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INSTRUCTIONS FOR REPAIR SHOPS = we The main purpote oF ths menus sto provide the Serves Stations wih bate Information regarding the dlemaming, evernauing, repairing, reosser bly {9nd coring of the Lense 175-1. “he ft sation cover: the main featues cf the machine, dellowed by lagroms and layouts ivsrating the fundiining oF the engine grou, Together withthe flee covering the lube Ths seeor secon explains i 76 operezons, amply illustrted, the dismantle Ing ane reassembly of he engine ane lhar tnpottam gloups, together sh detalle on ih timing eerings of the fievhee! magneto, The thd secion fully covers the electcel equiament and circa, followed ‘bys chapor on the earburetor, ie satings an! unin ‘The fourth scion Isls opetations from No, 101 t0 115 covering the servicing of the machine curing the gusraries pio Tw fith section aver 2 let of standard repsic operations with the co responding nell limes enpleyed by ovr spaced, mucharics \Wear limits for pans whieh are subject Yo wear arid Tear ae given in the Sin section fellowed by chapte on he saigsaning of fora tnd fares Finally we give» lit of fools necessery forthe rapid ancl corect execu af the Gismaniling ara reazarbly. SUMMARY {sin feats Layout of engine group and its furcoring Exploded ilstation of 1V Engine Lubteaion_lagram Dismanting and reassenty of oncioe The lecrcal equipment Leyout of electrical equipment Wiring Diagram promos. Wiring Diagram post.rod, ‘The Carbuettor Servicing dicing Guarantee period Standard 1epalrs and times Wear inte Stnighening of front Fee and teane Workshop Toole Index Hesdlamp tear swith wy en ate Front take ner Sterng tok ltetont sed oar brake pl i MAIN FEATURES MAIN FEATURES Maximum Length 72" 0.825 mn copzcty 170 «x ‘Maximum wid (andlobre) 28° (0.710 mi) Compression ratio 25 Moximum Height 42° 0.070 mi) enim output 84 HP ot 6000 RPM. Ground Clearance ier (0.185 Lubin Pots Whoslbste 51° 0.290 mt Fist 900 myles - 8% Oi) Frame Cental beam "ype in cel BP Energol SAE 30 | | fbn From 900 miles - 6% Oi! BP Energol SAE 90 ody In presed tee shea | Front Suspension Trang inks and varlsble Kicker by Fede ples helen springs eupled fo shock alata ‘Sarburctior Delloro mB 29 895, ear Susparson Swinging engine unt coupl- Air Fir Diaphragm type. ecto shock nbxorber wth wo umes h SP°M2% enon ineariee Flywhoo! Magiato Fiko = type AVS 28.6:140 Cente Sine U type with ter ree, - E For 10s Uninsen weight 26 Ths. (120 Kes) External HT. Col Piso -C. 121281 fro meni as ; Bosch 11 6/3. otal Fuel Tank Capacity galls (5 lives) Spock Plog During runningin pence Roserve 2% pints (1.2 tres Mong reset 18mm) Heat ange 225 Bosch sale. | biseimim epece! 4 mph, (109 kimhrd ‘Aller ronmingin period = (lo CUNA standard) Hest range 225 or 240, Fuel consumption 94/m9.8.(32 lires/100Km) Borch scale (lo CUNA stenderde) Ionian acan Fined at 26° 19 26" belove 0c Engine Single cylinder two. arcke forced fan cool. latch (Malt isc type in of bath ore 60 7m, Transmission Double ain dive with tor: Stoke 60 mm ue imitator Incorporated, Four speeds in constant Inet, stern vely sngaced 1p tear aie Bp means cursortype gem shilir with atk Rovio = Beer Wheel Revs/Crankehaft Revs Veh, Gear - 1/1432 aed. Gear | 1/977" Get Gear 70 ih. Gow = 1/549 WHEELS AND ORAKES Intrcangeabla whens me Prose stl in twa hives Brokes Ezaansion type, cable con trae. Tyee aze Tore" Tye pressure - front 1 Mee (1 Ko, «m1 ‘ye prossure = tear (tdar 21.5 sin nly) (1.5 g/g: ems ‘Tyre pressure - ‘ar (will 35.6 fbs/39. in essen (25 Kg, sgams, Stecncl sgipment Flywheel macners Buin awrite on hareeban Poston of suit (Classe) bashing ohn ‘OFF thoy in vert pesifon) Bay nding ight riding - on city gts Be Medial cage 4 pole 2707 seminal 5 ay apo: Headlamp and horn switch Full bean! and dipped fem placed near TH. Tle gti, Fine 8 for 81 Amp. Banery 7 Amp he 6V Stop Light sch Tear Bike Peal uti, Poston vent Vamp ior Hilane wind | Sigman! 4 25/25 evaw Rew Lamy tay aM Specdomete Exploded illustration of TV Engine Aescristlon of ilusiration on pape 10 DISMANTLING AND REASSEMBLY ENGINE DISHANTIING NOTE To cary out the dismanting ofthe wear wes! ond heck absorber, the neat of the machine must be ated fond rsied on the wooden suppor Used in Operation 10 (Gee Fa. 4) op. foie the machine on to ft stand andl take of side panel Dismarnla tha lencer, unscrewing the theoo ruts fixing i Ho the crakeate (lOmm panne’) fed the east tn, on evlinder Using tool No. 57842, Dlemantic tre R Mand footboad, unecowing the ho mute Ming i 0 the frare (Sei spare no, the serew fixing he rere comes piece, fed the fe screws Pcne the footboard bree! (lim epaneen. See FO. | Tales off K/Stort pada estas! he deli, un seve the rion sping Sing mr [Oma £900 il Feoren the eo pel bas (mm sane tli leer tom i shalt allowing the ening "9 “alos! grisly with the Nalp of > crewibivet See Fig. 2 | Romave the pds) return spring cover aftr ectecing ite dep, S68 Fig, 9 ee op 6 Drain all from crankcase; unscrew cain va (Onn Allen Key No. 57836) cllecing oi in roe Eluieh edble om ester dd crankerse cover Free rear Sroke cable ffom pedal brake (ed ‘191m spare To remove fear broke lever on 14 = Te diamante x the Ainge, Witdraw the wo nec ings cnge, the distance pce and shire 20 the ck Slo shall See Fig. 6. The orquedamp hes beon convaiy set before sessmbly In order 1 slip whom torque reaches 14 = 16. kam, The chain should never be washed in poral 1 dutch, apy clutch comprosior tea No. 56606, fre the icp by means of « ‘he Five nuts fing tlre Sm) spas screwdnver, sao Fig 7: Remove too, withdraw remove flange (sing H neceacary 2 oxtractocs, ieee dies ace! ocd ae te Sen 1.25 ee eral itotheaeeadee hale), together with main gesr cluster heft and Yo vermave geet sha soppem flange, unscien a aoa slide Out Kick Sart shaft. S00 Fig 8 ” To remove Kick 63 pinion: xr orelip. Saw Fa. 9 Te remove reat wiicel, make sure hel the crankcase is supported; remave lack washer if Imounteel (Gem spanner, umcrew he. self locking wheel nut (27mm spanned); withdraw ‘el fom Is shaft by means of axtractsr No 37028, or hing 16 with mallet, See Fig. 10. on, 18 2 ‘To mmove sie shat oxtfac the two ctl and Lierantia the brake Shoes, open up beoring ack ae wenaces cl lt with soak No STATA, Lnscew busing lock nut (Gémm spanner, tap shaft with mallet 10 fr8e bering. Wihdrow shaft op roller cage. See Fig, 11 To temovn exle abatt gone Elta the tne ne, th the hale of seweeriverz, withdenw the toner S20 Fig 12. erelips el slid out the various pa Tos remove Carburetor with fier licoameat the ctigke eble, lonsen ezcuring ring an carburetor ard the fiter eipnuts (lor hose ens) (nm spanner disconnect fuel pipe, Remus cau Yor and Sher. Unscrew dhoke contol suppoM ond boa To rereve L, Hand fentooard unscrew the four (8 fring cuts 8m spanner) ene the screw Sans frame eonnestion piece Remove spark plug 2mm spanne”) move Engine Cowl the, reer path of Conkeasa ns high 85 posible, unecro the fo | fefews fing the cowl [@ & Linwn spemner) | ease ee ace + 25 Samove Corurtior induction merifeld (mm Spanner Remove Cylinder. See Fig. 14 To remove Psion; xae! eudaeon pin celia, push out gudaeon pin, usrg @ hand Bush pin Er appropiate Tool. Remove pater rings 21 To remove Cowl Cover unscrew the three sews (Grim sparse + 29 - Romeve fon dust cover by «eleesng she ciel, » 90.- To remove flyhee! locking rut; apply flywheel holding feo! No. 58013 and unser tut by ‘means of the 19mm box spanner Tool No 37276, See Fig. 18 To remove flywheel; apply extractor Vo, 37058 and holding eal No, $8013, S60 Fig. 16, + To remove flywheel cowl and Flange unsrew ‘he fing scrows (6mm spanner Bees nest el ies rary tet espe EE boxer, a Op 24 Te renove Sintor Plate, withdraw the screws 22 ‘ung tis to the Nyse supper lane, ting Cote, it fon timing a ail cores, 10 mark the orion af tha plate bofor rrr eal 0 Felliate the taning. See Fig. 17 To remove fyuheel support ‘lange; withaw the se stews Ming this fo the eronkeaze (10m spanner) and apply axiacter No. 57828, tng three. of tho salon plate Azing screws See Fig. 0p. 36 Te serove the wheel side main bearer extiac the ol <9 cieclp, zie cit the il Seah ath hl oF a sarewelrvet extract thn 9ext irlp ae ine nut washer; withctaw the THC res holding the bewsing Flange, ne reve the veaiing bY Vina extradar No, 5789. See Fig. 19 To remove clutch bell houslog lade nut fick: tan out tab washer, lack howsing wit Tool NO. 5721, uacow wt afthend thread) (27mm tox panne) See Fig. 20 23 00.38 - To remove Cluté Bell Housing; coy extract ENGINE REASSEBLY No. 57840. See fig. 21 To resssomble the engine follow the dismaning operat Tons inversely, nainely Operation 4 "0 1 bearing in rind the fllowing > 39 Remove Cranichstt from canksase by t9ppine em elizeh side with males, > 4) - To remove Crankease from frame; remove gear Op, 27 & 26 - Refiting the pion anc! cylinder; in the 24 ange cabls 42. Lif the upper potion of the hanalabsr group Iust the amount requed ro resdh and unscrew = he Tour deaws which bald Ion speedomater fim. Fige the spesde cxble ftom the stwsse motor by ngans of he knurled ry venave the speedo Ralder Bess tis teeing the upper por of the handlebsr unt. Tha :eecdomater con Now be freed from the Unit See Fig 97, TO REPLACE CONTROL CABLE INNER WIRES. ‘Op, 43 - Pull out the inner sires of the eables from the j handlebar end after having liconerted the ther end fom the rexpective trons. for the thats cebte ie nesesary 10 unsoiger tho ‘pple othe cafauttior end of the cable. ond Frsclder of Filing new cable, Replace~ent ‘vires can than Ee neared into fhe ovr from tho Farland siatiiititiacniait ia Me 26 TO REPLACE CAMLE QUTEES, Op. 44 - Remave the heodlame by unscrewing the four Fring Screws and ducornecting eleicel wees 945 Raneve the headlamp costing and the front rmutguard by taking ou fe hvo screws fing the peodiamfs easing to he trams whi ae placed In te hesdlgmp recess (10 fm. pr et, senove the four sews xing he and Tome casing (0 10 lowell together ih tne (hia eaeus Sng the mudguad [& mm. spare neve Fig. 28 4» 46 - Slide me cable outers through their eaainng TO REMOVE CLUTCH CONTROL AND FRONT BRAKE LE: ERs. Op 47 The lover pivot im ie hold by 2 rrining plas) {led behing the cable nipple, To remove the lover it 2 neezieery 19 looren the ioner cable tnd rere he ripe from is seat then drow ‘ut the retaining pin by rears of all hook Pall out the sivot pin and remove she lever. See Fig 29. TO REMOVE THROTTLE AND GEAR CHANGE CONTROL SHAFT. (Op, 48 - Att hoving toed the outer extents of the font brake and clue cables, loosen the dame haleing the able contol roller (@ mn. span net) and remove the bol. Withdraw the shaft by tapaing with 2 emall punch on the head of the stall; the lich lever suppor wil lide oF whan is shaft is wlthdrauny while the front brake lever suosortromine fixed so the hanelatier aed can be enaved by unscrewing the twa locking screws placed near tho head lame contol site. When firing new thle ard gear Gienge contol shafts the tnt grips ‘hou be removed before leozeing the cable ania alle See Fg. 10. DAMAGE TO THE RAIN AND /OR HEADLUNP SYITCHES, (Op, 49 - The dering of tha Seay af the mais sulich fr the heagloma swiich Is no! recommends Tn cate at aimage to ether af these neo 8 ches replace them with few parte which ore Supplied corpheie wilh their respective cobes, “FO REANOVE HANDLERARS. Op. $0 - Corry out Qpnratines 21 and 42, remove the faow Fxing tbo handlebar f0 tho. veing {GQ e eptnnen, Tost No” STROH, witha Fanlenar from the the front fork tapping it snneath win a mat YO SGACVE THE FRONT FORK. Gp. SI = Aft hnving, camaved the fanslebes (Op. 2), tciew the siaarng.sojystonnt ring endl the ball ee cng eng fook No 40890, A087 fide ou front fork. See Fig. 3) 70 cot TROL THE ALIGNAMENT SETWEEN HANDLEBAR AND FRONT WHEEL Op. 92 Cony out Operations 44 & 45 and sight check ‘he postion of the handlebar with respect 10 the font wheel. itis necessary to adjust the ston of the handlabsr loosen tho bolt ‘ng the handleost to the stecrng group (10 mn. Spanner) Too) Ne. S726, en! tighten up agin fot having cated our the adjust. REASSEMBLY. Corry ou! the above mentioned Operations plaeng handler 20 that they ara placed cxacly Fig, $2 op. 53 2 55 Jy (Cperation 62 fo 41}. Check with cate the (ofthe ele esas and contol cables tnd the show In To avoid dhafing and nerow angled bends. FUEL TANK. Remove the betty toaethor with iis supoas boy unserving the ts quts faing tece 10 tho bracket on the feme (10 men, spanner Enply all geo from ror ooden ale Induction tube clip screw ond with rw tube fom air chamber in frame Remove patrol tap control rod by exacting (9p.57 - Remove pool tap from tak (16 mm sso). 3 $a © Remove ne tank oppor saps @ mm box | Sonne + 59 Take old ofthe tank fom the Aywtee ste Of ie machine rote Ht ck ad sida oot ot frais Soo Fo 9. TO REASSBMBLE. Follow the ebove epson: invera (Gp 59 1953) 38 | DISMANTLING AND REASSEMBLY OF FRONT SUSPENSION AND WHEEL | Qp. 60 - Raise mechine on its stand | loosen front toh nee ae | ae > 61 ~ Remove whoo; loosen the two wheel nuts on the tring link, the nu) zing the right hard lever on the back plata (22 nym, snannat) and incline machine 1 remove wheel 62.- Remove the shack absorbate (10 mm, seenner + 68 = To ramave pivet pin on sailog link, unscrew | the Ries nt (19 rm. span + Gi = To remove lower buffer unsctow greme nipple under the Sever, emove sews fixing buffer (10 mm spannaty rereve tales wit te help cf « acewdlivar, $00 Fg. 35, | + 65-70 remave the ellng Hoke) apy Toot No, ST aed pp Ween stb 1 remove the lve. Se Fo. 38 | ee es eeet rent te eric end] piston guide ring, using forthe lest item # hock In eats of difeuty. See Fig. 87. ee ao a a Op. 47 - Ungeraw the Lt, wheel nut (oossied previous wih 2 punch from the left hand end and co fy) unaclew the wel lock aut (19 mi". span tors the brake shoe back plot, not ond sithdrae the lel hard atone pe p.69 = Remove the two oll seals at gah and of the +68 Wihdeew front wheel epindle by tapping it hub 38 j t ) p.70 - Exiaecrelip ftom lof hand side of hub and fap our sha bosringe with 3 eutable pune (Right hand bearing toward the right and let hone soworde sho lof TO REASSEMBLE. Follow the shove operations inversely (7010 60). Baar in mind that the oll seals must be fied the tlm outwards, so shat In case of excossve pres- sure being anpied ducing greasing, the xtra gress can esily come out, without damaging the sels SETTING AND TIVING OF FLYWHEEL MAGNETO. Op 71 - Remove cylinder Head (Op. 1. 2. 3. 8. 10, 20, 21, B2, 23, 24) snd Too! No, 57958 which con be losked into oition oy moan of seo ff the four cyngor sue, To his Took tthe lal gauge. See Fg. 39. > 72.- Remove cowl cover clip and fan cover to low acces tothe Mya! (Op. 28 & 29) > 70 + Check condition al gop of the contest pone when folly opened. The surface of the point should be fal and clean and if this is not 30, Feelify with a very fine file The cntence be fen the conte: pains ie. gap fully opened should be belween 1.35 anc O45 rms. whieh can ba easly checked by means ef feel g0 No. 48054 or any noemal type feet. IF the 36 gop Is Bigger er omeler than the above sled, fhe adjustment can be cavrieel aut hyough the ustinent sevew. To do this however, the fy ‘sheal mst be removed, 202 Op. 30" and 31 + 74 the crecking of the Hiring can be cased out lain the belo of the slecine Buzzer ever ‘No, 5017. To 6o this the key inthe main switch has 16 be fined to the dey ding > poslion zannecing one of the buzz wltes to the green vine LT on the Mywhes)lunetin bok of te fhe ULI. Coll feed! junction box while she ator ‘wie of the Bosse will be conic fo enh ‘eich nach eonnaction ofthe co ‘Turn crane! oni top dosd conte is found Leng dial gauge to zero in this Sool Switch on the electric buzzer at the TG and ‘urn the fywhest oly in lock = direction, (2. in the opposite tection to that shown by the arrow reared The flywheel), When he bouzzer light goes out, which indlestes that the ootae points ave close ake ths al vaading. his shovid be botwoon 28 ond 44 nme oe feigending to 40 male of flan of te ty {rer 9 measurarsent of 32 parmeter oF the “he pints clone bafore ot 3 ter the above, fenave fywtheal (ting et ‘nly, loosen the scree Ping. rato pl row the plate if 9 clockwise ration 10 44 Yence or in anticlockwise dkaction 19 veer SU Has mame corrert eantct pol operIng Weched, Sue Fi 99 THE ELECTRICAL EQUIPMENT 4 1 } 1 i i i] l LECTRICAL EQUIPMENT, 2 WIRING. The elctcal cieait of the racine is feel by the Ay seal meogneto which supplies curont 19 the H.T, Coil nd to the dual fama 6 V. 25:25 W. Headlamp Bul Furthermore through « reciise the Ajwheal mas the charge fo the Eatary (6 V. - 67 A.) whi supple current 10 the 6 Vs S/W. Healanp Pilot light the horn ard 10 the two roar lam soplight libs (8 V. 3 W). The 12 V, 25 W. speedometer bulb and the & V. 3, rear Bght are fod nectly fom the lipwhee or the rary faccding tothe potion of the main switch boy. Gn the st caries of machines, a every pasion of the atch recifer is feeded tough Interedite connection of light xl. Soe Inyou! drawing of the slecrlel enuipment Fig 40 ond the wiring elagram Fi. 41 A. On the second vies of machinat (poste) rectifier is sill foeded sh ough intesmesiae catnactian of light ell then oh Fe In pasion <0» or «2, When switch (gn poston <1 reser Ie feeds! through tenminal conrecion of ie Commutation ls obleinad through « lay mourtd Seheter ‘vith cectiier and Susy, connines a 2 bigger bom. Feed 40 {in tho some posiion of the rectifier andl fine box of the promod. machings, s¢@ layout of electrical equipment a, AD). Wing Diagram sesvlies modified os shown inFig 418 Tho Wain swith hes 5 postions. Front let 70 right = Pie tight, speedometer hr and rear lighten for patking of riht ~All lights out daytime parkirs — Daytime ina (no light on — Headlamp pile light, rea ight and speed fight on, Wistoing hn iminaied esc. — Headlamp, cear lamp, speeds tlh on Wight ting in the county. The ewiteh key con only be exteacted fram the switch “ohn inthe pasion vf engine wor. The Rvoway awit contol forthe heed (main bam 7 dipped bs) which alsa ineluds the horn, buon oc nes he fat fore wish rip on the handles ee Eee Rywheel nagneto Rect & an Ne. 15017010 5081280 Foto (Prewnod, sroctines en) Rect. 15081220 Fis Relay @oetmod machines nly MAIN FEATURES OF ELECTRICAL EQUIENENT characteris, 2 lgytion Coit ith groan can necting wire, At_8. Rywhesl peed of 150 rm, wit lights ‘ff 9 spork ovee a gap ofS mms. shoul! be given. 1 ighaing coil with wo wires, (teoin wit Fr lights blue wite for rectfiee! Thi coil shaukt he 2.6.0 cone 38 SON wih @ 1.33 @ load on ro Boeifer erent 8 mp Inverse currant 8 0A, men. Fuse Sor Bamps, Berger avers 26278, Invero euirent 3 mA. use 5 lor 8) amp, Description Part No HT. col 00st 1984 iss 0089 1000 och) Poa owls 508.270 Twosway 15081250 seh en 15080240 Sp light 15081260 wine Characters, Alternating current Open snes yee Foe, For headleme beams and! com taining hot puth Betton 2C. @ V. with 12 W. max. abe Fited 10 the roar brake contol prea). Layout vf electrical equipment = Hesdlame 15080008 Twin foment 6 V 25/25 Wh. Bulb Hilame 15080004 &:v 8 Fsicon 39 mm long Pilot Bulb Rear & Stop 15082004 Three 5V3 W Festeans. 30 mm Light Bulbs Jong, Specelo Bulo 15087002 12.2.5 W. otiery —‘SOSTI7 6 V-47 Ah CHECKING OPERATIONS The following instuments a9 needed for the dedi Rev. counter from © te 6000 hem. Yotometer for DC. 0 10 Arp. Mat for OC. 0-5 a liom, Motor fer CC. 0-10 mA. Hylometer for betery lewd contol ering cieit tesier. A megmahrte: ie cecommended HEADUAMAP ADJUSTMENT, chock tyro proseure (2 P200 9) Poce a veries! screen in Wont f seater as shown jn Fig. 42 (ine Fig. 16 in fhe instruction manual provided ‘with thie machine lac the rashine uncer ity normal [oad earyiog ‘2 Se gk ly eres il 02 heck edn seen na care ui a et en a ote 101 - CLEANING OF CARBURETOR, Sex poregraph Grier Carborston Matniorancs Page 54 Check earburation 8 correct wily special refer rence jo the adlusinent of the slaw Unring 1o2 - CLEANING AND ADIUSTING OF CONTACT POINTS. Follow Operation No. 1, 20, 21, 28, 29,73, ea - CHECK BATTERY ACID DENSITY AND LEVEL {To daranlls Barsty too. OF. 53. The liquid ‘ould be five mms higher shan the 199 of Separators. IF the loval is lower acid iil! Sidtoe Measuse cera of aekd which shoul 1125 a/ ee 55, 554 57, wath itr in petrol. Check patil ‘ap 10 ensue that al hole aro clean and the reserve control works eficenly. ‘CHECK TYRE PRESSURES. Front 14 Ibs./eain Roar With diver only 21 Ibs/zqim, With ‘iver & pilion passenger, 35 bs. /sn, (CLEAN CYLINDE® HEAD PISTON MteT AND EXHAUST FORTS. Carry vt Op. 1.2.3, 8, 10, (CHECK AND ADJUST STEERING. Carry aut Op. 50 and tighten steering adustnent sng fr all race ring #0 a8 to eliminate any fro ‘erk eat ptey CLEAN EXHAUST SILENCER Carty oul Op. 1, 2 3, dsmanilo lonsor from machine, ramove ‘exhaust exlenson, exhaust tube and plug. Use # flame for burning carbon deposits than tap ‘he silencer 0 that these carbon deposits Fall out of the apertras, Check front and rear shock atuorbere, Asc ‘win that the

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