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MAJOR AI(3GIREG,ATE,S --

3.46: ee, A~R OOOLEil)', 4 SrTRiOKIE. SPARK I'GNI1U!O,N ENGIINE TI!M!I,NIG SliDE

EN,G,IINE

Drc5TRI,l3-UfOR SHAFT !ileAi'!! 'TlIP!.UM ClHeS-i C:O~"Efl G

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m

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dr,ai!l'Qed olllQ(lil:s arccUlmliJllal:ed un '~Farnkca:SQ.

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From

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!!J;FQ,Rj(' ~Q

W' IEIEl AND WUB A:S:SIEMBLY -IFIR,ON'I

'it if'mI'U '!MICe!Ili'!i'Il'i (iii! 2:-1S].

IFmM'IM'Iee!i:~,

1.1F~~i!I~l~ FfM'I,l'1u:b~1

S. fmnndJ;,~

.
n ..

~m)

6. frtgJl'Rlb~'
1: flWlUlIWb re!tJ!i

iI
;'

f\mn~~'Y.!l~!'~WiljfiJ -'(IiI'1UII I~'~.

~'l

b'IXM!f'P - Ul:l;~' __. 10. IF:!'(!I"Iih,j) - .oshel (~stde,~ '~1_ l~r(If'Ithub fl:-. -_l!i_~he:r~~_' ~2. IF:mnU_~d~ ~ 1XiIai"

t3~~,~~
1 I~t~~dwlili",
I

15. !Fi~I;~;_'~' 'Iii II=\'N:Im~~~_~.

17_ IF:r~lI:brabJ, 5l".oI~1!I

t8. Wa:sflcll'i'l'cOl~ ._~'fiR

til INIlUiON~sJJoe, ;!O.L IF1roiiiI ~ ;:im IMiIiII ~t

'.

'n

~111 ' - an 1L1!Ig OOtI:f ~I~!O

fM~Il!~mJI~~~ll i:l. f_c . tn'_~ J: ~m

!4l

wa-_- ~_,

._ ,-<~IGaiIi.

r~
,--

NuI,i!fficitl~~LifIg

etJn IIiIti'I SA.

WH ~1E:[lAN 10H Ule< ASSEMlBt'Y ~ R.I~AR

UL l?is.laOO! ooll~' ~!'.i:u~t~Met iill".;er !ii:1d~~ 'is, .Re~f t:!u:blfiH~' eallar (du;sJi t»iI'!r ~O. Ri.jlr ~riil.\~ d"tiMi i:Iw Ijni~ ~ti(:oi;i."rolI~dJi 21_ f.t.B'M bil\!':(l!i i5ti~ ~j!illv,i 1~. ~;.r bt.;j!j;t Q:lI,'Q, 511ii!~ li!i;.;ii!1ItiiJt eGIiI 'rJ, !Riv lbr.:!~ I;Q1,'C~' plilL'fi Bi5SHnbl:! :~, ~ar ihlfll' iik;ll3IlI;:B >lliliiar (lfnim '$"~e) ~.

'w~', Rt~r h~
, .

I:e.arilllJlllSr;i!!~

~er.=~e)

2-5. fl~.BI br.aki'!'i!JIGI!I ~1l1I Nu~toe.~lti~~'~lJlin 2~. ~:i:~r 1"I.I1Ir ~~ ~ [ilIA ,['p II IIi) al. ~~ pifll mIl rCi!r Ilfil~ BlIIlhlMl' 2~.. Ra.r iNIlikB op!!'riilW'l.il ~"i'i ~U. Ftil!.r 1~~i!I (tim, i!)l,!,Ijll 2;1, Hltjr :titi~~cCilH'fJlI~ ~ t;o.l~_h pili ~It1Il ~, 1F!.i:li;f lb_ilkti ~i.,jn.!II ~'I"I b'.!iJJ, p1i:I &1N~I' ~. ~ilrLr. ~.a~ e9mbmhlPlri ~ r. j .3<'i" ~91ltitIine f,~~rli ~i'ing 3:), IF:el!' lbr~M: llPetCin~1e:-.li!1I1i!:l~~',A:i:iY.

3~.

Wa~Iii¢t.'~~at ~~

~~jf

1, RN" wh!!;l!il r.l.m! Wni 2"'!~ ;2, RatJl' \\'~~ SJ»k~ (du:i~PlXlIft"I '~B-!:!JL;y] ,3. Ft~;a~'w'hijj'l ,ip~Ii~' ~!ll~ ~m' ;1Id~-IliMr,1 ~. RJl:3lf 1,1110 I-;pm!i ~J!I~~ ,§.\ 'C!if'l,i't l!'il,[~ 'liitJi bBJI'IfI1 ~\ Flt~ trubo [ilipi'Pj ~~,,~~'An)'. 1. 1t11:J!1' hub< d!.!l~ ~!1~r ,B. It~· tw'b, ,",uiit og'ltl !:!f.'e'JI!1

'i~ IRI!1!';Ut'.rJiI i!~ MT '~Ifl, !!!:~r I!!i,,~ !lij;i.~'\1I~ ~~l

'9'. lR~r ,h...b tlIIN"~ 'I)' ,ii~ ~iD, R!!\Jr ihu:'b ,~ti!\l[!i!i~B, (11m ; ~_ ~I!itl' li'iut.Ioo~n ibl!:ai!l~ 1~.R«!~ t'!'l.!t; ~rc;iiilCll!::, (~m~m.I' ;,~ IRM~' ~~ iWbo ,(kirnj) u_ IRHr ~J.&1I<iI~kl!t .w~h! lQb.bor

3~'. ~I,!!t fe.!:!t.' b.~, iI!,Iilt' 3&. ~ii1ar ~bo .aif/YBI'e"J ~'iilH) i31t ~I!\fjr iwb'.I!Id1'nl~iI' ~~HJ'
iIIIllt ~~ki"ilit![fl~ ,I'i-\;lb- !JJ1!i!I'e,~ ili1. !%luI milf 1'iLrt! li.¢Ilrlli! ~'2. l~a~' liUll! i!I~d~ ~pU piI:'I

I
1
,
~j

TittEl! mahi!t~n,arnoe sc!1liiil(t,,,II'e dQta 1!lll:dhere ''NiH iiJeap, you majli!tefii!i'ii YO:iJ'rStlille., mOlor,c:vc::le metic!l.!I(\!!J!5ly arid to 9 ~t aJ r.oli1lS ilroub.1e ~ro.e serviC:i9, The ~~dllJll~' pro,vlde.o herrein is! Ibased l!iPOIi"! aVi9i'ag0 1l'1(lI'ngl OO!'idlUons and hruficatieSi, 'rh;;!, Kms ,ai, whh::h f!l;;gu'la!l" JlT1spedion5" i':!(j]jiJSIlM~nts. replaeements andl lutllllicalions aFellQ ba c.;;Blflifcd Ollt. The fre.quency ()!~'liIte jjj,ahnlenilulIil::e mJUtst bel St!Qr~e!iled ,CliIiIIPii!lfI,(Iirngl Up-(ifll the :$EiiVtilrli)!' ,of ~he dr,i!!i~f'iI!)r(i(lnd~tl(iins, 'Cla-'lf'~!i:I molnm)!l!.1le i!i:;, • .re.ed tn raj'l,!'1:l!il'y' ,dll:ls~,y. ~:nrvir(lf!;ment COl!lta.(t ~hi!1! eares~: Royal Enfleld Ii!ibl~ho.risle.4 n ,e.e'NiiCe centr,e 'ror exp.!9rt ~~~OOI and Ie ~,iIirl)i' out U1!el if"EI!iiium~,ed ili1tJIll i'UJ nee, mii
f':J;lIEE; :& 1l'iR"nCIili Il!I, I 'Which ,i!t1IIe~ 8'arilla,.

'1111

R. R R Chi!:ek ~evell
1

R
1!;!1!,I'JeT)."

R RI~ IR R 1Ft IR :500 IK'ID$.olf .e:amliiliiii as ii'CClill!ir~

1

Engiri,G' otl llJte.[ [6ulle!t

S,

a~i;JIl~lilCaii'a 15.'00)
Ele~tra ~ ~OO),

l~ngil'li!1 @fl filter (Bullet M~~lm~)'

~ , 6 [6

Ien'9jm,e' ~Iil slltain@r 'fB!IIIie.! ~51l) I

T:I!IPPC81~

I c I c I R. 1 c: I c. Icc

0:

C;

eRe
C ,F!: c G
A I

eel
eRe
iQ.

C
IR

I
C

FAt

I IEn"il'l-s oB slr.ainiCf (8ul~.e.Mael!ll'i5mD:~ CB P-Qint:; (;350 I- ~O O"GJ

I c.
I
1

I c.
A

Icc

C
A
A

eel

1c
/li, 1l!, A

A. I A II A A.
A IA

A
R

,A,

A
A

A R

A A
A L.

~ I S_~fk ~Iug 10. i HT ,lead r'(l~(::r~e.I!:, 11 I All 'filter elema;nl,

II

A I C

A Ii:

A I

A ~ IA:

R
_

III C

1c

c.1

iI

~ '0

II C IR

II

C C

c
I

'I~
14

I fiJoHank
1

F'Utail mtel' (a50

i IEI8lCtra l Bullet ~BQIli$rflg;,

C
_

nlfJ:

C.lR_

Icc

C.

c
I II

ft

c
J

rs

8i'O~IL~1er 18(1:': (llhliUIiJ! Mac.J:lI!5lO1o)

Drnf-!'! IEWI)'

~{lOOI 1K:_I1!1l5: A
n

A
I I

I'

20< BnaidGld M~~ (,5ll.® CC) aoa~k , r..eal'is. 2'1

1

II
m

II I

I I

I I
1

II R I

II
II

I I
!

I
II I

I IR I

I
II

I
l_ ,

H:~8e PAV (.0

!inmat li'rIaJr.lirafod (500 eC)

[n

,e!1Jckll'eaks

I~

22 I .. " ti\;B!aIJie pipe

A: Adjlusra

rFl~et

Irr.;~t\o' : 1"(1 lIlIiIi£iIlilllte'!liRnec;t aJiiiilif 30.iJ1lO

0': Il ·CiIl!r.OO~~5'8fr': Fa;!i;o J' RUlli CHllil; I : 11f1!:;!ip~'i;;t ~ Ly'biicr 1.0 R: ,Repl e b Il(llfn;, p!~ 1I"1;Ipe8i1Ui,B :Sill iifle 'flequeinoC)" levels, S,PEI(;lfiedi ~II}O \e;" ill ~F1:5ul~atioi'1! ~1i1 ·e[ ,RO'!li~'1Eniliek:i Au:[t:JQrii5iBd Mmce een!rEI.

c: cre~n

f~.angi) (500 tOe) ,~r,;,f!;;l'ak:5i

IIII

s.
IN'i:!.

~:!lqCRmp:fl'ONl
[!Kms;

Wh len '~i·.rii I

FREE i9,EaV~CE.
ti::lr!]ljj'

PAl D SER\lIi!:;:E
,, I

f~ 11(1 DO)
MCll1itn. :

0.'
1.S
I

:3

12 U 18 :2'1
I I I
'D 'H'

14 ,2:7

se
I

2~' I

Rubber If'II~t manlr.okI (Ekullet Ma(lh~smJo I i500 er-ae.W'leiilIJ(Si Oee<ompreS5Cr oablll! [p.1ay

oc~

3 I 6;
I I

9
R

:2, 1

Adjust ,eve;ry 1000 IGms er ~

I
I I

i r ,as roquircdl
I A

2:5 I lfilet , IEXII'Iiln.JS! val1/·e .e!li.lI~"ii'l9 '2J6 C;yliFider ttaad 1'= 2'7
1E:';Iiiti,Ll'. .. t S').i'5l tern

0.'
D

0
ILl

2.e
29

iPli'irn,ary Oh.f.'I In ILen~iOIli

A R, .

A
RIRI

A R
R

A Ft.
R

,Pi,

A. R

Clu ten (loll

Clu t·ch"'re~ play' Olta j" Ill!»: g~,~a ~e1 oil Cluteh ,a'(:~l"IIattii'lgail'm Rear Ib ake ~Elillal pivot B:e'i!bEil)'uuminal$ (apply
P-Ei!tOI!li!UIIM JelJy)
,

R
ai5i

,Pi; I R

eh eck 1&v.~1 lI\!IBiFy §OO' Kf'li'is Qr lI!!ai1le. as reqlll red

I

30 S.1
32
;'3

Ai1Jus' !!3r¥ery. 10001 [Kms 'or eerUer

I~ 11Ft

I!1SQuiredl

On(!lOl: ,Iewl !'J.lj.iCiiY'1.000 Km~, or e arlier es requ IlI"ed

l l
I

L L

I:.
IL

L
llI

l l!.

L l

L L

L L

L L C

l L

34

C ·C
I

C
I

C I

135
'3S

B::!1rtery EI acti"t!Iy.!c level

E.artn ~rc eye)e>t ~bef1iln<lltJauoliY carrier)

,

37
38

iR!D~ r

On aiFli

At

A, R 11;, A A I Iii. A A A A I I LI.II)ric3lle ~",-er)" :3;000 I<Jms, or 'BIInJer as, r6Qulre<d I

I
I

C I 'C ~ I
~

G
1

C
I I

C. I

C
I

For .. ' I Fi"(Inl oral!e. IP'B~' Rear' bra~ ,p~a~

F~Qi'i~ J Rear !;,tr;!i!ke ('..am!!

R
Adjust A@j~~t

Cli\fN::1i: Ie el ev-e 'Y " OQ(I' ,!(ni'$ or earlier

'E!lI,I'ery
EltV8'i)!'

a~ lirs-qui r$tl r~l!,Ji~d

,,

39
40
4,'1

'1000 Kf11!5i O~ eilrrili-er'

l l.

1i!I~

1 [000 Km.s or eailll.er a!l: llfi.qulred I

L

142
I

Steering [bill I talCS ,S;p~k&s; IliQlhtFlfilS$.

I

L I I I I I
,

l I
I

4,3

I I I I I

~ I ~ I I

I
I

4~, Wbe.-e.1 rifi1'1i n.ml5.iJt

4,5 T;;."i"@
",Qat

I
I

45

H~ M ~e'l,!"E!n~, ki~'k: Slat.tl!l f' P~V'l!iit

Lu'b-iice11&

reNal)'

1!JOO Il()nrI~O~ eal1llef !!:!is~;quired f: Fa¢e J Ru n IQru'l.

At :;AdJ !S.~ ~: 1!'n:spliJct

~
[N~~!(i' ,t

C:
L

(:n.Q~1!'!!

Lubrh:::o .,e'

~, ,

~. [iI' .~c:' I'll;) lOin Is,~· . ~ pm: e

Ihe 5·9J in & ffi;l qU{j ~ C Y. QBtilte.

fo maii'il~n:HH~e ~'ftre r 30,O:WO Krns pi$. repeal

in (iOi'lSUlI1..a
j)f!

levels

SI:I eci"ie dl

.e b.t1 VI;!.
,

W!~11~ ROo/al e:nfl'6ldi Aur!Jh..OJ!$ed 5ierv,i~

"

·L
Visoo~ity· API f1S1tll'L'g

SA!:: ,20W'~5QI

S~

(1t

,above

LEVEL CH E'C K,

~~~~~~--~~, ,,f ~nl~f11

lIhe (1;1 '(,'Om 'Ifming chs:i't [

./

[Right lLovel :
IBe~weiijn "IRI"aiiild 'L" of d~p.$.lick

,.;'. T~p. UP. ur M.qJul"edl ulpl@ """ mark en

cUpstiek

OIL. CHANGIE ~ {E,V.ER.Y·I(I·~o.KlMS).

.,/'
.,/'

. _oCe~'RelP~gce ,o~1 'HIler element e¥~ ry

12000'

K,eep 'Yetl~els on level glMund S'hillil lti.e ,e:l!lg~f1[e: and 'W,arm IUP, Ibef'Ore' dmlr:i~ng,-==~-=="'~--

~ms"

"

B ring pl:Gi~!Oif'Q

~Q

c!tJimiP~'e:s:!Sicil'll

S;~IF'O ~ k

rDC
,Set by !I1O'!ill!l9i the ummel:er ng,~dl~
d!l:lililijlctf,ofll ~,homn~g~;Uv'l9iito ~i!lr'O!,

.t'

~emove' t.a,ppet eover

rods,

,:i!lli'Id cn[ec~

!push

,r!
0/'

IPIJ$~ !'(ids '10 b.l~ U'lll!.ml~b ~'rae''wJ~htiu.t !liP' &.

down IPi'al!!"'.
~f'r,noorJ"J!iC~. ad]UJilt al~ ,(~llow~ :

~
0/'

Fm up with SAlE :2GW~50 (i(il

C;a,p:!lcit!;": 2 .25 lIls

,.I'

,AcijiJtS.'~, :e!OI"EIW the,

'rOT

:zero dleBirn

11,00 ,~md

~hlJmb~:ush rokilrUon

,... 'T!glrn~en lock nut alUld (,hedk

f. -p-PE"Te, .. ~I!~
'A '"

"JI-U' - 'S' liiirl" AWl. -.:- "'fIMIIiii:lltJiT

,Iii;

20

D ElCARBONIUSI,(I4:C;
CyJinder head

,~~¥1EFt.Y112,,000 KMS,)

;/
./'

Witlil a iPQ~,a~o'.Q'1,o$ii;Ii~h E,!l tl!!J 1;;11;1' at

end,

ii)filQ

,iF..re P !i!!,re .

,;;II

:s Q'~U1tiolll by

IlI1i i xi

IIIg 11 1k'91.

C;B!Jsl&c oo~~ w~t~ 8

Ur.$" >of

WSl~~~,

NO'llB :: Pi'(iipa

r€:1

the :~PJ'VUlUOll'll ~ft!

p~:a~,Ite

c:onh1! ioe,i'" II)", nol .a~III!)'W C3 ustte s-odi:a ,0 r tlTi,e sol~'U@~ '~fJ CQ 11ilI(l in 'oontacl: wiiHlII :$!kilil Or cloU..
.t' ,r!

S~r!JJb OIJ.!i't Cii1!ilMl;t!on with

oBi SiOi",a ~e~'

-I
01'

Fiill'~flIe p~pelwith.

Iha

SiOII!,!!~o!1

,Sifimil;arlr', deC!i!!~bof'ii!:le; pl~lQn .andb~nel

I<iGiGl~ 'r'Of 4:5 ii.o 60 rndnutes

.aISi)

~
-I

EXHAI1J.ST IB,E,NID! PIIP E

MIE1lCHA~~C:~1!b ~Je,iVi~OD
./ ./'
it'

Ritlmeve 'tliil.e s~hJ'tr;Qit! 'Ch::,tm ~fH:1 [pipel 'llhij)~OIi.!9nIIY 'In watEi:r"

I'IUl!llIfi I~lig

l:§1ik~, mm wl'ile filope ,of' JOcm Length IlLo!l:l(sen Oil,J~,SlPl]nes at ' fit the other

A.IIR IFII LIIER Ca.liAN~N 13,

(I!;VU;RY 3.000 Iii<MS~

one E!'f'id.

i9iod'

~Q

a drill !iii (JIll

r.

;/" ;(

,lirfaS!!I!n: it Jntil ~h!91 ,p~Pill ~!ilId operl!l~e Lilia dlllYll. 'Th;a' IDas€!

eut

:a!!ild

,;5pIII'le:s of tn!!ll wbei r'upiBl wiJI r'€l',moy.e t iiiEll c;a;rbo.~

..t'

BIQ'MV 'COimp,fie53edl ,a~l'[15 PS~ ~ ~rom ~ns;ld:e0 bill,

21

.,t.

~f,~he P!i:ra1~. fiI'(j:rgh'l. ls Ig;N:()rred~eerreel it

..I

'fiOiSJ~: :assembly Check ~hefloat he iglht again,.

tlhe

ib:r be.n!:lin;'

tOftgl!.!e •

lOW [U!)LE.ADJ USJiMENT

I~EVERY3;'iIl10KMS) ~.iti!1I.'fI·ij t
./ Usa

[llg'h~'~)i) meGk J~n orSlC~s..I hol~Si I

CllOggJrngl

.;

I~' (hlf:illiclhi'e,. tre.~lalCe Wiith new.

CAftBURETI'OR
CLEAJI! ~NG ~EVER,Y' 3li,(1IQ~ IKM$)
.J'

R)llIimove tlh;e· ,fijUI~n 81'1d pilo.~ .11ij·~sOlean

-/

wi~h 'OOJm1~;re!5lse!lml air

,0;1'

FbOA" IiE IGNT ,AIl,JIUST1' I:!INrT

(E,~RY' 3.000 K1MS)

,;;!

TtlS h!le'!Ii! U"i!Ii air ,SOf6W fully andilo.D:sen It out by !!:lIneand half [l!,unl, Tlig1"neri AuxillsliY al'r &cr~w' iulrry,.
Sta III :a!lldl YI'~Tfn up 'flhte engime.

01"

Fi~at ,,/

11:-d1

8!tght : :26,to, 30' ram

IRe move,

~rne fl~oat

cha mlbe ~ [body and

gas.ket
.; Ho.ldlll1e mi>.dng chambe·r bad;;." in iIT!;llE!li1ed
poslii:iOflI

,,/

H',o1_ th e flo at so that II:$. ion 9 ue ju'sl.

CQnE:a01.5 'the s~riliil!} nIJaR:

needle '!;(j31v tJ'"

loaded p3unge,F of'th€l -'IfiISliIJ'e' 'Iha·tthe' s,p~~ng

[loaded pj!Ji'iI~iEI'~ is f1jQ,t de;press~d.

./
tl'fJliglll: f'wm the mixing ell amber b. Ddly. faCie i:o top. of ~he flo-at..

lLoo's~'Ii1'~ alir s Cr\9W ~o gat MSlhIl9:S~ hie

e!h!gIlI'l!;l!s:J;!Iee~ .

;/

loosen
,_..J

l'h~ s:Eo1Pscr,ew and set low id Ie

GREA.S~NG
OISiliRlliU1"OR S.IAFiIl": U;VER,Y J~~O i(MS~

speed ~'o.'900

to '1 o.()i(~R1PM

...... Gre'ssiS' -_" a gll'\e~e ~th

,.;' lOOSEU','lti;Q ;au:dl1sQ air scr.ew D1half tumEilllgiffle R,PM Ineftl ases;

gliJin

UlNIT~ONTI,MIIN(), ,AD,J'USTMIE,Nl
(E'M'ERV ~(lOO Kgl~0:111,kir'IBIIlIWErr 3MJ- ~::j,!~

~~

-/ ot'

loosen

tine ttiu-O'~Je _

~t!Ie.5pe;c:d'bl 90 I) to out ,i3li1xil81!1{ Slfr screw

-umo RPM

:s~oP sCre'~V and

,f;iiI;d

IRe~e\BlI,the above '1\\1'0 smlls YflIm 'l.umi'ng

,does net ii'!I1CHefaSe

iQliIgil'leRPM

TlHROTiLJ~ CAJ8.LJEF REI~ PLA.Y' ADJlIU8TMEJNi

FJ,ae' Pli!lIy : 11 Iln :2 mm
,/' Lillosenl 'ttl~ 10eK.i;'U.iit

.; ,.;' P WII: i8I 'wood en pi ill I'!Jk und liH 'Ce n Ue shmd ie9.[s; ~IO' U~ellrIB'aT wh!E!~el I~ 1~1fffi{!
(r'om the' Qili1ourT!d,
0/'

en ga,; 6., 'JOI~r ~h 9~a r by' ro.t~,tlfilg tn e.

rear wn'eel andl 9.~J'rtjf'lg ~h~ gear leve,r 5Himu ~iine.o.u51IY,

./

SCJ'@lW

in 'tltlll ,cab'le adjuster tOI increas.e

'tne p.lay. andl t;:ol',e-w OUf~,UH~ catile ~dlJus,tE!ir

'~Oreduoe 't1a6play •

.;'-' T 19hle n 'U''1€t. lock I1n.d.

SPARK PIlUG
CLEAN
.£

A."~ AD\JU

sr: EViE[RY

,3.0(1 iKMS 0

elas n ililsUJle Wi'~1n,a poinlta(j[ iSleni per -"easuro amldl adjM:3 ' 'tIl1le

.,/'

Rotate
,a Ilil d

'~h.Et rear wt:re'ei, as 5,110'o'm

~ "Ulmg

.I

's ap

m,a' il,i&W rrr te 'T lJC

ill

to O.S mrn

comp.~eS$io.n ,3~n]k,e.

./

Maxlrnuliii clo~lt:.wise reading ofelial l~dijc!l;'iWs·iDC.

garuga

.,/
J"

Ch.ept:KM~h a t:eeler ga.ugil

./

lE:n!5.i.liii'i9 CB

rD.!Il!ck plalte SOi"!i#W,s .are at IiH~

pJate sliO!S.

-/

centre

or b{l,c:k

./'

Tli,jli"n ~ ~

wheel as SIFiO·WflI IJ.!fltillti:e: dial g~Uig,

.,/
..I'

C~e'aln~he ce, p,olnhi

Il:.oo,sii!if!

ne e'd le Iho~d ~ngl rGvolutfons

rna kels 3,
•

"[1.1 II

.81nUc

I ec k ~

ilS'

~he' IiJ'!loV,i;1I!),IQ'

iPII'j'S· TO Pi.itNr il'l!il ~1)'i',!t!;IU; .I.L.. 'iii\

-/

AtlijllJ!g,t Cha
1iI"I0000e 'the

9&[P.

Use

$Cf@W

dinive

tQ

'I"

Tum ~gf'litio!i"! $'li/itcllTr 'ON'; ammEl'ter d~flect 1.0 ~

'Vre!

'*_

11

CiS ~(I,lnt M(I!i,!'slb'le ·JarVl-

si'tie,

""

,.,. A,s, inrl~ca'[edl by ,eJnmeh:!l!" ~!.!st deifi~e'bing b!ii[!CK: !tQ. :ZierJOo

REIAlRDI

N'G & AJrJVAJNCI NO

..t

.'"

rm

tine [ne.E!)~:Ue Iriilak€l s 2:.2 clock.'Wi5ie.

re'i,i'oli.iltion

[l.e. Q.8mIFri.befor@1

"joe"
'20' I
,r/' ,.

N~.edna IPCisi~ion ,as shown oabQ'i,i'6',)

NOle ~i'ii.'J ~,€! caire not
iFead~nQl

~o C. ross

For relai'ding,
R:@dlL!J(:e' 'Ihe

ce poillilt gSip.

N'ole :. I r Ihe- n,eedH'e OMSS8S ',20' r,e,fl,gJif1Q f,epea! the' above "our sltelpS 10. el~imi~!lI18'l~m~g g,eari ,bsc:kl a'sh n
El'r:~(Jcl'tlil'!
1119

'"

Move b~IS'1l!ipilate in cloCkwise

directi'on!.

nmof!l 'Umln91.

./
iii'

Fer adwndng.
Inli:;::ma$1BiIhe C B [PO~r!i~, glap'

./'

Loo:s!~nthe brac~plal~ ~oldillilg:SQIH~'~ and! adjlJst Mck plarle. sU;di tlilliat CIS point JU$,t opens, .•

,Ii

Move IhQ base p~arEe'~n antr~od!;wrse cU!itt;l:clir;m.

25

.;

RertlliJlJ'i:!

tlhe ,etMiIP5:.

,t

Ro;ta~Iil'the ,elilg'ine '~O a\Scerta~n ~h~~ U11~ mtor dOG's IFIIQt come iii! ¢Q;ritt!¢\ w!'~h Ui'e

:s~al~f.
HI~'Tl~lO'
~~J

'LT,oI'IIN' ~,.y, _ ~,",II" ",U n·," '~. " " __I\( ,F"LIIi:i:: .;!i;.III;Ji IN'- Q ~~~'M'lG .. ,I

.r~j,C-RV

,Ili' ii'io'!'i'i)I

i"'Ue'~, V-.ll.u~,~ !Il'IIi.mrQ$'

,;I

IR..emove the ~eltrol tal"!'k

PI1H]llilh~' d,ra'in ho~e

,,/

;I'

POil.llff' 5!(lOlml

O'f ne:1rh tkl9'ro~ene'l :sl'!;a,ka and

d~II'II'II.

c WUJ'Cti
O~I!.I.EVIElIt. CHECK: U:,VE~Y' 1 ~iOO KMfS)

~ /4r.'

;/ nL~ cllJi~clli!,oil sho U!!\d! s~ow~

'" vigmO'iJsly ~ha'k.,e 'the '~an'k: ~or ,2 tf:) 3 minl!.i:tes.,/' I'f not. oop

oo,ze G1J't

up' wilt.

SAE

1] 0

W ~ 30 oil.

.,t

Remmre t\he ,striIIP;S,

Romhil :s~a!lji .
- -,-~uc .. il">LE ~~,_y i!i;1~1' PETROL. TA.I~n, - INir"!; (E!il\ER,Y

,,/

Ih!l1i' ~11I~1iln;e: ;asGefiB!~n ~hfi:!~ lhe ,to

i''Owr doe'!5i Ii"i!Ot oaMe; in ~~nl;ad with ItH~;

~o~ "~$} ~
~ IDliii

,t
,<j'

IRLemO¥e

'~h~pe~rol tan'k
11m! 1;!j,Iil!,d
il~ llIiI'O'l/!~ kQfQ:$il}fJoi: al~ClI s(:lreWi5:.

IPlu'Qlilhe' dr~lfJJ h,ol;~

~11JtI~,

'!I"

PoIUW!600 ml of f'resih Iksro3-Q.n~'; !sh~,ke :tine:!

draJin. -./ BI:Olf! oolTtipre'~,61edl a'l~to ,dry' ~he tank.

'CLJUl'CH
oml. LEVIEL !c-HiCK~ (E,y,oE~Y' 1 ~lOQ KM~)

./

,pur! a n:eilllidf'yl !j)f <far1PIijJli'~e~ :S:il;i~I~S

lit

i11'II

./

Lo015:ii1ifllI' r~m@vei ;~~e !e'!.!'€~ p'IU9 ..

./ " Vigor(Hl~ly $h~'ke 'the' t;lln'k 'j,or :2

iii 1f'llUites:.
~Q

Tlte clly~C~,oil $ho U!td$~ow~y O~'4a' ~lJt If not, l'O,Pup, with ME 101 W .. 30 ell.

,,/

Oil, CHlAN'G Ii~ ,"'_' ~EVBRYilOOO KMSJ .

.I

1iglnh;l!1 flll!(l:iI",<'JndllelVE!1 pi'L!giS•

CAfULE END OILWNG : {l~VER"M":nmoK ":S,)

rI'

~~ep Ihe ve~:cl'" on level groLmd Di'a~n'tl:"n~ oil bV ~OOS!lfiiITlQ

{:Qver out'EU"
~h;~d'!~,1ncase

-I

'Wi'th a !llI i"e.;ase QU n. g'~le:aiQi 'It!~ ,clu!cn G actuatilng ARM '~Jhlr(lIJl'9f1J the, gli'eas,e njl!l'p~e'
ii"'"' __

----=_~~"",...... ....

.I

illglhten

'Ifle ctruain ~,SQ Oov~il"hol.Q':ill"fut

-.t
.j'

,/
"

Ramove .he I,~¥ellplug

R'el'mJiV!!!I 1hIil!! 'filler 1P1u'g
f'ttUT

~,€'mQII,['e.1'tfile. ,adj,ushlll'" Relil'Ul;'/e

'~tI bi!.lill and c:1u:~chreds rr~ml e

,SAE 1OW ~,3®' oilllhmUlgh 'tile, fill(i'F

!l!ilal n shall,
.j'

pru91 '" lW11'U'ile, ,oiIIQQi~eSi IOU~iff'Clm the 1'9tV~1philQ'

,hole

Appll( grease 'Of! Ihen" lRe'"i~,~h~m.

..t'

CLUTCH CA,BUE FIREE PLAY:

~IEEVEiRY'1000 Ill( 5)

Frs, pJa(y: 2,~lmm

28

'WITH ,AJDJUSlIE:lft, SCIRE,W

;I'
¢'

,/' ./ ;;{
.j"

loosen! tl!1e IlDck nut ilgh tellil ttil!91 Slcn~w tin resi$!tance NOW, ~s,[e1t '

~oo:s~noilI;1.i!~ b(Y % turn

uU.J~

bOOSiiJllil;ad.ju s,~er I~(:k i'iU,Ji~, S cf!ew !ilUl~ ~ttl'a' ~ldJ us,l:e F' 'ri II the rl g hit S!lao)i;n~5's, is i.'H~h~eved 'Ti:gh~ell1ile ~ocl!:: ut, n n VAlViE 'l~MING

iJ'ighb~1liI look

0;/

F'II.!! neh malri;:$,

~N; to.

On C~ilir'ilk $,h1;a~t piilil i,o Ill"

exfui!iiJSi'l. ea FFli whee~ :Bind; ~1]ij!1iI

in!et ea,~

Wi'iB@!~

'iNn enl ~d:Skiirt! il:s :ail iDG.

(The' T'i fliii~91

¥'

B'Ii~rmgl '~hel P i:s;!:O:n to TDe p@smollijl

pin h:m t.!~y w,~,ywi II bel at 1,2 '0" dock

'"
- ,~'

PoeUion the IEl(hausl ca m, 8iligmu:Jg i~ lW(Ii

pi!Jlii~h m~r,k.s wflltJl the two I!i!U neh m~rn8i

,/

S.(i ~W' out ~~~ ,adjllls~er 'to Ifletdll!,d(:lQ! thle play-

./'

S(;(eW

~11i

th!iii ,adjus;!Q~

10 iaillClEiiC:! S!e tilliij!

play.

T49 hlellllil'u;!I

~Q;~knUi~'.

PRJiMAR¥ 'tHAI N 'IEIN:SION

,AD.JUS,lIM EilNT ~,~VI~RY lO~O KMSi,) . ,,/ C~ii3iok, ih€! :$Ia;ckllil€,ss ar~lh e I~~ullltrle. 'tine of'
-.I' F~!!iIc€: [he

i[J':J~el: c,alml. aligni Fiig Us ,~iflg!$

lhiz::' sil'il!a111e Plil neh marK.

iCOp ron.
·. ' ' I' I'f' m-', .... '....... '" "'"_'d_:J'""',!OIII ,""'" flO. U;IJ~S .... ""' to ~ !o>""

IPUlflch m~rk ¥rith

(lin Uile: exlnl:a YSl calli],.

1l';IE'AR BOX
l'l;Jll;!i : II!..~,'VEL Ctil:E:CiIi( ~ llEVER:l!i' ~..~c!(I; IKP!.'liS, .; 1R.,emon.le' ~e level ~!llJ;g

j
~

Fi II II'! a S.oi;l'.a~ b{ll)'i: wllh l,i\eedol ·00;' {WaCle LIIlilBm'CANrrC'lHIlANtGE : (EVRY' ~2,OID. K.MS). 13
1 I

'gre.'.8Js"e ....

;/

StEm ,aoo walrm Up Ene eogl!iil

.;/ 'fm the 'S'l'iag,g; saans

~eilie~ _:ole. plUg

oQ'Zling iOUl~'f'Forn'lh,e

SiIELEC:1'o.Jlt ,ADJ US"fE1R. PUli:TiE AiWUS; 11!IElNif

jl~~P-IIA1!

i. ~p

PUlJ'll;

Remove '~hegee!r tlIox end

CIl;I!!/.er

rI'

Ft(l;mo'i,e

the

IilllJlls

aJnd the' fool ~ol1itl'QI

.,t. .f'

l'f it d'oe~:not

f:l:i!1I lilltll:O ~er InQI.J'~'al. Vile

rt9utr,al

s~opp'larte.

ntEUJliIlral1~!I]r¥in'IrB,ve~1 is leISS,

""
./ .f'

Loosen, UilCi a;tIj;us'tE!lr ph:,!!ltie.lph'il$_ Mo¥o the ~djlJ:s.tcr· pla~e ,BS Ir,eqlJliredl M (!I~e. It h fjl adJIJ s.~e~ pl'al:e Ill! : An'~icloeik wiSi's dh·leC~O.f'i 'm.o ,m,al<.'1lI! '1s.l gear 8rngSrQernen I. ,eaSliet'. '* Clock. wise dir,ecHon to make 21l'1d1. :)rd a IilId ,,'Iih gear e'ngliil glem'aln'f
e~:sle'F, Tigl'Jt<ern 'the Fi~: It! e

,to. filfS'~ !8l11!a~. 819 n;a;unl 'elY'eli 'ttJave~ morre• h~

I'r it ·~sses, Ithrough Llcose'liiI '~ihe s.~rew IOlJ n e Uhllllri ,B;E.{Iopp'e~
it: am

./"

a iil,d hun tin e ea m 1:0 cermet '~he travel o'f' 'It! e If!G;u~r,alinder f

e cee ntrtc

laver.
IREAiR CHA!IIN
S ~Al~ KNES:S AD\oJl!IIS·il~,EINT :

.I

ad.lu:sc.e.r

pila/t!!' IPillll.

'/.
./
;;t

Clilectk, s:laO'klness
Slelil::klru;~:s:s ~:o.,Ibel ,25, to 30 lin f'ill U

0/
,I'

Fi~ -rool. cOflih'ljJI~ sm1P pll~e 3ii!'!dnut

'ge.'ar' b.o.~ '~I!'idlC(JIV1er

,more cr
.......

181$$, ,a:djUllSlas

folllOW's :

G,[AR Q,PEitA T'CIFIl, SEblEICTO'R: ASSEMBi!:.'¥' AlDJUSirMENrr

Loosen!! ~he lcd,

0;(

in !ont·

T I g ki(:e!iil th(li !;JeanF ope ~ a!,~(iliI" :3! e. ~€IleJO,r a~sam~rly ifui'ly

e

.;

Lo oSien

the iliIlB'ar oplerat'Qr' :S€l~€lc.mr ~ull it

cliclii;s 'two ~1mQS.

~
./

TBghhm tille., rock flYI•

Cl1le'~ S:9ar shVftiEng.

nt 'ar'9b'~. loO\s~ (he

gear' olPe~,ekir by one m(ll~e cUet.

.;;r

iLoose n ~Iiil 1!'1I!JIt

,/
J"'

·S~inGeell' io 4tl1
Depf~ss Itle· nUilJutral1 l€l·ver,
hlFlliIlf'ig !rt9ar wlTlee«,

whller !!l,Qm1I~ly.

'(ie,ar ifil\omt 41h mLl!s,'~

{alii

r.nrm.o,u!Ei' neunl.
31

REAR, C;HAB.N
CI!;,E.A_N ~NG ANID LlJIiBRICA.1ICNl r"c,;JER:lIf 1O!l:~ KJfWS)

,~
-,/

Clean
o10tfJiL

~he; "haif!1 usi ng ,a cl'9ii31iilp~~;~e;[if

=

A~p~'y:SAE 2iOiW
Il:ihain ..

!SO ,oi~ml!erally

OIl

~hE!'

~'
0/

"f'

'If. I

. ILIrn!,j];:.,EI"\l!I!!l~~ e - ~~-""""',r

~;o,

""g_ms. an baiL'h sldes iI:iIl __ _

eh 3 IIII S,I.8I'clii:nlE!nS:$,

:2 5 to 30
adl'ill;ei!Jedi . ..; ClileekiiiJrndi

n'1II1f11

i:s,

R'¢'a:l\eJ,'~h~'lift! e:elllfli run t~!!!I ~a;n SIever.s'l ~1.rme·!S,. WI~~ .off '~he'e':ocee:s:s '011 II.IISi~ga dlesn dry cl'cdh.
A~R. RlCMOV:AJL : ~cVER.Y:i30moKMS)

en:s !.liTe' ~'tla~ ~11i1iiII'IlJlrnber or

nOh::~I!1I;S ;;mFiil the PUiI'I;!:h!

mart

O!l1 '.he C~ifii':I

to It1 e 11I!O!~ca, i\'les;~if'119 on ~tJ.'8i p!1llI alf'e' !I3;q1!ll81 01'1

ll:IilJ'~h:sidil;HiL

"

Wlli ill e refitti'ngl,

Olr

elns~ IDe ccfr,e(:.: C!lurec!ion

~Qck,Iin,k.

FIRO,~i ,F(U'tIK
IL. "'I!.!IIE'"",,U LE _ -=''''I~ _ ~ P1I"I~~L~,
-~-;I\~

• Jiel~,Ie'''''V <ion,'" • \!Ii:i:'" 1i:.rti.IIJ ~~!.! . .1

a K'Ii;Ii~~
-r ·I!'~'r.:II~1

./

l!Hang 'Ihel tl1l:aJi'n 'rIOt ,5 !m!iD1!ute:s,'~ ;a~IQIW' ~tj.i~

Ikeir'O$ii9:!i!i1i;!! '1:0dlf~lln.

,,f'

Check 0111eij,!\elw~thl :a :5 rnrn dl:a, rod ~

TIh_elewl to ~ e 37 to

.r

ae, mm

.E

Hela'~ gr~~.S'~ (m,y~tlipurlPQ.$;s')1:0 ~,20ol!'C

'')\nnM_~ ~, IF'r.'- ,. ;r,f'II

;;.' IPnaoe the 'an:alnl

.t'
,;I'

~tnemolten glrEliiase •

,Allow 1tJ,i~ greasel t'OI 000'11" R,e,!miil)V€! chain maim t~!91 '~rtI\a:s:~",

ot'

,ReIiliQW

lIJ't~ GX:eess ,®re~iSe

Hilled cle:an

tlmel

choSlin 'WJth a, IP~ace of dry tlo~h

,/'

R!9m@Ye

Spni'icg s1'!Jdi iiUld ~nd drain oIl

iilllil•

ligl!rtoD 'tihe :5l~~iI!l9 §i~Q,jd

.(" POIJlF

20~) fin I ,c;-r Me 10 W'~,30 0.11 ~a;ch in

~e9 ..

SHO ClK AiBSO RiBE!R,ADJUSTM ENT

,£

Irl!ta adjustlaF

at U'1Ie.[bottom ot ~l1e SPriJl91

k.ee'p tlie ,a;dIJY:5l~er .Elt 3r<l

~as '~e In;ol:c.~e:s.

F -I"

FO'f normal

1JS<!1,

!Fit and l6gJht~n ih:e IPltrgJ5creW_

i"Ii'l!I~h.

rn~l'l(lnmAS!E
~F-IfW."Qi 'T )]IO'f

,.I'

iWllm

me adju$t'tlr as

sh!JIwn in iIile ,~ic~!.I re

f'ili' ni'Ul:iII!l;3,S

Ing or redlu(:~l'rIg the $pril'llg

'be-tfl si01'1 ,

34

,,/

,/
./

dlt o :s.pliing ':e!'i$'iQlf'li ror h£t3l,!)' roOad ,8Illdi t,o.ugh n:Jidl o.per;aUoll1l. Rediuoo the :spring tension for smoo~h
!ftCret'!S!e jrdadl and. 10\'11' ~Qad ,ope.f'Bljon.

REAR SPIROICKEi IDRUI ,. BEARING,

'GREASING
,ot" "i"

(EViERY : '1.2~Q.OO tel'!.

s.,.

Re:movo 'tI'iIiIli' sll'~OClke.,(!lrum ,aISS9'ii'libly ..

Se'leoc" th~' same a(!]ju$'ter IPOS ltlen bOUil LH &. RH

'~O[,

P,ack 'Gmase •
R1!I1P~aoo 'greas.e ,51-EISI wi.'th

enoe " aDool"ib.;e\FS"

-/

naw.

WHE,EL, RIM
]1r/teE G'UT CiHi5,CKIINIG

,,/

Re.m ~h,e,s{pr(!u::ke:t ,9:sr;ambly.

IfROINf 18RAKE
ADJ U. 8t1M ~N]T

.I'

IP(EI roa:dilh6' di!:!!leauga

the r~m

OMI

to ~helfaee

,~r
.t

<:

,/

,Slowl,), ji'O'tal€l, 'lbe wl1eel.,

'IlU t.

.;- TliIEi b~lllIllfldreM~" lie'i;idlnglis Ihe lace

,.t

i'

Deprees.

ri"Oiil~ btake

lever fu I~' and. clITleG'k

,r:;Ii$tillnCQ ibo!l:v,re,en handg,rip

anti I'ever

Is ,20. • 3i1l rnm, fClllrnw.

If '!]iifl i$ rrH~;$.adjurG;1 as.

S8Nl'ce lLrimil : :2 mm

-/

Loosen iliha fock. nul at the LH for~ e-f'l.d

and] Wi'f! ~l!iIt 1.tI~ ali:Jj.IJls.l:er :S:Cl'ev~!' ~1'Ie ~II diiS-taiiiCl9 from tiro ke !',eVi!u' COlme$. 1:0' 20 1:0

inner
i'
,j'

-raoe,.
iirt€l' IiiUlFl;OUfti.

to l'Ialiill1 grip

,slowly lFCiliIile iltI6' wheel. The 'kl!'tall i!fid!Ic.arted re:agilTlg is Service Urii'i It : 2 IT'! m.

ao iirilin

RJEAJR.IBM.KlE,
PEIDAJIL HEU'S.HII .ADJ U,sUd clNT

~
cI'

l.oosen

Ilink roo li"Iul~ '1 &. s.

../' 1l..oo.5iiElO

'Iurn link. ii\od :2 as shown ,S!b.~v.e] ::; ~lmfjs.

..t
.,/'

Th.e· stlo.!1 i·ever" moves kYwardis [!'li~l;Ia~ positiO'li.

Appl,y the b rakt;ll iEI.nd Ik.ee.;p rt ~l:Iplle~.

'Ihe' Io.d. m.l~"

.,/

n~e lP~dal :SIOO\p- till 'ltl.e, Pl':nl IP'odlaill,and foot !'·es~ ·aii. ~1.lltlfl; ~same.lilV _ _"lI~lliderliltJe

ll.ilvn ~n,I Qut

y'"

lock [nl4ft.
'101 3.{l.

PEDAI..,PbAY·AD'J I SlMENl
P,et!1e!l1 play' 25 rnm

i/'

Th lis.

WQ

!.!lId 1!'!i!l!O VQl ~h e. s:IiI'Ot~. II ElfY'i!!I[r 4·

ttiwai"d'e· ~ppay d~r,eetJ!!m. ;/ S,l:<il[p hll~iillinEi 1II11T1:1!i: [rod

:2

Wf!IQn

hliQIlh
.,t'

reslsLar'l;e:e I~. ('(iU mr ~blmnr!l'l!ll"

T IU!f,!'!! ii iil/o IJa.'1.1''1<1:::

pedal play.,
iDII!""iI ~~-.

a'dtUrSl te r If!iUit

'r,o. r 00 rr as~

lighten

Ute I[nifc

rod iIl~l1$11,& :3..

LEVER PllrYtnr I UB,R!ICA irlON

(EVlelR.¥

"'KE F'~ ~-=D',l

AL-" ..

,-_.

BllIS'"
":__.__:_.l

:j"KliMK~:S:~

..;'

AP;P~Y '~.-W drops

of' Elngi'rLr9. ii:jojlj t 'the leVi&r a

p'iv:oC-

g,~

111:iII::I,Il!.-K:'E I

j"

,C=i!i; 1UI,~mi!j-= ~Kli"l~~_~,al

••

j!;,Ii:!!'II"JI~ ~\3

R.e!'fli1~O

~heb;r.riil~e· over j!illa~~, ¢

"" ./'

Clean the br,81ke, ,C'-am :9JffiI~ apply' gil'E'eiSii9'. RB'~a .co.'I,i'~\!" [pl-aw'Itle

srn:,ERllNi(;i PiLA V,ADJ US1iIMElNIl

(EVER¥ 3,0~Oi.K'MS)

./
0/'

Ke,ep al 'WOo{l1~npl~nk Il.!Indl~r nll~S!~and'.

Rioc'k 'llile '(ront end ,Sind '(eel] Iils pl'::i~tai~,

,S'~~m ·sn.d. top

,ii' ,J'

li9td~11 1iiI~,adm~lfmIp CIl.ll:sI!f!g ,;d~en :screw. ·Tt9tj,'~enlWOWfi pi atel bolts.

STIE,ERJIINGBALL ,RA}C:E: lU BFUC\A nO'NI

(~VEIR.1" 12',OWo. f,('~<S,~
.,t"

IDEC\OMPRESSO:R

'CAS,LE

1PlJl;,Y ADJ! U:5TME!M'Ii'

IRemovSi S.b~~>e.l~n.gtElli'n iiJj:sseil1flbly. $

cmcam IIndl tCtIlI'ck ~tJ.Q; IbBiIIIe., anti

!i,Ei,~~

.I'

Adj'Ulst 'Wi~11iI ~djiJst~r scr~

pl~y

'~jln4,

"to 5.

I1IUlfl

IhrQ,l,JlglTtiy

ter

d~mi;;ll{le:5

I pit'tings.,

I
>I"

at 11.aN!!lIil" Is

8chieVE!{I_

di!iOl:!Ii!liL! I1i'!liOfi_

iig hl,OilTl

'~ne ,10'0)1;

nul

C;A18,lE CUEANING
./ R emoye tine d ilrt with (k,e rCl'$e ne as
sm.o.Wf'i.
I!lEI'IBSE E

I ,/
r

I'ac;k ~ rease on Ihe OOI!omboll r_,

I
l'
WHIEEIIL ,Al.IGNM ENrT CH Eel(

I!

"

f'aa:: g:re.:ase Ollll Ihe

Assemrtlle

IO~'

balllll'.;Ioe,

"

Ull!i[!l 'te,ering i5ilem_ S

./

ifHold 'the, vehicle

OJ'! ill

i.Jprighl, of~ the standi

le\ileL gi'l)il!Indi

36

./

S,~r~I:oh

,;iI

s~lfilng ~ibo IJI~, '1 ®O mliB ,a'OOWl9iIt! e;

'U'IGi

g,f'QlJlld alon!]

wheel3.

Ilf .tle 5.tri'ng IQuches onl~ It! Fee poinlJ5. t he

't"'.!'j'11J

O'JI!

wh eals, the
re;8ilj'

,i!fj

IigrH'Jliie'n I; i is

II'r'Ihe s~rililgi '~oli.!loh!l!ls po'ilfll.s en 1iiliE!' I~~r 'iwo'

whee III;);uild 'lW~ ~01fitS; ,01111 the if>tO!1lt

iin;oo~~ell:lt
'" Ad]Uls i: the
pO!iin'l$.

whe;e,i

wl1ne'i9". w i~h elh~lill'll

'lOilJ!Ohe:so 'r,out

(Four point oonlii1Cit) UlIiIi!i(flj 'whe!f!lls aria lK11e. a!iSf:!ed-

;aJdjIl.lS~i9ii" Call'lill tlill '~Il!81 string

1,

iEI"iIS,Y ~Q",

'!OEll 'i;I\0.h Ild,e

IHIli,eds

'1111113' 91i"'V (::19 y~u :5i

Ci:iililt\ _ mpl:a't:~ by

proper inves:tig\~uOiITI and: i Ilalysis

2. KrQep, U'iQ. v'eJhjele

W'On::. P~e'

on

iii

ifil,fIil,p so as 1.0. :stall'ilc :ti!i11il

wonk, f.aSftof ilhi:$ 'way.

3.. Arrrii,nge pe,rits: 119ffiO'v.oed In bay,G .. n~aUy4. ,lnsJ,peGt aU Pf!lrl:Sl", ,deClldQ It!iE:! parts 'YO!.!! needl

rot

seii'V e flEl ,Sind IProeliffl [to On~' then isla lit e!551embly.

5~ C,lhEl'IEHl!

~IH eem p'oneli1litlSl ('I >l:(le: p't, r'lJJb be r' i!llllid

"Ill

e1ecUiica1lllafts)

clean kefosenll

oill mll<e;dl

wUtfl

2,% IEnglne oil.

6,. Never
"1.

YIlSG

panni for deanin!), t,t is !Cosllrer and]

~~'IPMT~ HBI!.RY

h.ai2: 0 Ifd 0. Il.I $.

Alp:ptry I!IJbJ~8ibi!19 lOll gn pi$b)n. p1s:ton, r ng, and

c.yUl'ilthu Dlflfe before arase,mbly ..

_-

;l!,1f1;,i1,

9. A:ppltlf ,0[1 IOn 'tlu'l9ads of D.tlilts a nd nuts" 110"Re;pla(;~' washers, seals" s.askets ,and c~li,olips
wlilile"O!jl(l!rllila!;.!!li'n91.
1 t J!dways, !Jsa lright IODls while 'Work f,e s~er.
s.Cil1ew8."
$.~lf~1l'

w!Jrkllrc ~o' maim: '~he:

i0indl

d1epell1tiat!ile.

t2'" USIa ilm,p.act 5c~,e!W !:U,i'iv'e.r ro:r Jooo€lnln'91 .Jammed

1.3" HeatUle ~JIUlilillnrlJm bil::i!lrlng oores

fiJI[ femOI!,i'a.~,i!lnd

"sl'H~Nn'tdy or be.arlngs.

1141" IEinsllJlre. :e.e..alin{jl ,8umia,Ces. :a~e c~eBfi, andl rre~,'r~~m

Sooriimlg ,aJiilO warillagre. 11,5.,Wnelll ush1!'9Iliql'!l~d '9:E1:51ket" EUilSu.ue

ft dli;)!!lils !!lot

,nijiW

Inm illle ithreadilIld !holes.

1[16..While
,9SS(l'Iin'bllIllQI,

,ensure,

*'
'it

'*

Arn:Mi' nun!!;; ,alii Ute p:ls!on. (;aca:s emalJJls~ ~s~(f!Q. Tt!e ~lPetileM of 'the chal'nt [lock kI: face ,oppC!~ue tQ I!lorm:el ,di~ec.Uon O'~ chain a'Ji;)!~ltlon.
The; ftlU.mbel!l·'O'rn~lttllG'~ ~'romitlle punch marts

'

~l~

........

or '!tI,~chain iiidjllJSler cams to. 'Ilmel I'lok:h: r&:diIl'll9 OFi! Ihe pili'll ,Ellie to be !G(llJal ,811 ,& RH :5id~s. LH

17'. 'Check 'fo~

1 ,~, 'TigM~flI

lto;nri!lC:Iil"!!E!lSS

Q'i ,;:Jssf::mniJit!i',iillker each

'~O c;.ofrec.t

!S:1:ag9'.

:alilnYII:s, and

IbOllts,

'loD'J'\!il,U sa
S19ifl

1 '91.

AJliW,aty.s

:smea,~' il 0'1" 9rEN!:ISiE!! on '~he011 o

O;l,Jlt~if

n~s
achieve

be~on;!!!1fI!5~amrng.

Z{l!. A~p~y spelCifH en

lileU)iH' se~,lilng"

S!l.Jrface,
,~111

or Si9:9!rs
dI grealae.

itO

2'1. iUls!Il only Il"~GOliT!me!iildledl,011s

:22. We',ar 'g0919 Delis,alffidi

lni.a,diltne,

~IIO'M'QS

whi ile us ilngl 9 rilil

dii I1g

,2l. I~$e rl!lbb(l;r apiiO~:S whi 10wQcMkirmg on ba,t~eries. :2~,.1i{;j3'1!!1 p ,a b o,'~;~~~,,of W,8ig,nliin.gl 50dl!ti!

w.a~e~ SQ.lilIUOiFII

ft~tro ., ,~O glm~ to i(m~ ~~tr~ warier} ha"'~r a~ ba!Me~ ,cJiJ:a rglng ,~lrfN:'!o ~ilue ~n calS(1; ~r ai!Jci:del1itSl~ b!Ml:e~
,i!cG~ :e;'pllnag'i3!.

BliIIICl~S~M~

(!jl!.:!idle

'C:)OM~ONIEIN'fS liNSPECTIIO~1
OILE'AJ\~~NG
.:*

tlINi'f .:rnm

MJ](. 2.% ~llIg!nBl '(lilll~th elean ilreroSClaiJ !ol~

.• C3~.a11i all oomJ~fIlell1ils liI'II'U!ie .abO·vel :sollilUtin ':iIi:' IDil'j' i1h!'1:;mJ wlitillltlrt oomp~e5l~edair

~_.-' .-..._,.,

~O~·
... ..= -.-~..!....

.. s.

I~'S,P'EOTION
Vlsl!iatiy iilil~PG~t .he Ico.mpgnemJL~ lQII the IQI10'r.lfng :.

*' Brea~s *. Cii21cb *. ScOring

'dI!:' 'dIi:'

*. S'EliEurJi}.rmm~_i9:
18End

Seuffi'J1Iil

'*f~t *-

*. PiUi'ng
C'{iflFOSSOOIil

*. 1Di:'«Io:lo.1mttkm
n rooool,ok. oheCk dimE!lI!Isio:n:a1~ifl!i!n!;Si .as; follow$ :
._ fI;.j'ewOOIlllpilfl€IlII-S,' dJlll11eruslo~~,itO be be~el1!! !'!ie-w ",iniif'li'l.\irn'i, ~nd now' ma:&mJl~
lim!!:s

.•, R.epl:i!ice (lkjl paQ lbey.Qnd ~~ _. _lDim~nJSaoflS: 31!E!' ~nmLllil'Jlieters

(m.m)

I~W

[Mil\.

!llDiiII
~1lW K111

!l.4iJM_liiing

~ew·~~
?:ti~limn

iI)i.W§

,Oj~n
'0,'I71!i

!l'-Q:;I~

o];iz-· -

sss
-

ijIl,05:7
O,'~7~

J!.~O iOJO:2JS Oiil!:i"t

O.t.~

~u:s.

1~1

,~----:~--i~~~~=O"""~"&3tS::"'.-,+-, ~~~"";;"';~~'!lI~·.3~i'C~ =

,/\ ~OO

!MIn. I
1:1:

I lBlul

13.!50 0,1! [0[.33,

A 300

1~~~~~~~~O~.5~,O~I-=~~~~~o~,!O~,-i .00 I '~.'OO _O,,_!_

~
Si':i'VK:e;L

1D~:r-

e.ss

e.ss

iQ.'sr

OIiS;O <0.001

20..01

1'9.1"

19.. 11

0.10.$
Q,cri"~

I I

F~' ~It~'~uliIal.>!)lIiliS
j)if,

~MJ 100 (]~11i'

;&prejd

~i"i i!:WifIli,"

,~I:e

SUIiOI 8elN!{:e Guid e

UNtil':
Im'Ii

la--.iI

:s5Q; I

!S'oo.
0.00 0.02

"2
o.tf:f.

0.1;11:1

[~IrLtlingl ~5 I Al:5O OJ]o. I 0.00

o..i,II~

o:::O~
O'!

om
O.G!5

[MAfw iiMi,

:50:0 "ii.itO 4 ..80' ,41JOO' 45

,A'3i§O ';.j!'(jl

~_I~O

.tl_o.o

O:A'O

~M'

8.ulle~ Servire Qiuide

UNIT: rnrn

I Bl.:Il 3:50

:!.()O

S.DIJ

s.ee

PiO JS

GOOD

!New Mln_ !New M8X. ·~!eer.;IT'Ii

eUlI~€lJtSe.'I"vice GlUliide UNIT:mm

0.. 11 il)
~~@

S(lO 0.00 0.10 0.20

li.[gb'lli(

iii U§..

A:l§O

0.00.
0.10 0.2:0-

0.00 0.' 10 0.2.0

O.gg
O,O~

B!.!!lIet Sell'\lice 'G~~d~ UNIT: i!mn

gii! ~$Q'

~QO
~
·41

!"ig!,!~jlj!'rlm :50~5

~ ,,;.

~
o1i

A:38l! :iil

'i

'I

~.B'H!' iMlm.

2:

-zis, Nil

roo

RICH '1 .

'TOO LEAN Engine over heaillS

J. 4_

IBlaQ'k ,caJtiOrl! aoctimJWlra:tioo OJ'i 5P8IIl"tk.plug lip

Ic:t«lElsstVi9'
p.(l1ffOIr1Ffl~'

3~ 4.

'WhitiSh sPaJrkp.'-ugl tip, Ernatic',engifle ruhrlfng ~nd jijiiiktng

Engil"i_E!'lruns

blU['$n wti ils :s~ke

5..

im,p.rov~ on

fij'ffl0

V'a:1 f iii! ir '~Iler o

5.

bel~er wJiJ~1'Ii choika ros "OPf.

1----4----+----~1_---_f_----..,'~

!i.1I<D:IU!!I!iI:

,~;:;ml:ilL!:Ii!.'U!b'liII
mJIlJtli!~1i!

iF'!lJINC1'IO(NI ::

j;o m~~ll't~lln a p ji'$d'e;hHm~nea petrol in 'rJoa:t ch9irnbew.

:i;

~evel ,Of

FUEl.. IF LOW

Pe't~ 'ta!f'ilk~.".....'i,i!lJp
CarbUirE·tor

m ......

'

Hose

,,~.-+,

ill1h::it ~..... ' Flai!3,t VaJ~ ,----- -

,:a.
,~

~!!-&lfIi!l '!o!!iI\fi!'

..

~
fIMj

.;;.

di£iI'fi tot t

STAR.lU~IG ,SYSTE,M:
f'i!JJf\I)C,fION :: 110 SUlPpny adtflHoo:e1 !l)ei!rOl i_C! ~mpi9f!~a!rl P,IL,OW:i
,Air Milttilile

'tm~,,ooJi.del1lsali'Ol1 of pe;rol '~hen eFl{!ine lis,cdld.

"fUt}

pe-ft

II Ven~)J~

.[J.

1. ~fI :2. .sUiiil~~j ::3. IEI'I'iilLlbi'ii

~iJ Il;ri

i5. .!UI ,lnI.i'loi~!PmriI 'ili. iC~

di~i'itI'bM

IFUlNCllC1N ~: itO sUpp~' Air pe'rol m'ixty~ ~,too en~line 'WorD 0 to, i4 d1rome pos:JliIlr
f',~j)'~ I I '"' a;·II'!"Jt ''i;'je"

~age

!I;.I,~

!lJL.

,Clflaifli\be-r

RQart

$.. B,)J!M:Ii orm!}ll ·4. IP~'~~~1

~

15..iPkiljill
$. Ani' ,ICHiw 1. J'tIt l'!IIIitdh!1

2'.

Mi!i~ ;d]iliWilj;3j

~~

:3. Mi!iIl'l\Jlit

~. l!:m~~JQn!1Jb~
~. ~jjj

i!!Jr F-'l!I:mrII11

'it AIr JQ~

[~tnNCiIl10;N::
TCII t5lU;p~I;Y petro'J mi:i:!il.lre air

10 theeefl~ine

flfQlil11 ~

t@ (tlU thn)Wie op-e.n

~l~~"

FLOW' :~ (AIr)

AJ~'

ViM_run II

..

~·n,ol[ A~n' P,ertrol mlxti!JirQ

l!:'1

'.

'THlROITLIE, POSIiTION

IIL$aidAcid l8:attlBty has IP'Q$ii1ive ~eiltE!!$,

S!Il!pilli',a.ro:r

• Lead peliQ)i;iile - Made of irlSulBitllmg ma!'e\lim

Negnil,ile plate
lE~clroly~~

,~ ,Sponge' reatJl S:ulp2HJri'(i ai;~1

'*, DI':s.tiill!i:rtllwa~er"

B~tl~rystores elec~rica~ energy ~i'1I t~12: 1\~rml of Cinel'liUCi!! ener'!lY,. Fu!Ly C-I1arged tJallBf)!' \loltage 2:.2 pe~ iW"1I ~u1I¥ dls~h,~u'ij~dDaRei)' ¥OHs,ge1 ,,'1'5 ~~_r'CEi[1
Amiper;e
HOI!l!I':S,

,(A!HI' indicart9

:ti)ij:

catp.a)~lity Of"thi!l

ba;tte'ry, to 'OOJlFI;E!; ito ~'ully iJns~her.g;ed ~om:lIUon

Amp;li:r,e Hour ~:.A!HI) D:i':s<ct!atglttg c~mrellll:(A,i'x Di!9chilrgiri~ tiours (lH) ;;;;: lEg :: 1(I, A.H mei!n$lti~t I't'~ak~~ 1I1(b 1"13, :E! "ulr('j' c~'1ged 1191' '["Oil'

drro'h:argied oollltlUtll,J(lusly at 3 OOr1$.'lial1't r3~e

ar OJ'Iiij alllilpelie

battBiJ)i'
l ..

wttfllfl

"OTE

: Uliis i!1\Pof1::anl.l0 ensure iha~ '~lne a u·lilhur.lc acid s added to the disti lied 'W.ate~ ran _ riot 'oIke versa. S'~ir:;lInd check the' spe~iflc gmvirty Or eU~¢lml~OO .and add SIIJ lp;hlJlIr~c acid till rl e spc9clililc Qi';aMi!y bacornes ~,240

1limper~tu ro cd' ehirl1c:trclyt·· :

Goall 'tha: iIlll~ctro'ly,L'e' llO aooul. 40 (:Ileg. C l::Iei'Oi"ei ~1111m91 U'IG baUef)!' !UlP~O the mE!i):jml!..i'i'i'i ~e'l.i'l9l l1Idi;:a~e!j ~lln ~

or 2to

'~11i m 9ti10Yl'l the p-a~e6·.

SQiIlk.l ng pell"l;od : Ikc~p 'tl't.elb:::rUi!!'y wi~1'iGilec~roly~e m~ed aOObn. t;a~t a I'l hour befCl,re (iOmmenCEI"i''Iilerit rOT IbIpGU:11IC ve I wmil eleC'ti'tl~yt!9 ,Ii n !ll!Oes.siii'Y, T"'!9111 11:H11. I them Ol:li ~~arge', or ,;:half{l!ltlg, f,oP

10 ho.urs

.tlhia II'g~,lfigl:
:;;':;ena rge
ill

tlIs,·ecllballter!P' W't!,el1 Ulie is.,peci~ic 9iiaJjflny of ele!C~rolyle ul",e' ;

is. lless 'tfileu, '1 ,:220

a:h~r'9~11'll9Procca
i,

T~' up 'the ~ectFoJllfM!i lovel with d iSli!ledl wal;El1i"

2.
'3_ "\'I., 5. 6,

Co.nne~t tile IP-o.5litive· a.nd Iile.illi\i!li~ ~efmii'ials o-P'batte.ry. Ie} the pil)$m~e and! frlG'9Iai.hi'iE!l ~entii!in9JISi '0-11'
lltl~ cQrtls;lalilll eurrent bauery dharger. Keep 8:11barUery filler' ea ps O'J}en. Sw.il.On.o~
(fI.g

,pow ·r ONK;!fF s;'iillCl'! and. f'I:$Uffl 'tlll.:iii ~tJe ,oo·9l1"g,eli' is OPG·.ramhre.

SwHch O~ U~i!Ii eha rtll[n.;g ON/OFF s·'lNih:~h

O,ISOOl'llllec~ Ine batt,elfl/ "'Ii'OM lihe ,ohar>Qer wimen 1'1.1 Iy

chafged ..

F~Q'1'.li g:a 6i8hllg .2',

'~rorne·le·"ti'QI~I:e1 ~i:)r'more ~h;al1i9Cll mi!llJlJle:il!, '1J~!!'Il(J1$p:B(;mC

3, c,oI1lSlactuliiv.e reaJd!ingi ta~1!II1ITIn rillt~rvaJs, 0' ;301 Inflirili.!iil:es, each ~~ re,ad constantly i
gt~lty, Volta9i3 : 6V B.ar~le!)i' ~16,6 V; 1.2"1BatteiY ~13.2 V

3,

2,.
3., 4·.

!Use !Oi'iIly oon!9,tant~CU"'EI!n'~ b~lt~ery d'l:arg·~r of correet NeiY!Elr i"!emo-ve 'Ilmel IiIler .~p S9al:s,; 'HII 'you whe·n S!Unospil'til!iric: alr o!Jli1ta~· ~he. pl~~e$-

(:Iil~ rgirll91

ra!le.

are r,e:ady '!o ChsU'ge lhe battory ,.HydraUoi"! m~., OCCt!l~

Keepl ~iil ililllfhF caps

"amoved whlhol ~tn~lrgIn'~'.

,s,
IS. 1'"

Use onlv diratilled water '~o'to,!, ulP 'moe levell alit,er ILheinnis I char'Sl fl,g. Curin9
1

lli 9 cliliiilrglrngi to oooillil"'~j elecl~yte-

cnliiiugili1g'" Ihe rj)!rI~oeilJoly.te~el11p.err:!iilt!tl'e ,s;houldl !l'rI!l)'t e~(H!1t~d ~.5.;"c. ~f f1119.Csssapt, diS(Xln'tiflru:e

Eru1iufe. !hal; ~he ba~1)eii'l,e:s·:a.r~i,kep'~'on

:a no.liI..Ii'i'u:!·taHit SI!.u1~:oa wf'i lie cnl!lr{lllfllg.,

'WlnUe Jb:;ilfllQ

a
:E1t.

K.ee,p. 'rire undl5p.aJfI(

SfWi!IIlI '[rom 1:!'8;tte.ry ctIJ:E!'Fgi!J'irg IC!!meIJ.

,V!JDe to ~lTie balh::ry'.

Be' :$lJIr~ t'O

oor1re...c.U!f ,. Avoid

caj'JlliU3(:~ th0 IQ~g vent

~l to'

~hel rrnOi'Q:rC)rl; ~

I~'!.i'!\~ it

Q,

iii;ll'miJi1J91

'tll1e m¢:tor~le·

witllo!.1t eonlr\ec-tif'l£i ~he baittery.

1. ell ee'k ~l'ie:,e.llectro.~y't'e le,vel and ~'(i!P ir necesaa lI,p"

IY'10 th.e mark cr 2 to 4 mm albO'!,!le the :6iep'a r~hit

1

,\fiU1J dr"iilliedl water every 'w~l2k,

2,
J,

I~ee

I·

baUer)"

su,rn:aoe dean

;311111 ~ry.
l

Never 'O\lri!l!r Gha rge ~he b;at~ery • ~ dl81magifls '6rJ e m!!i1!Uery.

Is· not in

'':;'' Reii!'1ov~' Ihe baiter}!' ~'JiOm'the llIlokllrc),coj'e and IS!'or'el II :sapalfatG:lr when itihe mO'!Qn;ycll,ij o.pe (:',aUOn for IfnQ!l'{l; lttalITl lillie monlJ1;
·5,. Recharge

,elOred Ibetteil'n~S'enoe

!H

m.o!'!lln,
011

6,,, CI10ek the :l'eii.minal:s; and ~Iblles for corrosion. Appiy pe~j()~eiIJm Jelly

Lernminals

'fo lPl'"evernt

oorms.io.n.

H:r~l:er is, IIlISle~ to check :~dl1c gmvi1yo.~'~" The 'RDal. Q nadoa!ion in ll!lilvel w~lh title· el'eCi' Ol)li'te ln iit is ~ne.speCifiC: [!lJfB'liuty 0.1 ~EIi ehEiic:troly~Q_
j,

'The :ae~i'i'a mMeil'ials, ln ~he plii1l~eSia r'!Q ClOlnverl.f1dlllflit.o lead supfJliu,e during discha.rge· ..T~i$. le,ad .sulphate lis l~oor,Hi€:ne,d ro .fICitive lib"Ial~rullli[ls dl!llrirngl recflalige·, Ilnh~ balt,(j;il"Y 1I~~II1i:S: In d~s<ohariged oolrldiiiion (or ICing perio'CI s lOr' ~:;u::e:s.sq,u8111U1y o~acid I; II.n81~d In ~he e{h8iitrol)!1te. Ute lerald :sulphate' Is converte-d '~O han:! cryslaltin:e $Wlbsiarnoe. Tfili'5i lis s~lpl'1aUcm.
Su~~hial.ed banerhl,:l:8 do ili;g~lak;e 1i,01i1f'lile! I ct"illI~!!ig II;!~. dllillrlng cha.rglng tne. lead! :$YI1Pha~e ~Yi!!mot 91e~ Hl·converted t'o. active' ma~er,ialg:.s.uc~ lbal~telTiie',s. may show nmmal VG tage w'tl"! o!Jlload. but do riot ~ake

~ood ..

ihe. posiluve ,9iii1d lF1JegaUve plall:ij!s; remain .suDmerged ln eledmolyte. [H,~¥er. 'lUhlen eie.(;~ro~e ~evel is: lndica~EIi, iLhe iIi!(:live Ii!ilSi~,e.rlii!1[i,l$ on Ule p i!lI~e germ.expcse"dllO atmospheric .aii!"..The :ac~&vama~l3lrJ;aj~; ·~he.nreacHs rMlllh wa~ter''Ilapol.l~· Q'Fi 'the atmesphere, rlDrrnlng whUa spots. on ~hl2'pli:lkl' .. Thl~ Is hi)'''dralion ..
~es:s:'UiJan 'the' miiilimum

The' a~ti'!.l'~· mal.erj:al of tf'!,e plait~:s f.a]lIil!':l91of~ is, .sltiedld~i'ig. OveF ·chalrg;lfII9 .and Irough] mt8ndlllin91 are tm.e rnaIn CiIUJIS{l'S, '~or'it [Over dhargJn~ Qf Ute Iba~t·ery also malt' CtallJlSIll! bblckl~ng I',;il( 'U'I e prSlt<es. reli"idei'ing ~m.iE! baUery LJn:se.'rviceabl~·. Over c.nargrjJilg1 means c.nargl'ng o.f I.he b.a,nery wntr eXC;Qss.IV0 C _ rrent.

.s.part Pill 9 ms, a v~~i pari_ of II'gnUI'g.;n ,1ii1,y.,5II-em.iThey ore $UbJeCil~d to !h gil Q:lmlmstlofll !pFessllrre (e Il)und ,4il1 limei6i Itt!} iIlIJlllOi!).M'roo [pf'e!S'Sl!!~'i9.i), ~!i'uelilse lh[j;a~~f!f'I0.l\e rltJif!1I1I 2000 ,~g.(:,_ I,mpen~ut$)' and sCII,I\ere vibrn'Ul;;'!ns" IIJ$~ gf ~cifl9.di SPalrk,plug] ij!5 U'lcrnriore very i!l'!;iXliit!li!il~ 'r!:f! gMd parformll!fl~e: 0'"' an engli'lo..

Thel ~ark P.l'lfi!IIl ~5i:!iI~rcd :!I4Jctil ltha:t Its i;i Il!;!!klrOOEiI;l,'W11l1rl~:t~nd IDs, '!j, - _ rralln£ll t~rn~fl twes ,or the e,ngilil8; ~ ll'i(Jt e;J'hOliglh 1:0'

prev,ernUllul1ng hblt~!dl eti!1l~

W' iiJli05d agio 'niiioo.

:S~If~ pllllg wIlth larg(!l ff'iii!i!DI:a:II!:t! i_p ~!.Irllllla

el'c.dliod'e., lfema:'ln h~u:ar.

,!ilif!e:a.

C.~nti'iil

S,p.IIl\k, plug wibh J9!$$, in:!ul ~o.r~p ;lii1u~a,oe fllJe, eCilU ~ ~04s fiis-~r.

,m

el~l]\ode

11..Nmma~ tUillii'flQ. boll1l In elty ,and hlgD:!~ay 2. M05lIJy ~IDp and 'go ci. y. crMng 3" Ml)6!t~ iholllyY b~~;n!i19. tl:5t~nii'ilstll h~ ml:G;p~m1 s

~"rma~ feco!"mmend\E!tio!li U'..s:ehotter pluS

US'EIie»:ldeir ~~Llg

IBillow 4S0 deglC C~l!l!ile ,4.00de~.C ~50 ,~o,~5.0de9.c': 800' ~e!}-C

Jlli~ilO ,8.;5.(1'

Raped s~a!'fi:: plug] f~jjl'ii1g i'eadln:g]l'll mlSlrlling _, iUs'(!; of :s.p-attPI~ ~der Si91r oleanlng

1!Jh~1li r,e:qulred
•

'~empf3;iiatUt

Normal. iEilllrns OOO!1I~l!!ltlio.nl ~a;~ilIiU(JSttN3~'Come iil!i oonitall:Jt: Vlilh C:~iJiC'b~od.Les. Remahl 'coli1!11i fOJ~~iil91 [pB'rk!;d's.

~ ADw; ignitiOO 'temp~rauue.

Ca uses pre·r{lJ1iUO!l1. etec:trode • meldn!;J. ulild b\1[LSI.ers OJli Ifi:so!i181~F $utt.aQe. u'se or s(~r~ pf''!.iiS nottg;r ttJ3!111 requirea.

de(w-C c';au~

Bullo ,

.sN

ce 8u[t! o

)(

(:)!Ilnder ,head threadl, E~rHl

C~i1ban, depo.$i~ on e pilSed U"ire,ad. A,emov,aIl (II ~!Jg .lrom c.-yl[ooer he.aOl da.mag€!s . liUOO I!I' de' o

9iM-S (l1!.i'!!!if ti'leii!llect

;Ir

Ov.er he~:thl1lg ~re·lgniitiol'il Darn s. , e' to

p[-S~0rJ

.*
'K' 'JilT

.spad;, plugl r,em,cwal (:Ii'moull:

'*
iir.'
JI!f

StaJ~jnSl ~u'l)tl~m
f/wIH:~Airir'ii~

IbIlUi'C'IJH in li'tlri's-t '01 fj@~

Spel

rli;,~IY9

(II1JlE!!

te re.:sldue on cylil"lde

r' [Mad ifl'hreaJds.

1,

II),ark B own

ve

161'01.· n

, .' INQl'm<aJ~m'j}1.!s~1 C<11

. C(lI'I'!aii:lt

lOw iEh'l)W,i"iI

IIIJn.Jl1r!g of engililli;l

ll;;Jiht BiJOWfl, G reyieh [Br'(llLVi'!

2,
Slh'llliflg [M~Ck WM

- Oil 'foulmg ... [Oil tB·akage

['0'

ce r . on delPoirsl:S:
:l Wll'Jil.\$tJ Bf~f]I to Whitlsn Grey

(:o!ifi~!.ial.ion <:iI'llmlter,

... Eng 110' ~ HlI!1ll'lf!gln sllghtlv Q\i'!erhe,!ij,'te.d r=~~;,;;;;",:::""",-._' con!ji~ion

4, Du11 til!!,SIC Ii:: " 'lj,IIe!,Vii)lIly carbon (i)e',pGslI.s:

*"

'* T'co r,i~

5.. iM~itC,d eII;!lO'i'i~t1Ie and bJismred porcelain

*" Corc;l!I!Jil' G~ar.k plJug lover I!leated il\!iilllgili'Llli and overne:awdl

*- low H.T. v(ld(;.a;- EI' :
pllbj _ chJ{iit'O

*' E~:(~$'SiiM.1;!i ,e;IGii:iCr.OOE!' !!lap.

*" Coiitlfml!o~!9,

ail pw.tKi4 IFIilb:~Uro. Re!arnii:!I!!i iglidltJem timi'r1g1

!Q.\!f.
$jp (lild!

o.P.OtaliOA

spal11<,

'. USIi1I0'" i!l:!ngelr lFe:aC1i $,pa1nll: plug! IE ~:!!I:sI're C!lfttlOll (f<e!poslt lilTIcylinder OF exl"ulu.!!st aysmm. '•. 'i!''oo., far adva need! ~!ln.iuonIiml'n.g.

*" Use ,~f'!ho.t s;~ark lpilu;

.
'

... TIOO'Ileiilln air

pe't~ mb:lure

i'4agJe.e~ilf1g the :t;.j)a rk pll!J;~ mairt~a1la'!1ce J9'iE1nllla[ly leaes '~o iJjifffiOiJlt sta rilfig of! n.d ,pO 0 Ii' p'&rt'(Jr~ iiloe', I' the i5ip~rkpiug i:S"lJ\sedfor ,a Jong panodi 'lttIiil.el~lrwe9ra(!\Jaiiy burns, 8w,a)",an-d ~JfDOlillbuilds IJP,a:ionc' 1M InaldG ~m1, Ol!iCe in ~OOO iKrf.ts or ,el.:rIle.r. 'Ilile ~tu91 :s;lIlouldllt!e 1f\elIF1l1O'W'E1' '~ii' ~1"I:S:(:iie~:H(!IIm. sle!il!rlir]9 ~i'I;dl ~se'r~ii1g ~!'Iel'gSi~-

Calf!)o:n dC!postr~5: on 'tifie 'Slpal1:; iP1u9. ;e',:f:atJ!ishe:s, a i~hUlI,n'be ween (;ef\h~r and aa:l1ih eJ!e~odle<~. 'llI1at i!iMve~l-S gooCi ,sparlkr.ng and eauses m~Si'IiJii'!g" CiQalll '~I!Je. deposits· Itlll ~etiodl~al~)!', ~ithi a ,epa~k pt.USI d&iJllIr!l'l:9 '!'oQl/m~ctJin!li!. C~I!lC~. spark pl1ug r'or wom oul: ccritn !f!!nd el!rvlle..re~ee.nd!ls, n the ,ear!l1 ele.elr(ld'i]1 ; 19d'ge .a.nOrenter ere(:~r'Odel MIlas: ,'educed, in tU3r:g:ht" li"eplaIC'€l It ~~h new. has \"IOoJ'11 ff to ,a'knife o
l

EL[ECT\A,~C,Alii OOMP'OINE,NTS

~[NS[PECTiliO[N

Y A V \I"

Sla.oll' Coil OlJiPIJI, wi re' COIOlllij"$,

V W
G y
A

·Vio.~et

VVhite GIII",e.e'l1

Y,eII01,"I
AmbiBif

~,

II y.' ~ EAIRTH

I~'

, V ~ If

II Y'·A

I ~I~'I[),5· to., 0.7' Ohms, I

J ----t II 0).,,5, to. 0.7' Ohms

Iw
~.

.. G

I ~.0",5
II

h'jl

1.0 Ohms
Ohms]

G,ID 1,0 2.0

1

ACI\j)s.~,'-'if

& 'Ilt, wlh head! mghts 'on, al :20ill0 CQnflec~ V w(th "G'_ Across VG.& W, wHh hB',aa Ighl:s 0111. at 200.0 npm, minimum O\,it~pl"lt ~ ~3 wits

rpm, min'im'Um !!Jul.put .' 1·j volllS" ,ACf'!lSS'V~& "V'; '",un Tranica.l.Or ;and :stop !amp
on .aft 2000 rpm ~.mF'iimUIiIil o.u~Pl!\ 13 Vo~~. ~

:2 EMil OFF
IQ~
I~

,4,

18,

S'

1'1

'~3,

11S

OfF

'I

I (lrfl
H;Jlil

I~,
I I
0-

-,d

ill.

RI

II ..-

....

'

~,

'

'C'OfiUfLul~y bet'l,l're~n terrniliie!!l:s iS~ S!M~ C'O!'i!Unw~y,~'l.m:!J.n [>s;rm,illl1ii!ilts,no!' conl!le~d No, conUnli.!l!¥ ba~~e:efi!'t.iIi!lliiml'nah;;, 'i:Of1li1l€G!_ool

__
~.-==

:SWnCH O!<~
SHO~rM!/'I~ OflE R,;~ C:I~C~ II'lF

SWlrTCIi

__

INOT"OK

~ Clean 'tne e-leo~es ;artd set gilip ro, ®.s ntiii'Ii ~ CI!OI;!iH Ute p11JQ1 iilill !Hi ;Spatk pfug ,cJaan;@i[;QlI1lO 1I"€sber' ~'Tes~, p3iJg ~w~lro:pe\f i3p8J~inllg in ~e les~sr 'the
I"

!Llgtl!l: ~IMe'. :solld, oorrHruJQUs SPi!~1t ISEIElI'!n U'l19' i [l'Ii\irrfOr of ~he;tes~I';l:~'

m' ,side

.$p:A.RI< RUG
'OK.

II Yi~J~.zywr [red :5pait; If!w\l'mIit1~l1Il~ rIO spark: e

t5:,park iSS, SE!U;(!!iiI In 'ilh;e ~e5!te~mntor

SPAJRK PLUG NOT aM,

~A~'~~

qF'G,~1I1r"

~I;"!; 1(;

~:EJO

~I-~

"",'jjj'ITY' ,,e;,,,,,,~ i~,Ii1~, .. n, Pi' - '.~ \~di "'Il..!IIE'CL'"

Primary'vdoding r,e:llij;M)ajtOe {A.~~),~ 1:04 Ohms, Seooflclary' Wiilldffl,Q1 re:5ii!S'talil~e (A.,IC} 7 [10< 8

~ml) Ohm$

,.,VE iF'O
"'fOUC:H I I

'" ViETO
'TOIIJj C H

,~NIDleA'fIC'~
SHOU ILD 1f3IE

V 16
¥
181

Rtf'

O~I ON

,S'EIle;cI, HM meber (Otrm S~~te:).1 mllJl[~me~:ef O in Dis-'l:lharge IMe 'CO!ld!9fi~e:r by 't'(jiLf,nclIil'n IUS ~ 'wilIh iDS, lead Tooch CoO iildell5'ef',;:!, body With on;e ~be' aJf'!dl OOfiich!lli'ilsat':$ le",§!I~~irn iItle olJ1le~ !PftItJ~ ~1lti~, myltlimf)l~il'_ The muljfjlln~bl}rll1Ieedle dle'mects ,Sind !l'E!il\j~J1!S -_I I OX ~ ~, INOTQ(KI The needl!'e does f1!~tlI'Il.Q"I/e ,art ,alii ~ The llieec,(Je moves and! relfi!!siin:s U'!et,E; f I

..t:h_
'r~'1

.~

,1 '

,JVNL_

or.

Ce'11

--- ~~I

,tL

I'==@=-·
~'

".,I~tr='
",g"

++
.... _

I ~~'~~'

I'

---I

~~

,.. =i>f-

'--Dh-

iii
I

I
~

! I til
~...._~

:~~

I
I

...
.._w

I
,!

1~p1]nP

c u
11

u
c .. u
4:
!IN
'!r""

I~
I

,:

~i'<~'~"~" _"il, ~-~· ,~ "'1;·

-

~
Ii

I'

I'

~.

I!
I

;1-·'
i!

~,l~

".

,.

1'1

I!

[I

I , I,"

~II
~ ~
5_

,
-

I~
tJ
I

I
I

I
(.f a
~

~ ~

I
I
:1,

I I'~ I
Ie' I"
I I
II
I

II'~I
II~

iil

Id·· -I 1'10'1 '., "·11

I

I-~..-,: 1-;
I
I
I

I~

~I

I;~

I~
:~

I
i

iJ It ~,

iii

~J
I

~ ~
-

L, ~ ~
~'

I ~I

'.'
I

~,

----...

I ....

I
I

I'II'~' ,~ r II J ;11(' I
1

,II

($1

'I

1"

>"" 'N
i"""

1;;11

I I

..

I,; II
!~i:~

I-

~.

I,

. C

t,
II!I~I

~'

e II)
C!i'Ji

'.........

Leafm{!te ar COmp"I3iS1S€ld a[r pelFcil mb:hlre reduces, HIIaloo.mpr,e!i!S'5[o.l'IIlpreS;!i!ut'e Tine' ~e~ik~ge6 can ~k~: 5:iIIlGe l!!Iah~~ do-wnlMi1n,ds ~tocram. case ii:fIIlJPW,Bi~~'
l•

IC;()'M PRES·S;IONI [L!lghllnl'rt,gI

PRESS1!JJIRE 10. '13~)P;S!I

IEhdlet : [90 10 1 ~:5 PSI

Ii'c:l!ugh cyll'ni!er he:arl.

Down wardllle>aik
Worn
,~,

sss : '1'10

(BIQW-:by)' oe.e.lilIr~ d,Ue.,'to. ~

C:a.1.!ia~ 'for e~ss,Jve

U1ge

c£J\JllPrtiSsio:n

PIl'ES5itJ!oo: ';

pi$Wn nl1'lg;s, ~·rllntller OOFe,. =:K~etSi$~G deiBil1'i!lII1IOE!I be'~lNeI'!;U,![p1S;it:l,n ,and

cllJUsoQi:'e-d

Ciu'Don del)cus'lt lin {tie 'c.yllndeli,.,

cy.~I'n(j@r Scoredi ring groO'VEII land Q!il( Flis-It:lo" U,pwa:li'd IflfilafkEt'ii;iI!!:;:CUr:& ,d:u

.'
'.'
"III'

w',~

cd 1l'1linner elll ililO: . r hG{;:I.d '9a~ket F,acing or coyJl'nder irRe.:ad J !UlrO(l1<~ L we r 'OOI!l P.~'I_.j!; ale I'1i PII'C,SStilre f1li1di1cate 5 Ciom~feBOOI leqk!l:'f!ge.To determine whelfuter 1111:9
Je.a~e..9~~~caJ rs i:Qwards ihgJI bottom O\F ItO the ~iJP, a !wot~c@~p're.s5iicll'l!~eS'~ Ito. be 'ts'klfilri,

I!. 00. 5'B1 e}'rill!dll~' hEli;;ld nuts,

:SktwnJ~1~llIc£err head gasket

'II

lioe!i"iJ

'-'I!;;;.'

'alwi se~tifiln ~- --til

lll.eaky deoompres-6or v,a.lva

ICOI1f1,PH!<iSIOJ:'i test Q\IlIabloa us

'i!o'

to Ylf1i;d'e~_,'la IiId ::
;[lit

P1RC'tEDWI RlE 1. liilInduC(ii:SO'nl!l!i: 11Jb.. 0.11 to the elilQine (trrNo ~tmke:S;'wi~n,!an oll,cslll wit! il!I~) 2. ,Frea;s !thedeoomp"~~r ,and GII'8!1lk etJgine the
'MO! OJ

WmeD1ler .any eQ(oo.ss.[v'fj leak,15 ,pliesemt

'IJnreel times..

'. t
;2'.
"!:I

~Jyes, Is ii, towafi'dls, U1aIbottom Oleali!l and fit '~hel ,I!li'trniter. cn5-'Ufe (:'Ii!J~" 'Qfi~r.!ilBS,weU. '19>.,'..1', _..iI ,,-, ""llll'I'" onelna " o~au-~ililiJl'!.I1 WilD t!!p """, i;;I!

Iq).

IP'RO'C;ElWruJI RE

.....

4. is.

6.

SWiItJ'i ofjf' U1!a, ~'fig'lne, Remo-ve 'tJi'le.:!Spalik, plug. Hold lJTte CQmpre:s!5ionl geUJ9~;[pressed on 'to lh~ ~p.grlr. plug hO'le\'

~allli:el~hel comp,re:ss,ioilll re'ad'~i1!9 .aIS !1ili~~I'wn!iKIEI!arfler, t 1111 -et tea,t, if 'tJf!!el COMprBS$km w PI'ijiSSIjII\0. r.s l"1~helr IOl!!ly upto 6< PSI mIfD lhalof drj' ite~~. leakagel is 'lbe "[rom : V,a!v.es, iilIeeompre:ssor pJunglr;l:r and I Oli 'cytlfildtS~ Ill'as'a'tlg~k'€lt. If tlile 'wei: r'e<~n9 pre~$u!'le is hl!1ll1lw 1b'1mme 'Unu:m 5< ,PSI, U1.iji19a,l<.ag~' eecurs 3c
lhe'lil
t.owalFds the ~ii'i'!"

"I'.
;8:." 9.

Hold Ilro'lilile on

(IliD

!open p!OsiUon\.
:lQ;tartQ~ ~igd31 Ilvro or

Sft!1'!~all'lJy k~cik. 'lihe kick thli~i2i IIi'Ji'i.eS ..

Ael!i'no¥~ gaug e ;and ch_'Ck ~he !oom,pre5:5-'jo~

pa;essura

~rIi U1Q

gauge.

EiNlG,lNIE 1. Cii~mk, in p

rnit 7fe,'"
Fi~t}

~:a:8
'92;

2
,::Ii, 4"

Crank, iiii~~!rrt, plllllon, r1i!.d rW~ C~ank, ease s~udl n!jf~, 1Mj" Crank,
ci1lS1!1 :e;U1dI m.utso 5116
lIU,lIt

92
.

9
'1'1 ,5
:9 00

9 '1'1

5" I!I.

Cyl1nQ;E!1~ b~$e s1ud C!!JIlindelf IbaSiEii st!Ud

5 '9
t1

s.
ii'

"I,

10. 11. 12. 13.

Cr:an.i<,eaas d'ra1n 1p,11Ll:9.l~' C:ylll'iCler ihe:adl m'OYfiillin~ studs C~~iflder iheadl nu~s lllillPpet gliJ~¢e 'T~ppeft cover liliUts,
'T1lminQ,wve;r s!;rew,S em '~Jl'e:r $w'd

112:

12
:24

:93

cOO ,8 10

10
,8 12 17

8
114-

1-4.
115.
16.

em 'fIlR'E::F

cc.vl!l!" fIIut

OU !pllP:e bai"ijQ.' ImUs R(i!gk~1r (:ovElr :6~~.;mlll~S;

17
'114.~ 20
55 ~ ~

'7
20
\55

SIP~,rk,PIilJ,gj 1:8. IFwn~ ,dtiv~ !spft!e~et IF:lillt 19" ,AU~'ftI!!:1:tor ro1Q,r r)l!Jf~,
,2(1'.

17.

iE:M:liilallll!5ll[pl'pe iinOYil't~lngl studs,

IExliiHi!iJ!:st
&,

54, 12:
IQ

21.

[pIpe IlIlOI.!!f!tirllgl

n'!.i!~$i

C.I!.IJIKIHl
1.
,;2',

IGlEAiR BOiX

ClUJI~h ~S!ii!ITe'ITIDuolilllg IiIUft

55
~!O
€liS

55
1,0

9\,

G:e<eu bo:;.;, li;:ml ~Ilwr 1OO1~ %11' G:tJ!arm~Jnls~:a!~l!"I;U~

65

1,

,2:" 3,
·41" :5,

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3,5

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,20 :25-

1:3

15
65
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fIil I'i l!.lft g, 1iII1lIihGi

6,
7,

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ss

33