BSA 825 STARFIRE Workshop Manual Download Page 1

Page: 1 / 158

www.bsaunitsingles.com

Summary of Contents for 825 STARFIRE

Page 1: ...I 1 fa Ii f l 7 1 ri f www bsaunitsingles com...

Page 2: ...S 844 VICTOR C25 BARRACUDA 844 SHOOTING STAR U S A 825 STARFIRE U S A Service Department B S A MOTOR CYCLES Publication Reference No 00 41 3518 67 LTD BIRMINGHAM II Telephone Y Ctonia 2381 ARMOURY ROA...

Page 3: ...n 3 J d d m l o rJ r I v Ui N lt Page 3 www bsaunitsingles com...

Page 4: ...LU F V o o d o F U LJ J f t a G N ltf Fage 1 www bsaunitsingles com...

Page 5: ...f LU d E d F a I d o Lr v ED N tr www bsaunitsingles com...

Page 6: ...q 3 d F v z F o o I t d d f t r CD f F Page 6 www bsaunitsingles com...

Page 7: ...l as a quick work of ref erence to everl the skilled mechanic Ali information and data given in this manual is correct at the time of publication but beca use olttrre constant development of B S A mot...

Page 8: ...nt attention is required he will know best how to make suitable arrangements with the factory It is important to remember that no machine can tre accepted at the works without a prior appointment This...

Page 9: ...URY ROAD BTRMINGI AM 11 Telcphont No lCtoria 2381 In all communications and frame numbers the model must be together with all quoted with full engine prelix or suffix letters YORLD SERVICE ARRANGEMENT...

Page 10: ...ollowing are CARBURETTER CHAINS ELECTRICAL EQUIPMENT REAR DAMPERS SPARKING PLUG SPEEDOMETER Amal Limited Holdford Road Witton BIRMINGHAM 6 Renold Chains Limited Wythenshawe MANCHESTER Joseph Lucas Lim...

Page 11: ...s ask oLtr deqler to help v hen repnirs are needed Labotrr time u ill be greatly reduced iJ pro7trierury articles such as legshields r raslt bars carriers or fbre glass fairings or renlov d belore h a...

Page 12: ...FITTING THE FRONT MUDGUARD AND WHEEL Place the front mudguard betrveen the fork legs and assemble the stays making sure that each r rut and bolt is tightened secltrely Fit the front r vheel and screw...

Page 13: ...changed without the advice of a plug specialist Place the tools instruction manual and other literature into the toolbox BATTERY fhe battery is supplied in a dr v charged conditior r and must not be...

Page 14: ...ANY CELL WHERE IT HAS RISEN HIGHER THAN THE PLATE PACK TO BRING IT BACK TO PLATE PACK LEVEL 3 Batteries used under these conditions are up to 90i2 charged but if time permits a lreshening charge of 4...

Page 15: ...roll Before starting the engine nrake sure tl rat tl rere is no packir rq material in or rrorrnd the carbu retter intake and air cleaner Whilst the engine is ru6nin q ral e off the oil filler cap and...

Page 16: ...Poge Ito12 Ito40 Ito8 Ito13 1to9 1to14 1to16 1 1to8 1to9 LUBRICATION ENGINE FRAME AND FITTINGS CARBURETTER FRONT FORKS SERVICING TOOLS WHEELS BRAKES AND TYRES ELECTRICAL EQUIPMENT TORQUE WRENCH SETTI...

Page 17: ...GD 7 GD 7 GD 7 GD 6 GD 6 GD 6 GD 7 GD 7 GD 6 GD 7 GD 7 GD 7 GD 9 GD 8 GD 9 GD 9 Rings Valve Guides Valve Springs Valve Timing TRANSMISSION Chain Sizes Clutch Gear Ratios Sprockets FRAME AND FITTINGS F...

Page 18: ...ssure valve spring free length valve spring ball diameter release valve spring free length release valve ball diameter CAMSTXAFT Journal diameter Journal diameter Cam lift inlet left hand right hand Z...

Page 19: ...n Free length inner Free length outer Fitted length inner Fitted length orrter 38 10 mn 42 418 rnm 30 9372 nrm i33 3248 mm 2032 mm 254 mm 6 731 mm 381 rnm 1 500 1 670 1 2t8 1 312 VALVE TIMING Tappets...

Page 20: ...oller 24 Con rod small end bush bore Crankpin diameter Crankcase bearing drive side Crancase bearing gear side Flywheel shaft diameter drive side and gear side Gearbox layshaft and gear side bearings...

Page 21: ...r itch push rod diameter GEAR RATIOS Cearbox top Multi plate 4 5 t61 4 1 65685 9 0 I 875 rvith integral cush drive 4 242 mm 42 0687 mm 228 6 mm 4 7025 mm third second first Overall top third second fi...

Page 22: ...minium l0 1 0023 0028 05842 011l2 mm 0042 0053 10668 13462 mm Brico BSS 5004 tsrico 8 Brico 8SS 5004 0tr25 1 5875 nim 3 175 mm 2 1432 2 8956 mm 2 3876 2 540 mrn 0254 0162 mm 3302 mm 2283 mm 125 001 01...

Page 23: ...l 750 1 262 1 370 79248 7 950 mm 12 7127 12 7254 mm 46 8376 mm 0381 0635 mm 35 56 mm 44 45 mm 32 0548 mm 34 798 nm 2032 mm 254 mm 8 6868 mm 381 mm 508 635 mm 19 05 mm IGNITION TIMING Piston position...

Page 24: ...bearings drive side and gear side 8125 20 637 5 mm Gearbox layshaft diameter drive side and gear side 6245 625 15 8623 15 8750 mm Gearbox mainshaft bearing drive siCe 30x 62x 16 mm Gearbox mainsl raft...

Page 25: ...op third second first Overall top SPROCKETS Engine CIutch Gearbox Rear wheel CHAIN SIZES Primary Transmission 1 0 1 24 i 65 2 65 6 92 B 6l 1 1 40 18 36 2 1 teeth 52 teeth 16 teeth 49 teeth Duplex 375...

Page 26: ...iameter Damper tube bush outer dian reter Damper tube bush inner diameter Damper tube br rsh length WHEELS BRAKES WHEELS Rim size and tvpe front Rim size and type rear Spoke sizes Front long 20 Front...

Page 27: ...5 r5625 r5 48 99 84 r 5 48 99 84 3 25 18 3 50 r r 8 16 p s i l7 p s i 177 8 nim 28 575 mm 177 8 nrm 28 575 mm 3 9687 mm 82 55 x 457 2 mm 88 9 x 457 2 mm 1 125 Kg sq cm 1 i5 Kg sq cm Battery Coil Conta...

Page 28: ...length Handlebar width Seat height Ground clearance Overall height WEIGHTS 53 83 27 32 8 42 320 lbs 85 lbs 134 62 cm 210 82 cm 68 58 cm 81 28 cm 2432 cm 106 68 cm 145 Ke 3e Kg n t f Machine unladen E...

Page 29: ...ers Page A 9 A t2 A 8 4 4 A 11 A 9 A 5 A 5 A 6 4 7 4 7 A 7 A t0 A 10 A 3 4 2 A t2 A 11 A 11 Changing Oil and Cleaning Scavengc Non Return Valve Crankcase Oil Pipe Union OIL PRESSURE AND NON RETURN VAL...

Page 30: ...iles 3 200 Km Drain and refill the oil tank Check oil level in gearbox Clean tlie oil filters Examine pump bail valv Grease centre stand Lubricate prop stand oil 11 Oil front brake cam spindle 5 Greas...

Page 31: ...recommended lubricarrts for use in temperate climates lu cottntries where climatic conditions are extreme obi iously some variation in grade will be found necessary to provide adequate lubr icatiorr R...

Page 32: ...A4 LUBRICATION 844 B25lC25 I tr _ f it r tti z Frc A 2 Engine lubricution cliugrant slrowing the ball valves 844 bottom www bsaunitsingles com...

Page 33: ...flow more readily The oil tank filter is screwed into the lower right hand corner of the tank see Fig A 3 Obtain a sr ritable receptacle with a piece of stiff material to use as a chute unscrew the fi...

Page 34: ...to emit clouds of smoke when started it is quite possible that the feed line non return valve is not seating properly thus allou ing oil to run back lrom the tank Tl ris is the valve jn the inner tim...

Page 35: ...This one of the more common troubles happens when one of the non return ball valves is sticking off its seating t can also be caused by a badly worn pump or one rvhich is loose on its mounting Indica...

Page 36: ...evident il the rril changing has been neglected Sliglit marks can be igrrored br rt ar ry metal embedded in the gear teeth must be removed The most likely point of wear will be foLrnd on the driving...

Page 37: ...he fixing screws and rvithdraw the contact tireaker piate The pivot points ol the auto advance unit should be lightly oiled again at 5 000 mile 8 000 Km intervals After lubricating leplace the plate t...

Page 38: ...front is the drain screw D see Fig A 12 Note that these screws are fitted rvith aluminium rvashers to ensure oil tightness To drain the oil take out th e chain inspec tion cap A at the top of the case...

Page 39: ...rt also acts its the damping medii rm Because of the latten fr rnction it is essential tliat the amount ol oil in ezrcl r ibrk leg is exactly the same Oil leakage nrid vay up the tbrks usuallr indica...

Page 40: ...several hours During their manufacture the inner cables are greased with a molybdenum based grease which forms a semi permanent lubricant and should therefore give long service before need ing attent...

Page 41: ...iston Piston Rings Small End Bush Reassembly after Decarbonising Checking Valve Cleararlces REMOVING THE Etr GINE UNIT TRANSMISSION Description B 6 8 6 8 7 8 1 8 8 B 8 B 8 8 8 B 9 8 9 B t0 B l0 B tI B...

Page 42: ...2t il 8 24 8 25 8 25 8 25 8 27 8 34 Gear Cluster Gearbox Bearings i GEARBOX REASSEMBLY SEQUENCE OF GEARCHANGING SPLITTING THE CRANKCASE HALVES BIG END AND FLYWHEEL ASSEMBLY 844 BrG END AND FLYWHEEL A...

Page 43: ...844 B25 C25 ENGINE B3 t r p r x o q e Ftc B l q 844 engine exploded www bsaunitsingles com...

Page 44: ...B4 ENGINE B 44 B25tC25 I K J pp 4 ffi u e www bsaunitsingles com...

Page 45: ...each contair r tl reir own oilbath Pouer fi oil the eugine is transmitted tlirough the engine sprocket and dLrplex prii nary chain to the clutch assembly lvhich has a built in cLrsh drive I ere the dr...

Page 46: ...vorking area on r rhich to operate anci roon to place parts as they are removed To facilitate lemoval ol the cylinder head fon decarbonising first take off the petrol tank as detailed on page B 14 Wit...

Page 47: ...subjected to a great deal of wear making the correct valve clearances diflicult to determine During their manufacture the pads B25 C25 and the pins B44 are case hardened and no attempt should be made...

Page 48: ...ed rvith special valve guides having a fixed valve spring cup These guides and the cylinder head they are fitted irr cannot be interchanged with those tused on laler engines Valves Valve heads can be...

Page 49: ...e springs with service tool No 61 3340 to allow the split collets to be inser ted in the top collar A Iittle grea se on the valve stem will assist in keeping the collets in position as the valve sprin...

Page 50: ...tion if there is any deep scoring as this will cause loss of compression and excessive oil consumption The cylinder barrel on botl r the B44 and B25lC25 is fitted with an austenitic iron liner enablin...

Page 51: ...and locate it with the top of the piston to ensure if is square in the bore Measure the gap between the ends of the ring with a feeler gauge The correct gap wherr new is between 009 014 in and althou...

Page 52: ...hardwood placed across the crankcase under tl re piston skirt The piston ring gaps mr rst always be equally spaced round the piston that is at 120 apart to resttict gas leakage through the gaps to tl...

Page 53: ...ogether with its sealing washers and tighten the fixing nuts to a torque wrench setting of I0 lb ft Reconnect the rocker oil feed pipe s using new copper sealing washers where necessarv Replace the ex...

Page 54: ...he cover plate and gasket Note Models made after engine No C25 2050 have modified rocker spindles and the method of adjustment is reversed that is the rocker spindlgs are turned inwards towards eerch...

Page 55: ...ear the attach ment is by two triangular plates welded to the frame tr rbe the engine being held by one stud with two nuts A second fixing point is located below the crankcase comprising one long bolt...

Page 56: ...pective positions to facili tate refitting If the joint has not already been broken tap the cover gently with a hide mallet to release but have a suitable receptacle under neath to catch any remaining...

Page 57: ...laced Standard thickness is 167 in 14 242 mm Frc B 19 The tags orr the outer edge ol the plates should be a reasonable fit in the chainwheel slots and should not be hammered up lf there are burrs on t...

Page 58: ...cket can now be pulled off the mainshaft splines If the oil seal is suspected of being faulty or leakage has occurred it shoLrld be renewed Check that the sprocket boss is not worn or damaged as this...

Page 59: ...rn the clutch chainwheel to locate over the keyed shaft Place the thick washer with the recess outwards in position against the clutch sleeve then the tab washer and fixing nut After tightening the nu...

Page 60: ...p run ofthe chain between the sprockets Finally tighten the stator fixing nuts Having completed the assembly ol the pri mary drive the primary cover can notv be re placed Apply jointing cement to both...

Page 61: ...d to the condenser The n rovable contact can now be lifted off lollowed by the fibre u asher and fixed contact The contacts mLrst be free lrom grease or oil If they are blackened or burnt clean with a...

Page 62: ...cot er To release lree the spring from the kickstart spindle and withdraw the quadrant complete with layshaft needle bearing When fitting a new spring first locate the hooked end of the spring in tl...

Page 63: ...s are clean apply a smear of grease to a new gasket and place the qasket in positiorr on the crankcase face Locate the pr rmp over the studs replace the fixing nuts and tighten evenly to a torqLte r r...

Page 64: ...screw The gearchange return spring pivot bolt need not be disturbed Take out the large split pin from the outside of the cover and withdraw the cam plate pivot pin This job will be simplified if a su...

Page 65: ...properly mounted on a rvorkbenclr The la shaft second gear is helcl agerinst the fixed gear high by one circlip When examining the gears look lor cr rcked chipped or scuffed teeth the latter vrill sho...

Page 66: ...ng soft metal clamps to tighten the nut fully Holding the cover face down place the lay shaft low gear with its shim C Fig 8 35 and sliding gear third in position on the cover Fit its selector fork th...

Page 67: ...016 080 081 C Standard shim D 078 080 in 083 085 in Befbre proceeding with check the gear selection for A B 40 3020 40 3 r 26 40 3t21 40 3r r9 40 30 I 9 40 3r20 40 325ri 41 3012 4t 3074 engine assemb...

Page 68: ...Reference to Fig B 39 will show both quadrant plungers in the cam plate windows ready to move the gears from second to first or neutral or back again When the cam plate is moved to third gear positio...

Page 69: ...7 J l l 829 844 BzslCTs ENGINE SELECTOR AND CAMPLATE IN NEUTRAL POS ITION N EUTRAL POSITION www bsaunitsingles com...

Page 70: ...830 ENGINE 844 Bzslczs SELECTOR AND IN FIRST GEAR CAMPLATE POSITION Ig GEAR _ www bsaunitsingles com...

Page 71: ..._ 844 Bzslczs ENGINE SELECTOR AND CAMPLATE IN SECOND GEAR POSITION 83 I d Frc B 39 www bsaunitsingles com...

Page 72: ...832 ENGINE 844 Bzs lczs SELECTOR AND IN THIRD GEAR CAMPLATE POSITION www bsaunitsingles com...

Page 73: ...844 BzslCTs ENGIN E 833 SELECTOR IN FOURTH AND CAMPLATE GEAR POSITION crnn www bsaunitsingles com...

Page 74: ...ulting in oil leaks The best method to use is to tap the gear side shaft rvith a hide mallet so enabling the drive side half of the case to be drawn away complete with flywheel assembly The flywheel a...

Page 75: ...the drive side shaft to within 002 in and the gear side shaft to within 0005 in BIG END AND FLYWHEEL ASSEMBLY B25lC25 Models Removal of the connecting rod from the crank shaft is quite straightforwar...

Page 76: ...crankshalt centrally on to the rollers and revolve a few times Allow the assembly to come to rest then mark the lowest point on the flywheels with chalk This wilt indicate the heaviest part of the ass...

Page 77: ...d 005 in This is controlled by shims fitted between the crank web and the inner face ol the right hand bearing The shims are available in thick nesses of 010 in 40 66 and 015 in a0 69 If however the o...

Page 78: ...ose tl re generator 8 48 inspection cover at the primary drive case to rotor It will be seen that a timing rnark is scribed on to the lace of the rotor and that a pointer is mounted at tlre base of th...

Page 79: ...act breaker cam B and temporarily fit another w rsher C having a hole just large enough to clezrr the cam inner bearing see Fig 8 50 thus allowing the n asher to bear against the top lace of the cam R...

Page 80: ...curately and if any difficulty is experienced in obtaining the correct setting as detailed above advantage should be taken of this service Checking the trgnition Timing with a Stroboscope If the conta...

Page 81: ...nue ic 4ff23 INDEX CARBURETTER Exnorro Dna wnc Page C 2 c 3 c 3 C 4 c 4 c s DESCRIPTION DISMANTLING AND REBUILDING HINTS AND TIPS TRACING FAULTS INSPECTING THE COMPONENTS TUNING THE CARBURETTER c 8 c...

Page 82: ...s MIXNG CHAMBER THROTTLE NEEDLE THROTTLE VALVE CARBURETTER TLE SPRING NEEDLE CLIP PILOT JET NEEDLE J B M ET MAtN JET FI OAT NEEDLE o F i 6t ET HOLDER u FLOAT CHAI 4BER EODY Ftc C 1 Cnrburetter explode...

Page 83: ...provide a weli outside and around the needle jet u hich is available for snap acceleration DISMANTLING AND REBUILDING THE CARBURETTER IJnscrew the air filter reiease the two fixing nuts and withdraw...

Page 84: ...e i Ensure that the float is not punctured by shaking it to see if it coritains irny firel Do not attempt to repair a damaged float If tliere is any doubt about its condition re place it r vith a new...

Page 85: ...be fitted There are many other causes of high petrol consumption and it should not be assumecl that the fault lies in tlie carburetter alone Air Filters lf a carburetter is first set with ar L air li...

Page 86: ...d noting how the engine runs If the engine runs better weakness is indicated but if the engine runs worse then the mixture is too rich To remedy proceed as follows To Cure Richness Position 1 Fit smal...

Page 87: ...access to the main jet the t loat chamber must first be remclved two screv s The main jet can nor v be unscrer ved lrom it holder in the rnixing chamber base D Needle and Needle Jet The needle is atta...

Page 88: ...e in posi tions 2 and 5 With engine idling too last witlr the twist grip shut off and the throttle shut down on to the throttle adjusting screw and ignition set for best slow running 1 Screw out throt...

Page 89: ...Clutch Cable Front Brake Cable Exhaust Valve Lifter Cable FRAME ALIGNMENT FRAME DIMENSIONS DUAL SEAT MUDGUARDS PROP STAND HEADLAMP REMOVAL OIL TANK REMOVAL Poge D l0 D 10 D 8 D 5 D l I D t2 D 12 D 12...

Page 90: ...D2 FRAME AND FITTINGS 844 B2siC25 Ftc D 1 Frante dimentions www bsaunitsingles com...

Page 91: ...d round otherwise measurements will be affected Figure D 3 shows the basic set up for checking the frame though variatior s can ol colrrse be used according to the facilities available Place the block...

Page 92: ...D4 FRAME Af D FITTINGS 844 B25iC25 5c v fi A j I www bsaunitsingles com...

Page 93: ...ngr ride to tlre Llppermost swing ing arm lr rg Unscrew the small bolt at the base of the guide release the front fixing nut and bolt then u ithdraw the chainguard from the rear TI re chain glricle ca...

Page 94: ...t collets to be inserted Do not lLrbricate the plunger rod or br rshes The dampers have three load positions light medium and heavy see Fig D 6 and the_v nrust be set in the light load position before...

Page 95: ...t ntust be established tlrat the bushes are in sood condition Frc D 7 Clrcciiittg the svin qittg ut ttt Using the same r nandrel that rvas used for the srvinging arm pivot on the frame see page D 3 se...

Page 96: ...ithdraw the seat rear wards to disengage the front clip from the frame tie bar The clip is held tc the base oi the saddle by twc r nuts with washers and is slightly offset Replace in the reverse order...

Page 97: ...Note on reassembly that a spacer is fitted between the lower stay and the right hand fork leg its purpose being to allorv suflj cient clearance for the front brake cable The rear mudguarcl mr rst be...

Page 98: ...e by a peg which passes through a rubber grommet mounted in a frame bracket A small self tapping screw retains the grommet in its housing Having released the top mounting bolts raise the tank to disen...

Page 99: ...engage from the clip at the base to release the light unit assembly Press the main bulb adaptor inwards rotate it to the left and lift it off Pull out the parking bulb holder from its location in the...

Page 100: ...fit the top cap Do not tighten the cap fixing screws until the throttle valve has been checked for correct operation Fiually attach the cable to the frame replace the cable stop at the twist grip and...

Page 101: ...After replacing the cable use the cable ad juster and locknut on the bracket to obtain the correct setting Ensure that there is ample slack in the cable to allow the exhaust valve to close properly w...

Page 102: ...FORK FORK ALIGNMENT DESCRIPTION OIL SEALS LEGS Page F 2 E 4 E 6 E 8 E 5 E 6 8 4 E 2 E 6 8 2 HYDRAULIC DAMPING REBUII DING FORK LEGS REMOVING FORK LEGS REPLACING FORK LEGS RENEWING STEERING HEAD RACES...

Page 103: ...ent Ifthe movement is lumpy the balls are indented into the races or broken ln either case they and tlre cups and cones should be renewed To adjust the steering head assembly slacken the clamp nuts C...

Page 104: ...g fhe cups can be renroved with the aid of Ftc 8 3 Removing thc top ctrp service tool No 6l 3063 Slacken off the liut on the tool sr rfficient to allow the tool to be screwed into the cup then tighten...

Page 105: ...nable the damper rod locknut be neath the cap to be loosened The cap can then be unscrewed from the damper rod top Screw service tool No 6l 3350 minus the large nut and washer into the top of the fork...

Page 106: ...at its base by one large Allen screw After removing the Allen screw take out the two circlips at the damper tube top releasing the damper rod with valve and bush The damper valve assembly is secured t...

Page 107: ...and nut and tighten the latter until the leg is drawn firmly home into its taper Tighten the pinch bolts in the bottom yoke before removing the tool Using service tool No 6l 3765 raise the damper rod...

Page 108: ...tube a sharp blow with a soft mallet and recheck If a hammer is to be used remember ts protect the tube with a piece of wood The measure of success will of course depend on the extent of the damage a...

Page 109: ...ectional view of a front fork leg extended Note the four 3132 in diameter bleed holes in the main tube and the transfer holes at the base of the damper tube When the forks are compressed a double damp...

Page 110: ...he area between the two fork bushes is compressed and forced through the four bleed holes back into the main tube The damper valve as it rises creates a vacuum and draws oil into the damper tube via t...

Page 111: ...lv Bearings REAR CLIAIN ADJUSTMENT REAR WHEFI WHEEL WHEEL WFIEEL Replacement Brake CanT Brake Shoes Remrrval Replacement Pressu res ALlGNMENT BALANCING BUILDING Remcr ral and Replacemeut F 5 HLrb Shel...

Page 112: ...u in the brake adiuster completely and discotrnect the front brake cable by unscrer ving B RAKE STOP t CA BLE ADJ U STER SLOTTE D CLEV 5 tlre nut and bolt holding the toggle to the brake piate lever I...

Page 113: ...te the brake plate anchol peg in the recess ou tlte inside ol the right hand flc rk leg and ti shteir thc rvhccl spindle fully Befbre locking the spindle rvith the pinch bolt clepress the lorks once o...

Page 114: ...eplacement Service when complete relined shoes can be obtained in exchange for the old ones at a moderate cost This scheme applies to tlre British Isles only for those who cannot make use of this serv...

Page 115: ...ing of the bearing Apply a liberal coating of grease on to the inner face of each bearing Place the left hand bearing over the spindle with oil seal outwards and drive it into the housing Finally repl...

Page 116: ...ght Note that the holiow spindle is fitted with the short end on the left hand side and aiso that the bearings are fitted with their oil seals outwards Rear Brake Drum and Bearing The brake drum is re...

Page 117: ...brake anchor strap to the srvinging arm lug is tightenecl secr rrely BRAKE ADJUSTMENTS fhe brakes must be adjLrsted to give maximut u efliciency at all times and for this to be main tained the shoes s...

Page 118: ...ten botl chain adjuster nuts evenly until the correct chain setting is obtained After adjustment tighten the wheel spindle and anchor strap nuts re check the setting ol the chain and adjust the rear b...

Page 119: ...ne l rand over two spokes at a time and pressing them together Il tension l ras been lost there rl ill be no rin uing tt rr ie and tl re spokes r r ill move freely across each other When a spoke needs...

Page 120: ...ignntetrt WHEEL ALIGNMENT Steering li ill be affected if the wheels are the slightest bit oLrt of alignment out of tracki Since the fl ont wheel canuot be adjusted in this respect it is the rear wheel...

Page 121: ...he vr ell of the rinr except at the point beirrg n orked The rvell is the centre section 3 The tyre beads u ill slip over tl re rini qr ricker ar rd damage rvill be avoided il the beads and the Ievers...

Page 122: ...repair is absolutely clean before applying soh r tion A rag dampened with petrol rvill help to clean the area but it must be completely dr1 before soiution is applied Remenrber tl rat when leplacing...

Page 123: ...in the well of the rim this is most important see Fig F i9 If necessary use a tyre lever for the last lew inches as in Fig F 20 Turn the wheel over and check tliat the bead is concentric with the rim...

Page 124: ...h the valve hcle before screwing clorvn the knurled nut and finally replace the dr rst cap TYRE PRESSURES The recommended inllatiori pressi_lres of l7 p s i front tyre and l7 p s i rear tyre are basec...

Page 125: ...Continuity D Constructing a 1 ohm Load Resistor COIL IGNITION SYSTEM Description A Checking the Low Tension Circuit B Fault Finding in the Low Tension for Continuity C Ignition Coil D Contact Breaker...

Page 126: ...een attracted to the pole tips and put the rotor in a clean place until required for refitting B dTTERY INSPECTION AND N AINTENANCE Description The container for the model PUZ5A batterl is moulded in...

Page 127: ...cid 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 ex plosive The readings...

Page 128: ...id out in Part 8 to locate the fault s Failure to locate a fault in the low tension circr rit indicates that the high tension circuit or sparking ptug is fauity and the procedure detailed in Part E mu...

Page 129: ...d should be replaced Battery voltage reading at this point but not at the ignition coil terminal indicates that the white lead has become open circuit broken or disconnected Disconnect the black white...

Page 130: ...r page B 21 To test for a faulty condenser first switch on the ignition then take voltage readings across the contacts lvhen open No reading indicates that tl re condenser internal insulation has brok...

Page 131: ...e combr rstion chamber during cornbustion and indicates that tlre piston ririgs or cylinder borc is worn To rectify this type of fault tl re above mentioned items should be checked with special attent...

Page 132: ...onsidered Normally the type of plug quoted in General Data is satisfactory for general use of the machine but in special isolated cases condi tions may demand a plug of a different heat range Advice i...

Page 133: ...epltirs or retteri ittg the stator It is beyoncl the scope of this matlttal tcr give instrr rction lor the repair of firulty stator windings Horvever the rvinding specificatioll is given in the Table...

Page 134: ...tion that the alternator A C or rtput figures r ere s rtisfactory Any farult at the alternator will of course reflect on the rectifier test results Similarly any flar rlt in the charging circuit wirin...

Page 135: ...horting or aged and the rectifier should be renewed Reclifi er te t sequen e PART C Checking the Charging Circuit for Continuity This test utilizes the machine s own battery to test for continuity or...

Page 136: ...ill also be low therefbre the maximum charging culrent rvill florv into the battery from the aiternator At first none of the curreut is by passed by the Diode beczruse of it being non conducting due t...

Page 137: ...ers a When the voltage across the Zener Diode reaches 12 75 volts the Zener current ammeter must indicate zero s Increase engine speed until a Zener current of 2 amperes is indicated on the ammeter At...

Page 138: ...ce of unit assembly To do tl ris slacken the screw at the top of the headlamp shell iust behind and adjacent to the rim and prise off the rim and light unit assembly The bulb can be removed by first p...

Page 139: ...cess being gained to eacl r of tl rem by first removing the rim and light Lrnit assembJy Frc G ll Beant ud iustntent TAII AND STOP LAMP UNIT LENs sECURING IIEIGTIT OF CENTRE OF LAMP FROM GROUN Frc G 1...

Page 140: ...r o z c o I I aL o 6O c F o s o E z e c oo Z ee J z Or 8 zt C o z 9 5 I pd s 2 Z i 2 o u ux f s i t rd Tg rtt ll I IE lr l c g L F U c z tr z f J c I u F J i F U Y c z I c U e L o U f F l _cr U z 9 E...

Page 141: ...3125 B S C 0 875 W F 0 625 B S F 0 31s U N F 0 4315 B S C 0 3125 B S C 1 0625 W F 0 3125 B S C 0 50 B s c 0 2s B s c 0 625 B S C 0 3t25 B S C 0 25 B S C L0 20 26 20 20 24 20 26 20 26 20 26 20 zo 26 0...

Page 142: ...DAMPER ROD RECOVERY TOOL FORK LEG REMOVAL AND ASSEMBLY TOOL FORK OIL SEAL ASSEMBLY TOOL FORK OIL SEAL EXTRACTOR FORK OIL SEAL HOLDER REMOVAL TOOL PINION EXTRACTOR SET PISTON RING SLIPPER REAR DAMPER...

Page 143: ...Jz SERVICE TOOLS 844 Bzslcz s Frc J1 Valveseqt cutter pilot No 6I 3293 Valve seat cutter No 6l 3300 Vqly e seqt cutter holder No 6l 3290 Flc J 2 llalve grinding tool No 6l 5035 www bsaunitsingles com...

Page 144: ...TOOLS 13 Ftc J l alve spring compressor b 61 3340 Frc J 4 Piston ring slipper No 6l 3101 75 80 mm 844 No 6l 3682 65 70 ntm 825 C25 Frc J 5 guide t itting and extrocting punch No 6l 3382 L L u lve www...

Page 145: ...LS 844 BzslC25 Frc J 6 Small end bush extractnr No 6l 3653 844 t o 61 37 94 B2s I C25 Contqct breaker cam removal tool Na 6l 376I Frc J 8 Clutclt sleeye extractor No 6l 3583 I I I N b Frc J 7 www bsau...

Page 146: ...JII i It S 1963 li i ir rl Avenue Colu ii l Oi io 4 ZZB Js Frc J i0 Clutch locking tool No 6l 3114 fA E ffi I f6 E fl Frc J 9 Clut ch nut screvrdriver No 6l 3140 Frc J l1 Pinion extractor set No 6l 37...

Page 147: ...13 Cranl shaft balance v eight Vo 61 3809 825 I C25 Frc J 12 Crankpin nut socket No 6t 3710 844 Frc J 14 Rear damper dismantling and assembly tool No 6l 3503 Frc J 15 Fork leg remoyal and assembly to...

Page 148: ...Frc J 16 Fork oil seal ltolder rentot al tool No 61 3005 Ftc J 18 Forl oil seul ussembly tool l lo 61 3007 Frc J 17 Forlc oil seal exttactor 1 o 61 3006 Frc J 19 Fork damper rod recot ery tool 1Vo 61...

Page 149: ...J8 SERVICE TOOLS 844 Bzslczs Frc J 20 Steering ltead cup extractor No 61 3063 Frc J 21 Wheel bearing retainer peg spanner No 61 3694 www bsaunitsingles com...

Page 150: ...S F AND B S W SCREW THREADS B S C SCREW THREADS B A SCREW THREADS MILES PER GAI LON TO GALLONS TO LITRES LITRES PER lOO KILOMETRES PTNTS TO LITRES POUNDS PER SQUARE INCH TO KILOGRAMS PER SQUARE CENTI...

Page 151: ...330 2 584 2 I 838 2 1092 2 4 101 6 355 6 609 6 I 863 6 1117 6 5 t27 O 381 0 635 0 I 889 0 1143 O 6 152 4 406 4 660 4 I 914 4 1168 4 7 177 8 431 8 685 8 939 8 1 193 8 8 203 2 457 2 711 2 I 965 2 1219...

Page 152: ...7156 7lt6 4375 ll l125 29 64 453125 r 1 5094 tsl32 468 15 11 9062 31 164 484375 I 2 3031 112 5 12 7000 FRACTIONS DECIMALS MM 33 64 5 I 5625 1 3 0969 t7132 5312 s 13 4937 35164 5466 75 1 3 8906 9lt6 s6...

Page 153: ...2 08662 2 48032 2 87402 3 26 772 3 66142 4 2 12599 2 51969 2 91339 3 30709 3 70079 5 2 16s36 2 ss906 2 9s276 3 34646 3 74016 6 2 20473 2 s9843 2 99213 3 3858 3 3 77953 7 2 24410 2 63750 3 03 I 50 3 4...

Page 154: ...0635 WIRE GAUGES No or Gaucs llrpnrraL Sra rorno Wrne G rucr BnowN Su lnpu s Ai rrRtcnr Wrni Gaucr MII LIMETRES itLLt1 1 l RLs 0J00 000 00 0 I 2 3 4 5 6 7 8 9 l0 1l 12 l3 14 l5 l6 t7 18 t9 20 2l 22 2l...

Page 155: ...7132 I 28 35 64 ja t54 2t 132 21132 5 1t 27 i64 oa t3 16 DIA TAP DRILL rNcu 177C 2055 AREA AT THD ROOT sQ lN CORE DIA PITCH DIAMETER NUT NT T THICKNESS uerN 0235 6433 3250 7058 391 3 1 3399 1 4619 03...

Page 156: ...RS EFFECTIVE 0 0133 0 1117 o I 397 0 031 25 0 0165 0 0166 I o rse 0 03 125 I o rszs 0 1709 0 I 983 0 2813 lrrl I r I _t_ _ lru _ _ __ _ u _l_ u rl 26 it _ _ r26 t_ II 0 r 543 o 1 778 0 5215 0 437 s I...

Page 157: ...71 3 9f1 16 17 66 I 2l r q i 16 c s7 I 3t z1 55 i77 1q t6r l7 l2 t 2ri 3 1 l161 c 66 3ll 0 6 r R 97 l36l 4 8 I 73 3 87 t7 t6 6t I 22 2 34 I 27 8 sl l r7 4 41 74 3 s2 r7l 16 1 2ll 2 5s I 271 0 27 rrl 8...

Page 158: ...968 2 350 J J 5 116 6 49P 7 881 9 263 10 64 12 o28 I3 4t l I t06 2 489 3 v 1 5 254 6 6i6 8 019 9 401 r0 784 1 2 166 13 s49 1 244 2 627 4 009 5 392 6 774 8 t57 9 540 10 922 12 305 13 687 t0 20 30 40 50...

Search results

Summary of Contents for 825 STARFIRE

Reviews:

Related manuals for 825 STARFIRE

Brands by name

Popular brands

BSA 825 STARFIRE, Workshop Manual

Search results

Summary of Contents for 825 STARFIRE

Reviews:

Related manuals for 825 STARFIRE

Brands by name

Popular brands