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Table of Contents

Table of Contents2
Preparing the Motorcycle for Repairs3
Vehicle View3
Checking the Motorcycle for Technical Condition4
Methods for Checking the Vehicle's Parameters7
Mounting and Dismantling Operations8
Checking the Engine for Technical Condition by Noises and Knocks9
Engine Troubles11
Troubleshooting of the Motorcycle Units11
Power Transmission Troubles17
Running Gear Troubles19
Control Mechanism Troubles24
Electrical Equipment Troubles27
Removal and Installation of the Engine Together with Gear Box29
Disconnection and Attachment of the Sidecar30
Removal and Installation of the Gear Box30
Intake and Exhaust Systems Removal and Installation31
Fuel Supply System Removal and Installation32
Wheels Removal and Re-Fitting32
Main Drive Removal and Installation33
Front Fork Removal and Installation34
Removal and Installation of the Handlebar Together with Control Cables34
Electrical System Parts Removal and Installation35
Rear Suspension Removal and Installation35
Dismantling and Assembling the Engine38
Engine Reconditioning38
Removal and Installation of the Cylinder Head38
Removal and Installation of the Cylinder39
Removal and Installation of the Piston and Piston Rings39
Cover of Timing Pinions Removal and Installation41
Removal and Installation of the Tappets41
Camshaft Removal and Installation42
Centrifuge Removal and Installation42
Clutch Removal and Installation44
Flywheel Removal and Installation45
Clutch Disks Removal and Installation - Diagram46
Connecting Rod Removal and Installation48
Crankshaft Removal and Installation48
Nominal Sizes, Tolerances and Interferences in the Engine and Clutch51
Maximum Permissible Values of Wear and Clearances in the Engine56
Repairing the Crank and Connecting-Rod Assembly56
Repairing the Engine Units and Component Parts56
Crankshaft Repair57
Cylinder Repair57
Piston Repair58
Piston Rings Repair58
Cylinder Head59
Piston Pin Repair59
Valve Timing Gear Repair59
Removal of the Valve Springs - Diagram60
Checking the Valve Seat for Play62
Characteristics of Valve Springs63
Pressing out the Valve Seat63
Push Rods64
Tappets64
Valve Rocker with Pin64
Camshaft65
Oil Pump65
Repairing the Lubrication System65
Valve Timing Drive Pinions65
Oil Lines66
Repairing the Clutch Mechanism66
Repairing the Engine Crankcase and Covers66
Repaired Engine Adjustment and Running-In67
Ill69
- Gear Box Cross-Section70
- Clutch Release Mechanism Removal and Installation71
- Gear Box Dismantling and Assembling71
- Repairing the Gear Box71
- Repairing the J\La in Drive ~276
Running-In Conditions69
Repairing the Wheel R.s88
- Wheel Hub Dismantling and Assembling90
- Replacing the Rim and Spokes91
- Tyre and Inner Tube Repair91
- Wheel Assemblies and Components Repair91
- Wheel Hub Repair91
- Fork Leg Dismantling and Assembling93
- Front Fork Dismantling and Assembling93
- Front Fork Repair93
- Front Fork Component Parts Repair94
- Front Fork Shock Absorber Dismantling and Assembling94
- Sizes, Tolerances, Interferences in Front Fork Basic Mating Members95
- Dismantling and Assembling the Rear Suspension96
- Rear Suspension Repair96
- Repairing the Frame96
- Shock Absorber Dismantling and Assembling96
- Shock Absorber Sectional View98
- Handlebar and Control Cables Repair99
- Rear Suspension Lever Removal and Installation99
- Throttle Control Grip Dismantling and Assembling99
- XI. R.epair.ing the Handlebar. and Control Cables99
  - Carburetor Dismantling and Assembling100
  - Fuel Supply System Repair100
  - Repairing the Clutch and Brake Cables and Levers100
  - Carburetor Repair101
  - Intake and Exhaust Systems Repair101
  - Petrol Tank/Petrol Cock and Hoses Repair101
  - Repairing the Fuel Supply System Units101
  - Sidecar Body Repair102
  - Sidecar Dismantling and Assembling102
Repairing the Sideca,, 1102
- Checking the Storage Battery for Condition103
- Electrical System Devices103
- Sidecar Frame Repair103
- Storage Battery Specifications103
- Determining Degree of Discharge from Specific Gravity of Electrolyte104
- Generator Specifications105
- Generator Winding Data105
- Checking the Generator for Proper Operation106
- Checking the Generator in the Motor Duty106
- Checking the Generator on Motorcycle107
- Determining Rotative Speed of Generator107
- Generator Dismantling and Assembling107
- Repairing the Generator108
- Current-And-Voltage Regulator109
- Winding Data109
- Current-And-Voltage Regulator Check110
- Current-And-Voltage Regulator Adjustment111
- Breaker and Ignition Advance Automatic Device Specifications113
- Ignition System Devices113
- Diagram of the Electrical Equipment and Colour Coding of Wires114
- Automatic Device Characteristics115
- Spark Plug115
- Two-Tap Ignition Coil Specificatins115
- Distributor-And-Contact Breaker Unit Specifications119
- Ignition Coil Specifications119
- Repairing the Headlamp119
- Electrical Equipment Circuit Diagram120
- Lighting and Signalling Equipment121
- Horn Data122
- Wires122

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