Motobecane 40 User manual

TA 8LE Of CONrEN TS
DE:S IG tlAT ION
Techni cal S pec l fl Clt t o ~
T001s (sPec 'a l s ~ lc e )
Use of the Stro ke Ll~ l t e r
[ngine ~ va l
Refi tt ing the [ nqine on the fr ao@'
Diu
ssellbll ng t he hg t llP
Plston C,llr'lder H.l t dl lng
£UIlll\i1 Uon of
tlle ty !i nller llead , nd t)' l h l< ler
Re ,ss _ lI ng the Eng ine
Dearbollil lng the En ,ln e
"llsIo
¥1 ns· Dec: , rtoorI ll ln, · llef lt t l n.g the El" ~ lI s t
Tes tf "\l Ign it ion TI.,I ",
Rewvl nll An d Rtfi ttill9 t ile f l )'W~ E' E' 1 Hlqne lo
Adjllst ipg the I gnit ion Po in U and f!J ni th m Ti Jll ing
.,vlft g .~ d Ilet ltt l l19 tile C.rtlilrelor
D1n$$~ l, ... d ANn_l, of ~reto r
~ $ c r ip t i on and DpeAt ion of ne l'KIIl nu. nc Varf' tor
V. r1a to r Ic .. ~o i@ n tl p .rt s)
llew:! win, t tle ' ~ 1r1a tor
ttluu en l, and h l$ S4'riI ly of Va r 1l t o l"
Adjus tl nli and ltefi tt lng t ile V.M. tor
~ vt ng · Ref i t t l n g - o; s, S$ ~ 11 ~ · Rr ' ~ I e. bl i n v the Cl ut ~
IlietIovhg ." d Re f lttl n9 Or1 Ye fl !"u ll"
~ v h 9 trld Rle f ittln, 0 8 C ~ n k '}e4 r . 1leplac in, C rant" ... r
8usMngs
~ 1ac i . g Oppe r En9in tNountt nCj flexi~le ~~ i n ~
Replaeina cables
Re p la ei llt the r,.....
~I~ t ile 1'1$ 1. f ort An NQly
RefItU"9 t!le II.IIt Fo rt As I_ l, . Rerr'O'rillq ... ltCIlll! f -j tt h llJ
tt-e fo rt ~ I e te
Rr p ll ebg Fo rt. I.4 Mngs and S prin llS
Itso.,ln g th elIrIfIdlelMrs
~v l", tile S te ui ", Ile , d
llIefi tt ln til the St e. rh g lINd
ReMov 1n9 ... nd Re fi t t ing the front and R e. r H ~ ~l ,
$lep l .d ng UIe B nt. Shoe s
JlNlnoill'jl the ~ n te r Sh nlf. tile s.. ddl . , Rtp li cl _o t~
P ed,a lOlein ",,4 the [IIt1n. D rive Ch in
1ll!p l . e1ll9 the r"".t Wlle el Adj u, tlltent ~ s , CU PS , (lnd
Jol ts ,,'
ItepJ. ciftg Al! l r IIlH l 5.1 11 Ile arh 'ls
Check WlHl Al lgnw:nt
RNovl. g anlf Rd
1t tillll (tie f ront and near r t:Ode r<s
Renovj ng ... ~ d R lf l tt lrl9 ue Shock A ~ l o r t>e rs ~nd t lte
Sw ing Am
Troubl'J S h oo t 1 n ~ Gu ide
Wi ri ng Olagr ... 6Volt
lti rl ~ q Oh gram 12 ~o lt
PA GES
I
., ..
7
e.s
10. 11
12,13
"
IS,16
11,11.rs. zc ,21 ,22
"
" '"
26,21
re. ,.,
30, 31
12,33
34 ."
"
"
)8, 39
40, 41,1.2
41.1.4
4 5. 16
H,U
" ,so
51 .st , 5]
5-4 ,55
Sfi,n ,5 8
S9,60
"
"
"
..
es
66 ·
66
69,10
ll ,n
73, 14
"
16,n
78, 19
ao,IlI ,
llZ .83 ,84
es
'"

ALPHABET I CA L IN DE X
DES IGHA TlCNt
Br ol kes (replolcl lHJ tile brak e s hoes)
Cables (replolclng)
Colrlluretor(re-:ovillg
ol nd ref ittill9 )
Col rbureto r (s t ripp ing oln d reolss e.b l inQ)
Ce
nter SU nd (re-ov lng)
Ch a ins ( re p laci ng)
Cl u tc h (re-o vln q. refitti ng. repla cinq . reolsse.blln q)
Cr
oln kge ol r (rernovi llg. refittin q. re p laci ng crolnkqear
b1l5hing5)
Cy
li nder He ol d • Cy li nder (exol m inati on)
Engi ne (
remo vi ng)
Engine ( refl t ti llq)
Ellgine (dh .S5 ed> li llj '
( llgi ne {re .ss entl li ng
Engine (decolrbolli
zing )
( Xh
ol llst (reMOvi ng. decarboni zi no, olnd refitt inQ)
Front oln d Ru r Fenders ( relIlO vlng and ref itt ing )
Fl
nible B lISh in ~ ( re pl ol<:i ng)
Flywlleel
Ma 9'M!to (re-:av ing oln d refittl/IQ )
For k ( rem vi ng t he In f ort as se-Clly)
Fork { re f i t t ing the In f ork a sse-b ly . reMO vi ng . nd
re fitt ing th e fo rt c~lete }
F ork ( ~ l olci n g bvs hl~ and sp ri ngs)
Fr a..:! (replacing )
Freew ~1 ( replac illg)
Kall d le ba rs (reIIOvi nQ)
Ign l
ti Oll (ch ecking til ling)
Ign
itio n ( adj U5 t1 ng the ig n iti on po illt5 ol nd t i. i ng)
Match ing (pls t oll -c yli nder )
D ri ven Pu ll ey (removi ng olnd ref itt illq)
Saddl e ( rep, aci n l)
Shock Abso rbers relllOv'n<J and r ef i tt ino)
S te eri llC) He ad (removi ng)
St l!l!ri ng Head (r efit ting)
St roke Llmltl!r (use )
Techni
cal Speci f lC. t ions
Tools (s pec l. l s ervice)
Tro ub le Shoot inq Guide
Var h
to r (de5crl ptl on and oper .c i on)
Var la to r ( COflIlIOIIl' nt s p arts )
Var
la to r ( re-o vi ng)
Ya rla tor (d is . s se-b ling and reas s e.bl l"9 )
Vol ri .tor (a dj ust i nq and ref itt ing)
Fron t and Re ar Wheels ( reMO ving . nd refitt in g)
Fron t ~h ( re placing oldjllStIleftt cones . CUPS . and bolts)
Reol r Wheel ( re pl .c ing ball ~a rings)
Whee ls (cbeck alig~ nt)
Wi ring Dlagr•• 6 Volt
Wi ring Diagra. 12 Vo lt
"'"
..
S4 .55
32 . 33
" .35
"
69.10
45.46
49,50
15, 16
'.'
10. 11
12.13
17, 1!l.19. ZO .2 1. 22
ea
24.25
76.77
51 .52.53
28.29
59.60
51
62
56.57.58
"
"
26.27
JO .31
U
41.48
"
78.79
64
65
7
1
e-s
80.8 1. 82.!l 3. 84
"31
38.3 9
40
.41.42
4].«
66 .67
11. n
73 .7 '
"
es
..

TECH N IC l\l $ PEC IF IC I\ T IO NS
DI ME NS IONS
Ov e rall l engt h (i nch es)
O verall Wi dth (inc hes)
Ove rall Height (inch es)
Weight (pounds)
M8 TOBEC AN E
4 _ SERI ES
66. 19
24.82
3'1.00
90 lbs .
58 ; O~ O §A ~iR IES
69 .34
24.82
3
9. 79
103 l bs .
/1 0T OBEC AN E
ZSER IES
63.40
24.82
38.80
88 lbs .
FRAME
Type: Pressed S te el
Suspe nsion; Telescopic Front For k YES
Re ar Suspe nsio n .
Shock absorbe rs NO
Bra kes: Front and Be ar DrLlll
Tires: Pressu re Front 21 p .s.1.
Pressu re Re ar 26 e.s.t.
Fuel C apaci ty: (U .S. G allo n)
Fuel M
ixt u re : 4 oz. of hig h
qual i ty 2 ·c yc le
011 p
er ga ll on
of gaso lin e
M
il es P er Gallon : 143
ENGI NE
Type: Si ngle cyl inder , ai r- COO led , z-cyc te
Bo re and St ro ke: 1.5 3 X 1.6 4 Inches
C omp re ss ion Ba tio: 7.8:1
Ca rbure tor; Gurt ner
En9ine
Displac e ~nt ; 49cc
19n
ition: Fl yw heel Ma gneto
EI ECTR IC Al
P rio r to January 1, 1978: 6 v olt
After January 1. 1978 ; 12 v olt
"s
V£S
143
.8
143
VEH! Cl E I DEN ll E ICA ll ON NUM BERS
[ n9ine: Ident if i cati on plate on eng ine cyl in der head
Frame: Iden tif ic at ion p la te on fr ont of fra me
Ma ximum Speed: 2 0. 25, and 30 MPH
.0 1

SP EC I AL SERV ICE TOOLS
."
PART NO. 100001
CIRC
lI P PLIERS
P ART NO. 100002
CI
RC lI p PLIERS
PAR T NO. 100003
GREASE FITTI NG WREN CH
PA RT NO. 100004
S TRO KE lIl1lTER
PART NO. 100005
FLY WH EEL W REN CH
I
PA RT NO. l ll'XlO6
B US HI NG EXT RACTOR
P AR T NO . 100007
HA GN ETIC E X TR AC TO~

SPECIAL SERVICE TOOLS
=~ ! ~: '"'(1\
~ .. wsA 1
PA RT NO. 10 0008
PIS
TO N PIN TOOL
PAR T NO, 1 0000 9
PE D AL BUSH IN G TOOL
PA RT NO. 100 01 0
CRA NK CASE SEA L TOOL
PART NO. 100011
CRA NKSHAF T BEAR I NG PULLER
. 03

SPEC IA LSERVICE TOOLS
PART NO, 100012
FORK TOOL
PART
NO ,100013
. TIM IN G TOOL
PART NO. 100016
__.PRESS - STEERI NG HEAD RACES
PART NO. 100017
THICK NESS GAUGE - METRI C
PART NO, 1000\ 4
TUBE
PART NO, 1000\5
BLADE 120x 30MM
PART NO, 1001) 18
SPOKE WRENCH - 18
""

PART NO. 1000 19
F ORK PIV OT WREN CH
~
I
,
.'
PART NO, 1000ZO
C LU TCH PULLER
PART NO. 10002 1
C
AM PULLER
SPECIA L SERV IC E TO OL S
PAR T NO. 100023
SQUARE DR IVE
PAR T NO. l OG ON
FL EX I BL OC EXTRA CT OR AND
IN STA L LIN G TOOL
PAR T NO. lOOOl5
PIS TON PIN EX TRAC TOR
PART NO. l OOOlZ
FREE WHEE L W REN CH
. 05

SPECIAL SERVICE TOOL S
. 06
P AR T NO. 1000.,6
VARIA TOR HOLDER
P AR T NO. I OOOZ 1
VARIA
TO R WREN CH
PART NO. !OOOZ8
GRE ASE GU N
PA
RT NO. 1000"9
SPARK
PLUG WR E NC H
_ ~~ iWlT.NO. 1000 31
TI MING LI GHT
PART NO. COIl.,9
fORK WRENCH

USE OF -T HE STRO KE LIM I TE R
I MPORTA N T
For all types of en~ines to be serv iced, the use of the stro ke
limiter , No. 100004, is requ i red in lllCls t disass e mbl y and re a s-
sembl ing operation s.
This tool is designed to lock cra nksltaft revolut ion at m id -s t ro ke
and o
ffe rs tlte advantaqe of le aving bo th It ands f ree to perfonn
the ope rat ions requi red.
DO NOT US E THE STR O KE LIM ITER ON E NGI NES FI TTED WIT H F LA T- TOP PED
PISTO NS.
Afte r Itaving sc re we d the limite r into the wlt o le tltreaded leng th
of t he spark plug Itole , br ing tlte p is ton to res t aga in st It
gen tly.
R07

ENG IN E RE MOVAL
Remove both side covers (scre wd river).
Disconnect t he suppressor cap.
F ree t he ceccecresscr cable nipp le using a screwdriver (fig .1) and
disco n nect t he cable.
lOl)sen the nut s ecuring t he carbureto r cJa~ (llimI socke t) and re mov e
the ca rb u~to r .
Disconnect the w ir es at the te rm ina ls behind the fl)'\'heel maqneto
stato r plate and sl ide them out of the guide sprinq.
D isco nnect t he grey wire at the ignition coll and slide it out of the
support brac ket in the fr ame.
Re mo ve the belt from the pulle y groove and pass it in fro nt of the
pedal (fig . 2).
,
F .. _1

E NGI NE RE MOVAL
CO NT'O .
Loosen the lowe r engine mou n ting n ut dnd w it hdraw t he bo lt (l0rrrn open
wre nch and socke
t) .
Loosen the se
lf- loc king nut of the upp er engine moun t (1m wrench).
Drive out the upper engine mounting u
le only as fa r as the f ir st
spacer (f ig. 3) .
Bef
or e renJ v in g the engine , car ef u ll y note the locat ions of the upp er
engine mo unt spacers .
Tilt the engine and remove it (fig. 4) .
f;';'. •
'"

REF ITT ING THE EN GI NE ON THE FRAME
!nS ll@ ct tile upll@r en9'tne .un tl nq fl exib le bushin as . nd In suld lon rin g
f
or good c onditi on ( fig. I).
Fit t ill! engine throu9h u pper . u ntt nq bo lt (oll@ ,-, te nfor ~v.l) .
Check tha t sp. c ers . ~ co r~c t l 1 lined up and IloI ke sure to inser t the
e1e ring of the 9round Iu d between the spacer .nd C1 li nder he.d
(R.H. , f ig 2).
Tt911ten
but do not loc k u pper en 9ine lOun ti ng nu t.
Insert the S Cl'@Of in to till! l oooe r en9i ne _ unt in9 br l cke ts .n d In to the
space r- which is fit In with the ten sion Sp rin 9s (fig. 3) .
o
RO 10
... . 2
f .. _3

REFI TTI NG THE EN GIN E ON THE FR AME
CO N T'n ,
Tighten and lock lower en gine lOOun t1 n9 nut (lO Iml wrench ).
Refit the carb ure to r a ll the way on to t he i nlet pipe dnd loc k t he
carbu
re tor s ecur ing clamp nut (llmn socket ).
Re connect t he eecore ressc r cab le {scre wcr-tver}.
Re conne ct t he wi res to the spade connection s behind the fl yw heel mag-
net o stator pla te [pass t hem t h ro u~h the guide spri ng. if equipped)
(f ig. 4).
Slide the grey wi re through the suppo rt brac ket on the fr ame and re-
connect it to the ign it ion coil (st raig ht ~em a l e te rm inal ).
Lock t he upper engine mo u nti ng nut ( while hol ding the ot her end of
the bolt - 1 2nTn wrench) a fte r havi ng i nst all ed t he bel t (f ig. 5).
NO TE : Make ce rta in to lock upper engine mo unting nut a ft er having in -
st
all ed the belt. Th en the eng in e is in a medium swing lnq position ,
which
will preve nt the f lexi ble bushings f rom susta ining damage.
Refit th e suppressor .
Refit b oth si de covers .
,
\
ij
RO II

DIS ASS E MBL I NG THE EN GINE
Engine r emo ved .
R emo ve th e exhaust usi ng 10"", ~ n d ll"'" socke ts to loos en exha us t c la mp
and a 32"", open wrench t o loosen the nut conn ect i ng t he exhaus t to the
cyl inde
r.
Set th eenctne i n a vice by In se rt i no a sp ace r between the lo we renatne
mo unt pl at es so t hat the asse mb ly may be f i rm ly clamped (f io. 2) .
Re mo ve belt c over usfnq a screwdr i ver for var -t eter eeetnes or a 1 01m1
socket for D imo by cl u tc h engi nes .
R
emov e t he flywheel mag neto· (See page 28).
Re mo ve t he var iat or or the cl u tc h ass emb ly acco rdi nq to t he type of
machi ne servi ced (See pages 38 and 43).
Pro gre ss i vely loosen t he cyl i nder head nu ts at opposite corne rs .
Re mo ve t he cy li nder head and t he qas ket ( Hlmn sock et ).
Re
mo ve the cyli nder and cyl i nder base gas ket.
NOTE: Aft er Jul y , 1975, our en9 ine s are f it ted w it h pis tons ha vinq LE VELLE O
UP RI NGS WH I CH CO VER THE LO CAT IN G PI NS ( fig. 1).
W it hdra w t he p iston ri ngs .
St uf f a ra9 i n
to t he crankcase mo ut h and re mo ve t h" wri st pi n clips usinc
fl at no se pll er s (f i g. 2 ).
Drive out the pi s to n pi n lIsi nq t he pin ext ract or tool, 100025, (f ig , 3).
'i
Ol d -s ty le
P
is to n
.~=t
New- st y le
Pisto nFi g. I
RO 12
fi g. 2

DI SA SSE MB LI NG THE ENG I NE
C ON T'D.
W \t lldril., the needl e cage f ro. t he con ·rod s-. II end.
loosen
illl crilnku se reU in ill9 nut s .
~-.e the crilnkcase f ro. the ylce.
Re.Jye the crankcase reta1 nl1l9 bo lts alld l owe r ~i ne -oun tillCl stllds
(note the pos it ion of the studs alld of the brilcket for the belt lIUa r4) .
To prewetlt the crilnksh ft JourMl f~ o ~ rheil tin~ illse rt the blade .
100015. 011 i t. Repeat the ope ra tlo ll fo r the other joorna l.
Hut ., Uh apropane torch the crankc ue h alf fil cin g the c1utctl s ide
ilround the o uts ide of th e cra nkstl.. ft bu ri ng (begin wit h t his side be-
cause it Is then e asy to n par. te cr..nkca se she lls )( fig. 41 .
The creeeeese ha lf w ill drop ilwa y on n s own ( fig. 4).
Re pe..t the operat io n f or the ot her cr..nkc..se h.. lf (f1g. 4).
While ~h e c r d " k" d~ e hilhe se re hot . r" may " t he oil s e~ h with iI screw-
d
riv er u p pin g from the ou ts ide to the In si de of the c ra n ~c u e ha lf.
h t ract the crankshaft bear1ngs us i n~ th e crankshaft bea ri no pull er,
100011 (f ig. 5).
Note the ilr ran geme nt of sh llllS beh1nd the cranksha ft support be. r1nn 1f
the c
ra nksha ft Is so f it te d.
Fi g. 5
fig. 4
RO 13

PIS TO N CYLI NDER MA TC HI NG
The s poo re poort n "'n l iste d bl!l ow
concern pis tons fi tted with ln e ll !'d-up ri ngs thn . re _ nted
In li eu of f o..- rpistOflS Ise rtes 168$3 t o 168591.
., ,,
12273 ------- ••••• ••••• •• • • ---- ------. . . II
21274 •••• ••••• _._ •• _. __ . _•• __• •••• _ loA
22275 ------------ •• •••••••••••••• ----- -A
21276 ••• ••• •••••••• •••••_ _. _. ________ _ C
22271
•• •• -- -------- ---- •••• ---- ----. . . . [
22218 •
•• • ------- --- . ---- _••_ •• ••• __ G
22219 • •• ••• •••• •• •• ••• J
22280 -------•• ••• •••••••• ----- -- -- -. .. . l
22281 •• • •• •_•• ••• _•• •• __ • •• ••• II
22435 ••••• -- -- -----••• ••• ••••••• -- - -- -- P

E XAM IN AT I ON OF THE CY LI NDER H EA D A ND C YLIN DER
b ami nation of tile Cy linder H ead :
Clleck
tllat the cy li nder head bo tt om base is fla t (qr ind It with <1 sur-
face p
la te if ne cessa ry ).
Refit the spark plug <1 nd check the dec o-press or va lve for leakage by
pouring
fuel in the c ~s t i on ckaoober ( fiq. 1) .
E ~c ep t in c a ~ of abso lu te ne ~ss lty . the dec ~resso r val ~ should not
be n!'IIOv ed f roll the cy li nder Ilead ass e-b ly.
In case of le<1k age and i f the valve is not wo rn out . ta p the va lve head
gent ly to seat .
E um in 4tio n of the Cy linde r :
Hak e su re t hat the cyl imler ....11 hne ither s cuffe d not scored (l <1 ck of
chno-Iu- plated surfac e).
Me uure the p iston eteerenee (d if fe re nce between the . in i_ cy li nder
bo
re and the lIIoI ~l_ piston diamete r) . the p is to n r in q end gap (f ig. 2)
and the cl earance between r ing and groove.
....
... '
RO 15

RO 16
EX AM IN AT I ON OF THE CY LIND ER HE AD AND C YL I NDER
CO NT'D.
- If i nsta lling a new p iston , refer to the matching lis t on page 14.
CLE ARA NCES IN 1'0'1
ST A NDARD MAXI MU M
P is ton Clearance
(sl drt}
0 .DD5 to 0.010 0.050
R1 ng end gap top
ri ng 0
.10
,0
.10
0.40
second
ring
0.10
Ring groove to p ri ng 0.03 to
0.060 0.15
S
ide gap second
ring
Fit the small end needle cage and insert the wr is t pin in it (fiq. 3).
Th e pin should t urn fre ely wi t hout ver tt eat play .
c>
F ";I. J

REASSE KBL IN G TH E E NG I NE
NE YER IItST AL L LlS ED GAS KETS ; A1.lIAY S lIS E M EW ONE S•
• Wht n f it ting a _ enlline crankcase or a _ cra nhhfft, tile s ide ph y
Sh
Ol.l ld be a dj u ste d.
SIll[ P LA Y ADJ US TI£ NT :
To er te ct th is operation . you need two dUllll)' bearlnlls t hat you u n lUke
yo
urself .
use emery cl oth on the inner and oute r races of t wo new bea ri ngs {d ia ...
16 x 42 x 13 - No. 16906} u ntil the be aring s can ro tate f ree ly on the
crankshaf t j OUrmNS and the crankcase she ll hous in gs , T his opera ti on
mus tbe done without cr ankcase sea ls:
Pla ce the dlJlllll}' bea rlnlls on the crankshaft tape red ends.
P la ce th is us edll y int o the crank cue .
FH the crankcu e p,fi per gasket .
NOTE : FrGlI Janua ry I, 1916, the paper yu ke l ~ . II"9 I t>t! o:.unk use h.olvu
has been subst itu ted by a spec ial se.l ln ~ ca.pound. Ki!'Ye rt hel ess . when
u nic in'll an en 'll 1ne, we rec_nd cl un in 'll tho rough ly tile lU ti ng surfacl!!S
and fitti n'll a p,fipe r 9ISk et .
Pla ce th is as u-b ly In a vice (oYe r lower luqs and crankc as e upper sc ..-s ).
lto
ll9"' h a ss u s the txls tl~ side play with a de pth ullpe r 'lla ullE' .
Disjo int crankc ase halves and p la ce washers between the two c ra nksha ft
balance wel 'll ht s and bea ri ngs in order to ba lance the con -rod between the
shel ls .
' SIDE P LAY •I /I OMM
RO 11