Allstate 788.94493 User manual

OPERATING INSTRUCTIONS
AND PARTS LIST FOR
MOTOR SCOOTER
,..----- MODEL NUMBER 788.94493
This is the Model Number of your Allstate Motor Scooter. It will be
found on a plate fastened on the outside of the hinged door under
the seat. 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 service at all times. We suggest you keep it with other
valuable papers.
SEARS, ROEBUCK AND CO.
Scooterworks USA Inc.
5709
N. Ravenswood
Chicago, IL 60660
ph: 773.271.4242
fx: 773.271.5012

fii. I - AllSTATE: • Cruiaaire. Motor Scooter
Location 0/. aerial Number
Location 0/' engine Number
WARNING
In order to keep your ALLSTATE Scooter In perlect
runnmg condillon and not to void the guarantee. always
have your machme repaired at a Sers. Roebuck and
Co. Store.
Special care should be taken in regard to the fuel
mixture which
should be regular gasoline and .)Ij of
the make. grade and 1''1 the amount prescnbec in this
booklet.
Ethyl gasoline ahould never be used.
Do not use Allatate compounded motor oil or other
Premium :: ~ -'-. Duty Motor Oil with detergents.
The inexpenenced operator should exercise co lIar.
m applymg front wneel brake. to aVOid locklni;;
Fii. 2 . Controla 0/ AUatate Scooter
1. Gear change tWlslgnp with c!u::n
control lever· 2. front brake lever· 3
Throllie control gnp. (. Light and dim.
mer switch - 5. front b-ake ,awl' - 6
Rear brw pedal - 7. KJc:ltstarter • 8
Gem .hilter - 9. Rear brake Jaws - 10.
Clutch • 11. Carburellor. au cleaner .
12. Choke control lever - 13. fuel cock
-3-

Fiq. 3 - EDqine inalallation aDd auapenaiona.
I Sl~~rtng column and front !u!p~n!ion • 2. Engin~ • 3. Crankca!~ hall. clutch sld~. wIth sWinging arm - 4. R~ar susp~nslon
apring with hydraulic damp~r.
MAIN SPECIFICATIONS
Fram •.• Of pressed and spot.welded steel sheet.
with stream-lined monocoque-type structure.
Suapenaion. •Front wheel: coil spring. Rear wheel:
coil spring and coaxial hydraulic shock absorber.
Engin •.• Two-stroke. flat co:;t iron cylinder and
cast aluminum alloy cylinder head.
Displacement. 123.57 cc. (7.48 cu. in.)
Bore. 54 mm. (2.12 in.)
Stroke 54 mm. (2.12 in.)
Effective
power at 5000 rpm 4.5 HP.
Compression ratio .6.5: I
Fuel
conaumption.
(Gasoline· oil mixture)
Max. speed.
Wheel ba ...
Max. width on handleban
Max. lenght of the scooter
Max. height
Min. height of floorboard.
Turning circl •.
W.ight (unladen)
130 miles per gal.
46.6 m.p.h.
40.4 in.
25.7 in.
68.3 in.
28.7 in.
8in.
59 in.
178.2 lbs.
Transmission. -Directly [rom enarne to rear wheel
through clutch. cushion drive and ge'ar box
Starting. - By means of kickstarter. nght hand Side
of scooter.
Gear box. - 3-speed drive with mesh gears in od
bath. Its two-c::Ible control IS coupled with that of the
clutch.
on left hand side of handl~bars.
Clutch. - Wet type; multiplate. with facrngs of corle
composition applied to the dnven dISCS
Iqnition. - By fl'lwheel magneto
...------------erJ~
/~
6
Fiq. 4 - (qnilion diaqram
I. Ignition coil in f1ywh~~1 magn~lo _ 2. Rolor cam . 3. Br~akcr
4. Cond~n!~r - 5. Sporkplug - 6. Engin~ CUI-OU! on !wl!ch
-·4-

Fi9. 5 • S.c:tiOD 01 .DgiD ••
. PIston· 2. Cranbhafl • 3. Clutch - 4. Mainshafl •
5. Gear shifter· 6. Flywheel magneto. 7. Kl:k-
starter· 8. Crankcase hall. clutch aide. with aWing.
Ing arm.
Lighting ana nom. - 0] •• fwnet. ; .. _.
both
head lamp (two-beam). tail lamp. hom '-
light.
Brake&. -Lxpanding type.
Front
brake: control lever on right hand side of handle-
bars.
Rear brake: control pedal on right hand side of floor·
board.
Wh
•• 1&. •01 pressed steel sheet. interchangeable
and easily removable. since they are assembled in an
automobile-like system.
Tires: dia.
3.50 x 8 in.
Fuel tank. -Total copacity: 2.03 gals.;
Reserve: -
0,5 gals.;
Three-way
cock: copen. - c closed •. c reserve.
St .. ring Lock. -A suitable security lock'is arranged
on the lrame. near Jhe handlebars. Turning the key
counter-clockwise and the handlebars to the left. the
lock engages the lugs welded on the steering column.
so that the
madune can only tum around. Tum the key
clod:wise and the handlebars beck to normal position
lor releasing the
steering system (see fig. 6). Do not
attempt to
TIde the machine unless the key is in. and re-
mams in the lock. and the handlebars ere moving Ireely.
Do not lubricate the steering lock.
Central Stand. - A two-leg stand is arranged under
the floorboard. A strong return spring hold it in contact
with the floorboard and keep it from vibrating while
the scooter is
being ridden.
---8
·r.r..~---7
6
Tool Kit. • 1 lour-end box wrench (11 - 14 • 21 .
~m); 1 double open-ended wrench (8-14 mm);
.:::-.;lle open-ended wrench (7 mm); I screw-driver.
Tnese n::'ld tools are contained in a canvas roll which
is placed In the left wing with on air pump.
Speedometer (See Table XX). - On request the
Allatate scooter con be equipped with the speedometer.
which has its housing in the middle of the handlebars
and odds to the performance and appearance 01 the
scooter.
Fig. , - Security lock
1. Normal position - 2. Closed
-5-

r
2
~
-rr
~
I)
~ -.tt -.rT
ftUJIIII -
l1li
~
i
tB
y•
~"
: 3
I
\
L-.T1Ul[
•
",
; 15--r.-+ ;-7
'-- .:.'-.",J '
Fiq. 7 • Scheme 01 Eleetric Wirillq
: fiywh~~1 magn~lo . 2 Low tltnsion lltrminal • 3. STOP light (6 V • 3 W bulb) • 4. Tail lamp (6 V • 3 W bulb) • 5. Sparkplug
. 5 STOP switch. 7Light and dimmer SWitch .• 8. 6V . W22W double filament bulb· 9. Hom· 10. Inside view of hltad lamp •
.
~ LIghts 011 •BHltad lamp and tail lamp on . C Country bttam • D: Traffic bttam • E: Englnlt cut-out . f. Horn bullon.
. 6 ..

HOW TO ASSEMBLE THE SPEEDOMETER (WITH MILE DIAL)
(See fig. 8)
Take 011 the head lamp and disengage Ihe top shell
of handlebars from the inside hub, then remove the
cover
of the speedomeler housing from the top shell.
-WIth the
help of apilot wire slide 'in into the steering
co umn from the 100 end the sheath • A. for the
fex drive. unt it 'emerges from the bottom end
(mdic:Jled with an crrow in :he figure).
Assemble packir;g •
C. ana Ihen the speedometer
head. B. on the upper sheD of handlebars; fIt the
packing. D • and support. E • on speedometer boss,
then
secure fJrmly with nut • F •.
Pull the pilot wire
out of the sheath, greose the flex
drive
generously and slide it in.
-Place the
upper end of the flex drive mto housing
mthe speedometer head and secure both flex drive
and sheath by means of knurled ring • G '.
Re-assemble the upper shell and head lamp.
Unscrew the plug •H• from the swinging hub.
Fill up with grease the hub in order to'luc:lcate the
portion of 1he wheel spmdle meshing ... nth the spee-
dometer drive pinion • I •
-Mate the pinion • I • to
the support bush • L • and
screw the latter on the wheel hub, thus allOWing an
axial play of 0.25-0.8 mm (0.01-0.03"). If the play is
not
as prescribed. assemble shoulder washer • M •
between the bush • L. and toe hub.
-Slide the rubber cap • N '. the threaded ring •0 •
and biconlcal ring • p. over the sheoth end; fit the
washer .• Q. on the cable portIon which protrudes
from the sheath, pass the latter between the front
brake control cable and the wheel. then screw and
tighten threaded nng • O. on bush • L. and po-
SItion
rubber cap • N '.
Make sure that the end of the flex drive enters the
square sect on hole of the speedometei dnve pinion
Rotate fne wheel by hand for several times In order
to make sure that It turns freely
Fig. 8 • How '0 cu ... mel. lb. ap •• dom.'.r unit
Due to the Simple and conventional deSign of the
Allstate scooter, no particular skill IS requITed for ItS
operation, nor skilled pers~nnel lor ItS maintenance.
The tash con be quite well carned out by any
customer. even unexpenenced. by core/ully follOWing
some general rules.
OPERATION
Fuel lupply. -Fuel mIxture should be composed
of reg lar gasohne and Allstate Outboard Motor Oil.
S.A.E.
30. or Allstate Regular Motor Oil S.A.E. 30. in the
following proportion:
- 0.5 pmt of oil to I gallon of gasoline.
Do not use AllsttIte compounded motor oil or other
Premium Heavy Duty Motor Oils with detergents.
Keep the breather of filling cap clean.
Oil level. -Remove the level screw, on crankcase,
mer ked • OLIO, and mdlcateci on pag II Fig 18. to
check
01 level 10 gear DO>: belore slartlng the engine
The scooter standing upnght. 011 should Just be about
to flow out; otherWise top up with ALLSTATE REGULAR
S.A.E.
30.
Running.in. - Important rules to be followed while
running-in (1'200 miles) :
-Do
not exceed follOWing speeds'
1st gear 9.5 mph
2nd gear 19 mph
3rd gear 31 mph
Do not hold these max speeds for long periods neither
use full throttle opening up-hill.
Warning. - 1/2 pint of oil should be mixed 10 each
gallon of gasoline both dunng and after running-In
Starting. - Open the fuel valve, put the gear box
m neulral and shghlly open the throllJe In slow running
poSItiOn, kick the slartlng lever.
See Fig. 9; note the three positions of the fuel valve.
open, closed. reserve.
Caution. -Do not open throttle wide when releasing
clutch.
-7-

In case of starting troubles, see that the carburetor
is not flooding, i. e. mixture is not dripping from it.
Engine flooding can be overcome by either one of
the following
methods:
(a) Push-start the scooter: shift into second gear,
declutch and push the machine; suddenly release the
clutch lever
and pull it back as soon as the engine start::.
(b) Close the fuel cock, remove the spark plug and
rotate the engine by means 01 the !tickstarter. Wipe the
plug dry
and replace. Open the fuel cock and !tick the
starting lever.
If, instead. the engine is not flooded. close the
choke valve by pulling the lever situated under the seat
and kick the starting lever again.
Setting the machin. in motioD. •Let the engine idle,
depress the clutch
and tum the gear change twistgrip
so that the line
engraved on it coincides with the num-
ber 1(lst gear) engraved on handlebars (see Fig. 11).
Now let in the clutch gently, while opening the throttle
gradually
to set the machine in motion.
~.~
~
J
" •. I . FeediD. c:ircW1
1. Fuel tank • 2.. Fuel coc:k le'l'er: a) ReserYe, b) Open, c) Closed
• 3. Air cleaner - 4. Float - 5. Maximum iet - 6. Idling jet -
7. Throttle slide • 8. Idling adjuster - 9. Adjuster on throttle
control cable - 10. To the cylinder.
" •• 10 • Openrtlo_ .. carr .. I lor atcatmv tIM ealli· e
A: open the luel lank _ B: selecl • neutral •• C: choke (wi:h cold enqine) • 0: throtUe control qrip In ic:lllnq position - E: depre ..
the kicltstart!r and tum qrip • D. bT short slrokes.
-8-

G.ar change •• Alter reaching the required speed
in 1st gear, close quickly the throttle, depress the clutch
and tum the gear change twistgrip so that the engraved
line is opposite number 2(2nd gear) let in the clutch
and open the throttle gradually.
Repeat this procedure lor
changing into 3rd gear.
(See Drive system on fig. 11 l.
For changing down. close the throttle. depress the
clutch
and tum the gear change twistgrip to the requi-
red position.
Fi9. 11 •Dri .. IYllelll
I. Gear change twillgrip • 2.. Clutch cantrol lever • 3. Gear
change conlrol cablel - Gear .hiller • 5. Selector Ilem - 6.
S.lector • 7. lit gear pinion. 8. 2nd \lear pinion - 9. 3rd \lear
pinion • 10. Mainshall - II. Cuah gear • 12.. Clutch.
N.B. - POI IlionI 1·2·3 of the gear cban\le twUl\lrip correlpond
10 III. 2nd and 3ro:! \lear relpeeuvely; • C. indJcatel the
neutral polilion.
When you reduce the speed of your machine. chan-
ge down with no delay.
Do not tum the gear change twistgrip while the en-
gine ia not running.
AI .oon as gear change trouble. ariMo particularly
when the control become. hard. cuatome,.. should haYe
their machin.. adjusted at a Sears Roebuck and Co•
•tore.
Fig. 12 -DiamaDtliD, U.e troDI wll .. L
Tir ... -The wheels are interchangeable. i. e. they
can be assembled either in (ront or rear. provided oi
.
course that they are enflated to pressures respecltvely
hereunder prescribed.
When aflat tire is to be replaced. unscrew the
lour
nuts which secure the wheel to its flange. pull wheel
sideways off the studs (see fig. 12), repair it or replace
with spare wheel.
To remove the tube, deflate it itrst. then separate
the felloe from the ring by unscrewing the nuts which
join
them (see fig. l~).
Tire pressure should be 18 psi on rear wheel. 11 psi
on front wheel. If the Allstate is ordinarily ridden by
both driver and passenger, the pressure 01 the rcer tire
should be 28 psi.
StoppiDg the en~. - Push the cut-out button
(see fig. 7. letter "E .. ); fuel vapors remain in the cylmder
in this way, and the next start will be much easier.
-9-

Brake adju.tment. -Brakes are properly adjusted if:
-the wheel rotates freely when respective control
lever or
pedal are in resting position;
-the braking action startS
as soon as respective
controls
are operated.
These conditions are achieved adjusting the cables
by means of screws indicated with an arrow in Fig. 14.
®
fill. 14 •Brake ad!llStIDe"
Adju.tment of clutch controL - Adjustment of clutch
controls is
achieved operating on. adjusting nut (aJ.
screwed to the engine braket (see Fig. 15). by means
of open end wrench 82199 in the tool roll.
a
fiV. 15 • Ad!uatmeat of dutch coatrol
0) A.djustlng nul -b) Clutch leyer. engine side
The cable is to be tensioned or loosened. as the
case may be. so that control 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 riding conditions.
MAINTENANCE
Slow running adjwatm.nL - No han'" tool is required
for this job; idling revs can be raised by simply tighten.
ing the screw which
presses on carburetlor cover and
vice-versa.
Cleaning the scoot.r. -Brushing kerosene and
wiping dry with dean rags is advisable for outside
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 oil dust with a very soft feather. Do not use a
cloth
and keep your fingers oil refiector surface.
Befor ... tting the mac:hiD. in motion. (if it has been
delivered directly to the customer by the Factory) check
oil level in
gear box by unscrewing from the cranckase
the level screw marked • OUO. (see Fig. 181. The
scooter standing upright. oil should just be about to
now out.
AJter the tint 600 mil... - Replace oil in the gear
box by the procedure as explained in the lubrication
chart. page 11. The crankcase can be drained through
the hole indicated in Fig. 18.
10 -

Eury 1.200 mil •• :
(1) -Remove the air cleaner from the carburettor and
wash it in a 30~. gasoline-oil bath.
(2) -Check oil level in the gear box (see above).
(3) •Clean the sparkplug electrodes with very fine
emery cloth or suitable files.
and adjust the gap
to .6 mm. (.023").
Inspect the insulation material of sparlcplug; re-
place the latter
if the porcelain is cracked. Whash
with neat gasoline.
Use the
sparkplug type AllSTATE No. A4 ISO.
Important: using the proper type of sparkplug will
eliminate
many engine troubles.
(4) •Clean the two lubricators on front wheel hub and
refill them by means of agr-ease gun.
NoB. • All operatioDa indicated hereunder ahould
be carried out by aSEARS atore.
(5) • Clean and adjust the breaker points of the fly-
wheel
magneto (see Fig. 16) to .4 mm. gap (.015").
Eury 1.800 mil ... - Grease the felt which lubricates
the cam of Ilywheel magneto.
In case 01 shoclc-absorber troubles, overhaul or
simply clean the assembly and change oil.
These operations
should be carried out by your
'SEARS store.
Fig. 15 • Ir.aker poiAta
Enry 3.000 milu. - Clean the muffler and decar-
bonize the engine as explained hereunder. Remove the
muffler. the cooling hood. the
cylinder head and the
cylinder (see Fig.
17). Decarbonize the piston crown and
the cylinder ports from all carbon deposits. Decarbonize
the inne:- side of the cylinder head. Clear carefully the
cylinder from carbon deposits.
.
Heat the exhaust pipe of the. muffler and clean it
either by scratching it inside with ahook wire or blow-
ing
air through from the other orifice; in both cases the
muffler
should be held so that the exhaust pipe is turned
downwards ..
Diauu :
(l) • In such a case, cleanin9 the scooter throughly is
advisable.
(2) • Start the engine and run it at low revs in neutral.
Pump 60 ce. of Allatate aegular Oil SAl: 30 or
Allatate Outboard Motor Oil through hole in the
air cleaner into the carburettor iniake. by meana
01 an oiler.
(3) •Rest the floorboard on two wooden blocks in Order
.to
take the weight off the tyres.
(4) •Drain all fuel from both tanlc and carburettor.
(5) • Grease all unpainted metal parts.
Fig. 17 • Q.-iDlJ the cyliDd.r laeacL cyliDd.r cuad pUlOD
- 11 -

LUBRICATION CHART FOR AIJ.STATE
PART TO BE
I
OPERATION
TI ME
TYPE OF LUBRICANT
LUBRICATED I
Enqine
,Mix
qasoline
'With the
followinq
amount of
At
each
rdfillinq of the fuel
Allstate Regular
SAE
30
or
lubricatinq oil:·
tank
Allstate
Outboard
Motor Oil
i-
0.5
pint
of oil
to
I
qallon of
qasoline.
Gear Box
I
Warm
up
the engine and drain off all oil. After the first 600
miles
IPour
some fresh oil in and run the engine lor
a
lew seconds. Dram again and refill with
Allstate
Regular SAE 30
ne"; oil.
Refill with
new oil to oil levcl hole.
Every 1200 miles
front wheel hub Lubricate with grease gun.
Every
1200 mlles
Hiqh Pressure Chassis Grease
Joints on
brake I
Grease.
Every
1200 miles
Allstate all - purpo.e
control.
I
Gear
Lubricator SAE
140
Shock·absorber
Change oil. Only when the shock-absorber Allstate Shock
is out of order Absorber nuid
I.
Control cables
C1l1OTl and
lubricate.
Every
1800 mil.s
Allslate all - purpose
Gear
Lubricator SAE 140
fell 01
nywheel
Small
of grtMIse on
the fel:!.
i
Every
11m miles Allstate
BtMJring Grease
spot
I
cam
I
Ratchel quadrant
Grease.
Every
1800 miles Allstate all - purpose
01 qear .hiller
II
Gear Lubricator
SAE 140
I
["&II( U8IIUTtO
IU.S Taft IlGULU SA( JO
(lit aLL) Tift OY!'IOA!!Q Ml)!pI! ill.
Fi,. II •Lulniccrtioll acbellle
I. Filling hole - 2. Draining hole
- 12-

LOCATING TRO UBLES AND RUNNING IRREGUlARITIES
Carry out following checks when the engine do •• not start easily or runa irregularly.
INCORRECT BUNNING
DIF'FICULT STARTING
R.-hm.
S.. No. 2of lhis paragraph
AdilUt (a .. Fig. 14. page 9)
Wash with gaaolin. or r.plac.
R.plac.
Clean with pure gasoline and
blow dry. DIp the m.tal wad-
ding inlo a30% gasolln,-011
bath
R.l.as. operating and lubn-
callnq the I.v.r on lhe back
o( the c1.aner eale
fit proper jet <.63 mm)
Replac.
Clean or r.plae. both needle and
floal chamber cov.r
I
I
:ar. !
Lubricat. or, if nec.asary, re-
p:ac.
AdllUt
become. I
col_
4. • Clutch trouh!' ••
Locating the trou~_le' __ '_I Remedies
I
a) Clutch snatchel: I
Ext.rnal steel plate wrongly I Turn convex bee towards plates
assembled . . IWilh cork
Gear pinions not lubrlcaled j Top up oil level. Tighten the
properly , screw on draining hole
bl Clutch llips:
Springs leable Rep~ace
Plates with cork worn or burnt Replace both plales and springs
c) Clu:ch does not disengage
compl.lely :
ExceSlive play on control Adjust
cable
ExceSilve conv.xity of Ileel Replact.
plat.l.
tx.uiv. play
50 • High ha.l COIIaWDplioD
I • Fu.l l.v.l too high in
bur.llor:
a) noat perlorated
b) noat n.edl. valve not
properly hlling into ill
•• ating
II •Air cleaner chok.d or dirty
S •• GaClr piDiolU cli •• 1l9C19. of
OWIl a~~orci
Gear cnange conirol cabl.1 out Adiusl
01 ad,lUtm.nt
Spring of .tilT\lp broken, le.bl. Replace
or miumg
Exc.ssive play belw .. n actuat- Replace
ing ann and g.ar ahift llanoe
or wrong positioning of the
arm.
Sel.ctor annl chaml.red Replace 'lhe selector
Dog. of g.ar pinionl chipped or : R~plac. the pinionl
worn '
7 •• CoDuola _t opeJ'ClUD9 pro-
peri,
Inn.r cabl.. rlUted
m • nap of choke valve lticking
in cloa.d or partially c1e.-
ed polltlOn
IV - Diam.t.r of main j.l orihce
wrong or increaaed
V • R.tard.d ignition
VI • Poor compr.uion.
... SteeriD9
atiJf
Top rac. of top ball bearing Slack.n
too .tight
Bottom rac.. of the two ~- Replac.
ing. pitted
1 Q. • p_ bralI:iD9
Stroke of ~ or l.ver too 1000g
Brake lininga oily or wom down
Brait. cirwna and lininga aerat-
checl
I .. Eac.ui.. play of .... riDg
collUDD
Top rac. 01 top bearing loos. Tighten
Remedies
R.-time ignition
S .. page 7
R.plac.
Clean (s.e page 10)
R.I.cae
R.I.a.e
Turn (0 • reserve •. Refill as soon
as possible.
aJ Unscr.w and remove the
mam ,et. II Ihe luel system i~
elhclent, tuel will come out.
b) B10." Irough ,et orifice 10 en-
sure that it IS clean.
Remove and wash in gasoline -
Blow
dry
Diaconn.ct Ihe plug lead. Check
if sparking oc:urs b.tween
lead and erankcae when Ihe
kicutart.r is operat.d.
Clean. Correct gap 10 .6 mm.
(.023-)
Replace th. plug
Clean with .uitabl. file. or v.ry
.tin •• m.ry paper
Correct 10 .4 mm. with I •• l.r
gaug. (.OlS-)
R.place
Tight.n (21 mm box wr.nch)
Clean the ringa and groov ..
Set the bead properly and tigh·
t.n the nUll
R.p1ace or c1.an the plug and
corr.ct th. gap to 0.6 mm <.023-)
Clean
0) FIt CD a cald.r aparkplug
b) Re·tim. the ignition
R.p1ac.
Tigbl.n
Ie s.. paragrapb •Dillieu1t atart·
ing., No. I
Locallng the
trouble
1 •• F'lIel .y.lem
fu.1 tank empty
fuel does not now to Ihe cClTbu-
rettor all hough the luella;) is
open or In position • r.serve •
filler on carburetlor (
fuel tap body
Carburettor body Clogg.d,
Main lei \ diTlY
Atomizer
Packing of fuel tap I
float needle valve sticking on ill
seating
1. •CMkllUCltiOIl
Engin. llooding
float perforated
Air cleaner chok.d or dirty
Choke !lap Iticking in position
• closed.
3. • lpi tiOll
Sparkplug dirly
Pore.lain of lparkplug crack.d
Break.r poi nil dirty, partially
worn or pitted
Gap betw.en break.r poinl. in·
correct
Br.ak.r points complet.ly worn
or pitl.d
Timing wrong
1 .• Lack of pow.r I
Muli.r outl.1 pipe carbonized I C1.an (I" page 10)
Induction pipe 10 cylind.r loose Replace the packJng betw •• n
Pipe and cyli"\d.r. Tlghlen
lb. null on CYllnd.r Iluda.
Deearbonize cylind.r, pi.ton
and cyllnd.r head
R.plac.
Exhauat port partially closed by
carbon d.poait
Cylind.r ba.. gcak.t not tight
Sr-arking plug carbon-eoat.d or
wllh 'XC'Sll'r' .leclrod. gap
Carbon peoria on .parkplug in·
'1Ilation
Pre-ignition
Tip 01 ~ntact break.er 100M
Cond.naer aer.w 100M
Nol .nough mixture Dowing
the earbur.lIor
1. • P_r ~omJWeouiclia
Spark plug not w.ll aer.wed
down in cylind.r beacI
Cylind.r head not titting properly
into th •• pigot on tot> 01 cy.
lmd.r
Pi.ton rings gummed up
3 .• Exploaiou ClI .WIl.r or car·
bllT.llol
- 13-

-14-
-i

_________ p ART S LIS T _
TABLE I
@
19~16
,26278
PARTS IJST fOR ENG~
Crankcase -Cylinder
(C)
(ToUU: l)
Part I
Table
DESCRIPTION
IPart
Table
I
DESCRIPTION
Number Section
Nwnber Section
,I
I
318 DGaaket. copper,
of sparkplug
46261 A-B
Stud. long, cylinder fastening
2040
CAdjuster
of rear brake and clutch
45$)84
CBolt.
securing crankcase halves
2444
C
Nul
47219 BGaalcet.
crankcase
13903
DSparkplug. with gasket
.(6741
D
Cap. rubber. for sparkplug
18064
DWriat
pin
"n80
D
Head. cylinder
18113
A ~. piston. normal
81075
A
Cylinder
19195 ARing. piston.
1st oversize
81076
AGaalcet. cylinder
base
19196
ARing. piston.
2nd oversize
81887
BPiston. with inserts, normal
81888 B
Crankcase halves (Parts n. 12869 -
19197
ARing, piston.
3rd oversize
40313 . 40316 . 46&31 - 46684 -
19356
ARing. piston. 4th oversize
46702 . 47160 - 47161 - 47219 .
47944 . 47945 - 47946 - 47947
19394 D Wn.t pin, lst oversize
47948 - 48035 - 80992 . 81842 -
19616
B
Seal. spring loaded, for crankshaft
82086 - S. 1107. S. ~057 - S. 3107
- S. ,(512 - S. 12485 . 48000 -
26278
BBall
bearing. of crankshaft
48002 . 47999 - 46261 . S. 10790)
- 15-

Part. li.t for eaqiDe -Crankr:a.e •Cylinder •Continued
Part Table I
DESCRIPTION
Part
Table
I
DESCRIPTION
Number Section Number Section
82237
AHood. cooling S. 1107
A-B-C Nut. for locking
cylinder head and
82752 CPiston. with standard
wrist pin
crankcase halves
(Parts n. 180&4 - 81887 - S. 6611)
S. 3057 A·B·C
Waaher. plain
82753
CPiston. with wrist pin. 1st oversize
S. 3107 A·B·C·D
Washer. spring
(Parts n. 180&4 - 92754 - S. 60 11 )S. 1-447
CNut.
spacer, hood fixin9
82754
BPiston. with inserts, 1st oversize
S. 4512
A
Stud. securing cranxcose. halves
gz755
BPiston. with inserts. 2nd oversize
S. 6615 CCirc:lip. for locking
gudg~on pin
82756 BPiston. with inserts, 3rd oversize
S. 6977
A·C
Washer. spring
S. 10001
D
Screw. hood fixing
82757
BPiston. with inserts, 4th oversize S.
12485 BBolt. short,
securing crCJ'!.ki:ase hal-
83250 DEngine. g.a.
ves
PARTS LIST FOR ENGINE
Cnmlrehaft -Clutch
(T.uLE m
Pan
ITable I
DESCRIPTION
Part I
Table
I
DESCRIPTION
Number
s.ctlon
Number Section
.97
B X..,. woodruU, for crankshaft
~53'}
DPlcrte. smooth. of
clutch
(clutch side) 32005 D
RlDq. elastic. for stopping
clutch
267
BXey. woodruff, for crankshaft I
plates
(flywhe<!1 side) 40312 BSpindle. hollow, for
hydraulic shock-
686
AWasher. shake proof. for nut se<:u-
absorber
ring flywheel 40316 .BBush. bottom,
rubber, of shock-
14457 CSpring. for fixing
dutch centralizing
absorber
plate 4&266
BCirclip. locking
spacer
16821
CPlate. clutch centralizing 46267 C
Packing
17781 CGasket.
between dutch cover and 45'258 C
Spacer
crankaae
46271
CPiston. slotted thrust.
of clutch
19301 CBreather. with inserts
467104
C
Co?er. dutch, with inserts
19312
B
Washer. shim. of dutch gear
46717 CLe"er.
outer, dutch control
20375
BNut. castle. for
securing clutch
4&718
C
Le~. inner, dutch control
21856 DBody·
dutch
46740 CSPfiD9. return.
of outer dutch con-
21868 DCup. clutch
spring
trol lever
22313
B
Washer. spring, for castle nut se- 47944 A Spindle. hollow, for engine suspen-
curing clutch sian
22886
DSpring.
dutch
47945 A Spacer. flywheel side
- 16-

TABLE n
@
46717
Pcuta llat for engine -Crankahcdt • C!utdl • Continued
Part I
Table
I
DESCRIPTION
Part
Table
I·
DESCRIPTION
Number Seclion Number
Seellon
0) 47946
C
Spacer. clutch side
81071 C
Coyer. clutch. with lever and thru>il
47947
CBush.
rubber. clutch side
piston (Parts n. 193U I - 4G271 -
46714 • 46717 - 46718 • 46740
47948
CW
ashor. ~ain
S. 6708)
48035
DBush.
rubber. fiywheel side
83033
·.B Bron1e bush of con.rod ~mall er.a
S. 3056
B
Washer. plain. for secunng clute::
81000
A•
Crcmlcsh
aft
cover
81001 CClutch. g.
a. (Parts n. 21866 - 21868
S. 3106
B
Washer. spring
• 22886 - 23511 - 32005 - 81004 •
S. 6708
C
Padting. betw~n clutch cover COG
81007)
outer IE-Vf'o
81004
DPlale. clutch. with cork
S. 1206£
ANut.
secunng f:ywheel
81005
I
D
Gear. clutch
S. 13913
B
Whaaer. plain
g10D?
BPlate. spring.
of clutch S. 14413
B
Scre •• sec-uring clutch C::lver
a) Parts 48988 or 4B9B9 can be auembled inllead of lpacer 47946. \0 attain an axial lorce in the buah 47947 \0 91ve 0.;- 1.5 mm
(0 +.06") cOlIlpreuion.
-17-

-------------------------------- __ TABLEm
(J;;)/
snw
:D
PARTS LIST FOR ENGINE
Gear box •Rear wh .. 1Dange (TABLE III)
Part I
Table
DESCRIPTION
Part
Table
I
DESCRIPTION
Number Seclion
Number
Section
61
AClip. spring, lor
brake jaws
12869 B
Screw. for dust cover
2021
ASc:rew. lor joining
brake drum
to
17821
DSelector. gear
flange
a)
17B24
CGear. 2nd
speed
2035 B
LiDk. brake
19H7 CClJ'Clip.
retaining shoulder washer
2036
BBolt. for securing
cable
to brake
a)
18558
C Washer. shoulder. normal. of gear
links pinions
2082
BPin. for rear brake links
a)
19611
CG.a:r. 3rd
speed
2098
ASplit pin. for locking castle nut
a) 20321
C
Washer. shoulder. 1st oversize
2442
ANut. for securing wheel
a) 20322 C
Washer. shoulder 2nd oversize
7563
ABall
bearing of mains haft
a) 20323 C
Washer. shoulder 3rd oversize
7884
B
Arm. rear brake control
a) 20324 CWhaMr. shoulder 4th oversize
7886
A
Pad
23831 ADrum.
rear brake
a) Th. total axial plOT of the auembly ·of the 3 gear pinion. in respect to their Hat mu.l be contained between .006" and .olr.
Shoulri this play exceed .aid toleraneell. the nonnal .houlder wa.h.r mu.t be replaced br another with proper o.e~ize.
-- 18-

PcutI llal lor eniine - Gear box· Rear wheel ilanve • ConLlnu~d
MaiDahaft. g.a. (Parts n. 17821 -
18447 _ 18558- 46605 _ 47190 _ S. 13815
82085 • S. 13768)
ParI
Number
25990
46605
46688
46696
46099
46700
46702
46803
47190
a) 48349
81'229
820S(
ITable
Seclicn
A
C
A
A
A
A
B
B
C
C
A
C
DESCRIPTION
Spring. return, of brake jaws
Stem. selector
Ring. locking ball bearing
Axl.. cam. of rear brake
S.aL spring - loaded of mainshaft
Circlip
Duat cover
Deneetor
Bush. guide,
01 selector stem
Gear. low speed
Jaw. rear brake. with lining
IPari
Number
a) 82085
82120
S. 1207
S. 2314
S. 3110 bis
S. 3204
S. ~208
S. 13768
Tabl..
Section
D
A
B
A
A
B
B
C
A
DESCRIPTION
Mainahaft
Flange. female spline, with inserts
Nut. on bolt securing brake links
Nut. castle, for
securing wheel
flange
Washer. spring, for nut securing
wheel'
Split pin. on pin for brake links
Split pin. for cam axle
Washer. tab, on selector stem
Waaher. plain, for nul securing
wheel flange.
a) The IOlal axial play ol the auembly 01 the 3 gear pinion. in relpect to their aeal mlal be contained belwHn .006" and 012".
Should thil play exc:oed laid toleranc .. ,the normal lhoulder 'Wasber mUlt be replacod by another 'With proper overl11e.
PARTS LIST FOR ENGINE
Cuah
gear • Kicbtarter
(TABLE: JV)
Pan
ITable I
DESCRIPTION
Part I Table
I
DESCRIPTION
Number Section INumber Section
2457
DBoller. for multiple
gear
483«7
CGear. multiple
17887
C
Spring. of cuah drive 48348 C
Gear. starting
17888
C
Gear. outer, of c:u.sh drive 81842
ARoller
31157
C
Washer. plate, of cush drive springs 82086
A
Cage. roller bearing
3'2494
DBall
bearing, 01 multiple gear
82128
BKic:katarter
46618
DLayabaft
83014
COri..... cushion. g.a. (Parts
n. 17887 -
46631
B
Plug
17888 - 311S7 - 48347 - S. 10776)
'{67'42
CBuJfer. for
starting sector
S. 1209
DNut. for
securing layshaft
47160
ARaee. roller
bearing of mainshaft
S. 3057
B
Waabar. plain. 01 kickstarter
47161
A
Washer. shoulder, roller bearing
S. 3109 D
Washer. sprin';l. for
nut securing
layshalt
47'218
ASpring. return,
of kickstarter
S. 57'23
ARiTet.
se=U1 ing pr:Iwl
47226
B
Scre •• securing kickstarter
S. 6637
DCirclip. lor locking multiple
gear
47996
DSector. starting, with
parts 47998 -
ball bearing
S. S723
S.6721 B
Packing
47998
APcrwl
S. 10776
CBiTet. for
securing plate washer
47999
CBlad•• long, for starting
sector
S. 10790
C
Bi ....t. for securing blades
.{8000
CBlade. short, for
starting sector
S. 12824
D
Waaber.
plain,
for
nut
securing
48002 C
Pad. blades
layahaft
- 19-

________________________________ TABLE IV
__ 82128
@
47996
Sll637
.I
PARTS LIST FOB ENGINE
FlTWb .. l Magneto •Fcm
5.1)77'&
{
@
©
(TULE V)
Part I
Tabl.
I
DESCRIPTION
Part I
Tabl.
I
DESCRIPTION
Number Section Number Section
603 0Screw. for
securing coils 16416 CBreaker. with platinum point
619 0
Washer. plain. for securing coils 16417 CAxle.
breaker
622
C
Washer. shim. of breaker
16418 C
Guaet. contact
624
CNut 16419 CRiD9.
insulating
16420 CCam
625 CFork
spring
16421 0
Blade felt. with inserts
662
"'-0
TermiDal 46750 0
Condenser
6'74 BCarclip. for flywheel
extraction 46075
...
Cam
2856 BSc:rew. long. for
securing fan cas-
46764
...
Cable. earth. with terminal
ing cover
46766
...
Grommet
2946
B
Scre~. short. for securing fan cas-
47191
...
Flywh .. L with inserts (Parts n. 6562
ing cover •46675 -S.
IOnS)
3213 cSc:rew.
securing condenser and felt 47576 BFcm
blade
47sn
Beo..r. fan
casing
65~ B
Washer. plain. of com
82150
...
Coil ignition. g. a. (Parts n. 82852 -
1,(501
.... I)
Terminal
4676& -827(6)
-?f'l -