Benelli sprite-barracuda Install guide

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Sprite - Barracuda SHOP MANUAL
125cc 200cc 250cc FOUR AND FIVE SPEED
COSMOPOLIAN MOTORS. .INCORPORATED
JACK~ONVILLE & MEADOWBROOK ROADS, HATBORO. PA. 1904
.r (215) OS 2.9100

t:NulNt: - ::ingle cyiinaer 4 strOKe - uver lledO vaives - oore :J4 rnm. - .:truKe ::"l mill. - \..yiiiiuei
displacement 123,7cc. - Compression ratio 9,5 to 1 - CV. 16 at 8.800 R.P.M. - Distribution with
stand3rd cam - Intake open 30° BTDC - Intake close 75° ABCD - Exhaust open 75° BBDC - Exhaust
close 30° ATDC - Valve clearance with hot motor 0.006" - Forced lubrication by gear pump
60 L/H Oil capacity 2 qts - Gravity fuel supply 98 to 100 octane - Carburetor UB 22 BS - Ignition
by alternator flywheel magneto with external H.T. coil - Ignition advance 19° - Plus automatic
advance of 25° - Point gap 0.016" - Marell¡ Plug CW 260 L - Champion plug N. 3 - With multiplate
clutch - Costant mesh gear box - Foot shift pedal - Primary transmission by helicoidal gears -
Secondary transmission by chain 1/2" x 5/16".
FRAME . Combination of pressed steel and tubular " Double action hydraulic front fork -
Rear swing arm with adjustable hydraulic shock absorbers.
TIRES - Pirelli 2.75 x 18" (rib.) front wheel - 3.00 x 18" (univ.) rear wheel - Expanding type
brakes.
LIGHTING EQUIPMENT - Alternating current 6V 7 amp equipped with battery to ensure
steady supply of current to lights and horn - Large 130 mm. headlight - Headlight: 6\1 25/25
S. B.
OVERALL DIMENSIONS - Length 76.44" - Width 27" - Height 36.64" Weight 229 Ibs. (DRY) -
Fuel tank capacity 3,5 gallons - Reserve .05 gallons . Maximum speed 7~ MPH - Fuel
consumption 90 MPG.
MOTORCYCLE 200cc. (Technical data different from 125cc.)
ENGINE. Bore 66,5 mm. - Stroke 57 mm. - Cylinder displacement 197,9cc. - Compression
ratio 8,8 to 1 - CV. 19,5 at 8.600 R.P.M. -Carburetor UB 22 B5 - Ignition advance 9" 30' -
Plus automatic advance of 29" with flywheel magneto ADP 791 AN.
. (Note: with flywheel magneto ADP 54/2ANB ignition advance 17' - plus automatic advance
of 25").
TIRES - Pirelli 3.00 x 18" rib. front whee! - 3.00 x 18" univ. rear wheeL.
OVERALL DIMENSIONS. Weight 231 Ibs. (DRY) - Maximum speed 90 MPH - Fuel consum-
ption 85 MPG.
MOTORCYCLE 250cc. (Technical data different -from-1-25cc.)--------------------
ENGINE. Bore 74 mm - Stroke 57 mm - Cylinder displacement 245.1cc. - Compresskin ratio
8,5 to 1 - CV. 24 at 8.500 R.P.M. - Carburetor US 24 B5 2 - Ignition advance 9'" 30' - Plus
automatic advance of 29° with flywheel magneto ADP 79/AN and ADP 78/2ANB.
TIRES. Pirelli 3.00 x 18" univ. front wheel - 3.25 x 18" univ. rear wheeL. .
OVERALL DIMENSIONS. Weight 232 Ibs. (DRY) - Maximum speed 95 MPH - Fuel cons'Jmption
80 MPG.
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, 2:
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2B
1Front fork 14 Petcock 27 Rear foot rest
2Front fender 15 Tool box 28 Stand
:i Headlamp 16 Strap 29 Kickstart
4Switch key 17 Seat 30 Foot rest
,. Clutch lever 18 Rear light 31 Brake pedal
.)
Ii Dimmer switch 19 Rear fender 32 Oil drain plug
i' Damper 20 Shock absorber 33 Clutch adjuster
BHandlebar 21 Chain guard 34 Frame
9Front brake lever 22 Rear wheel 35 Horn
10 Throttle control 23 Rear hub 36 Front wheel
li Gas cap 24 eh ¡¡ 37 Front hub
1:1 Carburetor 25 Chain adjuster
1 :3 Gastank 26 Rear fork
3

Special tools are made in order to facilitate disassembly and reassembly operations, and used
with metric wrenches, will enable you to perform all necessary operations.
A B~
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A Thread protecting bushings
B Piston pin shaft extractor -l
C Piston extractor .J
o Countershaft sprocket holder
E Countershaft sprocket wrench
F Engine pinion holder
G Engine pinion puller
H Engine pinion puller
I Flywheel magn~to holder
L Flywheel magneto extractor
M Clutch hub holder
138&139/MB
144/nB
141/HB
140/HB
13 11MB
1431MB
146/HB
13 21MB
1371MB
1301MB
N Clutch spring tool
o Universal puller
P Cam follower bushing extractor
Q Crankshaft spacer
R Kich starter spring holder
S 5mm Allen wrench
T Shifting drum puller
U Cam gear extractor
V Engine support
i 3 SIHB
133/HB
134/HB
G 276
1421MB
G 262
136/1113
147/HB
1451MB
4

Before performing any operation, it is advisable to thoroughly clean the machine, in order to
prevent any dust particles from accumulating on engine components.
"'
1 ) Remove engine oil, using 27mm wrench to unscrew oil plug. Then remove oil filter
assembly.
2) Loosen carburetor clamp with 8mm wrench and pull out carburetor after air fìlter has
been removed.
-:3) Remove electric wires from junction box.
4) Unscrew fuel lines with 12mm wrench.
5) Pull out engine breather tube.
6) Loosen clutch cable clamp and pullout cable.
7) Pullout the spark plug cap.
8) Remove with pliers, master link clip, master link and chain.
9) Unscrew foot peg bolts with 17mm wrench. Remove knurled nut of brake rod.
10) Remove exhaust pipe and muffer.
11) Unscrew lower engine stud nut using 17mm wrench - press out stud.
12) Remove upper engine studs nuts with. 14mm wrench, also studs and engine from frame.
To reassemble, reverse above instructions.
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Engine view flywheel magneto side
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Engine yiew clutch s.ide
NOTE:
Due to the unique characteristics of the engine, most of the operations shown in this book
can be made with the engine on the frame. Only if the crankcase must be split, will engine have
to be removed.
By removing the left hand cover, the flywheel magneto, clutch adjuster and countershaft
sprocket are accessible.
By removing the right hand cover, the clutch, preselector components and cam distribution
gears are visible. These are operated in oil bath, therefore, this cover must be perfectly sealed.
The cylinder head, rocker arm and cylinder are removable from the front side.
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tool Sf removing the three fastening
screws.
Remove the flywheel magneto nut, using
19mm wrench, holding at the same time,
the flywheel with tool i.
Lock the flywheel puller L in position and
with 22mm wrench, loosen the flywheel
from crankshaft. Tap on the puller bolt
slightly with a hammer if the flywheel is
hard to remove.
Before removing the backing plate, it is
advisable to made a reference mark on the
crankcase in order to facilitate the
reassembly operation.

Remove clutch lever support screws using
tool S. With screw driver, unscrew flywheel
protection cover fastening screws.
Holding kick starter spring with tool R,
remove with screw driver the spring
fastening screw.
To remove countershaft sprocket it is necessary to:
i) Lift up the safety washer loop.
2) Install the special tool D.
3) Remove the nut with special wrench E, holding at the same time the countershaft sprocket
with tool D.
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Wi th lOmm socket wrench, remove the 4
rocker cover fastening screws. Pull out
cover and aluminum gasket.
Before removing with 12mm socket wrench:
the four cylinder head nuts, be certain
that the piston is in compression stroke
position. Pull out the rocker arm support
carefully in order. not to damage the
threads of the cylinder studs.
Pull out the cylinder head, gasket, cylinder
and base gaskets.

Remove with plyers the two piston pin
circlips.
Insert the pin B in the tool C. Install the
tool C on the piston. (It is advisable to
slightly heat the piston before removing
the pin).
Turn the spindle until the piston pin is
removed from the connecting rod.
NOTE: It is not necessary to remove the piston rings, to remove the piston.
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After the shifting lever has been removed,
unscrew the 10 Allen screws with the
tcol S. Tapping slightly with plastic
hammer, pullout cover.
Dismantling of the clutch
With the special curved tool N, disconnect
the five clutch springs.
Remove the clutch plates and the short
clutch rod.
Lift up the loop of the safety washer (bent
over the nut).

Holding the clutch drum with special tool
M, unscrew the locking nut using 17mm
wrench. Then pullout the clutch drum,
thrust washer, clutch crown and second
thrust washer.
Pullout the preselector shaft.
Holding with special tool F, the engine
pinion gear, remove the cam gear and
engine pinion gear locking nuts.
With special puller G, remove the el1~ine
pinion gear.
NOTE: If the special puller G can not be
use, use puller H.
Using extractor 0, pull.out the cam gear.
NOTE: Use special puller U with gear
having two threaded holes.
12

After the nut of the selector drum has
been removed, using 11 mm socket wrench,
pullout drum with special tool T.
Extract the Woodruff keys of the engine
pinion gear, cam shaft and desmodromÎc
shaft.
To remove the Woodruff key, it is ùdvisable
to use a small pin in order to rotate it.
To install Woodruff key, hold with pliers
and tap slightly.
How to split the crankcase:
Remove the four oil pump bolts with 10mm wrench.
Use 11 mm wrench to unscrew crankcase stud nut from one side, then pull out the stud.
Unscrew and remove the Allen bolts, using tool S. The screws are indicated on sketch on page
14- 15
With a pin, press out the crankcase
centering bushing.
1 3 .

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Install the protecting bushing A tightly
on the crankshaft.
It is advisable to slightly heat the crankcase
before proceeding to split it. (140° F. H.)
Tap slightly with plastic hammer on
primary shaft and crankshaft until the
right hand crankcase is separated from
the other half.
Remove all the components and clean
thoroughly.
To disassemble the crankshaft from the
left hand side crankcase, install tightly
the coarse threads protecting bu~hing and
proceed as per above instructions.
Heat the crankcase at approximately 1401
to 1800 Fahrenheit before removing bearing
from it.
To remove the camshaft and final gear
drive bearings from left hand c.rankcase
(flywheel magneto side), dismantl.: the
two bearing covers and press out.
To replace the cam follower busliings,
use special extractor P as indicated ,in the
figure alongside.
16.

the seeger rings and other components.
NOTE: The two half crankcase are joined without gaskets, therefore, any imperfections of
the conract faces must be corrected.
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List of seeger assembled on 5 speed engine
crankcases
Left hand half crankcase, (Flywheel
magneto side).
No. 2 seeger rings type 47 J assembled
into the main bearing seat.
No. 1 seeger ring type 47J must be
installed after the large bearing is
assembled.
Right hand crankcase (clutch side).
No. 2 seeger rings type 47 J assembled
into the main bearing seat.
No. 1 seeger ring type 40J assembled
into the camshaft bearing seat.
No. 1 seeger ring type 40JV assembled
into the primary shaft bearing seat.
No. 1 seeger ring type K assembled into
the secondary shaft bearing seat.
NOTE: This seeger most be installed (after
the crankcase are joined).
List of seeer rings assembled on 4 speed engine crankcases
Left hand half crankase (Flywheel magneto side)
No.1 seeger type 47J assembled on the main bearing seat.
Right hand half crankcase (clutch side) FOR 200cc and 250 ce.
No. 1 seeger ring type 47 J assembled into the main bearing seat.
Right hand half crankcase (clutch side) FOR 125ec.
NO.2 seeger ring type 47J assembled into the main bearing seat.
NOTE: All the other seeger rings are interchangeable.
After all the seeger rings are installed into the half crankcases and before the installation of
all the bearings, it is necessary to heat the crankcase at approximately 1400 to 1800 Fahrenheit.
1 7

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List of bearings installed into left hand
crankcase (5 speed engine).
1 Bearing 25-47-14 for crankshaft (inner
side ).
1 Bearing 20x47x20,6 (double race) for
crankshaft (external sid~).
1 Bearing 25x52x12 for primary shaft
installation from the external side of
crankcase.
The bearing must be even with crankcase
face externally_
1 Bearing 12x32xl0 for camshaft.
1 Steel bushing for secondary shaft needle
cage installed internally.
1 Cam follower bushing.
Install the seeger rings J 47 from the
external side. Then install the oil seal
20x47x8.
Install oil ring into the kick starter shaft
hole.
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1 Bearing for crankshaft installed ex-
ternally (20x47x20,6 with double races).
1 Oil seal 20x30x7.
Install the crankshaft oil seal into the
threaded ri ng (20x30x7).
Assemble gasket and ring on the external
side of crankcase.
The oil seal and plate of the fìnal gear
drive are assembled on the external side
of crankcase.
The special supporting screw of the dust
protecting plate must be installed on the
upper side of the engine (see picture
alongside) .
Install the cam shaft bearing cover with
the respective gasket and lock the three
screws tightly.
Install the fìnal drive gear (internally)
and from the external side, press in the
countershaft sprocket spacer.
Assemble the countershaft sprocket.

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Install th
the final ~ ,two clutch rod
rive gear. oil seals inte
Assembl.e special safety .
waSher
Use spe . I
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countershaft 0 s D and E
Bend safty sprocket nut (F;o lock the
washer 0 '" . i -LB 65)
v-r nut f- .
ace.
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