Check Carburation (Fuel Feed section)

CHECK STARTING
Check that the carburation is correct especially the slow running. Check starting controls (choke and cable). When choke is closed the cable wire should not be in tension. This can be verified by seeing that the cable has an axle play of not less than 1/16"

1. 174

ADJUST BRAKE AND CLUTCH
The brakes must be adjusted in such a way that the wheels are free to rotate and the braking action begins as soon as the respective controls are acted on. The rear brakes are fitted with two separate adjustment i.e. adjustment of the cables and adjustment of the shoes. The cable adjustment refers to the hand control while that of the shoes refers to the hydraulic foot control. After any shoe adjustment check the hand control adjustment. See « Brakes ». The clutch must be adjusted in such a way that it will begin to slip when the clutch lever is in the position illustrated in Fig. 74. The adjustment is carried out by means of the cable adjuster fitted at the crankcase.

Check hydraulic equipment of the rear brakes according to the details given on the Brakes page - Operations 111 to 116.

CHECK CYLINDER HEAD NUTS AND EXHAUST TUBE RING
Carry out operations 1 and 9 up to the removal of the cowl, then check cylinder head nuts (14mm box spanner) the exhaust tube flange nuts (11mm spanner). Check the silencer elastic mounting nuts

CHECK AND ADJUST STEERING
Carry out if needed operations 90, 93, 94 (Handlebar dismantling ) after having lifted the front part of the vehicle. Tighten steering lock and ball race cone (tools 40482 and 65390) so as to eliminate any axial play on the front fork. The fork must rotate freely.

CHECK HANDLEBAR CLAMP
Carry out this check thoroughly (14mm spanner).

CHECK WHEEL AND RIM NUTS AND SCREWS IN GENERAL

CHECK CONTACT BREAKER POINT GAP AND BATTERY ACID LEVEL
To check contact points, carry out operations 1, 24, 25. To check battery acid level, see Electrical Equipment- Battery Maintenance. The liquid should be 1/4" higher than the top of the cell separators. If the level is lower add distilled water. Check density of liquid, which should be 1.26 g/cc, equal to 30"Be. ll the density is lower, charge battery until this has reached the prescribed value.

CHECK TYRE PRESSURES
Front - 28.4lbs/sq.in ( 2 Kg/cm2)
Rear - 49.75 lbs/sq.in (3.5 Kg/cm2)

CHANGE ENGINE AND DIFFERENTIAL BOX OIL
Engine
Drain oil from engine (warm) through the drain plug on the gear box (No. 3 Fig. 75) and the plug on the rear gear box cover (No. 4 Fig. 76). Clean the magnetic end of the drain plug of any metallic deposits. This operation to be carried out at all oil changes. Refit the two plugs, unscrew filler plug (No, 1 Fig. 75) and oil level plug (No. 2 Fig. 75) add approximately 1 gill of fresh oil through plug hole, rotate the engine for a few minutes, drain oil completely through drain plug. Replace the drain plugs, tighten and proceed to refill with fresh oil until this starts to flow from the oil level plug hole. Fit and close the filler and level plugs. The approximate quantity of oil needed is about 42.30 ozs, of BP Energol SAE 90 gear and differential oil.

Differential
Unscrew filler and drain plugs on rear axle, and let oil drain out completely. lift drain plug and pour oil into filler plug hole until it reaches the threaded portion of the hole. Refit filler plug. Approximately 6.35 ozs of BP Energol SAE 90 EP Differential oil are required.

ADJUSTMENT OF GEAR CHANGE AN GEAR CABLES
This is done on the adjusters fitted at the level end of the gear box case. The cables must not be too tight otherwise this will make the gear change operation stiff. Check reverse gear lever 41031020 and the stop quadrant 41031033 on the gear box. Check all gears for correct meshing with the corresponding gear position marks on the handlebar.

CHECK TRANSMISSION SHAFT JOINTS
Check all nuts and belts fixing the joints, the condition of the rubber yoke, and protection hose.

CLEAN PETROL TAP FILTER AND CHECK RESERVE DEVICE
Detach tap from petrol pipe, empty the tank and remove the tap.
Wash out the filter and remove the cap.
Check that all holes are clean and the reserve control works correctly.

CHECK ELECTRICAL CIRCUIT, HEADLAMP ADJUST­MENT AND BATTERY ACID LEVEL
Check the main switch in all its positions so that the lights are on or off with engine running or at a standstill, as accordingly stipulated.
Check the functioning of the two-way headlamp and Flasher indicator switch on the handlebar and the efficiency of the horn.
Carry out Headlamp adjustment
To check battery acid level

CLEAN AND CHECK SPARK PLUG GAP
Remove sparking plug, check to ensure it is of the long reach type and has a heat range to the value of 225 Bosch scale. If necessary, clean the electrodes and adjust the gap which should be between 0.5 and 0.6 mm i.e. 020/024 inches.

DECOKE AND CLEAN SILENCER
Carry out Operations, 1, 17, 7, 9, 28, 29, 30 and proceed with the decoking of the cylinder head and cylinder ports (See Engine decoke).
Dismantle silencer, use a Frame to burn out the car­bon deposits, then tap silencer so that these deposits are removed.
When refitting silencer, apply a thin layer of metallic scaler (example - Bostonia No. 3 of Bostik Ltd.) at the cylinder end of the exhaust tube and silencer body.

CHECK FRONT AND REAR SUSPENSIONS
Check that suspensions are riding correctly. Any play on the front fork trailing links to be eliminated by tightening all the nuts and bolts. Check the rear leaf spring, pin and brackets and the conditions of the stop buffers.

CLEAN CARBURETTOR AIR FILTER
Unscrew the fly nut on air intake pipe. Remove pipe from filter box and withdraw filter cartridge. Clean cartridge by shaking and blowing with low pressure air hose. Do not wash in petrol.