect the fuel hose to the
carburetor.
— Loosen the clamp carburetor (key
8) and tilt the carburetor to the left.
Unscrew the fixing screws of the mixing
chamber cap and remove the cap with the
plug and the control (screwdriver) (D).
On GA carburetor. 14, (Fig. 49, Page 24)
there is no need to disconnect the gas control, to remove the mixing chamber cap. Indeed, the control disengages as
follows:
Tighten the set screw on the side of the carburetor.
Lift the cable grain by pressing the cable into the carburetor, and flipping the air filter side grain, a slot provided in the
throttle valve will release the grain.
When reassembling, do the opposite.
Disconnect the control change speeds by loosening the two
clamps (E) of the sector and removing cables (8 key); to facilitate
reassembly, mark the position of the cables on the sector.
Disconnect the lighting wire (blue).
Loosen the notched nut muffler (0.74 key) (Fig. I) and the pot of
the fixing screws on the back (key 12 in the case of model Sports
key 8 in the case of the model Tourism). Remove er seems pipe
and muffler (attention to the seal).
 REMOVAL OF ENGINE
Loosen the front bolts (G) and rear (H) for fixing the engine
to the frame (key 14)
(Fig- 2).
Remove the two
rear bolts (H)
(under the head of
the screw, a
washer and a
washer GRO wer).
Support the engine
and remove the
front bolt (G) (under
the nut a flat
washer and a lock
washer) (Fig. 0 and
2).

2 g-
REMOVING
THE ENGINE
Remove the carburetor.
Drain the engine, why remove the level and drain plugs (key 14) (Fig. 3).

Fig. 3
 REMOVAL OF ENGINE
ENGINE SUPPORT p 0.91

We present, here against a very usable medium for all

engines of our chain drive mopeds.

With the engine mounted on a lockable swivel axis in four

positions, thus obtaining a perfect accessibility of all organs.

This support is delivered by our Service Parts

as rr 0.91. F, g.
4
 REMOVAL OF ENGINE

REMOVING THE CYLINDER HEAD AND CYLINDER

TOOLS
tube key 12 - Rubber mallet
— Remove the spark plug cap. If you are having some difficulties, proceed as
follows: push the cap completely, the pinch at the base between thumb and forefinger
and pull it vertically (fig. 5).
— Unscrew the four bolts holding the cylinder head, after having unlocked
staggered to prevent distortion (tube key 12). Remove washers and two to the frame
motor mounting flanges. Remove the cylinder head and gasket (fg. 6).

If the cylinder is glued to the piston at

bottom dead center, knock small rubber
mallet blows on the intake pipe and the
exhaust outlet (not hit on the fins which
are very fragile). Attention to the seal by
removing the cylinder.
Remove the seal.

REMOVING THE VALVE DECOMPRESSION

— Fix the cylinder head to the grip 2 by means of bolts (see Fig. 7).
— Cutting the end of the pin to compress the spring and remove the pin.
— Remove the valve.

REMOVAL OF BODY DECOMPRESSION

TOOLS
Screwdriver - 19 pipe wrench
— Fix the head as in the previous chapter.
— Open the spring using a screwdriver engaged in the
buckle and slide the head of the body decompression.
— Unscrew the body decompression using a 19 tube key.
— Unless it is damaged, do not remove the copper seal
remains in its seat as a result of compaction.
 REMOVAL OF ENGINE

REMOVING THE PISTON 0.6

— Remove the two circlips with the special pliers 0.4 (f, g. 9). 1
— Driving the axle by means of the tool 0.12. Attention to the needle bearing (fig. 10).

0.61 - Clamp for installation and

removal of the segments.
TOOLS
Clip 0.4 - 0.12 Tool - clamp 0.61

Fig. 9

Fig. 10

REMOVING THE MAGNETIC WHEEL

Dismantling the rotor

— Remove the wheel cover. TOOLS
— Unscrew the nut end of the
crankshaft using the special tool
0.92 by proceeding as follows:
— Place the 0.92 tool on the nut,
— Screw the bolt on the few
available threads of the nut of
the steering wheel,
— Screwing the nut against to
bring the tool to support the nut
of the steering wheel,
— With a key 18 placed on the
body of the tool 0.92, loosen the
flywheel nut by immobilizing the
rotor with 0.21 claw.
— Unscrew without removing the hard
vo- lant 0.45 thrust screws then
implement this tool by screwing it
fully onto the rotor.
— Immobilize the rotor with 0.21 claw
and screw the screw thrust of the
hard wheel to take-off of the rotor
(17 key).

Fig. II
 REMOVAL OF ENGINE

Fig. 12

REMOVING THE STATOR

TOOLS : Screwdriver

— Unscrew the two cap screws (screwdriver); not to be confused with the screw Truss head fixing the contact breaker
(fig. 12).
— Release the stator.

— Push the lighting grommet to the inside of the wheel and remove the lighting wire, be careful not to damage the
connector plug.

REMOVING THE COVER RIGHT

TOOLS Tourn evis

Fig. 13

— Unscrew and remove the 6 cover fixing screws (screwdriver), 4 short of over 2 long sides of the release lever.
— Remove the cover (if it is stuck, act on the disengaging lever) (fig. 13).
 REMOVAL OF ENGINE

REMOVAL OF OUTPUT GEAR

TOOLS
Burin - Claw 0.21 - Key Tube 17

— Fold the nut lock of the output pinion (chisel).

— Immobilising the pinion receiver using 0.21 claw provided on said pinion (fig. 14).
— Unlock the fastening nut of the output gear (key 17 tube).
— Remove the nut, the brake and the gear.

REMOVAL OF ALL PRIMARY DRIVE

TOOLS
Burin - Press 0.7 - Key 17 Key 21 - Claw 0.21.
special tool (see page 9, Fig. 16)

— Fold 3 brakes nut fixing the clutch plate.

— Compressing the clutch spring with the special press 0.7.

Unscrew the nuts 3, remove the brakes and relax the
progress springsively (Fig. 15).

— Remove the tray and spring.

8
 REMOVAL OF ENGINE

— Fold the brake screw securing the support of

the discs.

— Immobilize the clutch holder with special tool

(fig. 16).

— Unscrew with a tube 17 of the key of the

support fixing screws. Remove the screw and
the brake.

The tool above is economically feasible by

taking an outer support plate harvester clutch

(Catalog No. 24409 Part 3 speeds) on which will

weld a handle.
— Fold the brake of the nut fixing the driven
gear (Fig. 17). Fig. 17

— Immobilize the pinion with the claw 0.21

and loosen the nut with a wrench 21. Reset the nut and the brake.

— Disengage the clutch assembly, primary channel and driven gear.

— Remove the washer bearing working crankshaft.

 REMOVAL OF ENGINE

OPENING ENGINE BLOCK

TOOLS
Burin - Key 8 * Tool 0.47 - 0.47 Tip D - Maillet.

Fig. 18

On right housing (Fig. 18):

— 2 fold the nut fixing the brake
support plate working crankshaft.
Loosen and remove the nuts (8
key). Reset brakes and the
backing plate.
— 5 loosen and remove the securing
nuts (not touching the fixing screws
of the bearing plate of the bearing
of the primary shaft).
Fig. 20

Fig. 19
and the endpiece 0.47 D. and if necessary one or two mallet
side silenbloc, (to avoid damage to the joint faces, not to
introduce tool elsewhere than three clearances provided for
this purpose). Pull well in line with both hands to disconnect
the crankcases
(Fig- 20).

Off the two half-casings with the aid of 0.47 tool (Fig. 19)

10
 REMOVAL OF ENGINE

TOOLS
STRIPPING THE HOUSING LAW Burin - Key 8

— Remove the sliding gear (Fig. 18).

— Fold the brakes of two fixing screws of the bearing support plate.
— Loosen and remove the two screws (key 8) brakes and the bearing support plate which immobilize the axes of fork and of intermediate
pinions (attention to share in foil thrust washers and other of the intermediate wheels) .
— Remove the shaft and all the intermediate gears.
— Remove the axis of the fork and fork.
— Using a mallet, the drive input shaft.
— Unscrew the nut securing the gear locking sector (8 key). Attention flat washer range and under the nut.
— Remove the sector, the finger and its latching spring and of the fork lever.

TOOLS
STRIPPING PAN LEFT Mallet

— Using a mallet, drive the gear box shaft (fig. 18).

— The assembly being released, release in order:

— the great thrust washer,
— the first gear,
— the centering ring of the pinion,
— the small thrust washer.
- Remove the outer gear output side, the spacer remains in place in the gasket.

TOOLS
EXTRACTION OF CRANKSHAFT
Tool 0.47 - 0.47 D

— Uncoupling the casings, the crankshaft remains in

place on the left case where it is press-fitted on the bearing. To
remove it, proceed as follows (Fig. 21):
— 0.47 Fit the tool by screwing on the two bosses of
the stator holder 2 with screw H5.I5. Use the tip 0.47.D.
— Screw until complete extraction of the crankshaft.

— Clean sealing faces of the casings of the right

cover, the positioning pins and rubber mounts and their
location.

IMPORTANT : For extracting ball bearings, refer to

the instructions on pages 12, 13 and 14.
This operation will be done only if absolutely
necessary and with all the recommended tools.
Fig. 21

he
 REMOVAL OF ENGINE
EXTRACTION
BEARINGS
ON HOUSING LAW

crankshaft bearing:
place in the tool 0.14 A (fig. 22) 0.14 C guide (diam.
20 mm). Heat 80 to 100 ° and place the gearbox side
crankcase facing the tool engaging the crankshaft
bearing on the guide.

Expel the seal assembly and bearing using

the tool 0.77 B using the small diameter side.

primary shaft bearing : Same operation

in the previous paragraph but use the big side of the
hunt 0.77 B.

EXTRACTION OF BEARING ON CARTER

LEFT

Crankshaft bearing : As for the right case, use the tool 0.14 0.14 A and C. Guide

Remove stop Paulstra seal.

Heating (80 to 100 °) and place the housing (flywheel side facing the tool) by engaging the bearing of the crankshaft on the guide.

Hunt all seals and bearing using the tool 0.77 B using the large side.

If, during operation, you experience excessive resistance, check if a spacer washer has not slipped into the groove of the seal stop.

ROLLING OUT THE GEAR:

This bearing is not pushed very hard, simply heat the pan as PREVIOUS ously and drive turnover hitting a few small strokes with a
hunting what conch.

12
 WINDING MOTOR

0.77 B FITTING THE BEARING AND SEALS IN THE LEFT

H II
§11 j

COVER

0.77B

77F

Bearing (fig. 23) and

joints (fig. 24) of the
crankshaft 0.62
Using 0.62 A tool that is placed in the ring D and 0.62
'order, HAS
Fig. 24
centering 0.77 A.
Placed on this assembly, the
preheated casing (80 to 100 °) the
chamber flying facing downwards.
— Install seal guide 0.77 F on the housing.
0.76 — Tallow gasket, insert it into the guide, the seal spring directed towards the
interior of the housing. The push using the tool 0.77 B. Do not exaggerate, so
B as not to deform the joint.
— Remove guide 0.77 F and put the foil in support washer.
— Lubricate the bearing, the place and hunt in the housing with the tool 0.77
B.
— Put the corrugated lubricating washer.

.0.76 C —
—
To the second joint as the first.
The bearing assembly attached slidable as the casing is hot, remove
carefully vertically and the casing of the guide.
— Place the stop ring.

Bearing and seal of the output pinion

(Fig. 25)

— Place the preheated casing on 0.76 A tool room flying upwardly facing.
— Place gasket 0.76 C. Guide
— Tallow gasket, insert it into the guide, the lip facing upwards and push the
tool with 0.76 B.
— Remove guide 0.76 C, grease and place the bearing which is hound to
the same manner as the seal. Do not exaggerate not to deform the joint.
 REASSEMBLY OF THE MOTOR

Bearing (fig. 27) and crankshaft seal (fig. 26).

— As the left case, use the tool provided with the 0.62 A 0.62 D 0.77 washer and guide A.

— Heating the casing (80 to 100 =) the place on the tool room flying batch down.
— Place gasket guide 0.77 D on the casing.
- For correct positioning of the seal in the housing we recommend using an existing joint centering ring in the crankshaft
cyclo 2 speeds available through our Parts Service as No. 34544.

- Place 34544 ring in the joint, the tallow, put it in the guide and the drive 0.77 D using the tool 0.77 B.

- Remove the guide 0.77 D and 34544 ring, place the lubricated bearing and the drive as the seal.

primary shaft bearing.

— Placing the heated casing, the chamber flying facing upward, on the tool 0.62 A equipped as above of 0.62 D and
0.77 tools A.

— Place the bearing and the drive with the tool 0.77 B.

14
 WINDING MOTOR
TOOLS
Key 17 - key 8
special tool (voir'page 9, fig. 16)

Fig. 28
PREPARING THE HOUSING LAW
(To reassemble the engine)

— Place the crankshaft by engaging the spline side in the bearing (fig. 28).

— temporarily mounting side clutch: the thrust washer and the clutch holder; screw block and the support fixing screws
by immobilizing the latter by using the special tool (fig. 16. page 9). Leave the device in place until mating housings
(17 key).

— Place the fork of the lever.

— Grease and put into their housing the spring and speeds sector of the locking finger.

— Lubricate the notches then mount and secure the locking sector - washer and lock washer as the nut (8 key).

— Put in place in its bearing primary shaft.

- Take in hand the process of intermediate gears.

 WINDING MOTOR
PREPARATION OF LAW CARTER (Continued)

— Directing the small gear upwardly and engage the y axis, oriented retaining notch forward.
— Once committed axis, placing the foil in bearing washer (large sprocket side).

— Put together, axis and intermediate wheels, in place (the player in the fork and the shaft in its housing).
Placing the player of the gear box shaft on the fork, small jaw facing downward (side primary shaft).
Engage in the housing the shift rail from the side where the retaining notch is located.

Fig. 29

— Return the casing carefully, properly orient the axes of fork and of intermediate pinions and mount the support plate working
so that it engages the notches of fork shafts and idler gears.
— To the screw-locking and screw block and bind the brakes (8 key).

— Establish the gear box shaft in the sliding gear by engaging with the smooth side and place it in order:
— the small thrust washer
— the centering ring of the first pinion
— the first pinion
— the great thrust washer.
— Put the thrust washer by clicking on the axis of intermediate gears (Fig. 29).

COUPLING HOUSING
TOOLS
0.95 tool - Tool 0.47
— Thoroughly clean the sealing surfaces of the two case halves, coat of hermetic.

— To the gasket on the left housing.

— 0.95 mounting the tool on the crankshaft to prevent the deterioration of Paulstra flywheel side seals (fig. 30 page below
against).

16
 WINDING MOTOR
- Couple partially hand housings, check
parallelism.

Fig. 31
— Using all tools 0.47, 0.78 B and 0.47 D mounted on the left
casing, bringing the gasket into contact planes. Ensure that they
remain parallel when the mounting pads engage (fig. 31).

— Screw nuts 5, tighten progressively starting from the central

nut.

— Remove the 0.95 tool.

ASSEMBLY OF THE CLUTCH ASSEMBLY Clutch locking tool - key 17 - Claw 0.21 - key 21 - Press 0.7 - Key 7.
GEAR RECEIVER

TOOLS

— Remove the clutch holder and bearing washer provisionally mounted.

— To the bearing support plate, the screw-locking, screws and block cast off the screw-locking, and then install the support
washer.

— Try locking gears and put the box in two. "

— Assemble the clutch and pinion receiver chain, placing the assembly on the crank shafts and input shaft.
Warning ! ensure that the bearing supporting ring is seated on the crankshaft behind the clutch holder.

- The clutch holder, placing the brake screw, and the screw block (key 17 of tube) by immobilizing the clutch using the special
tool Fold the screw lock (Fig. 32).

17
 WINDING MOTOR
ASSEMBLY OF THE CLUTCH ASSEMBLY GEAR - The counter driven gear, turn the nut retainer and
RECEIVER (Continued)
the nut. Immobilize the pinion with 0.21 claw
lock nut (tube key 21). Fold the nut retainer
(Fig. 33).

— On the clutch carrier, placing the spring, the plate, compressing

the assembly using the release 0.7 (fig. 34).

— Put the nut 3 brakes, nuts 3, the block (7-key). Removing the
tool 0.7 and the cast nut brakes.

ASSEMBLY OUTPUT GEAR

TOOLS : 17 Key - Claw 0.21

- On the axis of the output gear, introducing the spacer, placing the output gear, the nut retainer and the nut, and screw block
(17 key) immobilizing all with 0.21 claw placed on the driven gear. Fold the nut retainer (Fig. 14 page 8).

ASSEMBLY COVER RIGHT

TOOLS : Screwdriver

— Clean sealing faces the right housing and lid, coat of her- metic and implement the joint.

— Put the lid on the housing and introduce the 2 large share fastening screw and the other of the release lever, then the
four short screws. Visser and progressively block the 6 screws. Clean excess hermetic.

18
 WINDING MOTOR
PISTON ASSEMBLY

TOOLS

Centering 0.93 - Tool 0.12 - Clamp 0.4

— Before reinstalling the segments (Fig. 35), it is essential to

clean without distorting the grooves of the piston. Use for this,
a segment piece. Check end gap segments that should be of
3/10 mm max. For that introduce the segments in the cylinder
and control the game using a gauge.

— Cleaned, if required, the grooves of the retaining ring for

stopping the piston axis.

— Engage the piston pin of the piston until it is flush with the
inner boss.

— Soak the needle cage in the light oil and place it in the
connecting rod.

Gripper for disassembly and remontagedes

Present the piston on the connecting rod, la'lettre cue directed
piston segments
towards the front of the engine (exhaust side). Engage the
special centering 0.93 to it passes through the needle bearing
and will center on the axis of partially assembled piston ..

0.12
IMPORTANT
This special centering 0.93 is needed to
correctly perform this operation.

— 0.12 Fit the tool provided with the endpiece 0 along

II. 62 and screw to engage the axis 3/4 of its travel
(Fig. 36).

— Then remove the 0.93 centering and implement a

snap rings.

— Push the shaft until it stops on the first snap ring.

— Removing the tool and 0.12 to the second

retaining ring (clamp 04).

— Ensure that the retaining rings are in the

grooves.

19
 WINDING MOTOR
CYLINDER REASSEMBLY TOOLS: Wood block

— To facilitate this operation (Fig. 38), we

recommend performing a wooden wedge
conforms to that of Figure 37.
— Clean the joint plane (pan gasket which
overflows).
— Place the dry seal.

— To the piston pressing the wood block

described above.
— Guide segments of the slots in the face of the
pins positioned in the grooves.

— Engage the cylinder upright; no need to hit the cylinder must come down by hand because the chamfer at the base of the
cylinder closes segments.
— Remove the wooden block and push the cylinder bottom.

ASSEMBLY OF DECOMPRESSION
TOOLS
0.52 Tool - 19 tube wrench

Warning ! the sealing of the valve has a large influence on the engine
operation. Examine the seat and valve before reassembly. If necessary, lap
the valve to the seat with emery hotpot very thin, with 0.52 the tool (Fig. 39).
After lapping, if the valve has any fault, do not hesitate to change it.
— Make sure the copper seal remained in place.

— Screw and strongly block the body of the pressure on the cylinder head
(19 tube key).
— Insert the valve in the body of the pressure.

— Fit the spring.

— Put the pin and crush the end (must be done carefully because in case
of loss of the pin, the valve fall into the cylinder, where the risk of
accidents and engine damage).

20
 WINDING MOTOR
ASSEMBLY OF THE HEAD TOOLS
Tube 12 key

— Place the dry seal. Attention to the orientation, the hole provided on the cylinder for the evacuation of gas decompressor
must match that of the seal.
— Place the cylinder oriented with the same precautions as the seal.
— Place the engine hangers directing them back, put spring washers and nuts that are screwed and blocked staggered
(tube key 12).

ASSEMBLY OF MAGNETIC WHEEL TOOLS

Screwdriver
— Clean the cone of the crankshaft.

Fig. 40
— Present and replace the stator on the crankcase rubber grommet sealing the wheel.

— Screw 2 of the stator fastening screw, a washer and a washer Blocfor flat head (do not pinch the lighting wire).
— Refit the rotor, screw without blocking the nut to stalling.

SETTING AND ADJUSTING THE STEERING WHEEL MAGNETIC

TOOLS
Dummy plug rT 0.24 - 0.21 Claw - key 18 - 0.92
Tool.

Must be done before putting in place the engine on the frame.

— 0.24 Screw tool into the cylinder through the plug hole and search the top dead center by rotating
the wheel (fig. 41); note on the slider position.
— Slowly rotate the wheel of a turn in the direction of travel, to bring the piston to 3 mm before the
top dead center. Check its position on the scale.
— Without moving the piston to rotate the rotor to bring the pins of the rotor and the stator facing
(fig. 42, page 22).
— Lock rotor in this position with the claw 0.21 and 0.92 of the special tool (see page 6 use).

WARNING : To lock the rotor with 0.92 tool, take the following precautions:
- Screw bolt and loosen a half turn before tightening the nut against.

21
 REASSEMBLY OF THE MOTOR
- Set the breaker:
TOOLS : Screwdriver

To pins of the rotor and the stator facing it, unlock the
breaker (Fig. 42).

Acting with a screwdriver inserted into the setting

screens for the contacts of the breaker start to take off in this
position. Then relock the bracket screw contacts (Fig. 43).

Very important : When the timing is correct the

maximum opening of the contact grains is about 4/10.

However this opening can vary conveniently from 3 to

5/10.

Never adjust the spacing of the contact breaker points to

a specific rating, the running of the steering wheel does not
depend on the distance but the precise opening contacts
breakout point indicated by the concordance of the rotor
bearings and the stator.

REASSEMBLY ENGINE ON THE FRAME

— Place the carburetor on the engine without tightening the
collar.

— Screw the plug, plug wire to spark plug, fix the wheel
cover and check if all organs are in place on the engine.

Fig. 44

- Ensure that the gearbox is locked in position 2 'and the control handle to the handlebar for adjusting.
- Suspend the motor on the frame by the front bolt (G) (Fig. 44) (insert the bolt through the left side). Putting a flat washer,
lock washer and nut, not to block.

22
 WINDING MOTOR
CONNECTING THE CONTROLS TOOLS
Key 6 - key 14 - key 8 - key 12 Screwdriver - key 0.74
— Disengagement (key 6).
— Change speeds by fixing the cables previously spotted on the
sector (key 8) does not shake for the setting.
— Carburetor handing bushel and the air damper and the two
screws from the star washers chamber cover under the
screw heads on J.14 on GA 14 cable hook the grain (see
page 3), s' ensure the functioning of the air flap.
— Switch and bringing the rear mounting bosses of the motor in
the pocket of the frame.
— Engage between the gusset plate and the bosses of the
casing, the left spacer, partially insert the screw through the
left side (Blocfor and flat washers under the heads).
— Engage the second right spacer between the gusset plate
and the bosses of the motor, drive the screws, a square cage
nuts, screw and block the two screws (key 14) (H fig. 44).
— Block before the pin (key 14) (G Fig. 44).
— Block plumb carburetor (8 key).
— Connect the fuel hose to the carburetor.
— Connect the decompressor controller (key 6). Leave a small
gap to the controller. Fig. 45
— Connect the illumination lead.
— Two fittings placed near the engine allow quick connection
of lighting son.

screw rear
mounting bolt in the
case of the Sport
model and key 8 for
Tourist model). Up
the drive chain and
reput the clip taking
counted orientation.
Carry out the
adjustment of the
chain tension.
— Double wire connection provides the flywheel - headlight switch input (wire identified by a raised line) and the connecting
switch output - red light.
— Replace the entire pipe and muffler, careful not to forget the gasket into the cylinder exhaust manifold (0.74 key to the nut
and key 12

TOOLS
flat pliers - Key 8
SETTING THE CHANGE OF CONTROL
SPEED
— Put on cydo crutch.
— Carefully screw on the two tensioners A and B (Fig. 47).
— Put the mark on the shift knob of opposite velocities of figure 2 (2 'speed).
— Make sure the lock industry is locked in position 2 (see sketch).
— Pull on a wire with a clamp so that the sleeve is held firmly on the sleeve
stop; then re-lock the cable clamp nut (8 key).
— Perform the same operations on the other cable.
— Make sure the latch engages well in the slot 2 of the sector need to act on
the turnbuckles, although re-lock the nuts against these tensioners.
— After this adjustment, made maneuver the handlebar grip by rotating the rear
wheel for successively latching the speed and neutral by ensuring that in
each position the latch engages well in the corresponding cells.

Fig. 47
 DESCRIPTION CARBURETOR

Carburettor Type GURTNER J. 14, center tank and

settling tank - air valve with automatic return - nozzle 64, passage
14, 522. Adjustment (Fig. 48).

Carburetor GURTNER GA type. 14, to

central tank, setting 580 nozzle 62. (Fig. 49).

SETTING
TOOLS : Screwdriver

The carburetor is adjusted at the factory, only one can be

modified idle adjustment.
This setting is important, it keeps the engine running while
the vehicle is stopped.
The adjustment is made hot engine air flap open, with the
screw on the left side of the carburetor (this screw is accessible
through a hole in the left cowling).
1 Tighten the set screw.

2. Turn on the motor (crutch on vehicle)

then put the gearbox in neutral.
3. With the engine warm, slowly unscrew
the adjusting screw so as to reduce as much as
possible the engine speed, the engine does not
stall.
If the engine stalls diet is too low.

REMOVAL
TOOLS : Screwdriver

To disassemble the air filter, remove the

rubber sleeve, unscrew the screws and pull the
filter cartridge into the axis of the carburetor.
On GA carburetor. The nozzle 14 is located
at the bottom of the tank on the right side of the
carburettor, can be unscrewed with a screwdriver.
The fuel filter is located on the right side of
the carburetor when reassembling the cover, pay
attention to the proper centering of the seal in its
housing. Filter cleaning is done with pure
gasoline.

24
 REMOVAL CHASSIS

REMOVING THE TELESCOPIC FORK

TOOLS
Key 14 - key 8

— Unclip power brake front and

counter.

— Unscrew and remove the front

wheel (key 14).

— Unscrew the two nuts cap

located on the upper plate of the
fork (key 14) flat washer under
the nut.

— Out the lower assembly of the

fork.

— To exit the springs, by

unscrewing the lower rod and
remove the entire rod and
spring. Attention to the flat
washer and rubber grommet
(39787 fork - fig. 50).

— To exit the springs unscrew (key

8) the fastening bolts mudguard
stays on the fork and pull the
entire paw and spring rod
(37017 fork - fig. 51).

WINDING TELESCOPIC FORK

- Make the reverse operations of disassembly.

NOTE
Before reassembling the lower tubes, coated bearing grease
copiously the sliding tubes and the fork springs.

25
 REMOVAL CHASSIS

REMOVING THE REAR SUSPENSION AND PEDAL

TOOLS

— Remove cowlings left and right. pliers. Screwdriver. ac 8-I0-I7-I4-I2

Key Q ER9
— Unfasten the chains and the rear brake control. ° * Mallle 'ac 0-7't'
— Remove the rear wheel.
— Reset the chain guard (keys 8 and 14).
— Déclaveter and remove the left crank (key 10 -Fig. 53).
— Out of the bottom bracket tube the spacer (or the) shims.
- • Remove the bottom bracket with the right crank up (be careful not to lose the washer against the crown of the crankset).
— Loosen and remove the nut against the notched right side tube axis of the frame.
— Removing the spacer washer.
— Unscrew and remove the nut notched.
— Remove the thrust washer.
— Loosen and remove mounting bolts lower dampers (key 17) flat washer under the head of each bolt (fig. 52).
— Unscrew the notched nut of the muffler on the cylinder (0.74 key).
— Loosen and remove the two bolts of the clamp of the hinge axis of the fork (key 12).
— Remove the support (on Sport model) and the muffler.
— Remove the tube axis by means of a mallet.
— Attention to two spacer washers located between the fork and frame on either side of the frame.

NOTE : The dampers are not removable and require no maintenance.

26
 ASSEMBLY CHASSIS

REFITTING THE REAR

SUSPENSION AND PEDAL

— Introduce the fork on the

frame, placed between the
fork and frame on either side
of the frame, the spacing
washers (corrugated
washers)
(Fig. 52-53).
— For the left side of the frame,
insert the tube axis. If
necessary hit a few flicks of
plastic mallet.
— On the tube axis right side,
placing a washer and screw
the nut notched by eliminating
the lateral play.
— Secure the isolators
on the fork (key 17) flat
washer under the screw head.
— Fit the support (on Sport
model) and the muffler.
Introducing the two bolts of
the clamp of the hinge pin
(heads up) washers and
spring washers under the nut.
And screw block (12 key).
— Screw and lock nut notched
muffler (0.74 key).
— On the tube axis, placing a
washer (not notched thin washer).
— Screw block and against the nut (lug wrench).
— Refit the pedal in the following order (Fig. 53):
— Put the thrust washer on the bottom bracket axle, against the crown.
— Grease and introducing the crank axis in the tube axis.
— Square (or) adjusting washer, then the spacer tube.
— Place the left and pin-crank. Attention guide the key in the opposite direction to that of the right crank (10 key).
— Refit the chain guard (keys 8 and 14).
— Reinstall the rear wheel and put the strings (note the direction of quick couplers).
- Staple brake control, back rollovers.

ADJUSTING THE TENSION

CHAIN DRIVE
TOOLS
Key 19 - Key 10

— Loosen the two axle nuts (5) (fig. 54).

— The nuts of two tensioners (4) of a same number of turns for each
of them until the chain is stretched, not to exaggerate, the wheel
must rotate freely irrespective of the position of the rear fork, for
pendulum suspension vehicles. Block axes nuts (5), then the
tensioning nuts (4).

TT
 PRACTICAL TIPS TROUBLESHOOTING

ENGINE DOES NOT START (cold or hot)

causes defects remedies

No ignition or misfire.

Fouled spark plug or short circuit, spark inside.

Catch the breaker does not open, broken or Mounting a clean spark plug.
worn heel.
Change the latch.
The breaker remains constantly open, catch
seized on the axis.
Disassemble and unjam the axis with emery
cloth very fine. Go to the graphite oil. No
excess may clog the contact.
Defective ignition coil, low or slammed. Check and replace.
primary circuit to ground.
Ensure that a chip or a metal foam is not
bonded to the spring latch or the wire
connecting the coil of the breaker to the
capacitor.
Change him.
Capacitor to ground or damaged.

The essence does not

happen regularly and
carburetor jet. Tip blocked.
Filter the fuel tap or clogged carburetor.
air hole of obstructed tank cap. Check and clean if necessary.
Nozzle clogged.

4) Unclogging air jet or with a tire pump.

Gasoline comes fine but cold Check and adjust the idle speed (see page 24).
starts are difficult. Check the tightness of the intake pipe on the
Slow set incorrectly. cylinder, check the tightness of the
carburetor on the pipe.
additional air intake. Ensure that the needle closes well or cleaning.
Arrival of too much gasoline, Change him.
the engine floods.

The needle remains stuck and firmer. ONMENT ROAD

ENGINE PiThe float is punctured.

GOOD ART IS ILLEGAL BUT Functi

causes defects remedies

Irregular spark when you

too hot candle made autoignition or fouled
push the engine. spark plug (hot spot).
defective capacitor (back to the carburettor).

Early seizure breaker.

Mounting a colder spark plug or clean, or
change (used spark plug)
Check his hot operation.
defective isolation; possibly change the
capacitor
Disassemble and unjam with emery cloth very
fine; back to the graphite oil.
No excess may clog the contact.
Start difficulties with lit
lighthouse. On the road,
missed when lit lighting.

Steering deregulated, opening contacts no Retuning (see page 21).

longer benchmarks.
Worn contacts. Too spacing. Decrease the catch heel and edit contacts or,
preferably, change the switch.
Candle worn, fouled electrodes. Clean or replace the spark plug if necessary.
Contact dirty (too high contact resistance). Clean with a special lime
demagnetized steering (electric power
weakened). Make remagnetize by a specialist.

28
 PRACTICAL TIPS TROUBLESHOOTING

ENGINE PART BUT WELL OPERATIONS ROAD

IS ILLEGAL (Continued)
causes defects remedies

proper functioning 1) insufficient

of gasoline Arrival, filter tap or clogged
t) Check flow tap (1 liter in 5 min.). Check the flow
medium-speed engine but carburetor in part. of the carburetor.
collapses when
pushes the motor 2) Low Ignition coil. 2) Check and change.
full speed. 3) Leakage to the seals of the crankshaft. 3) additional air intake. Check. Repeat the seals if
necessary.

4) Air filter contaminated. 4) clean.

S} air damper partially obstructing the air flow.
5) Check the control of the air flap.

The engine lacks power.1) cylinder and piston abnormally worn.

I) Check and change the piston and the cylinder.

(The hard chromium on aluminum cylinder is
not boring cylinders).
2) of the piston segments glued in the grooves.
2) descaling carefully gorges. The segments
should be free. Do not damage the grooves.

3) Segments "slumped" leaky cylinder 3) Replace the segments and the cylinder head
head
gasket. gasket.
4) worn Segments, set to cut too much. The 4) To check this game out with care
segment is in the cylinder, the end gap must segment and introduced into the
not exceed 3/10 mm. cylinder. Replace the segments if
necessary.

5) One or more split segments. 5) Check the state of the piston and the cylinder
and replace the segments. Beware of debris
flying possible in the room.

6) Repeat the calibration (see page 21).

6) up firmly Steering (lack of advance).

7) Carburetor adjustment. 7) Check if the plug emerges well the emulsion
chamber otherwise adjust the flexible
control.

1) be
The lack of power may Faulty spark plug.
1) Clean or replace the plug.
occasioned
also by 5ionnè
ignition disorders. 2) Leakage to the capacitor mainly hot. 2) Replace the capacitor.

3) Ignition coil defective early breakdown. 3) Check and replace the spool.

4) Steering demagnetized, in this case there4)isMake

a remagnetize by a specialist.
weakening of your light.

Starting the engine 1) Nozzle too strong. !) Replace the nozzle.

so-called 4-stroke.
2) Lack of air (clogged filter). 2) Clean the air filter.

3) air control overtightened. 3) expanding the air control.

4) Excess oil in gasoline. 4) Empty the tank and fill with proper mixing.
Remind the customer the percentage shown
in the maintenance manual.
 PRACTICAL TIPS TROUBLESHOOTING

CLUTCH SHOOTING
causes defects remedies

The clutch slips. 1) worn Ferodo discs. 1) replace.

2) limp spring. 2) Replace.
3) Command too tense. 3) Repeat the command setting.

4) The door-stop plate gets stuck

4) Check alignment lugs of the plate and tightening

the nuts.
5) clutch cam hard in its housing. 5) Alibrer and grease.

Drain and make the level with the

The clutch causes cold. too thick oil.
recommended oil.

DEFECTS OF TRANSMISSION
causes defects remedies

The speeds are dropping on. 1) Control of adjustment. 1) Retuning (see page 23)
2) notched Sector deteriorated handle. 2) Change the sector.

3) The lock stop is not working. 3) Check the status and change it if necessary.
Lubricate carefully reassemble.

4) worn lock Sector. change.

Passage of hard speeds. 1) Lock Off does not work.

1) Check its status and change it if necessary.
Lubricate carefully reassemble.

2) handle or control seized. 2) Remove and lubricate.

3) Circuit faulty command. 3) Eliminate too accentuated elbows.

4) Clutch pedal adjustment. 4) Retuning.

30
 TOOLS

Mounting bearings and crankshaft Mounting bearing and output

jointsPaulstra jointPignon

076B
0.77 D Extraction of
bearings

.0.76 C

Gold

.076A

0.77 D - O Guide Paulstra Clutch side

A 0.62 - 0.62 Guide D - ring thickness
0.76 A - Centering
0.77 A - centering washer. 0.77 B - 0.76 B - Hunting

Hunting 0.76 C - O Guide Paulstra

0.77 F - PaulstraCôté wheel attached 0.14 A - Support Guide
Guide
0.14 C - Travel Guide, diameter 20 mm

Dismantling of the crankshaft

0.47

.0.47
0.95 - flywheel side mounting socket. D

0.4 - circlip pliers for piston pin.

0.47 - 0.47 D Base -

Tip
 TOOLS

Mounting the crankshaft

0.47 - Base
0.78 A - Nut
0.78 B - Vis (nozzle 10, no 100).

0.92 - OBERU wrench for removing

the nut flywheel.

0.52 - Tool for valve grinding

32
 TOOLS

0.7 - Tool for the contraction of the clutch spring.

0.12 - Tool with end caps for mounting and assembly of the piston pin.
 TIPS
ORDERING SPARE PARTS

— So that your orders are carried out quickly and without risk of error, they must
be submitted in a clear and precise.
1. Use to the exclusion of any other paper money saving Special Order.
2. Specify the serial number of the part.
3 indicate in all cases the number of the same engine in the case of parts of
the part cycle.
4. For engine accessories such as carburetors and flywheel, do not forget to
indicate the brand and type.

— This information allows us to correct our récemments possibly some change and
avoid a match that makes you lose time.

— Return parts : All returned item must be accompanied by a letter telling us:
— The nature of the piece.
— The purpose of this return.
— We can indeed receive the parts:
1. For implementation of the guarantee.
2. To repair.
3. As a model for providing consistent new parts.
4. As non-compliant, etc ...

— No credit can be done without the two numbers of the corresponding flow is
indicated on the application.

— Standard exchange : Avoid the immobilization of the client machine by letting it

run for you request the exchange engine, taking care to tell us:
The number of the engine to be replaced.

— Upon receipt of the new engine will we return the used.

— Respecting these recommendations, your relationships with our spare parts

service will be improved.
You'll satisfaction expeditiously following the accuracy of your desires.

34
S3JLON
S3J.ON
"OQ)

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