Sears Free spirit 8080 Operating instructions

drepair
Sears
SEARSMOPEDS
MODELNO'S
80808084
80818085
80828086
8083
PART NO. 80848
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CONTENTS
PART1
SECTION I PAGENUMBER
RoutineMaintenanceChart3
RecommendedLubricants4
LubricationandMaintenanceProcedures5
SECTIONII- ENGINE,CLUTCH,REDUCTIONGEAR
SpecialTools 16
Specifications18
TechnicalData19
Dismantling23
Re-Assembly28
Installation32
TroubleShooting33
SECTION III - FUELSYSTEMANDCARBURETION
Operation/Adjustments36
ExhaustSystem40
TroubleShooting40
SECTIONIV- IGNITIONSYSTEM
IgnitionTiming42
TroubleShooting44
SECTIONV - FRAMEANDFORKASSEMBLY
Frame46
RearFork46
ShockAbsorbers46
FrontFork47
SteeringHead47
TroubleShooting49
SECTIONVI- WHEELHUBSANDBRAKES
Brakes52
FrontandRearHubs52
TroubleShooting54
SECTIONVII- ELECTRICALSYSTEM
GeneralDescription' 56
TroubleShooting57
WiringDiagram58
SECTIONVIII- TECHNICALDATA
TorqueReading& Specifications60
AssemblyTolerances62
MetricConversionTable63
INDEX 65
PART 2
PartsManual67
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1.800.965.1977

SECTION I
LUBRICATIONANDMAINTENANCE
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LUBRICATIONANDMAINTENANCE
ROUTINEMAINTENANCESCHEDULE:
ThegeneralandperiodicmaintenancerequiredforFREESPIRITMopedsisclearlydescribedin
thefollowingpages,andshouldbeperformedatthemileageintervalsshowninthefollowing
chart.
LUBRICATION& MAINTENANCECHART
OPERATIONSTOPERFORM
Tirewearandcondition
Throttlecableadjustment
Checktirepressure
Checkgearboxoillevel
Cleanandlubricatechain
Cleanairfilter
Changegearboxoil
Checksparkplug
Decarbonizeengine
Cleanexhaustbaffle
Retightenscrews,nuts(inc.headnuts)
Cleanfuelvalveandlines
Cleancarburetor
Idlespeedadjustment
Checkignitiontiming
Adjustclutch
Checkbrakes/linings
Check/lubricatehubbearings
Steeringbearingadjust/lubrication
Lubricatecontrolcables
Adjustchaintension
Lubricatefrontfork
First
300
X
X
X
X
X
X
X
X
X
X
X
X
X
Frequencyinmiles
Every
600
X
X
X
900
X
X
X
X
X
X
X
X
1,800
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
3,600
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
7,200
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOTE: Abovetimescheduleappliestomopeduseondrypavedsurfaces.Ifmopedisusedin
wet,muddyorsandyareas,maintenanceshouldbemorefrequent.Alwayscheck con-
trolsandlightingbeforeanytrip.
3
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LUBRICATIONANDMAINTENANCE
RECOMMENDEDLUBRICANTS
GASOLINE-OILMIX
1)Mixtureofregulargasoline
2)Mixtureratio50: 1 withspecialtwostrokeoil
GEARBOXFLUID
1)5.74 oz (170cc)AutomaticTransmissionFluid,Type"F
MACHINELUBRICATION
GREASE(TYPE)LUBRICATION
1)Lithiumbasegrease
OIL(TYPE)LUBRICATION
1)SAE90
2)SAE30
4
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LUBRICATIONANDMAINTENANCE
LUBRICATION
Changinggearboxoil
1)Warmuptheengine./ Stopengine.
2)Removetheoilfillingplug(figure1/1)andoildrain
plug(figure1/2).
3)Drainoil.
4)Replacedrain plug.
5)Fillwithfreshautomatictransmission fluid-TYPE F
ONLY-(approx.170cc)tobottomoffillingscrew
hole.
6)Replaceoilfilling plug.
Fig. 1
Cleaningandoilingthechains
CAUTION: ENGINESHOULDNOTBERUNNING.
Thelonglifeofchainsdependstoa greatextenton
careandmaintenance.Chainsshouldalwaysbe
cleanedandlubricatedregulary.Whenrefittingthe
chains,takecarethatthetensioniscorrectandthe
connectinglinksareproperlyplaced- withtheclosed
endpointinginthedirectionofchaintravel(figure2).
Fig. 2
Greasingcycleparts
Bymeansoflubricatinggrease
(forqualityseelubricationchart)(page4)
Speedometerdrivelubrication(Notmodel8080)
1)Atthelubricationnipple(figure3/1)oneortwo
strokesoutofthegreasegun.
Kickstandbearing
1)Removethestandspring.Remove3 hexagonbolts.
Removestand.Greasebothhalvesofthestand
pivot. Fig. 3
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LUBRICATIONANDMAINTENANCE
Ji
Fig. 4
Bymeansofoil
1)Brakeadjustingscrewonfrontandrearwheel.
2)Adjustingscrewforstartingclutchcable.
3)Chaintensioningscrews.
4)Workingsurfacesofbothbrakelevers.
5)Bowdencables.
Lubricatingtheignitioncam:
Lubricatethegreasefelt.Thelubricantmustnotreach
thebreakerpointsasthiswouldcauseprematureand
excessivewear.
MAINTENANCE
PleasecontactanauthorizedSearsAutoCenterfor
workyoudonotwishtocarryoutyourself.Theagent
willbepleasedtoadviseandhelp.
Checkingsparkplugs
Unscrewspark plug, connecttohightensionleadand
placeplugbodytoearth,forinstanceonthecylinder
head. A strongsparkmustbevisiblebetweenthespark
plugelectrodeswhenoperatingthestarter.Oiledup
plugsordirtyelectrodesdonotsparkandmustbe
cleanedfirstwitha pieceofwoodora steelwirebrush.
Fitonlyreplacementplugshavinga heatvaluein
accordancewiththeenclosedchart(page18).The
electrodegapshouldbefrom( .016-.020in)0.4to
0.5mm,iflarger,adjustbybendingtheearthelectrode.
Whenreplacingthesparkplugensurethreadmatches
properlyandtheplugcanbescrewedineasily.Never
applyforce.Screwinplugbyhandfor2 to3 turns
beforeusingthesparkplugspanner.
Appearanceoftheplugtipcantellyouhowyour
enginehasbeenrunning.
MAINTENANCE
Decarbonizingtheengine(figure4)
Carbondepositsonthecylinderhead,pistoncrown
andintheexhaustportsarenormalwithalltwo-stroke
enginesandcaneventuallyleadtotroubleifnot
removedintime.Combustiondepositsfromoilaswell
asfromfuelmustthereforeberemovedregularly.
Cylinderheadandpistonhead
Carbondepositsonthecylinderheadandpiston
crownshouldberemovedonlywitha soft,bluntedged
instrumenttoavoiddamagetothelightalloycasting.
Scratchingshouldbeavoidedsinceeverynewscratch
willharbourmorecarboninfutureuse.
Onlyscallydepositsneedberemovedfromthepiston
crown, thereisnoneedtodisturbthepistonifitis
coveredonlybya uniformlayerofoilcarbon.Before
refittingthecylinderhead,thoroughlyremoveall
carbondepositsandscrapingsfromthecylinderwall
witha nonfrayingsoftclothandsmearthesurface
lightlywithmotoroil.Beforeassembly,turnoverthe
enginea fewtimestomakesureitrunseasily.Then
cleanthejointingsurfaceswitha cleanrag.Tighten
thefourcylinderheadnutscrosswise(7ft/lb)(10 Nm).
L
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LUBRICATIONANDMAINTENANCE
Exhaustport
Inordertocleantheexhaustport,removetheexhaust
pipe. Bycranking,turntheengineover(withthespark
plugremovedtoreducecompression)untilthepiston
reachesitslowestpoint.Removetheoilcarbonfrom
theexhaustport.Cautiouslytakecarenottodamage
thepistonorcylinderworkingsurfaces.Whencleaning
theexhaustport,itisalsoa goodideatocleanoutthe
muffler.
Cleaningthemuffler(figure5)
Unscrewandpullofftheexhaustendpiece.Remove
oil-carbondepositsfromtheinsideofthemufflerusing
ascraper.Alsoremovecarefullytheoildepositsfrom
thefasteningdeviceandfromthepipesoftheexhaust
endpiece.Replacethegasketsifnecessary.The
machinehasbeenstandardizedwithoriginalmufflers
only.
NOTE: Forfurtherbreak-downofexhaustsystemrefer
todiagramonpage40
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Fig. 5
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LUBRICATIONANDMAINTENANCE
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Fig. 6
Cleaningtheaircleaner
Removethelefthandchainguard.Loosenscrew
(figure6/1and6/2)oftheclipontheintakesilencer
andpullaircleanerassemblyfromthecarburetor.
Removefrontpartoftheaircleanerusinga drift,
carefullypushoutfilterscreen.Washfilterscreenin
gasolineorsolventandallowittodrythoroghlybefore
replacing. Fitagaindamperpipe,filterscreen,andair
cleanerassembly.
Cleaningthefuelpipesandlines
Emptyfueltank.
Pullthefuelpipefromthefuelvalveandcarburetor
andblowitclear.Unscrewthefuelvalve.
Cleanthevalveandstrainerbymeansofgasoline.
Cleaningthecarburetor
Maintenanceoperationsonthecarburetorareoutlined
inSection III, FUEL SYSTEMANDCARBURETION.
Cleaningthemainjet,needlejetandfloatchamber.
D
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
Closethefuelvalve.
Removethelefthandsidecovering.
Removetheintakesilencer.
Loosencarburetorclampingscrew(figure7/1).
Pullthefuelpipefromthecarburetor.
Turnthecarburetorwithitsfloatschamber
(bottom)towardstheclutchsideandpulloff.
Undoscrewsandpulloutthetoppartswith
throttlepistonandchoke(figure7/2).
Screwoffthefloatchamber.
Unscrewthemainjet(figure8/5)beingscrewedin
theneedlejet(figure8/4)andcleanbyblowing
throughorbyusinga stiffbristle.Neverusea
pieceofwire.Also,unscrewneedlejetandclean.
Cleanthefloatchamber(figure8/8)withgasoline.
Washcarburetorbodyandblowthrough.Make
surethattheboresarenotcloggedwithdirt.
Whenrefittingthejets,tightenthemproperly.
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LUBRICATIONANDMAINTENANCE
Adjustingtheidlingspeed
1)Warmuptheengine.
2)Completelyclosethetwistgrip(throttledown).
3)Iftheenginethreatensto stall, screwintheadjuster
(figure7/3)untiltheengine,inwarmcondition,
regainsitseventickover.
Now,withtheidlingadjusted,adjusttheplayofthe
throttlecontrolcable.
1)Loosencounternutofthecableadjuster(figure
7/4).
2)Screwcounternutofthecableadjuster(figure7/5)
untilthereisa playonboththethrottlecableand
thethrottletwistgrip.Thecoverofthethrottlecable
canbepulledoutfromthecableadjusterbyappr.
.08in.(2mm),beforethethrottleslideislifted,i.e.
beforetheenginestartsrunningfaster.
3)Maintainpositionoftheadjusterandtightenthe
counternut.
I
Fig. 7
Explodedviewofthecarburetor(seefig.8)
1Inletmanifold
2Carburetorbody
3Throttleslidestopscrew
4Needlejet
5Mainjet
6Floatneedle
7Float
8Floathousing
9Hoseswivelconnector
10Throttleslider
11Jet-needle
12Chokevalve
13Chokelever
14Topcover
15Slidespring
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Fig. 8
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