Solex Manual S3800

7/25/2019 Solex Manual S3800

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VeloCruz PO Box 902021 Sandy, UT 84090

Phone: 801.733.4578 800.393.7101 Fax: 801.383.6070

www.velocruz.com [email protected]


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i

Techical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Principle of Operation of the 2-Cycle Engine . . . 2

Ignition3

Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Automatic Compound Clutch . . . . . . . . . . . . . . . 6

Special Service Tools . . . . . . . . . . . . . . . . . . . . . . 7Engine Repair Operations . . . . . . . . . . . . . . . 8-29

Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Engine Guard Rail . . . . . . . . . . . . . . . . . . 9Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Stator and Stator Bearing . . . . . . . 12-13Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Drive Roller Assembly . . . . . . . . . . . . . . 15Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . 16

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . 17Cylinder Head . . . . . . . . . . . . . . . . . . 18-19Cylinder. . . . . . . . . . . . . . . . . . . . . . . 20-21Carburetor . . . . . . . . . . . . . . . . . . . . . . . 22Crankcase End Cover . . . . . . . . . . . . . . 23Connecting Rod Assembly . . . . . . . . . . 24Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . 25Engine Supports and Axle . . . . . . . . . . 26Engine Decarbonizing. . . . . . . . . . . . . . . 27Decompressor . . . . . . . . . . . . . . . . . . . . 28Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 28

Ignition Timing . . . . . . . . . . . . . . . . . . . . 29

Engine Component Parts . . . . . . . . . . . . . . 30-32

Electrical Connections, Solex 3800 D.O.T. . . . 33

Engine Trouble Shooting Guide . . . . . . . . . 34-36

Cycle, Frame, Controls Repair Operations. 37-50

Front Wheel Assembly. . . . . . . . . . . . . . 37Wheel Axle . . . . . . . . . . . . . . . . . . . . . . . 37Wheel Bearing Play . . . . . . . . . . . . . . . . 38Front Brake Mechanism. . . . . . . . . . . . 38Front Brakes. . . . . . . . . . . . . . . . . . . . . 39Front Mudguard . . . . . . . . . . . . . . . . . . 40

Mudguard Supports . . . . . . . . . . . . . . . 40Steering Races. . . . . . . . . . . . . . . . . . . . 41Front Forks . . . . . . . . . . . . . . . . . . . . . . 42Kick Stand. . . . . . . . . . . . . . . . . . . . . . . 42Crank Spindle . . . . . . . . . . . . . . . . . . . . 43Crank Assembly. . . . . . . . . . . . . . . . . . . 44Handlebar . . . . . . . . . . . . . . . . . . . . . . . 44Throttle Twist Grip . . . . . . . . . . . . . . . . 45Left Handgrip . . . . . . . . . . . . . . . . . . . . 45Saddle Assembly . . . . . . . . . . . . . . 45-46Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . 46Rear Brake Drum . . . . . . . . . . . . . . . . . 46Brake Shoes . . . . . . . . . . . . . . . . . . . . . 47Rear Brake . . . . . . . . . . . . . . . . . . . . . . 48Rear Wheel Bearing. . . . . . . . . . . . . . . . 48Rear Mudguard . . . . . . . . . . . . . . . . . . . 49Mudguard Support . . . . . . . . . . . . . . . . 49Luggage Carrier and Supports . . . . . . 49Headlamp . . . . . . . . . . . . . . . . . . . . . . . 50Rear Lamp. . . . . . . . . . . . . . . . . . . . . . . 50

Control Cables . . . . . . . . . . . . . . . . . . . . . . . 51-52Brake Cables. . . . . . . . . . . . . . . . . . . . . . 51Throttle Cables. . . . . . . . . . . . . . . . . . . . 51Decompressor Cable . . . . . . . . . . . . . . . 52

Torque Diagrams . . . . . . . . . . . . . . . . . . . . . 53-58

Solex Wiring Diagram . . . . . . . . . . . . . . . . . . . . 59

TABLE OF CONTENTS


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1

TECHNICAL DATA

Dimensions: Overall length ...............................66 inchesOverall width.................................24 inchesOverall height...............................41 3/4 inchesWeight............................................68 pounds

Frame: Type.................................................Pressed steel

Front brakes ................................CaliperRear brakes..................................Internal expansionTire size .........................................1.75 x 19Tire pressure F/R........................32 psi

Fuel: Capacity ........................................1/3 U.S. gallonMixture...........................................Mix 4 ounces high quality two-stroke oil

with 1 gallon unleaded gasoline.

Engine: Type .................................................Single cylinder, two-strokePower...............................................0.8 HPCapacity........................................49 cc

Electrical System: Ignition and Lighting..................FlywheelSpark plug.....................................Champion L86, Autolite AE32,

Bosch W174 T1Headlamp......................................Sealed beam 6 voltTaillight/Stoplight ......................Trade no. 1154 6 volt

Performance: Speed.............................................20 MPH

Identification Engine number.............................Seven digit number engraved on the rearof the engine housing. 9.6

Serial number ..............................Located on the frame steering. 9.1


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PRINCIPLE OF OPERATION OF THE 2-CYCLE ENGINE

As the piston rises, it opens the inlet port and begins to draw a fresh mixture into the crankcase.This is because the increasing crankcase volume lowers the crankcase air pressure below atmosphere.At the same time, combustion chamber pressure begins to increase. See figure 1

Piston reaches top of its stroke, spark plug ignites the mixture. See figure 2

Rapid expansion of ignited mixture pushes the piston down. The inlet port closes. See figure 3

Fuel supply: As piston descends in cylinder, it creates air pressure in the crankcase which escapesthrough the fuel pump port in crankcase to the fuel pump causing the fuel pump membrane to expand.As piston rises in cylinder, a vacuum is created inside the crankcase causing the fuel pump membraneto contact. This process now creates a pumping action in the fuel pump, and to keep the gas flowing inan upward direction to the carburetor, the pump has two check balls which act as one-way valves.

Exhaust begins. The burned gas is forced out due to high pressure in the combustion chamber. Seefigure 4

Transfer port opens. Descending piston forces fresh mixture through transfer port to combustionchamber. The incoming fresh mixture helps to push exhaust mixture out. See figure 5

Exhaust port closes. Compressions begins. See figure 6

2

ExhaustPort

InletPort

T

Figure 4

ExhaustPort

InletPort

T

Figure 2

ExhaustPort

InletPort

T

Figure 5

ExhaustPort

InletPort

T

Figure 3

ExhaustPort

InletPort

T

FuelPumpPort

Figure 6

ExhaustPort

InletPort

T

Figure 1


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3

IGNITION

Flywheel Magneto The Solex ignition magneto is of a compact, rotary magnet design. Itprovides a high voltage for the spark plug and low voltage current forlights and horn. Facing each other inside the flywheel are 4 fixed magnetsspaced at 90 degrees. Alternate magnets show alternate north andsouth poles. Inside the flywheel is a cam which opens the points and a

key to locate the flywheel on the crankshaft.Ignition Circuit The ignition circuit consists of an ignition coil with the primary winding,

contact points to interrupt the primary circuit, a condenser, and a sec-ondary winding.

Operation As the flywheel magnets rotate past the coil, a current is induced in theprimary winding. The primary winding of the ignition coil sends the currentto the moving contact which, at the closed position, is grounded to thefixed contact. As the flywheel rotor revolves, the cam opens the points;the current is no longer grounded and, therefore, must move. The currentmoves to the secondary winding of the ignition coil, producing a high ten-

sion current which goes to the spark plug lead and ignites the mixture inthe cylinder.

Condenser A condenser is a tight roll of two strips of foil sandwiched between threeinsulator strips. Because of its large metallic surface area, a condenserhas the ability to store small amounts of electrical energy. The amountof stored energy depends on the condenser size (rated in micro-farads)and the applied voltage.

Furthermore, electrical occilations, a phenomenon known as resonance,occurs whenever a charged condenser and matched inductive coil areplaced together in a closed circuit.

The condenser is in parallel with the points and acts as a safety valve byproviding a path for the current to follow when the points open. Currentflows to the condenser instead of jumping the point gap, thereby pre-venting burning of the points.


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CARBURETOR

Principle The Solex carburetor is supplied with fuel by a crankcase pressure acti-vated fuel pump. Fuel is pumped from the fuel tank through the fuel pumpto the carburetor at which time the fuel needed is metered through thefuel jet, combined with air. This mixture goes to the cylinder.

The Solex carburetor consists of 13 parts:

1 Carburetor body w/diffuser 8 Throttle barrel2 Air jet 9 Cable bracket3 Fuel jet 10 Carburetor slide4 Inlet manifold olive 11 Slide fixing bolt5 Inlet manifold nut 12 Slide spring6 Choke assembly 13 Carburetor filter 7 Choke lever

Operation The fuel is delivered to the carburetor through the fuel supply pipe, atwhich time it is filtered (A). The amount of fuel needed is then meteredby the fuel jet (B) into the cylinder, and the surplus fuel delivered by the

pump is returned to the fuel tank through the overflow pipe (C). This prin-ciple avoids the need of a float because there is always the properamount of fuel at the jet. See figure 7

After the fuel is metered through the fuel jet, it combines with air fromthe air jet (D) through the choke assembly (E) to the mixing chamber (F)and proceeds through the diffuser (G) which vaporizes the fuel mixture.This vaporized fuel mixture proceeds through the air horn (H), throughthe throttle barrel (I) to the inlet pipe, then to the cylinder when the inletport is opened (See figures 1 thru 6).

Throttle Barrel The throttle barrel controls the amount of the vaporized fuel entering

into the cylinder.When completely opened, it draws more air through the air horn, which inturn increases the fuel mixture in the diffuser, which in turn causes themotor to turn faster.

As the throttle barrel closes, the amount of air drawn through the airhorn decreases, which in turn decreases the fuel mixture in the diffuser,which in turn causes the motor to turn slower.

Idle The throttle barrel has been modified by the factory to give a proper con-trol when idling. There is a special manufactory control on this modifiedbarrel indicated by a blue spot on the carburetor body. his modification

is so critical that the company does not wish you making this operation,but suggest you replace this part if the carburetor does not have thiscontrol mark.

Choke The choke lever control the amount of air entering through the air jet. Byclosing the choke lever, you decrease the amount of air, thereby enrichingthe full mixture in the mixing chamber, which in turn creates more com-bustion in the cylinder; thus, allowing your engine to start more easilywhen cold.

4


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5

D

E

B F G

C

H

I

A

CARBURETOR BODY

THE SOLEX CARBURETOR

AIR FILTER

A-Fuel Filter

B-Fuel JetC-Overflow PipeD-Air Jet

E-Choke Assembly

F-Mixer Chamber

G-DiffuserH-Air HornI-Throttle Barrel

Figure 7


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AUTOMATIC COMPOUND CLUTCH

Clutch Components The automatic compound clutch is comprised of: a drum, integral withthe drive roller, and a system of bobweights and shoes integral with thecrankshaft. See figure 8

The vaned rotor and the flywheel magneto cover form a fan which coolsthe engine when it is running and enables it to idle without overheating.

WARNING: Never run the engine with the flywheel cover removed.

Clutch Action The clutch is a single action, centrifugal clutch that starts the engine aswell as propels the machine.

Starting the Engine When stationary, the flyweights (F) due to the action of the springs (S)press the centrifugal clutch arms (A) and pads (P) against the driveroller drum (D). When the front wheel begins to revolve, the engine isturned. See figure 9

Normal Running When the throttle is opened the speed of the engine increases, forcingthe flyweights further away from each other, thus forcing the centrifugalclutch arms and pads further against the drive roller drum transmittingpower from the crankshaft to wheel through the drum and the driveroller. See figure 10

Normal RPM at full speed is 3800 RPM.

Slow Down and Idle When the engine reaches idling speed (1500 RPM), the flyweights moveoutwards due to centrifugal force. During this time the centrifugal forceis overridden by the power of the springs. The pressure of the pads onthe drum is reduced by the contraction of the centrifugal clutch armsallowing the clutch pads to slip while the engine continues to run. Poweris now discontinued from the drive roller drum and drive roller allowing theengine to idle. See figure 11

6

Figure 8 Figure 9 Figure 10 Figure 11


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7

SPECIAL SERVICE TOOLS

Part # 200001 - Valve Reamer

Part # 200002 - Stud Extractor

Part # 200003 - 21mm Deep Socket

Part # 200004 - Stator Plate Extractor and Installer

Part # 200005 - Flywheel Puller

Part # 200006 - Brake Tool

Part # 200007 - Bearing Extractor

Part # 200008 - Clutch Limiter

Part # 200009 - Stroke Limiter

Part # 200010 - Engine Mount Plate


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8

ENGINE REPAIR OPERATIONS

Operation Sequence The following operations are described in a sequence which results incomplete disassembly of the engine, if reassembly of each operation isnot carried out.

Muffler

Removing 1. Loosen, but do not remove, the nut securing the muffler to the mud-guard. Loosen the nut securing the exhaust pipe to the right hand enginesupport. Use 10mm wrench. Figure 12

2. Pull on the muffler to remove it from the mudguard.

3. Pull the muffler outwards, while pulling down on the exhaust pipe nearthe engine support, and free the pipe from the upper section of theexhaust pipe.

Solex owners are advised to consult their dealer at each 3600 miles formuffler inspection.

The muffler should be replaced at this interval if restricted at all. Whenfitting a new muffler, check that no obstruction enters the exhaust pipe.

Reassembling Reassemble in reverse sequence.

NOTE: The muffler stay must be inserted between the mudguard supportand the mudguard and pushed in fully to prevent vibration. Leave a spacebetween the exhaust pipe and the front fork to prevent noise vibration. Ifthe muffler comes in contact with the front fork after tightening themuffler mounts, pry it away using a heavy screwdriver.

Figure 12


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Engine Guard Rail

Removing 1. Loosen the bolt securing the engine guard rail to the fork assembly(10mm wrench). See figure 13

2. Pull gently on each side of the engine guard rail at the clamp positionand lift the rail forward and over the engine.

Reassembling 1. Reverse the procedure.

NOTE: There are two caps inside of the engine guard rail tube.

Figure 13


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Engine

Removing 1. Set the machine on the support stand. See figure 12

2. Loosen the front brake.

3. Remove the front wheel (17mm wrench).

4. Remove the flywheel cover.

5. Remove the engine cover.6. Disconnect the lighting wires.

7. Disconnect the throttle and decompressor cable (7mm and 10mmwrench).

8. Loosen the nuts on each side of the engine supports and remove thebolts (10mm wrench).

9. Loosen, but do not remove, the upper nuts on each side of the enginesupports (10mm wrench).

10. Lift the engine form the fork support slots and remove.

Reinstalling Reverse the procedure.NOTE: After installing, check and adjust: throttle (pg. 28), decompressor(pg. 28), front brake adjustment (pg. 39), and check lighting.

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Rotor

Removing 1. Remove the stroke limiter plug and insert the stroke limiter asdescribed. Unscrew the stroke limiter slowly while turning the flywheel andstop as soon as the flyweight just catches the stroke limiter (tool#200009).

2. Loosen the flywheel cover plate nut and remove the plate and rubber

seal and remove the rotor nut (14mm wrench).3. Install the flywheel puller nut with the flange of the nut to the rear(tool #200005).

4. Install the flywheel puller plate on the flywheel and tighten the threefixing bolts (10mm socket). See figure 14

5. Loosen the flywheel puller nut until a cracking noise is heard (14mmwrench).

6. Continue to loosen the flywheel puller nut and remove the rotor.

7. Remove the flywheel puller plate and the nut from the rotor (use

10mm wrench).8. Place the rotor on the workbench with the open side up to preventforeign metal objects connecting with the magnets.

Reassembling 1. Lightly oil the felt pad on the stator plate assembly.

2. Reverse the removal procedure.

NOTE: The key on the rotor bushing aligns with the slot on the crank-shaft.

Figure 14


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Stator and Stator Bearing

Removing Stator 1. Loosen the two bolts securing the top left horn coil and remove (7mmwrench).

2. Turn the coil to one side and reinstall the bolts (7mm wrench).

3. Loosen the drive roller cleaning bolt and disconnect the spark pluglead from the stator plate and wires. See figure 15

4. Loosen the bolt securing the engine engagement lever. Do not remove(10mm wrench).

5. Loosen the two stator plate fixing bolts and install the stator platepuller tool on the crankshaft (tool #200004).

NOTE: Remove the stroke limiter but do not replace the stroke limiterplug.

6. Screw in the stator plate puller wings until each wing fits over the cor-ners of the ignition and lighting coils. Hold wings firmly and screw in thestator plate puller until stator plate is free of the crankshaft. See figure 15

7. Remove the stator plate puller and the stator.Removing Stator Bearing 1. Insert the stroke limiter (tool #200009).

2. Install the bearing extractor tool with the tool flanges over the bearing(tool. #200007).

3. Screw in the extractor and remove the bearing.

12

Figure 15


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Reassembling Bearing 1. Lightly spray lubricate and inside lips of the bearing.

2. Heat the stator housing and insert the bearing with the open side ofthe bearing in the stator housing.

Reassembling Stator 1. Insert the stator plate bolts. See figure 16

2. Align the stator plate with the engine engagement lever bolt.

3. Fit the stator plate puller extension pipe on the tool and install the

puller on the crankshaft (tool #200004).

4. Turn the wings of the stator plate puller clockwise until the stator isinstalled on the crankshaft.

NOTE: Install the stator on the crankshaft to within 1/8 inch of itsseating.

5. Tighten the engine engagement lever bolt by hand. Tap on the statorto correctly align.

6. Tighten the stator plate puller wings until the stator is fully seated.

7. Tighten the engine engagement lever bolt fully (10mm wrench).

8. Remove the stator plate puller.

9. Tighten stator plate bolts (10mm wrench).

Figure 16


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Clutch

Removing 1. Loosen the nut securing the clutch assembly to the crankshaft(tool #200003).

2. Using both index fingers, expand the flyweights and withdraw theclutch assembly from the drive roller housing.

NOTE: Inspect the clutch linings and replace the clutch assembly if worn.

Reassembling NOTE: The X marked on the clutch arms indicates the outward facingside of the clutch when mounted. See figure 17

1. Squeeze the flyweights together and insert in the drive roller housing.

2. Install the nut on the crankshaft.

3. Fit the clutch wrench over the nut with the arm of the wrench alignedwith the front side of the engine engagement lever bolt hole. Insert a boltthrough the arm of the wrench into the bolt hole to hold the clutchwrench firmly (tool #200008).

4. Tighten the crankshaft nut fully.

5. Remove the bolt and clutch wrench (tool #200008)

14

Figure 17


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15

Drive Roller Assembly

Removing 1. With the left index finger, press one side of the oil seal while rocking theseal on the other side with the right index finger. Gradually withdraw theoil seal over the thread of the crankshaft and remove.

2. Remove the drive roller nut and washer (tool #200003). See figure 18

3. Remove the drive roller.

Reassembling 1. Lightly grease drive roller between the roller and crankcase flanges.

2. Align the flange of the drive roller with the engine engagement leverbolt hole and insert a bolt.

3. Fit the washer and drive roller nut and tighten slightly (tool#200003).

4. Fit the oil seal.

Figure 18


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Fuel Tank

Removing 1. Disconnect the fuel recirculation pipe from the carburetor. See figure 19

2. Loosen the fuel inlet pipe nut on the fuel pump (10mm wrench).

3. Loosen the fuel tank mounting bolts (10mm wrench).

4. Remove the fuel tank.

5. Loosen the fuel outlet pipe nut.6. The fuel filter is located at the fuel outlet.

7. To remove the filter, insert a 2-inch, #6 or #8 sheetmetal screw in thefuel outlet.

8. Screw into the filter and pull.

9. Replace the gas tank filter if fouled.

Reassembling Reverse the procedure.

NOTE: Never tighten the fuel outlet pipe excessively.

16

Figure 19


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Air Filter

Removing 1. Loosen the air filter cover and remove the air filter unit (10mm wrench).See figure 20

2. Hold the cover and tap lightly on the protruding lip of the air filterhousing until the cover is free of the housing.

3. Pry the filter ring loose and remove the filter (screwdriver).

Installing 1. Reverse the procedure.

NOTE: Check that the gasket on the carburetor inlet is in position.

Figure 20


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Cylinder Head

Removing 1. Disconnect the lead to the spark plug and remove the spark plug lead(10mm wrench). See figure 21

2. Loosen the spark plug (tool #200003).

3. Loosen the cylinder head bolts and remove the cylinder head (10mmwrench).

4. Remove the air filter support bracket.

5. Remove the decompressor cylinder head plate.

6. Remove cylinder head spacers.

7. Loosen and remove the brass nut connecting the decompressor valveassembly.

8. Scrape all carbon deposits from the cylinder head. DO NOT scrape thedecompressor valve seat (scraper).

9. Place a little oil in the decompressor valve port and insert a valvereamer to clean the port.

18

Figure 21


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Reassembling NOTE: Always fit a new decompressor valve after having reamed thecylinder head valve seat.

1. Insert the decompression valve in the cylinder head with the slot on thevalve end facing a 1 oclock direction (screwdriver).

2. Place the valve spring on the valve and fit the decompressor valvebrass nut.

3. Tighten the nut also aligning the slot in the nut to the 1 oclock direc-tion (10mm wrench).

4. Hold the decompressor valve and loosen the nut counter clockwise onecomplete turn.

NOTE: Always fit a new cylinder head gasket.

5. Fit the gasket, and place the cylinder head in position in the cylinder.

6. Insert the air filter support bracket in the slots on the cylinder headwith the screw hole facing to the front of the motor.

7. Insert the cylinder head spacers.

8. Fit the decompressor cylinder head plat in position and connect theengine decompressor lever in the slot in the decompressor valve.

9. Insert the cylinder head bolts placing one washer on the top of theplate on the cylinder head bolt at the decompressor lever.

10. Tighten the cylinder head bolts progressively at opposite corners to8.5 - 9 ft. lbs. (10mm wrench).

NOTE: Never tighten the cylinder head bolts excessively.

If the decompressor cable has been disconnected, connect and adjustthe decompressor as described (see page 28).

SOLEX 1919


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Cylinder

Removing 1. Disconnect the fuel recirculation pipe on the fuel pump.

2. Loosen but do not remove the fuel inlet pipe nut on the carburetor andturn it (14mm wrench).

3. Loosen the lower cylinder mounting nuts and take off the lockwashers(10mm wrench).

4. Remove the stroke limiter plug and insert the stroke limiter (tool#200009).

5. Turn the flywheel in a counterclockwise direction until the crankshaftflyweight catches against the stroke limiter.

6. Turn the flywheel in the opposite direction until the other end of thecrank flyweight catches the stroke limiter.

7. Unscrew the stroke limiter slightly.

8. Turn the flywheel in a clockwise direction about 1/2 inch and screw inthe stroke limiter fully.

9. The piston will be held in the T.D.C. position.

10. Remove the cylinder and gasket. See figure 22

11. Loosen the bolts securing the exhaust manifold and remove the mani-fold, gasket and carburetor (10mm wrench). See figure 23

12. Scrape carbon deposits from the cylinder exhaust port and clean thedecompressor vertical port on top of the cylinder (scraper).

13. Clean the manifold exhaust port (scraper).

20

Figure 22


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21

Reassembling Reverse the procedure.

NOTE: Always fit new exhaust manifold and cylinder base gaskets afterremoval.

1. Place the slots on the top and bottom piston rings facing to the frontand the slot on the center piston ring facing the 11 oclock direction. Oilthe piston.

2. Check the condition of the cylinder mounting studs. If bent or dam-aged, extract and fit new studs.

3. Tighten the cylinder mounting nuts progressively at opposite cornersto 8.5 - 9 ft. lbs. (10mm wrench)

NOTE: Never tighten the cylinder mounting nuts excessively.

4. After assembly, check the compression.

5. Place the left hand flat on the cylinder and turn the flywheel back andforth.

6. Adequate compression will be visible by the suction on the hand.

Figure 23


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Carburetor

Removing 1. Unhook the cable pulley spring.

2. Loosen the nut connecting the carburetor to the intake manifold(14mm wrench).

3. Remove the fuel jet and the air jet and clean (10mm wrench andscrewdriver).

4. Clear all passages with an air stream giving special attention to thecalibrated hole of the jets.

5. Remove the fuel filter and replace if fouled.

6. Remove the throttle pulley slide nut and disconnect the slide (10mmwrench).

7. Withdraw the throttle barrel and clean.

8. To remove the choke assembly: Press down on the choke barrel on thespring loaded side and remove the choke lever. Remove the choke barrelfrom the carburetor.

Reassembling 1. Reverse the procedure.

22


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23

Crankcase End Cover

Removing 1. Loosen and remove the eight bolts securing the crankcase end cover (10mm wrench). See figure 24

2. Remove the cover and gasket.

Reassembling 1. Oil a new gasket and place in position.

2. Secure the gasket by inserting the two upper bolts and tighteningslightly (10mm wrench).

3. Cut the gasket carefully to the form of the crankcase end.

4. Insert the remaining six bolts and tighten slightly (10mm wrench).

5. Fit the cylinder.

6. Tighten first the two cylinder mounting nuts on the crankcase fully(10mm wrench).

7. Tighten the other two cylinder mounting nuts on the crankcase endcover fully, and then unscrew them 16 turn (10mm wrench).

8. Tighten the crankcase end cover bolts progressively commencing atthe lower bolt (10mm wrench).

9. Then tighten the two cylinder mounting nuts on the crankcase endcover fully (10mm wrench).

Figure 24


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Connecting Rod Assembly

Removing 1. Insert the stroke limiter as described (tool #200009). See figure 25

2. Remove the crankshaft end nut and washer (14mm wrench).

3. Remove the connecting rod assembly and bushing.

Reassembling 1. Change bushing and washer if necessary.

2. Reverse the procedure.NOTE: Check that the piston is facing the same direction as on theremoval. (Flat side of the bearing against the crankshaft counterweight.)

24

Figure 25


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25

Fuel Pump

Removing 1. Loosen the four bolts securing the fuel pump housing to the engine(7mm wrench). See figure 26

2. Remove the fuel pump.

3. If the fuel pump has been removed with the plastic pump seating piece,pry the seating piece loose and remove the diaphragm.

Reassembling 1. Clean the plastic pump seating and place in position on the crankcaseair port with the concave side facing the fuel pump.

2. Tap the center on to the air port lug.

NOTE: Always fit a new diaphragm after having removed the fuel pump.

3. Check that the plastic fuel pump ball is correctly seated in the fuelport of the pump.

Figure 26


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Engine Supports and Axle

Removing 1. Unhook the suspension springs on each support and remove with theengine mudguard. See figure 27

2. Release the engine pivot pin nut locks.

3. Loosen the engine pivot nuts (14mm wrench).

4. Loosen the front nuts and remove the bolts and spacer (14mmwrench).

5. Remove the engine support.

6. Loosen the suspension friction plate tension nuts and remove thesprings and guides (10mm wrench).

7. Remove the engine axle.

Reassembling 1. Before tightening the engine axle nuts when reassembling the engineaxle with the crankcase and the engine supports, these parts must be inthe same position as the motor on the front fork against the wheel.

26

Figure 27


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27

Engine Decarbonizing

Removing 1. After a number of miles, carbon obstructs the various passages in theengine, and hinders its efficient running. See figure 28

2. To remove this carbon, first dismantle the cylinder head, after takingoff the air cleaner body, the carburetor and the manifold.

3. Scrape the carbon deposit off the cylinder head and the top of the

piston.

4. Clean the exhaust port thoroughly, as well as the manifold and checkthat no carbon deposit obstructs the latter at any point.

5. Pass a 5mm drill through the vertical hole of the decompressor and a3.5mm drill through the angular hole on the cylinder head.

6. Clean and lap the valve; change it, as well as the spring, every time.

7. The exhaust system cannot be dismantled; it should be changedafter 5,000 miles.

8. When fitting a new exhaust pipe, pass a 6mm drill through the outlet

pipe, as it may be obstructed by a drop of paint.Reassembling NOTE: When reassembling use new gaskets. Check the ignition timing on

the flywheel magneto. Adjust the plug gap to 5/10mm (0.020"). Clean orchange the air filter if necessary. Adjust the throttle control.

Figure 28


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Decompressor

Adjusting 1. The decompressor valve opens correctly when the travel of the decom-pressor engine lever is between 1/8 inch and 1/32 inch.

2. Loosen the cable guide nut and adjust the tension on the cable untilcorrect adjustment is reached (7mm wrench).

Throttle

Adjusting 1. Insert the throttle cable cover end in the upper cable holder on thethrottle arm. See figure 29

2. Loosen the cable pulley nut and wind the cable from left to right overthe pulley and under the washer of the cable pulley nut.

3. Tension the cable.

4. Tighten the cable pulley nut.

5. Start the engine.

6. With the throttle twist grip rolled to the front and the throttle off,the engine should idle smoothly.

7. If the engine runs too fast, loosen the cable pulley nut and adjust theposition of the cable on the pulley until correct idling speed is reached.

8. The correct engine idle is 1500 rpm.

28

Figure 29


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29

Ignition Timing

Adjusting 1. Remove the engine and flywheel covers.

2. Remove the rotor cover plate and rubber seal (14mm wrench).

3. Turn the flywheel rotor until the contact mark on the rotor isaligned with the stator plate rupture mark.

4. Connect the red lead of a timing light to the grey wire of theignition coil.

5. Connect the black lead of the timing light to ground.

6. The light should be on when the rotor contact mark is in alignmentwith the stator plate rupture mark.

7. To adjust the timing, loosen the fixed contact holding screws andadjust the cam screw until the light goes off.

8. Turn the flywheel slightly counterclockwise and the light shouldgo off.

9. Turn flywheel back to rupture point. The light should just go on.

10. Check above procedure again. If correct, tighten the holdingscrews fully.

11. Reassemble the rubber seal and rotor cover plate (14mm wrench).

12. Fit the flywheel and engine covers.


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ENGINE COMPONENT PARTS

30


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31



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32


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33

ELECTRICAL CONNECTIONS SOLEX 3800 D.O.T.

Light Coil A. Black wire with large male connection

B. Yellow female connector - large

1. Powers

a. Headlight switch - brown wire

b. Electric horn - yellow wireHeadlight Switch and

Light Connections A. Power from coil - brown wire

B. Power to headlight and taillight - black wire

1. Headlight grounded - black

2. Taillight grounded - black

a. G middle or upper post - ground, black wire

b. T right hand post - taillight power, black wire

Stop Light Coil A. Black wire with male connector - little

B. Red female connector - little

1. Powers stoplight switch - red wire to each brake lever switch

2. From switch to taillight assembly - green wires

a. S on taillight left hand post - stop light

b. G middle or upper - ground

Ignition Coil A. Power to spark plug lead

1. Points interrupt circuit in the ignition coil

2. Coil produces current

3. To spark plug lead

4. And spark plug

B. Engine cut-out switch

1. Lead from upper post of the condenser - grey wire - smallfemale connector

2. Lead from engine cut-out switch - purple wire - small purplemale connector

3. Switch when closed grounds the ignition coil, condenser andpoints, stopping the engine


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34

ENGINE TROUBLE SHOOTING GUIDE

WARNING: Put the engine cut-out switch in ON position. To find out if the cause of the trouble isdue to bad ignition setting or a faulty part, take out the spark plug, keep it connected to the pluglead, hold it against the cylinder and turn the engine over.

Symptoms Possible Causes Checks and Remedies

There is a regular spark Spark plug fouled Brush the electrodes, clean and adjust

the electrodes Incorrect spark plug gap the gap to 5/10mm (.5mm).Replace the spark plug if necessary.

Incorrect timing Remove the flywheel cover, align thecontact point on the flywheel with therupture point on the stator plate andcheck with a lamp (ground and grey wire).

There is an intermittent Spark plug lead unscrewed Remove the engine cover, unscrew the plugspark or no spark from stator plate or the lead retaining plate.

insulator is faulty (R=6) Disconnect the plug lead from the statorplate and replace with a new one.

Ignition coil (R=3) Check by substitution.

Condenser (R=150) Check by substitution.

Faulty wiring connections Check for good connections.in the magneto

Loose flywheel magnets or Magnets should not move or come inwarped flywheel contact with magneto coils. If loose

replace the flywheel.

The engine runs in 4-stroke Ignition timing Check the spark plug and timing.cycle or lacks power Excessive carbon built-up Decarbonize.

At idle, the engine stalls Contact breaker Defective, replace it

Clogged air cleaner Faulty, replace it.

Carbon build-up Decarbonize.

Carburetor jetted to rich Lean out the air and fuel jet.

Loose fuel lines Check for tightness.

Rotor hitting magneto coils Center the magneto coils, or if necessary,replace rotor.

Fuel supply Fuel pump Check fuel tank for fuel supply.

Check fuel flow at overflow pipe.Check fuel pump; fittings; pump membrane;pump check balls.

Check fuel suction line and clean or replace.

Check fuel tank filter and replace.

Check fuel supply pipe and clean or replace.


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Fuel supply (continued) Carburetor Check fuel filter, replace if needed.

Check fuel jet, replace if needed.

Check air jet, replace if needed.

Check throttle barrel, replace if needed.

Crankcase Check fuel supply.y in crankcase by removingthe lock pin bolt.

Ignition Spark plug Check spark plug gap, clean or replace plug.

Check spark plug lead:a. contact at plug, clean and tighten;b. contact at coil, clean and tighten;c. spark plug lead, replace if needed.

Stator plate Timing:a. check timing;b. check fixed contact, clean or replace;

c. check moving contact, clean or replace.Check condenser, substitution.

Check ignition coil, substitution.

Check cut-out switch ground connection.

Engine is noisy or runs Carburetor Fuel jet too big, replace.poorly Air jet to small, replace.

Fuel pump Fuel pump membrane is porous, replace.

Ignition Timing, advanced too far, retime.

Compression Loss of compression, check and tighten:a. crankcase cover bolts, if loose,

check and replace gasket;b. cylinder base, if loose, check and

replace cylinder base gasket;c. cylinder head, if loose, check and

replace cylinder head gasket;d. decompression valve, (see

carbonization.

Carbonization Cylinder head, decarbonize:a. decompression valve, replace;

b. clean and ream valve seat, valvereamer.

Exhaust port, decarbonize:a. Decompressor valve port, ream or drill;b. exhaust manifold gasket, replace.

Exhaust pipe and muffler, clean or replace.

35


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36


Engine runs with choke Fuel supply too lean Fuel jet too small, change.partly closed Air jet too big, change

Partial air leak, check the following forrestrictions:

a. fuel tank;

b. fuel pump;c. carburetor;d. fuel jet.

Engine runs and stalls Carburetor Carburetor obstructed:a. fuel jet, remove and clean;b. barrel, remove and clean;c. air filter, clean;d. fuel filter, replace.

Fuel supply Fuel pump faulty, replace:a. fuel pump membrane, replace;

b. fuel pump seating piece, replace.Ignition Spark plug faulty, regap or replace.

Spark plug lead faulty:a. connector not making contact with

carbon lead, tightenb. carbon lead broken, replace.


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37

CYCLE, FRAME, CONTROLS REPAIR OPERATIONS

Use of the recommended workshop support stand is advised for the majority of the followingoperations (tool #100030).

Front Wheel Assembly

Removing 1. Raise the front wheel off the ground.2. Loosen the axle nuts (14mm wrench).

3. Pull the wheel downwards to remove from the fork brackets.

4. If whitewall tires are fitted, deflate the tire before removing thewheel to prevent the brake shoes from scraping the sidewalls.

Reassembling 1. Reassemble in reverse sequence.

NOTE: Check that the wheel is correctly aligned in the forks.

Wheel Axle

Removing 1. Remove the wheel. See figure 30

2. Remove the axle nuts, washers, and dust caps (14mm wrench).

3. Place the wheel in a vice securing on the cone counter nut.

4. Hold the upper cone with a cone wrench and remove the cone counternut (15mm and 17mm wrench).

5. Loosen and remove the hub cone.

6. Lift the wheel to the end of the axle to expose the ball bearings.

7. Inspect the ball bearings and the condition of the axle, replace if

necessary.Reassembling 1. If the axle is to be replaced, lift the wheel off the axle and secure the

new axle with the hub cone and washer cone counter nut in the vise, thenreplace the wheel.

2. If the ball bearings on the opposite side ofthe hub are to be replaced, first assembleone side of the hub and turn the wheel over,repeating the procedure.

3. Grease the axle and pack the ballbearing races with grease.

4. Replacethe hub cone, tightenand release 1/4 turn.

5. Continue to reassemblein reverse sequence.

Figure 30


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Wheel Bearing Play

Adjusting 1. Loosen the axle nuts and the cone counter nuts.

2. Adjust the hub cones. To reduce play, tighten the hub cones. Toincrease play, loosen the hub cones.

3. When correct adjustment is reached, hold the hub cones with a conewrench and tighten the cone counter nuts (15mm and 17mm wrench).

4. Tighten the axle nuts (14mm wrench).

Front Brake Mechanism

Removing 1. Disconnect the brake cable from the brake bar assembly at the brakemechanism. See figure 31

2. Loosen the nuts securing the brake mechanism to the forks (14mmwrench).

3. Loosen the nuts attaching the brake mechanism to the mudguard

(10mm wrench).4. Remove the brake mechanism and brake shoe blocks (10mm wrench).

Reassembling 1. Reassemble in reverse sequence above.

NOTE: Check the condition of the brake shoes and replace if necessary.Check the front brake adjustment.

2. When replacing the brake mechanism cover plate, make sure that theprotruding flange on the inside of the plate locks into the brake spring.

38

Figure 31


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39

Front Brakes

Adjusting 1. Minor adjustment to compensate for wear of the brake shoes and playat the brake levers is carried out at the right handlebar lever. See figure 32

2. Check that the engine engagement lever is pulled to the rear.

3. Unscrew the locking nut and the adjusting nut slightly (10mm wrench).

4. Spin the wheel by hand, adjusting the amount of free play on the brakelever until the brake shoes take hold and stop the spin, by turning theadjusting nut and applying the brake lever.

5. The amount of free play at the end of the brake lever should be about1/2 inch.

6. Tighten the locking nut (10mm wrench).

Additional adjusting 1. If further adjustment is necessary or after replacing the brake shoes,proceed as follows. See figure 31

2. Turn the handlebar to the right for easy access.

3. Remove the brake mechanism cover plate (10mm wrench).

4. Grip the brake shoe blocks and pull to the left until the right brakeshoe is touching the rim of the wheel.

5. Push brake bar adjusting tool and turn to the left, tensioning thebrake cable until the space between the left brake shoe and the rim ofthe wheel is about 1/4 inch.

NOTE: Check that the adjusting wheel returns to the locked positionafter removing the brake tool.

6. Push on the left brake shoe block until the space between the left andright brake shoes and the rim of the wheel is equal.

7. Replace the brake mechanism cover plate, ensuring that the protrud-ing flange on the inside of the plate locks into the brake mechanismspring.

Figure 32


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Front Mudguard

Removing 1. Remove the front wheel (page 37).

2. Loosen the brake mechanism cover plate nuts and remove the coverplate (10mm wrench). See figure 31

3. Loosen the nuts securing the brake mechanism to the mudguard andwithdraw the bolts from the inside of the mudguard (10mm wrench).

4. Loosen the two lower mudguard nuts and remove the splashguard(10mm wrench).

5. Pull the mudguard from the mudguard support bolts and remove.

Reassemble 1. Reassemble in reverse sequence.

NOTE: Check that the muffler bracket is fully inserted between the mud-guard and mudguard support.

Mudguard Supports

Removing 1. Loosen the two lower mudguard support nuts and remove the bolts(10mm wrench). Remove the splashguard. See figure 33

2. Loosen the nut attaching the horn and mudguard supports to theengine supports (10mm wrench).

3. Remove the supports.


NOTE: Check that the muffler bracket is fully inserted between the mud-guard and mudguard support. Check that the mudguard supports aresecured to the engine supports as described on page 11.

40

Figure 31


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41

Steering Races

Removing 1. Remove the front wheel as described on page 37.

2. Remove the handlebar with cables and wires attached and drawto the front over the engine. See figure 3

3. Loosen the bearing cup lock nut (23mm wrench).

4. Remove the serrated washer.5. Remove the threaded seat holding the fork and engine assemblies inthe frame steering tube.

6. Remove the ball cage and upper bearing cup.

7. Raise the steering tube and frame and withdraw the fork assemblyfrom the steering tube.4

8. Replace the bearings as necessary, grease the upper and lower ballcages and the threaded seat.


Figure 33


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Front Forks

Removing 1. Remove the engine guard rail (page 9).

2. Remove the front wheel and mudguard supports (pages 37 and 40).

3. Remove the engine and engine supports (page 11).

4. Remove the front brake mechanism (page 38).

5. Remove the engine shield (page 40). See figure 336. Loosen the nuts on the left and right hand fork legs.

7. Remove the fork Legs.

Reassemble 1. Reassemble in reverse sequence.

Kick Stand

Removing 1. Tilt the machine and empty the fuel from the fuel tank into a can.

2. Turn the machine over and support the frame in the recommendedworkshop support stand.

3. According to model; drive out the rivets or loosen the nuts and removethe bolts on each side of the kickstand (14mm wrench.

4. Unhook the spring. See figure 35

5. Lower the kickstand ad lift from the frame.

Reassembling 1. Hook the end of the spring to the kickstand.

2. Hook the other end of the spring into the frame and insert the kick-stand into the frame.

3. Lower the kickstand and rivet, or insert the bolt, in the right hand sideof the frame from the inside.

4. Fit the washer and nut (14mm wrench).

5. Raise the kickstand and rivet, or insert the bolt, in the left hand sideof the frame from the inside.

6. Fit the washer and nut (14mm wrench).

7. Lightly lubricate the bolts.

8. Tighten the nuts and punch lock.

42

Figure 35


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43

Crank Spindle

Removing 1. Slip the cycle chain from the crank sprocket wheel. See figure 36

2. Remove the wedge nut and tap out the wedge on the sprocket wheelpedal crank (13mm wrench).

3. Pull on the left hand pedal crank and remove the crank spindle fromthe crank assembly with the left pedal crank.

4. To replace the crank spindle, remove the wedge nut and tap out thewedge on the left pedal crank.


NOTE: Grease the crank spindle before inserting into the crank assembly.Check that the spacer is fitted to the crank spindle before attaching thewasher and inserting into the crank assembly from the left.

Figure 36


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Crank Assembly

Removing 1. Remove the kick stand (page 42).

2. Remove the rear wheel (page 46).

3. Slip the cycle chain from the crank sprocket wheel.

4. Loosen the rear brake adjuster nut and remove the adjuster (10mm

wrench).5. Loosen and remove the bolts securing the crank assembly to the mainframe (14mm wrench).

6. Loosen the nut on the right hand lower rear fork brace (15mm socket).

7. Withdraw the bolt from the left hand lower rear fork blade.

8. Remove the crank assembly. See figure 36

9. To replace the crank assembly, remove the crank spindle as described.


NOTE: Check that the spacers are in position on the bolt of the lower

fork blades. Punch lock the nuts after tightening.

Handlebar

Removing 1. Loosen the throttle twist grip collar screw and remove the grip withcables and wires attached (allen wrench).

2. Remove the left handgrip (page 45).

3. Loosen the left handgrip collar screw and remove with cables and wiresattached (allen wrench).

4. Loosen the handlebar support bracket bolt and remove the handlebar

from the bracket (12mm wrench). See figure 37


44

Figure 37


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45

Throttle Twist Grip

Removing/Replacing 1. Loosen the throttle twist grip collar screw and remove the grip withcables and wires attached (allen wrench). See figure 33

2. Pull back the shouldered end of the throttle outer cable cover andremove the cable from the cable guide.

3. Pry back the rubber twist grip flange and remove the cable end ball.

4. Pull on the rubber grip and remove the grip sleeve or cut the length ofthe rubber grip with a razor or knife and remove.

5. Replace parts as necessary.


NOTE: Never refit a frayed cable. Fit a new one. When tightening the twistgrip collar screw, use caution to avoid breakage.

Left Handgrip

Replacing 1. Cut the length of the handgrip with a razor or knife and remove.2. To fit a new handgrip, first soak the open end of the grip in gasoline.

3. Tap the grip into position on the handlebar.

Saddle Assembly

Removing 1. Loosen and remove the nut and washer of the support bolt connectingthe luggage carrier to the frame (14mm wrench).

2. Withdraw the support bolt from the opposite side of the machine andremove the spacers.

3. Loosen the nuts on the upper mounting bolts and remove the washersand bolts (14mm wrench).

4. Withdraw the saddle and seat post from the frame seat support.

5. Loosen the nut and remove the two washers on the bold securing themain saddle spring to the seat post (14mm wrench).

6. Withdraw the bolt and remove the third washer from the spring side.

7. Remove the spring from the saddle cradle with a twisting action.


NOTE: Ensure that the three washers of the bolt securing the mainsaddle spring to the seat post are correctly located.

Adjusting 1. The height of the saddle can be adjusted to three different positions.Raise or lower the seat post to the next higher or lower position aligningthe mounting holes.

2. Insert the two upper bolts and fit the washers and nuts. Do not tighten.

3. Insert the support bolt, washers and spacers.

4. Fit the nut, but do not tighten.


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5. To adjust the angle of the saddle, grip the saddle at the front andrear, press down firmly or lift, either the front or rear until the desiredangle is reached.

6. Tighten the two upper nuts and the nut of the support bolt (14mmwrench).

Rear WheelRemoving 1. Raise the rear wheel off the ground.

2. Disconnect the brake cable from the hub assembly.

3. Loosen the axle nuts (17mm wrench).

4. Pull the wheel to the front and slip the cycle chain from the free wheel.

5. Remove the wheel.


NOTE: Check that the rear brake functions correctly. Check that the

anchor lug on the hub engages in the slot in the frame.

Rear Brake Drum

Removing 1. Remove the wheel as described.

2. Remove the axle nut on the brake drum side of the wheel (17mmwrench).

3. Remove the spacer and withdraw the brake drum. See figure 38

NOTE: Do not touch the brake shoes or braking surface of the brakedrum with grease.


46


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Brake Shoes

Replacing 1. Remove the wheel and brake drum as described (page 46).

2. Set the brake drum in a vise.

3. Lift first one brake shoe and with a turning movement, detach thespring and remove the shoe.

4. Remove the second shoe.5. Attach the springs to the new shoes.

6. Fit one shoe in position while holding the second shoe upright.

7. Fit the second shoe with a slight turning movement in the oppositedirection to removal. See figure 38

NOTE: Check that the brake mechanism functions correctly by operatingthe rear brake lever.

8. Lightly grease between the cam and the backing plat of the brakeshoe.


47

Figure 38


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Rear Brake

Adjusting 1. Minor adjustment to compensate for wear of the brake shoes and playat the brake lever is carried out at the left handlebar brake lever.

2. Check that the engine engagement lever is pulled to the rear.

3. Unscrew the locking nut and the knurled adjusting nut slightly (10mmwrench).

4. Spin the wheel, adjusting the amount of free play on the brake leveruntil the brake takes hold and stops the spin, by turning the knurledadjusting nut and applying the brake lever.

5. The amount of free play at the end of the brake lever should be about1/2 inch.


Additional adjusting If further adjustment is necessary or after replacing the brake shoes,proceed as follows:

1. Loosen the locking nut on the rear brake adjuster attached to the

crank assembly (10mm wrench).2. Adjust the rear brake by turning the adjusting screw.


4. On the rear hub assembly and inspection hole is provided to permitinspection of brake linings. Replace the dust cap after the inspection ismade. See figure 38

Rear Wheel Bearing

Replacing 1. Remove the rear wheel (page 46).

2. Withdraw the brake drum (page 46).

3. Remove the hub axle. See figure 38

4. Pry loose the dust cap on the freewheel side of the machine.

5. Extract the bearing. Inspect the hub axle and replace if necessary.

Reassembling 1. Reassemble in reverse sequence. Insert the bearing by lightly tappingon the bearing body.

48


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49

Rear Mudguard

Removing 1. Remove the rear wheel (page 46).

2. Disconnect the wires to the rear lamp.

3. Loosen the three nuts securing the rear lamp assembly to the mud-guard and remove the assembly (10mm wrench).

4. Loosen the nut on the mudguard support and remove the bolt andwasher (10mm wrench).

5. Withdraw the wires through the hole in the mudguard and loosen theclips retaining the wires to the inside of the mudguard.

6. Loosen the two nuts securing the mudguard to the luggage carrierand remove the bolts (10mm wrench).

7. Withdraw the mudguard to the rear.


Mudguard SupportRemoving 1. Remove the rear wheel (page 46).

2. Loosen the nut securing the mudguard support to the mudguard andremove the bolt and washers (10mm wrench).

3. Loosen the nuts on the luggage carrier supports at the hub and with-draw the bolts from the inside (14mm wrench).

4. Remove the mudguard support to the rear.


Luggage Carrier and Supports

Removing 1. Remove the rear wheel (page 46).

2. Loosen the nuts on the luggage carrier supports at the hub (14mmwrench).

3. Pull gently on the mudguard supports and remove from the bolts.

4. Pull gently on the luggage carrier supports and remove from the bolts.

5. Loosen and remove the nut and washer of the support bolt securingthe luggage carrier to the frame and seat post.

6. Withdraw the support bolt from the opposite side and remove thespacers (14mm wrench).

7. Loosen the two nuts connecting the mudguard to the luggage carrierand remove the bolts (10mm wrench).

8. Remove the luggage carrier. To remove the luggage carrier supports,loosen the two nuts on the inside of the luggage carrier and remove thebolts (10mm wrench).



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Headlamp

Removing 1. Remove the headlamp by pushing down and then pull out that connectsto the lever touching the bulb. See figure 39

2. Disconnect wire.


Rear Lamp

Removing 1. Loosen the screws and remove the lens (phillips screwdriver). See figure 40

2. Remove the gasket.

3. Remove the bulb.

4. Disconnect the wires.

5. Loosen the mounting bolts from the rear of the rear lamp bracket(10mm wrench).

6. Remove the rear lamp body.


50

Figure 39

Figure 40


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Decompressor Cable

Replacing 1. Loosen the cable clamp at the decompressor lever cylinder headbracket (7mm wrench).

2. Pull back the shouldered end of the outer cable cover at the decom-pressor lever on the throttle twist grip.

3. Remove the cable from the guide in the decompressor lever bracket

and remove the cable end ball from the lever.

4. Pull on the cable at the cable end ball and remove the cable from outercover.

5. Grease and fit a new decompressor cable as described for the brakecables.


NOTE: Check that the spring is correctly placed between the lever andthe decompressor cylinder head bracket.

2. When squeezing the decompressor lever at the throttle twist grip and

decompressor cable end at the cylinder head bracket should travel about1/8 inch and never less than 1/32 inch.

3. Loosen the cable clamp and adjust the tension on the cable until thecorrect travel is obtained.

52


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53

TORQUE DIAGRAM


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54

TORQUE DIAGRAM


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55

TORQUE DIAGRAM


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56

TORQUE DIAGRAM


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57

TORQUE DIAGRAM


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58

TORQUE DIAGRAM


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59

HEADLAMP

BLACK

GREEN

VIOLET

RED

GREY

BLACK

BLACK

TOSPARK

PLUG

FLYWHEELMAGNETO

HORN

YELLOWW

HITE

GREEN

RED

BROWN

RED

GREEN

LEFT&RIGHTHAN

D

STOPCONTACTOR

BLACK

GREEN

REARLAMP

RIGHTHAND

STOPCONTACTOR

GREEN

RED

SOLEXWIRINGDIAGR

AM


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VeloCruz 650 North Main PO Box 540080 North Salt Lake, UT 84054

Ph: 801.593.6783 800.393.7101 Fax: 801.593.6790


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66/84

a1

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a2

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a3

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a4

Carburetor Fuel Pump . . . . . . . . . . . . . . . . . a5

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . a6

Support Engine Lever . . . . . . . . . . . . . . . . . . a7

Cycle Part I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . a8

Cycle Part II . . . . . . . . . . . . . . . . . . . . . . . . . . a10

Fuel Tank Covering . . . . . . . . . . . . . . . . . . . . a11

Pedal Drive Chain . . . . . . . . . . . . . . . . . . . . . a12

Front Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . a13

Lighting Signals. . . . . . . . . . . . . . . . . . . . . . a14

Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . a15

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a16

Hub Front Wheels . . . . . . . . . . . . . . . . . . . . a17

Hub Back Wheels. . . . . . . . . . . . . . . . . . . . . a18

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . a19

TABLE OF CONTENTS


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a2

Ref.# Order# Description

1 SPM 90837 Air filter cover

2 SPM 90820 Air filter base

3 SPM 90758 Air filter

4 SPM 90759 Air filter fixing ring

5 SPM 91525 Internal gear washer M66 SPM 90841 Hexahedral screw M6x12

8 SPM 91263 Decompressing lever

9 SPM 90421 Cylinder head fixing screwM6x45

10 SPM 90786 Space holder for cylinderhead

11 SPM 90980 Air filter house suspensionbridle

12 SPM 93106 Sparking plug

13 SPM 90848 Ignition cable fixing nut M414 SPM 90859 Decompressor valve nut

15 SPM 90792 Decompressor valve spring

16 SPM 90858 Decompressor valve

17 SPM 90821 Cylinder head

18 SPM 90437 Cylinder head gasket

19 SPM 90496 Cylinder

20 SPM 90016 Cylinder base gasket

21 SPM 90000 Hexahedral nut M6 forcylinder fixing

23 SPM 90497 Piston crank rod withcrankpin bush

24 SPM 90817 Piston ring 39, 5x1, 7

25 SPM 90849 Crankpin bush

26 SPM 90024 Space holder ring tocrankshaft

27 SPM 90867 Crankpin nut M10x1

28 SPM 91342 Crankcase with crankshaft

29 SPM 90413 Crankcase cover w/drop bolt

30 SPM 90414 Gasket to crankcase31 SPM 90019 Washer M6

32 SPM 90015 Stud bolt

33 SPM 90415 Screw M6x20



36 SPM 90073 Bearing

40 SPM 91297 Piston (simple)

41 SPM 93200 Crank rod with crankpin bush

NR SPM 90055 Fixing ring to piston pin

NR SPM 90185 Piston pin

NR SPM 90568 Complete engine

NR SPM 91013 Gasket set

NR SPM 91456 Lipped washer NR SPM 93059 Decompressing valve set

NR SPM 93060 Cylinder gasket set

NR SPM 93061 Engine fixing set

NR SPM 93062 Piston complete

NR SPM 93105 Sticker for filter cover

ENGINE


68/84


1 SPM91287 Complete friction 0/ 42mm

2 SPM90978 Clutch

3 SPM90816 Clutch structure

4 SPM90815 Clutch spring

5 SPM90977 Cap washer

6 SPM91348 Flat washer

7 SPM90491 Friction nut

8 SPM90484 Flywheel cover fixture

9 SPM93063 Clutch bell

10 SPM93072 Friction 0/ 42

NR SPM93137 Friction 0/ 42 (steel)

CLUTCH

a3


69/84


1 SPM90845 Flywheel

2 SPM91400 Stator

3 SPM90074 Bearing

4 SPM90772 Spark roll

5 SPM93117 Lighting roll 2 out5 SPM90571 Lighting roll 1 out

6 SPM90802 Condenser 0,2 mF

7 SPM90833 Stator insulating facing

8 SPM90832 Stator contact bolt

9 SPM90421 Hexahedral head screw M6x45

10 SPM90763 Hexahedral head screwM4x20

11 SPM91303 Hexahedral head screw

M4x812 SPM90775 Contact breaker

13 SPM90971 Flywheel nut

14 SPM90970 Caoutchouc gasket forflywheel

15 SPM90969 Wadding plaque

16 SPM90972 Low nut

17 SPM91014 Contact breaker anvilhammer (2 pc)

18 SPM90934 Ignition cable

19 SPM90843 Cable end for ignition cable

20 SPM91299 Borne HT

21 SPC91390 Screw bolt

22 SPM90780 Placket binding cable

NR SPM93139 Electric ignition

NR SPM93068 Flywheel fixing set

NR SPM93113 Service set

NR SPM93116 Stator (full)

FLYWHEEL

a4


70/84


1 SPM90921 Carburetor

2 SPM90854 Carburetor fitting strip

3 SPM90851 Regulating valve with blank

4 SPM91346 Carburetor fuel filter

5 SPM93107 Air filter house gasket ring6 SPM90407 Air jete

7 SPM90501 Starter valve lever

8 SPM90440 Starter valve

9 SPM90853 Carburetor closing disc

10 SPM90869 Regulating lever spring

11 SPM90924 Regulating valve lever

12 SPM90856 Regulating lever screw boltM6

13 SPM90920 Regulating lever disc

14 SPM90183 Fuel jet

15 SPM90932 Fuel pump

16 SPM90023 Membrane of fuel pump

17 SPM90434 Seat of membrane for fuelpump

18 SPM90763 Hexahedral head bolt M4x20


NR SPM93108 Connecting plug

NR SPM93132 Seat of valve for fuel pump

CARBURATOR FUEL PUMP

a5


71/84


1 SPM90785 Inlet pipe

2 SPM90753 Exhaust pipe

3 SPM90041 Gasket to inlet pipe

4 SPM90442 Carburetor and inlet pipegasket ring

5 SPM90445 Inlet pipe connecting bolt

6 SPM90964 Fuel pipe


NR SPM93138 Exhaust pipe for Solex3500

EXHAUST SYSTEM

a6


72/84


3 SPM90792 Decompressor valve spring

8 SPM90558 Engine supports right andleft

9 SPM90779 Dust protective plasticplate

10 SPM90987 Engine lift spring

11 SPM90778 Engine sliding

14 SPM90022 Friction washer

15 SPM90800 Friction plate nut

16 SPM90030 Motor axle

17 SPM90026 Flat washer 0/ 8,5

18 SPM90031 Silent block

19 SPM90988 Nut lockplate

20 SPM90935 Lockscrew

21 SPM92167 Collar nut

22 SPM90000 Nut M6

23 SPM90474 Screw bolt24 SPM90824 Flat washer

25 SPM90202 Engine lift out lever

26 SPM90053 Hexahedral nut M8x1

27 SPM90027 Flat washer 0/ 6,3

NR SPM93064 Engine support set

SUPPORT ENGINE LEVER

a7


73/84


1 SPC90190 Framework

2 SPC90883 Saddle support space holder

3 SPC90872 Main support (rear fork)right

4 SPC90875 Main support (rear fork left

5 SPC90885 Seal upholder right

6 SPC90888 Seal upholder left

7 SPC90469 Luggage carrier upholder

8 SPC90996 Rear mudguard arm

9 SPC91008 Front mudguard

10 SPC90991 Rear mudguard

11 SPC90880 Luggage carrier

12 SPC90891 Drive chain protective cover

13 SPC90897 Pedal house cover, leg

holder14 SPC90540 Protective plate (engine

cover)

15 SPC90894 Stank fork

19 SPC90528 Front mudguard arm right

20 SPC90534 Front mudguard arm left

21, 22 SPC93067 Rubber mudguard set

23 SPC90453 Toolbox

24 SPC90850 Toolbox sponge

49 SPC90999 Stand spring

50 SPC90893 Decoration latch

51 SPC93111 Pump

52 SPC90907 Saddle

53 SPC90909 Saddle cover

55 SPC93066 Fork bearing56 SPC90549 Engine lift out fixing plate

62 SPC90755 Cable cross leading toframework

63 SPC90939 Cable packet front

64 SPC90806 Support fork pin + bolt

65 SPC91004 Premounted fork

NR SPC90910 Saddle spring back

NR SPC91294 Head of fork

NR SPC91386 THI-BLOC nut M6

NR SPC93065 Framework fixings set

NR SPC93070 Label to framework

NR SPC93071 Fork fixings set

NR SPC93073 Tool set

NR SPC93133 Counterdie SOLEX white(2 pcs)

NR SPC93134 Counterdie SOLEX black(2 pcs)

CYCLE PART 1

a8


74/84

a9

CYCLE PART 1


75/84


29 SPC90056 Hexahedral bolt M6x10

30 SPC90000 Nut M6

31 SPC90019 Washer 0/ 6,5

32 SPC90903 Hexahedral bolt M8x1-109

33 SPC90936 Flange socket to saddleupholder

34 SPC90054 Washer 0/ 8,1

35 SPC90053 Hexahedral nut M8x1

36 SPC90409 Hexahedral head screwM10x1-110

37 SPC90901 Stay ring II. frame

38 SPC90473 Hexahedral nut 10x1

39 SPC91235 Screw D 9,5x14 L:55mm

40 SPC91236 Nut M9,5x1

41 SPC91900 Stay ring I. frame

42 SPC90076 Hexahedral nut M643 SPC90968 Washer 0/ 6,3

44 SPC91209 Screw M8x1-13

45 SPC90077 Square nut M8x1-13

47 SPC90551 Screw M6x12

48 SPC90803 Screw M8x1-14

CYCLE PART II

a10


76/84


1 SPM90918 Fuel tank set

2 SPM91376 Tank cup with gasket

3 SPM90557 Tank cup gasket ring

4 SPM90979 Fuel suction pipe

5 SPM91345 Tank fuel filter 6 SPM90770 Flywheel cover

7 SPM90917 Tank support fixing set

8 SPM90827 Engine mudguard

9 SPM91449 Binder for crash tube

10 SPC90145 Crash tube, clouding over protective

11 SPM30749 Overflow pipe

FUEL TANK COVERING

a11


77/84


1 SPC91307 Pedal house with bearing

2 SPC90465 Bottom bracket axle

3 SPC90485 Bottom bracket axlewasher

4 SPC90476 Space holder ring to pedalaxle

5 SPC90905 Driver arm left

6 SPC90965 Driver arm right

7 SPC90061 Pedal wedge

8 SPC93109 Drive chain 83

9 SPC93080 Drive chain link

10 SPC93110 Pedal pair

PEDAL DRIVE CHAIN

a12


78/84


1 SPC93085 Front brake

2 SPC90423 Flange brake key mounting

3 SPC90508 Flange brake cover

4 SPC90513 Brake arm right

5 SPC90514 Brake arm left6 SPC90512 Bridge for brakes

7 SPC90481 Flange brake contract spring

8 SPC92169 Flange brake nut M6

9 SPC90076 Hexahedral nut M6

10 SPC93202 Screw for front brake

11 SPC90070 Brake lining

12 SPC91296 Brake shoe13 SPC90502 Brake shoe holder

FRONT BRAKE

a13


79/84


1 SPM90204 Engine cover

2 SPM90205 Headlight with bulb

3 SPM90574 Bulb 6V-15W-26S

4 SPM90767 Contact button

5 SPM90834 Light switch6 SPM90831 Headlight switch spring

7 SPM94133 Screw M4x8

8 SPC93069 Light switch kit

9 SPC93114 Rear lamp with stop

10 SPC93083 Rear light

11 SPC93124 Rear light (GB)

12 SPC93140 Rear light (Japan)

13 SPM93112 Bulb rear lamp 12V-4W

14 SPC93115 Bulb for stop lamp

15 SPC93079 Reflector

16 SPC93075 Ringing

17 SPC93122 Electric horn

18 SPC93127 Button for electric horn19 SPM93120 Switch for rear lamp

20 SPM93126 Cables for stop switch

NR SPC90569 Cable packet front + rear

NR SPC93123 Circle reflector (Belgium)

NR SPC93128 Yellow plate (Belgium)

NR SPM93077 Engine cover fixing nut

LIGHTING SIGNALS

a14


80/84


1 SPC90190 Handlebars

2 SPC90192 Stem bow bolt

3 SPM90193 Right (gas) hilt

4 SPM90199 Left hilt

5 SPM90194 Fixation of right arm6 SPM93085 Rubber hilt right

7 SPM90197 Cursor to front brake cable

8 SPM90196 Cursor to gas cable (gascursor)

9 SPM93084 Brake lever right

10 SPC93203 Plaque for protection of hands

11 SPM93102 Cable fixing roller

12 SPM93086 Brake lever pin + nut

13 SPM93087 Rubber hilt left

14 SPM93088 Brake lever left

15 SPM93089 Decompressing lever (onhandlebars)

16 SPM93090 Decompressing lever fixingring

17 SPC93091 Mirror

18 SPC90206 Bow bolt with nut

19 SPC93136 Cursor (3) for gas spindle

NR SPC93141 Mirror binder

HANDLEBARS HILTS

a15


81/84


1 SPC92174 Front brake cable

2 SPC90974 Rear brake cable

3 SPC92177 Nut for fixing decompression

4 SPM2178 Decompressing cable

5 SPC91371 Rear break cable crossleading

6 SPC93092 Decompressing cable endfixing element

7 SPC91446 Decompressing cable sleeve

8 SPM93104 Gas cable

CABLES

a16


82/84


1 SPC90058 Front wheel hub with bolts

2 SPC91358 Front spoke with nut

3 SPC90052 Front wheel dust protective

6 SPC93095 Protective band

7 SPC93103 Rim

8 SPC90799 Inner tube

9 SPC90751 Tire (1,75x19)

NR SPC91298 Front wheel without tire andinner tube

HUB FRONT WHEEL

a17


83/84


1 SPC91395 Rear wheel hub with bolts

2 SPC91405 Brake shoe complete

3 SPC93098 Brake shoe

4 SPC93100 Freewheel

5 SPC91359 Rear spoke with nut

6 SPC93095 Protective band

7 SPC93103 Rim

8 SPC90799 Inner tube

9 SPC90751 Tire (1,75x19)

NR SPC90943 Rear wheel without tire andinner tube

HUB REAR WHEEL

a18


84/84


1 SPC93130 Saddle bag, black

2 SPC93142 Saddle bag, burgundy

3 SPC93143 Saddle bag, blue

5 SPC93145 Solex hat

6 SPC93146 Speedometer

NR SPC93147 User guide (French)

NR SPC93148 User guide (English)

ACCESSORIES


7 SPC93145 Solex T-Shirt

8 SPC93148 Solex Mock T-Shirt

9 SPC93149 Solex Fleece Vest

10 SPC93150 Solex Wind Jacket

11 SPC93113 Solex Service Toolset

Documents

Solex Manual S3800