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Specifications for valve guide material, dimensions, and clearances.
Details specifications for valve springs, including free length and coil counts.
Specifications for valve timing, including tappet clearances and opening/closing points.
Specifications for rocker arm bore, spindle diameter, and tappet clearances.
Specifications for camshaft journal diameters, clearances, and lift.
Specifications for tappet tip radius, diameter, and clearance.
Specifications for tappet guide block bore diameter and interference fit.
Specifies ignition timing settings for crankshaft and piston positions.
Details specifications for tachometer drive gear shaft and housing.
Specifications for timing gear pinions, including number of teeth and fit on camshaft.
Specifications for contact breaker gap setting and advance range.
Lists internal and overall gear ratios for the transmission, and engine RPM at 10 MPH.
Specifications for mainshaft high gear, bearing type, length, and spigot diameter.
Specifications for mainshaft and layshaft diameters and lengths.
Specifications for mainshaft and layshaft bearings, including bore and shaft diameters.
Specifications for kickstart ratchet mechanism bore and spring.
Specifications for kickstarter spindle diameter and bush bore.
Specifications for gearshift plungers, springs, and quadrant return springs.
Specifications for telescopic fork type, spring details, stanchion diameter, and cable length.
Lists components and specifications for the electrical system, including battery, coil, and lamps.
Details fuel tank capacity, oil tank capacity, and basic motorcycle dimensions.
Provides dry torque settings for various engine and chassis fasteners.
Describes routine lubrication tasks and frequency for the motorcycle.
Lists recommended lubricants from various manufacturers for different motorcycle units.
Details the engine's lubrication system, oil flow, and components.
Step-by-step guide for changing engine oil and cleaning or replacing oil filters.
Information regarding oil pressure specifications and checks.
Details the function and maintenance of the oil pressure release valve.
Step-by-step guide for removing and refitting the engine oil pump.
Procedure for removing and refitting the oil feed pipe to the rocker arms.
Details the function and maintenance of the anti-drain valve.
Instructions for lubricating the contact breaker points and cam spindle.
Lubrication procedures for the gearbox and transmission components.
Lubrication of the primary chaincase and its components.
Procedure for cleaning, lubricating, and maintaining the rear drive chain.
Instructions for greasing the steering head bearings.
Lubrication procedures for wheel bearings.
Lubrication of the telescopic front fork components.
Locating and using lubrication nipples for greasing points.
Methods for lubricating throttle, clutch, and brake control cables.
Procedure for lubricating the speedometer drive cable.
Lubrication of the rear brake pedal spindle.
Procedure for changing the hydraulic fluid in the braking systems.
Detailed description of the inclined 750cc three-cylinder engine and its construction.
Procedure for removing and refitting the entire engine from the motorcycle frame.
Steps for removing and refitting the engine's rocker boxes.
Inspection of the engine's push rods for wear or damage.
Procedure for dismantling and reassembling the engine rocker boxes.
Procedure for checking and adjusting valve rocker clearances.
Procedure for removing and refitting the engine's air cleaner assembly.
Description of the Amal type 626 concentric carburetors used on the motorcycle.
Procedure for removing and refitting the motorcycle's carburetors.
Procedure for dismantling and reassembling the carburetors.
Inspection of carburetor components for wear and damage.
Procedure for synchronizing and resetting the carburetors.
Steps for synchronizing the throttle slides on the carburetors.
Guidance on adjusting carburetor settings for different altitudes.
Procedure for removing and refitting the cylinder head assembly.
Specific steps and considerations for refitting the cylinder head.
Procedure for removing and fitting new valve guides.
Procedure for removing carbon deposits from engine components.
Procedure for re-seating engine valves.
Procedure for removing and refitting the cylinder block and tappets.
Inspection of engine cam followers for wear.
Inspection of engine tappet guide blocks for wear.
Procedure for removing and refitting engine pistons.
Procedure for removing and replacing piston rings.
Inspection of pistons and cylinder bores for wear and scoring.
Table of suitable piston and bore sizes for engine rebore operations.
Procedure for removing and refitting the contact breaker unit.
Procedure for adjusting the contact breaker points gap.
Procedure for setting the engine's static ignition timing.
Procedure for checking and adjusting ignition timing using a stroboscope.
Procedure for removing and refitting the engine timing cover.
Procedure for removing and refitting valve timing pinions.
Procedure for extracting camshaft pinions using extractor screws.
Procedure for checking and setting the engine valve timing marks.
Procedure for reassembling the engine crankcase after servicing.
Inspection of crankcase components for wear and damage.
Overview of the primary drive system, including clutch and chaincase.
Details the motorcycle's clutch mechanism and its operation.
Procedure for adjusting the clutch operating mechanism.
Detailed steps for adjusting the clutch operating mechanism and cable.
Procedure for adjusting the primary drive chain tension.
Procedure for removing and refitting the outer primary chaincase cover.
Procedure for refitting the motorcycle's clutch cover.
Procedure for dismantling the primary drive assembly.
Procedure for reassembling the primary drive assembly.
Procedure for checking and correcting primary chain sprocket alignment.
Procedure for refitting the inner primary chaincase.
Procedure for renewing the shock absorber rubbers in the chainwheel.
Procedure for removing and refitting the chainwheel and engine sprocket.
Inspection of primary drive components for wear and damage.
Procedures for repairing, lengthening, or shortening the rear drive chain.
Overview of the transmission system, including gear shifting and components.
Explanation of the gear shifting sequence and operation.
Procedure for removing and refitting the transmission outer cover.
Procedure for dismantling and reassembling the kickstart mechanism.
Procedure for dismantling and reassembling the gear shift mechanism.
Procedure for dismantling and reassembling the gear shift cross shaft.
Inspection of gear shift and kickstart components for wear.
Procedure for renewing kickstart and gear shift spindle bushes.
Procedure for dismantling the motorcycle gearbox.
Inspection of transmission components for wear and damage.
Procedure for renewing mainshaft and layshaft bearings.
Procedure for reassembling the motorcycle gearbox.
Procedure for changing the transmission sprocket.
Overview of the motorcycle's frame and attached components.
Procedure for removing and refitting the motorcycle's fuel tank.
Procedure for removing and refitting the motorcycle's styling covers.
Procedure for removing and refitting the motorcycle's oil tank.
Procedure for removing and refitting the battery carrier assembly.
Procedure for removing and replacing rear fender, lifting handle, etc.
Procedure for adjusting the rear suspension settings.
Procedure for removing and refitting the rear suspension units.
Procedure for dismantling and reassembling the suspension units.
Procedure for removing and refitting the motorcycle's swinging fork.
Procedure for renewing the swinging fork bushes.
Procedure for removing and replacing the rear section of the motorcycle frame.
Procedure for checking and correcting the motorcycle frame alignment.
Details for fairing attachment lugs and the steering lock mechanism.
Procedure for fitting replacement seat covers.
Simple repair procedures for minor bodywork damage.
Procedures for removing small and large dents from body panels using dollies.
Instructions for cutting, polishing, and waxing the final paint coat.
Overview of the motorcycle's braking, wheel, and tire systems.
Description of the disc brake system components and operation.
General maintenance procedures for the braking system.
Inspection and maintenance of the brake disc.
Inspection and replacement of brake pads.
Procedure for checking the hydraulic fluid level in the brake system.
Procedure for flushing and cleaning the hydraulic brake system.
General procedure for bleeding the hydraulic brake system.
Specific notes and procedures for bleeding the rear brake system.
Description of the master cylinder and control lever body.
Details regarding the master cylinder components and function.
Procedure for removing, dismantling, and refitting the front brake cylinder.
Procedure for removing, dismantling, and refitting the rear brake cylinder.
Procedure for dismantling and reassembling the brake caliper.
Notes on using correct replacement parts for the brake system.
Procedure for removing and refitting the front wheel.
Procedure for removing and refitting front wheel bearings.
Procedure for removing and refitting the rear wheel.
Procedure for removing and refitting rear wheel bearings.
Procedure for checking and correcting front and rear wheel alignment.
Procedure for balancing wheels and adding weights.
Procedures related to building motorcycle wheels, including spoke tensioning.
Procedure for adjusting the tension of the rear drive chain.
Procedure for removing and fitting motorcycle tires.
Information regarding the fitting and purpose of tire security bolts.
Maintenance recommendations for motorcycle tires.
Description of the telescopic front fork and its components.
Procedure for adjusting the steering head bearings.
Procedure for dismantling and reassembling the front fork legs.
Procedure for renewing the steering head bearings.
Procedure for checking and correcting front fork alignment.
Explanation of the hydraulic damping system in the telescopic forks.
Introduction to the electrical system section of the manual.
Procedures for inspecting and maintaining the motorcycle battery.
Weekly checks and maintenance for the motorcycle battery.
Table and guidance on specific gravity readings for battery electrolyte.
Permissible electrolyte temperatures during battery charging.
Information on the condenser pack used in the ignition system.
Details of the ignition coil system, including testing and fault finding.
Information on sparking plugs, including checking and replacement.
Details the charging system, including alternator, rectifier, and Zener diode.
Procedure for testing the rectifier's functionality.
Procedure for bench testing the rectifier using a battery and voltmeter.
Explanation of the Zener diode's role in regulating battery charging current.
Maintenance procedures for the Zener diode and its heat sink.
Location of the Zener diode in the motorcycle's electrical system.
Details on the electric horn operation and troubleshooting.
Description and maintenance of the motorcycle's headlamp.
Procedure for removing and refitting the motorcycle's headlamp.
Details on the tail and stop lamp unit, including bulb replacement.
Information on the motorcycle's fuses, rating, and location.
Details on the ignition switch operation.
Information on the motorcycle's flasher lamps.
Description of the various warning lamps on the motorcycle.
Details on the front and rear stop lamp switches.
Details on the oil pressure switch and its function.
Information on the 2MC capacitor ignition system.
Identification of the terminals on the capacitor unit.
Procedure for testing the capacitor's serviceability.
Guidelines for wiring and installing electrical components.
Important service notes related to the electrical system.
Troubleshooting steps for a slow or struggling starter motor.
Procedure for removing the starter motor assembly.
Procedure for removing the starter drive assembly.
Procedure for removing the starter motor solenoid.
Procedure for removing the starter motor itself.
Diagram illustrating the motorcycle's complete electrical wiring.
Introduction to the service tools section, explaining its purpose.
Lists and illustrates service tools specific to engine maintenance.
Lists and illustrates service tools specific to transmission maintenance.
Lists and illustrates service tools specific to wheel maintenance.
Lists and illustrates service tools specific to front fork maintenance.
Lists and illustrates service tools specific to frame maintenance.
Table for converting fractional measurements to decimals and millimeters.
Table for converting drill sizes between letters, numbers, and millimeters.
Table for converting wire gauges between Imperial Standard and AWG.
Table for converting liquid volumes from pints to litres.
Table for converting imperial gallons to litres.
Table for converting pressure units from PSI to kg/cm².
Table of BSW screw thread specifications, including tap drill sizes.
Table of BSF screw thread specifications, including tap drill sizes.
Table of UNC screw thread specifications, including tap drill sizes.
Table of UNF screw thread specifications, including tap drill sizes.
Specifications for valve guide material, dimensions, and clearances.
Details specifications for valve springs, including free length and coil counts.
Specifications for valve timing, including tappet clearances and opening/closing points.
Specifications for rocker arm bore, spindle diameter, and tappet clearances.
Specifications for camshaft journal diameters, clearances, and lift.
Specifications for tappet tip radius, diameter, and clearance.
Specifications for tappet guide block bore diameter and interference fit.
Specifies ignition timing settings for crankshaft and piston positions.
Details specifications for tachometer drive gear shaft and housing.
Specifications for timing gear pinions, including number of teeth and fit on camshaft.
Specifications for contact breaker gap setting and advance range.
Lists internal and overall gear ratios for the transmission, and engine RPM at 10 MPH.
Specifications for mainshaft high gear, bearing type, length, and spigot diameter.
Specifications for mainshaft and layshaft diameters and lengths.
Specifications for mainshaft and layshaft bearings, including bore and shaft diameters.
Specifications for kickstart ratchet mechanism bore and spring.
Specifications for kickstarter spindle diameter and bush bore.
Specifications for gearshift plungers, springs, and quadrant return springs.
Specifications for telescopic fork type, spring details, stanchion diameter, and cable length.
Lists components and specifications for the electrical system, including battery, coil, and lamps.
Details fuel tank capacity, oil tank capacity, and basic motorcycle dimensions.
Provides dry torque settings for various engine and chassis fasteners.
Describes routine lubrication tasks and frequency for the motorcycle.
Lists recommended lubricants from various manufacturers for different motorcycle units.
Details the engine's lubrication system, oil flow, and components.
Step-by-step guide for changing engine oil and cleaning or replacing oil filters.
Information regarding oil pressure specifications and checks.
Details the function and maintenance of the oil pressure release valve.
Step-by-step guide for removing and refitting the engine oil pump.
Procedure for removing and refitting the oil feed pipe to the rocker arms.
Details the function and maintenance of the anti-drain valve.
Instructions for lubricating the contact breaker points and cam spindle.
Lubrication procedures for the gearbox and transmission components.
Lubrication of the primary chaincase and its components.
Procedure for cleaning, lubricating, and maintaining the rear drive chain.
Instructions for greasing the steering head bearings.
Lubrication procedures for wheel bearings.
Lubrication of the telescopic front fork components.
Locating and using lubrication nipples for greasing points.
Methods for lubricating throttle, clutch, and brake control cables.
Procedure for lubricating the speedometer drive cable.
Lubrication of the rear brake pedal spindle.
Procedure for changing the hydraulic fluid in the braking systems.
Detailed description of the inclined 750cc three-cylinder engine and its construction.
Procedure for removing and refitting the entire engine from the motorcycle frame.
Steps for removing and refitting the engine's rocker boxes.
Inspection of the engine's push rods for wear or damage.
Procedure for dismantling and reassembling the engine rocker boxes.
Procedure for checking and adjusting valve rocker clearances.
Procedure for removing and refitting the engine's air cleaner assembly.
Description of the Amal type 626 concentric carburetors used on the motorcycle.
Procedure for removing and refitting the motorcycle's carburetors.
Procedure for dismantling and reassembling the carburetors.
Inspection of carburetor components for wear and damage.
Procedure for synchronizing and resetting the carburetors.
Steps for synchronizing the throttle slides on the carburetors.
Guidance on adjusting carburetor settings for different altitudes.
Procedure for removing and refitting the cylinder head assembly.
Specific steps and considerations for refitting the cylinder head.
Procedure for removing and fitting new valve guides.
Procedure for removing carbon deposits from engine components.
Procedure for re-seating engine valves.
Procedure for removing and refitting the cylinder block and tappets.
Inspection of engine cam followers for wear.
Inspection of engine tappet guide blocks for wear.
Procedure for removing and refitting engine pistons.
Procedure for removing and replacing piston rings.
Inspection of pistons and cylinder bores for wear and scoring.
Table of suitable piston and bore sizes for engine rebore operations.
Procedure for removing and refitting the contact breaker unit.
Procedure for adjusting the contact breaker points gap.
Procedure for setting the engine's static ignition timing.
Procedure for checking and adjusting ignition timing using a stroboscope.
Procedure for removing and refitting the engine timing cover.
Procedure for removing and refitting valve timing pinions.
Procedure for extracting camshaft pinions using extractor screws.
Procedure for checking and setting the engine valve timing marks.
Procedure for reassembling the engine crankcase after servicing.
Inspection of crankcase components for wear and damage.
Overview of the primary drive system, including clutch and chaincase.
Details the motorcycle's clutch mechanism and its operation.
Procedure for adjusting the clutch operating mechanism.
Detailed steps for adjusting the clutch operating mechanism and cable.
Procedure for adjusting the primary drive chain tension.
Procedure for removing and refitting the outer primary chaincase cover.
Procedure for refitting the motorcycle's clutch cover.
Procedure for dismantling the primary drive assembly.
Procedure for reassembling the primary drive assembly.
Procedure for checking and correcting primary chain sprocket alignment.
Procedure for refitting the inner primary chaincase.
Procedure for renewing the shock absorber rubbers in the chainwheel.
Procedure for removing and refitting the chainwheel and engine sprocket.
Inspection of primary drive components for wear and damage.
Procedures for repairing, lengthening, or shortening the rear drive chain.
Overview of the transmission system, including gear shifting and components.
Explanation of the gear shifting sequence and operation.
Procedure for removing and refitting the transmission outer cover.
Procedure for dismantling and reassembling the kickstart mechanism.
Procedure for dismantling and reassembling the gear shift mechanism.
Procedure for dismantling and reassembling the gear shift cross shaft.
Inspection of gear shift and kickstart components for wear.
Procedure for renewing kickstart and gear shift spindle bushes.
Procedure for dismantling the motorcycle gearbox.
Inspection of transmission components for wear and damage.
Procedure for renewing mainshaft and layshaft bearings.
Procedure for reassembling the motorcycle gearbox.
Procedure for changing the transmission sprocket.
Overview of the motorcycle's frame and attached components.
Procedure for removing and refitting the motorcycle's fuel tank.
Procedure for removing and refitting the motorcycle's styling covers.
Procedure for removing and refitting the motorcycle's oil tank.
Procedure for removing and refitting the battery carrier assembly.
Procedure for removing and replacing rear fender, lifting handle, etc.
Procedure for adjusting the rear suspension settings.
Procedure for removing and refitting the rear suspension units.
Procedure for dismantling and reassembling the suspension units.
Procedure for removing and refitting the motorcycle's swinging fork.
Procedure for renewing the swinging fork bushes.
Procedure for removing and replacing the rear section of the motorcycle frame.
Procedure for checking and correcting the motorcycle frame alignment.
Details for fairing attachment lugs and the steering lock mechanism.
Procedure for fitting replacement seat covers.
Simple repair procedures for minor bodywork damage.
Procedures for removing small and large dents from body panels using dollies.
Instructions for cutting, polishing, and waxing the final paint coat.
Overview of the motorcycle's braking, wheel, and tire systems.
Description of the disc brake system components and operation.
General maintenance procedures for the braking system.
Inspection and maintenance of the brake disc.
Inspection and replacement of brake pads.
Procedure for checking the hydraulic fluid level in the brake system.
Procedure for flushing and cleaning the hydraulic brake system.
General procedure for bleeding the hydraulic brake system.
Specific notes and procedures for bleeding the rear brake system.
Description of the master cylinder and control lever body.
Details regarding the master cylinder components and function.
Procedure for removing, dismantling, and refitting the front brake cylinder.
Procedure for removing, dismantling, and refitting the rear brake cylinder.
Procedure for dismantling and reassembling the brake caliper.
Notes on using correct replacement parts for the brake system.
Procedure for removing and refitting the front wheel.
Procedure for removing and refitting front wheel bearings.
Procedure for removing and refitting the rear wheel.
Procedure for removing and refitting rear wheel bearings.
Procedure for checking and correcting front and rear wheel alignment.
Procedure for balancing wheels and adding weights.
Procedures related to building motorcycle wheels, including spoke tensioning.
Procedure for adjusting the tension of the rear drive chain.
Procedure for removing and fitting motorcycle tires.
Information regarding the fitting and purpose of tire security bolts.
Maintenance recommendations for motorcycle tires.
Description of the telescopic front fork and its components.
Procedure for adjusting the steering head bearings.
Procedure for dismantling and reassembling the front fork legs.
Procedure for renewing the steering head bearings.
Procedure for checking and correcting front fork alignment.
Explanation of the hydraulic damping system in the telescopic forks.
Introduction to the electrical system section of the manual.
Procedures for inspecting and maintaining the motorcycle battery.
Weekly checks and maintenance for the motorcycle battery.
Table and guidance on specific gravity readings for battery electrolyte.
Permissible electrolyte temperatures during battery charging.
Information on the condenser pack used in the ignition system.
Details of the ignition coil system, including testing and fault finding.
Information on sparking plugs, including checking and replacement.
Details the charging system, including alternator, rectifier, and Zener diode.
Procedure for testing the rectifier's functionality.
Procedure for bench testing the rectifier using a battery and voltmeter.
Explanation of the Zener diode's role in regulating battery charging current.
Maintenance procedures for the Zener diode and its heat sink.
Location of the Zener diode in the motorcycle's electrical system.
Details on the electric horn operation and troubleshooting.
Description and maintenance of the motorcycle's headlamp.
Procedure for removing and refitting the motorcycle's headlamp.
Details on the tail and stop lamp unit, including bulb replacement.
Information on the motorcycle's fuses, rating, and location.
Details on the ignition switch operation.
Information on the motorcycle's flasher lamps.
Description of the various warning lamps on the motorcycle.
Details on the front and rear stop lamp switches.
Details on the oil pressure switch and its function.
Information on the 2MC capacitor ignition system.
Identification of the terminals on the capacitor unit.
Procedure for testing the capacitor's serviceability.
Guidelines for wiring and installing electrical components.
Important service notes related to the electrical system.
Troubleshooting steps for a slow or struggling starter motor.
Procedure for removing the starter motor assembly.
Procedure for removing the starter drive assembly.
Procedure for removing the starter motor solenoid.
Procedure for removing the starter motor itself.
Diagram illustrating the motorcycle's complete electrical wiring.
Introduction to the service tools section, explaining its purpose.
Lists and illustrates service tools specific to engine maintenance.
Lists and illustrates service tools specific to transmission maintenance.
Lists and illustrates service tools specific to wheel maintenance.
Lists and illustrates service tools specific to front fork maintenance.
Lists and illustrates service tools specific to frame maintenance.
Table for converting fractional measurements to decimals and millimeters.
Table for converting drill sizes between letters, numbers, and millimeters.
Table for converting wire gauges between Imperial Standard and AWG.
Table for converting liquid volumes from pints to litres.
Table for converting imperial gallons to litres.
Table for converting pressure units from PSI to kg/cm².
Table of BSW screw thread specifications, including tap drill sizes.
Table of BSF screw thread specifications, including tap drill sizes.
Table of UNC screw thread specifications, including tap drill sizes.
Table of UNF screw thread specifications, including tap drill sizes.
General| Bore x Stroke | 67 mm x 70 mm |
|---|---|
| Compression Ratio | 9.5:1 |
| Transmission | 5-speed |
| Front Suspension | Telescopic forks |
| Front Brake | Single disc |
| Rear Brake | Drum |
| Displacement | 741 cc |
| Power | 58 hp @ 7, 250 rpm |
| Torque | 60 Nm (44 lb-ft) @ 5, 500 rpm |
| Fuel System | 3 x Amal carburetors |
| Rear Suspension | Twin shock absorbers |
| Wheelbase | 1, 473 mm |
| Fuel Capacity | 19 liters |
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