BSA Victor Grand Prix Instruction manual

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VICTOR SEFIIES HEZ
1966, 1967 and 1968 MODELS
REVISED EDITION
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WORKSHOP MANUAL
FOR 844 MODELS
VICTOR GRAND PRIX
VICTOR ENDURO
vrcToR SPECIAL (t967)
vrcToR SPECIAL ( le6B)
Service Department
B.S.A. MOTOR CYCLES
Publication Reference No. 00-4128/0/00.
LTD.
BIRMINGHAM II,
Telephone 02 a -772-2181
ARMOURY ROAD
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Please Note!
Replacement parts or accessories must be of
B.S.A. origin or as approved by B.S.A. Motor
Cycles Ltd.
In this respect your attention is drawn to the
Terms and Conditions of B.S.A. Guarantee.
I
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INTRODUCTION
This manual hars been compiled to provide comprehensive service information for the B.S.A. owner arld
for the workshop fitter wishing to carry out either basic maintenance or major repair work. The instructions
are written in great detail but, because of the specialised skills and the equipment required to carry out
some of the described repair work, the inexperienced owner is strongly advised to consult his B.S.A. dealer
should he doubt his own ability to carry out a satisfactory job.
The manual is divided into sections dealing with the major assemblies and these are sub-divided into
the individual operations required for maintenance or repair. It is hoped that by using this arrangement,
the manual will be found most useful as a quick work of reference to even the skilled mechanic.
All information and data given in this manual is correct at the time of publication but because of the
constant development of B.S.A. motor cycles, changes in the specifications are inevitable.
Anyone finding this manual to be at variance with the B.S.A. machine in his possession is advised
to contact the Service Department, uhere up-to-date information will be quickly provided"
ENGINE AND FRAME NUMBERS
Both the engine and frame numbers, together with prefix and suffix letters, must be quoted in full on any
correspondence relating to the machine or on any enquiry regarding this manual, to either the dealer or
the Service Department.
The engine number is stamped on the left-hand side ol the crankcase immediately below the cylinder
base. The frame number is stamped on the left-hand steering head support plate, just forward of and below
the fuel tank"
Page 7
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FACTORY SERVICE ARRANGEMENTS
UNITED KINGDOM
REPLACEMENT PARTS
B.S.A. replacement parts and exchange units are distributed through a national network of B.S.A. dealers,
each of whom holds a stock of fast moving parts. Approximately 200 of these dealers have been selected
for appointment as specialist B.S.A. replacement part stockists and each of these stockists holds a compre-
hensive stock of B.S.A. replacement parts.
A complete list of appointed stockists is printed at the end of this manual, and also in every B.S.A.
Parts Catalogue.
REPAIRS
Most appointeC B.S.A. dealers are able to carry out major repair work, and owners are asked to make
all repair arrangements through their chosen dealer.
In the great majority of cases local repair will be possible and this will avoid the expense, inconvenience
and the possibility ol the machine being damaged in transit to or from the Works for repair.
Should your B.S.A. dealer decide that Service Department attention is required he will know best
how to make suitable arrangements with the factory. It is important to remember that no machine can
be accepted at the Works without a prior appointment. This appointment can be made either by letter
or by telephone.
GUARANTEE CLAIMS
In the interests of all conccrned it is best that any owner of a new motor cycle, wishing to claim assistance
under the guarantee, should do so through the dealer from whom his machine was purchased. All B.S.A.
dealers are familiar with the proc€dure designed by B.S.A. to give quick service to any owner of a B.S.A.
motor cycle who may find himself in difficulty.
Page 8
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TECHNICAL ADVICE
B.S.A. Service Department staff are experienced in dealing with technical problems ol all kinds arrd will
be pleased to help in the event of difficulty. The correct address of the Service Department is as follows:-
B.S.A. MOTOR CYCLES LIMITED,
SERVICE DEPARTMENT.
ARMOURY ROAD,
BIRMINGHAM II.
Telephone No. 021-11?--2381
In all communications the model must be quoted with full engine and frame numbers
together with all prefix or suffix letters.
WORLD SERVICE ARRANGEMENTS
In most markets of the world, B.S.A. has an appointed distributor to whonr all service enquiries should
be addressed.
The names of these distributors will be lound at the back of this manual, and are also Iisted iu all
B.S.A. Replacement Part Catalogues.
Page 9
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PROPRIETARY PARTS
Equipment uot of our manufacture which is
guaranteed by the manufacturers and not by
lacturer concerned or their accredited agents
the manufacturers concerned :-
CARBURETTERS
CHAINS
ELECTRICAL EQUIPMENT
REAR DAMPERS
SPARK PLUGS
SPEEDOMETERS
TYRES
cycles is of the highest quality and is
or repairs should be sent to tl.re manu-
possible assistance. The follorving are
fitted to our motor
us. Any complaints
who will give every
Amal Limited,
Holdford Road,
Witton, BIRMINGHAM 6.
Renold Chains Limited,
Wythenshawe,
MANCHESTER.
Joseph Lucas Limited,
Gt. Hampton Street,
BIRMINGHAM 18.
Wipac Group Sales Limited,
London Road,
BUCKINGHAM.
Girling Limited,
Birmingham Road,
WEST BROMWICH, Staffs.
Champion Sparking Plug Company Limited,
Feltham,
Middlesex.
Smith's Motor Accessories Limited,
Cricklewood Works,
LONDON N"W.2.
Dunlop Rubber Company Limited,
Fort Dunlop,
BIRMINGHA}'d 24.
Page 10
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T_
U.S.A. SERVICE ARRANGEMENTS
REPLACEMENT PARTS
B.S.A. replacement porls are ovailable tltrough a National Netvuorlc o.f B.S.A. dealers covering the entire
United States.
These B.S.A. rnotor cycle dealers are listed under "Motorc:ycles" in the yellow pages of -,-our locttl.
lelephone directory.
All requests for pLtrts inust be macle through li'anchised B.S.A. dealers. lhey are not sold clirecl to B.S.A.
ovners by the two Jactory branches.
GUARANTEE CLAIMS
In the interest o.f all concerned the ov'ner oJ a nev, motorc.ycle wishing to clairn assistance under the guorentee
must do so through the dealer f'ront whom his mqchine wos ptrrchased"
REPAlRS
B.S.A. dealers are capoble o.f servicing ancl repairing B.S.A.motoreycles, a.slc your dealer to help when repairs'
are needed.
Labour time v'ill be greatly redut'ed iJ proprietaD) articles, such qs legshields, t:rash bars, carriers or Jibre
glass.fairing! are removed be.fore handing the rnachine over.fbr repair. Ar:cessories suc'h as mirrors or badges
shoulcl always be removed before entrusting a nruchine to an independant carrier.
TECHNICAL A DI/ICE
The B.S.A. Service Departntent staff at tlte two U.S.A, f'actory brancltes are experienced in clealing w,itlt
tec'hnical questions o1'all lcinds ancl r,ill be pleused to help in the event oJ- difficulty
The Factory Branch Addresses ttre shotrn below':-
F,ASTERN
WESTERN
B.S.A. INCORPORATED.
639 Passaic Avenue,
Nutley,
NEw Jgnspy 07110.
B.S.A. MOTORCYCLES _ WESTERN,
2145 E Huntington Drive,
Duarte, C,q,I-tFonNtA. 91010.
In all comntunications the .full engine and .frante numbers with all prefx and sffix letlers and .figures
musl be quoted as v,ell as the year ttnd model o.l' the motorcyc'le in questiotl'
Page I 1
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WORLD DISTRIBUTORS
REMOVING THE MOTORCYCLE FROM THE CASE
Norn -Check that the packing case is the RIGHT SIDE UP before dismantling The TOP hers stencilled
markings on it, the bottom does not'
I Prise off the top boards with a suitable pinch bar
2 Take out the top packing and loose parts from around the motorcycle
3 Remove one side of the case and take out the motorcycle and auy remaining loose parts. Check that
you have all the small parts belore discarding the wrappings. Retain tlre Test Card in case you find
it necessary to report any loss of parts or damage during transit.
FITT'ING THE FRONT MIJDGUARD AND WHEEL
l. Put the machine on the prop stand and place a suitable support under the engine.
2. Locate the front mudguard between the fork legs and fit the braces"
3. Pull out the wheel spindie from the fork ends and fit the lront wheel. Insert the spindle from the left-
hand side and use a suitable bar to screw the spindle right home. The spindle has a left-hand thread.
4. Check that the brake plate stop is correctly located in its recess at the rear of the right-hand fork leg.
5. Depress the fbrks once or twice to enable the left-hand lork end to position itself on the spindle before
finally tightening the pinch bolt. If this precaution is not observed. the fork leg rnay be clipped out
of position and will not function correctly.
6. The support can now be removed from under the engine.
FITTING THE HANDLEBAR AND ATTACHING THE CABLES
l. Place the handlebar in position, fit the handlebar clips and after adjusting for suitable positiorr secure
with the four fixing bolts.
2" Feed the cables through the appropriate guides and re-position the control levers.
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3.
4.
,5.
Attach the clutch, front brake, and exhaust valve lifter cables to tl-reir respective levers.
The front brake cable will be found among the loose parts and must also be connected at the fi'ont brake.
Fit the throttle control complete with cable and tighten the firing screws.
Check eacli control for correct operation and adjust as llecessary.
FITTING THE SILENCER.
Locate the silencer witl-r clip. over the er.rd ol tl-re exhaust pipe.
Secure to the frarne bracket with the nut and bolt and tighten the clip firrrrly on to the pipe.
FITTING THE REAR LIGHT
l. Pass the rear light cables through the hole iir the mudguard arrd colinect each cable to its respective
sr-iap connector.
l.
2.
nut
fir
2.
3.
2
)
Locate rear Iight on the mr-rdgr-rard ancl flx loosely at the top r,vith one
Position the number plate bracket over the lower rear light fixing holes
tighten secr-rrely.
from below the guard.
the two bolts with nuts and
4. Finally, tighten the top lixing nr-rt and check the cables
SI'ARK PLUG, TYRE PUMP AND TOOLS
Take out ancl discard the plastic plug from the spark plug hole, fit the spark plug and conr-rect the
high-tension lead. The plug supplied with the machine is best suited to all-round operating conditions
and sliould not be changed withor-rt tl.re advice of a plug specialist.
Snap the tyre purnp into its mount belorv the saddle on the right-hand side of the lrame.
The tools, instruction m:rnual and other literature can now be placed to one side.
FINAL CHECK
It is the duty of the dealer to see that every nut, bolt and screr'v is tight and correctly {rtted belore the ntotor
cycle leaves his shop. The dealer is responsible if a customer returns and complains of rattles. missing nuts
or fractures caused by vibration. It should be noted tliat 90f" of all vibration problems can be traced to
loose engiire mountings. Do not simply take it for granted that the factclry has done everything right.
Takc the precaution ol checking everything yourself.
STAR.TING THE MOTOR. CYCI,E
Fill the oil tank, primary drive and gearbox to tl.re required levels with correct grades of oil (see page
A.3).
Befbre starting the en-qine" nral<e sure that there is no packing material in or erround the carburetter
air intake.
While the engine is runniug, take offthe oii tank filler cap and check that the oil is circr-rlating correctly
througl.r the return pipe. After replacing the oil tank cap the machine u,ill be complete and ready for use.
Page I 3
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CONTENTS
GENERAL DATA
Section
GD
Page
Ito12
I to 15
Ito36
1to10
Ito15
1to9
1to20
Ito25
.l
1to8
LUBRICATION
ENGINE
FRAME AND FITTINGS
CARBURETTER
FRONT FORKS
SERVICING TOOLS
WHEELS, BRAKES AND TYRES
ELECTRICAL EQUIPMENT
TORQUE WRENCH SETTINGS
CONVERSION TABLES
Page 14
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844 GENERAL DATA GDI
ENcrNs
INDEX
Bearing Dimensions
Camshaft
Camshaft Bearing Bushes
Carburetter
Cylinder Barrel
Cylinder Head
Ignition Timing
Oil Pum
Piston
Piston Rings
Spark Plug
Tappet Clearance
Valves
Valve Gr,rides
Valve Springs ...
Valve Timing
TnlNsurssltN
Chain Sizes
Clutclr
Gear Ratios
Sprockets
FR,q.us ,q.No FtrrtNcs
Front Fork
Front Fork Bushes
Rear Dampers ...
Swinging Arm ...
Wnrrls, BR,qrEs lNp Tvnes
Brakes
Tyres
Wheels
Wheel Bearings
ErecrRrclr-
ClpA.crrms
EeurpurNr
Ba,src DlueNsroNs
Wercgrs
PrsroN Drspla,ceinnNT AND CReNrslrapt DEcnErs
Vrcron GReNo PRrx uoonrs oNr-v
NOTE
Items applicable to Victor Enduro and Victor Special (U.S.A.) models only are
rnarked with an asterisk. For details of corresponding items used on Victor
Grand Prix models, refer to pages GD.10 to GD.l2.
Page
GD.4 5
GD.2
GD.2
GD.4
GD.4
GD.4
GD.3
cD.2
GD.2
GD.2
GD.3
GD.3
cD.3
GD.3
GD.3
GD.3
GD.6
GD.5
GD.5
GD.6
GD.6
GD.6
GD.6
GD.6
GD.7
GD.7
GD.7
GD.7
GD.7,8
GD.8
GD.8
GD.8
GD.9
GD.lO
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GD2 GENERAL DATA 844
ENGINE
"PISTON
Material "Lo-Ex" Aluminium
9.4 : I
Compression ratio
Clearance (bottoni of skirt) .003'-.0035' (..0162-.0889 mm.)
Clearance (top of skirt) .006"-.0065' (.1524 .1651 mm.)
(both measured on major axis).
,I.PISTON RINGS
Material compression (top)... Brico 8SS.5004 (chrome-plated)
compression (centre) Brico 8
tcompression (top and centre) Brico 8 (tapered)
-scr aper Brico BSS.5004
Width-compression (top and centre) .0625' (1.5875 mm.)
Width-scraper .125' (3.175 mm.)
Depth .120'-.121' (3.048-3.2258 mm.)
Clearance in groove .001"-.002" (.0254-.0508 mm.)
Fitted gap (maximum) .014' (.3556 mm.)
Fitted gap (minimum) .009" (.2283 mm.)
OIL PUMP
Pump body material Zinc base alloy
Typ"
Drive ratio Double gear
5:1 t4:l
Non-return valve sprirlg (free length) .5'
Non-return valve spring ball (diameter) .25' (12.7 mm.)
(6.35 mm.)
Oil pressure relief valve spring (free length) .6094' (15.4781 mm.)
Oil pressure relief valve ball (diameter) .3125' (7.9375 mm.)
*CAMSH.AFT
Journal diameter (lefl-hand) ... .5598"-.5603' (14.2189-14.2316 mm.)
Journal diameter (right-hand) .7480'-.1485' (18.9992-19.0119 mm.)
Cam lift (inlet) . .345' (8.763 mm.)
Cam lift (exhaust) .336" (8.534 mm.)
Base circle radius .386' (9.8044 mm.)
CAMSHAFT BEARING BUSTIES
Bore diameter (fitted) left-hand .561'-.562' (.14.2494-14.2748 mm)
Bore diameter (fitted) right-hand .1492'-.7497' (19.0291-19.04238 mm.)
Outside diameter (left-hand) ... .719' .120' (18.2626-18.2880 mm.)
Outside diameter (right-hand) .908" .909' (23.0632-23.0886 mm.)
Camshaft clearance (left-hand) .0012'-.0017' (.03048-.0432 mm.)
Camshaft clearance (right-hand) .0012' (.03048 mm.)
tApplicable to 1968 Victor Special.
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844 GENERAL DATA GD3
VALVES
Seat angle (inclusive)
Head diameter (inlet) ...
Head diameter (exhaust)
VALVE GUIDES
Material
Bore diameter ...
Outside diameter
Length
Cylinder
90"
1.535" t.540',
t.401'-1 .4r2',
.3095" .3100'
.3090" .3095"
Phosphor Bronze
.3120'-.3130'
(38.9890-39.1160 mm.)
(35.131-35.864 mm.)
(1 .861-1.814 mm.)
(.7 .848-7.861 mm.)
(7.9248 7.950 mm.)
(12.1121 12.7254 mm.)
(41.2186 mm.)
(.0127-.0635 mm.)
(38.10 mm.)
(42.418 mm.)
(30.9372 mm.)
(33.3248 mm.)
(.2032 mm.)
(.254 mm.)
(6.7469 mm.)
(.381 mm.)
Stem diameter (inlet) ...
Stem diameter (exhaust)
5005"-.5010"
head interference fit 1.859"
.0005'-.0025'
VALVE SPRINGS
Free length (inner)
Free length (outer)
Fitted length (inner)
Fitted length (outer)
,IVALVE TIMING
Tappets set to .015" (.381
Inlet opens B.T.D.C.
Inlet closes A.B.D.C.
Exhaust opens B.B.D.C.
Exhaust closes A.T.D.C.
mm.) for checking purposes only.
1.500'
t.670'
t.218'
1.312',
51"
68"
78'
)t
*TAPPET CLEARANCE (Cold)
Inlet
F,xhaust
IGNITION TIMING
Piston position (B.T.D.C.) fully advanced ...
Crankshaft position (B.T.D.C.) fully advanced
Contact breaker gap setting ...
SPARK P{,UG
Type
Gap setting
Thread size
Champion N64Y tChampion N5Y
.020" min.- (.508-.635 mm.)
.025" max.
14 mm. dia. x
.J 5" reach.
008"
.010'
.2656',
28"
.015',
fApplicable to 1968 Victol Special.
(19.05 mm.)
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a
GD4 GENERAL DATA 844
'KCYLINDER BARREL
Material Aluminium with austenitic iron iiner
79 mm.
90 mm.
.010' & .020' (.254 &..508 mm.)
Bore size (standard)
Stroke
Oversizes
CYLINDER TIE,A,D
Material Aiuminium alloy
lnlet port size ... 1.0625' (26.9875 mm.)
Exhaust port size 1.316'-1.318' (34.9504-35.0012 mm.)
f lnlei port size 1.125' (28.575 mm.)
tExhaust port size 1.250' (31.75 mm.)
x'CARBURETTER (fitted up to Engine No. ts44EA.101)
Type Amal 389/235
Main jet 330
Pilot jet ... 25
Needle jet size . . . .106' (2.6924 mm .)
Needle position
Throttle valve . 31L
Nominal choke size 1 .15625' ('9.3687 mm . )
Throttle slide return spring (free length) 2.5' (63.5 mm.)
'1'CARB{JRETTER (fitterl on and after Engine No. 84484.101)
Type
Main jet Amal 930/1 (concentric float chamber)
224
(63.5 mm.)
Pilot jet ... 25
Needle jet size ... .101' (2.1118 mm.)
Needle position 2
Throttle valve . 3
Nominal choke size 30 mm.
Thi'ottle slide retuni spring (free iength) 2..5'
BEARING DIMENSIONS
Clutch roller (25) .1875" x (4.1025 mm. x
.1815' 4.7025 mm.)
Con-rod big-end bush (bore) ... 1.1101'-1.1106" (44.9605-44 9732 mm.)
Con-rod big-end roller (24) .250" dia. x (6.35 mm. r
.254' 6.35 mm.)
Con-rod small-end bush (bore) .7503'-.7506' (19.0576-19.0652 mm.)
Crankshaft bearing (drive.side) 25 x 62 r 17 mm.
iApplica.ble to 1968 Victor Special
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844 GENERAL DATA GD5
BEARING DIMENSIONS- co n t inu e d
Crankshaft bearing (gear-side)
Crankshaft diameter (drive-side & gear-side)
Gearbox layshaft bearings (drive-side & gear-
side)
Gearbox laysha
side) ft diameter (drive-side & gear-
Gearbox mainshaft bearing (drive-side)
Gearbox mainshaft bearing (gear-side)
8125',
6245',-.625',
25 t. 62 x 17 mm.
.9841',-.9844',
0.5" r .625" x
(24.9961-25.0038 mm.)
(12.1 >< 15.875 r
20.6375 mm.)
(15.8623-15.8750 mm.)
(15.875 /. 39.2815 y
11.1125 mm.)
(19.01l9-19 .0246 mm.)
(15.8623-15.8750 mm.)
(19.1008-19.1262 mm.)
(29 .9466-29.9720 nm.)
(19.05-19.055 mm.)
(4.242 mm.)
(42.0687 mm.)
(228.6 mm.)
(4.7025 mm.)
On and after engine
No. 844EA.101.
5.33
6.6r
8.79
14.12
Gearbox
Gearbox
Gearbox
Gearbox
Gudgeon
mainshaft diameter (drive-side)
mainshaft diameter (gear-side)
sleeve pinion (internal diameter) ...
sleeve pinion (external diameter) ...
pin diameter
TRANSMISSION
30 x. 62 x 16 mm.
.625" t. 1.5625" x
.4315',
.7485',-.149',
.6245',-.625',
.l52',-.7 53',
1.179"-1.180"
750',-.1502',
CLUTCH
TYPe Multi-plate r,vith integral cush drive
Number of plates:
Driving (bonded
Driven (plain) segments) 4 5
Overall thickness of driving plate & segments
Clutch springs ...
Free length of springs ...
Clutch push rod (length)
Clutch push rod (diameter)
,.GEAR RATIOS
Gearbox-top ...
-third
-second
-first
Overall-top
-third
-second
-first
f Overall-top
-third
-second
-first 14.20
.167',
4
r .65685',
9.o',
.1875',
1.0
1.24
1.65
2.65
Prior to engine
No. B44EA.l0l
s.36
6.65
8.84
14.20
5.36
6.6s
8.84
fApplicable to 1968 Victor Special.
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