VeloCruz • PO Box 902021 • Sandy, UT 84090

Phone: 801.733.4578 • 800.393.7101 • Fax: 801.383.6070

www.velocruz.com • info@velocruz.com
 TABLE OF CONTENTS
Techical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Principle of Operation of the 2-Cycle Engine . . . 2
Ignition3
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Automatic Compound Clutch . . . . . . . . . . . . . . . 6
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . 7
Engine Repair Operations . . . . . . . . . . . . . . . 8-29
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Guard Rail . . . . . . . . . . . . . . . . . . 9
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stator and Stator Bearing . . . . . . . 12-13
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drive Roller Assembly . . . . . . . . . . . . . . 15
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cylinder Head . . . . . . . . . . . . . . . . . . 18-19
Cylinder . . . . . . . . . . . . . . . . . . . . . . . 20-21
Carburetor . . . . . . . . . . . . . . . . . . . . . . . 22
Crankcase End Cover . . . . . . . . . . . . . . 23
Connecting Rod Assembly . . . . . . . . . . 24
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Supports and Axle . . . . . . . . . . 26
Engine Decarbonizing. . . . . . . . . . . . . . . 27
Decompressor . . . . . . . . . . . . . . . . . . . . 28
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 28
Ignition Timing . . . . . . . . . . . . . . . . . . . . 29
Engine Component Parts . . . . . . . . . . . . . . 30-32
Electrical Connections, Solex 3800 D.O.T. . . . 33
Engine Trouble Shooting Guide . . . . . . . . . 34-36
Cycle, Frame, Controls Repair Operations . 37-50
i
Front Wheel Assembly. . . . . . . . . . . . . . 37
Wheel Axle . . . . . . . . . . . . . . . . . . . . . . . 37
Wheel Bearing Play . . . . . . . . . . . . . . . . 38
Front Brake Mechanism . . . . . . . . . . . . 38
Front Brakes . . . . . . . . . . . . . . . . . . . . . 39
Front Mudguard . . . . . . . . . . . . . . . . . . 40
Mudguard Supports . . . . . . . . . . . . . . . 40
Steering Races. . . . . . . . . . . . . . . . . . . . 41
Front Forks . . . . . . . . . . . . . . . . . . . . . . 42
Kick Stand. . . . . . . . . . . . . . . . . . . . . . . 42
Crank Spindle . . . . . . . . . . . . . . . . . . . . 43
Crank Assembly. . . . . . . . . . . . . . . . . . . 44
Handlebar . . . . . . . . . . . . . . . . . . . . . . . 44
Throttle Twist Grip . . . . . . . . . . . . . . . . 45
Left Handgrip . . . . . . . . . . . . . . . . . . . . 45
Saddle Assembly . . . . . . . . . . . . . . 45-46
Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . 46
Rear Brake Drum . . . . . . . . . . . . . . . . . 46
Brake Shoes . . . . . . . . . . . . . . . . . . . . . 47
Rear Brake . . . . . . . . . . . . . . . . . . . . . . 48
Rear Wheel Bearing. . . . . . . . . . . . . . . . 48
Rear Mudguard . . . . . . . . . . . . . . . . . . . 49
Mudguard Support . . . . . . . . . . . . . . . . 49
Luggage Carrier and Supports . . . . . . 49
Headlamp . . . . . . . . . . . . . . . . . . . . . . . 50
Rear Lamp. . . . . . . . . . . . . . . . . . . . . . . 50
Control Cables . . . . . . . . . . . . . . . . . . . . . . . 51-52
Brake Cables. . . . . . . . . . . . . . . . . . . . . . 51
Throttle Cables. . . . . . . . . . . . . . . . . . . . 51
Decompressor Cable . . . . . . . . . . . . . . . 52
Torque Diagrams . . . . . . . . . . . . . . . . . . . . . 53-58
Solex Wiring Diagram . . . . . . . . . . . . . . . . . . . . 59
 TECHNICAL DATA
Dimensions: Overall length ...............................66 inches
Overall width.................................24 inches
Overall height ...............................41 3/4 inches
Weight ............................................68 pounds
Frame: Type.................................................Pressed steel
Front brakes ................................Caliper
Rear brakes ..................................Internal expansion
Tire size .........................................1.75 x 19
Tire pressure F/R........................32 psi
Fuel: Capacity ........................................1/3 U.S. gallon
Mixture...........................................Mix 4 ounces high quality two-stroke oil
with 1 gallon unleaded gasoline.
Engine: Type.................................................Single cylinder, two-stroke
Power...............................................0.8 HP
Capacity ........................................49 cc
Electrical System: Ignition and Lighting..................Flywheel
Spark plug.....................................Champion L86, Autolite AE32,
Bosch W174 T1
Headlamp......................................Sealed beam 6 volt
Taillight/Stoplight ......................Trade no. 1154 6 volt
Performance: Speed .............................................20 MPH
Identification Engine number .............................Seven digit number engraved on the rear
of the engine housing. 9.6
Serial number ..............................Located on the frame steering. 9.1

1
 PRINCIPLE OF OPERATION OF THE 2-CYCLE ENGINE
As the piston rises, it opens the inlet port and begins to draw a fresh mixture into the crankcase.
This is because the increasing crankcase volume lowers the crankcase air pressure below atmosphere.
At the same time, combustion chamber pressure begins to increase. See figure 1
Piston reaches top of its stroke, spark plug ignites the mixture. See figure 2
Rapid expansion of ignited mixture pushes the piston down. The inlet port closes. See figure 3
Fuel supply: As piston descends in cylinder, it creates air pressure in the crankcase which escapes
through the fuel pump port in crankcase to the fuel pump causing the fuel pump membrane to expand.
As piston rises in cylinder, a vacuum is created inside the crankcase causing the fuel pump membrane
to contact. This process now creates a pumping action in the fuel pump, and to keep the gas flowing in
an upward direction to the carburetor, the pump has two check balls which act as one-way valves.
Exhaust begins. The burned gas is forced out due to high pressure in the combustion chamber. See
figure 4
Transfer port opens. Descending piston forces fresh mixture through transfer port to combustion
chamber. The incoming fresh mixture helps to push exhaust mixture out. See figure 5
Exhaust port closes. Compressions begins. See figure 6

Exhaust Exhaust Exhaust

Port Port Port
T Inlet T Inlet T Inlet
Port Port Port
Fuel
Pump
Port

Figure 2 Figure 3
Figure 1

Exhaust Exhaust Exhaust

Port Port Port
T Inlet T Inlet T Inlet
Port Port Port

Figure 4 Figure 5 Figure 6

2
 IGNITION
Flywheel Magneto The Solex ignition magneto is of a compact, rotary magnet design. It
provides a high voltage for the spark plug and low voltage current for
lights and horn. Facing each other inside the flywheel are 4 fixed magnets
spaced at 90 degrees. Alternate magnets show alternate north and
south poles. Inside the flywheel is a cam which opens the points and a
key to locate the flywheel on the crankshaft.
Ignition Circuit The ignition circuit consists of an ignition coil with the primary winding,
contact points to interrupt the primary circuit, a condenser, and a sec-
ondary winding.
Operation As the flywheel magnets rotate past the coil, a current is induced in the
primary winding. The primary winding of the ignition coil sends the current
to the moving contact which, at the closed position, is grounded to the
fixed contact. As the flywheel rotor revolves, the cam opens the points;
the current is no longer grounded and, therefore, must move. The current
moves to the secondary winding of the ignition coil, producing a high ten-
sion current which goes to the spark plug lead and ignites the mixture in
the cylinder.
Condenser A condenser is a tight roll of two strips of foil sandwiched between three
insulator strips. Because of its large metallic surface area, a condenser
has the ability to store small amounts of electrical energy. The amount
of stored energy depends on the condenser size (rated in micro-farads)
and the applied voltage.
Furthermore, electrical occilations, a phenomenon known as resonance,
occurs whenever a charged condenser and matched inductive coil are
placed together in a closed circuit.
The condenser is in parallel with the points and acts as a safety valve by
providing a path for the current to follow when the points open. Current
flows to the condenser instead of jumping the point gap, thereby pre-
venting burning of the points.

3
 CARBURETOR
Principle The Solex carburetor is supplied with fuel by a crankcase pressure acti-
vated fuel pump. Fuel is pumped from the fuel tank through the fuel pump
to the carburetor at which time the fuel needed is metered through the
fuel jet, combined with air. This mixture goes to the cylinder.
The Solex carburetor consists of 13 parts:
1 Carburetor body w/diffuser 8 Throttle barrel
2 Air jet 9 Cable bracket
3 Fuel jet 10 Carburetor slide
4 Inlet manifold olive 11 Slide fixing bolt
5 Inlet manifold nut 12 Slide spring
6 Choke assembly 13 Carburetor filter
7 Choke lever
Operation The fuel is delivered to the carburetor through the fuel supply pipe, at
which time it is filtered (A). The amount of fuel needed is then metered
by the fuel jet (B) into the cylinder, and the surplus fuel delivered by the
pump is returned to the fuel tank through the overflow pipe (C). This prin-
ciple avoids the need of a float because there is always the proper
amount of fuel at the jet. See figure 7
After the fuel is metered through the fuel jet, it combines with air from
the air jet (D) through the choke assembly (E) to the mixing chamber (F)
and proceeds through the diffuser (G) which vaporizes the fuel mixture.
This vaporized fuel mixture proceeds through the air horn (H), through
the throttle barrel (I) to the inlet pipe, then to the cylinder when the inlet
port is opened (See figures 1 thru 6).
Throttle Barrel The throttle barrel controls the amount of the vaporized fuel entering
into the cylinder.
When completely opened, it draws more air through the air horn, which in
turn increases the fuel mixture in the diffuser, which in turn causes the
motor to turn faster.
As the throttle barrel closes, the amount of air drawn through the air
horn decreases, which in turn decreases the fuel mixture in the diffuser,
which in turn causes the motor to turn slower.
Idle The throttle barrel has been modified by the factory to give a proper con-
trol when idling. There is a special manufactory control on this modified
barrel indicated by a blue spot on the carburetor body. †his modification
is so critical that the company does not wish you making this operation,
but suggest you replace this part if the carburetor does not have this
control mark.
Choke The choke lever control the amount of air entering through the air jet. By
closing the choke lever, you decrease the amount of air, thereby enriching
the full mixture in the mixing chamber, which in turn creates more com-
bustion in the cylinder; thus, allowing your engine to start more easily
when cold.

4
 THE SOLEX CARBURETOR

AIR FILTER

C
F G
B

CARBURETOR BODY

A - Fuel Filter F - Mixer Chamber

B - Fuel Jet G - Diffuser
C - Overflow Pipe H - Air Horn
D - Air Jet I - Throttle Barrel
E - Choke Assembly
Figure 7

5
 AUTOMATIC COMPOUND CLUTCH
Clutch Components The automatic compound clutch is comprised of: a drum, integral with
the drive roller, and a system of bobweights and shoes integral with the
crankshaft. See figure 8
The vaned rotor and the flywheel magneto cover form a fan which cools
the engine when it is running and enables it to idle without overheating.
WARNING: Never run the engine with the flywheel cover removed.
Clutch Action The clutch is a single action, centrifugal clutch that starts the engine as
well as propels the machine.
Starting the Engine When stationary, the flyweights (F) due to the action of the springs (S)
press the centrifugal clutch arms (A) and pads (P) against the drive
roller drum (D). When the front wheel begins to revolve, the engine is
turned. See figure 9
Normal Running When the throttle is opened the speed of the engine increases, forcing
the flyweights further away from each other, thus forcing the centrifugal
clutch arms and pads further against the drive roller drum transmitting
power from the crankshaft to wheel through the drum and the drive
roller. See figure 10
Normal RPM at full speed is 3800 RPM.
Slow Down and Idle When the engine reaches idling speed (1500 RPM), the flyweights move
outwards due to centrifugal force. During this time the centrifugal force
is overridden by the power of the springs. The pressure of the pads on
the drum is reduced by the contraction of the centrifugal clutch arms
allowing the clutch pads to slip while the engine continues to run. Power
is now discontinued from the drive roller drum and drive roller allowing the
engine to idle. See figure 11

Figure 8 Figure 9 Figure 10 Figure 11

6
 SPECIAL SERVICE TOOLS

Part # 200001 - Valve Reamer Part # 200006 - Brake Tool

Part # 200002 - Stud Extractor Part # 200007 - Bearing Extractor

Part # 200003 - 21mm Deep Socket Part # 200008 - Clutch Limiter

Part # 200004 - Stator Plate Extractor and Installer Part # 200009 - Stroke Limiter

Part # 200005 - Flywheel Puller Part # 200010 - Engine Mount Plate

7
 ENGINE REPAIR OPERATIONS
Operation Sequence The following operations are described in a sequence which results in
complete disassembly of the engine, if reassembly of each operation is
not carried out.

Muffler
Removing 1. Loosen, but do not remove, the nut securing the muffler to the mud-
guard. Loosen the nut securing the exhaust pipe to the right hand engine
support. Use 10mm wrench. Figure 12
2. Pull on the muffler to remove it from the mudguard.
3. Pull the muffler outwards, while pulling down on the exhaust pipe near
the engine support, and free the pipe from the upper section of the
exhaust pipe.
Solex owners are advised to consult their dealer at each 3600 miles for
muffler inspection.
The muffler should be replaced at this interval if restricted at all. When
fitting a new muffler, check that no obstruction enters the exhaust pipe.
Reassembling Reassemble in reverse sequence.
NOTE: The muffler stay must be inserted between the mudguard support
and the mudguard and pushed in fully to prevent vibration. Leave a space
between the exhaust pipe and the front fork to prevent noise vibration. If
the muffler comes in contact with the front fork after tightening the
muffler mounts, pry it away using a heavy screwdriver.

Figure 12
8
 Engine Guard Rail
Removing 1. Loosen the bolt securing the engine guard rail to the fork assembly
(10mm wrench). See figure 13
2. Pull gently on each side of the engine guard rail at the clamp position
and lift the rail forward and over the engine.
Reassembling 1. Reverse the procedure.
NOTE: There are two caps inside of the engine guard rail tube.

Figure 13

9
 Engine
Removing 1. Set the machine on the support stand. See figure 12
2. Loosen the front brake.
3. Remove the front wheel (17mm wrench).
4. Remove the flywheel cover.
5. Remove the engine cover.
6. Disconnect the lighting wires.
7. Disconnect the throttle and decompressor cable (7mm and 10mm
wrench).
8. Loosen the nuts on each side of the engine supports and remove the
bolts (10mm wrench).
9. Loosen, but do not remove, the upper nuts on each side of the engine
supports (10mm wrench).
10. Lift the engine form the fork support slots and remove.
Reinstalling Reverse the procedure.
NOTE: After installing, check and adjust: throttle (pg. 28), decompressor
(pg. 28), front brake adjustment (pg. 39), and check lighting.

10
 Rotor
Removing 1. Remove the stroke limiter plug and insert the stroke limiter as
described. Unscrew the stroke limiter slowly while turning the flywheel and
stop as soon as the flyweight just catches the stroke limiter (tool
#200009).
2. Loosen the flywheel cover plate nut and remove the plate and rubber
seal and remove the rotor nut (14mm wrench).
3. Install the flywheel puller nut with the flange of the nut to the rear
(tool #200005).
4. Install the flywheel puller plate on the flywheel and tighten the three
fixing bolts (10mm socket). See figure 14
5. Loosen the flywheel puller nut until a cracking noise is heard (14mm
wrench).
6. Continue to loosen the flywheel puller nut and remove the rotor.
7. Remove the flywheel puller plate and the nut from the rotor (use
10mm wrench).
8. Place the rotor on the workbench with the open side up to prevent
foreign metal objects connecting with the magnets.
Reassembling 1. Lightly oil the felt pad on the stator plate assembly.
2. Reverse the removal procedure.
NOTE: The key on the rotor bushing aligns with the slot on the crank-
shaft.

Figure 14

11
 Stator and Stator Bearing
Removing Stator 1. Loosen the two bolts securing the top left horn coil and remove (7mm
wrench).
2. Turn the coil to one side and reinstall the bolts (7mm wrench).
3. Loosen the drive roller cleaning bolt and disconnect the spark plug
lead from the stator plate and wires. See figure 15
4. Loosen the bolt securing the engine engagement lever. Do not remove
(10mm wrench).
5. Loosen the two stator plate fixing bolts and install the stator plate
puller tool on the crankshaft (tool #200004).
NOTE: Remove the stroke limiter but do not replace the stroke limiter
plug.
6. Screw in the stator plate puller wings until each wing fits over the cor-
ners of the ignition and lighting coils. Hold wings firmly and screw in the
stator plate puller until stator plate is free of the crankshaft. See figure 15
7. Remove the stator plate puller and the stator.
Removing Stator Bearing 1. Insert the stroke limiter (tool #200009).
2. Install the bearing extractor tool with the tool flanges over the bearing
(tool. #200007).
3. Screw in the extractor and remove the bearing.

Figure 15

12
Reassembling Bearing 1. Lightly spray lubricate and inside lips of the bearing.
2. Heat the stator housing and insert the bearing with the open side of
the bearing in the stator housing.
Reassembling Stator 1. Insert the stator plate bolts. See figure 16
2. Align the stator plate with the engine engagement lever bolt.
3. Fit the stator plate puller extension pipe on the tool and install the
puller on the crankshaft (tool #200004).
4. Turn the wings of the stator plate puller clockwise until the stator is
installed on the crankshaft.
NOTE: Install the stator on the crankshaft to within 1/8 inch of its
seating.
5. Tighten the engine engagement lever bolt by hand. Tap on the stator
to correctly align.
6. Tighten the stator plate puller wings until the stator is fully seated.
7. Tighten the engine engagement lever bolt fully (10mm wrench).
8. Remove the stator plate puller.
9. Tighten stator plate bolts (10mm wrench).

Figure 16

13
 Clutch
Removing 1. Loosen the nut securing the clutch assembly to the crankshaft
(tool #200003).
2. Using both index fingers, expand the flyweights and withdraw the
clutch assembly from the drive roller housing.
NOTE: Inspect the clutch linings and replace the clutch assembly if worn.
Reassembling NOTE: The “X” marked on the clutch arms indicates the outward facing
side of the clutch when mounted. See figure 17
1. Squeeze the flyweights together and insert in the drive roller housing.
2. Install the nut on the crankshaft.
3. Fit the clutch wrench over the nut with the arm of the wrench aligned
with the front side of the engine engagement lever bolt hole. Insert a bolt
through the arm of the wrench into the bolt hole to hold the clutch
wrench firmly (tool #200008).
4. Tighten the crankshaft nut fully.
5. Remove the bolt and clutch wrench (tool #200008)

Figure 17

14
 Drive Roller Assembly
Removing 1. With the left index finger, press one side of the oil seal while rocking the
seal on the other side with the right index finger. Gradually withdraw the
oil seal over the thread of the crankshaft and remove.
2. Remove the drive roller nut and washer (tool #200003). See figure 18
3. Remove the drive roller.
Reassembling 1. Lightly grease drive roller between the roller and crankcase flanges.
2. Align the flange of the drive roller with the engine engagement lever
bolt hole and insert a bolt.
3. Fit the washer and drive roller nut and tighten slightly (tool
#200003).
4. Fit the oil seal.

Figure 18

15
 Fuel Tank
Removing 1. Disconnect the fuel recirculation pipe from the carburetor. See figure 19
2. Loosen the fuel inlet pipe nut on the fuel pump (10mm wrench).
3. Loosen the fuel tank mounting bolts (10mm wrench).
4. Remove the fuel tank.
5. Loosen the fuel outlet pipe nut.
6. The fuel filter is located at the fuel outlet.
7. To remove the filter, insert a 2-inch, #6 or #8 sheetmetal screw in the
fuel outlet.
8. Screw into the filter and pull.
9. Replace the gas tank filter if fouled.
Reassembling Reverse the procedure.
NOTE: Never tighten the fuel outlet pipe excessively.

Figure 19

16
 Air Filter
Removing 1. Loosen the air filter cover and remove the air filter unit (10mm wrench).
See figure 20

2. Hold the cover and tap lightly on the protruding lip of the air filter
housing until the cover is free of the housing.
3. Pry the filter ring loose and remove the filter (screwdriver).
Installing 1. Reverse the procedure.
NOTE: Check that the gasket on the carburetor inlet is in position.

Figure 20

17
 Cylinder Head
Removing 1. Disconnect the lead to the spark plug and remove the spark plug lead
(10mm wrench). See figure 21
2. Loosen the spark plug (tool #200003).
3. Loosen the cylinder head bolts and remove the cylinder head (10mm
wrench).
4. Remove the air filter support bracket.
5. Remove the decompressor cylinder head plate.
6. Remove cylinder head spacers.
7. Loosen and remove the brass nut connecting the decompressor valve
assembly.
8. Scrape all carbon deposits from the cylinder head. DO NOT scrape the
decompressor valve seat (scraper).
9. Place a little oil in the decompressor valve port and insert a valve
reamer to clean the port.

Figure 21

18
Reassembling NOTE: Always fit a new decompressor valve after having reamed the
cylinder head valve seat.
1. Insert the decompression valve in the cylinder head with the slot on the
valve end facing a 1 o’clock direction (screwdriver).
2. Place the valve spring on the valve and fit the decompressor valve
brass nut.
3. Tighten the nut also aligning the slot in the nut to the 1 o’clock direc-
tion (10mm wrench).
4. Hold the decompressor valve and loosen the nut counter clockwise one
complete turn.
NOTE: Always fit a new cylinder head gasket.
5. Fit the gasket, and place the cylinder head in position in the cylinder.
6. Insert the air filter support bracket in the slots on the cylinder head
with the screw hole facing to the front of the motor.
7. Insert the cylinder head spacers.
8. Fit the decompressor cylinder head plat in position and connect the
engine decompressor lever in the slot in the decompressor valve.
9. Insert the cylinder head bolts placing one washer on the top of the
plate on the cylinder head bolt at the decompressor lever.
10. Tighten the cylinder head bolts progressively at opposite corners to
8.5 - 9 ft. lbs. (10mm wrench).
NOTE: Never tighten the cylinder head bolts excessively.
If the decompressor cable has been disconnected, connect and adjust
the decompressor as described (see page 28).

19 SOLEX 19
 Cylinder
Removing 1. Disconnect the fuel recirculation pipe on the fuel pump.
2. Loosen but do not remove the fuel inlet pipe nut on the carburetor and
turn it (14mm wrench).
3. Loosen the lower cylinder mounting nuts and take off the lockwashers
(10mm wrench).
4. Remove the stroke limiter plug and insert the stroke limiter (tool
#200009).
5. Turn the flywheel in a counterclockwise direction until the crankshaft
flyweight catches against the stroke limiter.
6. Turn the flywheel in the opposite direction until the other end of the
crank flyweight catches the stroke limiter.
7. Unscrew the stroke limiter slightly.
8. Turn the flywheel in a clockwise direction about 1/2 inch and screw in
the stroke limiter fully.
9. The piston will be held in the T.D.C. position.
10. Remove the cylinder and gasket. See figure 22
11. Loosen the bolts securing the exhaust manifold and remove the mani-
fold, gasket and carburetor (10mm wrench). See figure 23
12. Scrape carbon deposits from the cylinder exhaust port and clean the
decompressor vertical port on top of the cylinder (scraper).
13. Clean the manifold exhaust port (scraper).

Figure 22

20
Reassembling Reverse the procedure.
NOTE: Always fit new exhaust manifold and cylinder base gaskets after
removal.
1. Place the slots on the top and bottom piston rings facing to the front
and the slot on the center piston ring facing the 11 o’clock direction. Oil
the piston.
2. Check the condition of the cylinder mounting studs. If bent or dam-
aged, extract and fit new studs.
3. Tighten the cylinder mounting nuts progressively at opposite corners
to 8.5 - 9 ft. lbs. (10mm wrench)
NOTE: Never tighten the cylinder mounting nuts excessively.
4. After assembly, check the compression.
5. Place the left hand flat on the cylinder and turn the flywheel back and
forth.
6. Adequate compression will be visible by the suction on the hand.

Figure 23

21
 Carburetor
Removing 1. Unhook the cable pulley spring.
2. Loosen the nut connecting the carburetor to the intake manifold
(14mm wrench).
3. Remove the fuel jet and the air jet and clean (10mm wrench and
screwdriver).
4. Clear all passages with an air stream giving special attention to the
calibrated hole of the jets.
5. Remove the fuel filter and replace if fouled.
6. Remove the throttle pulley slide nut and disconnect the slide (10mm
wrench).
7. Withdraw the throttle barrel and clean.
8. To remove the choke assembly: Press down on the choke barrel on the
spring loaded side and remove the choke lever. Remove the choke barrel
from the carburetor.
Reassembling 1. Reverse the procedure.

22
 Crankcase End Cover
Removing 1. Loosen and remove the eight bolts securing the crankcase end cover
(10mm wrench). See figure 24
2. Remove the cover and gasket.
Reassembling 1. Oil a new gasket and place in position.
2. Secure the gasket by inserting the two upper bolts and tightening
slightly (10mm wrench).
3. Cut the gasket carefully to the form of the crankcase end.
4. Insert the remaining six bolts and tighten slightly (10mm wrench).
5. Fit the cylinder.
6. Tighten first the two cylinder mounting nuts on the crankcase fully
(10mm wrench).
7. Tighten the other two cylinder mounting nuts on the crankcase end
cover fully, and then unscrew them 1⁄6 turn (10mm wrench).
8. Tighten the crankcase end cover bolts progressively commencing at
the lower bolt (10mm wrench).
9. Then tighten the two cylinder mounting nuts on the crankcase end
cover fully (10mm wrench).

Figure 24

23
 Connecting Rod Assembly
Removing 1. Insert the stroke limiter as described (tool #200009). See figure 25
2. Remove the crankshaft end nut and washer (14mm wrench).
3. Remove the connecting rod assembly and bushing.
Reassembling 1. Change bushing and washer if necessary.
2. Reverse the procedure.
NOTE: Check that the piston is facing the same direction as on the
removal. (Flat side of the bearing against the crankshaft counterweight.)

Figure 25

24
 Fuel Pump
Removing 1. Loosen the four bolts securing the fuel pump housing to the engine
(7mm wrench). See figure 26
2. Remove the fuel pump.
3. If the fuel pump has been removed with the plastic pump seating piece,
pry the seating piece loose and remove the diaphragm.
Reassembling 1. Clean the plastic pump seating and place in position on the crankcase
air port with the concave side facing the fuel pump.
2. Tap the center on to the air port lug.
NOTE: Always fit a new diaphragm after having removed the fuel pump.
3. Check that the plastic fuel pump ball is correctly seated in the fuel
port of the pump.

Figure 26

25
 Engine Supports and Axle
Removing 1. Unhook the suspension springs on each support and remove with the
engine mudguard. See figure 27
2. Release the engine pivot pin nut locks.
3. Loosen the engine pivot nuts (14mm wrench).
4. Loosen the front nuts and remove the bolts and spacer (14mm
wrench).
5. Remove the engine support.
6. Loosen the suspension friction plate tension nuts and remove the
springs and guides (10mm wrench).
7. Remove the engine axle.
Reassembling 1. Before tightening the engine axle nuts when reassembling the engine
axle with the crankcase and the engine supports, these parts must be in
the same position as the motor on the front fork against the wheel.

Figure 27

26
 Engine Decarbonizing
Removing 1. After a number of miles, carbon obstructs the various passages in the
engine, and hinders its efficient running. See figure 28
2. To remove this carbon, first dismantle the cylinder head, after taking
off the air cleaner body, the carburetor and the manifold.
3. Scrape the carbon deposit off the cylinder head and the top of the
piston.
4. Clean the exhaust port thoroughly, as well as the manifold and check
that no carbon deposit obstructs the latter at any point.
5. Pass a 5mm drill through the vertical hole of the decompressor and a
3.5mm drill through the angular hole on the cylinder head.
6. Clean and lap the valve; change it, as well as the spring, every time.
7. The exhaust system cannot be dismantled; it should be changed
after 5,000 miles.
8. When fitting a new exhaust pipe, pass a 6mm drill through the outlet
pipe, as it may be obstructed by a drop of paint.
Reassembling NOTE: When reassembling use new gaskets. Check the ignition timing on
the flywheel magneto. Adjust the plug gap to 5/10mm (0.020"). Clean or
change the air filter if necessary. Adjust the throttle control.

Figure 28

27
 Decompressor
Adjusting 1. The decompressor valve opens correctly when the travel of the decom-
pressor engine lever is between 1/8 inch and 1/32 inch.
2. Loosen the cable guide nut and adjust the tension on the cable until
correct adjustment is reached (7mm wrench).

Throttle
Adjusting 1. Insert the throttle cable cover end in the upper cable holder on the
throttle arm. See figure 29
2. Loosen the cable pulley nut and wind the cable from left to right over
the pulley and under the washer of the cable pulley nut.
3. Tension the cable.
4. Tighten the cable pulley nut.
5. Start the engine.
6. With the throttle twist grip rolled to the front and the throttle off,
the engine should idle smoothly.
7. If the engine runs too fast, loosen the cable pulley nut and adjust the
position of the cable on the pulley until correct idling speed is reached.
8. The correct engine idle is 1500 rpm.

Figure 29

28
 Ignition Timing
Adjusting 1. Remove the engine and flywheel covers.
2. Remove the rotor cover plate and rubber seal (14mm wrench).
3. Turn the flywheel rotor until the contact mark on the rotor is
aligned with the stator plate “rupture” mark.
4. Connect the red lead of a timing light to the grey wire of the
ignition coil.
5. Connect the black lead of the timing light to ground.
6. The light should be on when the rotor contact mark is in alignment
with the stator plate “rupture” mark.
7. To adjust the timing, loosen the fixed contact holding screws and
adjust the cam screw until the light goes off.
8. Turn the flywheel slightly counterclockwise and the light should
go off.
9. Turn flywheel back to “rupture” point. The light should just go on.
10. Check above procedure again. If correct, tighten the holding
screws fully.
11. Reassemble the rubber seal and rotor cover plate (14mm wrench).
12. Fit the flywheel and engine covers.

29
ENGINE COMPONENT PARTS

30
ENGINE COMPONENT PARTS

31
ENGINE COMPONENT PARTS

32
 ELECTRICAL CONNECTIONS — SOLEX 3800 D.O.T.
Light Coil A. Black wire with large male connection
B. Yellow female connector - large
1. Powers
a. Headlight switch - brown wire
b. Electric horn - yellow wire
Headlight Switch and
Light Connections A. Power from coil - brown wire
B. Power to headlight and taillight - black wire
1. Headlight grounded - black
2. Taillight grounded - black
a. “G” middle or upper post - ground, black wire
b. “T” right hand post - taillight power, black wire
Stop Light Coil A. Black wire with male connector - little
B. Red female connector - little
1. Powers stoplight switch - red wire to each brake lever switch
2. From switch to taillight assembly - green wires
a. “S” on taillight left hand post - stop light
b. “G” middle or upper - ground
Ignition Coil A. Power to spark plug lead
1. Points interrupt circuit in the ignition coil
2. Coil produces current
3. To spark plug lead
4. And spark plug
B. Engine cut-out switch
1. Lead from upper post of the condenser - grey wire - small
female connector
2. Lead from engine cut-out switch - purple wire - small purple
male connector
3. Switch when closed grounds the ignition coil, condenser and
points, stopping the engine

33
 ENGINE TROUBLE SHOOTING GUIDE
WARNING: Put the engine cut-out switch in “ON” position. To find out if the cause of the trouble is
due to bad ignition setting or a faulty part, take out the spark plug, keep it connected to the plug
lead, hold it against the cylinder and turn the engine over.
Symptoms Possible Causes Checks and Remedies
There is a regular spark Spark plug fouled Brush the electrodes, clean and adjust
the electrodes Incorrect spark plug gap the gap to 5/10mm (.5mm).
Replace the spark plug if necessary.
Incorrect timing Remove the flywheel cover, align the
contact point on the flywheel with the
rupture point on the stator plate and
check with a lamp (ground and grey wire).
There is an intermittent Spark plug lead unscrewed Remove the engine cover, unscrew the plug
spark or no spark from stator plate or the lead retaining plate.
insulator is faulty (R=6Ω) Disconnect the plug lead from the stator
plate and replace with a new one.
Ignition coil (R=3Ω) Check by substitution.
Condenser (R=150Ω) Check by substitution.
Faulty wiring connections Check for good connections.
in the magneto
Loose flywheel magnets or Magnets should not move or come in
warped flywheel contact with magneto coils. If loose
replace the flywheel.
The engine runs in 4-stroke Ignition timing Check the spark plug and timing.
cycle or lacks power Excessive carbon built-up Decarbonize.
At idle, the engine stalls Contact breaker Defective, replace it
Clogged air cleaner Faulty, replace it.
Carbon build-up Decarbonize.
Carburetor jetted to rich Lean out the air and fuel jet.
Loose fuel lines Check for tightness.
Rotor hitting magneto coils Center the magneto coils, or if necessary,
replace rotor.
Fuel supply Fuel pump Check fuel tank for fuel supply.
Check fuel flow at overflow pipe.
Check fuel pump; fittings; pump membrane;
pump check balls.
Check fuel suction line and clean or replace.
Check fuel tank filter and replace.
Check fuel supply pipe and clean or replace.

34
Symptoms Possible Causes Checks and Remedies
Fuel supply (continued) Carburetor Check fuel filter, replace if needed.
Check fuel jet, replace if needed.
Check air jet, replace if needed.
Check throttle barrel, replace if needed.
Crankcase Check fuel supply.y in crankcase by removing
the lock pin bolt.
Ignition Spark plug Check spark plug gap, clean or replace plug.
Check spark plug lead:
a. contact at plug, clean and tighten;
b. contact at coil, clean and tighten;
c. spark plug lead, replace if needed.
Stator plate Timing:
a. check timing;
b. check fixed contact, clean or replace;
c. check moving contact, clean or replace.
Check condenser, substitution.
Check ignition coil, substitution.
Check cut-out switch ground connection.
Engine is noisy or runs Carburetor Fuel jet too big, replace.
poorly Air jet to small, replace.
Fuel pump Fuel pump membrane is porous, replace.
Ignition Timing, advanced too far, retime.
Compression Loss of compression, check and tighten:
a. crankcase cover bolts, if loose,
check and replace gasket;
b. cylinder base, if loose, check and
replace cylinder base gasket;
c. cylinder head, if loose, check and
replace cylinder head gasket;
d. decompression valve, (see
carbonization.
Carbonization Cylinder head, decarbonize:
a. decompression valve, replace;
b. clean and ream valve seat, valve
reamer.
Exhaust port, decarbonize:
a. Decompressor valve port, ream or drill;
b. exhaust manifold gasket, replace.
Exhaust pipe and muffler, clean or replace.

35
Symptoms Possible Causes Checks and Remedies
Engine runs with choke Fuel supply too lean Fuel jet too small, change.
partly closed Air jet too big, change
Partial air leak, check the following for
restrictions:
a. fuel tank;
b. fuel pump;
c. carburetor;
d. fuel jet.
Engine runs and stalls Carburetor Carburetor obstructed:
a. fuel jet, remove and clean;
b. barrel, remove and clean;
c. air filter, clean;
d. fuel filter, replace.
Fuel supply Fuel pump faulty, replace:
a. fuel pump membrane, replace;
b. fuel pump seating piece, replace.
Ignition Spark plug faulty, regap or replace.
Spark plug lead faulty:
a. connector not making contact with
carbon lead, tighten’
b. carbon lead broken, replace.

36
 CYCLE, FRAME, CONTROLS REPAIR OPERATIONS
Use of the recommended workshop support stand is advised for the majority of the following
operations (tool #100030).

Front Wheel Assembly

Removing 1. Raise the front wheel off the ground.
2. Loosen the axle nuts (14mm wrench).
3. Pull the wheel downwards to remove from the fork brackets.
4. If whitewall tires are fitted, deflate the tire before removing the
wheel to prevent the brake shoes from scraping the sidewalls.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Check that the wheel is correctly aligned in the forks.

Wheel Axle
Removing 1. Remove the wheel. See figure 30
2. Remove the axle nuts, washers, and dust caps (14mm wrench).
3. Place the wheel in a vice securing on the cone counter nut.
4. Hold the upper cone with a cone wrench and remove the cone counter
nut (15mm and 17mm wrench).
5. Loosen and remove the hub cone.
6. Lift the wheel to the end of the axle to expose the ball bearings.
7. Inspect the ball bearings and the condition of the axle, replace if
necessary.
Reassembling 1. If the axle is to be replaced, lift the wheel off the axle and secure the
new axle with the hub cone and washer cone counter nut in the vise, then
replace the wheel.
2. If the ball bearings on the opposite side of
the hub are to be replaced, first assemble
one side of the hub and turn the wheel over,
repeating the procedure.
3. Grease the axle and pack the ball
bearing races with grease.

4. Replace
the hub cone, tighten
and release 1/4 turn.
5. Continue to reassemble
in reverse sequence.
Figure 30

37
 Wheel Bearing Play
Adjusting 1. Loosen the axle nuts and the cone counter nuts.
2. Adjust the hub cones. To reduce play, tighten the hub cones. To
increase play, loosen the hub cones.
3. When correct adjustment is reached, hold the hub cones with a cone
wrench and tighten the cone counter nuts (15mm and 17mm wrench).
4. Tighten the axle nuts (14mm wrench).

Front Brake Mechanism

Removing 1. Disconnect the brake cable from the brake bar assembly at the brake
mechanism. See figure 31
2. Loosen the nuts securing the brake mechanism to the forks (14mm
wrench).
3. Loosen the nuts attaching the brake mechanism to the mudguard
(10mm wrench).
4. Remove the brake mechanism and brake shoe blocks (10mm wrench).
Reassembling 1. Reassemble in reverse sequence above.
NOTE: Check the condition of the brake shoes and replace if necessary.
Check the front brake adjustment.
2. When replacing the brake mechanism cover plate, make sure that the
protruding flange on the inside of the plate locks into the brake spring.

Figure 31

38
 Front Brakes
Adjusting 1. Minor adjustment to compensate for wear of the brake shoes and play
at the brake levers is carried out at the right handlebar lever. See figure 32
2. Check that the engine engagement lever is pulled to the rear.
3. Unscrew the locking nut and the adjusting nut slightly (10mm wrench).
4. Spin the wheel by hand, adjusting the amount of free play on the brake
lever until the brake shoes take hold and stop the spin, by turning the
adjusting nut and applying the brake lever.
5. The amount of free play at the end of the brake lever should be about
1/2 inch.
6. Tighten the locking nut (10mm wrench).
Additional adjusting 1. If further adjustment is necessary or after replacing the brake shoes,
proceed as follows. See figure 31
2. Turn the handlebar to the right for easy access.
3. Remove the brake mechanism cover plate (10mm wrench).
4. Grip the brake shoe blocks and pull to the left until the right brake
shoe is touching the rim of the wheel.
5. Push brake bar adjusting tool and turn to the left, tensioning the
brake cable until the space between the left brake shoe and the rim of
the wheel is about 1/4 inch.
NOTE: Check that the adjusting wheel returns to the locked position
after removing the brake tool.
6. Push on the left brake shoe block until the space between the left and
right brake shoes and the rim of the wheel is equal.
7. Replace the brake mechanism cover plate, ensuring that the protrud-
ing flange on the inside of the plate locks into the brake mechanism
spring.

Figure 32

39
 Front Mudguard
Removing 1. Remove the front wheel (page 37).
2. Loosen the brake mechanism cover plate nuts and remove the cover
plate (10mm wrench). See figure 31
3. Loosen the nuts securing the brake mechanism to the mudguard and
withdraw the bolts from the inside of the mudguard (10mm wrench).
4. Loosen the two lower mudguard nuts and remove the splashguard
(10mm wrench).
5. Pull the mudguard from the mudguard support bolts and remove.
Reassemble 1. Reassemble in reverse sequence.
NOTE: Check that the muffler bracket is fully inserted between the mud-
guard and mudguard support.

Mudguard Supports
Removing 1. Loosen the two lower mudguard support nuts and remove the bolts
(10mm wrench). Remove the splashguard. See figure 33
2. Loosen the nut attaching the horn and mudguard supports to the
engine supports (10mm wrench).
3. Remove the supports.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Check that the muffler bracket is fully inserted between the mud-
guard and mudguard support. Check that the mudguard supports are
secured to the engine supports as described on page 11.

Figure 31

40
 Steering Races
Removing 1. Remove the front wheel as described on page 37.
2. Remove the handlebar with cables and wires attached and draw
to the front over the engine. See figure 3
3. Loosen the bearing cup lock nut (23mm wrench).
4. Remove the serrated washer.
5. Remove the threaded seat holding the fork and engine assemblies in
the frame steering tube.
6. Remove the ball cage and upper bearing cup.
7. Raise the steering tube and frame and withdraw the fork assembly
from the steering tube.4
8. Replace the bearings as necessary, grease the upper and lower ball
cages and the threaded seat.
Reassembling 1. Reassemble in reverse sequence.

Figure 33

41
 Front Forks
Removing 1. Remove the engine guard rail (page 9).
2. Remove the front wheel and mudguard supports (pages 37 and 40).
3. Remove the engine and engine supports (page 11).
4. Remove the front brake mechanism (page 38).
5. Remove the engine shield (page 40). See figure 33
6. Loosen the nuts on the left and right hand fork legs.
7. Remove the fork Legs.
Reassemble 1. Reassemble in reverse sequence.

Kick Stand
Removing 1. Tilt the machine and empty the fuel from the fuel tank into a can.
2. Turn the machine over and support the frame in the recommended
workshop support stand.
3. According to model; drive out the rivets or loosen the nuts and remove
the bolts on each side of the kickstand (14mm wrench.
4. Unhook the spring. See figure 35
5. Lower the kickstand ad lift from the frame.
Reassembling 1. Hook the end of the spring to the kickstand.
2. Hook the other end of the spring into the frame and insert the kick-
stand into the frame.
3. Lower the kickstand and rivet, or insert the bolt, in the right hand side
of the frame from the inside.
4. Fit the washer and nut (14mm wrench).
5. Raise the kickstand and rivet, or insert the bolt, in the left hand side
of the frame from the inside.
6. Fit the washer and nut (14mm wrench).
7. Lightly lubricate the bolts.
8. Tighten the nuts and punch lock.

Figure 35

42
 Crank Spindle
Removing 1. Slip the cycle chain from the crank sprocket wheel. See figure 36
2. Remove the wedge nut and tap out the wedge on the sprocket wheel
pedal crank (13mm wrench).
3. Pull on the left hand pedal crank and remove the crank spindle from
the crank assembly with the left pedal crank.
4. To replace the crank spindle, remove the wedge nut and tap out the
wedge on the left pedal crank.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Grease the crank spindle before inserting into the crank assembly.
Check that the spacer is fitted to the crank spindle before attaching the
washer and inserting into the crank assembly from the left.

Figure 36

43
 Crank Assembly
Removing 1. Remove the kick stand (page 42).
2. Remove the rear wheel (page 46).
3. Slip the cycle chain from the crank sprocket wheel.
4. Loosen the rear brake adjuster nut and remove the adjuster (10mm
wrench).
5. Loosen and remove the bolts securing the crank assembly to the main
frame (14mm wrench).
6. Loosen the nut on the right hand lower rear fork brace (15mm socket).
7. Withdraw the bolt from the left hand lower rear fork blade.
8. Remove the crank assembly. See figure 36
9. To replace the crank assembly, remove the crank spindle as described.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Check that the spacers are in position on the bolt of the lower
fork blades. Punch lock the nuts after tightening.

Handlebar
Removing 1. Loosen the throttle twist grip collar screw and remove the grip with
cables and wires attached (allen wrench).
2. Remove the left handgrip (page 45).
3. Loosen the left handgrip collar screw and remove with cables and wires
attached (allen wrench).
4. Loosen the handlebar support bracket bolt and remove the handlebar
from the bracket (12mm wrench). See figure 37
Reassembling 1. Reassemble in reverse sequence.

Figure 37

44
 Throttle Twist Grip
Removing/Replacing 1. Loosen the throttle twist grip collar screw and remove the grip with
cables and wires attached (allen wrench). See figure 33
2. Pull back the shouldered end of the throttle outer cable cover and
remove the cable from the cable guide.
3. Pry back the rubber twist grip flange and remove the cable end ball.
4. Pull on the rubber grip and remove the grip sleeve or cut the length of
the rubber grip with a razor or knife and remove.
5. Replace parts as necessary.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Never refit a frayed cable. Fit a new one. When tightening the twist
grip collar screw, use caution to avoid breakage.

Left Handgrip
Replacing 1. Cut the length of the handgrip with a razor or knife and remove.
2. To fit a new handgrip, first soak the open end of the grip in gasoline.
3. Tap the grip into position on the handlebar.

Saddle Assembly
Removing 1. Loosen and remove the nut and washer of the support bolt connecting
the luggage carrier to the frame (14mm wrench).
2. Withdraw the support bolt from the opposite side of the machine and
remove the spacers.
3. Loosen the nuts on the upper mounting bolts and remove the washers
and bolts (14mm wrench).
4. Withdraw the saddle and seat post from the frame seat support.
5. Loosen the nut and remove the two washers on the bold securing the
main saddle spring to the seat post (14mm wrench).
6. Withdraw the bolt and remove the third washer from the spring side.
7. Remove the spring from the saddle cradle with a twisting action.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Ensure that the three washers of the bolt securing the main
saddle spring to the seat post are correctly located.
Adjusting 1. The height of the saddle can be adjusted to three different positions.
Raise or lower the seat post to the next higher or lower position aligning
the mounting holes.
2. Insert the two upper bolts and fit the washers and nuts. Do not tighten.
3. Insert the support bolt, washers and spacers.
4. Fit the nut, but do not tighten.

45
 5. To adjust the angle of the saddle, grip the saddle at the front and
rear, press down firmly or lift, either the front or rear until the desired
angle is reached.
6. Tighten the two upper nuts and the nut of the support bolt (14mm
wrench).

Rear Wheel
Removing 1. Raise the rear wheel off the ground.
2. Disconnect the brake cable from the hub assembly.
3. Loosen the axle nuts (17mm wrench).
4. Pull the wheel to the front and slip the cycle chain from the free wheel.
5. Remove the wheel.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Check that the rear brake functions correctly. Check that the
anchor lug on the hub engages in the slot in the frame.

Rear Brake Drum

Removing 1. Remove the wheel as described.
2. Remove the axle nut on the brake drum side of the wheel (17mm
wrench).
3. Remove the spacer and withdraw the brake drum. See figure 38
NOTE: Do not touch the brake shoes or braking surface of the brake
drum with grease.
Reassembling 1. Reassemble in reverse sequence.

46
 Brake Shoes
Replacing 1. Remove the wheel and brake drum as described (page 46).
2. Set the brake drum in a vise.
3. Lift first one brake shoe and with a turning movement, detach the
spring and remove the shoe.
4. Remove the second shoe.
5. Attach the springs to the new shoes.
6. Fit one shoe in position while holding the second shoe upright.
7. Fit the second shoe with a slight turning movement in the opposite
direction to removal. See figure 38
NOTE: Check that the brake mechanism functions correctly by operating
the rear brake lever.
8. Lightly grease between the cam and the backing plat of the brake
shoe.
Reassembling 1. Reassemble in reverse sequence.

Figure 38

47
 Rear Brake
Adjusting 1. Minor adjustment to compensate for wear of the brake shoes and play
at the brake lever is carried out at the left handlebar brake lever.
2. Check that the engine engagement lever is pulled to the rear.
3. Unscrew the locking nut and the knurled adjusting nut slightly (10mm
wrench).
4. Spin the wheel, adjusting the amount of free play on the brake lever
until the brake takes hold and stops the spin, by turning the knurled
adjusting nut and applying the brake lever.
5. The amount of free play at the end of the brake lever should be about
1/2 inch.
6. Tighten the locking nut (10mm wrench).
Additional adjusting If further adjustment is necessary or after replacing the brake shoes,
proceed as follows:
1. Loosen the locking nut on the rear brake adjuster attached to the
crank assembly (10mm wrench).
2. Adjust the rear brake by turning the adjusting screw.
3. Tighten the locking nut (10mm wrench).
4. On the rear hub assembly and inspection hole is provided to permit
inspection of brake linings. Replace the dust cap after the inspection is
made. See figure 38

Rear Wheel Bearing

Replacing 1. Remove the rear wheel (page 46).
2. Withdraw the brake drum (page 46).
3. Remove the hub axle. See figure 38
4. Pry loose the dust cap on the freewheel side of the machine.
5. Extract the bearing. Inspect the hub axle and replace if necessary.
Reassembling 1. Reassemble in reverse sequence. Insert the bearing by lightly tapping
on the bearing body.

48
 Rear Mudguard
Removing 1. Remove the rear wheel (page 46).
2. Disconnect the wires to the rear lamp.
3. Loosen the three nuts securing the rear lamp assembly to the mud-
guard and remove the assembly (10mm wrench).
4. Loosen the nut on the mudguard support and remove the bolt and
washer (10mm wrench).
5. Withdraw the wires through the hole in the mudguard and loosen the
clips retaining the wires to the inside of the mudguard.
6. Loosen the two nuts securing the mudguard to the luggage carrier
and remove the bolts (10mm wrench).
7. Withdraw the mudguard to the rear.
Reassembling 1. Reassemble in reverse sequence.

Mudguard Support
Removing 1. Remove the rear wheel (page 46).
2. Loosen the nut securing the mudguard support to the mudguard and
remove the bolt and washers (10mm wrench).
3. Loosen the nuts on the luggage carrier supports at the hub and with-
draw the bolts from the inside (14mm wrench).
4. Remove the mudguard support to the rear.
Reassembling 1. Reassemble in reverse sequence.

Luggage Carrier and Supports

Removing 1. Remove the rear wheel (page 46).
2. Loosen the nuts on the luggage carrier supports at the hub (14mm
wrench).
3. Pull gently on the mudguard supports and remove from the bolts.
4. Pull gently on the luggage carrier supports and remove from the bolts.
5. Loosen and remove the nut and washer of the support bolt securing
the luggage carrier to the frame and seat post.
6. Withdraw the support bolt from the opposite side and remove the
spacers (14mm wrench).
7. Loosen the two nuts connecting the mudguard to the luggage carrier
and remove the bolts (10mm wrench).
8. Remove the luggage carrier. To remove the luggage carrier supports,
loosen the two nuts on the inside of the luggage carrier and remove the
bolts (10mm wrench).
Reassembling 1. Reassemble in reverse sequence.

49
 Headlamp
Removing 1. Remove the headlamp by pushing down and then pull out that connects
to the lever touching the bulb. See figure 39
2. Disconnect wire.
Reassembling 1. Reassemble in reverse sequence.

Figure 39

Rear Lamp
Removing 1. Loosen the screws and remove the lens (phillips screwdriver). See figure 40
2. Remove the gasket.
3. Remove the bulb.
4. Disconnect the wires.
5. Loosen the mounting bolts from the rear of the rear lamp bracket
(10mm wrench).
6. Remove the rear lamp body.
Reassembling 1. Reassemble in reverse sequence.

Figure 40

50
 CONTROL CABLES

Brake Cables
Replacing 1. Push on the cable pivots at the brake levers and detach the cable end
balls from the brake levers.
Front Brakes: Disconnect the brake cable from the brake bar assembly
at the brake mechanism.
Rear Brakes: Loosen the nut of the cable clamp (7mm wrench).
2. Pull on the cables at the cable end balls and remove the cables from
the outer cable covers.
3. Grease the new cable(s) and slide in and out of the outer covers to
ensure that the entire length of the cable and inside of the outer covers
are well lubricated.
NOTE: Check that the outer cable cover shouldered end is well located in
position.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Adjust the brakes after replacing the cables.

Throttle Cables
Replacing 1. Roll the throttle twist grip to the closed position.
2. Loosen the cable pulley nut and release the cable from the pulley (7mm
wrench).
3. Release the cable shouldered end from the bracket on the throttle
arm.
4. At the throttle twist grip, pull back the shouldered end of the cable
outer cover and remove the cable from the cable guide.
5. Pry back the rubber twist grip flange and remove the cable end ball.
6. Grease and fit a new throttle cable as described for the brake cables.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Check that the throttle cable shouldered end at the throttle arm
is correctly seated in the bracket on the throttle arm.
2. Start the engine and check for correct throttle operation (page 28).
3. If the engine runs too fast when the throttle twist grip is in the
closed position, loosen the pulley nut and adjust the tension on the cable
until smooth idling is reached.
4. Tighten the pulley nut (7mm wrench).

51
 Decompressor Cable
Replacing 1. Loosen the cable clamp at the decompressor lever cylinder head
bracket (7mm wrench).
2. Pull back the shouldered end of the outer cable cover at the decom-
pressor lever on the throttle twist grip.
3. Remove the cable from the guide in the decompressor lever bracket
and remove the cable end ball from the lever.
4. Pull on the cable at the cable end ball and remove the cable from outer
cover.
5. Grease and fit a new decompressor cable as described for the brake
cables.
Reassembling 1. Reassemble in reverse sequence.
NOTE: Check that the spring is correctly placed between the lever and
the decompressor cylinder head bracket.
2. When squeezing the decompressor lever at the throttle twist grip and
decompressor cable end at the cylinder head bracket should travel about
1/8 inch and never less than 1/32 inch.
3. Loosen the cable clamp and adjust the tension on the cable until the
correct travel is obtained.

52
TORQUE DIAGRAM

53
TORQUE DIAGRAM

54
TORQUE DIAGRAM

55
TORQUE DIAGRAM

56
TORQUE DIAGRAM

57
TORQUE DIAGRAM

58
 RIGHT HAND
STOP CONTACTOR
GREEN
SOLEX WIRING DIAGRAM
RED

BLACK REAR LAMP

HEADLAMP
BLACK
GREEN

GREEN

59
VIOLET
RED

GREEN
GREY
RED
BLACK BROWN
BLACK

WHITE

YELLOW

TO SPARK PLUG

LEFT & RIGHT HAND

RED STOP CONTACTOR
FLYWHEEL MAGNETO HORN
GREEN
VeloCruz • 650 North Main • PO Box 540080 • North Salt Lake, UT 84054
Ph: 801.593.6783 • 800.393.7101 • Fax: 801.593.6790
 TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a2
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a3
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a4
Carburetor — Fuel Pump . . . . . . . . . . . . . . . . . a5
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . a6
Support — Engine Lever . . . . . . . . . . . . . . . . . . a7
Cycle Part I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . a8
Cycle Part II . . . . . . . . . . . . . . . . . . . . . . . . . . a10
Fuel Tank — Covering . . . . . . . . . . . . . . . . . . . . a11
a1
Pedal — Drive Chain . . . . . . . . . . . . . . . . . . . . . a12
Front Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . a13
Lighting — Signals. . . . . . . . . . . . . . . . . . . . . . a14
Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . a15
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a16
Hub — Front Wheels . . . . . . . . . . . . . . . . . . . . a17
Hub — Back Wheels. . . . . . . . . . . . . . . . . . . . . a18
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . a19
 ENGINE
Ref.# Order# Description 41 SPM 93200 Crank rod with crankpin bush
1 SPM 90837 Air filter cover NR SPM 90055 Fixing ring to piston pin
2 SPM 90820 Air filter base NR SPM 90185 Piston pin
3 SPM 90758 Air filter NR SPM 90568 Complete engine
4 SPM 90759 Air filter fixing ring NR SPM 91013 Gasket set
5 SPM 91525 Internal gear washer M6 NR SPM 91456 Lipped washer
6 SPM 90841 Hexahedral screw M6x12 NR SPM 93059 Decompressing valve set
8 SPM 91263 Decompressing lever NR SPM 93060 Cylinder gasket set
9 SPM 90421 Cylinder head fixing screw NR SPM 93061 Engine fixing set
M6x45 NR SPM 93062 Piston complete
10 SPM 90786 Space holder for cylinder NR SPM 93105 Sticker for filter cover
head
11 SPM 90980 Air filter house suspension
bridle
12 SPM 93106 Sparking plug
13 SPM 90848 Ignition cable fixing nut M4
14 SPM 90859 Decompressor valve nut
15 SPM 90792 Decompressor valve spring
16 SPM 90858 Decompressor valve
17 SPM 90821 Cylinder head
18 SPM 90437 Cylinder head gasket
19 SPM 90496 Cylinder
20 SPM 90016 Cylinder base gasket
21 SPM 90000 Hexahedral nut M6 for
cylinder fixing
23 SPM 90497 Piston crank rod with
crankpin bush
24 SPM 90817 Piston ring 39, 5x1, 7
25 SPM 90849 Crankpin bush
26 SPM 90024 Space holder ring to
crankshaft
27 SPM 90867 Crankpin nut M10x1
28 SPM 91342 Crankcase with crankshaft
29 SPM 90413 Crankcase cover w/drop bolt
30 SPM 90414 Gasket to crankcase
31 SPM 90019 Washer M6
32 SPM 90015 Stud bolt
33 SPM 90415 Screw M6x20
34 SPM 90679 Screw M6x15
35 SPM 91215 Screw M6x45
36 SPM 90073 Bearing
40 SPM 91297 Piston (simple)

a2
 CLUTCH
Ref.# Order# Description 6 SPM91348 Flat washer
1 SPM91287 Complete friction 0/ 42mm 7 SPM90491 Friction nut
2 SPM90978 Clutch 8 SPM90484 Flywheel cover fixture
3 SPM90816 Clutch structure 9 SPM93063 Clutch bell
4 SPM90815 Clutch spring 10 SPM93072 Friction 0/ 42
5 SPM90977 Cap washer NR SPM93137 Friction 0/ 42 (steel)

a3
 FLYWHEEL
Ref.# Order# Description 13 SPM90971 Flywheel nut
1 SPM90845 Flywheel 14 SPM90970 Caoutchouc gasket for
2 SPM91400 Stator flywheel
3 SPM90074 Bearing 15 SPM90969 Wadding plaque
4 SPM90772 Spark roll 16 SPM90972 Low nut
5 SPM93117 Lighting roll 2 out 17 SPM91014 Contact breaker anvil
5 SPM90571 Lighting roll 1 out hammer (2 pc)
6 SPM90802 Condenser 0,2 mF 18 SPM90934 Ignition cable
7 SPM90833 Stator insulating facing 19 SPM90843 Cable end for ignition cable
8 SPM90832 Stator contact bolt 20 SPM91299 Borne HT
9 SPM90421 Hexahedral head screw 21 SPC91390 Screw bolt
M6x45 22 SPM90780 Placket binding cable
10 SPM90763 Hexahedral head screw NR SPM93139 Electric ignition
M4x20 NR SPM93068 Flywheel fixing set
11 SPM91303 Hexahedral head screw NR SPM93113 Service set
M4x8 NR SPM93116 Stator (full)
12 SPM90775 Contact breaker

a4
 CARBURATOR — FUEL PUMP
Ref.# Order# Description 12 SPM90856 Regulating lever screw bolt
1 SPM90921 Carburetor M6
2 SPM90854 Carburetor fitting strip 13 SPM90920 Regulating lever disc
3 SPM90851 Regulating valve with blank 14 SPM90183 Fuel jet
4 SPM91346 Carburetor fuel filter 15 SPM90932 Fuel pump
5 SPM93107 Air filter house gasket ring 16 SPM90023 Membrane of fuel pump
6 SPM90407 Air jete 17 SPM90434 Seat of membrane for fuel
7 SPM90501 Starter valve lever pump
8 SPM90440 Starter valve 18 SPM90763 Hexahedral head bolt M4x20
9 SPM90853 Carburetor closing disc 19 SPM91389 Hexahedral head bolt M5x8
10 SPM90869 Regulating lever spring NR SPM93108 Connecting plug
11 SPM90924 Regulating valve lever NR SPM93132 Seat of valve for fuel pump

a5
 EXHAUST SYSTEM
Ref.# Order# Description 5 SPM90445 Inlet pipe connecting bolt
1 SPM90785 Inlet pipe 6 SPM90964 Fuel pipe
2 SPM90753 Exhaust pipe 7 SPM90793 Hexahedral head bolt M6x12
3 SPM90041 Gasket to inlet pipe NR SPM93138 Exhaust pipe for Solex
4 SPM90442 Carburetor and inlet pipe 3500
gasket ring

a6
 SUPPORT — ENGINE LEVER
Ref.# Order# Description 18 SPM90031 Silent block
3 SPM90792 Decompressor valve spring 19 SPM90988 Nut lockplate
8 SPM90558 Engine supports right and 20 SPM90935 Lockscrew
left 21 SPM92167 Collar nut
9 SPM90779 Dust protective plastic 22 SPM90000 Nut M6
plate 23 SPM90474 Screw bolt
10 SPM90987 Engine lift spring 24 SPM90824 Flat washer
11 SPM90778 Engine sliding 25 SPM90202 Engine lift out lever
14 SPM90022 Friction washer 26 SPM90053 Hexahedral nut M8x1
15 SPM90800 Friction plate nut 27 SPM90027 Flat washer 0/ 6,3
16 SPM90030 Motor axle NR SPM93064 Engine support set
17 SPM90026 Flat washer 0/ 8,5

a7
 CYCLE PART 1
Ref.# Order# Description 49 SPC90999 Stand spring
1 SPC90190 Framework 50 SPC90893 Decoration latch
2 SPC90883 Saddle support space holder 51 SPC93111 Pump
3 SPC90872 Main support (rear fork) 52 SPC90907 Saddle
right 53 SPC90909 Saddle cover
4 SPC90875 Main support (rear fork left 55 SPC93066 Fork bearing
5 SPC90885 Seal upholder right 56 SPC90549 Engine lift out fixing plate
6 SPC90888 Seal upholder left 62 SPC90755 Cable cross leading to
7 SPC90469 Luggage carrier upholder framework
8 SPC90996 Rear mudguard arm 63 SPC90939 Cable packet front
9 SPC91008 Front mudguard 64 SPC90806 Support fork pin + bolt
10 SPC90991 Rear mudguard 65 SPC91004 Premounted fork
11 SPC90880 Luggage carrier NR SPC90910 Saddle spring back
12 SPC90891 Drive chain protective cover NR SPC91294 Head of fork
13 SPC90897 Pedal house cover, leg NR SPC91386 THI-BLOC nut M6
holder NR SPC93065 Framework fixings set
14 SPC90540 Protective plate (engine NR SPC93070 Label to framework
cover) NR SPC93071 Fork fixings set
15 SPC90894 Stank fork NR SPC93073 Tool set
19 SPC90528 Front mudguard arm right NR SPC93133 Counterdie SOLEX white
20 SPC90534 Front mudguard arm left (2 pcs)
21, 22 SPC93067 Rubber mudguard set NR SPC93134 Counterdie SOLEX black
23 SPC90453 Toolbox (2 pcs)
24 SPC90850 Toolbox sponge

a8
CYCLE PART 1

a9
 CYCLE PART II
Ref.# Order# Description 37 SPC90901 Stay ring II. frame
29 SPC90056 Hexahedral bolt M6x10 38 SPC90473 Hexahedral nut 10x1
30 SPC90000 Nut M6 39 SPC91235 Screw D 9,5x14 L:55mm
31 SPC90019 Washer 0/ 6,5 40 SPC91236 Nut M9,5x1
32 SPC90903 Hexahedral bolt M8x1-109 41 SPC91900 Stay ring I. frame
33 SPC90936 Flange socket to saddle 42 SPC90076 Hexahedral nut M6
upholder 43 SPC90968 Washer 0/ 6,3
34 SPC90054 Washer 0/ 8,1 44 SPC91209 Screw M8x1-13
35 SPC90053 Hexahedral nut M8x1 45 SPC90077 Square nut M8x1-13
36 SPC90409 Hexahedral head screw 47 SPC90551 Screw M6x12
M10x1-110 48 SPC90803 Screw M8x1-14

a10
 FUEL TANK — COVERING
Ref.# Order# Description 7 SPM90917 Tank support fixing set
1 SPM90918 Fuel tank set 8 SPM90827 Engine mudguard
2 SPM91376 Tank cup with gasket 9 SPM91449 Binder for crash tube
3 SPM90557 Tank cup gasket ring 10 SPC90145 Crash tube, clouding over
4 SPM90979 Fuel suction pipe protective
5 SPM91345 Tank fuel filter 11 SPM30749 Overflow pipe
6 SPM90770 Flywheel cover

a11
 PEDAL — DRIVE CHAIN
Ref.# Order# Description 5 SPC90905 Driver arm left
1 SPC91307 Pedal house with bearing 6 SPC90965 Driver arm right
2 SPC90465 Bottom bracket axle 7 SPC90061 Pedal wedge
3 SPC90485 Bottom bracket axle 8 SPC93109 Drive chain 83
washer 9 SPC93080 Drive chain link
4 SPC90476 Space holder ring to pedal 10 SPC93110 Pedal pair
axle

a12
 FRONT BRAKE
Ref.# Order# Description 7 SPC90481 Flange brake contract spring
1 SPC93085 Front brake 8 SPC92169 Flange brake nut M6
2 SPC90423 Flange brake key mounting 9 SPC90076 Hexahedral nut M6
3 SPC90508 Flange brake cover 10 SPC93202 Screw for front brake
4 SPC90513 Brake arm right 11 SPC90070 Brake lining
5 SPC90514 Brake arm left 12 SPC91296 Brake shoe
6 SPC90512 Bridge for brakes 13 SPC90502 Brake shoe holder

a13
 LIGHTING — SIGNALS
Ref.# Order# Description 13 SPM93112 Bulb rear lamp 12V-4W
1 SPM90204 Engine cover 14 SPC93115 Bulb for stop lamp
2 SPM90205 Headlight with bulb 15 SPC93079 Reflector
3 SPM90574 Bulb 6V-15W-26S 16 SPC93075 Ringing
4 SPM90767 Contact button 17 SPC93122 Electric horn
5 SPM90834 Light switch 18 SPC93127 Button for electric horn
6 SPM90831 Headlight switch spring 19 SPM93120 Switch for rear lamp
7 SPM94133 Screw M4x8 20 SPM93126 Cables for stop switch
8 SPC93069 Light switch kit NR SPC90569 Cable packet front + rear
9 SPC93114 Rear lamp with stop NR SPC93123 Circle reflector (Belgium)
10 SPC93083 Rear light NR SPC93128 Yellow plate (Belgium)
11 SPC93124 Rear light (GB) NR SPM93077 Engine cover fixing nut
12 SPC93140 Rear light (Japan)

a14
 HANDLEBARS — HILTS
Ref.# Order# Description 11 SPM93102 Cable fixing roller
1 SPC90190 Handlebars 12 SPM93086 Brake lever pin + nut
2 SPC90192 Stem bow bolt 13 SPM93087 Rubber hilt left
3 SPM90193 Right (gas) hilt 14 SPM93088 Brake lever left
4 SPM90199 Left hilt 15 SPM93089 Decompressing lever (on
5 SPM90194 Fixation of right arm handlebars)
6 SPM93085 Rubber hilt right 16 SPM93090 Decompressing lever fixing
7 SPM90197 Cursor to front brake cable ring
8 SPM90196 Cursor to gas cable (gas 17 SPC93091 Mirror
cursor) 18 SPC90206 Bow bolt with nut
9 SPM93084 Brake lever right 19 SPC93136 Cursor (3) for gas spindle
10 SPC93203 Plaque for protection of NR SPC93141 Mirror binder
hands

a15
 CABLES
Ref.# Order# Description 5 SPC91371 Rear break cable cross
1 SPC92174 Front brake cable leading
2 SPC90974 Rear brake cable 6 SPC93092 Decompressing cable end
3 SPC92177 Nut for fixing decompression fixing element
4 SPM2178 Decompressing cable 7 SPC91446 Decompressing cable sleeve
8 SPM93104 Gas cable

a16
 HUB — FRONT WHEEL
Ref.# Order# Description 7 SPC93103 Rim
1 SPC90058 Front wheel hub with bolts 8 SPC90799 Inner tube
2 SPC91358 Front spoke with nut 9 SPC90751 Tire (1,75x19)
3 SPC90052 Front wheel dust protective NR SPC91298 Front wheel without tire and
6 SPC93095 Protective band inner tube

a17
 HUB — REAR WHEEL
Ref.# Order# Description 6 SPC93095 Protective band
1 SPC91395 Rear wheel hub with bolts 7 SPC93103 Rim
2 SPC91405 Brake shoe complete 8 SPC90799 Inner tube
3 SPC93098 Brake shoe 9 SPC90751 Tire (1,75x19)
4 SPC93100 Freewheel NR SPC90943 Rear wheel without tire and
5 SPC91359 Rear spoke with nut inner tube

a18
 ACCESSORIES
Ref.# Order# Description 5 SPC93145 Solex hat
1 SPC93130 Saddle bag, black 6 SPC93146 Speedometer
2 SPC93142 Saddle bag, burgundy NR SPC93147 User guide (French)
3 SPC93143 Saddle bag, blue NR SPC93148 User guide (English)

Ref.# Order# Description 10 SPC93150 Solex Wind Jacket

7 SPC93145 Solex T-Shirt 11 SPC93113 Solex Service Toolset
8 SPC93148 Solex Mock T-Shirt
9 SPC93149 Solex Fleece Vest

a19