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Instruction Manual

1. 161 5 Kennington Ln Reliance 1362 m SEI3 F Parks amp Son Ltd 404 High Street Lee Green Lewisham 0535 m SEIS West End Motors Ltd 171 High St Peckham New Cross 2589 w SEI8 Cleare amp Co Ltd Woolwich High St NG an w S W 6 Claude Rye Ltd 897 921 Fulham Road Renown Ryebikes Wall Fulham 6174 Green L dn S W 9 Pride and Clarke Ltd 158 Stockwell Road Brixton Priclarke 6251 Exe 3 London 19 Battersea Rise Battersea Clapham Junction 7816 m SW I7 Elite Motors Tooting 951 61 Garratt Lane Balham Elicemota Toot td Tooting Broadway 1200 London 208 210 Great Portland Euston Gofrabike w SW I Owen Bros E Wi Collars Ltd B S A Motor Cycle Spares Stockists continued Telephone Telegraphic Town Name of Stockist Address No Address Neath Fred Rist 16and 17 Windsor Rd 780 Newcastle on Dene Newcastle Haymarket 2 9165 6 Ened New Tyne Motor Co Ltd Newton J E Green amp Co 87 Queen Street 653 Abbot Newport R J Ware amp Sons 69 Commercial Street 66206 Mon 40 44 Wellingborough Northampton Glanfield Lawrence Road Northampton Ltd Norwich Chapmans Norwich 38 42 Duke Street 24727 Nottingham E W Campion amp Son Arkwright Street and 83444 Queen s Road Oldbury Bromford Garage Bromford Rd Worcs Bro 2225 Oldham Alan Taylor North 192 Manchester Street Main ern Ltd 4456 Oswestry R
2. rz PI i i Instruction Manual Ag Phim n t Models J Si 1946 1955 B31 3P c c O H V B32 35y c c O H V Competition B32 350 c c O H V Gold Star B33 500 c c O H V B34 5 c c O H V Competition B34 500 c c O H V Gold san PART No 00 4010 Instruction Manual for BSA B MOTOR CYCLES LTD ARMOURY ROAD BIRMINGHAM 11 Service Spares and Repairs Department WAVERLEY WORKS BIRMINGHAM 10 Telephones Birmingham VICtoria 3711 Telegrams and Cables SELSERV Birmingham B S A Motor Cycles Ltd reserve the right to alter the designs or any details of at any time without giving notice Copyright B S A Co Ltd Printed in England Reprinted July 1961 M C 618 74 5 This Instruction Manual is intended to acquaint the B S A owner with details of the controls general main tenance and technical data which may be required for normal operation of the machine It does not contain the information necessary to carry out complete stripping for major overhauls but if any owner feels he is competent to carry out this type of work a Service Manual and an illustrated Spares Catalogue for this machine can be obtained from your B S A spares stockist or local distributor Owners in the British Isles can obtain these publications direct from B S A Motor Cycles Ltd Service Department Waverley Works Birmingham 10 The Service Manual is priced at seven s
3. Cranbrook Road 0191 Ilkeston Ray Gamble Pelham St opp 873 Bath St Ipswich Revetts Ltd Clarkson Street 53726 7 Jersey Colebrooks J D 224 New St Johns Rd Central Colebrooks Poingdestre 642 Jersey Keighley Dick Ratcliffe Coldshaw Garage Haworth Haworth 3133 Kendal Tom O Loughlin Ltd 66 Stricklandgate 315 Kings Lynn Peter Guest Ltd 123 125 Wootton Road 4129 Kirkcaldy County Motors Kirk Junction Road Dysart caldy Ltd 5631 Lancaster Pye Motors w Parliament Street 3553 peel Launceston J Wooldridge 8 Son Western Road 21 Wooldridge Launceston Leeds Watson Cairns amp Co 157 8 Lower Briggate 33024 5 Watson Cairns Briggate Leeds Leicester E W Campion 8 Son Welford Place 58054 Lincoln Wests Lincoln Ltd 116 High Street w 21262 Liverpool 3 Cundles Liverpool 41 Byrom St Central Cundles Ltd 4 Central 4148 Llawhaden James Bowen amp Sons Llawhaden near Nar Llawhaden Llawhaden Ltd berth Pem 6 London E 6 Godfrey s Ltd 220 Barking Rd East Grangew d Gofrabike Ham 8088 Forgate t2 Godfrey s Ltd 418 Romford Road Gofrabike Forest Gate 234 5 Forgate 7 E 8 Eleanor Motors 265 7 9 Mare Street Hackney 5134 amp 3923 a E 18 Longstaff Ltd 88 High Road Bockhurst Woodford 6369 6757 5134 3923 NS Glanfield Lawre
4. W J Bladder amp Son 52 Sidbury 2438 Bladder S bury Worcester Worksop Ezra Sugden Ltd 109 Gateford Road 3053 Yeovil The Yeovil Motor Hendford w 267 Motor Mart Mart Yeovil York a C S Russell York Lawrence Street 8 23793 Russell L rence Ltd Street York 78 4
5. 3228 Bury St Barclay Motors Ltd Kings Road Corner 2345 9 Edmunds Cambridge King amp Harper Ltd Milton Road Corner 3201 Motors Cambridge Canterbury Hallet of Canterbury St Dunstan s Street 3046 Cardiff w NAKU Car 134 140 City Road 30022 i Robert Bevan amp Son 29 35 Castle Street 27477 8 Carlisle W T Tiffen amp Son lrishgate s 25024 mitan li Irishgate lisle Carmarthen Eddie Stephens Motors 22 23 Water Street Chatham Grays of Chatham Ltd 11 19 High Street 4005 Chelmsford Hadlers Garage Ltd New Street 4844 5 Hadler Chelmsford Cheltenham H amp L Motors Ltd Bath Street ma 2887 w yan Davies Bros Chester 34 Bridge Street w 25510 Ltd Chesterfield Walter Wragg Chesterfield Ltd W Goodridge amp Co East Street 2033 Ltd Ch 95 Lordswell Street 3622 Chichester w 72 114 Dumbarton Rd 1429 1 2 East Hill 6131 2 Market Place 859 Clydebank John A Weddell Colchester G B R Motors Ltd Colne Lancs C H Scholfield Motors Led Coventry Coventry Motor Mart 86 London Road 22146 7 Coventry115 Led MotoriMart Crawley Lewis Thirkell Led 60 62 The Boulevard 25507 Crawley Crewe Cookes Garages 10 20 Nantwich Road 2011 Cookes Motors rewe T2 B S A Motor Cycle Spares Stockists continued Telephone Telegraphic Tee
6. On racing chines an additional knurled finger adj i i at the handlebar lever a w aie Front Brake For Scrambles a 7in dia brake is used For adjustment see page 32 Other models are fitted with an 8in dia brake This is described on page 60 TABLE IV EXHAUST COMBINATIONS B32 B34 Exhaust System Gold Star Gold Star Plain Pipe extension length measured on outside of bend Scrambles m 53 ins 53 ins Clubman s Sa PO 43 ins 42 ins Pipe for use with Mega li phone length measured on outside of bend Er 35 ins 35i Megaphone length 104 ins 14 ins Megaphone major dia 348 ins 344 ins l h inversi Exhaust Pipe dia Touring 18 ins 13 Sa Exhaust Pipe dia Scrambles 18 ins 13 ins Exhaust Pipe dia Clubman s 1 ins 14 ins Gear Ratios Four ranges of gearbox ratios are i a for these models as follows 57 TABLE V di 7a 3 4 Internal Close Extra Ratios Standard Ratios Close Scrambles Top NG 1 000 Third 1 210 Second 1 758 First 2 580 To Special Order only 1 000 1 000 1 000 1 101 1 099 1 325 1 460 1 326 1 754 2 124 1 929 2 343 With suitable engine shaft and gearbox sprockets the above four ranges of gearbox ratios provide suitable gearing for the events shown in Tables VI and VII TABLE VI Gear ratios for B32 Gold Star Top Third Second First Touring NG so Scrambles se Racing amp Clubman s
7. SPARE PART CATALOGUES INSTRUCTION BOOKS TRANSFERS ETC Ali BSA DEALERS CARRY STOCKS OF B S A SPARE PARTS BUT THE OWING APPOINTED STOCKISTS MAINTAIN A COMPREHENSIVE RANGE Telephone Telegraphic Town Name of Stockist Address No Address Aberdeen J Dawson 24 26 Thistle Street 25556 4 w George Cheyne 147 179 Holburn St 50341 2 Motobyke Cycles Led Aberdeen Aberystwyth Gwalia Motor Co Accrington Bill Snape Ltd North Parade 525 uo 379 392 and 396 Black 4724 burn Road Aldershot Philips Bros Alder Birchett Road m12 Phillips Cycles shot Led Aldershot iloa J G Robertson 55 57 High Street 193 Cycles Led Andover Corbett amp Ellis An Weyhill Road 2991 dover Ltd ington Mains of Ashington Laburnum Terrace 3204 ry Eborn s Garage w44 Walton Street 3150 Eborn s Aylesbury Aylesbury Banbury Trinder Bros 2a Broad Street 11 Southam Road Oxon si Sheffield Road 2866 Taylor Dow Ltd paley T Garner amp Son le Bob Ray Led Nth Dev j 43 High Street 4266 on Basingstoke Fred Slade aa Hay Place London Rd ants Beth R U Holloway 8 Son 32 33 34 St John s Rd 5084 Bathwick Bedford The Imperial Cycle and Motor Cycle Co 147 Tavistock Street 2374 Belfast W J Chambers ma 106 amp 108 Donegall 27253 4 Fastmote amp Co Pass Belfast Biggleswade Bryants
8. The length of the brake cable can be altered at its lower end by means of a knurled thumbnut on the cable stop For Gold Star Racing see Handlebar levers page 57 Rear Brake Adjustment Finger adjustment is provided at the end of brake rod Do not set the brakes too closely since particularly in the case of the front brake its action may be too powerful Any friction between lining and drum will obviously impair the machine s performance In addition if carried to extremes the heat may melt the grease in the hubs and this may find its way to the brake linings For lubrication see page 16 Centralising 7in Brakes only Slacken the nut on the brake cover plate thus loosening the fulcrum pin in its slotted hole Apply brake when fulcrum pin will auto matically centralise the assembly and keeping the brake on finally lock up the nut See also page 19 Brake Cam Spindles These are lubricated with oil see page 18 32 Sparking Plugs The sparking plug is of great importance in satisfactory engine performance and every care should be taken to fit the correct type when replacements are necessary There is little to be gained by experimenting with different plugs as the make and type fitted by us as official factory equipment is best suited to the require ments of the motor This is Champion Type No L10S Competition models NAS Gold Stars see page 56 Fig 14 The sparking plug Remove each sparking plug eve
9. These are essential for correct engagement and locking and particular attention must be paid to their proper alignment on reassembly Rear Suspension Swinging arm type This suspension system incorporates two suspension units each comprising 46 a totally enclosed compression spring and an automatic hydraulic damping device The hydraulic dampers are entirely self contained and require no maintenance whatsoever These are correctly adjusted at the Works during manufacture and call for no subsequent attention Fig 18 Rear Suspension Unit Adjustment The springs fitted to the B S A suspension units are adjustable for load three positions being pro vided as seen in Fig 19 When sent out the springs are normaliy set in the lowest position as illustrated on the left If it is felt that conditions call for slightly stiffer springing due to the rider s weight or the nature of the ground this can be arranged in a matter of seconds by using the Cee spanners supplied in the toolkit in order to 47 turn the adjuster cams to the second position as shown in the middle illustration A little thin oil on the cam faces will facilitate this operation If a pillion passenger or luggage is carried it will be necessary to set the suspension units in the highest position turning the cams to the third position as shown on the right On and after Frame no CB31 871 for standard B models and CB32 461
10. dirty clean with a dry duster while the engine is slowly turned round If the commutator is very dirty moisten the cloth with petrol Labrication No lubrication is required to the dynamo as ball bearings are fitted to both the commutator and driving end bracket These bearings are packed with 63 grease during assembly and will last until the machine is in need of a complete overhaul MAGNETO Cleaning and Adjustment About every 3 000 miles remove the contact breaker cover and examine the contact breaker If the contacts are burned or blackened clean them with fine carborundum stone or fine emery cloth and afterwards wipe away dust or dirt with a petrol moistened cloth Check the contact breaker setting after cleaning To check the contact breaker setting turn the engine until the contacts are fully opened and insert the gauge provided on the ignition spanner If the setting is correct 012 to 015 in the gauge should be a sliding fit If how ever the gap varies appreciably from the gauge slacken the locknut on the fixed contact and turn the contact screw until the gap is set to the gauge Finally tighten the locknut Next examine the pick up which can be removed when the fixing screws are withdrawn See that the pick up brush moves freely and while it is removed clean the slip ring track and flanges with a soft dry cloth Lubrication every 3 000 miles The face is lubri cated from a wick contained in th
11. 5 6 6 77 9 86 14 42 7 73 10 24 13 56 18 11 5 28 5 80 7 00 10 15 TABLE VII Gear ratios for B34 Gold Star Top Third Second First Touring i a Scrambles au Racing amp Clubman s 5 0 6 05 8 79 12 90 726 9 62 12 73 17 0 4 52 4 96 5 99 8 71 58 The range of sprockets and gear ratios is given in Table VIII below TABLE VIII cua SE Gr Wheel 16 17 19 20 21 2 16 7 05 6 63 5 64 5 38 Po 19 5 93 25 6 4 75 4 52 46 16 7 73 27 26 6 18 EAR 19 6 50 6 12 5 20 4 96 These ratios are most commonly used Recommended gear ratios for various circuits are indicated in Table IX below TABLE IX Gearbox KA Type Top gear Circuit See Table e vV B32 G S B34 G S Aberdare we 2or3 5 93 5 28 Altcar NG 5 93 5 28 Blandford an Zor3 5 38 4 75 Brands Hatch Bo 3 5 93 5 0 Brough ae se 5 59 5 0 Eppynt j ae 2 5 93 5 0 Scarborough a 2 5 59 5 0 Silverstone 4a 3 5 93 4 75 Snetterton lt 3 5 38 4 75 Thruxton s 3 5 59 4 75 Clubmans de 3 5 28 4 52 Gearbox type 2 to special order only 59 Front Wheel Removal 8 in Brake only This hub 1s also fitted with ball journal bearings and adjustment is not required Dismantle the assembly in the following order 1 The brake anchor strap Take off the nut C Fig 20 on the cover plate and slacken the nuts D at
12. RE g 19 30 31 32 Petrol tank capacity gallons Petrol tank capacity mta Swinging TECHNICAL Atm suspension B31 3 gallons 2or4 Oil tank capacity pints a n 4 Oil tank capacity with Swinging dwan Gints 54 Gearbox capacity pints an 1 Primary chain oilbath fl oz 2 55 c c Primary one with Swinging Arm suspension a oz jw 8 225 c c Bore mm pr n an eu n 71 Stroke mm n a 88 Capacity c c ou 348 Valve clearances cold in a w n 003 Compression ratio a ou 6 5 1 Piston ring gap in Mak n ma Valve timing see page Mia Inlet a Opens Exhaus Opens Ignition timing fully distance in inches before t d c points open 002 in 7 16 Sparking plug n ou LI S Plug points gap in Max en 020 Min w a 018 STD S A Gear ratios Top es Third an a se 7 38 6 77 Second n oe ILS 9 86 First a va a 16 7 14 42 Front tyre a ou a 3 25 19 Bear tyre Gai F ou a yre pressures p s i Front for touring Rear Solo 22 Chain sizes and number of pitches ary in x 305 in 5 69 Rear Chin x fin 93 Engine sprocket teeth 17 Gearbox sprocket teeth 19 Standard carburetter main jet 150 Ditto with air cleaner 150 Monobloc Carburetter main jed 260 Ditto with air cleaner a pa 200 See special instruct
13. Teplace them at a later date Piston Piston Rings Whilst the engine is dismantled itis advisable to examine the piston rings and cylinder barrel Lift the barre upwards and forwards into the front angle of the frame and as the piston emerges from the barrel it Pe should be steadied to prevent possible damage When the barrel is removed cover the mouth of the crankcase with rag to prevent rust and grit falling in To remove the piston from the connecting rod it is first necessary to take out one of the gudgeon pin circlips This is best accom plished with a pointed instrument such as the tang of a file suitably ground Before the gudgeon pin can be withdrawn it may be necessary if the engine is cold to heat the piston with the aid of rags immersed in hot water wrung out and held round the piston Then supporting the piston tap the gudgeon pin through using a light hammer and a punch When the piston is free mark the inside of the piston skirt at the back so that it can be replaced the correct way round If the rings are stuck in the grooves great care will be needed to prise them free and to remove them from the piston All carbon deposit should be carefully scraped from the grooves and the inside edges of the rings If either of the rings shows brown patches on the face replace with a new ring Check the piston ring gap by inserting the piston in the barrel and sliding each ring independently up to the skirt of th
14. and should be thoroughly washed with petrol dried and replaced Note The pump is independently mounted and should not be disturbed PERIODICAL MAINTENANCE WEEKLY Cleaning Obviously regular and thorough cleaning will keep your machine looking smart and will help to retain both its new appearance and value But it helps also to lengthen its life and maintain efficiency if the cleaning process is carried out correctly Take special care to prevent dust and grit from working into such parts as hubs carburetter magdyno brakes and gearbox To rub dry and caked mud from the frame tank and mudguards means that the enamel on these parts will be subjected to an abrasive action which will quickly destroy the polish Soak the mud first and then float it off with copious supplies of clean water supplied either with a hose or a sponge If a hose is used take care not to direct the stream of water directly on to the hub bearings magdyno or carburetter When all dirt is removed dry and polish off with a clean duster The engine and gearbox are best cleaned with brush and paraffin and dried off when clean with clean rag On Iron engines an occasional coating of the cylinder head and fins with cylinder paint prevents rust formation and also helps heat radiation Oil Tank Inspect the level of oil It should never be allowed to fall below the level marked on the outside of tank When topping up do not fill the tank completely leave a
15. before compress the springs until the split collets can be inserted A dab of grease on the inside of the collets will serye to hold them in position until the spring is released Make quite sure that the collets are correctly located For Comp and Gold Star models see pages 49 and 51 respectively gt AA 4 Fig 17 Valve timing marks Standard Iron B engines only Insert the push rod cover tube into position in the cylinder head but do not screw up the gland nut Place the push rods inside the tubes and then lift the cylinder head into position It will be necessary to keep the head raised whilst the push rods are positioned on the tappets and then the rods must be correctly located on the rockers Now lower the head into position replace the acorn nuts securing the push rod tube and then screw up the long cylinder head and barrel bolts working in diagonal order until they are dead tight The push rod gland nut can now be tightened up Before replacing the inspection and tappet covers check tappet adjustments which should give 003in clearance at both valves 45 Connect up the oil feed and return pipes to the rockers and inlet rocker box Replace engine steadying stay Replace the rocker box covers the carburetter the exhaust pipe and silencer and finally the petrol tank and petrol pipe It is advisable to remove the sparking plug and clean it before replacing See page 34 Check that the gap between the points
16. cover tube can be detached head i e combustion chamber ports tc using an old knife or Similar tool Take care not to damage the Piston crown i ni ang Chaat Valves It is Not essential to Temove the rockers in order tO take out the valves and Springs but Careful note Should be kept of the Tocker assembly for replacement the spring followed by the steel washer and finally the aluminium oil seal washer Valve grinding should only be attempted if pitting is shallow If deep pit marks appear then the faces must Te cut with Proper equipment The valve should be Teturned to your dealer for Tefacing as attempts at grinding in in this case will result in Wear of the valve Seats and the valve may become Pocketed With con Sequent loss of efficiency Smear a small quantity of grinding compound obtain able from any garage or accessory shop over the face of the valve and return the valve to its seat 4 light sp inserted under the valve head greatly facilitates the grinding in Operation allowing the valye to lift and be Totated to a new position Periodically Hold the valve stem with the Special too Provided in the kit and TOtate the valve backwards and forwards whilst maintaining light urn Valve Springs After a Period of several thousand miles i ble to Tenew the valve Springs as these tend to lose their efficiency due to heat If the Springs are Tenewed whilst decarbonising it will save dismantling Specially to
17. culty will be experienced in changing gear as the clutch may not fully disengage in which case the control arm should be adjusted as explained on page 28 Chains Check that there is not more than half an inch up and down movement at the centre of the primary chain and not more than three quarters of an inch in the case of the rear chain fitted to Comp or plunger frames one and a quarter inch for swinging arm models If excessive adjust as explained on pages 30 to 32 EVERY 2 000 MILES Oil Tank Drain out the old oil preferably after a run while the engine is still warm wash out with flushing oil or thin machine oil NOT paraffin or petrol and refill with new oil Wash filter thoroughly in petrol or paraffin and make sure that it is absolutely dry before replacing Oil Pump Filter Remove the plate below the oil pump and wash the gauze filter in paraffin dry and replace Dynamo and Magneto See Electrical Section pages 63 64 Magdyno Fixing Slacken off the magdyno strap and pull the magdyno towards the nearside of the machine i e away from the timing cover This ensures that the oil seal is maintained between the magdyno pinion and the felt washer Holding the unit in this position re tighten the magdyno strap bolt Primary Chain Oilbath Drain and replenish with new oil to level of plug at side of case behind brake pedal On Comp models and machines fitted with swinging arm suspension the oilbath is slightly larger T
18. during manufacture and special tuning is selected as being the most suitable for the specification ordered by the prospective owner Thus if a low com pression piston is fitted and the machine is to be used for touring the cams in the first line will be employed The reminader of the table is devoted to competitive events where the highest possible performance is required and for these the owner is advised to follow the recommen dations exactly as given TABLE I PISTONS B32 Gold Star B34 Gold Star Component Com Component Com No Ratio No Ratio Complete Complete 65 1681 6 5 65 1245 6 8 65 1921 7 25 65 1930 25 65 1265 TS 65 1616 8 0 65 1285 8 0 65 2254 65 2260 8 5 65 1674 9 0 65 1532 9 0 65 2287 65 2300 65 1687 13 1 65 1279 11 0 These Pistons are for engines on and after engine number with prefix CB 52 The main jet size for alcohol fuels depends largely upon the actual fuel used as there are one or two pro prietary brands available at the present time in addition to pure methanol and the composition of these varies somewhat It is for this and other reasons that the figures given for alcohol and dope are subject to alteration If the machine has been ordered in the first place with the T T carburetter specially tuned for alcohol fuel it will already have a suitable main jet but if the owner is making the conversion himself he should take as a rough guide the
19. for Gold Stars excepting scrambles specification the lower cam ring is fixed to the body so that only one C spanner is required for adjustment purposes See F Fig 8 The frame pivot point requires no lubrication as this is fitted with silentbloc bushes Fig 19 Swinging Arm Suspension Supplementary Instructions for COMPETITION MODELS Cylinder Head and Barrel See similar instructions for Gold Star engines pages 49 to 53 except for references to engines with prefix letters C B and the following items Crankpin Standard crankpin and nuts and used for these models k Valves A special inner valve spring 65 1259 must be used with these valves The outer spring is the standard 65 1147 gt Valve Clearances and Compression Ratio See Technical Data page 4 48 Supplementary Instructions for GOLD STAR MODELS Cylinder Head and Barrel The cylinder head and barrel on these models are in aluminium alloy and the push rod tunnel forms part of the castings instead of taking the form of a separate unit with castellated gland nut as used on the other B models The valve seats in the cylinder head are of special heat resisting austenitic steel and are screwed and shrunk immovably into position When the valves require regrinding this operation is carried out in the normal manner The inserts cannot be removed and replaced conveniently by the private owner and if this should ever become necessary the cyl
20. the opposite ends of the strap 2 The brake cable This must be uncoupled first at the lever E on the brake cover plate and then unscrewed from the Stop F 3 Pinch bolt A The wheel spindle is locked by means of this bolt which is fitted to the nearside fork leg only It is only necessary to slacken the pinch bolt 4 The wheel spindle To unscrew a tommy bar of suitable dimension should be inserted through the hole in the spindle head at B Note that the spindle has a left hand thread and unscrews by turning in a clockwise direction 5 Withdraw the spindle from the nearside Support the weight of the wheel when taking out the spindle and the wheel can then be removed After removal do not let the weight of the wheel fall on to the bush which projects from the brake side of the hub Although the bush is pressed in it may if subjected to a sharp blow fall inside the cover plate so that the latter would have to be removed before the bush could be retrieved and located in position Separate Clip on Handlebars These can be adjusted radially about the fork leg centre or vertically and have a total up and down movement of approximately 15 inches Each bar is clamped in position by two bolts fitted with a plain washer at each end and a shake proof nut with nylon insert To remove the handlebars having slackened the bolts described in the previous paragraph it is necessary to release the fork legs from their tapers in the to
21. vary slightly to suit rider s requirements or different localities Turning the pilot air screw inwards enriches the mixture and unscrewing weakens it A richer mixture gives a slower and more reliable tick over but it is naturally undesirable to have the mixture too rich even with the throttle practically closed which is of course the throttle position for tick over so the best way to set the pilot air screw is to screw it in until the mixture is obviously too rich and then unscrew it until the setting is just right and further unscrewing increases the tick over speed unduly This may seem complicated but the effect of altering the setting is very noticeable and the rider will easily detect the symptoms It is doubly important to avoid over richness of the tick over setting if much riding is done on small throttle openings for this is what is known as running on the pilot and if the pilot setting is too rich the general petrol consumption will be adversely affected The running mixture can only be altered by adjusting the height of the needle in the throttle valve or by fitting a main jet of different size Such alterations should not be made except for very special purposes as dictated by abnormal requirements and only then on expert advice DECARBONISING THE ENGINE Decarbonising and top overhaul of an engine is extremely simple but it should only be carried out when the engine really needs it The usual symptom
22. w ss 25 27 72 amp 74 Short 3108 mead Street Birkenhead Bob Simister Ltd 540 544 New Chester Rock Ferry Rd Rock Ferry 1452 Birmingham County Cycle amp Motor 265 and 266 Broad St Mid 2671 Co Ltd 104 Bath Row Repairs closed Saturday p m Mid 2817 C E Cope amp Sons Ltd 481 487 Hagley Road Bearwood Edgbaston 17 2246 7 Shovelbottom s Ltd 376 Ladypool Road South Sparkbrook 12 2212 3247 Aston Auto Motors 173 177 Aston Road 6 Aston Cross 3201 2 TI B S A Motor Cycle Spares Stockists continued Telephone Telegraphic Town Name of Stockist Address No Address Blackburn S amp G Motor Cycles 15 17 Great Bolton St 6678 Blackburn Led Blackpool J Hall amp Son 102 6 Devonshire Road 22130 Blackpool Ltd opp School Blandford Badger Garages Ltd Salisbury Road 615 Bolton Charlie Robinson 119 and 121 Higher 3931 Motor Cycles Led Bridge Street Boscombe Craze Bros Led 473 475 Christchurch Boscombe Bournemouth Road 33231 2 Bradford Sidneys Motor Cycles 107 Manningham Lane 29889 n J K Hirst Ltd 41 Wakefleld Road 22543 Bridgwater Anderson amp Wall Ltd 18 St Mary Street 2416 Anderson amp Wall Bridgwater Brighton Redhill Motors Brigh 104 North Road sx 25281 ton Ltd Bristol S J Fair Motors Ltd 201 3 Cheltenham Rd 4 6238 amp 4 1015 Bromsgrove Ralphs sou 110 Birmingham Rd
23. wheel from the forks detach the brake cable and then slacken the pinch bolt A Fig 4 at the front of the nearside fork end Insert a tommy bar in the hole in the spindle end B and unscrew Note that the spindle has a left hand thread and unscrews when turned in a clockwise direction It can then be withdrawn and by sliding bush C in the fork end outwards to its fullest extent the wheel will drop out Following the replacement of the spindle and before pinch bolt A is tightened the forks must be depressed Fig 4 Removal of front wheel 20 sharply once or twice to enable the nearside fork end to align itself on the bush C If this precaution is not observed the fork leg may be clipped out of position and will not function correctly Do not forget to tighten the bolt A For removal of front wheel with 8 in brake see page 60 in Gold Star Section Forks There is no adjustment provided for the telescopic forks and the only maintenance likely to be required apart from the routine check on the tightness of nuts and bolts is attention to the oil level in the hydraulic damping system If after considerable mileage the forks appear to develop excessive up and down movement it may be an indication that the oil supply requires replenishing To do this remove the large hexagon headed cap A Fig 5 at the top of each fork leg and also the small drain plugs shown in Fig 6 After all the oil has drained out of each Mu HIT
24. 09 109 1 09 109 109 120 120 See individual specification in Certificate of Performance Models with engine prefix No BB Sparking Plug For normal road use or for fast touring the most suitable sparking plug is the Champion model NAS For the intermediate compression ratios Champion model NA10 or even the NA12 should be used the latter for really high duty work When using alcohol fuel with the highest compression piston a Champion model NA14 plug will be necessary The Champion NA14 is essential when racing on petrol or petrol benzole IMPORTANT For warming up with dope use the Champion L11S as a long reach plug with protruding points will foul the piston Oil Recommendations The oil recommendations as given in the chart on page 36 are suitable for most purposes but for ultra high speeds a castor base oil may be preferred For this purpose the racing grades of oil supplied by the firms tabulated in the lubrication chart are suitable It must always be borne in mind that castor base oil will not mix with mineral oil and if a change of lubricant is made care must be taken to ensure that the entire system is thoroughly cleaned out as otherwise a formation of heavy sludge may result with consequent damage to the engine Exhaust System Unless the purchaser orders a special exhaust system to suit his requirements the Gold Stars are fitted as standard with a normal exh
25. D in a downwards direction this will draw the gearbox backwards tightening the chain There should not be less than a total of half an inch up and down movement in the centre at the tightest point of the chain Finally retighten the adjuster locknut C and the two large gearbox fixing nuts A and B Note that after tighten ing this chain the rear chain will need checking Rear Chain Adjustment plunger spring frame Fig 7 Hold the hexagon 4 with a suitable spanner and unscrew 31 the spindle slightly by means of a tommy bar at C Slacken off the hexagon B on the left hand side of the hub then screw the adjusters D in or out as the case may be until the chain tension is correct with not less than 4 in total up and down movement at the centre of the bottom run of the chain with the machine on its central stand so that the rear wheel is in its lowest position Rear Chain Adjustment Comp and Swinging Arm models Unscrew the spindle B Fig 8 slightly with a tommy bar then slacken off the hexagon A on the left hand side of the hub Release the locknuts C and screw the adjusters D in or out as the case may be until the chain tension is correct with not less than 1 in Comp 4in total up and down movement at the centre of the bottom run of the chain To allow for any variation in chain tension the wheel should be rotated by hand until the tightest point is found with the wheel in its lowest position Front Brake Adjustment
26. Son 71 87 High West 71815 Street Glasgow C3 Bell Bros H P Ltd 215 229 St George Rd Douglas Douglas 6414 6414 A C4 J R Alexander amp Co 272 Great Western Douglas Alex Moto Led Road 3802 3 4 Glasgow Gloucester Harpers of Gloucester 23a Worcester Street 23187 Gloucester 23187 Grimsby H J Gresswell amp Son 13 15 amp 19 Osborne St no Ltd Guernsey Millard amp Co Ltd Victoria Road 777 Millard Motors Guernsey Guildford E Pascall Guildford 11 12 WoodbridgeRd Guildford uildford 2274 5 6 Harrogate a Proprietor 11 Bower Road 5125 H Baynes 73 B S A Motor Cycle Spares Stockists continued Telephone Telegraphic Town Name of Stockist Address No Address Harrow E T Pink Harrow Station Road 3328 Pink Harrow Hatfield W Waters amp Sons Ltd 32 Great North Road 2255 Hereford A Kear amp Co 52Commercial Street 2239 Kear Hereford Holbeach GordonWoodmanLtd 34 Fleet Street 3221 Hornchurch T W Kirby Ltd 10 Roneo Corner 8785 Hounslow Stanley s Motors 46 48 Lampton Road Hounslow Stanleys 19 Hounslow Huddersfield Earnshaw Manchester Road 1232 Hull Browns Witham Ltd 47 49 Witham 29802 Jordans of Hull Storey Street 24131 Gumption Hull Ilford me e d J Double 1 4 Mildmay Parade Valentine
27. The oil is added through the filler cap Ki on t i re Find FBR hand side of the box the hole ined oil level On Comp and Swinging Arm models the gearbox is fitted with a level plug see K Fig 13 In the case of new machines drain the gearbox after the first 500 miles as explained on page 19 EVERY 1 000 MILES Hubs Inject grease through the nipple in the centre of the hub Do not over lubricate as grease may be forced on to the brake linings and cause ineffective brakes Three or four strokes of the grease gun should be ample Do not lubricate with oil Steering Head Lift machine and place a box under the crankcase so that front wheel is clear of the ground Test for play in the steering head by trying up and down movement Check also that steering is free i e that the ball race adjustment is not too close If necessary adjust as explained on page 24 17 kopp ing Brake Cam Spindles A few drops of oil is all that is required 8 in Front Brake nipple one stroke of grease gun Tappet Adjustment for Gold Star models see page 50 Check when engine is cold The correct method of checking and adjusting tappets is explained on page 25 Clutch A few strokes of the grease gun at F Fig 11 will ensure free movement of the control arm There should be a slight amount of play in the clutch control arm on the gearbox or a short length of free cable at the handlebar lever end If the play becomes excessive diffi
28. a fi Fig 5 Front fork and steering head 21 Vcc oja l vate born leg replace the drain plugs and refill to the correct level B31 B33 5 fi oz 142 c c of oil in each leg B32 B34 Competition and Gold Star 7 fl oz 213 c c in each leg On no account must the fork Jegs be filled right up to the top or the forks will be unable to function The correct grades of oil for both types of telescopic forks are given in the lubrication chart on page 36 Removal of the Rear Wheel Plunger Spring Frame Fig 7 The rear wheel is of the quickly detachable type As it is fitted with ball journal bearings adjustment is not necessary To remove the wheel place the machine on its stand On machines fitted with touring mudguards first slacken the nuts at the slotted fixing stay ends disconnect the rear lamp by means of the special coupling when the rear portion of the guard can be lifted upwards on its hinge clear of the wheel To remove the wheel it is necessary first to hold the outer nut A on the left hand end of the wheel spindle with a suitable spanner when the spindle itself may be un screwed from the right hand side with the aid of a tommy bar at C Removal of the distance piece between the hub and the wheel bracket allows the wheel to be withdrawn Fig 6 Front Fork Drain Plug 22 sideways from its driving splines when it can be taken out rearwards Rear Wheel Removal Comp and Swinging Arm models This i
29. adverse performance over heating and valve burning Tappet adjustment should always be carried out with the engine dead cold and the clearances recommended above regarded as a minimum especially in the case of the exhaust valve 26 JUST TAKEN UP INLET VALVE TAPPET 18 RESTING ON BASE OF CAM DOTTED LINE SET INLET TAPPET CLEARANCE T0 00Sin TAPPETS AT MAXIMUM CLEARANCE DURING THIS PERIOD FALL FINISHES TAPPETS AT MAXIMUM CLEARANCE DURING THIS PERIOD FALL FINISHES TAPPET CLEARANCES CAN ONLY BE SET ACCURATELY WHEN TAPPET FOOT TS RESTING ON PORTION OF CAM WHICH GIVES MAXIMUM CLEARANCE AS CAN BE SEEN ON ABOVE DIAGRAMS THIS PERIOD IS RELATIVELY SMALL ON A B S A MAKE QUITE CERTAIN THAT CAM POSITIONS ARE CORRECT WHEN ADJUSTING TAPPETS Fig 10 Tappet adjustment 27 J Y pinion to slacken antite Ignition Timing it 1s a rare guta for the magneto AN a diffifib the ignition setting And it is not advisable to infetftf with the standard Seti unless it is known to be at fault It is however advisable to check over the timing after carrying out any adjustment to the magneto contact points as a slight variation of the points tends to advance or retard the timing Opening the points advances timing closing them retards timing WA If the timing requires re setting first check that the fully open gap at the points is between 010 in and 012 in Then remove the timing Cover a
30. aptor engaging its moulded recesses with corresponding projections on the bulb holder Press inwards and secure by turning the adaptor to the right The pilot bulb holder is a push fit in the reflector Refit the outer rim to the nacelle locating the bottom of the rim first With the Lucas prefocus type bulbs fitted in these lamps the filament is correctly positioned during manufacture in relation to the focal point of the reflector No further focusing is necessary Setting the Beam The best way of checking the setting of the lamp is to stand the motor cycle in front of a light coloured wall at a distance of about 25 feet If necessary slacken the bolts securing the headlamp and move the lamp until with the main driving light switched on the beam is projected straight ahead and parallel with the ground With the lamp in this position the height of the beam centre on the wall should be the same as the height af the centre of the headlamp from the ground Stop Light Switch This is operated by the brake rod through a spring It is desirable to see that any mud or grease is periodically cleared away from the switch and the operating mechanism should be oiled occasionally with thin oil Rear Stop Lamp The red transparent plastic portion of the lamp can be taken off by removing the two retaining screws Replacement Bulbs Lucas No Watts Headlamp Main iy ate 312 30 24 Headlamp Pilot ag 988 3 Stop tail lamp at le o
31. ar It is never advisable except in cases of emergency either to accelerate or to brake fiercely when the roads are greasy both are extremely dangerous HINTS ON RUNNING IN A NEW MOTOR CYCLE The rider who has just purchased a new machine will do well to remember that all the internal parts are just as new as the enamel and plating which can be seen and that they must be well run in before the engine can be given any really hard work The running in process is the most important period in the life of the engine and the handling it receives during the first 1 000 to 1 500 miles will determine the service it will provide in return It is advisable not to exceed half throttle in any gear If excessive speeds are used there is risk of piston seizure and other troubles and in any event until the machine has been run in it cannot be expected to give its best performance In particular avoid rapid acceleration especially when the engine is not under load and do not 11 allow the engine to labour on hills in a high gear when a change to a lower gear would ease the load on the engine Do not let the oil level in the tank get too low as economy in oil may prove very expensive at a later date Running consistently with the oil level too low may cause the oil to become unduly hot It must be remembered that the oil cools as well as lubricates and a new engine tends to run a l
32. assemble This operation is carried out as follows The Cleaner cover is attached by two screws in elongated slots the lower to the frame member below the seat and the other to the battery strap The rubber connection to the carburetter should be left in position on the carburetter inlet stub and slipped off the cleaner cover The filter is held in the cleaner cover by a wire circlip Note The domed surface of the perforated retaining disc must be replaced upwards Cylinder Head After the machine has covered its first 250 miles from new or after decarbonising check the tightness of the cylinder head bolts If they need to be tightened work in diagonal order to ensure that the head is tightened evenly otherwise distortion may result 35 Til 44 FIL 304i DO tin KEY LUBRICATION POINTS L indicates left hand side remainder right hand or both sides RECOMMENDED LUBRICANTS OILS COMP amp Engine Gearbox Front Forks G STAR FRONT FORKS GREASE Brand Summer Winter ONLY Mobiloil D A Arctic Mobilgrease No 2 X100 50 X100 30 X100 20 RetinaxAorCD Grand XL Castrolite Castrolease Prix Heavy Esso 50 30 20 Essogrease BP SAE SAE SAE Energrease Energol 50 30 20 C3 FOR OVERSEAS Recommendations as above if obtainable If not the following rule should be observed The Higher the Temperature the Higher is the S A a Number required ingine Gearbox Summer and Fron
33. aust pipe and silencer making them suitable for ordinary road work For racing events where silencers are not enforced these will naturally be discarded and an exhaust pipe of suitable length with or without megaphone will be employed Extension tailpipes are fitted in some cases as the length of a straight through pipe is determined partly oy the engine performance as influenced by the actual cams used and partly by the type of event in which the machine is to participate The rider will therefore be well advised to experiment on his own machine until he finds the most suitable length of pipe to suit his requirements As a guide see Table IV It should be borne in mind that a reduction in length will increase the maximum speed at the expense of aslightly reduced performance low down and conversely in the case of a pipe of greater length 56 Gearbox For road racing the gear change mechanism can be supplied to operate in the reverse direction Maximum Safe Engine Speed The maximum speed should not be allowed to exceed 6 800 r p m on the B32 and Tam E e B34 unless otherwise specified in the vidual Certificate of Perfo i i aida rmance issued with the Rev Counters These are available for Gold Star engines The conversion entails the fitting of a modified timing cover Tyres Sizes to individual requirements Front Tyre 3 00 21 or 3 00 19 Rear tyre 3 25 o SAA y 19 3 50 19 Handlebar Tetera Eront Brake and Clutch
34. b increase the tyre pressures as follows 140 Ib Rear tyre Add one lb per sq in for every 14 Ib increase pension 8 Ib heavier other extras or a pillion passenger or luggage mined and the pressures increased in accordance with the Dunlop THE CONTROLS 3f SPEEDOMETER LIGHTING SWITCH AMMETER ERIS a AIR LEVER HORN BUTTON IGNITION LEVER Sa FRONT ge BY BRAKE CLUTCH Ef LEVER THROTTLE TWIST GRIP Open in direction of arrow DIPPER FOOT GEAR CHANGE SWITCH PETROL FILLER CAP REAR BRAKE 4 PETROL TAP Fig 1 The Controls THE CONTROLS HANDLEBAR CONTROLS Twist Grip Throttle Controls the engine speed To open the throttle 1 e to increase the engine speed turn the grip towards the rider Full movement about one quarter of a turn Front Brake The lever is on the right bar below the twist grip throttle Pull the lever towards the bar to apply the brake and note that this lever operates the front brake only Carburetter Air Lever On the right bar and controls the supply of air to the carburetter allowing the mixture of air and petrol to be varied as conditions require Pull towards the rider to open i e to increase the supply of air Normal running position fully open Horn The control button is fitted on the back of the front brake lever Clutch Lever Larger lever below the left bar Pull towards the bar to declutc
35. bout one inch margin between the oil and top of tank If this precaution is not observed it is possible that oil will seep from the filler cap In the case of new machines drain the tank after the first 500 and 1 000 miles as explained on page 18 Tyres Examine carefully for cuts and remove any flints or metallic scraps which may have become embedded in the cover Check the pressures with a gauge and inflate to correct pressure if necessary See pages 3 and 4 16 Steering Head Give two or three strokes of the grease gun Brake Pedal Give two or three drops of oil occasionally Rear Suspension Plunger Type A few strokes of the grease gun Control Joints and Exposed Cables A few drops of oil Saddle Nose Bolt One or two strokes of the grease gun Battery Top up as often as necessary to maintain level of electrolyte one quarter inch above top of plates ALWAYS USE DISTILLED WATER WHEN TOP PING UP This can be obtained cheaply at any garage or chemist s shop see page 62 To gain access to the battery on machines fitted with swinging arm rear suspension remove the two bolts under the dual seat at the rear The seat can then be drawn backwards out of its front locating grooves and clear of the machine revealing the battery Remove the two small bolts holding the battery strap over the battery and unscrew the battery terminals The battery can then be lifted out dans Gearbox Ekamite oil level and top up if necessary
36. e contact breaker base To reach the wick take out the screw A Fig 21 securing the spring arm carrying the moving contact and lift off the backing spring C and spring arm The screw B carrying the wick can then be withdrawn At the same time unscrew the contact breaker securing screw D take the tappet which operates the contact spring from its housing and lightly smear with thin machine oil When replacing see that the backing spring is fitted on top of the spring arm and that its bent portion is facing outwards Renewing High Tension Cable A high tension cable showing signs of cracking or perishing must be replaced by 7mm rubber covered ignition cable To make the connection to the pick up terminal thread the moulded terminal nut over the cable bare the end of the cable for about in thread the wire through the washer removed from the original cable and bend back the wire strands Screw the nut into its terminal LAMPS Headlamp To gain access to the head and pilot bulbs slacken the front rim retaining screw situated at the top of the rim Disengage and withdraw the front rim and light unit assembly removing the upper edge first To remove the main bulb press the moulded adaptor inwards and turn it to the left Lift off the adaptor and withdraw the defective bulb Fig 21 Magneto contact points When inserting a replacement bulb locate the slot in the bulb flange with the projection in the bulb holder Refit the ad
37. e piston Check the gap with feeler gauges and this should not be less than 008 in or more than 012 in Fit new rings if the gap greatly exceeds the figure stated although a few thousandths of an inch extra gap are not serious It is advisable to check the gap of new rings before fitting and if the gap is less than 008 in the ends of the rings should be carefully filed to the correct limit It should be noted that piston rings are very brittle and unless handled carefully are easily broken This applies particularly to the scraper ring Re assembling When the rings are refitted replace the piston on the connecting rod see that it is the right way round smear the gudgeon pin liberally with engine oil and tap into position Then refit the gudgeon pin circlip Smear the piston liberally with clean engine oil turn the rings so that the gaps are on opposite sides of the piston fit a new cylinder base washer on the crankcase 44 liberally coat the inside of the cylinder barrel with clean engine oil and then compressing the rings in turn by hand carefully slide the barrel into position over the piston This operation will be simplified if the piston rings are compressed into their grooves by means of metal bands such as can be obtained from accessory suppliers Next replace the valves into their respective positions place the springs over the stems with the top collar in position and with the head resting on wooden block as
38. ed when the filler cap is removed 28 The adjusting screw 8 Fig 11 is locked in position by the nut A For Comp and swinging arm models see Fig 13 H and G respectively and after releasing the latter adjust the screw so that there is a little clearance between the ball and the clutch push rod Then re tighten the locknut and replace the filler plug Fig 11 Clutch and front chain adjustment Further adjustment is provided by the knurled thumb nut C E on Comp and Swinging Arm on top of the gearbox Remember however that some free movement in the control arm is necessary as if the adjustment is too close there will be constant pressure on the clutch with con sequent wear and loss of efficiency For Gold Star Racing see Handlebar levers page 57 3 Clutch Spring Pressure After a considerable mileage it may be desirable to increase the spring pressurel a little First drain the Primary chain oilbath as explained on page 18 and remove the outer half of the oilbath thus exposing the clutch It will be seen that the clutch plates are compressed together by springs the pressure of which is controlled by the nuts B Fig 12 and locknuts A To increase the spring pressure release the locknuts and tighten the nuts B slightly It is important that each of NO the six adjusting nuts are tightened equally to ensure even pressure otherwise the plates will slide unevenly and c
39. fact that the main jet for alcohol fuel should be at least two and a half times as big as that for petrol For certain fuels however an even larger size may be found necessary and the owner is advised to experiment with this point bearing in mind that a careful test of the mixture strength with respect to performance should be made as quickly as possible as full throttle work with a weak mixture is liable to cause rapid seizure It is advisable when using alcohol fuel to run with the mixture slightly on the rich side Any published recommendation for a given fuel should there fore be looked upon as a minimum In the case of the B32 for J A P racing fuel No 800 or No 850 should be suitable while for pure methanol a jet size up to No 1300 may be found necessary For the B34 Gold Star the sizes will of course be proportionately larger and will probably be up to 1700 The throttle valve and needle position may vary slightly to suit individual cases Petrol Tank A two or four gallon tank can be fitted if specially ordered Ignition Timing The best timing for the B32 on dope is inch advance and y inch advance on petrol or petrol benzole 39 35 inch Clubman s On the B34 use 35 inch advance for dope and 4 inch advance for petrol or petrol benzole fs inch for scrambles with engine prefix No BB 36 38 inch Scrambles and Clubman s Valve Timing Timing procedure is as described for other B models See page 46 T
40. h i e to disengage the drive between the engine and the rear wheel As the clutch lever is slowly released the drive is restored gradually Always declutch when changing gear Dipper Switch Fitted on the back of the clutch lever and actuates the double filament bulb in the headlamp giving either a normal or dipped beam Ignition Control Small lever on top of left bar Controls the advance and retard of the spark produced by the magneto Normal running position is fully advanced i e lever moved forward into the closed position See page 9 for starting the engine the lever should be slightly retarded ii 0 Exhaust Valve Lifter not illustrated in Fig 1 Small lever under left bar Pulling the lever up towards the bar opens the exhaust valve releasing the com pression in the combustion chamber and enabling the engine to be rotated easily FOOT CONTROLS Rear Brake Pedal On the left hand side of the machine and operates the rear brake only Gear Change Pedal On the right hand side of the machine and is used to effect the change from one gear to another To engage first gear from the neutral position the pedal is moved upwards Second third and top gears are engaged by moving the pedal downwards The pedal automatically returns to the central position ready for the next gear change When engaging a gear the pedal should be moved to its extreme limit since the gear change is of the positi
41. has just closed i e the tappet is just free to rotate This is the correct position for checking and adjusting the exhaust valve clearance Turn engine forward again until the exhaust valve clearance is just taken up but before valve actually starts to lift This is the correct position for checking and adjusting the inlet valve clearance Both inlet and east learancoy are 003 ip batay in the case of Gold Stars See page 50 It is advisable before inserting a feeler gauge between the lower push rod end and tappet end to check the clearance on the engine to lift the push rod with the fingers otherwise the weight of the rod may prevent the gauge being inserted correctly or may give a false tappet setting The actual adjustment excepting Gold Star engines on and after engine number with prefix CB See page 50 is carried out as follows Hold the tappet head A with a spanner and release the locknut B Fig 10 Apply a spanner to the flats on the tappet stem holding the latter stationary and at the same time adjust the head A up or down as required When correct clearance is obtained the locknut B must be tightened against the tappet head Clearances should again be checked before replacing the inspection and tappet covers If these instructions are disregarded and the tappets are adjusted at any other positions of the cams instead of at the precise positions just described there will be a risk of difficult starting
42. he actual valve timing for Gold Stars differs from Standard B models but the pinions are marked in the same way as the standard pinions to facilitate assembly In addition the inlet and exhaust pinions are marked IN and EX respectively 53 a gs TABLE II RECOMMENDED CAM COMBINATIONS B32 GOLD STAR B34 GOLD STAR No Type of Service Inlet Exhaust Inlet Exhaust 1 Touring 65 2448 65 2450 65 2448 65 2450 2 Scrambles 65 2454 65 2450 65 2454 65 2450 65 2444 65 1891 65 2446 65 2446 3 Road Racing Petrol Benzole or Pool Plain or Megaphone 165 2444 65 2446 65 2444 65 2446 165 1891 65 2442 4 Alcohol Megaphone 165 2448 465 2450 465 2448 465 2450 Fitted with Engine No prefix BB only Note Special inner and outer valve springs 65 1259 and 65 1249 respectively must be used with Touring or Scrambles BB engines All CB engines 65 1894 inner 65 1895 outer With engine shaft pinion 65 696 TABLE MI CARBURETTER SETTINGS Fuel Petrol or Petrol Benzole Alcohol 1 or Dope Carburetter S5 Monobloc 10T T Grand Prix Remote Needle 10T T Model F B32 B34 B32 B34 B32 B34 B32 B34 B32 B34 Choke size ins 1 1 we iw lk a 1a ikor aa am Main jet se 240 360 360 210 260 450 ma 1200 1700 Throttle valve 389 3 di 7 6 7 6 7 7 6 Needle position 2 3 3 3 2 4 4 3 4 Needle jet 1065 109 1
43. hillings plus sixpence postage and the Spares Catalogue is five shillings and sixpence plus sixpence postage Always quote full engine and frame numbers when ordering these publications CONTENTS Air Cleaner Competition and Plunger Models Air Cleaner Swinging Arm ken a Battery Hai a Brakes se NG Carburetter e Carburetter paoia Aw Central Stand tan 45 Controls a Cylinder Head and Barrel Removal Cylinder Head and Barrel Removal Competition Cylinder Head and Barrel Removal Data or ae Driving n F Decarbonising a a e Dynamo Sho AG Foot Gear change Na Forks sa a a Gearbox ou n a Hubs 4 si w Ignition Timing YU no Gold Star Tubrieation Chan a Lubrication System Oilbath Periodical Maintenance Piston and Rings p v Rear Suspension Plunger type ese Swinging Arm type Magneto n a n Rocker Assembly see Ronninpine ss Xx Si Spares Stockists ie Sparking Plugs Supplementary Instructions Competition Supplementary Instructions Gold Star Steering Head 3 xa Technical Date a Valves Valve Clearances Valve Clearances Gold Stars Valve Timing Wheel Removal Competition Models with Plunger Suspension _ with Swinging Arm Suspension Wiring Diagram Competition and Gold Star lunger B Models Swinging Arm B Models Wiring Connections Headlamp Cow a
44. inder head should be returned to B S A Motor Cycles Ltd Repair Department Mont gomery Street Sparkbrook Birmingham 11 local dealer overseas The valve guides are of Hidurel 5 and high tensile phosphor bronze inserts are used for the sparking plug bush and the bushes for the cylinder attachment bolts The cylinder barrel is fitted with an austenitic liner The cylindet head is attached to the barrel by means of eight bolts seven of which pass through the cylinder barrel fins while the eighth is situated inside the push rod tunnel and is easily accessible when the tappet cover plate is removed Of these eight bolts four serve to attach the cylinder head and barrel to the crankcase as in the case of other B models and the remaining four are inter spaced between these holding down bolts Engines on and after engine number with prefix C B five and three bolts respectively The cylinder head must be tightened down periodically and in any case after the first 500 miles have been covered In no circumstances must the eight bronze bushes in the head be interfered with since these are screwed per manently into the cylinder head Whenever the tightness of the cylinder head bolts has been checked the tappet adjustment should be checked immediately afterwards as this may be affected 49 Crankpin The Gold Stars are fitted with special crank pins and nuts which must not be interchanged with standard component
45. ions for S A indicates models fitted with Swinging Arm Rear Suspension NOTE The recommended inflation pressures are based on frames except for Gold Stars with a rider s weight Relgnt of 140 Ib If the Front tyre Add one Ib per sq in for every 28 Ib increase above above 140 Ib If the machine is fitted with swinging arm rear sus is carried the actual upon each tyre should be deter Load and Pressure Sched DATA B32 Comp B32 G S B33 B34 Comp B34 G S 2or3 3 20r3 2or4 3or4 20r4 34 4 34 5 si si 1 i i 1 1 8 225 cc 2 55c c 8 225 c c 8 225 c c 8 an cc 71 7 85 88 88 F 88 348 348 499 499 003 003 003 6 5 1 65 1 68 1 012 012 012 1012 012 008 008 008 008 Closes 65 after b d c 25 before t d c Closes 25 after t d 65 before b d c 7 16 s 4 7 16 A NAS si LI0S NAS a 020 020 020 020 s020 2018 018 018 01 018 STD S A 7 05 Si 5 0 5 0 5 64 10 25 p 6 59 6 05 8 24 16 45 kil 10 3 8 79 13 2 W 22 3 x 14 9 12 90 17 80 Bi 2 75 21 Ls 3 25 19 2 75 21 4 4 00 19 x 3 50 19 4 00 19 20 21 7 2 21 16 22 18 16 18 67 66 or 68 70 69 67 to 69 91 97 or 98 93 91 97 or 98 16 x 19 20 NG 16 19 16 150 s 200 200 ka 150 170 170 260 L 210 Gold Star models on page 49 Note 3 pint 5 fi oz 8 tablespoons Comp models with rigid frames and other B models MAA ider s weight exceeds 140 I
46. is correct and adjust if peceren a Veril antla jou drev alve Timing Tf the vans are removed for any reason note that the engine t pinion and cam pinions are marked to facilitate assembly As the cams are inter changeable the timing marks are duplicated on both pinions The dash mark only is used for the inlet cam and the dot for the exhaust cam see Fig 17 These instructions apply equally to Competition engines For Gen Stars fitted with special cams see page 52 Bak kce upphang m ni eects ispensi Ain Plunger type To dismantle the rear nd first detach the rear wheel Next detach the silencer by removing the right hand pinch bolt 4 Fig 18 Then release pinch bolts A and B and remove plugs C The central columns of the suspension units can then be tapped out from underneath and withdrawn through the top lugs When this is done the remainder of each unit can be slid off sideways from the bottom lug and laid ona bench for complete dismantling which consists merely of taking the various pieces apart carefully noting their re spective positions for subsequent reassembly The wheel spindle brackets which together with the bearing sleeves to which they are attached form the spring plungers can be separated from the sleeves when the pinch bolts D are withdrawn Note that each of these engages in a notch in its bearing sleeve and also that the bottom studs at A similarly engage in notches in the central columns
47. ittle hotter than one that is well run in One more tip that is worth while add a small quantity of upper cylinder lubricant to the petrol each time the tank is replenished If this is difficult to obtain add about an eggcupful of engine oil to every 2 gallons of petrol HOW THE LUBRICATION SYSTEM WORKS The engine lubrication system see Fig 2 is of the dry sump type operated by a double gear pump situated in the bottom of the crankcase on the right hand side All oilways are internal except for the supply and return pipes from the tank and the oil feed to the valve rockers The oil flows from the tank through a filter in the tank to the supply pump the inside crankcase union and thence past the pressure valve A to the oilways feeding the cam spindles and along the hollow mainshaft to the big end bearing After lubricating the big end and circulating through the engine in the form of mist the oil drains down through a filter in the bottom of the crankcase from which it is drawn by the return pump lower pair of gears past ball valve C and delivered up the return pipe outer crankcase union to the tank Oilis fed through a union situated in the pipe between the return pump and the tank to the rocker spindles and after lubricating the rockers and enclosed valves is returned to the crank case through an external oil pipe attached to the base of the inlet valve spring housing In the case of aluminium engines the oil retu
48. lutch drag will result After the adjustment is completed depress the clutch lever and spin the clutch by operating the kickstarter when the outer plate should be seen to revolve parallel with the other plates If not adjust individual fi Yans tak il he plates are true Plunger models The chain is adjusted by slackening the two large nuts under the gearbox one on the left hand end of the adjuster and one on the right hand side see D Fig 11 and screwing up the adjuster nut E This draws the gearbox rearwards tightening the chain Don t forget to tighten na when correct tension is obtained which should allow half an inch uj and down movement at the tightest point of the chain Note that after tightening chain rear chain will need adjusting hay ou Primary Chain with Swinging Arm models The chain a Fig 12 Clutch spring adjustment KAY an Spanns genom ak Fly kn vaxel ada w is adjusted by pivoting the actual gearbox backwards or forwards about its lower fixing bolt A Fig 13 This operation is carried out as follows Slacken the two large nuts A and B which lock the gearbox in position One of these nuts is immediately under and the other vertically above the gearbox The latter B also holds the adjuster in position D 0 B Pi NG Fig 13 Clutch and front chain adjustment swinging arm models only Release the locknut C on the adjuster and screw the actual adjuster nut
49. n 384 6 18 index WIRING CONNECTIONS FOR B S A HEADLAMP COWL When this is packed as a loose item i e not installed in position on the front forks it comprises an actual cowl unit with the three following items attached to it The Main Switch This is on the left hand side and has seven terminals or binding posts on its underside numbered clockwise Speedometer Head This has on its underside the con nector for the speedometer light on the side adjacent to the main switch the other items being the control for the speedometer trip and the actual drive The latter passes through the headlamp shell Ammeter This is on the right and has on its underside two terminals the one next to the speedometer head being the negative and the other being the positive 66 Fig 22 B Model wiring diagram negative earth early models 67 Fig 23 B Model wiring diagram positive earth with underslung pilot lamp CEB Fig 24 B model wiring diagram positive earth 1953 models 69 6 VOLT BATTERY MAGDYNO OR SEPARATE MAGNETO DYNAMO WHEN FITTEO STOP TAIL W 2291 LAMP Fig 25 B model wiring diagram positive earth 1954 55 models 70 B S A MOTOR CYCLE SPARES STOCKISTS GENUINE fave TIME AND POSTAGE BY CONTACTING YOUR NEAREST B S A STOCKIST B S A SPARE PARTS
50. n Name of Stockist Address Address roydon Godfreys Ltd 228 234 London Road Croydon Gofrabike 641 2 Croydon Bagsoham Reginald Smith Motor Imperial House New sex Cycles Ltd oad 3284 2786 Dalton in H Holme 2426 Ulverston Road 25 Darlington The Duplex Motor and 10 16 Grange Road 2071 Duplex Cycle Co Ltd Darlington 4 Whice Bra Bros Darling 201 205 9 Northgate 67757 on Ltd Dartford Schwieso Bros 177 Lowfield Street 4279 Derby Ingle s Provincial Gar Walbrook Road 45289 ages Ltd Doncaster W Cusworth Doncas 7 Hall Gate 4594 ter Ltd Douglas Gilbert Harding Led 18 Duke Street and Douglas LO M Market Street 170 Dudley Chas E Cope amp Sons 93 and 193 High Street 53464 td Dundee George McLean Ltd Ward Road m 5087 Vehicles Dundee Dunstable B G England Dun Half Moon Hill Lon 843 4 stable Led don Road astbourne Jempsons Led 118 120 Seaside 756 Jempsons urne dinburgh J R Alexander amp Co 10 14 Lothian Road 4455 Motorcycles Edingburgh im Farquh ase ase 55 57 Hi i naj quharson s 55 57 High Street 7188 Elgin 7188 Afleld D J Shepherd amp Co 434 6 Hertford Road Howard Enfield Led Enfield Highway 1631 P Pike amp Co Led Alphington Street 58241 Piko Exeter J Difazio Motor Cycles 25 Catherine Street 2913 O Carmichael 8
51. nce 28 32 Highbury Corner North Highbury Led 2791 TA ten Landon N I2 George Grose Ltd Street 4632 4 London m W 3 Whitby s of Acton Ltd 273 The Vale Acton Sh Bush 5355 6 a W55 Kays of Ealing 8 10 Bond Street Ealing Sparesokay 2387 Ealux London a W 12 Turners Stores 81 83 Goldhawk Road S Bush Shepherds Bush 2436 kewestoft R Wright 67 69 London Rd S th 645 Meeclesfiold A Watling sou ane 49 Buxton Road ese 3592 Maidstone Redhill Motors Maid The Broadway Maid 3096 stone Led stone Manchester 3 Tom Davies Motors 233 Deansgate Eye Ltd a Fred Fearnley Ltd 692 4 Ashton Old Rd Fernbike 1445 6 Manchester s Alex Parker 31 Palatine Road Wythenshaw Northenden 2062 Penfield Henstocks sss see 128 Chesterfield Road 329 Henstock 329 Mansfield Middlesbrough J T Dickinson Midd 160 162 Lindthorpe Rd 3861 Payacob lesbrough Led Middlesbrough k B S A Motor Cycle Spares Stockists continued Telephone Telegraphic Name of Stockist Address No Address 407 High Rd Finchley Hillside 2149 m N I2 Glanfield Lawrence 407 419 High Road Finchley Glanfin Led 0091 Norphone London w N15 Godfreys Ltd 94 96 8 104 High Road Sta Hill Gofrabike Tottenham 9960 London NW J Grose Ltd 379 381 Euston Road Euston 5231 _N W 10 Slocombes Ltd 251 253 269 271 Gladstone Neasden Lane 3355 Neasden m SEN Writers Ltd
52. nce a month take off the battery lid see page 17 remove the filler plugs from each of the cells and examine the level of the electrolyte in each cell If necessary add sufficient distilled water to bring the electolyte level with the top of the separators Do not use tap water and do not use a naked light when examining the condition of the cells The condition of the battery should occasionally be checked by taking hydrometer readings of the specific gravity of the electrolyte Readings should be taken after the motor cycle has been out for a run when the electrolyte is thoroughly mixed The specific gravity readings and their indications are as follows 1 280 1 300 Battery fully charged About 1 210 Battery about half discharged Below 1 150 Battery full discharged The readings for each of the three cells should be approximately the same If one cell gives a reading very different from the others it may be that electrolyte has been spilled or has leaked from this particular cell or there may be a short circuit between the plates In this case the battery must be examined by a Lucas Service Depot or Agent Finally never leave the battery ina discharged condition for any length of time wipe away all moisture and dirt 62 from the top of the battery and keep the terminals clean and smeared with petroleum jelly to prevent corrosion See Figs 22 and 23 Wiring Diagrams MAGDYNO The magdyno is a combined dynamo and magneto u
53. nd in so doing take care not to AG the small 02216 ini the timing cover which feeds oil to the hollow crankshaft It is advisable to leave three fixing screws in position half unscrewed and spaced equally round the cover while the cover joint is broken With the cover removed take off the nut locking the magneto pinion on its shaft and with the aid of a magneto pinion extractor withdraw the pinion Note The latter is attached to a tapered shaft and can only be released with safety by using the proper extractor To reset the timing turn the engine forward until the piston reaches top dead centre on the compression stroke Now turn the engine back until the Aeon has descended ie in B33 in This operation is simplified if top gear is engaged and the rear wheel turned backwards For Gold Star models see page 53 Turn the contact breaker in its direction of rotation until the points are just open not more than 002 in with the ignition lever in the fully advanced position Lightly tap the magneto pinion on to its shaft tighten the nut and carefully check figures and positions If setting is correct finally tighten the magneto pinion nut It is most important that the ignition setting is accurate Too much or too little advance will result in higher running temperatures and may cause piston seizure See also Magdyno Fixing page 18 Clutch The main clutch adjustment is totally enclosed in the gearbox outer cover and is expos
54. nit the dynamo being mounted above the magneto and driven through gears from the magneto driving shaft DYNAMO Output Control The dynamo is of the compensated voltage control type and is arranged to work in con junction with a regulator unit which is fitted alongside the cutout The regulator causes the dynamo to give an output which varies according to the load on the battery andits state of charge The dynamo also gives an increase Of output to balance the current taken by the lamps whenever they are switched on It will be noted that during daytime running when the battery is in good condition the dynamo gives only a trickle charge so that ammeter readings will seldom be more than one or two amperes A discharge reading may be observed imme diately after switching on the headlamp but after a short time the battery voltage will fall and the regulator will respond causing the dynamo output to balance the lamp load Maintenance About every 10 000 miles take off the cover band and check the brushes and commutator See that the brushes move freely in their holders by holding back the brush springs and pulling gently on the flexible connectors If a brush is inclined to stick remove it from its holder and clean its sides with a petrol mois tened cloth Be careful to replace brushes in their original positions in order to retai bedding The commutator should be clean free from oil or dirt and should have a polished appearance If it is
55. omatically returns to its original position i e disengaged On Competition and Gold Star machines the lighting switch ammeter and speedometer are centrally mounted the former two in a panel on top of the headlamp and the latter bolted to the top yoke Central Stand This is of the spring up type and so designed that when the machine is pushed forward off the stand the latter springs upwards and is automatically retained clear of the road DRIVING Preliminaries Before taking the machine out for the first time it is ng Y essential to examine the oil tank to ensure that an ade quate supply of oil is available The tank has a working capacity of 3 pints on competition models 44 pints on plunger B models and for machines fitted with swinging arm rear suspension 5 pints Use only high quality lubricants as recommended in the chart on page 36 Examine also the remainder of the lubrication points and verify the quantity of oil in the gearbox and the primary chain oil bath To Start the Engine It will help in balancing the machine if you stand astride it when first attempting to start Make sure that the gear control is in the neutral position i e between first and second gear Note that if the machine is in gear it will move forward when the kickstarter pedal is depressed If the engine is cold first depress the carburetter tickler momentarily Close the air lever retard the ignition slightly and open
56. on Parade 3338 76 A Motor Cycle Spares Stockists continued elchlione Telegraphic town Name of Stockist Address Address Whefficld I Walter Wragg Ltd Stanley Works Wel oe Sheffield lington Street 26098 hrewsbury J R Meredith Coleham Head 6529 ittingbourne Scoones Garage 9 West Street 6b Scoones Sittingbourne Bough Sid Moram Wexham Corner 23767 High Street outhampton Alec Bennett Ltd 152 Portswood Road 54081 2 3 Southport H F Brockbank 62 King Street 5054 Southsea Percy Kiln 65 Elm Grove Portsmouth Southsea 23734 St Albans Clarkes Ltd 164 London Road 53153 Bt Helens Geoff Duke Ltd Greenfield Rd Garage 3918 Lancs Bt Ives Hallens Hunts Ltd 8 10 The Broadway St Ives Hallens Hunts 3071 St Ives toekton on T Cowie Ltd Norton Road Shelton 65361 Tees Wiockport Theobald amp Coppock 6 Chestergate s 2843 Theobald Cop pock Stockport Hoke on J amp N Bassett Howards Place Shelton 2890 Trent Mourbridge Pearsons Cycle Depot 31 Market Street 5677 Wunderland Dunns Garage Sunder Wheatsheaf Corner 57666 7 af land Ltd North Bridge Si Swansea Glanfield Lawrence 13 14 Fisher Street 50311 windon Easters of Swindon 73 75 Cricklade Road 4196 2786 Teunton P Edwards Station Road 2943 Edwards Motor Motors Ltd Cycle
57. oy Evans Motor Willow Street 1144 3363 Oxford 2 Temple 69 St Thomas Street 47496 7 John Avery 228 2308 240 Banbury 57362 3 i Roa yi Faulkener amp Son 12 Cardigan Street 57279 Parkstone Bob Foster 472 6 Ashley Road 3500 1 Perth M Shaw amp Sons 143 High Street 483 2154 Plymouth Piko 63018 Pal 55 57 Westgate Millbay Road Peterborough Burrows Bros Plymouth P Pike amp Co Ltd T Griffiths Forest Gate i Pontardulais Pontardulais as castle on Tyne Plymouth Glam Jenkins 8 Purser Ltd 277 281 Copnor Rd Ke De BelO Lawrenca 147 157 iRratan Ri Percy Kiln Ltd 65 67 Elm Grove 23734 st Central Garage Charn Sales Dept Preston Loxhams Garage ntral les D Dept Preston 4243 Pulborough Gray amp Rowsell Bury Bury Gate Pulborough Bury 4 td Radcliffe Will Lord Motor 115 Blackburn Street 2002 Cycles Reading os ko Sioomfield 10 14 South Street 2635 Motors Ltd p vas Stocker amp Shepherd 129 133 Oxford Rd 52212 and pa Ltd Redhill The Redhill Motor and 50 54 Brighton Road 327 Cycle Works Ltd Ripon Yorks T Ellis 2 High Skellgate Ripon 1079 Rotherham Ernest Cross 55 59 Drummond St 3987 Salisbury Pankhurst Wey 78 79 Exeter Street 5222 3 mouth Ltd Scarborough E pee Gf Scar 149 Victoria Road 1857 borough Ltd a Sevenoaks Angus Motor Cycles Stati
58. p yoke and this is carried out as follows 60 Slacken the two pinch bolts D Fig 5 in the bottom yoke Remove the chrome fork caps A and screw B S A Service Tool No 61 3350 into the thread at the top of one of the legs Vigorously tap the tool with a mallet until the fork leg is released from its tapered seating in the top yoke Having released the fork leg it should be slid downwards sufficiently to permit the handlebar to be removed and then pulled up into its taper again by means of the service tool This will maintain the front wheel in position while the other fork leg is released This operation can be carried out without the use of the Service Tool by unscrewing each chrome fork cap a few threads and tapping it down with a mallet until the fork leg is released This method is not recommended except in an emergency as considerable strain is placed upon the chrome cap particularly when pulling the fork leg back into the top yoke Fig 20 Front Wheel Removal 8 in Brake 61 INSTRUCTIONS FOR THE MAINTENANCE OF LUCAS ELECTRICAL EQUIPMENT fitted to B S A B Group Motor Cycles The electrical equipment is designed and manufactured to give long periods of service without any need for adjustment or cleaning The small amount of attention which is required is described below and we advise riders to carry out the procedure outlined in order to ensure that the best service is obtained BATTERY About o
59. removing the air flange nuts When fitted with an air cleaner see page 35 By unscrewing the ring nut at the top of the carburetter the slides can be pulled right out and tied to the frame top tube out of the way while the main body of the instrument can be removed Take care not to damage the carburetter flange washer The pipe and silencer can be remoyed complete the pipe itself being a push fit in the cylinder head Removing the Cylinder Head For Comp and Gold Star models see pages 48 and 50 respectively Disconnect the oil feed pipe to the rocker spindles and the oil return pipe from the rocker box to the crankcase Note that the union screws for the oil pipe to the rocker spindles have a much smaller hole in the side than the union screw for the return pipe a point to remember when reassembling The exhaust valve lifter cable can either be disconnected or the exhaust rocker box cover removed leaving the cable intact Remove the inlet yalve rocker box cover Slacken the castellated gland nut securing the push rod cover tube to the cylinder head using the special C 41 the inspection cover at the top and tappet cover at the f base of the tube and undo the two acorn nuts clamping l the base of the tube to the crankcase 8 A m 2 3 a 5 5 2 5 g a i o 8 a tendency to stick a few light taps with a Wooden mallet under the exhaust port will loosen it With the head clear of the machine the Push rod
60. rns to the crankcase via the push rod tunnel Incorrect seating of the ball valve A may allow oil to transfer from the tank to the engine whilst the machine is stationary In this event unscrew the plug retaining the valve and remove spring and ball Clean the ball and its seating and replace If necessary to ensure a close 12 fit between ball and seat the ball should be replaced on its seating and dealt a sharp blow with a light hammer and punch to make certain that the ball beds on the seat in a satisfactory manner If the ball valve C should get stuck in its seating there will be no return of oil to the tank To correct remove the cover plate B below the pump insert a piece of wire into the valve orifice and lift the ball off its seating to free it To check the flow of oil in the lubricating system remove the tank filler cap whilst the engine is running Oil should be seen issuing from the return pipe from the crankcase Any restriction in the pressure release pipe see Fig 2 in the tank will cause an increase in pressure inside the oil tank and will result in leakage of oil at the filler cap This can be rectified by inserting a length of flexible wire into the pipe at its lower end just in front of the rear mudguard and pushing the wire right up the pipe thus clearing any obstruction In the case of Comp models and machines with swinging arm rear suspension which are fitted with an oil breather tower Fig 2a it is onl
61. ry 1 000 miles 1 500 km or so for inspection If the carburation system is in correct adjustment the sparking plug points should remain clean almost indefinitely An over rich mixture from the carburetter will however cause the formation of a sooty deposit on the points and later on the plug end face as upper view Fig 14 If therefore such a deposit is found clean it off carefully and check yout carburetter The continued use of leaded fuel may also eventually produce a deposit on the plug this time of a greyish colour 33 a Sann Ni pani _ A light deposit due to any of these causes can easily be cleaned off but if it is allowed to accumulate particularly inside the body the plug may spark internally with an adverse effect on engine performance if indeed it does not stop the engine altogether The plugs should be cleaned and tested at regular intervals and it is suggested that this service be performed at your garage on a special Air Blast service unit If eventually the cleaning process fails to restore the plug to its original condition of efficiency it should be replaced by a new one Fig 15 Setting the plug points When inspecting a plug also check the gap between the points This should be 018 020 in 45 50 mm and adjustment should be made by bending the side wire see Fig 15 Never attempt to move the centre electrode and it is always advisable to use the special plug gap tool ill
62. s Valve Rockers These are specially lightened and balanced for efficiency at high engine speeds Valves The valves are made from a special heat Tesisting steel and are Stellite tipped In no Circumstances should standard valves with end caps be substituted For safety fit a new exhaust valve at reasonable intervals Tappet Adjustment Check the valve clearances when the engine is cold and follow the special procedure described on page 25 Owing to the fact that the cylinder barrel and head are both of aluminium alloy the effect of expansion is more marked than in the case of cast iron cylinders with the result that valve clearance increases appreciably as the engine warms up i In the case of engines on and after engine number with prefix CB the actual adjustment is effected by means of eccentrics on the rocker spindles First disconnect the rocker oil feed pipe union nuts from the ends of the hollow rocker spindles Then slacken the large acorn nuts on the other ends of the rocker spindles This will release the rocker spindles and each spindle can then be turned independently in either direction by means of the hexagon adjacent to its oil feed union until the correct clearance is obtained This is checked at the lower end of the push rod aperture in exactly the same manner as for standard B engines Valve Clearances with engine cold see Table I1 Engine no with Prefix CB 006 in both valves Engine no
63. s T ton Thames Ditton Comerfords Ltd Portsmouth Road Emberbrook 5531 Torquay P H Sharam Ltd 244 6 Union Street 4184 and 7255 Troon w Cooper Bros 117 129 Templehill 925 Ayrshire Truro W H Collins amp Son Kenwyn Mews Truro Cornwall 2168 Tunbridge G E Tunbridge Ltd 21 London Road w 416 Motors Wells T bridge Wells Twickenham Blays of Twickenham 192 9 Heath Road Popesgrove Ltd 2103 8 1435 Vebridge Miles Motors 60 High Street 6000 6565 6 Wakefield Parkinson Wakefield 88 Ings Road 2087 Ltd Walsali The Motor Cycle Mart 12 Ablewell Street 3363 Walsall Led Werrington Jack Frodsham Led 37a Winnick Street 34713 77 B S A Motor Cycle Spares Stockists continued Telephone Telegraphic Town Name of Stockist Address No Address Watford Lloyd Cooper amp Co 61 Queens Road 2125 Lloyd Cooper Led Watford Wellington Bill Doran and Matt Park Street Garage Wellington 138 Salop WOH e re Westcliff on J Costin 8 Sons 233 241 London Road Southend Sea 42215 Weston Wyverns of Weston 3 Locking Road 524 Wyverns t super Mare Ltd eston s M 6 Weybridge W L Lewis amp Sons 51 Church Street 2210 Weymouth Tilleys Dorset Ltd 9 Frederick Place 72 Whitehaven Mark Taylor 21 King s Street 252 Wolverhamp C E Cope 8 Sons 168 9 Stafford Street 24605 6 ton Led Worcester
64. s are an increased tendency to pink a metallic knocking when under heavy load due to the building up of carbon on the top of the piston and inside of cylinder head a general falling off of power noticeable mainly on hills and the engine inclined to run hotter than usual Before commencing general dismantling rotate the engine until 38 OR NEEDLE POSITION Fig 16a The standard carburetter 39 CLIP NOTCH ADJUSTMENT Fig 16b Monobloc carburetter 40 the piston is at t d c on the compression stroke i e with both valves closed This will prevent any pressure on the valyes during the operation Preliminary Work It is first necessary to remove the petrol tank Turn off the petrol tap and detach the petrol pipe The tank is secured to the frame by a bolt through the steering head lug and two bolts to special lugs at the rear of the frame top tube When these bolts are removed the tank can be taken off Note the correct order of the rubber mountings for reassembly purposes On swinging arm models First remove the petrol tank strap which is located under the front of the tank and is held in position by two nuts The central tank locking bolt can then be removed when the rubber cover in the top of the tank is pulled off Next detach the high tension lead and remove the sparking plug Disconnect the steadying stay from the cylinder head to the frame and then take off carburetter by
65. s quickly detachable is fitted with ball journal bearings and therefore no adjustment is necessary To remove the wheel place the machine on its stand insert a tommy bar in the spindle end B Fig 8 and unscrew in an anti clockwise direction until it can be withdrawn The distance piece E can then be removed and the wheel withdrawn sideways from its driving splines when it can be taken out downwards and rearwards Fig 7 Rear Wheel Plunger Spring Frame Note The large nut B Fig 7 plunger frame A Fig 8 Swinging Arm Frame on the left hand end of the wheel spindle retains the whole of the brake assembly and should not be disturbed for purpose of wheel removal Wheel Alignment Make sure that the wheel is hard up against the adjusting stops when checking and also that the adjustment is equal on both sides of the wheel in the case of spring frame models so that the latter is in correct 23 alignment in the frame Adjustment is preferably carried out with the aid of a straight edge placed along the sides of the wheels In the case of machines fitted with tyres of the same size on front and rear wheels the straight edge should touch both sides of both tyres If the front tyre is of a smaller section than the rear due allowance will have to be made for this Steering Head It is first necessary to raise the front wheel clear of the ground a block or box under the crankcase is the best method Unscrew the damper knob
66. t Forks Winter SAE 40 20 Front Forks Comp and G Star only S A E 20 see page 21 36 WEEKLY LUBRICATION Ref GREASE Pagel Ref ou Page 12 Steering Head 17 1 Oil Tank N16 10 Saddle Nose Bolt 17 3 Gearbox 17 except dual seat Plunger Rear 7 Brake Pedal 17 13 Suspension only 17 8 Control Joints 17 Exposed Cables 17 LUBRICATION EVERY 1 000 MILES ay Ref GREASE Page Ref OIL Page 11 Hubs 17 6 in Brake Cam 18 Spindles Clutch Control Arm 18 16 Gin F Brake Cam 18 J Spindles LUBRICATION EVERY 2 000 MILES Ref GREASE Page Refi OIL Page 14 Central Stand 18 1 Oil Tank 18 3 Gearbox 4 Oiibath 9 Magneto Rear Chain SPECIAL NOTES Examine Engine Pressure Valve at 1 000 miles See A page 15 l and2 Clean Oil Tank and Crankcase Filters at 1 and 3 Drai Drain and Refill Oil Tank and Gearbox at miles 5 Aiek Fi Front Fork Oil Level at 10 000 miles 37 Carburetter So long as the engine continues to perform satisfactorily the carburetter is best left alone particularly by the experienced rider The only adjustment in which the owner is likely to be interested is the pilot air screw Fig 16a Fig 16b Monobloc which controls the slow running mixture This is set before the machine leaves the works but the best setting may
67. the twist grip a small amount Depress the kickstarter pedal until compression is felt raise the exhaust valve lifter and depress the kickstarter pedal a little more Release the valve lifter allow the kickstarter pedal to return to the top of its stroke and then give it a vigorous kick downwards This starting procedure should always be adopted as it allows the engine to gather sufficient momentum to over come the resistance of the next compression stroke Note that while it is necessary to close the air lever when starting from cold this should not be necessary when the engine is warm During normal running the air lever should always be kept fully open although a slight gain in power at low speeds on hills may sometimes be obtained if the lever is closed a very small amount The ignition lever should be fully advanced for normal running It may have to be retarded slightly if the engine is under an increased load The manipulation of this control is largely a matter of experience To engage First Gear Depress the clutch lever i e declutch and move the gear change pedal upwards to its limit If difficulty is experienced when engaging first gear when stationary rock the machine backwards and forwards maintaining slight pressure on the gear change pedal until the gear is felt to engage To Move Off Open the throttle slightly and gently release the clutch lever As the clutch engages open the throttle a little further and
68. ustrated obtainable at 2 from any Champion Plug stockist or from the Champion Sparking Plug Co Ltd Feltham Middlesex Feeler gauges are attached to verify correct gap When refitting a plug make sure that the copper washer 34 O45 is not defective in any way If it has become worn and flattened fit a new one to ensure a gastight joint Screw the plug down by hand as far as possible then use a spanner for tightening only Always use a tubular box spanner to avoid possible fracture of the insulator and do not in any circumstances use an adjustable spanner Paint splashes accumulation of grime and dust etc on the top half of the insulator are often responsible for poor plug performance Plugs should be wiped frequently with a clean rag Air Cleaner when fitted to Comp or Plunger models This being of the oil dip type needs to be dismantled and cleaned periodically The filter element should be washed thoroughly in petrol allowed to dry and then submerged in light engine oil for a few minutes Then take out allow the surplus oil to drain off and reassemble Air Cleaner fitted to swinging arm machines This is in front of the battery carrier and is coupled to the carburetter by means of a rubber elbow The filter element must be removed periodically when it should be washed thoroughly in petrol dried and then submerged in thin oil SAE20 for a few minutes Then take out allow the surplus oil to drain off and re
69. ve stop type Kickstarter Pedal Also on the right hand side of the machine but is situated behind the gear change pedal Depression of the kickstarter rotates the engine See instructions on starting the engine GENERAL Petrol Tap The tap is of the push pull type and is located under the rear end of the tank To turn the petrol on pull the serrated button out To operate the reserve control rotate button to right and pull out to lock in position To turn the petrol off reverse the above procedure Steering Lock except Comp and G Stars Do not introduce oil into the keyhole as this may clog the wards and wash away the specially prepared lubricant inserted before assembly However after con siderable mileage or under adverse weather conditions a few drops of thin machine oil may be applied to the periphery of the moving drum Lighting Switch On the left of the headlamp cowl and controls the lighting of the lamps as indicated by the following mark ings H Head tail and speedometer lamps L Pilot tail and speedometer lamps OFF Lights not in use but battery on charge Ammeter On right of the headlamp cowl Enables the rider to see at a glance whether the battery is being charged or discharged Speedometer This is set in the headlamp cowl The trip can be turned back to zero when the spring loaded flexible control under the speedometer is pulled out and twisted in a clockwise direction The control aut
70. when the clutch is fully engaged the machine can be accelerated to a suitable road speed ready for changing into the next gear To Change Gear Up Close the throttle disengage the clutch and press the gear change pedal downwards to its limit all these operations being performed simultaneously Engage the clutch and re open the throttle together immediately after changing Note Violent pressure on the gear change pedal is neither necessary nor desirable 10 To Change Gear Down Open the throttle slightly disengage the clutch and raise the gear change pedal upwards to its limit all these operations being performed simultaneously Re engage the clutch immediately Note The above movements are quite easy to perform and a little practise will ensure a rapid and quiet gear change When changing gear either up or down it is preferable after moving the pedal to hold it momen tarily in position with the foot until after the clutch lever has been released when the gears will be felt to engage Do not use an excessive opening of the throttle when starting and do not allow the engine to race when stationary Use the throttle control to govern the speed of the machine e g when descending a steep hill if a lower gear is engaged and the throttle closed the engine will control the speed of descent On very greasy roads the use of the engine as a brake is to be advocated particularly in conjunction with a change to a lower ge
71. with stem and the steering head locknut B Fig 5 Slacken the head clip bolt C Fig 8 Rear Wheel Swinging Arm Frame 24 Tighten the adjusting sleeve E until the slackness i e up and down play has been taken up Do not overtighten or steering will be stiff and the ball races may be damaged After adjustment is completed tighten the clip bolt C and the steering head locknut B Exhaust Valve Lifter The exhaust valve lifter cam must always be well clear of the rocker arm see Fig 9 other wise the engine will be noisy and the tappet clearances seriously affected Failure to check that there is clearance at this point may result in a badly burnt exhaust valve Adjustment is usually carried out by means of the cable adjuster screwed into the exhaust rocker box cover but the actuating arm can be removed and reset to any position on its serrated shaft Tappet Adjustment Before any attempt is made to adjust valve clearances verify that the exhaust valve lifter is correctly adjusted as explained in the previous paragraph EXHAUST VALVE Fig 9 Exhaust valve lifter adjustment Valve stem caps are fitted to B31 only 25 To check and adjust valve clearances it is most essential owing to the special design of the cam form see Fig 10 to adhere to the following procedure Remoye the inspection cover at the top and the tappet cover at the base of the pushrod cover tube Rotate engine forward until the inlet valve
72. with prefix BB 008 in inlet 010 in ex REMOVAL OF CYLINDER HEAD The head is removed with the rocker box in position without any special manipulation A Having removed all the extraneous components turn the engine over until the piston is at t d c on the com pression stroke i e with both valves closed which ensures that no pressure is imposed upon the valves 50 Replacement of Cylinder Head This is merely a reversal of the removal instruct ions It should be Stressed however that the rocker box must be fitted on to the head before it is replaced should be obtained Before tightening the fixing bolts the Push rods must be located top and bottom on their rocker ball ends and tappet heads respectively These Operations are easily observed through the inspection and tappet apertures All eight fixing bolts should be located in the head before finally tightening up Removal and Replacement of Cylinder Barrel It should be noted that when reassembling cylinder head fixing bolts Compression Ratios A range of compression ratios is available which enables the rider to adapt his engine 51 performance to suit a wide variety of sporting events These are indicated in Table I Cams Various cam combinations are available for the Gold Star engine and the selection of these depends upon the desired performance They are shown in Table II and as a general rule the pair of cams fitted to an engine at the factory
73. wo red painted cover fixing screws A and B Fig 3 are provided They are the level indicator and drain screws respectively The oil level should be determined with the machine on level ground off the stand Do not fill above this level or clutch slip may occur Brake Fulcrum Pin 7 brakes only Check tightness of locking nut on brake cover plate Central Stand Fulcrum Give one or two strokes of the grease gun Gearbox Remove drain plug at bottom of gearbox and drain out old oil Wash out gearbox with flushing oil and refill with new oil to level of filler plug On swinging arm machines the gearbox is fitted with a level plug see K Fig 13 Chains Remove both chains clean thoroughly in petrol or paraffin and then gently warm in a mixture of grease and graphite When cool wipe off the excess grease clean the sprockets and replace the chain Remember that when replacing a chain fitted with a detachable connecting link that the spring fastener must always be fitted with the closed end facing the forward direction of travel i e on the top run of the chain Fig 3 Primary Chain Oilbath Comp and Swinging Arm models ta ADJUSTMENTS CALLED FOR IN THE PREVIOUS SECTION Front Hub This is fitted with ball journal bearings and adjustment is not necessary The only attention required is periodical grease gun lubrication as described on page 17 Removal of Front Wheel 7 in Brake only To remove the front
74. y necessary to keep the short length of tube clear which projects horizontally from it under the seat To remove the oil tank filter for cleaning on Comp models and machines fitted with plunger frames see Fig 2 remove the oil pipe banjo union plug at the bottom of the tank The filter will come out with the plug On models B31 and B33 it is preferable to remove the toolbox first This is secured by three nuts and bolts one through the mudguard valance and two through the short vertical strip on the chainstay On swinging arm models Fig 2a it is not necessary to unscrew the oil pipe union the oil tank filter being attached to the large chromed drain plug screwed in the side of the tank The supply pipe which will be seen when the drain plug is removed draws its oil through the filter The filter should be placed in a can large enough to cover it with petrol and thoroughly washed Before replacing make sure that it is quite dry of petrol The pump filter can be withdrawn after removing the 13 Pressure release Plunger Models pipe IE OS NW an Drain plug Oil return pipe Qil supply pipe Swinging Arm Models Fig 2a Oil feed to rockers A return pipe to rankcase 7 Double gear type oilpump Gauze filter Diagram showing how oil is circulated from the tank throughout the engine and returned to the tank 15 cover plate

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