BSA D14/4 BANTAM SUPREME D14/4 BANTAM SPORTS Workshop Manual
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BSA D14/4 BANTAM SUPREME D14/4 BANTAM SPORTS Workshop Manual

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WORKSHOP MANUAL

for D14/4 models
BANTAM SUPREME
BANTAM SPORTS
BUSHMAN
Service Department
Telephone 021-772 2381
B.S.A. MOTOR CYCLES LTD.
ARMOURY ROAD
BIRMINGHAM 11
Publication Reference 00-4152/4/69

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Summary of Contents for BSA D14/4 BANTAM SUPREME D14/4 BANTAM SPORTS

  • Page 1: Workshop Manual

    WORKSHOP MANUAL for D14/4 models BANTAM SUPREME BANTAM SPORTS BUSHMAN Service Department Telephone 021-772 2381 B.S.A. MOTOR CYCLES LTD. ARMOURY ROAD BIRMINGHAM 11 Publication Reference 00-4152/4/69...
  • Page 2 Please Note! Replacement parts or accessories must be of B.S.A. origin or as approved by B.S.A Motor Cycles Ltd. In this respect your attention is drawn to the Terms and Conditions of B.S.A. Guarantee.
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  • Page 6 INTRODUCTION The object of this manual is to provide comprehensive service information for both the B.S.A. owner, and the workshop fitter, wishing to carry out either basic maintenance or major repair work. As some of the repair work described requires specialised skills and workshop equipment, the inexperienced owner is strongly advised to consult his B.S.A.
  • Page 7 Factory Service Arrangements (UNITED KINGDOM) REPLACEMENT PARTS B.S.A. replacement parts are distributed through a national network of B.S.A. dealers, each of whom holds a stock of fast moving parts. Approximately 200 of these dealers have been selected for appointment as specialist B.S.A. replacement part stockists and each of these stockists holds a comprehensive stock of B.S.A.
  • Page 8 PROPRIETARY PARTS Equipment not of our manufacture, fitted to our motor-cycles, is of the highest quality and is guaranteed by the manufacturers and not by us. Any complaints or repairs should be sent to the manufacturer concerned or their accredited agents who will give every possible assistance.
  • Page 9 U.S.A. SERVICE ARRANGEMENT REPLACEMENT PARTS B.S.A. replacement parts are available through a national network of B.S.A. dealers covering the entire United States. These B.S.A. motor-cycle dealers are listed under "Motorcycles" in the yellow pages of your local telephone directory. All requests for parts must be made through franchised B.S.A. dealers, they are not sold directly to B.S.A. by the two factory branches.
  • Page 10 CONTENTS Section Page GENERAL DATA 1 to 10 LUBRICATION 1 to 6 ENGINE 1 to 19 CARBURETTER 1 to 8 FRAME AND FITTINGS 1 to 12 FRONT FORKS 1 to 9 WHEELS, BRAKES AND TYRES 1 to 12 ELECTRICAL EQUIPMENT . . 1 to 15 CHAINS 1 to 3...
  • Page 11 D14/4 GENERAL DATA I N D E X SUPREME MODELS Page ENGINE: Piston . . Piston Rings Cylinder Barrel . . Ignition Timing . . Carburetter Bearing Dimensions TRANSMISSION: Clutch . . Sprockets Chain Size Gear Ratios FRAME AND FITTINGS: Front Forks Rear Dampers .
  • Page 12 D14/4 GENERAL DATA I N D E X – continued Page SPORTS MODELS ENGINE: Carburetter FRONT FORKS: Bushes . . WHEELS BASIC DIMENSIONS WEIGHT BUSHMAN MODELS ENGINE: Bearing Dimensions Forks Carburetter TRANSMISSION: Gear Ratios Chain Sizes BUSHMAN PASTORAL MODELS TRANSMISSION: Gear Ratios Sprockets Chain Sizes...

  • Page 13: Piston

    D14/4 GENERAL DATA ENGINE PISTON Material. . "Lo-ex" aluminium Compression ratio 10 : 1 Clearance (bottom of skirt) 0·0038—0·0039" (0·096—0·099 mm.) Clearance (top of skirt) . . 0·0077—0·0078" (0·195—0·198 mm.) (both measured on major axis) PISTON RINGS Material. . Cast-Iron Width .

  • Page 14: Bearing Dimensions

    D14/4 GENERAL DATA BEARING DIMENSIONS Crankshaft bearing (left- and right-hand) . . ·75 × 1·875 × ·5625" (19·05 × 47·625 × 14·2875 mm.) Crankshaft bearing outer (right-hand) 17 × 40 × 12 mm. Layshaft bush, left- and right-hand (bore) . . ·6105—·6115"...

  • Page 15: Gear Ratios

    D14/4 GENERAL DATA GEAR RATIOS Gearbox—(top) . . 1·0 —(third) 1·301 :1 —(second) 1·831 :1 —(first) . . 2·843 :1 Overall —(top) . . 6·57 —(third) 8·55 —(second) 12·03 :1 —(first) . . 18·68 :1 FRAME AND FITTINGS FRONT FORKS Type Coil spring, hydraulically-damped Springs:...

  • Page 16: Wheels

    D14/4 GENERAL DATA WHEELS, BRAKES AND TYRES WHEELS Rim size and type (front and rear) WM1-18 Spoke sizes: (front, left-hand) 12 s.w.g. × 8-1/16" (2·641 × 204·78 mm.) (front, right-hand, inner) 12 s.w.g. × 6½" (2·641 × 165·1 mm.) (front, right-hand, outer) 12 s.w.g.
  • Page 17 D14/4 GENERAL DATA CAPACITIES Petroil proportion See page A3 Fuel tank 1·875 gallons or (8·5 litre) 2·25 U.S. gallons Gearbox ¾-pint (0·5 litre) Front fork (each leg) ⅛-pint (0·07 litre) BASIC DIMENSIONS Wheelbase 50·0" (127 cm.) Overall length . . 77·5"...

  • Page 18: Bushes

    D14/4 GENERAL DATA D14 BANTAM SPORTS MODELS All general data is the same as that given in preceding pages for the Supreme models except for the following:— CARBURETTER Concentric R626/13 FRONT FORKS Shaft diameter . . 1·248—1·249" (31·70—31·72 mm.) Sliding tube bore 1·475—1·477"...

  • Page 19: Bearing Dimensions

    D14/4 GENERAL DATA D14 BUSHMAN MODELS All general data is the same as that given in preceding pages for the Supreme models except for the following:— BEARING DIMENSIONS Forks . . As Bantam Sports models CARBURETTERS (Concentric) Type . . Amal R626/12 TRANSMISSION (Standard D14 Bushman models) GEAR RATIOS...

  • Page 20: Tyres

    D14/4 GENERAL DATA GD10 TYRES Size (front and rear) . . 3·00 × 19" Pressure (front) ..17 p.s.i. (1·2 atm) Pressure (rear) ..22 p.s.i. (1·5 atm) ELECTRICAL EQUIPMENT (Direct Lighting) Alternator type . . .

  • Page 21: Table Of Contents

    D14/4 LUBRICATION I N D E X Page CONTACT BREAKER . . A4 CONTROL CABLES . . A6 ENGINE LUBRICATION ..A3 FRONT FORK . . A5 GEARBOX LUBRICATION . . A3 REAR CHAIN . . A4 REAR SUSPENSION .

  • Page 22: Regular Maintenance

    D14/4 LUBRICATION REGULAR MAINTENANCE Regular maintenance is essential if the machine is to have a long and trouble-free life. The following list of items requiring attention will also serve as a guide to the periods of time between servicing. The correct method of performing each operation will be found under the appropriate headings in later chapters.

  • Page 23: Recommended Lubricants

    D14/4 LUBRICATION RECOMMENDED LUBRICANTS BRAND GREASE FRONT Engine Gearbox POINTS FORKS Castrol Castrol Two Castrol XXL Castrolease LM Castrolite -Stroke Oil Shell 2T Two- Shell X100-40 Shell Retinax A Shell X100-20 Stroke Oil Esso Esso Two-Stroke Esso Extra Esso Multipurpose Esso 20W/30 (2T) Motor Oil Motor Oil 40/50...

  • Page 24: Steering Head

    D14/4 LUBRICATION It is therefore essential that the correct oil level be It is essential that no engine oil is allowed into the maintained. contact breaker housing and to prevent this, an oil seal is fitted behind the contact plate. To check the gearbox oil level remove the level screw and filler plug, and pour oil into the filler until it Periodical lubrication of the contact breaker cam...

  • Page 25: Front Fork

    D14/4 LUBRICATION The fresh grease will hold the ball bearings in position The capacity also is different being a third pint (175 during re-assembly. Check that the grease is as quoted c.c.) S.A.E. 40 oil to each leg. on page A3. WHEEL BEARINGS The correct number of ball bearings for each cup is The wheel bearings are packed with grease on...

  • Page 26: Rear Suspension

    D14/4 LUBRICATION REAR SUSPENSION Each of the two suspension dampers comprise a telescopic damper unit and a coil spring. During their manufacture, the damper units are sealed and therefore require no attention whatsoever. If they are damaged or become ineffective, they must be replaced. NOTE:—Should the damper bushes become noisy and squeaky do not lubricate them with oil.
  • Page 27 D14/4 ENGINE INDEX Page DESCRIPTION OPERATION OF THE TWO-STROKE ENGINE DECARBONISING: Silencer Removal of Cylinder Piston Piston Rings Cylinder Head and Barrel Small-end Bearing Big-end Bearing Reassembly after Decarbonising REMOVAL OF ENGINE . . ENGINE DISMANTLING . . CLUTCH PLATE DISMANTLING GEARBOX DISMANTLING REMOVAL OF CLUTCH HUB GEARBOX INSPECTION .
  • Page 28 D14/4 ENGINE FIG. B1. Engine exploded.

  • Page 29: Operation Of The Two-Stroke Engine

    D14/4 ENGINE OPERATION OF THE TWO-STROKE ENGINE FIG. B2. Diagram A. Shows the piston nearing the top of its The transfer ports are also open, allowing the stroke, compressing a charge of mixture from the compressed mixture in the crankcase to force its way previous cycle, ready for firing.
  • Page 30 D14/4 ENGINE The two-stroke is so called because a firing stroke These deposits are not harmful providing they are not occurs on one out of every two strokes of the piston, allowed to become too heavy and cause pre-ignition unlike the four stroke engine which fires once every and other defects which would impair the performance four strokes of the piston.

  • Page 31: Removal Of Cylinder

    D14/4 ENGINE Remove these parts, then with a pair of pliers pull the Should the barrel be found difficult to remove, it may baffles from inside the silencer and soak in caustic help if the two crankcase joint screws below the soda solution to dissolve the carbon.

  • Page 32: Cylinder Head And Barrel

    D14/4 ENGINE See also that there is sufficient clearance between the inner portion of the gap and the locating peg in the groove. This can be checked by closing the ring in the groove until the gap closes, proving that there is clearance at the peg below.

  • Page 33: Big-End Bearing

    D14/4 ENGINE REASSEMBLY AFTER DECARBONISING If the piston was removed from the connecting rod, replace it in its original position, (i.e., with the piston ring gaps at the front). Before fitting the gudgeon pin, smear it with oil and do not forget to replace the circlips.

  • Page 34: Engine Dismantling

    D14/4 ENGINE If any difficulty is encountered in unscrewing the nut, apply a few drops of penetrating oil to the threaded Before starting work on a complete strip-down of portion and allow to soak before attempting to the engine unit it is advisable to have the following unscrew it any further.

  • Page 35: Clutch Plate Dismantling

    D14/4 ENGINE The generator rotor is secured to the keyed engine shaft by one large nut and spring washer. Undo this, pull off the rotor and extract the Woodruff key from the shaft. Using the same method remove the self-locking nut securing the engine sprocket.

  • Page 36: Gearbox Dismantling

    D14/4 ENGINE FIG. B10. New clutch springs have a free length of 1-9/64" The crankcases are now about ready for splitting. (29 mm.) and if this length has reduced by more than First take out the twelve Phillips-head screws from 1/32"...

  • Page 37: Removal Of Clutch Hub

    D14/4 ENGINE Hold the crankcase assembly firmly in a soft-jawed vice gripping the gearbox mainshaft. REMOVAL OF CLUTCH HUB With the gearbox mainshaft held firmly in a soft- jawed vice, remove the clutch centre nut and washer, which will release the clutch centre pinion, thrust bearing and two washers and the clutch chainwheel.

  • Page 38: Attention To Flywheels

    D14/4 ENGINE FIG. B12. The pegs in the cam plate and quadrant should be If the bearing has noticeably deteriorated as the result secure and the dogs on the quadrant and the of neglect or abuse, the flywheels must be parted to corresponding claws on the selector plate should be in gain access to the bearing.
  • Page 39 D14/4 ENGINE FIG. B14. Reassembling the flywheels. FIG. B13. Parting the flywheels. Position the second flywheel over the crankpin and, using one of the stripping bars as shown in Fig. B14, press the flywheel on to the crankpin. The flywheel assembly must now be aligned within the necessary limits.
  • Page 40 D14/4 ENGINE Having checked the flywheels for concentricity, it The kickstarter ratchet engages on the clutch drum and will now be necessary to check the end float of the is followed by a spring, a retainer, and the circlip. shafts. Place a ·010" shim on the right-hand spindle Check that the ratchet spins freely on the clutch drum.
  • Page 41 D14/4 ENGINE Refit the return spring to the gearchange spindle. The ends of the spring locate over a projection on the cam plate mounting bracket, acting as a centralising device for the claw. Place the distance piece below the spring and replace the spindle in the case. Locate the selector claw, if it is not central it must be adjusted by bending the spring.
  • Page 42 D14/4 ENGINE FIG. B20. FIG. B19. Fit the distance pieces over each generator stud, and replace the stator. The stator is correctly fitted when Insert the hollow dowels into each end of the case. the cable assumes a three-o'clock position and is Replace the twelve short Phillips screws round the outward.

  • Page 43: Ignition Timing

    D14/4 ENGINE Engine assembly from this point should proceed as detailed in Reassembly, after decarbonising, on page IGNITION TIMING Contact Breaker Gap In order to maintain correct ignition timing the contact points must be set to the specified gap when in the fully open position.
  • Page 44 D14/4 ENGINE Piston Position Bring the piston slowly up to the stop by rotating the Before checking the ignition timing, the piston must engine as far as it will go, first in a clockwise first be set at the recommended position before top direction, then in an anti-clockwise direction.

  • Page 45: Clutch Adjustment

    D14/4 ENGINE An accurate means of checking the opening of points can be made by connecting a battery and bulb in circuit with the points, as shown in Fig. B23. Attach one lead between the moving contact spring and the battery terminal.
  • Page 46 D14/4 CARBURETTER INDEX Page DESCRIPTION DISMANTLING AND REBUILDING (Concentric Float Chamber) HINTS AND TIPS . . INSPECTING THE CARBURETTER COMPONENTS . . TRACING FAULTS. . TUNING THE CARBURETTER . . VARIABLE SETTINGS AND PARTS...
  • Page 47 D14/4 CARBURETTER FIG. C.1. Concentric carburetter exploded...
  • Page 48 D14/4 CARBURETTER DESCRIPTION DISMANTLING AND REBUILDING (Concentric Float Chamber) All the D14 Bantam models are fitted with an Amal carburetter having a concentric float chamber and a Unscrew the two fixing nuts and withdraw the cable operated air valve. The only variation between carburetter from its mounting studs;...
  • Page 49 D14/4 CARBURETTER Having dismantled the carburetter, carefully clean Ensure that the float is not punctured by shaking all parts in petrol (gasoline). Hard deposits on the it to see if it contains any fuel. Do not attempt to carburetter body are best removed with a light-grade repair a damaged float.
  • Page 50 D14/4 CARBURETTER Eliminate by fitting new joint washers and tightening Air Control the flange nuts evenly to a torque wrench setting of The air control should at all times be kept open except 10—12 lb./ft. when starting from cold. When the engine fires, the control must be opened.
  • Page 51 D14/4 CARBURETTER Having established whether the mixture is too rich or NOTE:—It is incorrect to attempt to cure a rich too weak, check if caused by:— mixture at half-throttle by fitting a smaller jet because the main jet may be correct for power at full throttle. (1) Fuel feed —...
  • Page 52 D14/4 CARBURETTER PARAGRAPH “C” — Main Jet PARAGRAPH “G” — Tickler or Primer The main jet controls the fuel supply when the This is a small spring-loaded plunger, in the float throttle is more than three-quarters open, but at chamber wall. When pressed down on the float, the smaller throttle openings although the supply of fuel needle valve is allowed to open and so "flooding"...
  • Page 53 D14/4 CARBURETTER SEQUENCE OF TUNING FIG. C3. (2) now gently lower the throttle adjusting screw until FOURTH — Needle with throttle in position 4 (Fig. the engine runs slower and just begins to falter, adjust C3). The needle controls a wide range of throttle the pilot air adjusting screw to get best slow-running, openings and also the acceleration.
  • Page 54 D14/4 FRAME AND FITTINGS INDEX Page D14 BANTAM SERIES FRAME DIMENSIONS . . D2 FRAME ALIGNMENT . . D3 SWINGING ARM: Removal . . D4 Alignment . . D6 REAR DAMPERS ..D6 PETROL TANK . . D7 DUALSEAT .
  • Page 55 D14/4 FRAME AND FITTINGS FIG. D1. Frame dimensions.
  • Page 56 D14/4 FRAME AND FITTINGS FRAME ALIGNMENT FIG. D2. The only satisfactory way of checking the D14 Figure D3 shows the basic set-up for checking the Bantam frame for correct alignment is on an engineer's D14 Bantam frame, though variations can be used, setting-out table.
  • Page 57 D14/4 FRAME AND FITTINGS FIG. D3. Frame on setting-out table. When the frame is set parallel to the surface of the table, the swinging arm pivot spindle should be vertical. This can be checked using the set square and internal calipers or a slip gauge between the spindle and the square.
  • Page 58 D14/4 FRAME AND FITTINGS SWINGING ARM FIG. D5. Swinging arm dimensions. On Bushman models only, the prop stand must also Removal Take off the rear wheel, mudguard, dampers and be removed, the bracket for which is held by two nuts chainguard, as described on pages F3, D9, D6 and D9 and bolts.
  • Page 59 D14/4 FRAME AND FITTINGS FIG.D6. Checking the swinging arm. The two phosphor-bronze bushes can be tapped out NOTE:—There may also be variation in the rear of the swinging arm pivot lugs with a suitable drift. dampers and a careful examination should be made of the overall length between the mounting eyes of each Alignment unit.
  • Page 60 D14/4 FRAME AND FITTINGS The removal and replacement of the mounting bushes will be found much easier if a little liquid soap PETROL TANK is applied. Turn off the petrol tap and detach the petrol pipe at its The spring is retained at its base by split collets and, union on the float chamber.
  • Page 61 D14/4 FRAME AND FITTINGS To remove the right-hand sidecover and back plate DUALSEAT on the Supreme models, first unscrew the two chrome- headed screws in the cover, these have a circlip fitted Should it be found necessary to remove the dualseat, on them behind the cover to prevent them from falling first loosen the damper top fixing bolts sufficient to out.

  • Page 62: Air Cleaner

    D14/4 FRAME AND FITTINGS Take off the left-hand sidecover and remove the CHAINGUARD coil, held by two nuts and bolts. Also take out one nut and bolt fixing the rectifier bracket to the top of the The chainguard is held by one nut and bolt to the rear guard.
  • Page 63 D14/4 FRAME AND FITTINGS Before replacing the air cleaner, check that the rubber "O"-ring fitted on the carburetter intake, is undamaged and fit for further use. Bushman Pastoral models These particular models are fitted with a special dry- element air cleaner which should be regularly examined at intervals of 1,000 miles (1,600 km.).
  • Page 64 D14/4 FRAME AND FITTINGS The headlamp cowl is fixed to the fork cover by Fit the replacement cable to the grip by inserting it four screws with nuts and can now be removed. up through the lower half and locating the nipple in its slot.
  • Page 65 D14/4 FRAME AND FITTINGS Finally attach the cable in the frame, replace the cable stop at the twist grip and adjust the cable as necessary (see page C4). Air Control Cable — Concentric Carburetter To replace an air control cable, first open the control lever to its fullest extent then, whilst pulling the cable, close the lever and release the cable nipple.
  • Page 66 D14/4 FRONT FORKS INDEX Page DESCRIPTION FORK LEGS: Supreme Hydraulic Damping . . Dismantling the Fork Leg . . Oil Seals Rebuilding the Fork Legs Replacing the Fork Legs FRONT FORKS: Bushman and Sports Hydraulic Damping . . Dismantling the Fork Leg . . Oil Seals Rebuilding the Fork Leg Replacing the Fork Leg...

  • Page 67: Removing The Fork Legs

    D14/4 FRONT FORKS DESCRIPTION HYDRAULIC DAMPING (Supreme) Figure E1 opposite, is a sectioned illustration of a front fork leg fully extended. When the fork leg is compressed the lower member rises, forcing the oil upwards around the top of the restrictor rod.

  • Page 68: Rebuilding The Fork Legs

    D14/4 FRONT FORKS Remove the large top cap nuts and screw service tool No. 61-3350 (minus the large nut and washer), into the top of the fork leg. Take a firm grasp of the lower sliding member and strike the top of the service tool sharply with a mallet.

  • Page 69: Replacing The Fork Legs

    D14/4 FRONT FORKS REPLACING THE FORK LEGS FORK DISMANTLING Screw service tool No. 61-3350 (minus the nut and Before starting work on the forks it is advisable to collar) into the top of the leg and pass the assembly up have the following tools and replacements available:—...

  • Page 70: Oil Seals

    D14/4 FRONT FORKS OIL SEALS If it is necessary to change the oil seal, place the lower edge of the holder on a wooden block and enter service tool No. 61-3006 into the top of the holder. Give the tool a sharp blow with the hammer and the seal will be driven out.

  • Page 71: Replacing The Fork Leg

    D14/4 FRONT FORKS FIG. E7. Using service tool No. 61-3350. Repeat the operations on the other leg. Before refitting the leg to the steering head, apply a liberal coating of grease to the spring and place the spring in position in the oil seal holder. REPLACING THE FORK LEG Now screw service tool No.
  • Page 72 D14/4 FRONT FORKS FIG. E8. Bottom yoke twisted. First slacken the top cap nuts and the pinch bolts in Should the tube be obviously bent but not kinked, both the bottom and top yokes, then loosen the wheel then it may be possible to carry out a reasonable repair spindle retaining caps.

  • Page 73: Renewing Steering Head Races

    D14/4 FRONT FORKS Place a strong support under the engine so that the The repair will be simplified and be very much front wheel is raised clear of the ground then, standing better if a suitable press is available to the repairer. in front of the wheel, attempt to push the lower fork legs backwards and forwards.
  • Page 74 D14/4 FRONT FORKS FIG. E11. Cup drift. Remove the dust cap and prepare to examine the bearings. There should be twenty-four steel balls in each race (see page A3 for details on lubrication). The FIG. E10. Removing top cup. lower cone can be prised off the column but, when fitting the replacement, care must be taken to see that the cone is seated squarely.
  • Page 75 D14/4 WHEELS, BRAKES AND TYRES INDEX Page FRONT WHEEL: Removal . . F2 Hub Dismantling . . F2 Fitting New Bearings . . F3 Brake Shoes ..F3 REAR WHEEL: Removal . . F3 Hub Dismantling . . F4 Fitting New Bearings .

  • Page 76: Front Wheel

    D14/4 WHEELS, BRAKES AND TYRES FRONT WHEEL Front Wheel Removal With the machine on its centre stand, place a box or small wooden trestle underneath the crankcase so that the front wheel is raised clear of the ground. Detach the brake cable toggle (A) Fig. F1, from the operating lever on the brake cover plate and the brake plate from the right-hand fork leg.

  • Page 77: Rear Wheel

    D14/4 WHEELS, BRAKES AND TYRES To remove the left-hand bearing, first prise out the circlip (H), then insert the spindle from the right-hand side and drive out the bearing with its dust cover. Sports models will have a shim fitted between the dust cover and the bearing face.

  • Page 78: Brake Adjustments

    D14/4 WHEELS, BRAKES AND TYRES Check also that the spring clip of the chain The brake side bearing and thrust washer can now connecting link is correctly fitted and has its closed be driven out from the opposite side using a drift end pointing in the direction of travel (i.e., rearwards against the outer race of the bearing.

  • Page 79: Rear Chain Adjustment

    D14/4 WHEELS, BRAKES AND TYRES The front brake adjuster is situated on the lower right-hand fork leg. Rotation of the screwed sleeve alters the effective length of the cable so adjusting the position of the shoes in the drum. The locknut should be tightened after each adjustment.

  • Page 80: Security Bolts

    D14/4 WHEELS, BRAKES AND TYRES SECURITY BOLTS Sometimes, particularly if a tyre is under-inflated, it will creep around the rim taking the tube with it. If this is not stopped, the valve will ultimately be pulled from the tube. It has been found necessary therefore, to fit a security bolt to the rim of each wheel on the Bushman models.

  • Page 81: Wheel Balancing

    D14/4 WHEELS, BRAKES AND TYRES Periodically test the tension either by "ringing", that is striking with a metal tool or by placing the finger and thumb of one hand over two spokes at a time and pressing them together. If tension has been lost there will be no ringing tone and the spokes will move freely across each other.

  • Page 82: Tyre Removal

    D14/4 WHEELS, BRAKES AND TYRES Assuming that the chain adjustment is correct the movement of the rear wheel will be made on the right- hand side chain adjuster which should be screwed in or out as necessary after the spindle nuts have been slackened off.
  • Page 83 D14/4 WHEELS, BRAKES AND TYRES FIG. F11. It will not be possible to pull the cover bead at (A) Fig. F11 over the rim flange until the cover bead at (B) is pushed off the bead seat (C) down into the well (D). Then the cover bead at (A) comes over the rim flange easily.

  • Page 84: Tyre Replacement

    D14/4 WHEELS, BRAKES AND TYRES TYRE REPLACEMENT Before a tyre, new or used, is replaced, ot should be carefully checked inside and outside for loose objects or nails, flints, glass and cuts. Do not forget that although there may be nothing visible outside there could be a nail projecting inside.
  • Page 85 D14/4 WHEELS, BRAKES AND TYRES Push the valve inwards to ensure that the tube adjacent to the valve is not trapped under the bead, then pull the valve back firmly into position. Before inflating, check that the fitting line on the tyre wall just above the bead on each side is concentric with the rim.

  • Page 86: Tyre Pressures

    D14/4 WHEELS, BRAKES AND TYRES TYRE PRESSURES The recommended inflation pressures of 17 p.s.i. for the front and 22 p.s.i. for the rear tyre, are based on a rider's weight of 140 lb. If the rider's weight exceeds 140 lb, the tyre pressures should be increased as follows:—...
  • Page 87 D14/4 ELECTRICAL SYSTEM INDEX Page INTRODUCTION ..G2 BATTERY: Charging the Battery ..G2 Routine Maintenance . . G3 EMERGENCY STARTING . . G4 FAULT FINDING: Charging Circuit . . G4 Rectifier . . G6 Switches .
  • Page 88 D14/4 ELECTRICAL SYSTEM INTRODUCTION The lighting and ignition systems of the Wipac alternator equipped model Bantam consists of a simple six-pole alternator generating set which supplies current through a metal plate rectifier to a battery, which then feeds the ignition system, lights, horn etc. The alternator ring carries six coils which are connected in three sets of two in series, as illustrated in the schematic diagram Fig.
  • Page 89 D14/4 ELECTRICAL SYSTEM During charging, keep the electrolyte in each cell Remember that a positive earth wiring system is level with the top of the separator guard by adding employed on the bantam series and ensure that the distilled water — not acid. battery is connected correctly, i.e., with the positive (+) side of the battery connected to earth.
  • Page 90 D14/4 ELECTRICAL SYSTEM Notes:—The specific gravity of the electrolyte varies If a Wilkson test set is not readily available, then the with the temperature. For convenience in comparing additional equipment listed below can be used as an specific gravities, they are always corrected to 60°F., alternative.
  • Page 91 D14/4 ELECTRICAL SYSTEM FIG. G2. Generator testing. NOTE:—It is essential that bulbs of the correct A low reading on one group of coils would indicate wattage be used throughout the system, as any coil failure and low readings on both groups of coils deviation will seriously upset the charge rates.

  • Page 92: Electrical System

    D14/4 ELECTRICAL SYSTEM Rectifier However, before attempting to carry out tests on the A rapidly flattening battery necessitates an immediate rectifier it is essential that the white, green and brown check on both the rectifier and alternator. cables are disconnected from the unit at the plug sockets.
  • Page 93 D14/4 ELECTRICAL SYSTEM Contact Breaker Check the contact breaker points gap and adjust to the recommended setting of ·012", as detailed on page B17. Check cleanliness of contact faces, these, if in good order, should have a light grey frosted appearance.
  • Page 94 D14/4 ELECTRICAL SYSTEM Ignition Coil (2) Connect a D.C. voltmeter (0-10 volts) across the Firstly, completely disconnect the ignition coil from battery terminals and an ammeter (0-10 amp.) the motor-cycle circuit, and connect the D.C. between the battery negative terminal and the voltmeter across the six-volt battery to produce a free ends of the wire resistance, using a crocodile continuity check.
  • Page 95 D14/4 ELECTRICAL SYSTEM FIG. G5. Generator testing (Bushman Pastoral models only). Generator Testing Column 2. The following table will apply in checking the Column 1. alternator outputs and the readings should be taken Value of lamp load only under loaded conditions as detailed in column 3 Readings taken or open circuit and column 4.
  • Page 96 D14/4 ELECTRICAL SYSTEM Premature Bulb Failure Examine the plug for signs of petrol (gasoline) The current feeding the bulbs when the headlights are fouling. This is indicated by a dry, sooty, black deposit in use is alternating current, provided direct from the which is usually caused by over-rich carburation, generator.
  • Page 97 D14/4 ELECTRICAL SYSTEM A plug of the correct grade will bear a light flaky If the ignition and carburation settings are correct deposit on the outer rim and earth electrode, and these and the plug has been correctly fitted, but over-heating and the base of the insulator will be light chocolate still occurs, then it is possible that carburation is being brown in colour.
  • Page 98 D14/4 ELECTRICAL SYSTEM FIG. G7. Beam adjustment. The headlamp has a reflector with an extremely The headlamp must therefore be set so that the main efficient reflecting surface provided by the now widely beam is directed straight ahead and parallel with the adopted aluminisation process in which a thin film of road when the motor-cycle is fully loaded.
  • Page 99 D14/4 ELECTRICAL SYSTEM Ensure that both the black (tail lamp) and brown If the horn fails to work, check the mounting bolts (stop lamp) supply leads are properly connected and etc., and horn connection wiring. Check the battery for see that the earth lead to the bulb holder is in state of charge.
  • Page 100 D14/4 ELECTRICAL SYSTEM FIG. G8. Wiring diagram (all models except Bushman Pastoral).
  • Page 101 D14/4 ELECTRICAL SYSTEM FIG. G9. Wiring diagram (Bushman Pastoral models).
  • Page 102 D14/4 CHAINS INDEX Page Chain Measurement Chain Alterations and Renewals Chain and Sprocket Inspection...
  • Page 103 D14/4 CHAINS CHAINS An early indication that the chain is being starved of oil is the appearance at the joints of a reddish-brown deposit. For chain lubrication details refer to page A4. The standard method of coupling a chain is by a spring connecting link, which is simple and effective.
  • Page 104 D14/4 CHAINS To shorten a chain containing an even number of pitches: remove the parts shown (A) Fig. H3, replace by cranked double link and single connecting link, parts shown (B) Fig. H3. To shorten a chain containing an odd number of pitches: remove the parts shown (C) Fig.
  • Page 105 D14/4 TORQUE WRENCH SETTINGS (DRY) Listed below are a number of nuts and bolts for which it has been found necessary to determine torque settings. It is most important that these settings are strictly adhered to. Over-tightening or non-uniform tightening of the cylinder head and barrel nuts for instance, can cause distortion, resulting in loss of compression, increased engine wear and poor fuel economy.
  • Page 106 D14/4 SERVICE TOOLS INDEX Page FLYWHEEL BOLSTER . . K2 FLYWHEEL PUNCH . . K2 FLYWHEEL STRIPPING BARS (2) . . K2 CLUTCH SPRING COMPRESSOR . . K2 SMALL-END BEARING EXTRACTOR ..K2 REAR DAMPER TOOL . . K3 WHEEL BEARING RETAINER PEG SPANNER .
  • Page 107 D14/4 SERVICE TOOLS FIG. K1. 61-3791 Small-end Bearing Extractor. FIG. K2. FIG. K3. 61-3206 Flywheel Bolster. 61-3191 Clutch Spring Compressor. 61-3209 Flywheel Punch. 61-3208 Flywheel Stripping Bars (2).
  • Page 108 D14/4 SERVICE TOOLS FIG. F4. 61-3644 Wheel Bearing Retainer Peg Spanner. FIG. K6. 61-5064 Rear Damper Tool. FIG. K5. 61-3796 Engine Sprocket Extractor.

  • Page 109: Service Tools

    D14/4 SERVICE TOOLS FRONT FORKS FIG. K7. 61-3824 Fork leg removal tool. FIG. K8. Oil seal extractor punch No. 61-3006. FIG. K9. Oil seal assembly tool No. 61-3007.
  • Page 110 D14/4 SERVICE TOOLS FIG. K10. 61-3633 Fork Leg Oil Seal Holder Tool. FIG. K11. Oil seal holder fitting and removal tool No. 61-3005.
  • Page 111 D14/4 CONVERSION TABLES INDEX Page INCHES/DECIMALS TO MILLIMETRES . . L2 FRACTIONS TO DECIMALS AND MILLIMETRES ..L3 MILLIMETRES TO INCHES . . L4 DRILL SIZES AND WIRE GAUGES . . L5 B.S.F. AND B.S.W. SCREW THREADS . . .
  • Page 112 D14/4 CONVERSION TABLES INCHES TO MILLIMETRES — UNITS Inches 254.0 508.0 762.0 1016.0 25.4 279.4 533.4 787.4 1041.4 50.8 304.8 558.8 812.8 1066.8 76.2 330.2 584.2 838.2 1092.2 101.6 355.6 609.6 863.6 1117.6 127.0 381.0 635.0 889.0 1143.0 152.4 406.4 660.4 914.4 1168.4 177.8 431.8 685.8 939.8 1193.8 203.2 457.2 711.2 965.2 1219.2 228.6 482.6 736.6 990.6 1244.6...

  • Page 113: Fractions To Decimals And Millimetres

    D14/4 CONVERSION TABLES FRACTIONS TO DECIMALS AND MILLIMETRES FRACTIONS DECIMALS FRACTIONS DECIMALS 1/64 .015625 .3969 33/64 .515625 13.0969 1/32 .03125 .7937 17/32 .53125 13.4937 3/64 .046875 1.1906 35/64 .546675 13.8906 1/16 .0625 1.5875 9/16 .5625 14.2875 5/64 .078125 1.9844 37/64 .578125 14.6844 3/32...
  • Page 114 D14/4 CONVERSION TABLES MILLIMETRES TO INCHES — UNITS .39370 .78740 1.18110 1.57480 .03937 .43307 .82677 1.22047 1.61417 .07874 .47244 .86614 1.25984 1.65354 .11811 .51181 .90551 1.29921 1.69291 .15748 .55118 .94488 1.33858 1.73228 .19685 .59055 .98425 1.37795 1.77165 .23622 .62992 1.02362 1.41732 1.81103 .27559...

  • Page 115: Conversion Tables

    D14/4 CONVERSION TABLES DRILL SIZES LETTER SIZE LETTER SIZE NUMBER SIZE NUMBER SIZE NUMBER SIZE NUMBER SIZE .234 .302 .2280 .1820 .1440 .0980 .238 .316 .2210 .1800 .1405 .0960 .242 .323 .2130 .1770 .1360 .0935 .246 .332 .2090 .1730 .1285 .0890 .250 .339...
  • Page 116 D14/4 CONVERSION TABLES B.S.F. SCREW THREADS AREA AT PITCH DIAMETER HEX. DIA. OF THREADS DIA. TAP CORE THD. BOLT DRILL THICKNESS BOLT FLATS CORNERS DIA. ROOT (INCH) INCH (INCH) (MEAN) MAX. MIN. MAX. MIN. (MEAN) SQ. IN. 7/32 28 .1770 .1731 .0235 .2018...

  • Page 117: B.s.c. Screw Threads

    D14/4 CONVERSION TABLES B.S.C. SCREW THREADS THDS. PER INCH BASIC DIAMETERS (INCH) DIA. OF DEPTH OF PITCH BOLT THREAD NORMAL (INCH) T.P.I. MAJOR EFFECTIVE MINOR (INCH) SERIES (INCH) SERIES 0.02500 0.0133 0.1250 0.1117 0.0984 5/32 0.03125 0.0166 0.1563 0.1397 0.1231 3/16 0.03125 0.0166...

  • Page 118: Unified Screw Threads

    D14/4 CONVERSION TABLES UNIFIED SCREW THREADS FINE (UN.F.) BASIC DIMENSIONS (INCH) DEPTH OF DIAMETER THREADS THREAD (INCH) PER INCH EFFECTIVE (INCH) MAJOR DIA. MINOR DIA. DIA. 0·0217 0·2457 0·2241 0·2022 ¼ 5/16 0·0254 0·3078 0·2824 0·2569 0·0254 0·3703 0·3449 0·3194 7/16 0·0305 0·4321...

  • Page 119: B.a. Screw Threads

    D14/4 CONVERSION TABLES B.A. SCREW THREADS AREA PITCH DIAMETER HEX. DIA. THDS. DIA. CORNE BOLT FLATS CORE THD. BOLT INCH DRILL DIA. ROOT THICKNESS MAX. MIN. MAX. MIN. SQ. IN. .2362 25.4 .1960 .1890 .0281 .2165 .2126 .2126 .2087 .413 .236 .2087 28.2...

  • Page 120: Pints To Litres

    D14/4 CONVERSION TABLES PINTS TO LITRES — — .568 1.136 1.705 2.273 2.841 3.410 3.978 4.546 ¼ .142 .710 1.279 1.846 2.415 2.983 3.552 4.120 4.688 ½ .284 .852 1.420 1.989 2.557 3.125 3.694 4.262 4.830 ¾ .426 .994 1.563 2.131 2.699 3.267...

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