Allstate 788.94370 Use and care manual

OPERATING INSTRUCTIONS
AND PARTS LIST FOR
OT
SC OTE
MODEL NUMBER 788.94370
This is the Model Number of your Allstate Motor Scooter. It will be
found on a plate fastened to the chassis under the fuel cock. Always
mention this number when communicating with us regarding the
Scooter, or when ordering repair parts.
HOW TO ORDER REPAIR PARTS
All parts listed herein may be ordered through any Sears retail or
mail order store. In ordering parts by mail from the mail order
store which serves the territory in which you live, Selling Prices
will be furnished on request or parts will be shipped at
prevailing prices and you will be billed accordingly.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
1. The Part Number in this List.
2.
The Part Name in this List.
3.
The Model Number of the item.
This list is valuable. It will assure your being able to obtain proper
parts selvice at all times. We suggest you keep it with other
valuable papers.
ScootelWorks USA Inc.
5709
N. Ravenswood
Chicago, IL 60660
ph: 773.271.4242
fx: 773.271.5012
EARS, EB cA O.

gs to
19ine
ss of
lders
rpm
wi h
ance
",ind,
scoo-
nor-
f be
Fig. 1 • Sun Motor Scooter
WARNING
,-----------.'
-'-
Fig. 2 . location of .erial number
Serial numbers are preceded by prefixes:
VMA 1 T, for frame; VMA 1M, for engine.
~ on
nbed
gear
seful
that
;ome
from
lrbu-
)wn-
use
stion
form
in
e in
et or
he
he
and
)ion
en-
order to keep your scooter in perfect running condi-
on and not to void the guarantee, always have your
achine repaired at a Seras, Roebuck and Co. Store.
pecial care should be taken with regard to the fuel
ixture which should be regular gasoline and oil of
e make, grade and in the amount prescribed in this
ooklet.
Ethyl" gasoline should never be used.
Do not use Allstate compounded motor oil or other
Praemium Heavy Duty Oil with detergents.
The inexperienced operator should exercise caution in
applying front wheel brake, to avoid locking.
Fig. 3 - Control. of Sean
Scoot..r
1. Gear chanC)<' two >tg"p with
clutch control leve' . 2. Front
brake lever . J. Throttle con·
trol grip - ~. L'Qht and dim-
mer switch .S. Front brake
jaws. - 6. Reor bra'e pedal -
7. Kic starter - •. Gear selec-
tor - 9. Reer brake jews.
10. Clutch. 11. Carburetor,
air cleaner. 12. Storter push
pull rod -13_ fuel cock. - 14.
Knob for locking tilting sad-
dle - 1 S. Lever for removing
engine flap.
-3-

. --_.-.
-'-'-'"
,
r----
I
/
\.
;'
----?....,P'""
.---_.
Fig. 4 - Engin. installation and IUlp.olio"
1. Steering column and front suspension· 2. Engine· 3. Crankcase half. clutch side. with swinging arm . 4. Rear suspension spring with hy.
draulic damper .. 5. Screw securing carburettor . 6. Bolt securing rear damper. 7. Bolt securing engine.
MAIN SPECIFICATIONS
Frame. - Of pressed and spot-welded steel sheet, with
stream - lined monocoque - type structure.
Suspension. Both front and rea r wheels: coil spring and
hydraulic shock absorber .
Engine. -Two -
stroke, flat cast iron cylinder and cast
aluminium alloy cylinder head. Cooling effected by cen-
rifugal fan which is embodied in the flywheel of the
magneto.
Displacemen 121.17 cc. (7.39 cu .in )
Bore
55 mm. (2.16 in.)
Stroke 51 mm. (2.01 in.)
Effective power at 4500 rpm 4.8 HP
Compression ratio 7,2
Transmission. -Directly from engine to rear wheel through
clutch, cushion drive and gear box.
Starting. - By means of kickstarter, right hand side of
scooter.
Gear box. - 4 - speed drive with mesh gears in oil bath.
I s two - cable control is coupled with that of the clutch,
Fill· 5 • IgnltJon di-vnm
1. H. T. coil. in flywheel
magneto • 2. Rotor cam
3. Breaker - 4. Condenser .
5. Sparkpulg . 6. Engine cut-
out on switch.
to 1
to 1
to 1
to 1
layshaft.
3
on left hand side of handlebars.
Engine to wheel transmission ratios:
First 14.74
Second 9.80
Third 7.06
Fourth 5.31
Clutch. - Wet type; multiplate, on the
Ignition. - By flywheel magneto.
118 miles per gal.
49.7 m.p.h.
45.7 in.
26.4 in.
65 in.
40 in.
8.9 in.
65 in.
160 Ibs.
Fuel
consumption:
(Gasoline -oil mixture)
Max. speed
Wheel base .
Max.
width on handlebars
Max. length of the scooter
Mu. height
Min. height of floorboard
Turning circle
Weight (unladen) :
-4-

F
,\
I
r
Lubrication. - By the oil in fuel
mixture for piston, cylinder, wrist
pin, can. rod, crankshaft, main bea-
ring flywheel side. The clutch,
the main bearing clutch - side and
gear box operate in oil bath.
Carburettor. - With float - chamber
(see fig. 11). Air goes to the car-
burettor through a large silencing
chamber with filter (air cleaner).
Model .af carburet or: Dell'Orto
SHB 16/16 - Venturi 16 mm. (0."
630) - Main jet 74/100 (0."0291 )
Idler jet 42/100 <0".0163) - Air
vent for main jet 140/100 (0."
0550) - Mixer 175/100 (0."069) -
Air vent to idler jet 130/100
(0."051) Starter jet 50/100
(0."0197).
Feeding. -Fuel feed to the ca rbu-
rettor is provided for by gravity
(see fig. 11) with gasoline-oil
mixture.
~
Fuel·~nk. Total capaciy: 1.5 gals.; Reserve: 1/4 gal.;
Three - way cock: "open" -« closed" -« reserve ".
Muffier. - Expansion and absorption combined type.
H .. ndleb .. rs. - Pressure die cast in light alloy and designed
so as to house both headlamp and speedometer. All the
control cables and electrical wires to this group are con-
cealed therein. (See fig. 3).
Steering column. - The steering column bears the hand-
lebars, clamped on its top end, and the front wheel
swinging hub, pivoted at its bottom end through a stub
axle.
Lighting and horn. - By flywheel magneto, feeding both
head lamp (two - beam), tail lamp, horn and stop light
(see fig. 8).
Brakes. - Expanding type .
Front
brake: control lever on right hand side of handle-
bars.
Rear brake: control pedal on right hand side of floor-
board. The rear brake jaws are hinged on independent
pivots.
Wheels. - Of pressed steel sheet, intechangeable and
easily removable, since they are assembled in an auto-
mobile -like system.
Tires: dia. 3.50 x lOin.
Steering Lock. - A suitable security lock is arranged on
the frame, near the handlebars.
Turn the handlebars to the left, then rotate the key and
push inwards, so that it thrusts the sliding bar against the
steering column. To ease the insertion of the sliding bar
into the hole of the steering column, slightly turn the
fig. 6 . s.rtion of engine
1. Air cleaner and carburettor - 2. Piston . J. Crankshaft - ~. Clueth
S. Mainshaft . 6. Gear shifter . 7. Flywheel magneto a. Kickstarter
9. Crankcase half, clutch side, with swinging arm.
handlebars from the limit stop clockwise. When the hand-
lebars are locked the key will now spring back to its
original position and can then be withdrawn.
To release the handlebars, insert the key in the lock, turn
fig. 7 - S-.:urity lod,
1. Normal position. 2. Closed
Not. .The arrows indicate the operation to be carried out for locking
( J) and for unlocking (2).
-5-

_. __ .. _ r-" .• 0.1 __ "" ~ ........ , '-VIII lllC:: IICIIUICUd(~
in he normal position. The key can be extracted from
the lock even if the handlebars are free.
Do not lubricate he steering lock.
Central
Stand. - A two - legged stand is arranged un-
der the floorboard. A strong return spring holds it in
contact with the floorboard and keeps it from vibrating
while the scooter is being ridden.
Tool Kit. - 1 box wrench (11 -17 - 21 mm.); 2 single
open - ended wrench (/ -8 mm.); 1 screw - driver. These
hand tools are contained in aroll which is placed in
the tool box.
Speedometer. - The speedometer has its housing in
the middle of the handlebars and adds to the perfor-
mance and appearance of the scooter.
Accessories (See specific Table of« Parts List »). - On re-
quest the Sears scooter can be equipped with the spare
wheel and bracket, and rear pillion seat.
ELECTRIC WIRING DIAGRAM
Note -The installation diagram here carried out and the position of the various units correspond to those which
are really mounted on the vehicle.
Going into details (see figure), there is to notice:
front side: headlamp, main switch and horn units.
in the middle, bottom: the brake pedal joined with the Stop - switch; fur hermore the L. T. socket, the
sparking plug, the flywheel magneto.
rear side: tail lamp provided with two bulbs.
A)
8LACX
Fig. 8 • S<:heme of Electric Wiring
A) Installation diagram . B) Electric scheme
B)
Fig. 9 . light .nd dip switch
Switching lever positions:
o - lights off • 1 . Head lamp and tail on.
Other controls: HI: Engine cut· out - A: Lever for country and traffic
beam. - B: Horn button.
-6-

OPERATION
Fuel supply .. Fuel mixture,
both during and after run-
ning in, should be composed
of regular gasoline and pure
mineral oil SAE 30 at 2%,
i. e.:
- ~,~ pint of oil to 1 'l~ gal-
lons
of gasoline.
When using pre -
diluted or
additive oils, or oils for out-
board motors, mix 'l~ pint of
oil per gal.
Keep the
breather of filling
cap clean.
Oil
level. -Remove the level
screw, on crankcase,
marked
« OLIO» as indicated on Fig.
20, to check
oil level in gear
box before sta rting the en-
gine.
The scooter standing upright,
oil should just be about to
flow out; otherwise top up
with ALLSTATE REGULAR
S. A. E. 30.
Fig. 10 • F .. ding circuit
1. Fuel COC'( lever: A) Reserve. B) Open. C) Closed - 2. Throllie slide
set screw· J. Idling adjuster - 4. Idling iet - 5. Starter valve - 6. Air vent
for idling ie -7. Air cleaner - 8. Air vent for main jet - 9. Starter jel - 10.
Float - 11. Mai:1 jet - 12. Throllie slide - 13. Inlet port - 14. Transfer
ports . 15. Exhaust duct.
Fig. 11 - Oper.tiona to corry out for rtarting the engine
·1
~
.\
A: open the fuel cock. B: seleCI • neutral. - c: operate starter. push pull rod (with cold engine) 0: throllie centrol grip in idling
pNition - E: depr~.. the kickst.rter .nd turn grip cD. by short strokes.
-7-

Running. in. - Important rules to be followed while run-
ning - in (600 miles):
Do not insist by fully opening out the throttle.
Change oil in the gear box and check that nuts and
bolts are not slack after the first 600 miles.
Starting .. Open the fuel valve, put the gear box in
neutral and slightly open the throttle in slow running
position, kick the starting lever.
With cold engine, operate starter push pull rod. Push
said rod back as soon as the engine fires.
See Fig. 10; note the three positions of the fuel valve:
open, closed, reserve.
Clution. -Do not open throttle wide when releasing
clutch.
In case of starting troubles, due to engine being flooded
(unvaporized fuel mixture has reached the cylinder and
combustion becomes therefore very difficult), proceed
according to either one of the following methods:
a) Push - start the scooter: shift into second gear, de-
clutch and push the machine; quickly release the
clutch lever and pull it back as soon as the engine
starts.
b) Close the fuel cock, remove the spark plug and rotate
the engine by means of the kickstarter. Wipe the
plug dry and replace. Open the fuel cock and kick
the starting lever.
For access to the engine and remove the spuk. plug,
rotate the lever fig. 3 - n. 14, then take off the engine
flap.
Extract the spark. plug, using the box wrench.
Fig. 12 - Drive system
I. Gear change twistgrip . 2. Clutch control lever - 3. GeO' change
control cables - ... Gear shifter - S. Sele<tor group - 6. I H gear
7. 2nd gear - 8. 3rd gear· 9. 4th gear - 10. Cush gear. 11. Clutch _
12. Mainshaft - 13. Stirrup for gear change.
N. B. - Position I - 2 - 3 - <I of the gear change twistgrip correspond to
1
st, 2nd. 3rd and 4th gear respe<tively; <0> Indicates the
neutrlll position.
Repeat this procedure for changing into 3rd and 4tl
gear and for changing down.
See the drive system on Fig. 12.
l
S(
e
T
a
sc
Slow running adjustment. - No hand tool is requi red
this job. Pivot the seat forwards, remove the tool b
idling revs can be raised or reduced respec ively
Do not turn the gear change twistgrip while the engi'
is not running.
As soon as gear change troubles arise, particularly wh
the control becomes hard, customers should have th
machines adjusted by a Sears Store.
Setting the machine in motion .. Let the engine idle, de-
press the clutch and tum the gear change' twistgrip so
that the line engraved on it coincides with the figure
"1,, (1st gear) engraved on handlebars (see Fig. 12).
Now let in the clutch gently, while opening the throttle
gradually to set the machine in motion.
Gear change. - On attaining the required speed in 1st
gear, quickly close the throttle, release the clutch and turn
the gear change twistgrip so that the engraved line
coincides with figure" 2" (2nd gear); let in the clutch
and open the throttle.
When you reduce the speed of your machine,
down without delary to avoid irregular engine
and stalling at low revs.
chane
,uooi~ )
W,
wI-
on
wI-
To
rirr
Tire
17
ridc
tl-
-8-

simply tightening or slackening the adjuster screw .. A )}
fig. 13 (i. e., n. 2, Fig. 10). This screw controls the throttle
slide valve.
On the carburettor body is a spring - loaded screw (" C })
fig. 13, i. e., n. 3fig. 10) that controls the flow of car-
burettor air through the duct from the idling jet, and
consequently the idling revs. We recommend that custo-
mers refrain from re - setting this screw (and the set
screw" B ", fig. 13, provided for adjusting the throttle
cable play) unless absolutely necessary or during di-
smantling and re - asembling operations that should, any-
way, be entrusted to a Sea rs Store.
- 9 -
.\
Ii
( front) wh •• 1
Fig. '4 . Dismantling th.
I
ii' /
I~
;./ ----_._------
o
o
~.
When aflat tire is to be replaced, unscrew the five nuts
which secure the wheel to its flange, pull wheel sideways
off the studs (see Fig. 14 L repai rit or replace with spa re
wheel.
Tire pressure should be 22,5 7 23,5 psi on rear wheel,
17 .7 18 psi on front wheel. If the scooter is ordinarily
ridden by both driver and passenger, the pressure of
the rear tire should be 33 7 35,5 psi.
Fig. 13 - Acce.s to cilrburettor ~nd ilir d •• ner lillY_
To remove he tube, first deflate, then separate the wheel
rims by unscrewing the nuts which join them (see Fig. 15).
Tires. -The wheels are interchangeable, i. e., they can be
assembled either in front or rear, provided of course that
hey are inflated to pressures respectively hereunder pre-
scribed.
Stopping the engine. Select in " neutral )}, then push the
earthing button. This will leave the cylinder full of fuel
vapours, and the next start will be much easier.

Fig. 15 . Removing the inner tube
Brake adjustment. -Brakes are properly adjusted if:
the wheel rotates freely when respectively control le-
ver or pedal are in resting position;
the braking action starts as soon as respective con-
trols
are operated.
Fill. 16 -Brolce adjustment
These conditions are achieved adjusting the cables by
means of screws indicated with an arrow in Fig. 16.
Adjustment of clutch control. - Adjustment of clutch con-
trols
is achieved operating on adjusting nut (a), screwed
to the engine sti rrup (see Fig. 17).
The cable is to be tensioned or loosened, as the case may
be so that c'ontrol lever, on handlebars, makes a stroke
of 2mm. (0.078") before lever (b), on engine starts
moving.
Wrong play in the control may cause the clutch plates
burning out even in normal running conditions.
Fill· 17 • Adjustment of clutch contTol
a
MAINTENANCE
Cleaning the scooter. - Brushing kerosene and wiping dry
clean rags is advisable for external cleaning of engine.
All painted surfaces should be washed with water, rinsed
by means of a sponge and wiped dry with a chamois.
Do not use kerosene on such surfaces, since it damages
paint and turns it dull.
If necessary, blow the head lamp reflector clean or wipe
off dust with a very soft feather. Do not use acloth and
keep your fingers off reflector surfaces.
Before setting the mllchine in motion, (if it has been
delivered directly to the customer by the Factory) check
oil level in gear box by unscrewing the level screw mar-
ked « OLIO,. from the crankcase (see Fig. 20). The scoo-
ter standing upright, oil' should just be about to flow out.
After the first 600 miles. - Replace oil in the gear box
by the procedure as explained in the lubrication chart,
page 12. The crankcase can be drained through the hole
indicated in Fig. 20.
\.
I
-10-

Every 2.500 miles:
--
I
1) Check oil level in the gear box (see on pages 10-
12) .
2) - Grease all joints on the brake controls and the gear
shifter.
3) . Clean the sparkplug electrodes with very fine emery
cloth or suitable files, and adjust the gap to 0.6 mm.
(0.023" ).
Inspect the insulation material of sparkplug; re-
place the latter if the porcelain is cracked. Wash
with neat gasoline.
Use the sparkplug type Marelli CW 240 N; Bosch
W
240 T 1; Champion L 86; AC 42 F.
Important: using the proper type of sparkplug will
eliminate many engine troubles.
4) -Pivot the seat forwards, remove the tool box and
the choke control cable, then dismount the fuel
tap rod (fig. 13, D - E); next unscrew the wing - nuts
«F J) (fig. 13) and remove air cleaner. Extract the
filter, wash in gasoline and if possible air blast dry.
5) - Remove the rubber plug of front suspension and
refill ·with grease the concerning housing.
6) - Clean the lubricators on front wheel hub and refill
them by means of a grease gun.
N. B. -All operations indicated hereunder should
be carried out by aSEARS store.
7) - Lubricate the speedometer drive pinion and flex
drive.
8) - Decarbonize the engine as explained hereunder.
Remove the carburettor (screw n. 5, fig. 4), the
rear wheel, the muffler, release the rear damper
unit (n. 6, fig. 4). then rotate the engine downwards:
remove the cooling hood, the cylinder head and
the cylinder (see Fig. 18). Decarbonize the piston
crown and the cylinder ports from all carbon de-
posits. Decarbonize the inner side of the cylinder
head. Carefully clear the cylinder carbon deposits.
Heat the exhaust pipe of the muffler and clean it
either by scraping internally with a hooked wire or
blowing air through from the other orifice; in both
cases the muffler should be held so that the exhaust
pipe is turned downwards.
Fig. 19 • Breaker points
A) Max. gap of breaker points cA. should be 0.011".0.019"
Every 5.000 miles:
3) Change the oil in the gear box, as stated on
page 12.
4) - Grease the felt wich lubricates the cam of flywheel
magneto (by a Sea rs Store).
In case of shock - absorber troubles, overhaul or simply
clean the assembly and change oil.
These operations should be carried out by your SEARS
store.
Fig. 18 • Cleaning the cylinder heed, cylinder and piston
Clean the breaker points.
In order to avoid ignition troubles or abnormal
running, have the breaker points adjusted in a
Sears store; the gap should not be more than
0.011"-0.019" (see Fig. 19) and the points should
begin to open when the current in the primary
ignition circuit has attained its peak value.
Grease the control cables.
1) -
2) -
I
11....
Disuse:
1) In such a case, cleaning the scooter throughly is
advisable.
2) -With engine not running remove the spark - plug,
next introduce 10 -"- 15 cc. of Allstate - Regulu Oil
SAE 30 or Allstate Outboard Motor Oil through the
threaded hole of the latter.
Then operate the kickstarter three or four times.
3) -Rest the floorboard on two wooden blocks in order
to take the weight off the tyres.
4) -Drain all fuel from both tank and carburettor.
5) - Grease all unpainted metal parts.
- 11-

LUBRICATION CHART
PAlT TO s.e
OPERATION
T I III E
TYPf OF LUBlICANT
LUBllCATtD
Engine Mix
gasoline with the following
amount At each refilling of the fuel
Non - detergent
SAE
30
of
lubricating
oil:
tank.
MOTOR
Oil
- % pint of oil to 1 y~ gall. of gasoline.
N. B. - With pre-diluted or additive oils,
mix % pint of oil to each gallon
of gasoline.
Gear
Box
Warm up the engine and drain off oil.
After
the
fi rst
600
miles Allstate
Regular SAE
30.
Pour some fresh oil in and run the en-
and every 5000 miles.
gine for a few seconds. Flush and refill
with new oil (about 8.5 oz.).
Refill with new oil to oil level hole.
Every 5000 miles.
Front wheel hub
Speedometer
lubricate with grease gun.
Every 2500 miles.
High
Pressure
Chassis.
flex
drive and
pinion
Joints on brake
Grease. Every
2500 miles. Allstate
all - purpose
controls
Gear lubricator ~AE 140.
Ratchet qua-
Grease.
Every
2500 miles.
Allstate all - purpose
drant of gear Gear lubricator SAE
140.
shifter
Control
cables
Clean
and lubricate.
Every
5000
miles.
Allstate
all - purpose
Gear lubricator SAE
140.
Felt of flywheel
Small spot of grease on the felt.
Every
5000
miles.
Allstate
Bearing
Grease.
cam
Shock-a bsorbe rs Change oil.
Only when the shock - ab-
Allstate
Shock
Absorber
sorber is out of order.
Fluid.
ENGINE LUBRICATED BY MIXTURE
ALLSTATE REGULAR SAE 30 /.
OR ALLSTATE OUTBOARP M;;OR ~i
~~
Fig. 20 - lubrication scheme
1. Filling hole - 2. Draining hole
- 12-
HIGH PRESSURE CHASSIS GREASE

LOCATING TROUBLES AND RUNNING IRREGULARITIES
Carry out following checks when the engine does not start easily or runs irregulany.
louting the lToubl. I Remedies louting the troubl. Remedie.
1------.:..------ ------------I-----.:..::.=..:~~....:.--.:.~---I-----------_l
4 .. Clutch troubln.
DIFFICULT STARTING
c) Clutch does not disengage
completely:
Excessive play on control cable. Adjust (see fig. 17).
Fuel tanl< empty.
Flter on c.roureltor
Fuel tap body
Carbureltor body
Main jet
Atomizer
Pac ing of fuel tap
2. - Cubuntion
Clogged
dirty
Turn to c reserve -, Ref.1I as soon
as possible.
Remove and wash in gasoline· Blow
dry.
a)
Clutch
snatches:
Gear
pinions not
lubricated
properly.
b)
Clutch
slips:
Spring
feeble.
Plates
worn
or
burnt.
s. - c..r pinions disenCJ-I94 of own
accord.
Replace.
Replace both plates and spring.
tngine flooding
Air c1e.ner choked or dirty
Starter valve sticking
3. - Ignition
Spar plug dirty
Porcelain of sparkplug crackee
Bre.ker points dirty. partially worn
or pilted.
See page B.
Clean (see page II).
Release.
Disconnect the plug lead. Check if
sparking occurs between lead and
crankase when the kickstarter is
operated.
Clean. Correct gap to 0.6 mm.
(.023·' ).
Replace the plug.
Clean with suitable f,les or very fine
emery paper.
Gear change control cables out of
adjustment.
Adjust.
Should the control have excessive
play in neutral, tension control
cables by screwing back the re-
spective adjuster screw (on coble
sheath end, ratchet quadrant side)
with open ended wrench.
If the cable tension in neutral is
correct but the reference marks of
the handlebars do not tally, tigh-
ten one of the adjuster screws
and uscrew the othe r one to the
same extent, so that the cable
tension is not altered.
Gap between breaker points incor- Correct (see fig. 19).
reet.
Breaker points completely worn or Replace.
pilted.
Do<;s of gear pinions chipped or Replace the pinions.
worn.
6. High fuel consumption_
Timing wrong.
Re· time ignition.
I Fuel level too high in carbu- Replace float pin.
rettar:
INCORRECT
1. .Lick of power.
t LL .~"''''''''''~fC)O:>r'-:I-u.:~ _
Mu er outlet pipe carbonized
Exhaust port partially closed by car-
bon deposit.
RUNNING
Clean (see page 11 ).
Decarbonize cylinder, piston and cy-
linder head. (See page 11).
II Air cleaner chocked or dirty.
III Jets or vents of the carburettor
blocked or dirty; incorrect or
increased diameter.
IV Retarded ignition.
Clean with pure gasoline and blow
dry.
Dismount and "e~n cerburettor in
gasoline and compressed air.
For type and diameter of jets and
vents. see page 5
Re - time.
2 .• Poor comprenion.
Sparkplug not well screwed down in Tight:n (box wrench).
cylinder head.
V Poor compression.
7. Controls not operlting properly.
See No. 2 of his paragraph.
Cylinder head not fitting properly
into the spigot on top of cylinder
Piston rings gummed up.
Set the head properly and tighten
the nuts.
Clean the rings and grooevs.
Inner cables rusted_
Excessive play.
8 .• Steering column b-e<omes 1tiff.
Lubricate or, if ne" .. ary. replace.
Adjust.
3 .• Explosions at muffler or carbu.
rettor.
Top race of top ball bearing lOO Slacken.
tight.
Sparl<ing plug carbon - coated
with excessive electrode gap
or
Replace or clean the plug and cor·
rect the gap 0.6 mm. (.023··).
Bottom races of the two bearings
pitted.
Replace.
Carbon pearls on sparkplug insula- Clean.
tion.
9 .• Excessive plly of steer. cofum
Pre· ignition.
Tip of contact breaker loose.
Condenser screw loose_
a) Fit on a proper type of sparkp!. Top race of top bearing loose.
b) Re· time the ignition.
10 .• Poor braking.
Replace.
Stroke of pedal lever too long.
Tighten.
Tighten.
Adjust (see Fig. 16)
Not enough mixture flowing to the
carburettor.
See paragraph cDifficult starting"
No.1.
Brake linings oily or worn down Wash with gasoline or replace.
Brake drums and linings scratched. Replace.
- 13-

TABLE I
PARTS LIST
14 2 3 4
"~
14 3
~ , 4
~
PARTS LIST FOR ENGINE
Crankcase - Cylinder -Crankshaft
20
(Table I)
i
-...
Figure I I
Number Spare Part
S.8499 1
DESCRIPTION
Bolt, long, for securing crank-
case halves
I
Figure I I
Number Spare Part
6 686
DESCRIPTION
Washer, locking
2
3
4
5
S. 3057
S.3107
S.1107
S.1545
Washer, plain
Washer, spring
Nut, for locking cylinder head
and crankcase halves
Nut and collar
7
8
9
10
46261
S. 8720
S.6977
S.7160
Stud, cylinder fastening
Seal, spring loaded, for crank-
case, flywheel side
Washer, spring, securing cylin-
der and head
Roller bearing, flywheel side
- 14-

12 267, Key
Figu,,, I
Number I
11
.. ,,, Parr I
S.8420 '
DESCRIPTION
Bolt, short, securi ng Li Gn r,,, " lOA
halves
I
Figure I Spare Part I
Number
I
17 I 91356
DESCRIPTION
Piston, 1st o/s, wrist pin
(with parts Figs. 30 -31 -
33) .
'-
I
-<-. '
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
111311
S.8421
110699
S.456
S.8731
S.6647
S.7125
110711
2856
110720
S.584
111666
S.1821
S.1510
S.7188
S.4515
a) 93233
S.6615
111307
111308
Crankshaft, g. a.
(with part. Fig. 29).
Bolt, securing crankcase halves
Crankcase, g. a.
(With parts Figs. 1 - 2 - 3 -
4 - 11 - 14 -
20 -34 T. I;
56 T. II; 21 T. III; 34 - 35-
36 T. VIII).
Stud, securing flange for jaw
Seal, spring loaded, for crank-
case,
clutch side
Circlip
Ball bearing, clutch side
Gasket, crankcase
Screw,
securing cooling hood
Spacer, securing cooling hood
Stud, securing fuel inlet joint
Clutch, drive gear
Washer, plain
Nut, sec. drive gear
Roller cage
Stud
Roller cage
Circlip,
for locking wrist pin
Wrist pin, normal
Piston, with standard wrist pin
(with parts Figs. 30 - 31 -
33) .
32
32
32
33
33
33
33
33
34
35
36
37
38
39
40
41
42
43
44
45
91357
91358
91359
110651
91368
91369
91370
91371
S.8419
110710
91324
S.3056
150716
S.3918
111446
318
98753
72843
111734
2946
Piston, 2nd o/s, wrist pin
(with parts Figs. 30 - 31 -
33) .
Piston,
3rd o/s, wrist pin
(with parts Figs. 30 - 31
33) .
Piston,
4th o/s, wrist pin
(with parts Figs. 30 - 31
33) .
Ring,
piston, normal
Ring, piston, 1st . o/s.
Ring, piston, 2nd o/s.
Ring, piston, 3rd o/s.
Ring, piston, 4th o/s.
Bolt, long
Gasket, cylinder base
Cylinder piston g.
a.
(with part Fig. 32).
Washer, securing cooling hood
Engine, g. a.
Stud,
securing exhaust pipe
Head, cylinder
Gasket, copper, of sparkplug
Sparkplug, with terminal
Cap, rubber, for sparkplug
Hood, cooling
Screw, hood fixing
a) Con - rods and roller cages are subdivided in 4 categories. and the category numbe~ is. marked on every con - rod and cage.
Assy: con - rod with cage of the same category. When ordenng roller cages, always indiCaTe the wanted caTegory.
- 15-

26
/
TABLE II
48
IJ 47 46 45
c~ f!X I /
~@~
~49
'---50
27
oI
\--V
I 28
:r
. :-29
~
.....
PARTS LIST FOR ENGINE
Clutch - Kickstarter
(Table II)
~~~u~:r I Spare Part I
DESCRIPTION
I Figure I
Spare ParI I
DESCRIPTION
Number
78478 Spring,
return, of kickstarter
8 S.6425 1Washer,
spring
I
278976 Sector,
starting 9
S.7130 .Ball
bearing, clutch side
3S.6721 Packing
10
S.906 Bolt, securi ng kickstarter
,
-.-
478473 Gear,
starting
11 S.12563
Washer, lock, of kickstarter
5110387 Plaque,
retaining,
spring
12
79077 Kickstarter
677232 Spring,
plate
13
S.6647
Circlip, locking
bearing
779670 Washer lock
14
78495\
Plate, spring, of clutch
- 16-

.......
,'
Figure I
Nb
Spare Part
urn er
15 78484
16 110921 t
DESCRIPTION
Spring, clutch
Gear, clutch
I
35 I
36
Spare Parr
78450
S.8818
DESCRIPTION
Arm, actuating clutch
Pin, actuating arm
~.
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
78594
110670
110669
110668
S.5772
150514
16821
14457
2/78453
79002
S.14413
S.7631
79083
S.12281
78586
78959
S.6706
78452
Spacer
Spring gear
g. a.
(With parts Figs. 14 -15 -
16 - 17 - 19 -20 -
21 ).
Body clutch
Plate, spring, of clutch
Rivet
Clutch,
g. a.
(With parts Figs. 37 - 38 -
39 - 40 - 41 - 42 - 43 - 44).
Plate, clutch centralizing
Spring, for fixing centralizing
plate
Thruster, clutch
Gasket, between clutch cover
and crankcase
Screw, securing clutch cover
Washer, spring
Cover, clutch
Bolt, securing clutch cover
Plug, actuating arm clutch
Arm, actuating clutch, g. a.
(With parts Figs. 35 - 36).
Washer, actuating arm, clutch
Spring, actuating arm, clutch
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
79474
150508
79476
79399
79478
79469
112390
79497
S.1107
S.3107
79001
S.12488
S.1205
90527
S. 7035
112377
S.1822
S.1508
S.11753
87685
Ring, spring, for stopping
clutch plates
Ring, oil container
Plate, outer, of clutch
Plate, clutch, with linings
Plate, driven, of clutch
Plate, inner, of clutch
Spring, clutch
Clutch case, inner
Nut, securing bracket
Washer, securing bracket
Bracket, supporting adjuster of
clutch
Bolt, securing bracket
Nut, setting clutch
Screw, setting clutch
Ball bearing, of multiple gear
Gear, multiple
Washer, locking clutch
Nut, retaining clutch
Key, retaining clutch
Plug, for hole crankcase, side
flywheel magneto
- 17-

TABLE III
PARTS LIST FOR ENGINE
~,
I
--I
Rear wheel hub. Gear group· L. T. socket
Figure II
DESCRIPTION
I Figure II
Number Spare ParI
Number Spare Part
85914 II
100492\
I
Stud, for drum of brake'
8I
2
5.12787
Split pin, for locking castle nut
9
61
3
5.2314
Nut, for securing drum
10
78522
4150051
Washer, plain, securing
drum
11 5.1108
5
100484
Drum, rear brake (with fig. 1)
12
111586
6
5.3108
Washer, spring, sec. wheel
13
97497
724410
Plaque, for brake jaw
14
\.
78366
- 18-
(Table III)
DESCRIPTION
Jaw, rear brake, with lining
Clip, spring, for brake jaws
Spring, return, of brake jaws
Nut, securing wheel
Disc, support brake jaw
Packing
Arm, rear brake control

Figure Spare Pan
Number I
DESCRIPTION
I
Figure ! Spare Part
Number I
DESCRIPTION
15
3/46699
Seal, spring - loaded of main-
shaft
41
5.5901
Circlipt retaining shoulder
washer
-1
16
17
7563
90899
Ball bearing
t
clutch side
Packing
42
42
a) 111996
a) 112008
Washer
t
shoulder, normal, of
of
gear pinions
Washer, shoulder, 1 st oversize
18
19
20
2990 Capt filler, oil
397 Packing
t
for cap
19301 Breather
42
42
42
a) 112009 Washer
t
shoulder, 2nd oversize
a) 112010 Washer
t
shoulder, 3rd oversize
a) 112011 Washer
t
shoulder, 4th oversize
21
78578 Buffer
43
a) 111596 Mainshaft
22
23
24
25
26
27
90527
Screw, setting change gear
5.1205 Nut
t
setting change gear
98787 Bolt
t
securing stirrup
90306 . Pivot pint for rear brake links
112214 Stirrupt for gear change
(With parts Figs. 27 - 28
31 - 33 - 35 - 36).
78945 Slide
t
stirrup, of gear change
44
45
46
47
48
49
50
112378
Gear, low speed
112379 Gear
t
2nd speed
112381 Gear
t
3rd speed
112380 Gear
t
4th speed
150110 i Spring
t
for balls
5.6379 Ball
5.1108 Nut
t
securing brake jaw sup-
port disc
23823, Screw t setti ng rea r bra ke
5. 1207 Nut
t
setti ng rea r bra ke
5.5771 Rivett for stirrupt of gear
change
S. 3108 Washer
t
spring
link, brake
link
t
brake
Washer
t
spring
Screw
t
for L. T. socket
l. T. socket g. a.
(With parts Figs. 59 -61 -
62) .
Bolt
t
for securing cable to brake
links
70744
85673
42047
94779
5.3109
5. 14402
5.3058 Washer plain
5.12761 Split pint for arm axle
5.1426 Nut, for securing bolt brake
links
53
58
59
52
57
55
54
56
51
60
Cover, of the act. lever
Union piece, for levers
Packing
Washer
t
spring, for cover
Stirrupt of gear change
Washer
t
spring, for stirrup
Circlip, for stirrup
Pin
78920
78597
78526
110716
5.3105
5.5962
5.6706
5.13010
36
38
30
35
29
32
37
28
34
31
33
~
\
39
40
99462
111589
Screw
t
securing cover
Selector, gear
61
62
78598
5.8230
Covert for L. T. socket
Screw
t
for L. T. socket
a) The total axial play of the assembly of the 4 gear pinions in respect to their seat must be contained between .002" and .012".
Should this play exceed said tolerances, the normal shoulder washer must be replaced by another with proper oversize.
- 19-

TABLE IV
I
-#
l
~ 2423
37 lIB' /31 29j' -a./
~ / ~ ~ ,-
~ 33 W32 .o@@g
36Jl.-S / ~7
/\
35 34
PARTS LIST FOR ENGINE
Flywheel .Magneto . Fan -Coils
(Table IV)
FiQure IPI
Number Spare art
DESCRIPTION
I
Figure I Spare Part I
Number
DESCRIPTION
2
3
4
5
6
48170
14501
a) 87400
101112
a) 85721
467661
Cap, for L. T. socket
Terminal
Sheath
Cable harness
(With parts Figs. 2 - 3 - 5).
Cable, to flywheel
Grommet
7
8
9
10
11
12
5.5981
79715
5. 3054
5.3104
5.963
90045
Circlip, for flywheel extraction
Clamp board
Washer, plain, securing clamp
board
Washer, spring, securing clamp
board
Screw, securing clamp board
Washer, plain, for screw secu-
ring stator
\. .1
-20-