BSA 1966 Victor Enduro Workshop Manual Download Page 99

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Summary of Contents for 1966 Victor Enduro

Page 1: ...0 T x o I 0 U 3 D z c l VICTOR SEFIIES HEZ 1966 1967 and 1968 MODELS REVISED EDITION www bsaunitsingles com...

Page 2: ...LS VICTOR GRAND PRIX VICTOR ENDURO vrcToR SPECIAL t967 vrcToR SPECIAL le6B Service Department B S A MOTOR CYCLES Publication Reference No 00 4128 0 00 LTD BIRMINGHAM II Telephone 02 a 772 2181 ARMOURY...

Page 3: ...e 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 I www bsaunit...

Page 4: ...l 1 X a o o z d d o F 9 J t s cs r F www bsaunitsingles com...

Page 5: ...o o 3 U LU o Aa dfr O rO 9H o d 4 r Oo zi LIJ ur z dt o Fo 9 9 t u L t ffi tr Pagc 4 www bsaunitsingles com...

Page 6: ...o 3 S U LU o a s d o F U z O di Jo nz 2 t tt z dfr Ou t Z Q9 t o U I s t F Page 5 www bsaunitsingles com...

Page 7: ...o o 3 J U LU o t d o F I o f o z LU d o U t u I F www bsaunitsingles com...

Page 8: ...ful as a quick work of reference to even the skilled mechanic All information and data given in this manual is correct at the time of publication but because of the constant development of B S A motor...

Page 9: ...majority of cases local repair will be possible and this will avoid the expense inconvenience and the possibility ol the machine being damaged in transit to or from the Works for repair Should your B...

Page 10: ...URY ROAD BIRMINGHAM II Telephone No 021 11 2381 In all communications the model must be quoted with full engine and frame numbers together with all prefix or suffix letters WORLD SERVICE ARRANGEMENTS...

Page 11: ...le assistance The follorving are fitted to our motor us Any complaints who will give every Amal Limited Holdford Road Witton BIRMINGHAM 6 Renold Chains Limited Wythenshawe MANCHESTER Joseph Lucas Limi...

Page 12: ...re needed Labour time v ill be greatly redut ed iJ proprietaD articles such qs legshields t rash bars carriers or Jibre glass fairing are removed be fore handing the rnachine over fbr repair Ar cessor...

Page 13: ...legs and fit the braces 3 Pull out the wheel spindie from the fork ends and fit the lront wheel Insert the spindle from the left hand side and use a suitable bar to screw the spindle right home The sp...

Page 14: ...ad The plug supplied with the machine is best suited to all round operating conditions and sliould not be changed withor rt tl re advice of a plug specialist Snap the tyre purnp into its mount belorv...

Page 15: ...I to 15 Ito36 1to10 Ito15 1to9 1to20 Ito25 l 1to8 LUBRICATION ENGINE FRAME AND FITTINGS CARBURETTER FRONT FORKS SERVICING TOOLS WHEELS BRAKES AND TYRES ELECTRICAL EQUIPMENT TORQUE WRENCH SETTINGS CONV...

Page 16: ...qrEs lNp Tvnes Brakes Tyres Wheels Wheel Bearings ErecrRrclr ClpA crrms EeurpurNr Ba src DlueNsroNs Wercgrs PrsroN Drspla ceinnNT AND CReNrslrapt DEcnErs Vrcron GReNo PRrx uoonrs oNr v NOTE Items appl...

Page 17: ...ar 5 1 t4 l Non return valve sprirlg free length 5 Non return valve spring ball diameter 25 12 7 mm 6 35 mm Oil pressure relief valve spring free length 6094 15 4781 mm Oil pressure relief valve ball...

Page 18: ...head interference fit 1 859 0005 0025 VALVE SPRINGS Free length inner Free length outer Fitted length inner Fitted length outer IVALVE TIMING Tappets set to 015 381 Inlet opens B T D C Inlet closes A...

Page 19: ...ominal choke size 1 15625 9 3687 mm Throttle slide return spring free length 2 5 63 5 mm 1 CARB JRETTER fitterl on and after Engine No 84484 101 Type Main jet Amal 930 1 concentric float chamber 224 6...

Page 20: ...6 6r 8 79 14 12 Gearbox Gearbox Gearbox Gearbox Gudgeon mainshaft diameter drive side mainshaft diameter gear side sleeve pinion internal diameter sleeve pinion external diameter pin diameter TRANSMIS...

Page 21: ...te 100 lb in colour identification Green pink SWINGING ARM Bush type Bonded rubber Bush diameter 1 250 1 253 31 75 31 8262 mm Housing diameter 1 241 l 248 31 613 31 699 mm Interferer rce fit 002 006 0...

Page 22: ...7813 19 984 19 997 mm Spindle clizrmeter rcar right hand 6686 6690 16 982 16 993 mm W EEL BEdRINGS on and after Frame No B44EA X01 Details as Victor Grand Prix model page GD li TtsRAKES Front diameter...

Page 23: ...Lucas 6H Lucas 2DS 506 Lucas ZD 7l5 50 40 watt 6 r vatt 2 watt 612l watt ll galls 2 U S 2 galls 12 34 U S 5 pints 6 U S 0 5 pint 0 6 U S 0 25 pint 0 3 U S 0 34 pint 0 4 U S 8 litres 9 092 iitres 2 84...

Page 24: ...o i o r a l o o cl m t w s c l O a l co oo i i q s c O co O O t o O c t t oo t o l o al i oo c co cr ca oq IJ r O i c t oo q i c l co c c C tr t co o t o F a l c l a l sf F l F N a l a l c t o t O z F...

Page 25: ...e Brico 8 CAMSF AFT Cam lilt inlet and exhaust 355 9 017 mm VALVE TIMING Tappets set to 015 381 mm Inlet opens B T D C 63 lrrlet closes A B D C J2 Exhaust opens B I D C 80 Exhaust closes A T D C 55 TA...

Page 26: ...ear leti liand ar rd riglit hand Rear brake drurn Spindle diameter rear left hand Spindle diameter rear right rand BRAKES Rear diameter Rear width Linirrg tliickness refl r Lining area sq in sq cm rea...

Page 27: ...IES BASIC DIMENSIONS 7 il 81 5 WEIGHTS 1 5 galls 1 875 U S 6 819 litres 4 25 pintsl5 3 U S 2 415 litres Wheelbase Overall length Machine unladen Engine gearbox less carburetter 133 985 cm 207 01 cm 25...

Page 28: ...rlrrns Orr PREssunE AND NoN RrrunN Var vEs DlsHrlNrLrNc nNo Rp q sspMBLrNG rns Or Pr N rp CoNracr BnpmER Grnnsox Pnrlranv Dnrvr Rrln Csa rN SreenrNc Hreo Racr Fnour FoRr WspBr Br q nrNcs CoNrRor CaeI...

Page 29: ...Arn REan Bnaxr C qun SprNorn Lunnrcars Rsa n Cu q ru EVERY 5 000 MTLES 8 000 KM Cnra sr Sprluomnrln L nrvr ENnuno aNo SpECral U S A oNr v LusnrcrrE CoNracr Bnra run C qn I968 Moorls ro sr LusRlc q rrp...

Page 30: ...0 SAE 2OW OTHER COUNTRIES Cnsrnor Mobil AF Mobiloil SLrper MobilArctic Energol Energol Energol I 40 30 20wl Mobiloil D Mobiloil Supcr Mobiloil Arctic Energol 30 Energol 50 Enorgol 30 Energol 20W SAE 4...

Page 31: ...A4 LUBRICATION 844 Frc A 2 Engine lubrication diagram shov ing tlte ball valves www bsaunitsingles com...

Page 32: ...iller cap and ballle unit are removed whilst tlie engine is run ning when the returning oil should be seen issuing from the return pipe The oil will in all probability contain air bubbles but this is...

Page 33: ...orL RETURN HEADE TAN K BR EATHEFI P P E CRANKCA SE CONNECTION Frc A 3 The lubricqtion system Grand Prix models ROCKER FEED CONNEC T IONS FILTEI PLUG G DI SCONNECT TO DFIAIN SYSTE M I si 1 Yo c l www...

Page 34: ...the filters in the header tank see Fig A 6 and sump Replace the pipe lines re make the joints carefully and prepare to re fill the system with one of the oils recommended on page A 3 Remove the baffie...

Page 35: ...If the ball will not drop it indicates a build up of sluclge which can usually be cleared by immersing the pipe in petrol for a short period ll there has been a tendency for the crankcase to lill wit...

Page 36: ...e setting However after prolonged use the spring does tend to weaken and corrode and must then be replaced lf there is corrosion it is wise to replace tlie ball also after first cleaning the valve bod...

Page 37: ...ve The non return valve in the scavenge pipe is described on page A 8 DISMANTLING AND REASSEMBLING THE OIL PUMP Flaving removed the oil pump froni the engine take out the four screws from base of pump...

Page 38: ...ing cover behind the auto advance unit Lubrication of the contact breaker cam and the auto advance unit pivot points however is necessary The contact breaker cam is lubricated from an oil soaked felt...

Page 39: ...large drain plug has been retained To drain the gearbox take out the dipstick and drain plug draining the oil into a suitable receptacle To fill replace drain plug first checking that the rubber O rin...

Page 40: ...g use only the grades recom mended on page A 3 REAR CHAIN On Enduro and Special U S A models only oil thrown off the primary chain is collected in a small well at the back of the primary case from whi...

Page 41: ...owners may not cover this mileage in a year in which case it is suggested that the oil be changed every l2 months To drain the oil unscrew the fork cap nuts and the small drain plugs in the lower ends...

Page 42: ...pecial U S A models only It is necessary to lubricate speedometer cable to prevent premature failure of the inner wire Care is also necessary to avoid over zealous greasing which may result in the lub...

Page 43: ...arrel Removing the Piston Cylinder Head Removing the Cylinder Barrel Reassembly after Decarbonising Small End Bush Piston Rings Description Cush Drive Checking Valve Clearances ReN ovrNc rHr ENcNe UNr...

Page 44: ...lteNrrtNc Gearchange Mechanism Gear Cluster Gearbox Bearings Gra Rnox RsassnN Islv SreusNcE SpurrrNc op GBancneNGrNG Brc ENo l Nr Fr vwnrEr AssEMsI v RrAssnrr rsuNc THE Cna Nrcesr lcNrrroN TrurNc Pist...

Page 45: ...844 ENGINE B3 i r l Q t Q i mc cw A riJ nsv Y NJr jy d S r4 ds www bsaunitsingles com...

Page 46: ...B4 ENGINE 844 J d sr i raES ft s trzq c Y s 6Y t g 9 Y i aW r lti 7 v g N _ FIc B ln Engine eryloded 1967 onwards www bsaunitsingles com...

Page 47: ...nkshalt and supplies oil to the big end assembly piston cylinder walls and the timing geafs The gearbox at the rear olthe right hand half of the crankcase and the primary chaincase are independent oft...

Page 48: ...der head first take off the petrol tank see page B 13 With the tank removed the engine steady bracket can be disconnected together with the exhaust valve lifter cable The exhaust pipe is a push fit in...

Page 49: ...d is still warm Note lhat the exl raust guide is counterbored at tl re end rvhich protrudes into the port Whenever new guicies have been fitted each valve seat must be refaced with a piloted valve sea...

Page 50: ...ted in the top collar A little grease on tl re valve stem will assist in keeping the collets in position as the valve springs are released Make sure that the collets are correctly seated in the recess...

Page 51: ...cylinder barrel must be replaced The cylinder barrel used on the Victor Enduro and Special U S A models is fitted with an austenitic iron liner enabling a 010 in and 020 in rebore to be carried out f...

Page 52: ...rings are fitted upside down oil consumption will become excessive Nors Chromium plated piston rings mr rst not be fitted to Victor Grand Prix models Small end Bush Small end bush wear is normally ve...

Page 53: ...n on the head or rocker box from valve spring pressure the piston should be set at top dead centre on the coinpression stroke Alternatively the r alr e rocker adjusters should be completely slackenecl...

Page 54: ...ust slide between the valve stem and pin see trig B 9 Holding the pin in its neu position retighten the locknut when the engine is quite cold Remove the rocker caps and take out the sparking plug to e...

Page 55: ...e the rocker oil feed pipes and the supply and scavenge pipes union beneath the crankcase Disconnect tl re generator and the contact breaker cables from the snap connectors behind the engine Also disc...

Page 56: ...ollowing notes as though the unit rvere on a rvork bench Removing Prirnery Driye Coyer The primary chaincase cover is held in place by ten Phillips head screws two of whicl r are the oil level and dra...

Page 57: ...ow be freed from the tapered mairrshaft enabling the clutch chainwheel chain and engine sprocket to be withdrawn together Inspecting the Clutch The four driving plates have segments of special frictio...

Page 58: ...ular piate and the sprocket fixing nut preventing the entry of grit which may damage the small oil seal lfthe washer no longer appears serviceable replace it lf it is necessary to change or renew the...

Page 59: ...ssary to turn the cltitch chainwheel to locate over the keyed shaft Place the thick washer with the recess outwarcls irr position against the clutch sleeve then the tab washer and fixing nut Afler tig...

Page 60: ...central bolt The bob weights when tl re engine is station ary are held closed by the springs retaining the contact breaker cam in the fully retarded posi tion This is necessary to make starting easier...

Page 61: ...s the ignition Although this variation is very slight it must be remembered that accurate timing is important in the operation of the energy transfer ignition system See pages B 33 to B 36 for full de...

Page 62: ...s to be removed care must be taken to avoid losing the operating rack and ball which are loosely located on the inside of the outer cover Jt is not necessary to remove the kickstart quadrant or spring...

Page 63: ...ump Ensure that the joint faces are clean apply a smear of grease to a new gasket and place the gasket in position on the crankcase face Locate the pump over the studs replace the fixing nuts and tigh...

Page 64: ...echanism First remove the timing covers as detailed on page B 20 Press in the cam plate plungers with a suitable flat bladed instrument and withdraw the gear change quadrant complete with spring The s...

Page 65: ...rst grip the shaft in a vice using soft metal clamps unscrew the kickstart ratchet nut then take off the special washer spring ratchet pinion sleeve and driving pinion The gearbox mainshaft can now be...

Page 66: ...third gear into the cover bearing replace the kickstart ratchet assembly and secure with the fixing nut to torque wrench figures quoted on page H l It will be necessary to hold the mainshaft in a vic...

Page 67: ...d check ing for end float but excessive movement between the gears and the ends of the splines must be corrected by fitting the appropriate spacers See Fig 8 26 for position of each spacer the thick n...

Page 68: ...st gear the plungers will enter the cam plate and move it to first gear position this in turn u ill operate the layshaft selector fork and will mesh the layshaft sliding gear with the layshalt first g...

Page 69: ...r 844 ENG NE 827 SELECTOR AND CAMPLATE IN NEUTRAL POSITION www bsaunitsingles com...

Page 70: ...828 ENGINE 844 SELECTOR AND CAMPLATE IN FIRST GEAR POSITION IgI GEAR Frc B 29 www bsaunitsingles com...

Page 71: ...828 ENGINE 844 SELECTOR AND CAMPLATE IN FIRST GEAR POSITION I GEAR l Frc B 29 www bsaunitsingles com...

Page 72: ...844 ENGINE 829 SELECTOR AND CAMPLATE IN SECOND GEAR POSITION GEAR www bsaunitsingles com...

Page 73: ...830 ENGINE 844 SELECTOR AND IN THIRD GEAR 3LP GEAR CAMPLATE POSITION www bsaunitsingles com...

Page 74: ...ENGINE 83 I SELECTOR AND CAMPLATE IN FOURTH GEAR POSITION www bsaunitsingles com...

Page 75: ...Remove the screwed plug and thoroughly clean out the drilling with paraffin Il possible use a high pressure air line to blow through the oil ways Should the big end and flywheel assembly require repl...

Page 76: ...vious sections but do not omit to replace the keys in the ends of the shafts before fitting the pinions or sprockets IGNITION TIMING Belore carrying out any check on the ignition tirning tl re contact...

Page 77: ...ead centre on the compression stroke At this stage the auto advance unit should be fieed from its taper and rotated until the contact points are about to open This will give an approximate setting on...

Page 78: ...t but before tightening rotate the cam in an anti clockwise direction until the bob weights are lully expanded hold in position and tighten the bolt Care must be taken during this operation to avoid r...

Page 79: ...ll 1961 Victor models made on and after engine No B44EA 101 have provision for checking the ignition timing with the aid of a strobe light Remove the small inspection cover at the for ward end of the...

Page 80: ...een fitted on and after Engine No B44EA 101 on Victor Enduro and Special U S A models only DgscnrptroN Page c 2 c 3 c 4 c 4 5 c 5 c 5 6 c 6 7 c 7 8 c 8 9 c 9 10 Dtsir raNtI tNc AND RseutI otNc Dtsua N...

Page 81: ...ck Locking Screw Clip and Notch Adjustment for Needle Position Jet Block Pilot Air Passage Tickler Assembly Float Needle w w Float Chamber Ncedlc Jct rhrottrerstop d A ts Pilot let Frc C l Carburetter...

Page 82: ...RBURETTER FLOAT SPINDLE FLOAT NEEDL FIUTER BANJO 9 iJr ET HOLDER 5 FLOAT CHAMBER BODY Frc C 2 Carburetter exploded concentric float chamber fltted on emd after Engine No 844 EAl l on Victor Enduro and...

Page 83: ...ing action in conjunction with bleed holes in the needle jet which serve the double purpose of compensating the r niriture from the needle jet and allowing the fuel to provide a well outside and aroun...

Page 84: ...the needle clip when taking off the spring and top cover Unscrew the banjo bolt which secures tlre fuel pipe banjo connector to the float needle seatin q block and withdraw the nylon filter The float...

Page 85: ...ottle Cable See that there is a minimum of backlash rvheir the twist grip is turned back and that any move ment of the handlebar does not cause the throttie to open Use the adjuster on the cable to ob...

Page 86: ...oo weak a mixture Testing with the air supply will indicate if a larger main jet and higher needle position are required Effect of Altitude on a Carburetter Increased altitude tends to produce a rich...

Page 87: ...C 5 page C 9 Nors It is incorrect to attempt to cure a rich mixture at half throttle by fitting a smaller iet because the rnain jet may be correct for power at full thrclttle The correct method is to...

Page 88: ...ing or lowering it Raising the needle richens the mix ture and lowering it weakens the mixture at throttle openings from quarter to three quarters open E Throttle Valve Cut away The atmospheric side o...

Page 89: ...and faster 2 Now gently lower the throttle adjust ing screw until the engine runs slower and just begins to falter adjust the pilot air adjusting screw to get best slow running if this second adjustm...

Page 90: ...tt r2 D t2 t3 D l3 D l4 D l4 D l4 D l4 D l5 S q opLr Pnop Srlxo Vrcron ENpuRo nNp Sprcrnl U S A oNr v ENrncv TneNspsR Corr RErR Bnn e Pnnrr RE rn Muoculnn C q RsunErrsn Arn Frlrnn OIL ra Nr RsN oveL V...

Page 91: ...D2 FRAME AND FITTINGS 844 c Po u rd sfr q o Frc D l www bsaunitsingles com...

Page 92: ...844 FRAME AND FITTINGS D3 c Oa uo 2 c cog T l _ 1 tvs www bsaunitsingles com...

Page 93: ...teel rule will also be required The mandrels must be straight and round otherwise measurements will be affected Figure D 4 shows the basic set up for checking the Victor Enduro and Special U S A frame...

Page 94: ...844 FRAME AND FITTINGS D5 c S b4 ai q o LL www bsaunitsingles com...

Page 95: ...ight of the main tube and subtract half the diameter of the tube Checks can now be taken at the engine mount ing lugs and other points of the frame Errors at any point should not exceed j in 79 mm CHA...

Page 96: ...oad positions Iight nredir rm and heavy see Fig D 7 and they nrr rst be set in the light load position before cii mantling Use a suitable C spanner to carry oLlt any adjustments LIGHT MEDIUM HEAVY Frc...

Page 97: ...ter should be inserted through the fork ends Both mandrels should be parallel to the surface table Should there be less tltan a mal alignment of the swinging arm fork it is per rnissible to correct it...

Page 98: ...drawn backwards to disengage its clip lrom the front mounting rod Norr The saddle on the Victor Grand Prix model is secured to the frame cross member bv one nut and bolt 844 VICTOR GRAND PRIX Victor E...

Page 99: ...d take off the pedal rvith retur n spring The fulcrum prn is fixed to the frame with one large nut and washer Nore On Victor Grand Prix machine the brake pedal fulcrum pin is held in place with one nu...

Page 100: ...r fibreglass outer covers retained by snap connectors and can kre taken offwhen the central fixing screws are released see Fig D l0 il o Ftc D I0a Air cleaner Vit tctr Sltecial 19681 The filters are c...

Page 101: ...eci and to re move the lollori ing iirstructions should be observed Firsl unscrew the tzink filt r plug and drain the oil into a suitable receptercle then terrove thc seat as describeC on page D 9 Und...

Page 102: ...ts slot Replace the top hall of the grip but before tightening the screws check tlrat the grip turns freely Do not replace the cable stop at this stage Remove the petrol tank as described on page 8 13...

Page 103: ...lront brake cable first completely loosen the cable adjusters and unscrew the nut and bolt holding the toggle to the lever on the brake cover plate Now pull the cable adjuster away lrom the handlebar...

Page 104: ...bracket on to the end of the lront bolt The inner fixirrg point consists of one long bolt three rubber bushes a spacer tube four plain washers and a nut The rubber bushes lielp to insnlate tlre batte...

Page 105: ...a l U S A MoDELS oNr v Page E 2 E 2 8 2 3 E 3 4 E 4 5 E s 6 E 6 E 6 7 E 7 E 7 8 E 9 AprusrrNc SrrnRlNc HEno RpxswrNc SrrrnrNc HsA n Racss Recps ReprovrNc Fonx Lrcs DlsnaxnrNc Fonr Lrcs Orl Sea rs Rrgu...

Page 106: ...amp cables fiom the multi connector on the frame below petrol tank The cable harness can now be freed from the rr rbber clips Take out the two headlamp fixing bolts with washers and spacers and lift t...

Page 107: ...front brake cable at the handlebar lever Protect the fuel tank with a piece of cloth take out the four bolts securing the handlebar clips and place the handlebar on the tank Slacken the pinch bolts c...

Page 108: ...on the adjuster cap and adjust the steering as quoted on page E 2 Reassembly frorn this point is simply a le versal of the dismantling procedure REMOVING THE FORK LEGS Before commencing rvork on the...

Page 109: ...om the lower sliding member Ftc E 5 Removing oil seal holcler Frc E 4 Fork tools unscrewed from the darnpor roC top Screw Servioe Too No 61 3350 minus rhe large nLrr and rvasher into the top of th lor...

Page 110: ...ed unless they require renewal OIL SEALS If it is necessary to change an oil seal place the lower edge of the holder on a wooden block and insert Service Tool No 61 3006 into the top of the holder Giv...

Page 111: ...tighten up from bottom to top that is wheel spindle bottom yoke pinch bolts top caps and finally the steer ing stenr pinch bolt in the top yoke lf after this treatment the forks still do not function...

Page 112: ...er the tubes when the steering column should be quite central Figure E l0 shows a bent steering column The final step is to check if the tubes are parallel when assembled into the top yoke only In thi...

Page 113: ...d damper tube progressively slowing the fork spring action When the top tube begins to fill with oil which can no longer be compressed the oil passes through the bleed holes and into the area between...

Page 114: ...ngs Rran WHEEI Vrcron ENouno AND SIECIAL U S A commencing Frame No B44EA l01 and Grand Prix models Removal and Replacement Hub Shell Bearings Brake Drum and Bearing Brake Drum Replacement Bnaxn Aplusr...

Page 115: ...uster completely ernc l disconnect the front brake cable by unscrer ving the nut and bolt holding the toggle to the brake plate lever Having released the cable toggle unscrew and reffrove the cable ad...

Page 116: ...ti clockwise directiorr until it is almost tight Locate the brake platte anchor peg in the recess on the inside of the right hand lork leg and tighten the wheel spindle fully Before locking the spindl...

Page 117: ...ailable protect the spindle head with a piece of hard wood before striking By inserting the spindle and bush from the right hand side it rvill be possible to drive out the left hand bearing Both beari...

Page 118: ...t the other end to enable the removal ol the strap from the plate Slacken off the pinch bolt in thc lett hand lork end and using a bar through thc head ot the spindle unsclew the spindle in tr clockrv...

Page 119: ...other trailing they must be fitted witlr the nilrrow side relative to centre web next to the brake plate Replacement brake shoes are available tlrrough the Exchange Service in the British lsles but f...

Page 120: ...e brake eutchcr strap or torque arm o lrom the srvinging arnt ILr3 the i lil3 bolt of which also secures the chainguide chain guard and brake Iight switch Disconnect the speedometer cable at its drive...

Page 121: ...hoes complete with springs citm attd fulcrttm pin after first uuscrew ing the nuts on the outside of the plate Tl re rear brake shoes are the same as each other but are not interchar rgeable with the...

Page 122: ...tEA l0l and Grand Prix models Rear Wheel Removal and Replacernent Rernoval of the real wheel does not affect the qhain or brake adjr rstments Unscrew and withdrarv the rvheel spindle o Fig F 8 using a...

Page 123: ...aring and ensure that the retainer on the left hand side is quite tight Note that the hollow spindle is fitted with the short er rd on the left hand side and also that tlre bearings are fitted with th...

Page 124: ...e bear ing and replace the cover plate complete with brakes shoes etc Place the assembly into the fork end and fit the chain adjuster washer and nut on to the spindle end If the chain terrsion was cor...

Page 125: ...d Rotate the wheel slowly until the tightest point on the chain is found then check its up and down movement in the centre of the chain run The total movement should be lls in and if it varies from th...

Page 126: ...e wheels As spokes and nipples bed down the tension will be lost and unless this is corrected the spokes will chafe and utimately break Periodically test the tension either by ring ing that is strikin...

Page 127: ...it means that there is more weight in one part than in anothet This is very often due to variation in the tyre and at nroderate speeds will not be rroliccd br rt at high speeds it can Lre very seriou...

Page 128: ...nches high alternately each side of the machine If the tyres are the same size and the wl reels in alignment the straight edge will be touching the tyres at four points on each side If the front tyre...

Page 129: ...but if the cap is plain and ii core removal tool is not available depress the centre of the valve and keep treadir rg the tyre to expel the arr Remove the nut s on the security bolt s and pr rsh the b...

Page 130: ...re or tube be patient and see that the area ol the repair is absolLrtely clean before applying solution A rag dampened with petrol will help to clean the area but it must be completely dry before solu...

Page 131: ...most important sec Fig F 27 lf necessary use a tyre lever for the last few inches as in Fig F 28 Turn the wheel over arld check that the bead is conceniric with the rim before proceeding fi rrther Rev...

Page 132: ...844 WHEELS BRAKES AND TYRES Fl9 Frc F 27 Fittittg the first bead Ftc tr 28 Completing the fitting oJ the f rst bead Frc F 29 Completing the fitting of the second bead www bsaunitsingles com...

Page 133: ...ssure and check fit ting lines again Inflation should not be too rapid particularly at the commencement to allow the beads to seat correctly on the rim See that the valve protrudes squarely through th...

Page 134: ...5 G l5 G 22 G 22 G 22 G 23 G 24 G 16 17 G 24 G 25 G 21 G 21 G 21 22 A B c D Corr IcNtrtoN Checking the Alternator OutPut Rectifier Maintenance and Testing arging Circuit lor Continuity Checking the Ch...

Page 135: ...r The rotor has an hexagonal steel core each lace of which carries a high energy permanent mag net keyed to a laminated pole tip The pole tips are rivetted circumferentially to aluminium side plates t...

Page 136: ...meter in series check the ignition coil primary for continuity The primary winding has a resistance ol approximately 0 5 ohms the reading on the meter should not be more than 4 amp An excessive readin...

Page 137: ...ccount should this test be made with the rotor in position otherwise partial de magnetisation will result SPARKING PLUGS It is recommended that the sparking plug be inspected cleaned and tested every...

Page 138: ...roughly before taking any further action When it is certain that none of the above rnentioned faults are the cause ol over heating then tl re plug type and grade should be cor rsidered Normally the ty...

Page 139: ...atterv connect volt meter to measure potential The bzrtlery and ammeter should then be con nected in series with the lighting coils and readings taken at the lollowing alterrrator speeds ALTERNATOR u...

Page 140: ...torcycle is fully loaded To achieve this place the machine on a level road facing a wall at a distance of 25 feet away With a rider and passenger seated on the machine sla ken the headlamp fixing bolt...

Page 141: ...tl ti0 llr I It i sO t z D en u 4 nr X i fi Fq Z nI P F PF l o i d 4 r i o l tr a n _l i lc it I 6 o u r u i f ct r g v z c Ftc G 3 Wiring cliagram for Victor Enduro and Special U S A Norr Models made...

Page 142: ...v T m 9 z x o v m m z v o z r c m o 7 3 o 3 o c 3 o c a v t I m l h v m 0 1l r g t 9 r T fnI jef s e 6 o2 Z B R q a g 6 r J o P c o t ul A o g o r t m u z t o D o o z I o t t m x m u Frc 14iring diug...

Page 143: ...een attracted to the pole tips and put the rotor in a clean place until required for refitting BATTERY INSPECTION AND MAINTENANCE Description The container for the model PUZ5A battery is moulded in tr...

Page 144: ...y acid or allow a naked flame near the electrolyte The mixture of oxygen and hydrogen given off by a battery on charge and to a lesser extent when standing idle can be dangerously explosive The readin...

Page 145: ...rocedure laid out in Part B to locat e the laLrlt s Failure to locate ri fairlt in the lorv lensiorr circuit indicates that the higl r tension circuit or sparking plug is laulty and the procedr rrc de...

Page 146: ...y and a replacement ignition coil should be fitted 6 With the contact points opell reconnect the ignition coil lead and then connect the volt meter across the contact points No reading indicates that...

Page 147: ...tirg the parts ensure that no oil or grease gets on to the contacts If it is felt that the contacts require surf rce grinding then the complete contact breaker unit shorrid be removed as described orl...

Page 148: ...r head not having zrn adequate conducting path Overheating is normally symptomised by pre ignition short plug life and pinking which can ultimately result in piston crown failure Unneoessary damage ca...

Page 149: ...g circuit hence the recti fier must be checked as given in Part B and then the wiring and connections as shown in Part C PART A Checking the Alternator Output Disconnect the three aiternator output ca...

Page 150: ...eck periodically that the rcctilier is firmly attl ched When tightening the rectifier securing ntlt hold the spanner iis shor vn in Fig G 8 for il the plc tes zrre twisted the internal connectiotls wi...

Page 151: ...as shown in Fig G 10 Note the battery voltage shoLrld be l2 voltl arrd then connect tl re voltmeter in Vl position rvliilst tl re fc llowing tests are conducted Frc G 9 The rec tifier shott ing lernti...

Page 152: ...ting a 1 ohm Load Resistor The resistor used in the following tests must be accurate and constructed so that it will not over Rect iJier test se luence heat otherwise the correct values ol curtetrt or...

Page 153: ...high TERM I NAL BLADE EARTHING G Depression of the system voitage due to the use ol headlamp or other lighting equipment causes tlie Zener Diode current to decrease and the balance to be diverted and...

Page 154: ...cription The liorn is of a high frequency single riote typre and is operated by direct current from the battery The method ol operation is that of a magnetic ally operated armature which impacts on th...

Page 155: ...ary arrd there is no provision for such FRONT RIM RETAINING SCREW 25 feet away rvith a rider arnd passenger on the machine slacken the two headlamp fixing boits at either side and tilt the beam unit u...

Page 156: ...warn ing light and the parking light acce s being gained to each of them by first rcrroving the rim and light unit assernbly Frc G 16 Stop and tail lamp disntantled The speedometer lighl is housed wi...

Page 157: ...J c U F U o I U F I f t U F U o o U U c U d L o F I o J o u I r l o z c o I c U E f o a U z J z I co UT t_ o d o Lz to Yo O o 2T L U iL o a 2e I c U I F O U o z E U 5 2i 3l Elbl Jl al E _l oJt E l o...

Page 158: ...rr 10 6016s 200 3sl4A 30 33 18120 s0 55 11 60 10 sl7 5o ss 2312s 0 3125 0 500 0 87 5 0 625 0 437 5 43125 0 s00 0 250 0 625 0 3125 0 2s0 r 062s 0 37s 26 I 0 s2s 20 I 0 820 20 I 1 480 20 I 0 919 20 I o...

Page 159: ...Fonr Dauprn R oo Rrcovrny Toor Fonx Lnc REuov q r lNn Assrirlsly J 6 J 6 1 7 J 5 J 1 1 1 J l J 5 J 3 J 6 J 4 J 8 1 2 J 3 J 2 J 2 1 2 J 3 Fonr On Ssar Assnr4nry Toor Fonr On Srar ExrnLcron Fonr Otr Sra...

Page 160: ...l2 SERVICE TOOLS B 44 Ftc Jl Valve seat cutter pilot No 6I 3293 Valve seat cutter No 61 3300 Valve seat cutter holder No 6l 3290 Ftc J 2 Valve grinding tool No 65 9240 www bsaunitsingles com...

Page 161: ...r 844 SERVICE TOOLS J3 Frc J 3 Yalve spring compressor tlo 6l 3340 Frc J 4 Piston ring slipper 75 80 ntnt No 61 3707 Frc J 5 Valve gtride ftting and extracting punch No 6l 3382 www bsaunitsingles com...

Page 162: ...ext r act o r No 61 3653 Frc J 7 Contact breaker cam remaval toal ftir 4CA Contact breaker No 6l 3761 Contact breaker cam removal tool Jbr 4CA and 6CA Contact breaker n o 61 3816 Frc J 8 Clutch sleev...

Page 163: ...844 SERVICE TOOLS Js Frc J i0 Clutch loclcing tool No 6l 3714 fA t ffi T fl Frc J 9 C lutch nut screyvdriver l o 6l 3700 Frc J 11 Pinion extlactor set No 61 3773 z fl ae V g ff www bsaunitsingles com...

Page 164: ...Ftc J t2 Crankpin nLtt socket No 61 31lA Frc J 14 Rear damper dismantllng and assembly tool No 6l 3503 Frc J 13 Flywlteel bolster No 61 3711 Frc J 15 Fork leg removal and assembll tool No 61 3350 www...

Page 165: ...Frc J 16 Fork oil seql holder removal tool No 6l 3005 Frc J 18 Fork oil seal ussembly tool llo 6l 3007 Frc J 17 Forlt oil seal extrector i o 6l 1006 Frc J 19 f ork damper rod recovery tool No 61 3765...

Page 166: ...J8 SERVICE TOOLS B 44 Frc J 20 Steering head cup extractor No 6l 3063 www bsaunitsingles com...

Page 167: ...AND B S W SCREW THREADS B S C SCREW THREADS B A SCREW THREADS MILES PER GAI LON TO LITRES PER IOO KILOMETRES GALLONS TO LITRES PINTS TO LITRES POUNDS PER SQUARE INCH TO KILOGRAMS PER SQUARE CENTIMETR...

Page 168: ...2 457 2 711 2 965 2 t219 2 9 228 6 482 6 736 6 990 6 t244 6 INCHES TO MILLIMETRES UNITS ONr INcs 25 3999 78 millimetres ONp Mprnr 39 370113 inches ONE Mrr E 1 6093 kilos oxe Krro 62138 miles DECIMALS...

Page 169: ...MILLIMETRES TO INCHES FRACTIONS 1i100 MM 1 INCHLS 0 0i 0 02 0 03 0 04 0 05 00039 001 18 00r57 00197 0 06 002 16 0 07 0 08 00276 003 l 5 0 09 00354 2 40158 2 75591 2 79528 3 70079 3 74016 3 22835 3 307...

Page 170: ...104 092 080 072 064 056 048 040 036 o32 028 024 022 o20 018 0164 0148 0136 0124 10 I 60 9 448 8 839 8 299 7 620 7 010 6 400 5 892 5 384 4 676 4 470 4 064 3 657 3 251 2 946 2 64t 2 336 2 O32 1 828 1 6...

Page 171: ...1 968 1860 0272 2245 2200 21 80 2135 522 61 245 slt6 l8 rl4 2412 0458 2836 2789 2769 2722 597 69 307 3 8 16 5116 2950 0683 3420 3370 3350 3300 707 82 370 7116 I4 23164 3460 0940 3991 3938 3918 386s 8...

Page 172: ...TIIREADS 0 0312s BASIC DIAMETERS rNcs 0 1397 i o tzzt 0 03846 0 03846 0 1983 I 0 1778 0 2295 0 2090 0 2608 a 2403 0 3545 0 4170 0 03846 o 05000 rllL6 0 521s 0 6609 0 634i oJrr5 oJoro a 7234 I o ssra 0...

Page 173: ...6 42 4 5 6 28 46 6 14 47 6 01 48 5 89 49 5 77 so 5 6s 60 1 7t sl s 54 61 4 63 s2 s 43 t 62 4 55 53 5 33 I 63 4 48 sJ s 23 I 64 4 41 s5 s 13 165 4 35 56 s 04 I 66 4 B s7 4 s6 67 4 22 s8 4 s7 63 4 16 59...

Page 174: ...oe s zsq s 192 o e e 67i4 g ors I 8rs7 l or I e 540 t0 7s4 t0 922 12 166 12 305 13 549 I l r 637 10 z0 30 40 50 50 70 30 0 0 I 2 3 4 5 6 7 8 9 10 20 30 40 60 70 fi0 90 16 093 32 187 48 280 o 3 l 80 46...

Page 175: ...PI BLIS IED BY SBRVICE DBPAR iMENT Printed in England at the B S A Press BS A MOTOR CYCLES LTD ARMOURY ROAD BIRMINGHAM 11 ENGLAND CopFight www bsaunitsingles com...

Page 176: ...1 r www bsaunitsingles com...

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BSA 1966 Victor Enduro, Workshop Manual

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