Villiers MARK 12D Operating Instructions And Spare Parts List
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Villiers MARK 12D Operating Instructions And Spare Parts List

Two stroke motor cycle engine gear units (including 11d/4, 7e/4, 8e/4 & 8e/r)
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OPERATING INSTRUCTIONS

S P A R E. P A R T S L I S T
MARK 12D
(Including llD/4, 7E/4, 8E/4
MOTOR
THE
WOLVERH A MP TON,
Telegrams:
'' VILLIERS ''
WOLVERHAMPTON.
Au�ust,
1955.
TWO STROKE
CYCLE
From February 1st, 1955, until furtheJ: notice,
all prices in this list are increased
VILLIERS
ENGINEERING
,
A N D
MARK SE
&
&
ENGINE
GEAR
by 5%
EN GL A ND
WOLVERHAMPTON
An
(20
lines)
8E/R)
UNITS
CO.
LTD.
Telephone:
2 2 3 9 9
departments.
Y,E.C.
7J.

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  • Page 1: Operating Instructions

    OPERATING INSTRUCTIONS A N D S P A R E. P A R T S L I S T MARK 12D MARK SE & & (Including llD/4, 7E/4, 8E/4 8E/R) TWO STROKE MOTOR CYCLE ENGINE GEAR UNITS From February 1st, 1955, until furtheJ: notice,...
  • Page 2 After a long period of service, your engine may require overhauling, and it is important always to make sure that only genuine Villiers replacement Remember that genuine Villiers parts are used. spares are made with the same fine workmanship as the original engine components.
  • Page 4 . ' . : -' "• ;. MARK 12D MARK SE & (Including llD/4, 7E/4, SE/4 & 8E/R) · and 197 c.c. c.c. TWO STROKE MOTOR CYCLE ENGINE GEAR UNITS...
  • Page 5 For Renold Cha in No. 1 10044 . Final Chain Line 2-ft ins . 2-ft ins. Bxhaust Pipe Dia. It ins. Villiers Type S.24 or Carburetter Villiers Type S. l9. · S . 25 . Carburetter Needle No. 3!-- 2 .015" out.
  • Page 6 INSTRUCTIONS FOR USING THE MARK 120 & MARK SE UNITS. Important. Provi ded that negative b atter y lead i s snit ab ly i nsu lat ed, and t he wiring i s i n goo d condition, no dam age to the R ecti fier wi ll occur if the engi ne i s u sed without the b att er y.
  • Page 7 STARTING. Mark and SE U nits. 'ON' Whon Cold. Turn petrol tap to the position. Flood carburette1 float chamber by depressing tickler. The carburetters fitted to these engines have a single lever control­ ling the throttle position, and to obtain a rich mixture for starting it is necessary to tum the air filter shutter·...
  • Page 8 Figs. 12 and 13. The Flywheel should not be removed unless absolutely necessary, and then it is advis­ able to use a Villiers "Hammer-tight" spanner on the centre nut which is exposed after removal of flywheel cover.
  • Page 9 points commence to open. Tighten up flywheel nut sufficiently to until piston at top of stroke, then timing turn crankshaft, rotate marks should be opposite one another. Finally, tighten centr!' nut with the hammer-tight spanner, and refit flywheel cover. This is Contact of the latest type requmng a screwdriver only Breaker...
  • Page 10 Operation bandl�bar twistgrip (or lever) control operates throttle slide and thereby regulates the amount of mixture Carburetter. entering the engine, whilst th� carburetter itself, automati- , cally meters and atomises the correct amount of ,fuel, to give the necessary mixture strength. achieve this automatic control of the mixture strength, two separate fu�l systems are fitted, namely the main-jet and pilot-jet systems.
  • Page 11 " four-stroking " or " eight-stroking " when the throttle is opened again. overcome this fault in the present range of Villiers Carburetters, an automatic air bleed to the pilot has been incorpo­ rated, which...
  • Page 12 Before. any attempt is made to tune the Carburette r it is Tuning Carbure tter. essential that the engine is in a good mechanical conditio n. 'l his means that there should be no air leaks at any of the joints, there should be a good spark at the plug points and also that there is no restriction in.
  • Page 13 ( 4) Range--t to t Needle Throttle Open. Adjustment:- The needle is adjusted by the grub screw in the top of the throttle- . screw down to weaken mixture, and vice-versa. The needle controls the mixture strength over most of the '' cruisiug range '' and must be correct tor good fuel conswnption and accel�ration.
  • Page 14 Detach the Air Filter by opening the Fixing Clips and periodically clean by dousi ng in petro l. LIGHTING SETS. Two types of lighting sets are supplied for use with the Mark 12D and Mark SE Engines, and although the magnetos are identical for both...
  • Page 15 TRACING TROUBLES. For the satisfactory running of any Villiers Engine it is essential that three main conditions are fulfill d, and by making a systematic and intelligent investigation the faults can usually be located. If...

  • Page 16: Engine Will Not Start

    FAULT F I NDING CHART. Sequence of Testing. Possible Trouble. Remedy. Engine will not Start. Depress tickler on carburet­ Turn tap to ON, refill tank, fuel reaching carburet­ ter to check whether fuel is ter, air lock in petrol pipe. clear air vent in filler cap.

  • Page 17: Engine Lacks Power

    FAULT FINDING CHART-( continued). Possible Trouble. Sequence of Testing. Remedy. Engine Four or Eight Strokes. Mixture too rich. :5trangler fully Lower taper needle by mov­ open taper needle a WEAKER position. Air f too high position. Lower needle adjuster may need cleaning. screw fitted in throttle.
  • Page 18 VILLIERS "DIRECT" LIGHTI NG SET. Wiring. Diagram M.2222D-Fig. 12 (Page 43). Mark 120 and U nits. Component. Part No. Headlamp Complete, M35 - 060088 Rim, Chrome, Less Glass 608157 Wire, Glass Fixing (Set of 4} 600308 Packing, Glass - 612220...
  • Page 19 VILLIERS AC/DC LICHTINC SET WITH RECTIFIER Wiring 'Diagram M.2232D-Fig. 13 (Page 44). Mark 120 and SE Units. Component. Part No. Headlamp Complete, Without Underslung 51005A Pilot-Less Switch and Harness - Headlamp Complete, With Underslung · 51032A Pilot-Less Switch and Harness -...
  • Page 20 Alternative specifications are made for manufacturers' ind1vidua l requirements, and the components fitted are detailed b e low. When ordering, a lways quote the part number of the component, together with the full ngine number. MARK 12D. Price Each, Qty , Illus. No. Description.

  • Page 22: Spare Parts List

    SPARE PARTS LIST. MARK 120 AND 8E ENGINES. number . When ordering spares, always quote the engine Note :- · e lug. quote. the part -Th is is ,stamp ed on the crankcas Always · num ber and description , not the illustration number, which is only ·fo r yo ur ass ist an ce .
  • Page 23 ENG I N E PARTS-continued. MARK 1 2D. MARK BE. Price DESCRI PTION. Price r>art l l lus. Part Q ty. Qty. Each. £ £ s. d. s. d. E.2924 E.2924 Washer E.2539 E.2539 Dowel in crankcase locating gear- E.76 1 9 E.76 1 9 E .
  • Page 24 MARK 12D A N D MARK SE. SPEED GEARBOX. Fig. l llus. pages 22-23. Part No. Q ty. Pric• E��&h; .. iltus. £ Gearbox, bushed B. 8298 Ball bearing 6205 seal E. 9728 E. 7882 Sprocket distance piece 1 5 teeth E.8230 E.8231 1 7 teeth...
  • Page 25 J tlus. U escnptzon. r,jty . l'rzce ach. !'art No. £ Spindle circlip E.6552 D.6996 Foot change lever - D . 6861 Rubber for lever E.425 1 Bolt for foot lever - E.4252 Nut for bolt E. 6543 Ratchet spring D.7951 Operating pawl E.7437...
  • Page 26 - ·; � Price Descri p tion. Part No. Ji. a&!J, /ltus. £ " Mainshaft Nut E . 4467 Dipstick E.747l Wash er for dipstick End plate nut E.6547 screw " . " E.6561 Dust cover screw " V. l57 ..: 2 Washer for screw 79 .
  • Page 27 ·26 22 19 23 25 27 28 4� 32 40 39 3 1 38 44 35 3 1 39 40 46 45 36 37 49 Fig.
  • Page 28 . · · .. · . . • 9 30 65 63 64 6 1 72 76 75 48 80 49 47 57 58 56 59 60 66 67 68 69 ENGINE.
  • Page 29 4-S PEED GEARBOX 1 1 , 0 /4, 7E/4 and M k. 8E/4 U nits . . (Fig. page 28). 6. Illustration on Note :-When ordering spares;, always quote the engine n umber. Always This is stamped on the crankcase lug. qLwte the part number and descript ion, not the illustration n u mber, which is only for your assistance.
  • Page 30 · · :' . · Part Description. Quan tity Prica £ C ra nk Pe da l . . . E.8833 K .S E.8832 K.S. Cran k K.S. Crank Pedal Spring and Ball £.8835 K.S . Cr an k Pe da l Bo lt E.8834 Op erat or Sha ft Sec urin g Pin E.8864...
  • Page 31 .::�-· •.r;-_ -·- 4-S P E E D GEARBOX. c l. . . ' • • · Fig. 6. � · � : · ''· · ·�'· ;· • · · · · • ·...
  • Page 33 3 S P E E D AN D R FVERSE GEARBOX For The Mk. 8E /R Unit 3 2) . (Fig. 7 . i llustration on Note :-When ordering spares, a lways quote the engine number. This is stamped on the crankcase lug . Always quote the part number and descriptio n , not the i l l ustrati on number , which is only...
  • Page 34 Part List Price Description llus . £ No . E.8872 1 1 6 �� · ;',- Gear . Box Case E.8873 Gear Box Cover E.88]4 Gear Box Cap E.8793 Gear Box Oil Seal E.8794 Oil Seal Retainer E.8795 Ball Race (Large) E.8875 Mainshaft Low Gear Pinion 23T E.8797...
  • Page 36 £ E.8827 Clutch Lever Adjuster Pin E.8828 Clutch Lever E.8829 . . . I nspection Cover E.8830 Inspection Cover Pin . E.883 1 K.S. Return Spring E.8832 K.S. Crank E.8833 K.S. Crank Pedal E.8834 K.S. Crank Pedal Bolt """'" E.8835 K S .
  • Page 37 . , __ , __ �--- - · - ----- -- A••-•·- --.-- -;-c - = ;_ � �.-�:,_: :_:_:;:___._.:. ·-- - · - - - " - - - · -···�-· -•--- ---· • ; _ - _ ,.,, .-.,-,___,_ •--- - ·...
  • Page 38 Ill u s. Part No. Description. Qty. Price Each. £ M . 1 85GE H . T . coil end-right-hand M. 1361E coil or M.2306- 1 046 1 0 1 0 l iE " " washer E.869 felt " 1 124 terminal M.21 10E cover...
  • Page 39 CA RBURETTE R, TYPE 5. 19. Fig. 9 . Ill u s. Part No . Description. Price Each. Q ty. £ V.840B Body with fuel bush V.854£ Body clip screw V.754E " " V . 355E Fuel Needle V.738E lever "...
  • Page 40 - · ·--·- · .·;'...
  • Page 42 2 {> ;,_. . ---- -- -- ---- -�. 15 I :r--- -- -- -- - Fig. 1 CA R B U RETTER, TYPE 5.24...
  • Page 43 CARBURETTER, TYPE S.25. 1 1 . Descriptio?t. Qty. Price Each. lll u s. Part No. £ Throttle cable complete assem- Quote Engine Spec. Rubber cover, cable adjuster - V.S26E Cable adjuster V . 1 05 Locknut for adjusteT V . 1 05 Top ring V.S15E Cable nipple -...
  • Page 44 "-i .• <',' T 1 . Fig. CARB U RETTER, TYPE 5.25 PARTS.
  • Page 45 CARBU RETTER, TYPE S.25-continued. Where the S.25 carburetter is fitted with a cable operated choke the standard air filter is not required, and the following parts are incor­ porated:- Description. Part No. Qty. Price Each. £ Carburetter body (replaces V. l l56E V.834D) V.942C Strangler body...
  • Page 46 ..-·· -�-···-- '"'--·--·-······- · , .. . , , 01=1= I. 1...SVaA I UP R.H. Oo\NN OOWI'I 1-j•.t.o I.-AMP 6.V..'f'Ar"' MI..A M BNT �AS FIL.L.aO " D I RECT " LICHTJNC SET. W J R J NC DIACRAM.
  • Page 48 . '-..ESTI MATES. If requested at the time of despatch, we are prepared to give an estimate before proceeding with any repair. This entails a certain amount of labour in dismantling to ascertain what new parts will be required, and therefore, in the case of any estimate not being accepted, a charge is made for our mechanic's time in taking down the engine for report and the re-building, and return carriage costs.
  • Page 49 2.-When sending parts for replacement, repair, or as pattern, the name and address of the sender should always be securely attached, and full instructions explaining what is required must also be sent separately by post. In no circumstances should instructions be sent only with the parts as they are liable to be lost or damaged in unpacking.
  • Page 50 The guarantee becomes void if any parts not made or supplied by THE VILLIERS ENGINEERING COMPANY, LTD., are fitted to a VILLIERS engine. To safeguard his own interests, the owner should always insist upon genuine VILLIERS parts.
  • Page 51 N O T E S •...
  • Page 52 . - ' CONTENTS. General:- Page · · Carburetter, deEcription Operation of Tuning of Chain case Clutch Contact breaker Data, Engine . . . Estimates Fault finding chart Fuel Gearbox Guarantee Lighting sets . . Lubrication . . . Magneto, general timing Repairs Running-in...

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Mark 8e

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