’ΔΆ CLUTCH ADJUSTMENT

This motorcycle incorporates an automatic centrifugal clutch. Perform the clutch adjustment by the following procedure.

1. Clutch must be adjusted with the engine shut off, loosen the adjuster lock nut (2).

  1. Turn the adjuster screw (1) clockwise about one turn. Do not turn excessively.
  2. Next. slowly turn the adjuster screw counterclockwise and stop when the screw starts to turn heavy.

A. From this point, back ofi the adjuster in the clockwise direction "1/8 to"1/4 turn, and then tighten the lock nut.

Check to make sure that the clutch operates properly alter adjustment. The engine should start easily with the kick starter without the clutch slipping.

  1. When changing gear, the clutch operation should be smooth and light, especially when shifting down in gear to the neutral position.

1. Clutch Adjuster Screw
2. Lock Nut

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’ΔΆ CLEANING THE DRIVE CHAIN

1. The life of the drive chain is directly affected by the amount of service.

Remove the chain by taking off the joint clip (1) and wash in solvent with a stiff brush to take dirt and old grease off.

After Drying it thoroughly, place the chain in a vessel containing a mixture of good grade engine oil and petrolatum (ratio of 300 gr of petrolatum to 1 liter of engine oil, SAE 30-50. and heat for 10 minutes at a temperature of 10 to 250 degrees farenheit (50-120 degrees celcius) while agitating.

Remove the chain and hang. After the grease hardens, wipe off the excess with a clean rag and assemble on the machine.

  1. To assemble the drivechain. loosen the rear axle allowing the ends of the drive chain to be connected with a joint. The joint clip should be installed so that the open end will face opposite to the direction of rotation.

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1. Drive Chain Joint Clip

’ΔΆ DRIVE CHAIN ADJUSTMENT

The tension of the drive chain will have considerable effect on the transmission of power from the engine to the rear wheel and on the life of the chain itself. Therefore, the chain should always be maintained at the proper slack, in other words; not too tight and not too loose.

Whenever adjustment is made. make it habit to lubricate the chain with engine oil.

  1. The maximum amount of the drive chain slack is measured by pressing the chain up and down at the midpoint between the sprockets. The maximum slack of the chain should be 0.4-0.8 in. (10-20mm)

1. Drive Chain

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  1. If adjustment is necessary, loosen the rear axle nut (3)
  2. Adjust the chain slack with the lock nut (6) by turning it in the clockwise, this will decrease the chain slack; turning it counterclockwise will loosen the chain. Upon completion of adjustment, the index mark (1) on both the right and left chain adiusters should be at the same reference marks (5) on the rear forks.

1. Finally, tighten the axle nut securely to prevent the nut from loosening.

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Rear Axle
Rear Axle Nut
Index Mark
Rear fork Reference Marks
Chain Adjuster Lock Nut

’ΔΆ FRONT AND REAR BRAKE ADJUSTMENT

Brakes are items of personal safety and should always be maintained in proper adjustment.

1. Front Brake

  1. Raise the front wheel off the ground by placing a support block under the engine. Spin the front wheel by hand and measure the amount. The front brake lever (1) must be moved before the brake starts to take hold. The lever free playshould be 0.4-0.8 in (1O-20 mm) at the end ofthe brake lever.
  2. When brake adjustment becomes necessary, perform the task with the front brake adjusting nut (3)

    Turning the nut in the clockwise direction will decrease the play of the lever and turning the nut counter clockwise will increase the play.

2. Rear brake

For the rear brake system, the rear brake lever and the rear brake pedal require adjustment.

  1. Place a support block under the motorcycle. raise the rear wheel, and then, press on the rear brake pedal while lightly rotating the rear wheel. Check the pedal free play (2) until the rear brake starts to take hold. The standard pedal free travel is 0.8-1.2 in. (20-30 mm).

2. The adjustment is made wilh the rear brake adiusting nut (1) The pedal free play decrease by turning the adjusting nut clockwise, while it increases by turning the adjusting nut counterclockwise.

  1. Next, check the free play of the front brake lever (1), The standard free play is 0.4-0.8 in. (10-20 mm) at the front brake lever tip.

4, This adjustment is made with the rear brake cable adjuster (1) after the lock nut is loosened, The free play becomes large by turning the adjuster toward lhe direction A (clockwise) while it becomes small by turning the adjuster toward the direction B (counterclockwise).

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’ΔΆ WHEEL REMOVAL

Removal of front and rear wheel is performed in the following manner.
1. Front wheel

  1. Place a suitable block under the engine to raise the front wheel off the ground.
  2. Remove the front brake and adjusting nut (1)
  3. Remove the Speedometer Cable (4)
  4. Remove the front wheel axle nut (2) and pull out the front wheel axle (3)
  5. The front wheel can be removed from the frame.

Note : Standard tire air prcssure is 17 PSI (1.2 kg/cm2).

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Front Brak Adjusting Nut
Font wheel axle Nut
Front wheel axle
Speedometer Cable

2. Rear wheel

  1. unscrew the drive chain adjusting nut and rear wheel axle nut.
  2. Remove the chain joint clip and drive chain,
  3. Unscrew the rear brake adjusting nut and disassemble the rear brake rod from the rear brake arm.
  4. Pull out the cotter pin (3) loosen the lock nut (4) and remove the torque arm setting bolt (5).
  5. Pull out the rear wheel axle and then the rear wheel can be disassembled from the frame,

Note: Standard tire air pressure is 20 p.s.i. (1.4 kg/cm2).

2. Thc tire should be replaced when the tread has been worn to less than 0.04 in. (1 mm) depth. Riding with worn tire is a hazard.

’ΔΆ BATTERY SERVICE

If the motorcycle is operated with an insufficient (low) battery electrolyte level, sulfation and ballery plate damage may occur. Inspecting and maintaining the eleclrolyte level is a simple, quick operation, therefore. it should be performed frequently as indicated in the service schedule on page 25.

  1. The 6V-2AH battery (1) is mounted under the seat.

Access to the battery is obtained by releasing the seat latch on the rear end under the seat and raising the rear.

2. Remove the battery setting rubber and raise the battery slightly to check

the battery electrolyte.

The correct electrolyte level is between the "lower" and "upper" level marks on the battery case

Battery
Upper level mark
Lower Level mark

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