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Servicing Circuit Breaker and Ignition Timer

Circuit breaker points that are bumed or pitted should be renewed or dressed with a clean fine-cut contact point file. The file should not be used on other metals and should not be allowed to become greasy or dirty. Never use emery cloth to clean points. Contact surfaces, after considerable use, may not appear bright and smooth but this is not neces-sarily an indication that they are not functioning satisfactorily.

Point faces must seat sąuarely against each other. If bent, square up by bending contact piąte.

Point gap with breaker lever fibrę on Łrighest point of cam, should be .022". Wrong gap affects ignition timing. Readjust by loosening the two lock screws and shifting adjustable contact piąte. Measure gap with accurate thickness gauge before retightening lock screws and recheck gap after tightening lock screws.

Keep breaker cam very lightly greased.

Steering Damper

(SEE DETAIL 15. PAGE 9)

Assemble in the order shown in Illustration 15. Be surę torąue arm registers in slot undemeath frame head. Lips on pressure disc must fit into slot in fork crown and slot in rod lock piąte. Turn actuating sleeve all the way into fork stem and then back it up Vi tum or morę. Register operating lever on actuating sleeve and see that lever has fuli left move-ment without bottoming sleeve.

Adjust by setting adjusting nut sp that operating lever must be moved nearly straight back from free (left side) position, before damper takes noticeable effęct. Tighten lock nut.

Servicing Handlebar Controls

To lubricate control parts, or to replace a throttle or spark control wire, or a damaged control wire housing, proceed as follows:

Insert a large heavy screwdriver through hole in end of grip and tum out end nut by using a wrench on screwdriver. Sometimes this nut is difficult to remove. In this case, insert a punch into slot in nut and strike it two or three sharp blows to start it. After removing grip spiral, working parts are access-ible. Remove plain roller, roller błock, and roller pin. Disconnect control wire at carburetor or timer. Plunger, with control wire attached can now be removed. Wire is fastened into end of plunger by means of a hexagon head screw with a hole through it.

If control wire housing is to be removed, first remove above named parts. Next, remove the smali set screw undemeath handlebar, just ahead of spiral locating shoulder on bar (on left bar, this screw is under headlamp dimmer switch). Control wire housing can now be pushed out through end of bar.

When reassembling control parts to handlebars, apply a light coat of grease or a few drops of engine oil to control wire as it is inserted into control housing, and lubricate remaining parts with grease (See "Lubrication Chart/' Page 15). Overgreasing of these parts will cause a messy condition around bars.

Grip spiral nut can best be started, without danger of Crossing threads, by holding spiral back with slight pressure against nut while starting nut with screwdriver. In this manner, shoulder on nut is held sąuarely against end of spiral sleeve. Always tighten nut securely.

After handlebars and Controls are completely assembled, connect control wires at carburetor and timer. Adjust Controls so throttle closes and opens fully with carburetor control grip movement and so timer fully advances when its control grip is turned to inward position.

KEYEO STEEL WASHER FIBRĘ WASHER OPERATING LEVER ACTUATING SLEEVE RELEASING SPRING PLAIN WASHER

FORK CROWN FIBRĘ DISC

-STEEL DISC WITH TOROUE ARM 'PRESSURE DISC ■ROD LOCK PLATĘ

ILLUS. 15

RING DAMPER ASS]

CUSHION SPRING ROD

ST!

LOCK NUT AOJUSTING NUT

CONE AND HANod-BAR LOCK NUT CONE LOCK PLATĘ ANDLEBAR FORK FITTING UPPER (AOJUSTING) CONE

BLY

Replacing Front Brake Control Wire

Remove control wire lower clevis clamp nut and puli wire out of clevis. Next, remove cotter pin and fiat washer from handlever hollow pin and puli pin out of lever. Control wire can now be pulled out through pin hole in handlever.

Insert new control wire, reversing procedurę in which old wire was removed. Apply grease or engine oil to new wire as it is being inserted. Handlever hollow pin must be reassembled before lower end of wire is connected. Narrow slot in pin straddles wire. Replace fiat washer and cotter pin at end of hollow pin.

Adjust wire housing to nearly maximum slack by tuming adjusting sleeve (Detail 27, Page 10) almost through the boss into which it is threaded. Insert end of wire through clevis nut, then through hole in clevis and back through clamp nut again. Puli wire snug through clevis and secure by tightening clevis nut. Excess wire can be cut off.

Adjust control, by means of adjusting sleeve, so that handlever moves freely about one-quarter of its fuli rangę of movement before brake begins to take effect. Tighten adjusting sleeve lock nut.

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