BSA B40 VICTOR W D 1967 Instruction manual

gA
WORKSHOP MANUAL
. FOR
MODEL 8.40. VICTOR W.D.
Service Department
B.S.A. MOTOR CYCLES LTD.
Publication Reference No. 00-4 l'33 /21 67
Telephone VlCtoria 2381
ARMOURY ROAD
I I, ENGLAN D
BIRMINGHAM
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INTRGDUCTICT{
This manunl has been compiled to provide colnprehensive service inforrnation to assisi the uorkslrop fitter
in carrl,ingout satisfactory repair tvork or basic maintenailce on the 840 A.W"D. nrotor-cycle'
It shoulcl be noted that the manual is divided into sections dea.ling rvith n-raioI asscnrblies itnd tlresc
are sub-divided into the individual operations required lor maintenance or rcpair' tly usine this arlangc-
ment, it is hoped that the manual will also be found most usetul as a qurick work olrel'crence.
AII the information arrd data given througlrout tlre manual is correct {t the tiine ol' publication btrt.
because of the constant development of B.s.A. motor-cycles, ciranges in the specilicuticllls are incvititble.
Should the manual be found to be at variance with tlre B.S.,A. machine in question. it is atlvised thr
that the Service Department be contactedo rvhere up-to-date infornration ivill be quickly prr:videcl.
ET.{GINE AND FRAME NUMBERS
Both the engine and frarne numbers, together rvith prcfix ancl suffix letters. must be quotecl in l'tril on anv
correspondence relatirrg to thc nrachine ot' ol1 any e nquiry regarding this manual, to the Servicc Department
The engine nurnber is stampecl on the left-hand side of the crankcase inrmediately belou' the cylindcr
base. The frame numbcr is stampecl on the left-hand side of the front engine mounting lug as indicated
in the drau,irtg bclow.
ENGINE NUMBER
FRAME NUMBER
Page 4
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PITOPRIETARY PARTS
Equipment not of our manufacttrre which is
guaranteed by the manufacturers and not by
faeturer concerned or their accredited agents
the manufacturers eoncerned ;*
frtted to cur motor-cycles is of tlre highest quality and is
us. Any complaints or repairs shouid be sent to the manu-
who will give every possible assistance. The following are
BATTERY
CARBUR.ETTER
CHATNS
ELECTRICAL EQUIPMHNT
R.EAR, DAMPER.S
SPARK PLUG
SPEEDOMETER
Varly Dry Accumulasors Limited.
By-Fass Road,
B,4RKING, Essex.
Amal Lirnited.
Holdf'ord Road,
Witton, BIRMINCHAM 6.
Renold Chains Limited,
Wythenshawe,
MANCHESTER.
Ioseph Lucas Limited,
Ct, Flanrpton Street, and
BIRMINGHAM I8.
Cirling Limited,
Birrningham li,oaef,
WEST BROMWIChI, Staffs.
Wipac Group Sales Ltd..
London Road,
BUCKINGHAM.
Champion Sparking Flug Company Lirnited,
FELTHAM, fulidcilesex.
Smith's Motor Accessories Limited.
Cricklewood Works.
LONDON N.W.2.
Dunlop Company Limited.
Fort Dunlop,
BIRMINICHAM 24.
TYRES
Page 5
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TICI{ I{{C,{L .ADVICE
B.S.A. Service Department staff are experienced in deaiiilg rvitlr technieal trrroblerns ol" all kinds and rvill
irepleasedtohe!pintheeventofclifliculty" Thecorrectacldressol'the$erviceDepartmentisasfolloivs:*
B"S.A. MOTOIT CYCI-ES I-Ih4ITED"
SE"RV ICE DEI'A RTN{ EI..IT,
AR.I\4O{JRY ROAD"
BIRMINC!-IAM II.
'ldephone No. VlCtoria 2381
!m a!! cornmuniea$ions ttre nionle! memt he quoteel with full engine ansl frarete numbers
together with all prefix or su{fix letfers.
Fage 6
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PREPARINC TFTE MACHINE
RAMOVING THE MOTOR.CYCLE FROM TI{E CASE
Check tlrrit the packing case is ttre RIGI-lT WAY UP before disrnantling. The TOF has stencilled markings
o* it, the bottorn does not.
Prise off the top boards rvith a suitable pinch bar anel take out the top packing material. Take off
one sirJe of the case and remove the four wooden packing case supports from the top.
Note that one support is held by two holted brackets to the lr:rndlebar clamp lugs. The rear support
carries the front ancl rear sat'ety bars, but these may be left attached to the support until they are to be fitted
to the motor-cycle.
Carefully withdraw the machine ltonr the case and check that you have all the loose parts before
discarding the wrappings. lletain the Test Cartl in case you mny fincl it necessary to report any loss of parts
or clamage clirring transit, Small items, such as the footrests, handlebar clanrp brackets. etc., ivill be found
in the pannier bag. The saddle and windscreen assembly are each paeked separately.
Put the machine on to its centre stand ancl proceed to fit the loose eornponents.
Norr:-lt is rnost important that nel selt'-locking nuts are used during assembly. Once a nrit ol this
type has been used, the locking device becomes inoperative, rendering the nut unfit for further use.
FTTTII\G THE }I,ANDLE8AR
Place the handlebar, complete ivith corrtrols and cables, in position and fit the clamp brackets loosely'
When a suitable handlebar position has been determined, the f'our clamp fixing bolts can be tightened.
Check each control for correct operatiou and make adjustments as neces$ary.
FITTING TT{E SAFETY B.A.RS
Detach the safety bars tiom the packing case rear support. which will have been remr"rved during case
clisrnantling"
Flace the front safety bar in position against the frame down-tube and attach loosely 1o the loiver
holes in the steering head plates. using one bolt" spacer (between the plates) and nut. Take out the front
engine mounting bolt which also secures the exhaust pipe trracket. The spacer on the bolt is only fitted
tbr packing purposes and should now be discarded.
Locate the lower brackets of the s:rfet1, bar over the engine mounting lug and securer together with
the exhaust pipe bracket, with the nut dnd bolt. The top llxing bolt can now be tightenecl futly. Finally.
connect the brown/blue and brown/black leads to their respective terminals on the horn.
The rear salety bars are in two li*lves and can only tre fixed together when in position below the saddle
support rail. Ensure that tlre bars are the correct way round, i.e.. fixing plates angled to the front" befcrre
securing together with the two "Nyloc" nuts and washers. Pass the two "U" bolts over the sacldle support
rail at each side and fix loosely to the safety bars with four "Nyloc" fluts and washers. The angleii fixing
plates should now be secured to the lugs on the sub-fiame, using the existing nuts and bolts. Note that
the right-hand bolt also reiains the exhaust pipe bracket.
Finally, tighten all the fixing bolts and nuts and check for rigidity.
FTT-TTNC THE SADDLE
Engage the front bracket, beneath the saddle. with the frame tie-bar and locate the rear fixing studs with
the support rail brackets. R.each belorv the saddle at the rear and fit the spacers, washers and nuts on to
the studs. T'igliten the nuts evenly ancl cheek that the saddle is secure.
Page 7
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FIT'TING THN FOOTRE.ST'S
Note thai the liont footrests are "handed'" arrcl, beeause of fhe cut-away ln the bosscs. can onl3, be litted
one way. T'he right-hirncl lootrest is correctly loceted x'itli the boss cut-alay at the togr and is secLrred by
a single nut. and bolt. The left-hand foritrest is fixed to its stucl by one nut and rvashen. the boss cut';xwatY
heing at the front.
The pillitw fciotrests are pre-ilssernbled to their anchor bolts and. like the front foofrests they *re
""handed". the shorten anchor bolt being the right"hand one. Each ;lsserubly is secured t* llie frame brackets
by one nut with a spring washer and plain washer.
FTTTING TP{E 1VINNSCREEN
The rvindscreen support menrbers are assernbled to the base of the screen and to complete tlre assenrbly
it will *nly be necessary to fix the centrat lrolt through the screen centre. Take off fhe nut. rvaslier, liner
and one halfl of the grommet. Pass the bolt througlr the hole in the screen and replace the small liner"
gromntet, washer and nut, so that the sereen is held between the grtlmn,let halves. The support rnembers
are helil to.eether at each side with clips, the bolts for whicli can now be tiglrtened.
'[ake out the lowen nuts and bolts fnor,i tlie handlebar clips and loosen tlre top bolts. Open up eaeh
clip antl fit over the handlebar, taking care not to lose the split liners, Ideplace the lower clip bolts ansi
nuts and clreck th;rt the liners arecorrertly positioned within thcelips. A"djust the position of thescreen so
that it is central and upright, then tighten all for.rr clip bolts evenly.
FETTiI\S TFtE R.AAR-VlF:W I*{[RR0R
Relense the lorver clip bolt in the same manilei"*s detailed flor the windscr*en clips. Position the mirror
on the right-hand half of the handlebar, next to tlre h'rake lever, replaee the clip bolt and nut anc!, after
checking that the split liner is correctly locaied, tighten the clip fixing bolts.
I-oosen the bolts on the smalier elips and adjust the rnirror to give good, unotrstrructed rear vision
frorn the riders position. Finally, tighten al! clip bolts and reeheck tlre setting.
8AT"TEft,Y
The battery is filled rviih acid and will require it$ first eharge before being put into serviee. Firl! details cf
the {irst charge proeedure are given on pfrge C.2 of the rnanual.
When ttre eharge operations nne complete, connect the cables to tlreir appropriate batfery tenminals"
the red eable being the positive {*i or eanth rvire.
FINAI- CFIECK
Before the motor-cycle is put into service every nut, bolt and serew rnust be clreckeel for security and eorrect
fitting" lt shoulcl be rroterl that 90 /. of all vibration problerns, leaciing to missing nuts, fractures and rattles.
can be traced to loose engine rnountings. Do not simply take it for granted tliat the flactory has done every-
thing mght, take the precaution of elrecking everything yoursell'.
linsure also, that suitable ad.lustments have been made to thre *ontrol eables and that ench control
functions correctly.
Fage 8
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STAR.T'ING TFIE MOTOR.CYCLE
Fill the oil tank" primary chaincase anel gearbox to the required levels u,ith correct grades of oil" full cletails
of which are given in seetion A of the ntanual. Pour some petro! into the fuel tank, switch on the igniticn
and start the engine. while the engine is running fake oflf itre o;l tank liller cap and clreck that the oi! is
circulating correctly through the rctilrn pipe. After replacing the {rller cap the machine will be c*mplete
and ready for use.
The individual rider rnay find it necessar"v- to ad.just the ferolbralce, handlebar, corrtrols etc". fo suit his
requirenrents' Details of these adjustrnents and full instructions on riciing the rnachine nvill Lre fcuncl im
the instruction rnanual,
Page 9
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CCINT'ENTS
frENER"A[- DATA
l-UBR.lCATlOr.,-
HNGINE
CARBUR.ETTER.
FR"AME AND FITTINCS
FRCINT L.ORKS
\ryF!EELS, ERAKES AND TYRES
ELHCTR.ICAI- EQUIPIVIENT
T0nguE wRENC!-t SETTIITGS
MACI-iINE TOOL KIT CHECK LTST
SER,VICE TOOLS
COhIVER.SION TABLES
-Sc,ltloll
GD
A
B
Ptges
It*8
I to l3
Iro35
ItoS
Ito12
ItoB
!tol6
!tol6
C
D
E
(.:
EJ
J
K
L
I
I
Ir08
Ito9
Fage [0
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B4O-AWD GHNERAL DATA GDI
INDEX
ENCINE: Pag.
CD.4
CD.2
GD.2
cD.4
GD.4
cD.4
cD"3
GD,2
GD.2
GD.2
GD"4
cD.3
GD"3
cD.3
cD.3
GD,}
cD.5
GD.5
CD.5
cD.5
cD.5
cD.6
GD.6
GD.6
GD.7
CD.7
cD.6
CD.i
cD.7
CD.7
CD.8
cD.it
BranrNc DtmrusroNs
Ceusslrr Bran,ruc Busnrs
CansuRrrren
CylrrqnnR Bannel
Cylrrunnn Hrau
lcnrnoru TlrurNc
Camsunrr
Orr. Puup
Plsrou
PrsroN Rrncs
$panr Pluc
Tepprr Clsnneucr
Vnlvrs
VelvE
Vnlve
Velvr
Curnrs
Spnrrucs.
Trwrrnc
TRANSMISSION:
Cunrw Slzrs
Clurcs
Grnn Rnrros
SrRocxrrs
FRAME AND FITTINGS:
FRorur Fonr
Fnonr Fonr Busuas
Rrnn Dalaprns...
Si','txctt*c ARrt
WI{EELS, BRAKES AND TYRES:
Bnlxes
Tvnrs
Wnrrm
Wueel Brenlncs
ELECTRICAL EQUIPMEIIT
CAPACITIES
BASIC DIMENSIONS
WEICHTS
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GD2 GENHRAL DATA B4CI.AWD
ENGTNE
FISTON
Material .". "Lo-Ex" Alumirrium
Compression ratio 7.0:l
Clearance (bottonr of skirt) .0021"-.0024" ("06554--.06096 mm,)
Clearance (top of skirt) "0051"---.0054' (.12954-.13716 mm.)
(both measured on rnajor axis!.
PISTOI{ RINGS
Nlateri:rl-cornpression (top) , Brico 8SS.5004 (chrome-plated)
{centre) tsrico 8
-scraper Brico 8SS.5004
Width--compression (top and centre) .0625' (1.5875 mm.)
Width*scraper .125' (3.175 mm.)
Depth .l2A'-.127' (3.048--3.2258 mm.)
Clearance in groove .001'-.002" (.CI254-.0508 rnm.)
Fitted gap-(maxirnunr) .014" ("3556 mm.)
Fitted gap-(mininnurn) .009' (.2283 mm.)
Oil,,PUMP
Pump bodv material Zinc base alloy
T-vpe Double gear
.5:lDrive ratio
Non-return valve spring (free length) .5' (12.7 nnm.)
Non-return valve spring ball (diameter) .25' (6.35 rnm.)
Oilpressure relief valve spring (free length) ,.. .6094' (15.4781 mm.i
Gil pressune relief valve ball (diameter) .3125' (7.9375 mnr.)
CAI\{SF{AFT
Journal cliameter (left-hand) ".. .5598'-.5603" {14.?189-14.2316 mnn.}
Journal diameter (right-hanct) "7480"*"7485" (18"9992*19.0119 mm.)
CanT lift (inlet and exhaust) .26rc' (6.6294 mm.)
Basic circle radius ,386" (9.8044 mm.)
CAMSHAFT tsEAR,XNG EUSHES
Bore diameter (fitted) teft-hand .561'-.562" (14,2494-14.2?48 rnm.)
Bore diameter (fitted) right-hand ^7492'-*"7497' {19.0297:19.04238 mrn.)
Outside diarneter (left-hand) ."" .719r*"12A' (!8.2626-18.2880 mm.)
Outside diameter {right-hand) "908"-.909' (23.0632-23.0f186 mm.)
Camshaft clearance {teft-hand) .0012'-.001?' (.03048--.0432 rrrn"}
Camshaft clearance (right-hand) "0012" (.03048 rnm.)
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B4O.AWD GENEMAL DATA GD3
VATVE GUIDES
Material ... Cast-iron
Bore diameter .". .3120'*"3130"
Outside diameter .5005'-.5010'
l-ength 1.859"
Cylinder head interference fit ... .0005"-.0025'
vA{,vns
Seat angle (inclusive)
Head diameter (inlet) ...
Head diarneter {exhaust)
Stem diarneter (inlet)
Stern diarneter (exhaust)
VALVE SPRINGS
Free length (inner)
Free length {outer)
Fitted length (inner)
Fitted length (ourer)
VAIVE TIIVI{NG
Tappets set to .020" (.508 mm.) lor checkin-s
purposes on!y.
lnlet opens B.T.D.C.
Inlet closes A.B.D.C. ...
Exhaust opens B.B.D.C.
Exhaust closes A.T.D.C.
TAPPET CLEARANCA (Cokl)
lnlet
Exhaust
IGNTTTON TIMTNG
Piston position (B.T.D.C.) fillly advaneed ...
Crankshaft position ( B.T. D.C.) tully advanced
Contact breaken gap setting
90"
| .470',-1.475',
1.407'"*t.4t2'
.3095',-.3 t00"
.3090'*.3095',
1.625',
2.03 125',
r.30"
I .37',
26'
70'
6l .5'
34.5'
(37.338-37.465 nnm.)
(35,737-35.864 mrn")
(7.851-7.874 mm.)
(7.848-i.851 mm.)
(7.9248-*7.950 mrn.)
t12.7177*12.7254 mm.)
(47.2186 mm.)
t.0127*.0635 rnrn.)
(41.275 mm.)
{51.5937 mrn.)
(33.02 mm.)
(34.798 mm.)
(.2032 mm.)
{.?54 rnm.)
(7.112 mm.)
(.381 s'nm.)
008"
.0t0'
.290'
33.5',
.0r5'
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GD4 GENERAL DATA B4O.AWD
SPARK PIUG
Type
Cap setting
Tiiread size
CYLINI}ER BARR,EL
Materia[ ...
Bore size {standard)
Strske
Capacity
Oversizes
CYITNDER. HE,AD
Material ."
lnlet Port size
Exhaust Pont size
CAREURETTBR.
Type
Main jet ...
Pilot jet ...
Charnpion N5
020'(minimunr) (.508--.635 mm.)
.025" (maximum)
i4 mm. dia. t. .75" reach (!9.05 mrn.)
Close grained cast-iron
79 rnm.
70 mm.
343 c.c.
.020' & .040' ("508 & 1"016 mnr-)
Aluminiunn alloy
I "0625' (25.9875 rnm.)
1.376*1.378" {34.9504-35.0012mm.}
Amal l*62614 (concentric ffoat chamber)
(2.6924 mm.)
t30
20
.t06'
2
Needie jet size
Needle position
Throttle valve
Nominal .t',olrr rir. '.. '..
Throttle slide return spring (free length)
BE,ARING T}TMENSIONS
Clutch roller (25)
Con-rod big-end bush (bore) ."
Con-rod big'end needle roller
Con-rod small'end bush (bore)
Crankshaft bearing (drive-side)
Crankshaft bearing (gear-side)
Crankshaft diameter (drive-side & gear-side)
Cearbox layshaft bearings (drive-side and
gear-side)
Cearbox layshaft diameter (drive-side and
gear-side)
Cearbox nnainshaf't bearing (drive-side)
Gearbox rnainslraft bearing (gear-side)
Gearbdx mainshaft diameter {dnive'side)
Gearbox mainshaft diarneter (gear'side)
Cearbox sleeve pinion {internal diameter)
Gearbox sleeve pinion (external diameter) .'"
J
26 mm.
3.0625"
.1875'x "1875"
l.8t l0'-[.8i 16"
38 x46x 20 mm.
.7503'-.7506"
25x62x17 mm.
25x62x I7 rnm.
.9841'-.9844',
0.5'x .625" x
.8 125'
'.748.5',*.749',
.6245',*.625',
.752',-.753',
1. t79',*1.180'
(77.7875 mrn")
@"7A25x4.7025 mm.i
(45.9994-46"0146 mm')
( t9.05?6-l 9.0652 rnm.)
(24.9961-25.0038 mm")
(12"7 x 15.875 x
20.5375 mm.)
(19.0119-19.0246 mm.)
(l 5.8623-! 5.8750 rnm")
(19.100S*i9.1262 mm")
t29,9466-29.9720 rnrn.)
(19.05*19.055 mm.)
.6245'*.6?5' (15.8623*15.8750 mm-)
30x62x l6 rnrn.
.625' x l "5525' x ( 15.875 >.39.2875 x
.43'15' ll.ll25 mm.)
Gudgeon pin diameter v5a'-.7502',
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B4O-AWD GENERAL DATA GD5
TRANSVINSION
CTUTCH
Type
Number of plates:
Driving (bonded segments)
Driven (plain)
Overall thickness of driving plate and segments
Clutch springs ...
Free length of springs ...
Clutch push rod (length)
Clutch push rod (diameter)
GEAR RATIOS
Gearbox--top ...
third
seeond
flrst
Overall-top
third
seeond
first..
SPROCKETS
Engine
Clutch
Cearbox
Rear wheel
CHAIN SIZES
Primary...
4
5
.t67'*
4
1.65695"
9.0"
. I 875',
t.0
r.57
2.36
3.05
5.94
9.33
14.a2
t8.t2
14.242 'r,m.l
(42.0687 rnm.)
(228.6 mnr.)
(4.7025 mm.)
23 teeth
52 teeth
l9 teeth
50 teeth
Duplex .375" >: 70 pltches
.5"; il8 pitches
Transmission
FRONT FORKS
Type
FRAME AND FITTINGS
Springs-free length
spring rate
number of coils
colour identification
Coil-spring (hydraulically darnped)
10.375'-10.5CI' (263.525--266.70 mm.)
?5127lb.lin"
2l t/t
Nit \
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GD6 GHNERAT DATA B4O.AWD
RNAR DAh4PERS
Type
Springs-free length
spring rate
colour identification
SWINGING ARM
Bush type
Bush dianreter ...
Housing diameter
FRONT FORK BUSF{ES
Outer diarneten (toP)
Outer diameter (bottorn)
lnner diameter (top)
I nner diameter {bottom)
Working clearance (top)
Wonking clearartce {bottom)
Length (top)
, ----41- /L-ra.--,\
l.engtn (uuttulil,
Shaft diameter ...
Sliding tube bore riiameter
Damper tube bush (outer cliameter) ...
Damper tube bush (inner diameten) .".
Damper tube bush (length)
Coil-spring (hydraulically damped)
8.40'
l00lb./in.
Creen/pink
(213.36 rnm.)
WHEELS,
W}IEEI,S
Rim size and type (front)
Rirn size and type {rear}
Spoke sizes:
front (long) 20
l'ront (short) 20
rear (long) 20
rear (short) 20
Bonded rubber
,.250',-1.253',
t.247',-l.24&',
1.4750',*l "4755',
1.473', .1.474',
I .250 -1.251'
1.2485"-i"2495"
0005"
.002"-.003'
? tt{'
I t{,
1.248',--1.249',
1.475',--1.477',
.6t65"--.6185',
.339'-..340'
53t25',
BRAKES ,{ND T'YR,TS
\,VM2-i8
wM3-t8
(31.75-31.8262 mm.)
(31 .6i3-31 .699 mm.)
(.0508*.1524 mm.)
(20.570---20.595 mm.)
(37.465-37 "477 mrn.)
(37 "414-*31.439 mnt.)
(31 .750-31.755 mm.)
{3l"ili-3i.737 mm.i
(.0127 mm.)
("0508-"0?62 mm.)
(53.975 mrn.)
r'?l 7i mm I
\Jr,rr rrrrrD.J,
(31.699-31.7246 mrn.)
(37.M5-37.515 mm.)
{15.6591-15.7099 mm.)
(8"5106*8.636 rnm.)
( 13.4937 mm.)
(3.251 x 2l 1.1375 mm.)
(3.251x 177.80 mnn.)
(3.251x 188.9125 mm")
(3.?51 x 187.325 mm.)
\
lnterference fit ... .002'*.006'
Spindle cliameter gl0'--"811'
I0 s"rv,g. x 8.3!25"
l0 s.w.g. x 7"
l0 s.w.g. x.7 .4375'
l0 s.w.g.x 7.375'
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B4O.AWD GENERAL NATA GD7
W}IRE[, tsEARINGS
Front (lett-hand and right-hand)
Rear hub (left-hand and right-liand)
Rear brake drum
Spindle diameter (front)
Spindle diameter (rear, left-hand)
Spindle diameter (rear, right-hand)
BRAKES
TYRES
Size (front)
Size (rean)
Fressure (front)...
Fressure (rear)
Alternator type ...
Contact breaker
ELECT'RtrCAJ,
Coil
Battery
Bulbs (headlight)
tsulbs (sropltait tight)
Bulbs (speedometer Iight)
Bulbs (pilot light)
Bulbs (ignition rvarning light)
.875" >1 2" ',< .5625' single seal
.875" x 2" x .5625" single seal
.875" >( 2" x .5625' double seal
.8740'-.8745' (22.t99*22.2t2 mm.)
.8745'-.8750' (2Z"Z|Z*ZZ.Z25 mnr.)
.(:85'-.686' { 17.399-*l 7 .424 mm.l
Front (diameter)
Front (width)
Rear (diameter)
Rear width)
Lining thiekness (front and rear)
Lining area sq./in. (sq./crn.)*front and near
7',
I.t25',
7',
t.t ?5'
.15625',
1s.48 (99.84)
3"25" x 18"
3.50"x 18"
3.5 galls. (15.91I litres)
5 pints {2.841 litres)
0.5 pint (.284 litres)
75 pint 1.426 litre)
(177.8 mnn.)
(28.575 mm.)
(177.8 mm")
{28.575 mm.)
(3.9687 rnm")
(82.55 x 457.2 rnm.)
(88.9x457.2 mm.)
l7 p.s.i. (1.195 kg/sq. cm.) I See page
l9 p.s.i. (1.336 kg/sq. crn.) .f F.l6
EQUIPMENT (6 votr)
Lucas RM.lg (encapsulatedl
Lucas 4CA
Lucas MA6
Varley MC7/l2N
30/24 watt
6/18 watt
3 natt
3 rvatt
2 rvatt
/
CAPACIfnES
Fuel tank
Oil tank
Primary chaincase
Gearbox
Front fork (each leg) 0.34 pint (.1893 litre)
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GD8 GENERAL DATA B4O.AWD
Wheelbase
Overall length
l-landlebar width
Seat height
Cround clearance
WNTGHTS
Machine unladen
BASIC NTMENSIONS
53',
82',
27,s',
32',
7',
350 lbs.
(134.62 crn.)
(208.28 cm.)
{69.85 cm.}
{81 "28 cnr.}
(17.78 cm.)
t 158.75 kg.l
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B4O.AWD L[JBRICATION AI
INDEX
ROUTINE MAINTENANCE
LUBRICATION POINTS
RECOMMENDHD LUBRICANTS
LUBRICATION SYSTEM
CHANCING OIL AND CLEAi{INC THH FILTER.S
OIL PRESSIJRE AND NON.R.ETURN VALVES
DISMANTLII..IG AND REASSEMBI-INC THE OIL PUMP
Page
4.2
fi .Z
4.3
4.5
A.5
4.8
4.8
4.9
A.l0
A.l0
A.II
A.I I
A.r2
A.t2
A"l2
A.l3
CONTACT BREAKER
GEARBOX
PRIMARY DRIVE
R.EAR CHAIN
STEERING I.IEAD
FRONT FORK
RACE
WHEEL BEARINCS
CONTROL CABLES
SPEHDOMETER CABI.E
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A2 TUtsRICATION B4O"AWD
Ref. Na.
I.
ROUTINE LUtsRTCATTON
DAILY
ExarurNe Gn Lsvel rn Tnun.
EVERV I,SCI0 MILES
GRgesr Corurnol Cnplss.
Cnnnse BR*ra Frnel Frvor.
Oru Bnarc Rou .lorNrs.
EVERY 2,0S0 l\4trLES
Dnnrru rrun Rrru rsr On TnNr.
CLrRh{ On Tenr Fllrrn"
Cleair Cnlmcnsr FrlrrR,
Csecn On Lnvel lN CrRRsox.
CuEcr OrL Ln,gL rN FnlrrlnRy Cuntxcnsr.
Gnrass Crrurnal Srarun (2).
On Bure Crm Srruplrs.
Gnanss Sprnoonrrrrn DRlvn Ururr.
Exnutnr AND !F NEcEssARy RENEw Olr- Fllr.en Cenrntncr.
EVERV 5,{}OO MILES
DnarN eNn RErnt GraRsox.
Dnnlru nxn REnLI FnrNuty CualrucesE.
LugRrcnre Coxrlcr BnEnreR Cnv.
LusRrcnrr Auro-npvnnce MEcnnrursm.
EV&RY 10,0CIs MILa$
Dnalr'l nNo R*llL FnoNl Fonxs.
Gnrnsr WHeEI BennrNcs.
GREnss Srsrnrruc Hrnn BsAnrNcs.
')
1
4.
Flc. A.l . Kt.v lubrirution pnints.
(l- indicates left-hand side, reniaincrer right-hand or boftr sides).
t 1412
9ter 7
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