PIAGGIO Allstate Cruisaire 1964 Use and care manual

OPERATING INSTRUCTIONS
AND PARTS LIST FOR
MOTOR SCOOTER
r------ MODEL NUMBER 788.94331
This is the Model Number of your Allstate Motor Scooter. It will be
found on a plate fastened to the chassis under the fuel cock. Always
mention this number when communicating with us regarding the
Scooter, or when ordering repair parts.
r----- 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 selVes 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
FOLLOWING 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.
SEARS, ROEBUCK AND CO.
Scooterworks USA Inc.
5709
N. Ravenswood
Chicago, IL 60660
ph: 773.271.4242
fx: 773.271.5012

Fig. 1 . AUST" TE • Crui.aira • Motor xoot.r
WARNING
lO<ltlon of fnm. Number
lo<ation of ."9in. Number
Fig. 2 • lO<ltlon of .. rill number
Serill numbers are preceded by pretixM:
V A 1~ T, for frame; VNB 5M, for 1"9;n •.
In order to keep your ALLSTATE Scooter in perfect
running condition and not to void the guarantee, always
have your machine repaired at aSears, 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 ~asoline should never be used.
Do not use Allstate compounded motor oil or other
Praemium Huvy Duty Oil with detergents.
The inexperienced operator should exercise caution
in applying front wheel brake, to avoid locking.
C\-
\
'lg. 3 • Control. of "Ilstat. xoot.r
1. Gear chenge twistgriO with clutch control
lever· 2. Front brake lever· 3. Throttle con-
trol grip . •. light and dimmer ,witch .
S. Front brake iaws .. 6. Rear brake pedal.
7. Kickstarter .•. Gear ,hi Iter .9. Rear brake
iaws .• 10. Clutch . 11. Carburettor, air
cleaner. 12. Starter push pull rod· 13. F"el
cock.

";. 4 • l"9In. Inltallatlon and .... p4n.I.M.
1
r--------/-I
6
Ignition .• By flywheel magneto.
Engin. to wheel trensmission retios:
First 13.35 01
Second 9.32 to 1
Third 6.64 01
Fourth 4.85 to 1
fit. 5 • 1 .. 1ti_ ojl ......
1. Ignillon coli in flywh_1 mlQn.«> ··2. Rolor ~m • J. Brea ..... ~. Con-
danlO" . 5. Sparlcplvg . ,. Engin. cvl· ""e on .wilch.
Clutch .. Wet type; multiplate, with facings of cod ..
composition applied to the driving discs.
Geer box .. 4 - speed drive with mesh gears in od
bath. Its two-<able control is coupled with that of ~ e
clutch, on left hand side of handlebars.
123.4 cc. (7.53 cu. in.)
52.5 mm. (2.06 in.)
57 mm. (2.24 in.)
4.6 HP
7 : 1
5000 rpm
MAIN SPECIFICATIONS
Trtlnlmlulon. Oi re<:tly from engine to rea r wheel
gh clutch, cushion drive and gear box.
SYrtlng .. By means of kickstlHter, right hand side
SCooter.
1. ~ c.olvmn and Irone svspension .2. Engln ... J. Cranlcc .... half, c1vtch sid., wilh swinging arm . 4. Raar svspension spring with hy-
dravlic damper.
IIv.f eonsumption:
1M. oil milcture) 130 miles per gal.
'P"d . 46.6 m.p.h.
bue . 46.4 in.
wldttt on hendlebus 25.7 in.
~;tn of the scooter 68 in.
~Ight. . . . . 38.7 in.
~Ight of. ·f1oorboud 8in.
drcl. 59 in.
(
un'ed.n) .182 Ibs.
~.m •.. Of pressed and spot-welded steel sheet,
th Itreem-lined monocoque-type structure.
M~nslon .• Front wheel: coil spring. Rear wheel:
I9ring and coaxial hydraulic shock absorber.
L,gln •.. Two· stroke, flat cast iron cylinder and
Iluminium alloy cylinder head. Cooling effected by
rifugal fan wich is embodied in the flywheel of
tn4Igneto.
lacement
-4-

lubrication. -By the oil in fuel
mixture for piston, cylinder, wrist
pin, con. rod, cranks aft, main bea-
rings. Both clutch and gear box
operate in oil bath.
Carburettor. - With float-cham-
ber (see fig. 11 ); air cleaner moun-
ted on the engine. Air goes to the
carburettor through a large inlet
tube and asilencing chamber with
filter.
Model of carburettor: Dell'Or-
to 51 20/15 C - Venturi 15 mm.
(0".59) - Main jet 82/100 (0".
0323) -Idler iet 42/100 (0".0163)
- Air-vent for main jet 120/100
(0".0473) - Air hole on mixer top
150/100 (0".05) - Mixer tipe BE 1.
- Air-vent to idler jet 140/100
(0" .055) -Spray nozzle 200/100
(0" .0788) - Sta rter jet 55/100
(0".0216) -Float chamber fuel le-
vel 20.5 ±1 mm. (0" .87) - Oil
recovery vent 50/100 (0".0197).
Feeding. -Fuel feed to the carburettor is pr.ovided
for by gravity (see fig. 11) with gasoline - oil mixture.
Fuel tank. -Total capacity: 2,03 gals.;
Reserve: V1 1/3 gal.;
Three-way cock: «open» . « closed» - « reserve ».
Mumer. - Expansion and absorption combined type.
Handleb.rs .. Pressure die cast in light alloy and
designed so as to house both headlamp and speedo-
meter. All the control cables and electrical wi res to
this
group are concealed therein. (See fig. 3).
Steering column .. The steering column bears the
handlbears, clamped on its top end, and the front wheel
swinging hub, pivoted at its bottom end through a stub
axle.
lighting .nd 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. The rear brake jaws are hinged on indepen-
dent pivots.
Wheels. - Of pressed steel sheet, interchangeable and
easily removable, since they are assembled in an auto-
mobile - like system.
Tires: dia. 3.50 x 8 in.
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
Fig. 6 • Sealon 0/ engine
1. Air cleaner and carbvrettor . 2 .. Piston· 3. Cranksnaft - 4. Clutcn
S. Mainsnaft .6. Gear snifter. 7. Fliywneel magneto· •. Kid starter
9. Crankcase n.lf. clutcn side. witn swinging arm.
attempt to ride the machine unless the key is in, and re-
mains in the lock, and the handlebars are moving freely.
Do not lubricate the steering lock.
Security lock on tool box wing. -The compartment
flap on the left wing of the vehicle is equiped with a
key operated security lock.
Centr.1 Stan. - A two - legged stand is arranged un-
der the floorboard. A strong return spring holds it in
~. 7 - s.cvrity Io«k
1. Norm.1 position. 2. Closed
- 5 -

'IV· • - Spar. wh •• 1 and buck.t
...
...
,\\\
I
I
I
I
" ~ //
-~~--- \/
", 10
5
,------------------- .. "'Tt---------..
--~!:O~~~__+_---.(O ------+-+-----+r"'"
Tool Kit. - 1 four - ended box wrench (11 -14 - 21
22 m); 1 double open - enQed wrench (8 -14 mm);
1 single open· ended wrench (7 mm); 1 screw-driver.
These hand tools are contained in aroll which is placed
in the left wing.
Speedometer. - The speedometer has its housing in
the middle of the handlebars and adds to the perfor-
mance and appearance of the scooter.
Accessories (See Table XX). - On request the Allstate
scooter can be equipped with the spare wheel and
bracket.
A
FiV. 9 - Schem. of EIKtTic Wlri"",
contact wit t' e oorboard and keeps it from :ibrating
wnile the scooter is being ridden.
Spare wheel .nd br.cket (see fig. 8). -The wheel
bracket sheet steel pressing, can be secured to the scooter
frame behind luggage carrier (see Table XX, «Spare
parts list»). _
It is very robust and simple and holds the wheel
in such a position where it is easily accessible.
1. Flywh~~1 m~n~to - 2. low t~nsion t~rminal
1. STOP li~ht (6 V . 3 w bulb) - 4. Toil lamp
(6 V . 3w bulb) -S. Spar"plu~ - 6. STOP switch
. 7. light and dimm~r switch - a. 6 V· 22/22 W
doubl~ r.lam~nl bulb - 9. Horn . 10. Insid~ vi~w
of heed lamp . A: Engin~ cuI· out: B: li~hls off .
c: H~ad lamp and toil lamp on . 0: L~v~r for country
and lrafioc beam . E: Horn button.

OPERATION
IF THE SPEEDOMETER (WITH MilE DIAL) HAS BEEN DISMANTlED, FOR REASSEMBliNG PROCEED AS
FOllOWS:
(See fig. 10)
Filii. 10· How 10 aU41mble the Ip .. dome4er unit
lodged in the square cut· out of the speedo. drive
pinion.
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.
Grease pinion cI ~ . support bush cL ~ assy through
lubricator on ring cK ~.
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 .,ny
customer, even inexperienced, by carefully following
some general rules.
Running- in. - Important rules to be followed while
running. in (1200 miles) :
Do
not exceed following speeds:
1st gear 13 mph.
2nd gear 19 mph.
3rd ge1H 25 mph.
4th gear 37 mph.
Do not hold these max speeds for long periods neither
use full throttle opening up - hill.
Change oil in the gear box and check thl!lt nuts and
bolts are not slack after the first 600 miles.
to flow out; otherwise top up with ALLSTATE REGULAR
S. A. E. 30.
With the help of ., pilot wire slide the sheath cA ~
for the flex drive, into the steering column, from
the top end, until it emerges from the bottom end
(indicated with an arrow in the figure).
Pull the pilot wire out of the sheath, grease the flex
drive generously and slide it in.
Assemble packing cC ~ and then the speedometer
head cB ~ on the bracket E, already mounted with
rubber buffer cF ~ fixing with the apposite screw
cU ~ and spring washer cT ~ ensuring that said
screw is not tightened too firmly to avoid deformation
of the speedometer head.
Insert 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 nut cG ~.
Now secure the group speedometer and bracket to
the handlebars by means of the screw cS ~ and
plain washer cR ~.
Completed the above operations reassemble the head·
lamp.
Fill up hub with grease in order to lubricate the
portion of the wheel spindle meshing with the spee-
dometer drive pinion cI ~.
Mate the pinion cI ~ to the support bush cL ~, then
mount ring (with lubricator) cK ~ on the latter;
screw the support bush cL ~ on the wheel hub. If an
axial play between drive pinion and centre pin of
0.25 to 0.8 mm. (0".01 to 0".03) is not obtained on
assembling the part cL ~ into the hub, interpose the
spacer washer cM ~.
Slide the rubber cap cN ~, the threaded ring c0 ~
and biconical ring cP ~ over the sheath end; fit the
washer cQ ~ on the cable portion which protrudes
from the sheath, P.,ss the I.,tter between the front
brake control cable .,nd the wheel, then screw and
tighten threaded ring c0 ~ on bush cL ~ and po-
sition rubber cap cN ~.
Ensure that the end of the flex drive is accurately
-1-
Keep the breather of filling cap clean.
Fuel $upply .. Fuel mixture, both during and after
running in, should be composed of regular gasoline
and pure mineral oil SAE 30 at 2%, i. e.:
- If.I. pint of oil 1% gallons of gasoline.
When using pre - diluted or additive oils, or oils for
outboard motors, mix 1,4 pint of oil per gal.
Oil level. -Remove the level screw, on crankcase,
marked c OLIO ~ 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

----
Stlrtinlil· . Open :ne fuel valve, put the gear", box
in neutral and slightly open the throttle in slow running
position, kick the starting lever.
With cold engine, operate starter push pull rod.
Push said rod back as soon as the engine fires.
See Fig. 11 ; note the three positions of the fuel valve:
open, closed, reserve.
C.ution .. Do not open throttle wide when releasing
clutch.
In case of starting troubles, due to engine being
flooded (unvaporized fuel mixture has reached the cy.
linder and combustion becomes therefore very difficult),
proceed according to either one of the following methods:
a) Push· start the scooter: shift into second gear,
declu ch 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.
FiQ. 11 . Feeding circuit
1. Fuel cock
lever: A) Reserve. BJ Open. C) Closed· 2. Floal . J. Air
eleaner and carburellor . J/l. Air filler .•. Slaner iel . 5. Sel screw
for lhrollie slide· 6. ThrOllle slide· 7. Air venl for main jel . a. Hole
on mixer top· 9. Mixer· 10. Main jel . 11. Idling let. 12. Air venl
for idling iel . 1J. Plug for inlet hole for oil: for laying up . 1 •. Idling
adju'ter . 15. Slaner valve· 16. Intake port· 17. Tran,fer pon, .
11. ExhauH
duct.
FiQ. 1::l • Opentlon. to clrry out I., ttlrtl"9 tho e"9;n.
"': open lhe fuel cock . B: 'elect c neulral •. C: operlle 'larter push pull rod (with cold' engine) . 0: lhrollie conlrol grip in idling
po,ition . E: deprell the kick'larter and turn grip • O. by ,hort 'lroke,.
- 8 -

1
:1
I
i
i
For acceu to the engin., take off the engine cowlin~
then proceed as follows.
Pull the lever «1 ~ (Fig. 13) and turn it so as to
release
it from bonnet. Then move the bonnet slightly
outwards, until front pivot t( 2 ~ is extracted from
the hole on the frame.
Push the bonnet from the front upwards and turn it
(see position indicated by dotted line), thus releasing
the
fixing hook «3 ~ from frame.
Move bonnet outwards round its hooked pivot «4 ~
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 turn the gear change twistgrip
so that the line engraved on it coincides with the figure
«1 ~ (1st gear) engraved on handlebars (see Fig. 14).
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
1
st gear, quickly close the throttle, release the clutch
and turn the gear change twistgrip so that the engraved
line coincides with figure «2 ~ (2nd gear); let in the
clutch and open the throttle.
FJ9. 13 • (nvI- bonnet ,.. .... 0 ... 1
1. EnQine
bonnet locking lever . 2. Front pivot • 3. Fixing hook •
4. Hooked pivot
Repeat this procedure for changing into 3rd and
4th gear and for changing down.
See the drive system on Fig. 14.
When you reduce the speed of your machine, change
down without delary to avoid irregular engine running
and stalling at low revs.
"9. 1 •. Od". "y"t.m
1. Gear change twistgrip . 2. Clutch control lever . 3. Gear chan9"
control c.ble. - •. Gear .hifter • 5. Sele<tor stem· 6. Selector· 7. 1 st
gear· •. 2nd gear - ,. 3rd gear· 10. 4th gear· 11. Mainshaft _ 12. Cush
gear . 13. Clutch.
N. II .. Positions 1·2 - 3 -. of the gelr ch.nge twi.tgrip correspond to
1st. 2nd. 3rd .nd 4th gear respectively; «0. indicales the
n~utr.1 position.
Do not turn the gear change twistgrip while the
engine is not running.
As soon as gear change troubles arise, particularly
when the control becomes hard, customers should have
their machines adjusted by aSears 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. 11). 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 Fig. 11 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-
setting this screw unless absolutely necessary or during
-9-

:'
FiV· 15 .Olsmlntlir>g th. front wh •• 1.
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 to pressures 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).
Av· 16 . h",o.ir>g Ik. Inno, IUbo
Tire pressure should be 18 -;. 20 psi on rear wh~
14 .'c- 15,.5 psi on front wheel. If t e Allstate IS ordi aril
ridden by both driver and passenger. he pressure c
he re,H tire should be 28.5 -;. 31 psi.
®
F1V· 17 . 8,.lto Idjurtmont
Br.ke .djustment. - Brakes are properly adjus ed if:
the wheel rotates freely when respective control le-
ver or pe~t ire in resting position;
the braking action starts as soon as respective con-
trols are operated.
These conditions are achieved adjusting the cables
by means of screws indicllted with an arrow in Fig. 17.
a
F19. 1 •• Adjustmont of clut.:h control
.) Adjusting nut • b) Clutch lever. eng,ne .ide
-10 -

MAINTENANCE
I
i
~
Adiustment of clutch control. . Adlustment of clutch
controls is achieved operating on adjusting nut (a),
screwed to the engine bracket (see Fig. 18), by means
of open ended wrench 82199 in the tool roll.
The
cable is to be tensioned or loosened, as the
Cleaning the scooter. - Brushing kerosene and wi·
ping dry clean rags is advisable for external cleaning
of engine.
All painted 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 paint and turns it dull ..
If 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 the level screw
marked" OLIO,. from the cranckase (see Fig. 21 ). The
scooter standing upright, oil should just be about to
flow out.
After the fint 600 miles. - Replace oil in the gear
box by the procedure as explained in the lubrication
chart, page 13. The crankcase can be drained through
the hole indicated in Fig. 21.
Every 2.500 miles:
( 1) - Remove air cleaner cover and unscrew the two
filter retainer screws. Extract the filter (n. 3/1
fig. 11 ) from carburettor, w~sh in gasoline and if
possible air blast dry.
(2) Check oil level in the gear box (see above).
(3) Grease all joints on the brake controls.
(4) Clean the sparkplug electrodes with very fine
emery cloth or suitable files, and adjust the gap
to 0.6 mm. (0.023").
Inspect the insulation material of sparkplug; re-
place the latter if the porcelain is cracked. Wash
with neat gasoline.
Use the sparkplug type Marelli CW 230 A- T;
Marell; CW 225 N - T; Bosch W 225 T 1 ; Champion
L 86; AC 43 F; KLG F70 or F 75.
Important: using the proper type of 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
1M carned out by aSEARS store.
case m~y be so that control lever, on h~ndlebMs, makes
a stroke of 2 mm. (0.078") before lever (b), on engine
starts moving.
Wrong play in the control may cause the clutch
plates burning out even in normal running conditions.
(7) - Lubricate the speedometer drive pinion and flex
drive.
(8) - 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 orifKe; in both
cases the muffler should be held so that the
exhaust pipe is turned downwards.
'i9. 19 . Bruhr points
.. )Max. gap of br.a'.r points cA. should ~ 0.0 II" . 0 019"
In case of shock· absorber troubles, overhaul or
simply clean the assembly and change oi I.
These operations should be carried out by your
SEARS store.
-" -

(1) .
Every .5.000 mil .. :
Clean the breaker points.
In order to avoid ignition troubles or abnormal
running, have the breaker points adjusted in a
Sears
stores; the gap should not be more than
0.011" .0.019" (see Fig. 19) and the points should
begin to open when the current in the primary
ignition circuit has attained its peak value.
(2) Grease the control cables.
(3) Change the oil in the gear box, as stated on
page 13.
(4) . Grease the ratchet quadrant of the gear shifter.
Disuse:
( 1) In such acase, 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 Allst.te. Regulu Oil SAE 30 or
AlIst.te Outboud Motor Oil through 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 carburettor.
(5) Grease all unpainted metal parts.
- 12 -
Fill· 20 . Cl .. ninq the cyllnd., hNd, cyllnd., and pinon

LUBRICATION CHART
PoUT TO BE
O'ElATION
I
TIM EI
THE OF lUB_ICANT
lUBlllCA
TED
iI
I
Mix gasoline with the following
amount
t
At each refilling of the fuel
iPure
mineral oil
SAE 30.
Engine
I
of lubricating oil: tank.
I
- ~~ pint of oil to/Vz gallons of gasoline.
I
I
N. B. - With pre-diluted or additive oils,
!
mix ~~ pint of oil to each gallon
I
of gasoline.
I
Gear Box
Warm up the engine and drain off
oil.
I
After
the first
600
miles
IAllsta e
Regular SAE
30.
IPour some fresh
oil in and run the en-
and every
5000 miles.
I
I
gine for a few seconds. Flush and refil I
I
with new oil (about 7 oz.).
I
Refill with new oil to oil level hole.
IEvery
5000 miles.
I
I
Front wheel hub
II
Speedometer
ILubricate
with grease gun.
Every 2500 miles.
High
Pressu re
Chassis
flex
drive
and I
pinion
!
Joints on brake IGrease. IEvery
2500 miles.
Allstate
all - purpose.
controls
Gear Lubricator SAE 140.
Shock-a bsorber
I
Change oil.
Only when the shock· abo
Allstate Shock.
sorber
is out of order.
Absorber Fluid.
Control cables IClean and lubricate. Every
5000
miles.
Allstate
all - purpose.
I
I
Gear Lubriclltor SAE
140.
I
Felt of flywheel ISmall spot
of grease on the felt. Every
2500
miles.
Allstate Bearing
Grease.
cam
Ratchet qua- Grease.
I
Every 5000 miles.
Allstate
all - purpose.
drant of gear
I
Gear Lubricator SAE 140.
I
sh i fte rII
HIGH PRESSURE CHASSIS GREASE
'19. 21 - lubrication Kheme
1. Filling hole· 2. Draining ho!e
ENGlNE LUBRICATED B

LOCATING TROUBLES ... ANO RUNNING IRREGULARITIES
C.rry out following cnecKs wnen tn. engine does not sbrt euily or runs irregul.rly.
lo<atin<jl tha troubla
OlnlCULT STAITING
Top up oil leyel. Tighten
on draining hole.
~ ReoloSe
e
I Replace both plates and springs.
Adiust (see r,g. 18).
I
Gaar pinionl dl"f>9Age of own.
a«ond.
a) Clutch snatches·
Gear pinions c,~ lubricated pro-
p"r1y.
Clutch slip.,
Springs f""ble.
Plates wom or bumt.
s.
dry.
i
ITurn
to c reserve t. ~efll cB soon IS b)
pOSSible.
i
~ Remoye and wash in gasoline. Blow c) Clutch does not diseng,oge Com.
pletely,
Excessive play on conlrol cable
Clogged.
dirty
1 .• Fual systam.
Fuel lank emply.
Filter on carburettor I
Fuel lap body
C.,bureltor body
Main iel ,
Atomizer
Pocking 01 lu,,1 tap
2 .. Cari><Jratlon
Timing wrong.
Breaker points complelely worn
pilted.
c..ar change control cobles Out of Adjull.
adiuslm"nt.
Engine /loading
Float perforoled
Air c1ean"r choked or dirty
Starter valve sticking
3 .. Ignition
Sparkplug dirty
Porc"lain 01 sparkplug crocked
Br ... ker points dirty. pHtially
or pitted.
Gap b..lw""n br"aker poinls
reel.
j Seepag" 8.
I Replace.
I
I Clean (se" page I 1 ).
Release.
I
I
,Disconn"ct the plug lead. Ch"ck il
I sparking occurs b..tw""n lead and
I crankase when th" kic",tart"r is
I operated.
i CI"an. Correct gap' to 0.6 mm.
(023").
i
; Replace the plug.
I
worn r Clean with suitable fdes or very fIne
I emery paper.
incor· Correct (see fog. 19).
or Qep/ace.
I
Re· time ignition.
Spring of stirrup broken. le"ble
missing.
s"lector amns chamfered.
Dogs of 9"ar pinions chipped
worn.
6. High fual cons~mptlon.
Should the centrol have exceSSr"'e
play in neutral, tensIon con:r::!!
cables by screwing back Ihe ro-
spective adjuster screw (on coble
sh"ath end. rolenet quadrant siCe)
with an 8 mm. open ended wrench
If the ceble tension in neutral is
correct but the reference marks of
the handl"bars do not tally. tighlen
one of the adiuster scr"w .'d
unscrew the ocher one to the U:;"le
extent. so Ihat the cable tensien
is noc altered.
or Replace.
I
I
: Replace Ihe seleclor.
or I Replace the pinion.
:
:
INCORRECT RUNNING
Elhaust port partially closed by car· D",arbonize cylind"r. piston and cy.
bon deposit. Iind"r h"ad.
Clean with pure gasoline and blo ..
dry.
:
Dismount and clean carburettor :n
gasoline and compressed air.
For type and diameter 01 j"ts ane
vents. see pa9" 5.
IFuel level too high in carb'J.
retlor,
Float perforato-d. Replace.
II Air clean", cho"",,d or dirty.
III Jeb or v"nb of the carburetlor
blocked or dirty; incorrect or
incre.sed diameter.
CI"an (s"e pa9" 11).
Replace.
1. .loclr of powa,.
Muffler outl"t pip" carbonized
Cylinder bOle 9asket not sealing
Sparkplug not w,,11 Icrew"d down In Tighten (21 mm. box wrench).
cylind"r head.
IV Reta,ded ignition.
V Poor compression.
7 .• Control. not oparatlng properly.
R,,· time.
Se" No. 2 of this paragraph.
Lubricate or, if necessary, replace.
Adjust.
• .• St .. rin<jl column ba<oma. ttl".
Top race 01 top ball b..aring 100 Slacken.
tight.
CI ... n the rings and grooves.
PisIon rings gumm"d up.
Cylinder heed not fitting properly s"t the h"ad properly and tighten Inner cables rusted.
inlO the spigot on top of cylinder the nuts. Exc"ssive play.
1. ExpiOilon. a' mu"'-- ar carb ...
,.ttor.
Sparki"Q plug carbon· coated or with Replace or clean th" plu9 and cor· Bottom race' of the two b..arings Replace.
excessive el"'trode gap rect th" gap to 0.6 mm (.023"). pitied.
Carbon pearls on sparkplug insula· CI ... n.
tion.
9 .• Ellcaul ..a play of rt .. r1nv column
Pre· ignition.
a) Fit on a proper Iype 01 sparkplug. Top race of top b..aring loose.
b) Re· time the ignilion.
Tighten.
Not enough mixture flowing 10 th" s"" paragraph
carbur"tlor. No. I.
Tip of contact break"r loose.
Condens"r screw loose.
Replac".
Tighten.
10 .• I'oor bralr1nv.
Stroke 01 p"d liar lev"i too lon9. Adiust (see Fig. 17).
Brake linings oily or worn down Wash with gasoline or replace.
cDiffICult starting >.
Brake drums and linings scratched. R"place.
14 -

PARTS LIST
27
a
;\~
12 33 32
31
2a
PARTS LIST FOR ENGINE
Cr.nkc.se .Cylinder
TABLE I
(TABLE I)
.J
Figure II
N b .Spare Part
urn er I
DESCRIPTION
I
Fi<;lure II
Number Spare Pl!IrT
DESCRIPTION
2
3
4
5
6
7
8
9
9
'9
9
9
S.1107
5.3107
5.3057
S.11288
2/84831
46261
5.6977
S.14441
52575
87432
87433
87434
87435
Nut, for locking cylinder head
and crankcase halves
Washer, spring
Washer, plain
Stud, secur. crankcase halves
Hood, cooling
Stud, long, cylinder fastening
Washer, spring
Screw, hood fixing
Ring, piston, normal
Ring, piston, 1st oversize
Ring, piston, 2nd oversize
Ring, piston, 3rd oversize
Ring, piston, 4th oversize
10
11
12
13
14
15
16
17
18
19
20
87685
84644
46741
93031
49290
5.12485
S.521
49502 I
23823 I
I
S, 1207 ,
I
I
2444 :
I
Plug, on crankcase, flywheel
side
Se.l, spring loaded, for crank-
case, flywheel side
C.p, rubber, for sparkplug
B.II bearing, of crankshaft
Seal, spring loaded, for crank-
case, clutch side
Bolt, short, securing crankcase
halves
Stud, for fixing carburettor
Gasket, crankcase
Adjuster of rear brake
Nut
Nut

P.rt, II" for .nQin. -Cranke:.t,. - Cylind.r - C~r': ue<:J
"
89267
4267
Piston, 4th oversize with Wr
pin (with figs. 24 - 25 -S
Crankcase assy. (Figs. n. t.
22 - 17 -10 - 1 - 3 - 2 - <
15-16T.I; 27-28-3C
9 - 10 - 31 - 32 - 26 T. I
1 - 4 -
26 - 24 - 25 - 3 - :
23-7T.IV; 31-33-3L
41 T. "I).
Gasket, cylinder base
Engine, g. a.
Cylinder
Head, cylinder
Gasket, copper, of sparkplul
Sparkplug, with gasket
DESCRIPTION
(TABLE II
DESCRIPTION
Washer, shim, of clutch gear
Washer, plain, for securing
clutch cover
Washer, spring
Screw, securing clutch cover
Gasket, between clutch cover
and crankcase
Breather, with inserts
Plate, clutch centralizing
Spring, for fixing clutch cen·
tralizing plate
Thruster, clutch
lever, inner, clutch
Cover, clutch, with inserts
Packing, between clutch cover
and outer lever
Spring, return, of outer clutch
control lever
87423
97453
89120
99262
93808
92230
318
13903
19301
16821
14457
46740
89858
83806
50100
5.6708
48834
5. 3056
5.3106
5.14413
:7781
26
12
13
27
17
18
19
24
14
15
16
23
28
29
30
31
32
33
20
21
22
IFigure
Number I Spare Part
Adjuster of clutch
Bolt, securing crankcase halves
Nut, spacer, hood fixing
Circlip, for locking wrist pin
Wrist pin
Wrist pin, 1 st oversize
Wrist pin, 2nd oversize
Piston, with standard wrist pin
(with figs. 24 - 25 - 9).
Piston, 1 st oversize, with wrist
pin (with figs. 24 - 25 - 9).
Piston, 2nd oversize with wrist
pin (with figs. 24 - 25 - 9).
Piston, 3rd oversize with wrist
pin (with figs. 24 - 25 - 9).
DESCRIPTION
DES C RIP T ION I ~~~u~:r I Spare Part I
- 16 -
PARTS LIST FOR ENGINE
Crankshaft. Clutch
Crankshaft (with part n. 87442
fig. 5)
Nut, securing flywheel
Washer, shake proof, for nut
securing flywheel
Key, woodruff, for crankshaft
(flywheel side)
Bronze bush of con. rod small
end
Key, woodruff, for crankshaft
(clutch side).
Washer spring, for castle nut
securing clutch
Nut, castle, for securing clutch
Spindle, hollow, for hydraulic
shockabsorber
Bush, bottom, rubber, of shock-
absorber
Circlip, locking spacer
87421
87422
87..20 I
2040
46684
5. 1447
5.6615
2/51992
87436
87437
86944
697
587442
820375
994727
2 5.12066 I
3686
722313
11 46266 I
21
22
23
24
25
25
25
26
10 40316
26
26
26
Fi"ure I
.,. Spare Parr
Number I
FiQure I Spdle Part
Number

_ 17_
TABLE 1/
DESCRIPTION
13
\ I~
GI 15
@~ 16
2
II
I
Figure I I
Number Spllre Part
DESCRIPTION
25
97984 lever, outer, clutch
33 32005 Ring,
elastic,
for
stopping
26
a) 47946
Sp~cer, clutch side
clutch plat~
27
59588 Bush,
rubber, clutch side
34 94780 Driving
disc, external, of clutch
28 59590 Washer,
plain
35
94425 Plate,
~mooth, of clutch
29
98028
Clutch, g. a. (Figs. n. 41 - 40 -36 94743 Plate,
clutch, with
linings
I
33 - 42 - 37 - 39 - 38 - 35 -37 59109 Washer,
spacer
34 - 36).
38
94380 Gear, clutch
30
I59589
Bush, rubber, flywheel side
39 94379 Plate, spring, of clutch
31
I47944 Spindle,
hollow,
for engine
40 22821 Spring, clutch
I
I
suspension
41
21868 Cup,
clutch spring
I
32
I47945 Spacer,
flywheel side 42
59369 Body,
clutch
I
36
Figure iI
Number I Spare Part
Puts "" of engine - Crankule •Clutch - Continued.
.) Parts 48988 or 48989 can be assembled instead of spacer 47946, to atlain an axial force in the bush 59588 to give 0 -;- 1,5 mm.
(0 -;- .06") compression.

r
I
TABLE III
.) The total axial play of the assembly of the 4 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 repla.~ed by another with proper oversize.
1IS.12131 Nut,
for securing wheel
10
46700 Circlip
2S.3111 Washer,
spring, for nut
secu-
11
97181 Axle, cam, of rear brake
with
ring wheel
packing
( fig.
12) .
387714 Washer,
plain, for nut securing
12
S.6714 Packing
wheel flange
13
78522 Spring,
return, of brake jaws
4S.12787 Split pin,
for locking castle nut
14
46688 Ring,
locking ball bearing
5S.2314
Nut, castle, for securing wheel 15
17821
Seledor, gear
flange
16
7563 Ball
bearing of mainshaft
6
2021
Screw, for joining brake drum 17 7886 Pad
to flange 18
78170
Jaw,
rear brake, with lining
723831 Drum, rear
brake
19
61
Clip, spring, for brake jaws
8
94535
Flange, female spline, with
20 85673 Bolt,
for securing cable to
(fig.
1)
brake links
946699 Seal,
spring - loaded of main-
21
S. 3204 Split pin, on
pin for brake links
shaft
22
a) 82085 Mainshaft
DESCRIPTION
PARTS LIST FOR ENGINE
Gear box . R .. r wheel fl.nge
DES C RIP T ION I ~~~~:r I Spare Part
N
FiQubre I Spare Part
um er
- 18-
(TABLE III)

Pam lilt for engine . GMr box . Rear wheel flange - Ccntlnued.
Figure I Spare Part
umber
23
24
25
26
27
29
30
31
32
33
34
35
36
37
38
42048
94779
42047
S.1426
S.3109
42043
5. 3208
78171
78521
78164
78163
92098
5.13768
47190
a) 18558
DESCRIPTION
Pin, for rear brake links
link, brake
link, brake
Nut, on bolt securing brake
links
Washer, spring
Arm, rear brake control
Split pin, for cam axle
Dust cover
Packing washer
Packing washer
Packing washer
Stem, selector
Washer, tab, on selecto( stem
Bush, guide, of selector stem
Washer, shoulder, normal, of
gear pinions
I
Figure I Spare Par
Numoer
38 a) 20321
38
a) 20322
38
a) 20323
38
a) 20324
39 18447
40 a) 51123
41 12869
42 92240
43
a) 59007
44
a) 51124
DESCRIPTION
Washer, shoulder, 1st oversize
(thickness: 2,2 mm. =
0".086)
Washer, shoulder 2nd oversize
(thickness: 2,35 mm. =
0".092)
Washer, shoulder 3rd oversize
(thickness: 2,50 mm. =
0".098)
Washer, shoulder 4th oversize
(thickness: 2,65 mm. =
0".104)
Circlip, retaining shoulder
washer
Gear, 3rd speed
Screw, for dust cover
Gear, 4th speed
Gear, 2nd speed
Gear, low speed
aj The alai axial play of he assembly of the 4 gear pinion in respect to their seat must be contained between .006" and .012".
Should I IS play exceed saId tolerances, the normal shoulder washer must be replaced by another with proper oversize.
Figure II
Number Spare Part
PARTS LIST FOR ENGINE
Cush gear • Kickmrter
DES C RIP T ION I Figure I5 dre
Number p
(TABLE IV)
DESCRIPTION
i
147160 IRace,
roller bearing of
main-
18
89913
Washer, plate, of cush
drive
shaft
springs
282086
Cage, roller
bearing 19 17887 Spring, of cush drive
381842
Roller
20
92074 Drive, cushion, g. a. (Figs.
n.
447161
Washer, shoulder,
roller
bea- 19 - 21 - 22 -18 - 17)
ring
21 58677 Gear, multiple
5I47218
Spring, return, of
kickstarter
22
89911
Gear, outer, of cush drive
6I77413 Sedor, starting
23
S.10790 Rivet, for securing blades
7I46631
Plug
24 48002
Pad, blades
I
8I
97338
Kickstarter g. a. (Figs.
n. 9 -
25
54071
Blade, long, for sta rti ng sector
I
10 - 11
-12-13)
26
48000
Blade, short, for starting sector
949642
Rubber sleeve
27
5.6637 Circlip, for locking multiple
10
I
5.8507
Bolt, securing kickstarter
gear ball
bearing
11
I
S.3109
Washer, spring
28 2457
Roller, for multiple gear
12
I
5.3060
Washer, plain, of kickstarter
29 94417
Layshaft
13
S.1109
Nut
30 32494 Ball
bearing, of multiple gear
14
S.6721
Packing
31 S.13940
Wuher, plain, for nut securing
15 46742
Buffer, for starting
sector
layshaft
16 58680 Geary
starting
32 58560
Washer, spring, for
nut secu-
17 5. 10776 Rivet,
for sec. plate washer
ring
layshaft
II
I

TABLE IV
5--
-
31
'--------- ~-----~/
20
PARTS LIST FOR ENGINE
Flywheel M.gneto • Fin
(TABLE V)
Figure IS P rt
Number pare a
DESCRIPTION
I
Figure II
Number Spare Part
DESCRIPTION
6 S. 3055
7S.3105
8
S. 10047
. 9 46675
10
97191
1
2
3
4
5
46764
14501
662
674
87594
Cable, earth, with terminal
Terminal
Terminal
Circlip,
for flywheel extraction
Stator, g. a. (Figs. n. 42 - 23 -
33 - 22 - 34 - 36 - 24 - 30 -
32 - 37 - 46 - 1 - 38 - 39 -
45 - 21 - 44 - 47 - 6 - 35 -
7 -
27 - 31 - 28 - 29).
Washer, plain, for screws se-
curing stator and coils
Washer, spring, for screw se-
curing stator
Screw, for securing stator
Cam
Flywheel fan (Figs. n. 16 -12 -
9-14-13-15)
11
12
13
14
15
16
17
18
19
20
21
22
23
97189
6562
S.10775
78070
S. 12533
2946
S. 3056
2856
47577
S.3106
83408
625
622
Flywheel, magneto g. a. (Figs.
n.5-10)
Washer, plain, of cam
Rivet, for securing cam
Dust cover
Washer, spring
Screw, short, for securing fan
casing cover and dust cover
Washer, spring
Screw, long, for securing fan
casing cover
Cover, fan casing
Washer, spring
Pad, securing low tension coil
No.3
Fork spring
Washer, shim, of breaker
_ ?n _