Sears Free spirit 8080 Operating instructions

drepair
Sears
SEARSMOPEDS
MODELNO'S
80808084
80818085
80828086
8083
PART NO. 80848
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1.800.965.1977

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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1.800.965.1977

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
I
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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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LUBRICATIONANDMAINTENANCE
Fig. 9
Checkingtheignitionsystem
Ignitiontiming
Theenginewillreachmaximumoutputiftheignitionis
correctlyadjusted.Thisisa veryspecializedoperation
andshouldbelefttoyourservicestation.
Forcorrectignititiontiming,thefollowingpoints
shouldbetakenintoaccount:
1)Contactbreakerpointsgap.
2)Firingpoint.
Contactbreakerpointsgap(forrecommendedgapsee
fig. 9)
Checkandadjustthegapthroughthewindowsinthe
flywheelmagneto(afterremovingthecover).When
adjustingthebreakergap(fig.9/1)loosenthe
fasteningscrew(fig.9/3)enablingtheanvil(fixed
contact)toberemoved.Forreadjustingthepositionof
theanvil,puta screwdriverintothesettingseat(fig.
9/4).Ifthegaphasbeenaltered,itisnecessaryto
checktheignitionpoint.
Forcorrectadjustmentoftheignitiontimingsee
SectionIV,page42.
Adjustingheightofseat
Loosenscrews(figure10/1)andadjustseatandseat
postasrequired.(Model8080ONLY)
Fig. 10
Fig. 11
Checkingdrivechaintension
Theproperslackofthechainmidwaybetweenthe
sprocketsshouldbe (3/4 in.)about2 cm.
Toreadjustthechain,loosenbothaxlenutsand
tightenbothchainadjustersuniformly.Thisprocedure
enablesthebackwheeltobekeptintrack.Retighten
bothaxlenuts.Refertofig.46,page48.
Adjustingthestartinglever
Whenoriginallyadjustingorreadjustingthecontrol
cables,necessaryduetoexpandingofthecables,itis
expedienttohavethisdoneina serviceworkshop.The
playofthestartingdevicelever(measured atthe endof
thelever)(figure 11, arrow),shouldbe2 cm (3/4 in).
Correctplayisachievedbytheadjustingscrew(figure
11/1).
10
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LUBRICATIONANDMAINTENANCE
Checkingthebrakes(figure12& 13)
Frontbrake
Thecorrectadjustedtravelmeasuredattheendofthe
handbreakeleveris
3/4
in.(fig.12).Forreadjustment
usetheadjustingscrews(12/1or12/2).
34in(2cm)
Q
Fig. 12
Rearbrake
Thecorrecttravel(measuredattheendofthe
handbrakeleveris
3U
in.(2cm).Readjustbymeansof
theadjustingscrew(figure13/1or13/2).
Brakelinings
Pryplasticinspectionplugsfromwheelhub.
Disconnectbrakecablefrombrakelever.Inserta feeler
gaugebetweenbrakedrumandbrakelining.Gap
shouldnotexceed.047",ateitherinspectionhole,see
fig. 12.Ifgapexceedsthismeasurement,referto
SectionVIonbrakereplacement.DONOTOPERATE
YOURMOPED.
VA in (2cm)
Fig.13
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LUBRICATIONANDMAINTENANCE
Fig. 14
Ceckingandgreasingthehubbearings
RefertosectionVIFrontandRearHubs.
Checkingandgreasingsteeringheadbearings
RefertoSectionV SteeringHead.
Retightennutsundbolts
Checknutsandboltsfortightness.Aboveall,besure
thattheenginefixingbolts,thewheelaxlesandthe
shockabsorbersaretight.
Removingthefrontwheel
Unscrewspeedometerdriveshaft(fig.14/1,notmodel
8080).Disengagebrakecable.Ifnecessary,loosenset
screw.Removeaxlenuts(fig.14/2).
Fig. 15
Removetherearwheel
Loosenchainadjusters(fig.15/1).Loosenbothaxle
nuts(fig.15/2).Turnbrakecablesleevesupport(fig.
15/4). Disengagebrakecablefrombrakelever
(fig. 15/3).Removechainadjusters.Pushwheel
forward. Removedrivingchainandpedalchainfrom
theirsprockets.Inclinethemachinetotheleft,pullthe
rearwheelout,forthispurpose,presspulleyslightly
forward.
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LUBRICATIONANDMAINTENANCE
Replacingtheheadlightbulb
Undoadjustingscrew(fig.16/1)toloosenthe
headlampreflector.Openspring(fig.16/2)andpullout
bulbholder.Replacebulb.
Fig. 16
Replacingrearlightbulbandstoplightbulb
Unscrewfixingscrews(fig.17/1)andremove lense.
Replacebulbandfitinreverseprocedure.
Stoplightbulb(top)
andrearlightbulb(bottom).
Changingtires(fig.18andfig.19)
Toremovetire,unscrewvalvecap,depressvalve
needletoletouttheair,unscrewrimnutand
completelypressbackvalve.Loosenthesteelwire
reinforcedtiresectionfromtherim,andpressthetire,
oppositethevalve,intothecentergrooveoftherim.
Thisgivessufficientspacetoliftthetireatthevalve
endovertherimwiththetirelever.(Forspiderwheels
seepage14,fig.19.)
Holdthetireoutsidetherimwiththetirelever,and
workroundtherimwiththesecondleveruntilthe
wholecircumferenceofthetireisoutsidetherim(Fig.
19/C).
Now,removeinnertube.Whenassembling,fitlightly
pumped-up innertubecoatedwithchalkintothetire,
havingalreadyfittedhalfofthetireovertherim.
Ensurethetubeisnotjammedortwistedandmake
surethattherimbandseparatingthetubefromtherim
isflatintherimcenter well.
Fig. 17
\
Fig. 18
13
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LUBRICATIONANDMAINTENANCE
TIRECHANGING SCEMATIC (Fig.19)
•
B
*
s
i
REMOVALOFTIREANDTUBE
CAUTION: Itisessentialwhenchanginga tiretoprotectthealuminumrimfromdamagefrom
thetirelever.Alwaysusea leatherorrubberstripbetweentheleverandrim(fig.A andB).For
finalremovalofthetireusea rubberhammer.
TIREMOUNTING
Placelightlypumped-up tubeintotireand over therimasmentionedonpage13. Butfor thefinal
stagesoftiremountingusea rubberhammertogettireovertherim(fig.D, E, F).
14
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SECTIONII
ENGINE, CLUTCH, REDUCTION GEAR
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SPECIALTOOLS
Fig. Description
ToolKit Compl.
1EngineHolder
2Lockingdeviceforflywheel
3FlywheelPuller
i/' 4 Mainbearingpuller
'- 5 Clutchextractor
l/6 Pressingsleeveformainbearing
6Supportplate
7 3up installer
8Ignitiontimingdevice
'/9 Sprockettool(IdleGear)
10Dialindicator
11 HubCone,thinspanner
12Spokespanner
PartNo.
3328*
3335
3332*
3329*
3338*
3337*
3330*
3333*
normalworkshopequipment
3331*
3341*
normalworkshopequipment
3340
3339
Pressing-deviceforconnectingrodbrush3336
Reamingandcentringtoolforconnectingrodbush3334
Feelergauge
Dialindicator
Caliperrule
Torquewrench
Assemblystand
normalworkshopequipment
normalworkshopequipment
normalworkshopequipment
normalworkshopequipment
localfabrication
TheseitemsareincludedintheToolKit
16
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SPECIALTOOLS
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17
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TUNE - UP SPECIFICATIONS
MODEL
1 HP
1,5HP
2 HP
SPARKPLUGS
TYPE
Champion L90
BoschW95-T1
(Bosch W10A)
Champion L-86
BoschW175-T1
(Bosch W7A)
Champion L82
BoschW200-T35
(Bosch W6B)
GAP
.016"-.020"
0.40-0.50 mm
.016"-.20"
0.40-0.50 mm
.016"-.020"
0.40-0.50 mm
BREAKERPOINT
GAP
.014"-.018"
0.35-0.45 mm
.014"-.018"
0.35-0.45 mm
.014"-.018"
0.35-0.45 mm
IGNITIONTIMING
.051"-.067"BTDC
1.3-1.7 mm
.051"-.067"BTDC
1.3-1.7 mm
.051"-.067"BTDC
1.3-1.7 mm
TIREPRESSURES
Front-26 P.S.I.
Rear -32 P.S.I.
CYLINDERHEADTIGHTENING
Tighten all cylinderheadnuts to7 ft/lb (10 Newton-meter).
18
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TECHNICALDATA
ENGINE
Maximumoutput1.0hpat3,500 r.p.m.
Maximumtorque1.63ft/lb(0.22 mpk) at3,000 r.p.m.
Compressionratio9.2: 1 (7.1: 1)
Maximumoutput1.5hpat4,500r.p.m.
Maximumtorque 1.79 ft/lb(0.248 mkp) at3,000r.p. m.
Compressionratio9.2: 1 (7.1: 1)
Maximumoutput2.0hpat5,000 r.p.m.
Maximumtorque2.06ft/lb(0.285mkp)at4,500r.p.m.
Compressionratio9.2 :1 (7.1 :1)
Bore 1.49 in.(38mm)
Stroke 1.69 in.(43mm)
Displacement48.8cc
Coolingaircooled
Lubricationpetroillubrication
Carburetor1.0hpBing1/14/164
Mainjet52/50
NeedleJet2.12A
Needleposition1stnotchfromtop
Carburetor1.5hpBing1/14/164
Mainjet52/50
Needlejet2.12A
Needleposition1stnotchfromtop
Carburetor2.0hpBing1/14/163
Mainjet68/66
Needle jet2.12A
Needleposition1stnotchfromtop
Ignitionmagnetoignition
Breakerpointgap.0137-0177in.(0.35-0.45mm)
Ignitiontiming.051-067in(1.3-1.7mm)
B.T.D.C.
Sparkplug 1.0 hpBoschW 95T1 (BoschW 10A)Champion L90
Sparkplug 1.5 hpBoschW 175T1 (BoschW 7A) Champion L 86
Sparkplug2.0hpBoschW 200T35(BoschW 6B)ChampionL 82
Sparkgap .016-.020 in(0.4-0.5mm)
DynamoFlywheelmagnetoBoschRCP16 V 26-5/10 W
Ignitioncoiloutsidethegenerator
POWERTRANSMISSION
Gearboxsinglespeedautomatic
Clutchcentrifugal
Primarytransmissionhelicalgears
Secondarytransmissionchain Vz" x
3/ie"
Pedallingchainchain W x W
19
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