FOR. RAL 6 STAR ST MOP with GENERAL MOPED GO., ING. : PERMA-LINED BLDG ; 50 OAK STREET ae EAST RUTHERFORD. NJ. 07073 S TEL: (212) 564-3876 @BLL PARTS ORDERS SHOULD BE ORWARDED TO. ; =. ~ GENERAL MOPED co ABO SEVENTH AVENUE - NEW YORK, Nov. 10001 . USS AC 4CONTENTS Tech ical Data. Part: List Frame Group....eeesseeee eee ee eee eeee ee eeees 239 Fron: Wheea| Assi nibs Ly oe on sevens 23 Roar Wheel Assembly. ..ceeeeeeeee sees . 45 Fron’ Fork Assembly....ceeeeeeeeeeee . 6-7 Rear Shock & Swing APM. ..ssseeeeeeneeeeeeneeeeenees 8-9 Handle Bar & Cable... sceeeseee eee eee e eee eee e ee eeee eee TWO-TT Fram: Assembly cecesseeecerssee eee eee e eter eee e eee eee e eee 12-13 Fuel Tank & Seatecsseeeeseese Tha 15, 16-17 18-19 Chain Cover, 20-21 Granl. & Pedhl Assembly.. + 22-23 MULE OF ASSPMDIY cee eee cece eee cece ete e eee enna ee BABS Fron Fender 4 Rear Fonder.. Speer ometer| Assembly Turn Signal Assembly.. 0.00... eee eee eee cece 26=27 Head Light Assembly... +2... .00eeeeeee cece teen eens sae BBA29 Tail Light Assembly. 30-51 Wire Harness & Electricity.. 32-95 Part List Engine Grou . Bh-h7 Cran: Case, Crank Shaft, Piston, Cylinder, Decompressor, + 34-35 CLUE Ne cece cee eee e eee ssee ee eenesteeeneeneeereneeeeeres 38899 Inta Gear Magn :to-Generator....cceee cece essen eeees serge 4o-ky Peda. Shaft. steer eee eee e ee ee eee eeee 4a-43 Carbiretar. - seeeeneeeeee - 2 hbabs Intaie Silencer.....- se teeeeeseneeneee - 46-67 Repa _r Tools & Mounting Jig.. semadtaccuwuresseskas 4B Qwne: Tool Kit & Repair ToO1S........eeeeeee eee Ag 50-53 59-57 58-63 64-65 Dismintling The Engine. . Working On Individual Parts..seesseeeeeeene Rebuilding The Engine Operitions After Engine Overhaul.a Tighteaing Toksion For All Nuts & Bolts 66 Assemtly Instructions. 67 Engine Startihg @ Preparation Instructions For Riding... 68 Adjustnent Pok Drive Che . 69 Brakes Adjusting. ....++ . 69 Mainteqance Of Battery. : 70 Essent Maiftenane Troubl sshootL Electrical Wifing....se.eesFran Front Suspension Rear Suspension Brakss Tire, Front & Rear Wheel Base Dime ision Fuel Tank Fuel Consumption Net feight Engi ve Engite Starting Engire Output Comp-ession Rate Exha ist Ignition Spar Plug Transmission Maxi num Speed Maxi um Steeping Head Light Tail Light Othe > Accessories TECHNICAL DATA Heavy-Gauge Sturdy Tubular Steel Frame Heavy Duty Telescopic Hydraulic Shock Absorber i Swing Arm & Telescopic Hydraulic Shock Absorber Dual Drum Brakes/Hand & Foot Brakes 217" x 2.25" Whe 1/8" 672"(L) x264" (W)xO"(H) 1.1 Gallon Capacity 170 Miles/Gallon S4kB 119 Lys. SACHS 505/1H, 2-Stroke Air-Couled Single Cylinder ("505/1A is also available) Pedal System 1.1 kw (1.5 PS) at 4000 1/min. Bt hqee BOSCH Magneto-Generater, Taillight 6V5W BOSCH W 175 T 1(with SAE connecting nut} Automatic Cluteh 20 MPH/1B, 25 MPH/1A 22°30" SAE Certified SAE Certified SAE Certified Front 4 Rear Turn Signal Assembly (Left & right), Rear Viow Mirror, ete. inlight 6v2aw‘TABLE- 1 FRONT WHEEL ASSEMBLYTABLE-1 FRONT WHEEL ASSEMBLY SSS REF NO. PART NO, QUANTITY DESCRIPTION 1 -1450-5q99 1 HUB ASSEMBLY (6. 7. 23. 25) 2 1150-5d08 1 BACKING PLATE ASSEMBLY (12-22, 24, 29, 33. 34. 36) 3 1150-5d97 1 HUB,RIM,SPOKE ASSEMBLY (1, 8, 26. 27. 28) A 1150-5da6 1 SPACER L/M 5 1150-505 1 SPACER R/H 6 1150-sqo4 1 HUB 7 1150-5q93. 1 ‘COLLAR B 1150-592 1 RIM 2.25%17 9 1150~5q91 1 TIRE 2.25x17 10 1150-5d90 1 TUBE 2.25x17 11 1150-5089 1 RIM STRAP 2.25%17 Oo 12 1150-3088 1 PANEL BRAKE 19 1450-5987. 2 BRAKE SHOE 1h 1150-5086 1 BRAKE CAM ! 15 1150-5985 1 SPRING BRAKE SHOE 16 1130-5084 1 BRAKE ARM 17 1150-5083 1 PINION SPEEDOMETER 18 1150-5082 1 WASHER SPEEDOMETER PINION 19 1150-5084 1 GEAR SPEEDOMETER 20 -1150-Sda0 1 RECEIVER SPEEDOMETER Ri 1150-scre 1 WASHER, GEAR BOX 220 1150-578 1 OIL SEAL, 39x47x5 2300 1150-5077 1 OIL SEAL, 17%32x6 zh 1150-5076 1 ‘OIL SEAL, 4.5x11x3.5 25 1150-5075 2 BEARING 6201 26 1950-sq74 16 OUTER SPOKE #12%176 27 1150-5073 16 INNER SPOKE 412x176 BB 1150-5472 3 NIPPLE 29° 1150-5d71 2 RUBBER PLUG 30. 1150-500 1 FRONT WHEEL ASSEMBLY (WITHOUT 1. 2. 3) oO 31 6210-07)10 2 PLAIN WASHER 10mm 32 6180-0110 1 LOOK NUT 10:0 35 6160-03)05 1 NUT Siem 34 6190-4006 1 SCREW lix6 1 AXLE 10145, 36 6110-5022 1 HOLT 5x22 .2 REAR WHEEL ASSEMBLYTABLE-2 REF No. REAR WHEEL ASSEMBLY PAl QUANTITY SCRIPTION ——— 1150-5499 2150~ 5498. 1150-5997 1150-5996 1150-5495 1150-5494 1150-5492 1150-5490 1150-5489 2150-5487 2150-5486 2150-5485 2150-5484 2150-5452 1150-5481 2150-5479 1150-5478 1150~ 5470 1150-5469 1150= 5468 1150-5467 2150-5400 1150-5491 1150-590 1150-5d89 1150-51 1150-51 1150-5 1150-5 1150-51 Reto 1150-50lr1 6220-11p6 6210-01p6 6180-0112 6160-01p8 6160-01b6 6160-01p5, 611 1=21p2 6110-8084 6110-50P2 noeee Busan sse6 BuUssn Gann HUB ASSEMBLY (5. 6. 28. 29) BACKING PLATE ASSEMBLY (8.99. 45, 264 27 37. 4O) COLLAR L/H TENSION BRACKET HUB BRAKE CAM CHAIN #415x 10% SPRING (REAR BRAKE LEVER) BRAKE ROD BRAKE ARM SPROCKET FINAL DRIVEN Lor ADJUSTER DRIVE CHAIN SNAP PIN TONGUED WASHER OUTER SPOKE #12%171 INNER SPOKE #12x171 JOINT, DRIVEN CHAIN HUB, RIM, SPOKE, ASSEMBLY(1. 7. 18. 335 30. REAR WHEEL ASSEMBLY (1, 2, 10. 20. 21) TIRE 2.25x17 TUBE 2.25x17 RIM STRAP 2.25417 BRAKE SHOE SPRING, BRAKE SHOE OIL SEAL 17x32x6 BEARING 6201 NIPPLE RUBBER PLUG SPRING WASHER 6mm PLAIN WASHER 6mm LOCK NUT 12mm NUT 8mm NUT 6mm NUT 5mm AXLE 12x172 BOLT 8x34 BOLT 5x22TABLE <3 FRONT FORK ASSEMBLYPABLE~3 /unnenTiveak assem | Sc REF NO. PART NO, Quantity DESCRIPTION 1 1150-5899 1 FRONT FORK ASSEMBLY (WITHOUT 5-11. 28. 29. 32. 54. 55) 2 1150-585 2 BOLT, FRONT FORK 3 150-5895 1 NUT, STEERING HEAD STEM 4 150-589 1 PLAIN WASHER 5 150-5893 1 RACE, STEERING TOP CONE 6 150-5892 ' STEERING BALL TOP RACE 7 150-589)1 1 STEERING BALL BOTTOM RACE 8 150-389) NG STEERING BALL 3/16" 9 “oc Saeh 1 STEERING CONE BOTTOM RACE 10 150-58: 1 Lock W 150-5887 2 KEY (SPECIFY CODE NUMBER) 12 130-5886 1 SPACER 3 150-586] 1 ‘TOP CROWN vi 150-38: 1 BOTTOM CROWN 15 150-585) 1 LEG, ASSEMBLY L/H 130-588 1 LEG, ASSEMBLY R/i 16 150-588} 2 OTL RING 17 150-588} 2 INNER TUBE i o-geab 2 BUST COVER 19 150-587 2 OTL SEAL 20 150-587 2 FORK NUT 21 150587] 2 GUIDE, FRONT FORK TUBE 22 1150-587 1 OUTER TUBE L/it 5150-586) 1 OUTER TUBE R/H 29 150-587} 2 STOPPER FRONT FORK SPRING ah 150-587, 2 SPRING 25 150~587P a SET FRONT FORK TUBE 26 150-587, 2 HOOK 27 150-586) 2 WASHER 28 5150-5867 2 UPPER HOLDER, HANDLE BAR 29 5 150~586) 2 UNDER HOLDER, HANDLE BAR 30 50-5864 1 CaP NUT, STEERING STEN 31 €220-110) 2 SPRING WASHER 8am 32 € 210-0104 4 PLAIN MASHER Sma 34 £310-010 2 PLAIN WASHER Gma ah 601 2 SCREW 6x10 35° € 110-805 u BOLT 8x55 36 €110-803 2 BOLT 8x30 37 € 110-601 2 POLT 6x10LABLES4 REAR SHOCK & SWING ARMTABLE-! REAR SHOCK & SWING ARM REF NO, PART QUANTITY DESCRIPTION 1 1150-6p99 SWING ARM 2 BUSH 3 SHOCK ASSEMBLY 4 PLAIN WASHER 5 CHAIN PROTECTING RING 6 SPRING WASHER 10m 7 PLAIN WASHER 10mm 8 LOCK NUT 10mm 9 CAP NUT 10: o NUP 10mm AXLE 10x160 12 BOLT 10x40TABLE-5, HANDLE BAR & CABLE em 8 16 8 fe wm 9 \Q \ jhe ao go geoO HANDLE BAR & CABLE TABLE-5 REF. NO. PART.|NO. QUANTITY DESCRIPTION 1 5150-6299 1 HANDLE BAR 2 150-6298 1 SWITCH L/W 3 4150-6297 1 SWITCH R/H ho 2150-6296 1 CABLE, THROTTLE 5 1150-6294 1 ‘CABLE, FRONT BRAKE 6 4150-6295 1 ‘CABLE, CLUTCH 7 3150-6292 1 GRIP L/H 8 3150-6391 1 GRIP R/H 9 3150-6390 1 THROTTLE PIPE 10 4150-6387 1 LEVER L/w (cLurcH) Nn 3150-6386 1 LEVER R/H (FRONT BRAKE) 12 150-6380 1 CABLE CHOKE 139 1150-6383 1 HACK VIEW MIRROR L/H Th 4150-6382 1 HANDLE LEVER ASSEMBLY L/# (2.10, 16.18.21.26, 27.28.29. 50x3.35. 36.3722.) 15 4150-6481 1 HANDLE LEVER ASSEMBLY R/H (3.11.16.17.18.22. 23.24,25.30.91.92.93.38x3. 35.36.3753. 16 4150-6480 2 BUSH 17 4150-6279 1 ADJUSTER BOLT 18 1150-6278 2 ADJUSTER NUT 19 ar58-676 1 CABLE HEAD 20 1150-6275 4 TIE STRAP 2 2150-6274 1 ADJUSTER BOLT 22 4150-6272 1 SPRING WASHER 2300 4150-621 1 PLAIN WASHER 24 4150-6270 1 LEVER, CHOKE 25 4150-6259 1 BRACKET, CHOKE LEVER 26 4150-5089 1 DECAL START 27 3150-9088 1 DECAL HORN | 28 = 3150-p0R7 1 DECAL OFF of 29 3150-9086 1 DECAL LIGHTS 80 150-9085 1 DECAL CHOKE 31 3150-9084 1 DECAL Stop 32 3150-9085 1 DECAL ENGINE STOP 33 3150-9082 1 DECAL L. TURN. R. 34 820-1105 6 SPRING WASHER Sam 35 6160-0105 2 NUT 5mm 36 6130-5040 Fy SCREW 5x30 37 6130-5085 5 SOREW 5x25FRAME ASSEMBLYTABLE-6 FRAME ASSEMBLY _— REF NO, PART NO. QUANTITY DESCRIPTION 1 4150-6699 1 FRAME ASSEMBLY 2 3150-6667 1 MAIN STAND 5 1150-6666 1 SHAPT MAIN STAND & 1150-6865 1 SPRING MAIN STAND 5 1150-6664 1 COTTER PIN 25x1 6 1150-6662 1 O RING T 1150-6659 1 ‘GROMMET 8 1150-6656 1 TOOL SET (9-12. 15) 9 1150-6655 1 TOOL BAG 10 1150-6654 1 WRENCH SOCKET 1 1150-6659 1 DRIVER 12 1150-6652 1 END WRENCH 10x12 13 3150-6653 1 INFORMATION PLATE 1h 1150-6649 2 RIVET (3mm) VS 1150-6648 1 END WRENCH 14x17 16 6220-1108 3 SPRING WASHER Smn 17 6820-1106 H SPRING WASHER Gum 18 6210-0110 1 PLAIN WASHER 10mm i] 6210-0108 6 PLAIN WASHER 8mm 20 6210-0106 1 PLAIN WASHER 6mm 21 6160-0108 3 NUT 8mm 22 6120-6015, 1 SCREW 6x15, 25 6110-8070 3 BOLT 8x70 ———————FUEL TANK & SEATTABLE-7_ FUEL TANK & SEAT — REF NO. PART QUANTITY DESCRIPTION 1 4150-9999 1 DECAL, FUEL TANK L/H 4150-9098 1 DECAL, FUEL TANK R/H 2 1 DECAL, FUEL TANK 3 1 DECAL’ REMINDER 4 L SEAT ASSEMBLY 5 1 SUPDORTING, TUBE 6 BEND T 1 FUEL TANK 8 1 FUEL TANK CAP 4g 1 FUEL ASS] io “Bisa FBoF TRL HOSE 11 3150-7b95 2 CLEP PUEL HOSE 12 6220-1) 10 1 SPRING WASHER 10mm Oo 43 6220-1106 2 SPRING AASHER 6mm 14 6210-01 10 z PLAIN WASHER 10m ae) 6210-0108 2 PLAIN WASHER 8mm 16 6210-0706 2 PLAIN WASHER 6mm VW 6160-0110 1 NUT 10am 18 6160-0706 1 NUT Gam 20 6111-0045, 1 BOLT 10x45 20 6110-6080 1 BOLT 6x80 ai 6110-6012 2 BOLT 6x12TABLE-8 FRONT FENDER & REAR FENDER ~16-TAULE-€ FRONT FENDER & REAR FENDER — REF NO. PART NO. QuaNnriry DESCRIPTION 1 2150-7899 1 FRONT FENDER ASSEMBLY (2. 3. 7x2 8x 2x2, axe 2 2150-7898 1 FRONT FENDER 3 2150-7897 1 SUPPORTING BAR 4 2150-7896 1 REAR FENDER 3 2150-7895 2 RUBBER 6 6220-1108 4 SPRING WASHER Sma 7 6220-1106 10 SPRING WASHER 6mm 8B 6210-0106 16 PLAIN WASHER 6mm 9 6160-0106 6 NUT Gum 10 6110-8010 4 BOLT 8x10 110 6110-6015 4 BOLT 6x15 120 6110-6012 6 BOLT 6x12 oOSPEEDOMETER ASSEMBLY TABLE- 9TABLE-9 . SPEEDOMETER ASSEMBLY = REF NO. PART QUANTITY DESCRIPTION 1 1450-8ap9 ' SPEEDOMETER ASSEMBLY (WITHOUT 2) 2 1150-8097 1 CABLE SPEEDOMETER 3 -1150-80p6 ' WIRE HARNESS SPEEDOMETER 4 150-8095 2 Gromer: 5 1150-804 3 LAMP 6V 1.54 6 1150-8099 2 PLAIN WASHER 7 1150-80b2 i SPEEDOMETER B 6220-116 2 SPRING WASHER 6mm 9 6160-0106 2 SUT GamTABLE~1 CHAIN COVER — BEF XO, PART NO. QUANTITY DESCRIPTION 1 4150-9097 DECAL CHAIN COVER L/H & R/H 2 hijo-9095 DECAL CHAIN COVER L/H 4150-9094 DECAL CHAIN COVER R/H 3 2150-7802 CHAIN COVER L/H & 2150-7H91 CHAIN GOVER R/Ht 5 3150-7889 SCREWTABLE=11 CRANK & PEDAL ASSEMBLYTABLE-1 CRANK & PEDAL ASSEMBLY REF NO. PART xt QUANTITY DESCRIPTH 1 2150-9299 1 CRANK L/W 2 1450-9298 1 PEDAL ASSEMBLY R/It 3 1150-9207 1 PEDAL ASSEMBLY L/H 2150-9286 1 GRANK R/i 2150-9295 2 COTTER PLAIN WASHER Gam NUT 6mm 6210-011 éigocotdepamune & MUFFLER ASSEMBLY. iTABLE-12 MUFFLER ASSEMBLY att lee RIRRRIIRIaeeeeenemmmmimeere emcee REF No, PART (xo. Quaxtary DESCRIPTION 1 2150-7099 1 MUFFLER ASSEMBLY (2, 3, 4. 8. 10x2. 11, ih) 2 2150-7098 MUFFLER BODY 3 sunspot EXHAUST PIPE i a50-qoos REND 5 50-71099 ’ SUPPORTING ARM 6 — 2150-7}092 1 BEND 7 6220-1108 3 SPRING WASHER Sem 8 6220-1106 1 SPRING WASHER 6mm 9 6210-4108 1 PLAIN WASHER Sam 10 6210-0106 2 PLAIN WASHER Gmum ti 6160-0106 : NUT 6mm re 12 6110-8b25 1 BOLT 8x25 4 15 2 BOLT 8x15 hg 18 1 BOLT 6x18TABLE~13 TURN SIGNAL ASSEMBLYTABLE- 13 TURN SIGNAL ASSEMBLY === REF NO. PART ho. quantity DESCRIPTION t g150-8P99 1 FRONT TURN SIGNAL ASSEMBLY L/1 3150-BR98 1 FRONT TURN SIGNAL ASSEMBLY R/E 2 3150-8297 1 REAR TURN SIGNAL ASSEMBLY 1/1 3150-8296 1 REAR TURN SIGNAL ASSEMBLY R/H 1150-8395 4 LOGK MASHER INTERNAL TOOTH 10mm 3150-8294 2 BRACKET BAR FRONT 150-8493 2 PRACKET BAR REAR 3150-8392 SOCKET 1150-8491 LAMP 6v BW 1150-8390 LENS 1150-8388 GASKET 150-8387 BULB SOCKET 6220-1}10 SPRING VASHER 10am 6220-1 }06 SPRING WASHER Gren 6220~-1]05 SPRING VASHER 5mm 6210-0110 PLAIN WASHER 10am 6210-0106 PLAIN WASHER 6mm 6160-01 10 2 NUT 10mm 17 6160-0406 4 NUT Gram 18 6130-5906 4 SCREW 5x6 19 6130-3423 5 SCREW 3x23 20 6110-6430 os BOLT 6x30 ———HEAD LIGHT ASSEMBLYTABLES 1! REF NO, PARE 2150-84 1150-84 1150-84) 1150-88 1150-844 Coa ee 3150-84 3150-8 03a 2150-58 1150-845 oraus 2150-84 1150-8 6210-014 6160-010 6130-501 9 8 0 6 6120-60: 6111-00! HEAD LIGHT ASSEMBLY QUANTITY 2 z 2 2 1 senso nee DESCRIPTION HEAD LIGHT ASSEMBLY (2-5. 10-12. 14.) RIM HEAD Licht SEALED BEAM GE 4667 MOUNTING SPRING CASE BRACKET A, HEAD LIGHT (6mm) BRACKET B, HEAD LIGHT ANBER REFLECTOR REFLECTOR GASKET RUBBER MEAD LIGHT HARNESS ADAPTER GASKET HEAD LIGHT PLAIN WASHER 1Qmm RUT 6am SCREW 5x10 SCREW 6x 20 BOLT 10x20TAIL LIGHT ASSEMBLY QUANTITY DESCRIPTION TALL LIGHT ASSEMBLY TALL LIGHT BRACKET BODY ASSEMBLY BULB 6V 21/3¢P GASKET Lens SPRING WASHER Siam PLAIN VASHER 5mm SCREW 5x15. SCREW 4x50. nem nm -30-32TABLE-16 WIRE HARNESS & ELECTRICITY es HEF NO, PART NO, QUANTITY DESCRIPTION 1 150-8899 ' WIRE HARNESS ASSEMBLY 2 150-8858 1 BATTERY 6NUB-24 3 150-8897 ’ HORN 4 150-8896 1 FLASHER 5 150-8895 i RECTIFIER 6 5150-8894 1 BRAKE SWITCH ASSENALY 7 150-8892 1 FUSE 104 8 150-8890 1 BATTERY STRAP 9 $ 150-8888 1 SPaitk PLUG CAP 10 5150-8887 1 FOSE 11 1 150-8885. 1 EARTH WIRE A 12 150-8884 : EARTH ¥IRE B 43 1 1502888 1 CONNECTING WIRE © ht az0-1106 2 SPRING WASHER 6muo 15 220-1105 2 SPRING WASHER Sum 16 216-0106 2 PLAIN WASHER Gam 17 ¢ 160-0106 2 NUT 6am 1B ¢ 160-0105 2 NUT. 5mm 19 € 410-6035 1 BOLT 635. 20 4110-6012 1 BOLT 6x12TABLE-17 — CRANKCASE, CRANKSHAFT, PISTON, CYLINDER, DECOMPRESSOR, INTAKE PIPE i ” 38 REF. NO, PART. NO AVA (AB DESCRIPTION 1 0287-140-000 1 rankease assty 287-140-003 1 Crankcase ass'y * in connection with Pig. 42 and 49 2 O240-176-002 10 10 Pillister head screw M 6x70 3 o640-003-002 4% & Fillister head screw M 6x55 4 640-001-001 1 1 Fillister head screw M 6x22 5 240-058-101 4 4 Stud M 6x20 6 ogit-ike-002 4K Washer 6.2x12«1.5 7 0316-057-002 4 «Hexagon nut M 6 8 0640-027-000 4 4 Oval head screw M5 * 14 9 O277-117-000 1 1 Cover ass'y with 1x0250-131-000 gasket 1xO0240-140-107 screw M14x1 for oil level check 10 0250-155-200 1 1 Gasket x = as required 298TABLE- 17 CR (CASE, CRANKSHAFT, PISTON, CYLINDER, DECOMPRESSOR, INTAKE PIPE REP. 30, 9 PART. NO. 1A 1B DESCRIPTION u 0230-107-000 1 1 Oi) seal 15%90x5.5 12 0246-008-003 1 1 Washer 25. 3x34x0.2 - 3 0232-120-001 2 Grooved ball bearing 6202 C3 DIN 625 ah 0246-009-001 1 Washer 15. 3x20%0.5 15 0288-114-000 i Crankshaft 16 0246-005-000 1 i Woodruff key 3x%.7 17 O232-157-001 4 1 Needle cage 12x15x19 18 0246-009-000 x = x Washer 15.320, page 9 19 0244-153-000 1 1 Washer 30x36.8%1.5 20 0230-106-000 1 1 O41 goal 15x35K7 21 0245-022-000 1 1 Spring washer for M 10xt 22 0942-072-100 4 1 Coller nut M 1x1 23 O24L=167-000 1 1 Cap ay 0286-3978-005 1 1 Piston assty ¢ 33:5 } Ssh 0286-378-006 1 1 Piston ass'y ¢ 38.3) 53 mm 25 0216-003-105 1 1 Gudgeon pin 26 o245-000-000 2 2 Wire spring ring 27 0215-009-000 2 2 Piston ring 6 35.0 28 0215-a10-000 2 2 Piston ring ¢ 38.3 250-154-000 1 1 Gasket 29 0219-146-210 1 Cylinder 0213-146-215 1 Cylinder 30 0291-022-200 1 1 Decompressor a 0291-021-000 1 1 Cable ass'y anote with solder nipple | Seeds aa No, 0291-020-000 length 32 o2g1-024—011 1 1 Outer casing 33 660-018-000 4 1 Protective cap 3h 0998-004-001 1 H Spark plug W 173 T 1 with SAE connecting nut 35 0250-156-100 2 2 Gasket 36 211-152-000 1 1 Intermediate flange (not appli- cable for cylinder with flange) 37 O267-114=201 1 1 Intake pipe * o244-114-209 1 1 Intake pipe 38 ozkk-100-008 2 2 Washer 6.2x10x1 39 ogho-085-102 2 2 Hexagon head screw M 6x35 ho 960-136-000 1 1 Rubber grommet (1 hole) “a 260-020-000 4 1 Rubber grommet (2 hole) 42 9251-121-000 6 6 Rubber mounting bush 4g o2b7-14h=100 3 3 Distance tube 4 244-168-000 7 1 Closing cap 6 13 as 1950-023-000 1 1 Sealing ring 10.5x1lx1 46 1726-080-100 1 1 Screw plug M 10x1 x = as required =35-TABLE-1 GEAR —— eeTABLE 1B GEAR PART. NO. /1A /1 DESCRIPTION 1 0285-122-001 1 1 Mainshaft ass'y with layshaft, 39 bearing needles, bearing ring and fixed gear 2 0244-006-000 x Washer 13.2x18, page > 3 0232-155-000 3 Bush 4 0245-121-000 1 1 Cirelip 5 9230-108-000 1 1 O41 seal 15x32x5.5 6 0236-105-101 1 1 Sprocket 11 teeth oO 7 026-056-000 1 1 Washer 8 O642-005-101 4 1 Hexagon nut M 12x1 9 285-123-000 1 1 Gearshaft ass'y with fixed gear 10 0247-105-000 1 + Bush 15,6%18%14.3 u 244-164-000 1 1 Closing cap ¢ 18 x = as requiredCLUTCHTABLE -19 CLUTCH em REF. 10. PART. NO. /1A /1B DESCREPTION 1 O640-107-100 1 1 Threaded pin M BxIxt4.5 z oz42-121-000 1 1 Hexagon nut M Sxt 3 O2Z48-150-200 1 1 Clutch Lever 4 O239-136-200 1 1 Torsion spring 5 o291-021-090 1 1 Cable assy quote with solder nipple fraavaves No. 0291-020-000 Length 6 0291-024-011 1 1 Outer casing Co 7 0660-018-000 1 1 Protective cap a o2k7-140-000 1 1 Bush 7.6x1221.2 9 1950-024-000 1 i Sealing ring 10 o240-181-102 1 1 Pillister head screw M 8x1 VW 0284-016-000 1 4 Pressure cup 12 0242-000-000 1 1 Hexagon nut M 10x1 3 0244-157-000 1 1 Washer as O244-154-000 x x Washer 24.8%44 page 9 o24h- 154-003 1 Washer 248x401. 7 15, 0258-014-200 1 3 Internal plate 1.7mm thick 258-014-101 2 Tnternal plate 2.5mm thick ° 16 5-122-100 2 2 Spring washer 17 O258-015-000 2 2 External plate 18 oz58-012.000 4 1 Clutch hab 19 agk7-141-000 1 1 wings 20 O284-015-000 1 1 Centrifugal weight ass'y with 1 « 0299-137-100 tension spring at 0258-016 100 1 1 Clutch plate 22 ozkh-11z-000 2 2 Washer 11. 9x23x1 23 o284-014-000 1 1 Clutch case ah 0292-192-101 1 1 Bush 11.7%16x16.5 x = as requiredTABLE-20 MAGNETO-GENERATOR “u@ : a 3 —_— REP. No. PaRT| NO. © 1/A 1/B DESCRIPTION 1 1 ' Magne to-generater 6 vole 17 Watt only available under Fig. 3 and § 4 0286-1]75-005- 1 1 Flywheel for ROSCH:0212-112-019 02 12-122=006 4 5 O286-254-008 1 ' Armagure base plate ass'y for BOSCH:0212-112-019 ~40:TABLE-2 9 MAGNETO-GENERATOR REF. NC. PART, NO, fA 1/B DESCRIPTION 6 2865-003-000 1 1 Protective cap against rain 7 0965-133-001 1 1 Ignition cabloge 8 263-121-001 1 1 Insulating hose 9 1 1 Cancelled 10 0265-109-000 1 1 Protective cap against rain W 0265-100-100 1 1 Spark plug connector, partly suppressed 0960-116-900 1 ' Bush. 0288-091-000 Spark plug connector, 1 suppressed vk o998-004-001 4 1 Spark plug W175 Ti with SAP connecting nut 3 1 1 Armature base plate for BOSCH:0212-112-006 6 165-008-000 1 1 Lubricating pad 17 Oghk-108-000 3° 3 Washer 4. 1x9x1.2 18 O240-106- 100 3 3 Oval head screw M lhctl 19 0265-052-003 1 1 Condenser 20 0265-G77-001 1 1 Connecting cable to condenser 2 983-106-000 1 1 Set of contact breakers 22 0240-066-009 1 1 Bearing pin 23 0283-107=000 1 1 Set of spares for contact breakers 24 0299-059-009 1 1 Lighting cable quote 25 99-059-016 1 1 Rear light cable required 9299-059-021 Stop light cable length 26 83-009-000 1 1 Short-circuiting cable 27 265-074-000 2 Cable terminal 28 0260-020-000 1 1 Rubber grommet (2 hole) 29 0260=020-005 Rubber grommet (4 hole) 30 0265=159-001 Generating armature with 2 connections (lighting and stop light ceili for BOSCH:021 oa o2h7-106-001 Bush 4.3%8x7 32 0265-139-006 Rear light armature for BOSCH: 02 12-122-006 a3 0246-025-000 Spring ring for M4 ae O240-122-000 Fillister head screw M 4x13 35 O265-113-003 1 1 Generating armature for BOSCH!0212—112-019 36 02 000 2 2 Fillister head screw 37 0265-142-000 1 1 Ten n armature for BOSCH:0212-112-019 O212-122-006 38 0-105-000 a Fillister head serew M 4x21PEDAL SHAFT TABLE-2 eeTABLE: 21 PEDAL SHAFT REF. PO. PART. NO. /1A. /1B DESCRIPT LON 1 O237=106-101 tt Pedal shaft 0285-121-000 1 1 Pedal shaft ass'y with Fig. 6, 7 and & 2 o285-120-000 4 ot Driver bush assty with washer brake Lever 3 250-165-000 10 Round sealing ring 19x2 & 0239-051-001 11 Brake spring 5 o252-007-201 +t Driver 6 oz34-106-001 tT Starting wheel 7 og4h-120-002 2 2 Washer 16.2x22x1 8 oghg-020-001 1 4 Cirelip 9 o2h7-149-000 1 1 Bush 16. 3¢2009 62 10 0250-164-000 2 2 Round seating ring 13x13 eeeTABLE=* CARBURETOR ——————SSSSeSeFSFSFSFSFSSSSFSFSFSFSSSFeFseFCARBURETOR —— REF. 0. PART. NO. 1A DESCRIPTION ' 281-124-005 1 Carburetor ass'y BING mark 85/12/101 (main jot 52,needle position 11, needle jet 2,17) 0281-124-000 1 Carburetor ass'y BING mark 85/10/1601 (main jet 50,ne0cdle position 11, needle jet 2,17) 2 0291-004-000 1 Cable with solder nipple No. 0291-003-000 ee teed 4 291-024-001 1 Outer casing, black f 784 h o291-024-011 1 Outer casing, mgt silver-coloured 4 0260-024-001 1 Protective cap 5 0261-143-000 1 1 Pipe bend ass'y with 2x hex= agon nut anc adjusting screw 6 0261-144-000 1 1 Cover plate with fastening screw 7 250-162-000 1 1 Gasket, 8 239-140-000 1 1 Slide spring 9 0244-109-000 1 1 Washer ° 261-018-000 1 1 Smal1 retaining plate " 0261-006-003 1 Jet needle, 33 mm long 0261-006-004 1 Jet needle, 36 mm Long 12 0261-146-000 1 1 Throttle valve 0261-148=000 Throttle valve 13 ozh2-110-000 1 1 Cap nut wh 0962-013-000 2 2 Sealing ring 15 0261-125-000 1 1 Hose connection 16 0281-109-000 1 1 Tickler ass'y with spring and forelock 7 0962-066-000 1 1 Clamping screw 18 0962-065-000 1 1 Adjusting serew)for throttle 19 0962-065-000 1 1 Spring valve position 20 Carburetor bedy, only available under Pigs] 2 0250-161-000 1 1 Gasket Ba 0261-142-000 1 1 Needle jet 2.17 25 O247-145-000 1 Ring (in needle jet) 23 0961-151-000 1 1 Main jet (quote required size) ah Available only under Fig.25 25 O281-125-000 1 1 Float ass'y with float needle and pin 26 0261-145-000 1 ' Screening sleeve 27 o261- 1 ' Float chamber 0261-1 Float chamber 28 ozh5-023-000 2 2 Spring ring for M 4 29 0241-028-001 2 2 Fillister head screw ESINTAKE SILENCERABLE-23 REF. 10, 1 2 x Bee 12 PM + NO, 0291-904-000 0291-02 0250-160-000 0225-007-100 0239-198-000 225-009-000 o244-160-000 2015-007-004 0225-011-000 9225-010-100 0225-008-005 0299-139-000 INTAKE SILENCER SS fia /1B DECRIPTION Carburettor ass'y see Fig. 1/1 Cable with solder nipple | quote No. 0291-003-000. $ required Outer casing, | Length silver-coloured Round sealing ring Wx1.5 Intake silencer housing Pressure spring Starting slide Shim Fillister head screw M 5x10 Filter holder Micronic air filter, intake 16 Intake silencer cap grey, intake ¢ 16 Stirrup a7REPAIR TOOLS AND MOUNTING JIG 18 8 a 46 - Pert No. 0076 065 108 0077 083.000 0276 023 001 0278 072 005 0276 154.000 0976 135 100 0976 150 005 036 182 000 776 180 002 (276.181 000 0276019 101 0276 175 000 0276 170 000 ‘O276 179 000 1476013 000 )476011 000 1440027 OOF 1476012 000 1447 099 000 1476014 002 0976081 000 ‘0776 087 000 (0276 085 006 C76 088 005 lapel ‘Gudgeon pin extractor Inset bush for gudgeen pin extractor ‘Gudgeon pin for piston Protective slasve bar crankshaft (power icko-off side) Protecting cop, bors 10 park edvancé timing gau Puller tor magnete ipeben M2615 Holding teal Yow clutch Hook wrench Pin sponnes, adjustable Intermediate plo Revolution count Torque wyonch * 1476013 000 ing inner dia, 58 men (228°) Bir grooved boil beoring ve | spore parts for Clampini Poller shelOWNER TOOL KIT OWNER Took KIT r 2 3 4 REPAIR TOOLS § 6 — REF. TO. PART. NO. DESCRIPTION 1 1150-6648 Double end wreeh 14/17 mn 2 1150-6625 Double end wrench 10/12 mm 3 1150-6654 Wrench socket 4 1150-6654 Serew driver "4" & "=" 5 115-6664 Wrench for stom cap nub 6 1150-6654 Stem nut locking wrench =49—DISMANTLING THE ENGINE Remave the engine from the frome end clean it thoroughly before dismantling, Intoke silencer, carburettor and ialake pipe Remove the lencer cop (1) and the micro: nic oir fi frame, Remove starter slide with contre! cable and prev sure spring Unierew carburettor and intake pipe (5). Remave gasket or gaske!, intermediate flonge and gosket. Unicrew the jntoke silencer housing (2) only in ease of neces Unscrew cover {3} with gorket Drain the gearbox oil, Movat the engine Mount ine [lower part of eronkeoss up- wards} with 7 hexagon hood screws [1] Mi 8 x 65 ond nuts fo the aouating jig Cylinder Unscrew the cylinder ond remove the cylinder flonge gasket. Note: ‘The cylinder con be rebored ones, ta be used the corresponding piston [see Spore Ports, Lie) When fit jinder oF 9 reconditioned eylindiar with piston, the colour mock (red or white) fon ihe piiton crown ond in the intake port of the cylinder must be of the same colaur, Fiston and cover Rernove both wire circlips. Puth out the gudgesr pin with gudgeon pin ex- Tevtor ond ner oun (0 Remove the needle cage, Pry ot the cover (2) or knock it off (use a sgrew- iver). Magneto flywheel Ingert odjvstoble pin spanner, os illustrated, un- screw the callar aut and cemave the spring washer. Slip on Hing cop and pull the mognete tywhael with puller (1Stator plore Remave the spark plug connector from the igni- ion cable, Unscrew 3 cross: head screw (2) wth woshers, remove the stolor plote ond the Wood: raff hey (2 Sprocket Apply the hook wrench [I] with its chain to the sprocke!, as illustrated, unscrew the nut [2) ond remove the special washer, Pull off the sprocket. Starting ad driving cites Unhook the torsion spring () Unscrow the filster fread screw (4) with, sealing fing, remove bush (9, chtdh lever (2, with come tral cable} ond torsion spring, Remove thrvst cup 5) with thrust pin -51-Baars 1 Wide 12 Hold the washer ()} with the halding tol. unsere the nut (2), Remove the washer (1), shims {4, Fig. 6), inner and ‘ovier plotes with sprang washers Remove the clutch hub (I) (if need be, loosen it by a slight blow). Remove Woodrulf key, if existing (te be omiited during rempunting}: Remave the clutch case {2 with centrifugal wei CAriing (ah cluich plate underneath it aad) the check plate. Remove bush [I] and check plate (2). Note: If the bush sticks; pull itoff together with the groo- ttl beanng fakes endongag the eeosed boll beoringsh Spliting the erankease idler head screws ond remove theCrankshott ond gearbox Remove pedal shaft (1), georshalt (2), cover plete ] moinghait [4) and exenkshoft (5) Unierew the crankcose lower part fram the mount. Bidttig 3 WORKING ON INDIVIDUAL PARTS Exchange of crankshaft bearings Pulling the greoved ball bearings nd 6) and wosher ball beonngs (3 shells (9), puller sleeve (7) and clamping ring (Bh Installation dimensions of crankshaft S775 mom (2.278 inh. Thee #5 no need to mecaure the crankcase Exomple: Fitting dimension af crankshot!: $775 mm 2275" Dimension of test and make sure turn signals work well. (Brightness) 11. 1» check if the free play of fr nt and rear brake is proper arg brake light ie bright enough. 12, bold cluch lever tightly with left hand and pedal by left foot. Give the throttle grip @ slight inside turning with right hand at the same time of pedalling. Engine then started. Feplace clutch. 13. 1f engine itself is cool, choke lever should be grasped together with clutch lever so that fuel mixture increasing jor which is helpful for ensy 3 arting. Replace cheke lever shen engine is warmed up.Ce eiaeenneee en pee Ad_ustment for Drive Chain Th: tensiow which chain gets is correct when chain itself has j= ‘em slack at the central point between two spreckets. Ad lusting process: to loosen rear wheel axle nut, Turn adjuster nu until Hoth testing mark and socket on adjuster get inte a line. Bri kes. Adjusting Th: free play at the end of front brake lever should be 2-Jom. In pect frdnt and rear brake every time before you drive the bile. Adjiet adjuster bolt and nut, if necessary. Check Spark |Plug 6 acces Chick spa. 4 plug and if necessary clean carbon & contamination ar‘und cap an? electrodes area with spark plug cleaner. Spork gap is normally ©. 5mm-0.6mm. If insulater is broken, replace a new one. Drive Chain Lubrication Th L cation of drive chain will be done depends on fact. — ~69~Maintena ice of Battery 1. To ;heck the level of battery electrolytic fluid often. Fil, with distilled water until it reach the HI MEST Level if .ou find battery fluid a wn below th LOWEST level. 2, Usig @ gravimeter to test the apecifie qravity of battery flud. If its spe gravity is less than 1.20 (20°C) , the battery should be charged. 3. If he bike will be stored for @ long time, it's suitable to tismount the battery from the bike and charge once o mon h. Whe) the botcom gap of electric channel built up with white dep sits thav indica wf the battery will to be of no use. Battery ( harge ng efficiency: o.4AH Cha: ge until the below items are proper. a) i pecific gravity: 1.26-1.28 (20°C) b) ‘oltage: 7¥-8¥ Cha ging time: 10-12 hours.By refe ring the following time table, please have your bike a periodic inspection and lubricat on so that it can be operated under better condition. Month of Riding Clean or adjuat spark plug Ignit on timige adjust Clean aiy clean Adjus. and clean carburetor Clean of] filter x |x |x Chain adjusting & lubrication x|x}x] x x Adjus front & rear brake x Inspe t front 4 rear brake shoe Check & adjust bearing ball ef handle Blect: olytic fluid check x After :irst 18 months riding, you say do the above umintenance ow ix months. T=Ttem Diffiieult or no starting Eng: ne sudden ato) during dei ing Hare steering Troubleshooting Possible Cause 1. Spark plug or ignition system a) Dirty spark plug Clean b) Wet spark plug Clean ©) Poor terminal contact Ad just d) Dirty breaker points Clean e} Incorrect point gap Ad just f) Incorrect ignition timing Adjust g) Faulty ignition coil Replace h) Condenser short circuit Replace 2. Ne fuel delivery a) Puel tank vent is clogged |b) fuel cock encumberred ¢) Fuel pipe clogged with dirt Dirty spark plug . Dirty breaker paints Fuel pipe is clogged Clogged carburetor fuel jets Worn or bad steering ball Replace bearing Stoering ball race too Adjust to standard tightened tenuion Low tire pressure Pump air eo required -72-—Possible Cause Brakes do not Brake show wern out Roplaca 2. Brake arm serration flectened | Replace 3. Brake cam vorn out Replace Turi signal out|1. Turn signal switch of crder 2) Poor contact of flasher relay | Replace b) Flasher relay short circuit | Replace ¢) Incerreet wire connection Correct d) Bad ground return for turn | Repair signal iteelz. . ©) Battery fuse blown out Roget 2. Bulb Replace a) Filament blown out b) Incarrect ‘voltage Replace Morr can't work|1. Morn diphragm worn 2. Bad ground return of horn Replace Repair button 3. Poor contact of wire Adjust Correct 4. Incorrect adjustment 5. Hattery fuse blown out Reset Head or 1. Bulb tungsten filament blown light out of out order 2. Poor contact of switch Repoir * blown our Reset Braks light aut |t. Fill 2. Brake switeh out of order Replace © Battery fuse blown out { Repl Adjust 4. Poor contact of wire “1+E lectrical, Wiring ee > ‘sii