Allstate 788.94495 Use and care manual

--I
OPERATING INSTRUCTIONS
AND PARTS LIST FOR
MOTOR SCOOTER
r------MODEL NUMBER 788.94495------
This is the Model Number of your Allstate Motor Scooter. It will be
found on a plate fastened to chassis under the fuel cock. Always
mention this number when communicating with us regarding the
Scooter. or when ordering 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 FOL-
LOWING 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.
...
co.
AND
. Printed in U.S.A.
ROEBUCK
SEARS,
F-1716
I
11-=-1 =============================================-.~ I
821762
1

INTRODUCTION
This model of motor scooter has a new and
modern type of engine in which the distribution
is realised by the crankshaft (rotary valve di-
stribution).
The carburettor, installed on the crankcase,
is in direct communication with the pre-compres-
sion chamber in corrispondence to the external
diameter of one of the crankshaft flywheels (see
fig. 11): the periphery of the flywheel rotates
very close to the crankcase, without touching it;
a
portion in the periphery of said web is ground
off, and controls the fuel flow to the pre-com-
pression chamber, thus acting as a rotary valve.
The recess on the web periphery has been
shaped in such a way as to give the maximum
volumetric efficiency, an asymmetrical distribution
diagram being achieved.
It must be noted that crankweb and crank-
, case are kept gas tight by 'the film of oil which
forms between them and not by direct contact;
in this way the system is not subject to wear
by friction, as is usually the case with similar
devices.
The intake pipe is very short; it is therefore
only the carburettor which slows down the flow
of fresh charge to the engine.
The advantages oJ a correct feeding system
are therefore clear; more power with low revs, and
so a more elastic engine. The intake pipe leads
therefore into the pre-compression chamber and
the fresh charge contacts directly the con. rod
big end; in this way the bearings are so efficiently
lubricated as to permit reduci<1g, the percentage
of oil in the gasoline (2"10).
The improvement which the rotary valve
brings to the thermo-dynamic performance of the
engine can be appreciated by considering the
flatness of the power curve; this, as is well known,
makes the engine capable of functioning on a
wide rpm range and of adjusting itself automa-
tically, with slight variation of speed, to all forms
or resistance which the scooter must overcome
(head wind, gradients etc.).
The proverbial climbing ability of this motor
scooter is enhanced in this model. All gradients
normally encountered on main roads can easily
be climbed in 3rd gear, even with two people
on board; any slope can be climbed at speed
in 2nd gear, while the 1st gear gives initial acce-
leration and is particularly useful on bad surfaces
and side roads.
Another advantage of the rotary valve is
that it eliminates back pressure, i. e. prevents
some of the fresh fuel from being pushed back
from the pre-compression chamber towards the
carburetttor and wasted, at the beginning of the
dovrnward stroke of the piston.
Engine performance is also improved by the
adoption of a spherical headed piston and a com-
bustion chamber on the cylinder head of a special
form which gives rise to higher turbulence, thus
resulting in higher compression ratio and thence
increase in both specific power and out-put.
Finally the carburettor, which is housed in
the air cleaner, is similar to those used in the
car industry, with plate-shaped slide valve and
immersed jets: this has reduced fuel consumption
and improved the general performance of the
engine.

fig. 1 - ALLSTATE. Cruisaire. Motor Scooter
WARNING
Location of frame Number
Location of engine Number
fig. 2 - Location of serial numbers.
Serial numbers are preceded by pre-
fixes: VA 12 T. for frame; V 18 I M.
for engine.
In order to keep your ALLSTATE Scooter in perfect
running condition and not to void the guarantee, always
have your machine repaired at a Sears, Roebuck and
Co. Store.
Special care should be taken with regard to the fuel
mixture
which should be regular gasoline and oil of
the
make, grade and in the amount prescribed in this
booklet.
Ethyl gasoline should never be used.
Do not use Allstate compounded motor oil or other
Premium Heavy Duty Motor Oil with detergents.
The inexperienced operator should exercise caution
in applying front wheel brake, to avoid locking.
fig. 3 - Controls of Allstate Scooter
1. Gear change twistgrip with clutch
control lever - 2. Front brake lever -
3. Throttle control grip - 4. Light an:!
dimmer switch - S. Front brake jaws. -
6. Rear brake pedal -7. Kickstarter -
8. Gear shifter - 9. R,ear brake jaws.
10. Clutch - 11. Carburellor. air cleaner -
12. Choke control lever - 13. fuel cock.
-3-

Fig. 4 - Engine installation and suspensions.
!. Steering column and front suspension - 2. Engine - 3. Crankcase half. clutch side, with swinging arm - 4. Rear suspension
spring with hydraulic damper.
MAIN SPECIFICATIONS
Frame. -Of pressed and spot-welded steel sheet,
with stream-lined monocoque-type structure.
Suspension. -Front wheel: coil spring. Rear wheel:
coil
spring and coaxial hydraulic shock absorber.
Engine. -Two-stroke, flat cast iron cylinder and
cast aluminium alloy cylinder head. Cooling effected
by centrifugal fan.
Displacement
123.4 cc. (7.53 cu. in.)
Bore. . 52.5 mm. (2.06 in.)
Stroke
57 mm. (2.24 in.)
Effective
power at 5000 rpm 4.6 HP.
Compression ratio . 7 : 1
Transmission. -Directly from
engine to rear wheel
through clutch, cushiOn drive and gear box.
Starting. -By means of kickstarter, right hand side
of scooter.
Fuel consumption:
(Gasoline -oil mixture)
Max. speed.
Wheel base.
Max. width on handlebars
Max. length of the scooter
Max. height.
Min. height of floorboard .
Tuming circle .
Weight
(unladen)
130 miles per gal.
46-.6 m.p.h.
46.4 in.
25.7 in.
68.2 in.
38.7 in.
8in.
59 in.
182 Ibs.
Gear box. - 3-speed drive with mesh gears in oil
bath. Its two-cable control is coupled with that of the
clutch, on left hand side of handlebars.
Engine to wheel transmission ratios:
First 12.2 to 1
Second
7.6 to
1
Third.
4.85 to 1
Clutch. - Wet type; multiplate, with facings of cork
composition applied to the driving discs.
Ignition. - By flywheel magneto.
.--------/-1
6
3
Fig. 5 - Ignition diagram
1. Ignition coil in flywheel magneto _ 2. Rotor cam - 3. Breaker
_ 4. Condenser - S. Sparkplug - 6. Engine cut-out on switch.
-4-

Lubrication. -By oil the in fuel mix-
ture for piston, cylinder, wrist pin, con.
rod,
cranshaft, main bearings. Both
clutch
and gear box operate in oil bath.
Carburettor. -With float-chamber
(see fig. 11); air cleaner mounted on the
engine. Air goes to the carburettor
through a large inlet tube and asilenc-
ing
chamber with filter having incor-
porated choke valve.
Model of
carburettor: Dell'Orto SI
20/15 B - Venturi 15 mm (0".59) - Main
jet 82/100 (0".03.2.3) - Idler jet 42/100
(0".0163) -Air-vent for main jet 100/100
(0".0394) -Air hole
on mixer top 150/100
(0".059) -Mixer
type E 2. -Air-vent to
idler jet 160/100 (0".063) -
Spray nozzle
200/100 (0".0788) - Float chamber fuel
level 20.5 ±1mm. (0".87) -Oil
recovery
vent 50/100 (0".0197).
Feeding. -
Fuel feed to the carburettor is provided
for by gravity (see fig. 11) with gasoline-oil mixture.
Fuel tank. -Total capacity: 2,03 gals.;
Reserve: ,-.J 1/
3.
gal. ;
Three--way cock: « open» -« closed» - «reserve»
Muffler. - Expansion and absorption combined type.
Handlebars. - Consisting of two arms in steel tube,
clamped in a support which is fixed to the steering
column. The central part of handlebars is completed
by two shells in pressed steel sheet. The headlamp
is installed therein. All control cables and electric wires,
to be connected to the handlebars, are concealed
inside it.
Steering column. -The steering column bears the
handlebars, clamped on its top end, and the front wheel
swinging hub, pivoted at its bottom end through a
stub axle.
Lighting and hom. -By flywheel magneto, feeding
both head lamp (two-beam), tail lamp, horn and stop
light (see fig. 9).
Brakes. - Expanding type.
Front brake: control lever on right hand side of
handlebars.
Rear brake: control pedal on right hand side of
floorboard.
Wheels. ~ Of pressed steel sheet, interchangeable
and easily removable, since they are assembled in an
automobile-like system.
Tires: dia. 3.50 x8in.
Steering Lock. -A suitable security lock is arranged
on the frame, near the 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
machine can only turn around. Turn the key
clockwise and the handlebars back to normal position
for releasing the steering system (see Fig. 7). Do not
attempt to ride the machine unless the key is in, and re-
mains in the lock, and the handlebars are moving freely.
5
Fig. 6 - Section of engine
1. Air cleaner and carburet tor _ 2. Piston - 3. Crankshaft
4. Clutch - 5. Mainshaft 6. Gear shifter - 7. Flywheel magneto
8. Kickstarter 9. Crankcase half. clutch side, with swing:ng arm.
Do not lubricate the steering lock.
Central Stand. -A two-legged :;tand is arranged
under the floorboard. A strong return spring holds it in
contact with the floorboard and keeps it from vibrating
while the scooter is being ridden.
Fig. 7 - Security lock
1. Normal position - 2. Closed
Tool Kit. - I four-end box wrench (II - 14 - 21 -
22
mm); 1 double open-ended wrench (8 - 14 mm);
1 single open-ended wrench (7 mm); 1 screw-driver.
These hand tools are contained in a canvas roll which
is placed in the left wing with an air pump.

Accessories (See Table XX). - On request the
Allstate scooter
can be equipped with the spare wheel
(and bracket) and speedometer.
Spare wheel and bracket (see fig. 8). -The wheel
bracket sheet steel pressing, can be secured to the
scooter frame behind luggage carrier (see Table XX,
c Spare parts list .).
It is very robust and simple and holds the wheel
in such aposition where it is easily accessible.
Speedometer. -The speedometer has its housing
in the middle of the handlebars and adds to the per-
formance and appearance of the scooter.
Fig. 8 - Spare wheel and bracket
.-------------------- WHlTE------_
9
BRDWII---"---',-"",--,,"--J/
~l*-4+--+--V1OLET-I--~
2
o-I----BLut ----.-.---...
~~~~---BLUE-----,
2
YELLOW~U;;p~I~~_t- _
YELL YELLOW
REO---r-~I"0~~~+--- REO -----+-1------1(;:
Fig. 9 - Scheme of Electric Wiring
1. Flywheel magneto - 2. Low tension terminal -
3. STOP light (6 V - 3 W bulb) - 4. Tail lamp
(6 V - 3 W bulb) - 5. Sparkplug - 6. STOP switch
- 7. Light and dimmer switch - 8. 6 V - 22/22 W
double filament bulb - 9. Horn - 10. Inside
view of head lamp -A: Engine cut-out - B: Lights
off - C : Head lamp and tail lamp on - D: Lever
lor country and traffic beam - E: Horn bulton .
5
~\<1----I-
-6-

HOW TO ASSEMBLE THE SPEEDOMETER (WIm MILE DIAL)
(See fig. 10)
- Take off the head lamp and disengage the top shell
of handlebars from the inside hub, then remove the
cover of the speedometer housing from the top shell.
-With
the help of apilot wire slide in into the steerihg
column from the top end the sheath cA. for the
flex drive, until it emerges from the bottom end
(indicated with an arrow in the figure).
-
Assemble packing c C. and then the speedometer
head c B. on the upper shell of handlebars; fit the
packing cD. and support c E • on speedometer boss,
then secure firmly with nut c F •.
-Pull the pilot wire au tof the sheath, grease the flex'
drive generously and slide it in. .
-
Place the upper end of the flex drive into housing
in the speedometer head and secure both flex drive
and sheath by means of knurled ring c G •.
- Re-assemble the upper shell and head lamp.
- Unscrew the plug «H. from the swinging hub.
-Fill up hub with grease the in order to lubricate the
portion of the wheel spindle meshing with the spee-
dometer drive pinion c I •.
-Mate' the pinion c I. to the support bush c L ., then
mount ring (with lubricator) «K. on the latter;
screw the support bush c L. on the wheel hub.
- Slide the rubber cap eN., the threaded ring cO.
and biconical ring c P • over the sheath end; fit .the
washer cQ • 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 ring cO. on bush «L. and po-
sition rubber cap eN •.
- Make sure that the end of the flex drive enters the
square section hole of the speedometer drive pinion.
-
Rotate the wheel by hand for several times in order
to make sure that it turns freely.
-Grec:zse
pinion c I • - support bush c L • assy through
lubncator on ring «K •.
B-Q C
z1;)
E--=u¥O .
r-·~G
:
Fig. 10 . How to aaaemble tbe speedometer unit
Due to the simple and conventional design of the
Allstate scooter, no particular skill is required for its
operation, nor skilled personnel for its maintenance.
The tasks can be quite well carried out by any
customer, even unexperienced, by carefully following
some general rules.
OPERATION
Fuel supply. - Fuel mixture, both during and after
running in, should be composed of regular gasoline
and pure mineral oil SAE 30 at 1. ':I., i.e.:
-1/
4pint of oil to 11
12 gallons of gasoline.
When using pre-diluted or additive oils, or oils for
outboard motors, mix 1/
4
pint of oil per gal.
Keep the breather of filling cap clean.
Oil level - Remove the level screw, on crankcase,
marked «OUO" as indicated on page 11 Fig. 20, to
check oil level in gear box before starting the engine.
The scooter standing upright, oil 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 (1200 miles) :
Do
not exceed following speeds:
1st gear 9.S mph
2nd gear 19 mph
3rd gear 31 mph
-Do not hold these max speeds for long periods neither
use full throtfie opening up-hill.
-
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, lift the choke rod. Push said rod
back as soon as the engine fires.
See Fig. lI; note the three positions of the fuel valve:
open, closed, reserve.
7-

Caution. -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 dif-
ficult).
proceed according to either one of the following
methods: f(
a) Push-start the scooter: shift into second gear, 1[1
declutch 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.
Fig. 11 • Feeding circuit
1. Fuel cock lever: A) Reserve, B) Open, C) Closed - 2. Float
_ 3. Air cleaner - 4. Choke lever - 5. Set screw for throttle slide
_ 6. Throttle slide - 7. Air vent for main jet - 8. Hole on mixer top
_ 9. Mixer - 10. Main jet - II. Idling jet - 12. Air vent for
idling jet - 13. Plug for inlet hole for oil: for laying up - 14. Idling
adjuster - 15. Intake port - 16. Transfer ports - 17. Exhaust duct.
B~
Z .!
!V
Fig. 12 _ Operations to carry out for starting the engine
A: open the fuel cock _ B : ~elect • neutral. - C: choke (with cold engine) - D: throttle coritrol grip in idling position - E: depress
the kicks tarter and turn grip • D. by short strokes.
-8-

-9-
.=---'
, --,
--'\
Fig. 14 - Drive system
1. Gear change twistgrip - 2. Clutch control lever - 3. Gear change
control cables _ 4. Gear shifter - S. Selector stem - 6. Selector -
7. 1st gear - 8. 2nd gear - 9. 3rd gear - 10. Mainshaft •
I!. Cush gear • 12. Clutch.
N.B. - Positions 1-2-3 of the gear change twistgrip correspond to
1st,
2nd and 3rd gear respectively; «0. indicates the
neutral position.
Do not turn the gear change twistgrip while the
engine is not running.
As soon as gear change troubles arise, ~ticularly
when the control becomes hard, customers should have
their machines adjusted by a Sears Store.
Slow running adjustment. -No hand tool is requir-
ed for this job. Idling revs can be raised or reduced
respectively by simply tightening or slackening the
knurled slotted screw on air cleaner steel sheet cover
(No.5. Fig. II). This screw controls the throttle slide
valve.
The adjuster screw for the throttle control cable is
installed on the air cleaner case. This screw is to be
reset only when necessary and while dismantling and
re-assembling. Opposite to said adjuster screw there
is on the air cleaner case a plugged hole for access
to another screw (spring loaded); see Fjg. II No, 14.
This screw controls the flow of carburated air through
the duct from the idling jet. and consequently the idling
revs. We recommend that customers refrain from re
Fig. 13 • Engine bonnet removal
1. Engine bonnet blocking lever - 2. Front pivot - 3. Fixing hool::
- 4. Hooked pivot
and tum the gear change twistgrip so that the engraved
line coincides with figure c 2" (2nd gear); let in the
clutch and open the throttle.
Repeat this procedure for changing into 3rd gear
and for changing down.
See the drive !iystem on Fig. 14.
When you reduce the speed of your machine,
change down without delay to avoid irregular engine
running and atallinq at low revs.
For access to the engine. take off the engine cowl-
ing, then proceed as follows.
-Pull
the lever c 1» (Fig. 13)) and tum it so as to
release it from bonnet. Then move the bonnet slightly
outwards ,until front pivot c '2 » disengages from the
hole on the frame.
Push the bonnet from the front upwards and tum it
(see position indicated by dotted line), thus releasing
the fixing hook c3»from frame.
-Move
bonnet outwards round its hooked pivot c4»
until the latter disengages from the hole on frame.
Thus the bonnet is removed.
For re-assembly, follow the reverse procedure.
Setting the machine in motion. •Let the engine
idle, depress the clutch and tum the gear change twist-.
grip so that the line engraved on it coincides with the
figure c I» (lst gear) engraved on handlebars (see
Fig. 1'4). 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

Fig. 15 - Dismantling the front wheel.
setting this screw unless absolutely necessary or during
dismantling and re-assembling operations that should,
anyway, be entrusted to a Sears Store.
Stopping the engine. - Push the earthing button.
This will leave the cylinder full of fuel vapours, and the
next start will be much easier.
Tires. -The wheels are interchangeable, i. e. they
can be assembled either in front or rear, provided of
course that they are inflated toyressures respectively
hereunder prescribed.
When aflat tire is to be replaced, unscrew the
four nuts which secure the wheel to its flange, pull wheel
sideways off the studs (see Fig. 15), repair it or replace
with spare wheel.
To remove the tube, first deflate, then separate
the felloe from the ring by unscrewing the nuts which
join them (see Fig. 16).
Fig. 16 - Removing the inner tube
Tire pressure should be 18-;-.20 psi on rear wheel,
14-;-'15,5 psi on front wheel. If the Allstate is ordinarily
ridden by both driver and passenger, the pressure of
the rear tire should be 28,5-;-'31 psi.
®
®
Fig. 17 - Brake adjustment
Brake adjustment. - Brakes are properly adjusted if:
the wheel rotates freely when respective control
lever or pedal are in resting position;
a
Fig. 18 _ Adjustment of clutch control
a) Adjusting nut -b) Clutch lever, engine side
-10-

-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. 17.
Adjustment of clutch control. - Adjustment of clutch
controls is achieved operating on adjusting nut (a),
screwed to the engine bracket (see Fig. IB). by means
of open end wrench 82199 in the tool roll.
The cable is to be tensioned or loosened, as the
case may be so that control lever, on handlebars, makes
a stroke of 2mm. (O.07B") 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
Every 5.000 miles:
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.
(B) - Clean the muffler and decarbonize the engine as
explained hereunder. Remove the muffler, the
cooling hood, the cylinder head and the cylinder
(see Fig. 20). Decarbonize the piston crown and
the cylinder ports from all carbon deposits. Decar-
bonize the inner side of the cylinder head. Care-
fully 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.
Clean the breaker points.
In
order to avoid ignition troubles or abnormal
running, have the breaker points adjusted in a
use Sears stores; the gop should not be more than
0.011 "-0.01 9" (see Fig. 19) and the points should
begin to open when the current in the primary
Ignition d,cuH has allalned ils peak value. /
Fig. l~ - Breaker points
•Max. gap of breacker points should be a all" -D.OI g"
(l) -
- 11 -
Cleaning the scooter. - Brushing kerosene and
wiping dry with clean rags is advisable for external
cleaning of engine.
All JXlinted 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 JXlint and turns it dull.
II necessary, blow the head lamp reflector clean
or wipe off dust with a very soft feather. Do not use a
cloth
and keep your fingers off reflector surface.
Before setting the machine 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 «OLIO» (see Fig. 21). The
scooter 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, JXlge 13. The crankcase can be drained through
the hole indicated in Fig. 21.
Every 2.500 miles:
(l) -Remove the air cleaner from the carburettor and
wash it in a 30 'Yo gasoline-oil bath.
(2) - Check oil level in the gear box (see above).
(3) - Grease all joints on the brake controls.
(4) - Clean the sJXlrkplug electrodes with very fine
emery cloth or suitable files, and adjust the gap
to 0.6 mm. (0.023").
Inspect the insulation material of sJXlrkplug; re-
place the latter if the porcelain is cracked. Wash
with neat gasoline.
Use the sJXlrkplug type Marelli CW 230 A- T;
Marelli CW 225 N-T; Morelli CW 225 A-T; Bosch
W
225 Tl; Champion L. 86; AC 43 F; KLG F 70
or F 75.
Important: using the proper type o[ sparkplug will
eliminate many engine troubles.
(5) - Grease the felt which lubricates the cam of fly-
wheel magneto.
(6) - Clean the two lubricators on front wheel hub and
refil 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 (if mounted).

(2) - Grease the control cables.
(3) - Change the oil in the gear box, as stated on
IXIge 13.
(4) - Grease the ratchet quadrant of the gear shifter.
Disuse:
(l) - In such a case, cleaning the scooter throughly is
advisable.
(2) -With engine not running and with throttle control
twistgrip
completely rotated, (full throttle opening)
pump 40 cc. of Allstate-Regulca Oil SAE 30 or
Allstate Outboard Motor Oil th~ough hole in the
air cleaner cover into the carburettor intake, by
means of an oiler. Then operate the kickstarter
three of 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 clrburettor.
(5) - Grease all unpainted metal parts.
~::
Fig. 20 . Cleaning the cylinder head. cylinder and piston
- 12-

LUBRICATION CHART FOR ALLSTATE
PART TO BE
OPERATION
TI ME
I
TYPE OF LUBRICANT
LUBRICATED
Engine
Mix gasoline with the
following amount of
At
each refilling of
the fuel I
Pure mineral oil SAE 30
lubricating oil:
tank
- '/4
pint of oil to l'h gallons of gasoline.
N.B. - With pre-diluted or additive oils, mix I
I
'/4 pint of oil to each gallon of gasoline.
I
----------
Gear Box
Warm up the engine and drain oll all
oil. After
the
first 600 miles and
Pour some fresh oil in and run the engine for
every 5000 miles
I
afew
seconds. Drain
again and refill
with
Allstate
Regular SAE
new oil (about 7oz.).
30
Refill wi h new oil to oil level hole.
Every 5000 miles
-
Front
wheel hub
Speedometer
flex
Lubricate with grease gun.
Every
2500 miles
High Pressure Chassis Grease
drive and pinion
- ---
Joints on
brake
Grease.
Every
2500 miles Allstate all - purpose
controls I
Gear Lubricator SAE
140
Shock-absorber
Change oil.
Only when the shock-absorber
Allstate Shock
is out of order
Absorber Fluid
Control cables Clean and lubricate.
Every 5000
miles Allstate all - purpose
Gear LUQricator SAE
140
--
Felt of flywheel
Small spot of grease on the felt.
Every 2500 miies Allstate Bearing
Grease
cam
Ratchet quadrant
Grease. Every 5000 miles
Ails a e all - purpose
of gear shifter
Gear Lubricator SAE
140
EN6NE LUBRICATED BY MIXTURE
ALLSTATE REGULAR SAE 30
OR ALLSTATE OUTBOARD MOTOR OIL
ALLSTATE SHOCK
ABSORBER FLUID
2
Fig. 21 - Lubrication scheme
1. Filling hole - 2. Draining hole
- 13-
HIGH PRESSURE CHASSIS GREASE

LOCATING TROUBLES AND RUNNING IRREGULARITIES
Carry out following checks when the engine does not start easily or rWlS irregularly.
Remedies
Locating the trouble I'
1----=---------- ------------
Locating the trouble
--- ----------------
I
Remedies
-
--------------
I --
DIFFICULT STARTING
3, - Ignition
Sparkplug dirty
Choke flap sticking in position
« closed.
Replace
Replace both plates and springs
Replace the selector
Replace the pinions
Should the control have exces-
sive play in neutral, tension
control cables by screwing
back the respective adjuster
screw (on cable sheath end,
ratchet quadrant side) with
an 8 mm open ended wrench.
If the cable tension in neutral
is correct but the reference
marks of the handlebars do
not tally, tighten one of the
adjuster screw and unscrew
the other one to the same
extent, so that the cable ten-
sion is not altered.
feeble I Replace
4. -Clutclh troubles
a) Clutch snatches:
Gear pinions not lubricated Top up oil level. Tighten the
properly screw on draining hole
b) Clutch slips:
Springs feeble
Plates worn or burnt
c) Clutch does not disengage
completely:
Excessive play on control Adjust (see fig. 18)
cable
5. - Gear pinions disengage of i
own accord I
Gear change control cables out Adjust
of adjustment
Spring of stirrup broken,
or missing
Selector arms chamfered
Dogs of gear pinions chipped or
worn
Turn to « reserve "Refill as soon
as possible.
Remove and wash in gasoline -
Blow
dry
Correct (see fig. 19)
Replace the plug
Clean with suitable files or very
fine emery paper
Release
Disconnect the plug lead. Check
if sparking occurs between
lead and crankase when the
kicks tarter is operated.
Clean. Correct gap to 0.6 mm.
I (023")
I
I See page 8
I
I Replace
Clean (see page II)
Clogged
dirty
Porcelain of sparkplug cracked
Breaker points dirty, partially
worn or pitted
Gap between breaker points in-
correct
Engine flooding
Float perforated
Air cleaner choked or dirty
2. - Carburation
1. - ruel system
Fuel tank empty
Filter on carburettor (
Fuel tap body
Carburet tor body
Main jet \.
Atomizer
Packing of fuel tap I
INCORRECT RUNNING
Not enough mixture flowing to See paragraph cDifficult start-
the carburettor ing., No. 1
Breaker points completely worn Replace
or pitted i
Timing wrong I Re-time ignition
1. - Lack of power I
Muffler outlet pipe carbonized I Clean (see page 11)
Exhaust port partially closed by , Decarbonize cylinder, piston and
carbon deposit cyhnder head
Cylinder base gasket not sealing Replace
Adjust (see Fig. 17)
Wash with gasoline or replace
Replace
Dismount and clean carburettor
in gasoline and compressed
air.
For type and diameter of jets
and vents, see page 5.
Replace
Re-time
See No. 2of this paragraph
Replace
Clean with pure gasoline and
blow dry. Dip the metal wad-
ding into a 30'10 gasoline-oil
bath
Lubricate or, if necessary, re-
place
Adjust
Slacken
Tighten
III -Jets or air vents of the car-
buret tor blocked or dirty;
incorrect or increased dia-
meter
IV Retarded ignition
V - Poor compression.
7 .. Controls not operating pro-
perly
Inner cables rusted
6. - High fuel consumption
I - Fuel level too high in car-
burettor:
Float perforated
iI -Air cleaner chocked or dirty
Excessi ve play
8. - Steering column becomes
stili
Top race of top ball bearing
too tight
Bottom races of the two bear-
ings pitted
9. - Excessive play of steering
column
Top race of top bearing loose
10. - Poor braking
Stroke of pedal or lever too long
Brake linings oily or worn down
Brake drums and linings scrat-
ched
a) Fit on a proper type of spark-
plug
b) Re-time the ignition
Replace
Tighten
Replace or clean the plug and
correct the gap to 0.6 mm (.023")
Clean
Tip of contact breaker loose
Condenser screw loose
Pre·ignition
Sparking plug carbon-coated or
with excessive electrode gap
Carbon pearls on sparkplug in-
sulation
2. - Poor compression I
Sparkplug not well screwed Tighten (21 mm box wrench)
down in cylinder head
Cylinder head not fitting properly I Set the head properly and tigh-
into the spigot on top of cy- ten the nuts
linder
Piston rings gummed up I Clean the rings and grooves
3. - Explosions at muller or car-
bureltor
- .. - 14 --

PARTS
LIST
TABLE I
©
~ &\~44
/"', @2040
S.1~7 5.3t \ ~
s.J057 \ -
46684
26278
87584
87GS5
26rS ~9290
I</~J~
~
:~~, 4661
87422
87423
89671
S.14441
~\~~.
~ ~'8 92230
@
PARTS UST FOR ENGINE
Crankcase - Cylinder (TABLE I)
Part
Number
Table
Section
DESCRIPTION
Part
Number
Table
Section
DESCRIPTION
I
318 D
Gasket, copper, of sparkplug
2/84821 A
Hood, cooling
2040 C
Adjuster of clutch 84644 B
SeaL spring loaded,
[or crankcase,
2444 CNut
flywheel side
86944 B
Piston, with standard wr'st pin (with
13903 D
Sparkplug, with gasket
2/51992 - S. 6615)
23823 C
Adjuster of rear brake
87420
B Piston, 1st oversize, with wrist pin
26278 B
Ball bearing, of crankshaft
(with 2/51992 - S. 6615)
46261
A-B
Stud, long, cylinder fastening
87421
B
Piston, 2nd oversize with wrist
pin
(with 2/51992 - S. 6615)
46684 CBolt,
securing crankcase halves
Piston, 3rd oversize with wrist pin
87422 B
46741
D
Cap, rubber, for sparkplug
(with 2/51992 - S. 6615)
45290 B
Seal, spring loaded, for crankcase,
87423
B
Piston, 4th oversize with wrist pin
clutch side
(with 2/51992 - S. 6615)
49502 B
Gasket, crankcase
8743'2 A
Ring, piston,
1st oversize
2/51992 A
Wrist pin
87433 A
Ring, piston,
2nd oversize
52575 ARing, piston,
normal
87434 A
Ring, piston, 3rd· ~versize
52625 A
Cylinder
- 15 --

Parts list for engine - Crankcase - Cylinder - Continued
Part
Number
Table
Section
DESCRIPTION
Part
Number
Table
Section
DESCRIPTION
II
87425 ARing. piston, 4th
oversize
I
IS.
5'21 B
Stud. for fixing carburettor
87436 D
Wrist pin, 1st oversize
S. 1107 A-B-C
Nut. for locking cylinder head and
87437 DI
Wrist pin, 2nd oversize
crankcase halves
87584
B
Crankcase halves (Parts n. 12869 -S. 1207 C
Nut
40313 -40316 - 4626,1 - 46'6-31 -S. 1447 IC
46684 -47160 -47161 -47944 -
Nut. spacer,
hood fixing
47945 -47946 -47947 47948 -S. 3057 A-B-C
Washer. plain
48000 -48002 -48035 -49502 -
51255 -54071 -81842 -a2086 -S. 2107 A-B-C-D
Washer. spring
87685 -S. 521 -S. 1107 -S. 3057
S.6615 C
Circlip. for locking wrist pin
-S. 3107 -S. 10790 -S. 11288 -
S. 12485)
S.6977 A-C
Washer. spring
87685 B
Plug. on crankcase, flywheel side
S.11288 A
Stud. securing crankcase halves
89120 A
Gasket. cylinder base
S. 1'2485 BBolt. short,
securing
crankcase
89871
D.
Engine. g. a.
halves
92230 D
Head, cylinder
S.14441 D
Screw. hood fixing
PARTS
UST FOR ENGINE
Crankshaft - Clutch
(TABLE II)
Washer spring, for castle nut se-
curing clutch a) 47946
Part'
Number
97
267
686
14457
16821
17781
19301
2G375
21866
21868
22313
22821
27172
Table
Section
B
B
A
C
C
C
C
B
D
D
B
D
D
DESCRIPTION
Key. woodruff. for crankshaft
(clutch side)
Key. woodruff, for crankshaft
(flywheel side)
Washer. shake proal. for nut secur-
ing flywheel
Spring, for fixing clutch centralizing
plate
Plate. clutch centralizing
Gasket. between clutch cover and
crankcase
Breather. with inserts
Nut.
castle, for securing clutch
Body clutch
Cup, clutch spring
Spring. clutch
Plate. clutch, with linings
Part
Number
27188
32005
40313
40316
46266
46271
46717
46718
46740
47944
47945
47947
47948
Table
Section
D
D
B
B
B
C
C
C
C
A
A
C
C
C
DESCRIPTION
Driving disc, external, of clutch
Ring. elastic, for stopping clutch
plates
Spindle. hollow, for hydraulic shock-
absorber
Bush. bottom, rubber, of shock-
absorber
Circlip. locking spacer
Piston, slo ted thrus ,of clutch
Lever. outer, clutch control
Lever. inner, clutch control
Spring, return, of outer clutch con-
trol lever
Spindle. hollow, for engine su-
spension
Spacer, flywheel side
Spacer. clutch side
Bush. rubber, clutch side
Washer. plain
- 16-

TABLE n
@
Paris lisl lor engine - Crankshaft - Clulch - Continued
84589
@
Part
Number
Table
Section
r.'::SCRIPTION
Part
Number
Table
Section
DESCRIPTION
I
48G35 D
Bush. rubber, flywheel side
8744:2
B
Bronze bush of can. rod small end
48834
B Washer. shim, of
clutch gear
89267
A
Crankshaft (with part n. 87442)
5'0100
C
Cover. clutch,
with inserts
2/50364
D
Plate. spring, of clutch
S. 2056
B
Washer. plain, for securing clutch
50370 D
Plate. smooth, of clutch
cover
S<l376
C
Clutch. g. a. (Parts n. 21866 - 21868
S.3106 B
Washer. spring
- 22821 - 27172 - 27188 - 32005
- 2/503&1 - 50370 - 85763)
S. 6708
C
Packing. between clutch cover and
84589 C
Cover. clutch with lever and thrust
outer lever
piston (Parts n. 19301 - 46271 -
461717 - 46718 - 46·740 - 50100 -
S. 12066 A
Nut. securing flywheel
S. (708)
85763
D
Gear. clutch
S.14413 B
Screw. securing clutch
cover
a) Parts 48988 or 48989 can be assembled instead of spacer 47946, to attain an axial force in the bush 47947 10 give 0 -;- 1,5 mm.
(0 +.06") compression.
- 17 -

---------------------------------_ TABLE ill
@
~~lny{§
~-----:::7/ .... ----"'--1)-'O>-\ 17'" B201lS ~sr"'47 47'90 '.1376' "'"'S
\
@
PARTS LIST FOR ENGINE
Gear
box -Rear wheel flange
©
(TABLE ill)
Part
Number
Table
Section
DESCRIPTION
Part
Number
Table
Section
DESCRIPTION
61 AClip,
spring, for brake jaws
a)
20322 CIWasher,
shoulder 2nd oversize
2021 AScrew, for joining
brake drum to (thickness: 2,35 mm. =0"
.09.2)
flange
a) 20323 CWasher, shoulder 3rd oversize
2,442
ANut. for
securing wheel
(thickness: 2,50 mm. =0".098)
7563 Ball
bearing of mainshaft
a) 20324 C
Washer,
shoulder 4th
oversize
A(thickness:
2,&5
mm. =0".104)
7886 A
Pad
23831 A
Drum, rear brake
12869 BScrew, for
dust
cover
42043 BArm,
rear brake control
17821
DSelector,
gear
42047 BLink,
brake
18447 CCirclip,
retaining shoulder washer
42048 BPin, for
rear brake
links
a)
18558
CWasher,
shoulder, normaL of gear
46605 CStem,
selector
pinions
Washer, shoulder,
1st 46688 A
Ring, locking ball
bearing
a) 20321
C
oversize
(thickness: 2,2 mm. =0".086) 46699 A
Seal, spring - loaded of mainshaft
a) The total axial play 01 the assembly 01 the 3 gear pinions in respect to their seat must be contained between .006" and .012".
Should this play exceed said tolerances, the normal shoulder washer must be replaced by another with proper oversize.
10

Parts list lor engine . Gear box . Rear wheel nange - Continued
Part
Number
46700
47190
a)
48349
51255
81229
a)
82085
82120
85073
858J.4
a) 87278
a) 87279
87714
Table
Sec:;on
A
C
C
B
A
D
A
B
A
C
C
A
DESCRIPTION
Circlip
Bush, guide, of selector stem
Gear, low speed
Dust cover
Jaw, rear brake, with lining
Mainshaft
Flange, female spline, with inserts
Bolt, for securing cable to brake
links
Axle, cam, of rear brake with
packing S. 6708
Gear, .2nd speed
Gear, 3rd speed
Washer, plain, for nut securing
wheel flange
Part
Number
89993
S. 1426
S.2314
S.3109
S.3111
S.3204
S.3208
S. 6708
S.12787
S. 13768
Table
Section
A
B
A
B
A
B
B
A
A
C
DESCRIPTION
Spring, return, of brake jaws
Nut, on bolt securing brake links
Nut, castle, for securing wheel
flange
Washer, spring
Washer, spring, for nut securing
wheel
Split Pin. on pin for brake links
Split pin, for cam axle
Packing
Split pin, for
locking castle nl.;!.t
Washer, tab, on selector stem
a) The total axial play of the assembly of the 3 gear pinions in respect to their seat must be contained between .006" and .012".
Should this play exceed said tolerances, the normal shoulder washer must be replaced by another with proper oversize.
PARTS LIST FOR ENGINE
Cush
gear -Kickstarter
(TABLE IV)
Part
Nu~ber
Table
Section
DESCRIPTION
I
Part
Number
Table
Section
DESCRIPTION
2457
DRoller, for multiple
gear 89025 CGear, multiple
17887
CSpring,
of cush' drive
89026 CGear,
starting
32494
DBall
bearing, of multiple gear 89059 DLayshaft
46631
DPlug
89911
CGear,
outer, of cush drive
467'42
B
BuHer, for starting sector
89913 CWasher,
plate, of cush drive springs
4716D
CRace. roller
bearing of mainshaft
89963
CDrive,
cushion, g.a. (Parts n. 17887
47161
AWasher; shoulder, roller
bearing
-89025 - 89911 -89913 - S. 10776)
47218
ASpring. return,
of kickstarter S. 1109 DNut. for
securing layshaft
47226
AScrew,
securing kicks tarter
S.3057 BWasher, plain, of kickstarter
48000
BBlade. short, for
starting sector
S. 3107 BWasher,
spring
48002 CPad,
blades
S.61)37 Circlip. for locking multiple
53681
CSector.
starting
D
gear
ball bearing
514071
ABlade. long, for
starting sector
S.6721 BPacking
58560
CWasher. spring, for
nut securing
layshaft
S.10776 CRivet. for
securing plate washer
81842
ARoller S. 10790 CRivet. for
securing blades
82086
A
Cage, roller bearing
S. 13940 DIWasher. plain, for
nut securing
87228
BKickstarter 1ayshaft
-
19-

47218-------8
.@
81842
/
47150 82086 co 47161
~"oo
~
~
53681
58560 5.6537
{ ~/46631
89911 89025 v
89963
TABLE IV
@
__ 87228
©
PARTS LIST FOR ENGINE
Flywheel Magneto - Fan
Part
Table
DESCRIPTION
Part
Table
Number
Sec ion
Number
Section
6G3
D
Screw, for securing coils
16417
C
622
C
Washer, shim, of breaker
16418
C
624
C
Nut
16419
C
625
C
Fork spring
16420
C
164'21
D
66.2
A-D
Terminal
46675 A
674
BCirc1ip, for flywheel
extraction
46750 D
2856
B
Screw, long, for securing fan
cas-
46764
A
ing cover 46766 A
2946
B
Screw, short, for securing fan
cas-
-47191 A
ing cover
47576 )
3213
C
Screw, securing condenser and felt B
blade
47577
B
6562
Washer, plain, of cam
83125
D
B
83282
A
14501
A-D
Terminal
83386
D
16416
C
Breaker, with platinum
point
- 20-
(TABLE V)
DESCRIPTION
Axle, breaker
Gusset, contact
Ring, insulating
Cam
Blade felt, with inserts
Cam
Condenser
Cable, earth, with terminal
Grommet
FlywheeL with inserts (Parts n. 6562
- 46675 - S. 10775)
Fan
Cover, fan casing
Stator
Link
CoiL low tension, No. 1