Villiers MARK 12D Operating Instructions And Spare Parts List Download Page 44 | Manualshive

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Summary of Contents for MARK 12D

Page 1: ...7E 4 8E 4 8E R TWO STROKE MOTOR CYCLE ENGINE GEAR UNITS From February 1st 1955 until furtheJ notice all prices in this list are increased by 5 THE VILLIERS ENGINEERING CO LTD WOLVERH A MP TON EN GL A...

Page 2: ...mportant routine attention and you will be well adv1sed to keep the book on hand for consultation when necessary After a long period of service your engine may require overhauling and it is important...

Page 3: ...THE MARK 12D MARK SE Including llD 4 7E 4 SE 4 SE R 122 c c and 197 c c TWO STROKE MOTOR CYCLE ENGINE GEAR UNITS...

Page 4: ...THE MARK 12D MARK SE Including llD 4 7E 4 SE 4 8E R 122 c c and 197 c c TWO STROKE MOTOR CYCLE ENGINE GEAR UNITS...

Page 5: ...10044 Final Chain Line 2 ft ins Bxhaust Pipe Dia It ins Carburetter Villiers Type S l9 Carburetter Needle No 3 2 015 out Carburetter Throttle No 2t Sparking Plug Plug Gap Spark Timing Contact Breaker...

Page 6: ...Due to the Self Mixing properties of Castrol Two Stroke Self Mixing Oil pint to one gallon of petrol represents a ratio of 1 20 actual lubricant to petrol and no pre mixing is necessary but it i s es...

Page 7: ...ain plug situated at bottom of crankcase so that accumulated n1ixture can be blown out If still not successful after having replaced drain plug the trouble must be found else where and reference shoul...

Page 8: ...connections differ however and reference should be made to the wiring diagrams Figs 12 and 13 The Flywheel should not be removed unless absolutely necessary and then it is advis able to use a Villier...

Page 9: ...a slightly oily condition and is impregnated with grease when new This can if visibly dry be oiled with a small amount of the heaviest oil available It is better however to soak the pad in a molten h...

Page 10: ...lot progression hole and the main jet system The op ation of the two systems is given below l a Pilot Jet System See Figs 3 and 3A for reference At idling speeds when the throttle is nearly closed the...

Page 11: ...the throttle slide and the other in the carburetter body When the throttle slide is shut these two slots line up and air can flow from the front of the Carburetter through the throttle slide and down...

Page 12: ...have a shiny black appearance if the correct main jet is fitted As an additional guide the engine should tend to four stroke at full throttle in bottom gear on level ground or high engine speeds in ne...

Page 13: ...d not be altered Important The only time when it will be necessary to remove the Centrepiece from the Carburetter Body IS when the hole in the Centrepiece is badly worn and when the correct mixture st...

Page 14: ...Speedo 6 Volt 17 amp M B C Rectifier Lighting Set Head Lamp Type 575 In this Set the current from the lighting coils is converted to D C by passing through a Selemum type Rectifier and then used for...

Page 15: ...ark at the right time in relation to the position of the piston on its upward stroke 3 The engine must be in good mechanical condition with no air leaks at the various joints There must also be effici...

Page 16: ...not making good contact on ignition coil Cracked insulation of adjust able contact breaker point Damaged insulating sleeving on wires connecting contact breaker to coil or condenser Fautly connection...

Page 17: ...and cylinder base joints Crankcase drain screw loose or missing Worn crankshaft bearinas or leaking seal Ignition timing too tar ad vanced Sparking plug lead detached Plug points bridged by od carbon...

Page 18: ...Catch Spring Rim Catch Terminal Sleeve Battery Contact Main Bulb 6 V 30 30 Watt S B C Pilot Bulb 3 V 15 Amp M E S Cable Harness Switch Handle Assembly Screw Sleeve Terminal Tail Lamp Type 529 Front As...

Page 19: ...bber Seal Panel Switchbox Spring Switchbox Fixing Rubber Ring Lamp Fixing Screw Washer for Screw Bulb Holder Lens Rubber Bead l Underslung Pilot Only Lens Fixing Wire Tail Lamp Standard Type 529 Bulb...

Page 20: ...ifold Mk SE and SE 4 and BE R 8 7095 1 4 0 0 Cylinder with separate inlet manifold Mk 7 E comp 8 8438 1 4 0 0 Cylinder with integral carb stub Mk 7 E camp 8 8439 1 4 0 0 Inlet manifold s traight Mk BE...

Page 21: ...e of gearbox is fitted parts numbered E8796 8805 E8799 and E8807 are replaced by the following E9028 Mainshaft Low Gear Pinion 27 T 15s 9d Wide E9029 Layshaft Low Gear 14 T 10s 6d ratio E9030 Mainshaf...

Page 22: ...4 5 6 7 8 9 10 11 1 2 13 14 15 16 17 18 19 c20 2 1 i2 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 4 1 MARK 120 Part No 8 8566 E 7339 E S808 E 8 1 48 8 8343 E 3934 E 4453 E 7306 C 8129 0 862...

Page 23: ...55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 7 1 72 73 E 761 9 E 1 962 E J 905 E 4093 E 8276 E 8401 B 8259 E 51 07 E 5547 E 57 1 5 E 4083 W 1 74 2 3 1 3 1 7 9 1 1 1 0 0 3 9 4 4 Set l 1 2 E 5354 E 5...

Page 24: ...locknut 1 Spring washer 1 Sealing disc 1 Oil filler plug 1 Washer for plug 1 Oil drain plug 1 Washer for plug 1 Layshaft bush 1 Stud for end plate 3 Dowel 2 Selector pivot pin 1 quadrant 1 plunger 1...

Page 25: ...rzce 1 ach s d Spindle circlip I 2 Foot change lever I 10 0 Rubber for lever I 1 6 Bolt for foot lever 2 8 Nut for bolt 2 4 Ratchet spring 1 I Operating pawl 1 12 0 spnng I I 0 spindle plate 1 2 0 dis...

Page 26: ...her for dipstick End plate nut screw Dust cover screw Washer for screw Joint Washer C case Gearbox 1 80 f j Adjuster locking plate Fixing screw Clutch adjusting screw lever Return spring Cap for sprin...

Page 27: ...13 14 16 IS 9 10 I I 1 2 1 3 7 6 26 22 19 20 23 25 27 28 34 32 40 39 3 1 38 44 35 31 39 40 46 45 36 37 49 Fig 5 I 24...

Page 28: ...S 5 4 I 3 2 9 30 65 43 63 64 6 1 72 76 75 48 80 49 47 57 58 56 59 60 66 67 68 69 5 ENGINE 25...

Page 29: ...correct oil level A grease nipple is provided on the exposed end of the clutch levE r and grease shou ld be applied periodically ADJ USTMENT OF CLUTCH OPERATING RODS Remove cover illustration No 4 the...

Page 30: ...Gear Pinion 26T Mainshaft Sleeve Layshaft Bush Box Gear Box Case Selector Plunger Selector Plunger Box Assembled Mainshaft Mainshaft Sliding Gear 2 1 T and 1 T Operator Fork Layshaft Layshaft Low Gea...

Page 31: ...7 8 12 r _ 21 54 4 SPEED GEARBOX Fig 6 r qs 36 37 cl J ttl...

Page 32: ...juster Pin Foot Change Rubber Foot Change Lever Gear Box Cap K S Crank Pinch Pin Nut Cover Pins 3 x CH l fir x t CH Quote length X t CH Clip Bolt for Lever Inspection Cover Inspection Cover Pin Nut fo...

Page 33: ...ovided on the exposed end of the clutch lever and grease should be applied periodically ADJ USTMENT OF CLUTCH OPERATING RO DS Remove cover illustration No 4 l then detach clutch cable from operating l...

Page 34: ...ini n Idler Pinion Shaft K S Stop Plate K S Stop Plate p K S Pawl K S Pawl Plunger K S Pawl Plunger Spring K S Shaft K S Oil Seal Ring K S Shaft Bush Inside Operator Inside Operator Anchor Pins 2 off...

Page 35: ...w N 27 1 J 28 17 33 32 29 54 53 50 13 14 38 39 40 37 0 I 30 35 Fig 7 3 SPEED AND REVERSE GEARBOX 35 41 42 _J...

Page 36: ...r Spring E 8839 50 Selector Plunger Box Washer and Nut E 8840 5 5 1 Dip Stick E 8841 2 3 52 Drain Plug E 8842 9 53 Operator Bush E 8843 3 0 54 Operator Shaft complete with lever E 8844 6 0 55 Control...

Page 37: ...90E M 1632E 482 M 2259 M 2572D M 1855E Description Flywheel cover assembly standard high output Screw pole shoe Top plate pole shoe iron brass Magnet Rocker arm spring Rocker arm Low tension lead Ligh...

Page 38: ...w point bracket Brass washer Insulating washer Point bracket Poin Bracket Adjuster Cam Insulating plate Condenser box assembly Condenser Box unit condenser fixing studs nuts washers oil pad and L T le...

Page 39: ...2704E Screw for spring 1 1 20 V 383E Washer small hole 1 1 21 V 38IE Banjo union 1 2 0 22 V 404E Filter gauze 1 8 23 H l04 X 8 Washer large hole 1 1 24 V 382E Banjo bolt 1 1 3 25 V 855E Main Jet 90 c...

Page 40: ...2 2 4 Fig 9 CARBURETTER TYPE 5 19 37 34 26 25 17 36 I 16 IS 9 10 13...

Page 41: ...needle lever Air filter clip Screw for clip Air filter Pilot jet Cup joint washer Float cup Bottom nut washer Bottom nut Pilot jet needle ipnng ior needle l JCkler spring Tickler split pin Washer sma...

Page 42: ..._ 35 3 3 1 0 29 8 2 7 2 3 2 5 24 1 8 15 I _ _ _ ____ I r Fig 1 0 CARBURETTER TYPE 5 24 39 19 14...

Page 43: ...djusteT Top ring Cable nipple Top disc Top disc fibre washer Needle adjusting screw Throttle spring Needle Needle collar Needle spring Throttle Carburetter body Cup washer Banjo washer small hole Petr...

Page 44: ...i 3 4 7 I 24 Fig T 1 CARBU RETTER TYPE 5 25 PARTS 41 37...

Page 45: ...washer 4BA Strangler lever and spindle not supplied separately Strangler plate Screw Washer spring t Lever return spring Cable pivot pin Nut Air filter with clip Qty 1 1 2 2 2 Price Each s d 15 0 15...

Page 46: ...u I w 6 f Ar MI AMBNT I it4 Ni M DIRECT LICHTJNC SET TCI F WJRJNC DIACRAM Fig 1 2 I R H 1 SVaA I UP 1 l l evEAIPOWN 1 j t o I AMP 6 V O W 50 w AS FIL L aO 01 1 I H Oo NN IOOWI I OoN I UP M 2222D J...

Page 47: ...11 _j a Q bl I T I I r I I I I I I I I I NMOO Ci I I I J I I I I E lit s g J O 44 iil 3 a 0 Q 0 z ii 1 0 z 1 J 0 J m ci LL i I I...

Page 48: ...mer if we consider that other parts are necessary to make an efficient repair In such cases we are prepared to supply the customer s requirements in spares but we do not undertake to fit them I MPORTA...

Page 49: ...our manufacture 6 We prefer to bench test every repaired engine before returning it to its owner It is therefore always advisable to send the engine complete with its magneto sparking plug and carbure...

Page 50: ...e respects As VILLIERS Engines and Accessories are liable to derangement by neglect or misuse this guarantee does not apply to defects caused by wear and tear misuse and neglect CONDITIONS OF GUARANTE...

Page 51: ...N O T E S 48...

Page 52: ...9 S 24 S 25 Engine 12D and SE Gearbox 3 speed CONTENTS 3 speed and reverse 4 speed Lighting set Direct Rectifier Magneto lllustrations Carburetter S l9 s 24 S 25 Sectional Contact breaker Engine Engin...

Page 53: ...c io l Barford Newitt Ltd Printers Wolverhampton 20 000 8 55 I...

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