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Bridgestone 350 Service Manual

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1. Replace 3 Worn crankshaft bearings Replace 4 Worn oil seals of crankcase Replace 14 TOLERANCES AND FITS A Engine 1 Cylinder compression 2 Maximum speed B Cylinder 1 Inside diameter Measure at 4 points along the wall Tolerances and Fits Standard 8 5 9 5 kg cm 121 135 Ibs in Over 160 km h 100 mph 61 005 61 025 mm 2 4018 2 4026 inches 2 Thickness of cylinder head gasket 3 Nuts Fitting torques C Piston 1 Maximum diameter at skirt 2 Maximum clearance between piston amp cylinder 3 Outside diameter of the piston pin 4 Piston ring free gap D Crankshaft amp Rotary Disc Valve 1 Inside diameter of big end of connecting rod 2 Inside diameter of small end of connecting rod 3 Thrust side play of small end of connecting rod 4 Thrust side play of big end of connecting rod 5 Outside diameter of left crankshaft A 0 95 1 05 mm 0 037 0 041 inches 250 300 kg cm 217 260 Ibs in 60 956 60 985 mm 2 3959 2 3967 inches 0 04 0 05 mm 0 0016 0 0019 inches 73 Permissible Limit 6 3 kg cm 90 Ibs in 61 1 mm 2 4055 inches 60 85mm 2 3914 inches 0 15 mm 0 0059 inches Select piston and cylinder to get above clearance when replacing with new one 16 994 17 00 mm 0 6678 0 6681 inches 0 15 0 35 mm 0 0059 0 0138 inches 30 008 30 017 mm 1 1793 1 1797 inches 21 00 21 013 mm 0 82
2. aqa J uu N HO Fig 103 Rear suspension Rear Suspension 51 2 Return stroke On the return stroke of the unit the valve on the oil control chamber closes and the damping oil flows out through the oil passage The oil overcomes strong resistance when it begins to flow in the gap between the inner tube and the outer tube and flows slowly back into the damping oil chamber Rebound is absorbed by this oil flow resistance C Adjustment of rear suspension To adjust the rear suspension remove the suspension mounting bolts and reposition the rear suspension onto the second set of mounting holes On the left side the rear hole is also used for the frame handle The spacer used under the frame handle should be kept on the other bolt when not used for the frame handle 52 Wheels 11 4 Wheels A Construction Tires Front 3 25 19 4ply Rear 3 25 19 4ply Drums Front 180mm 7 09 inches Rear 180mm 7 09 inches B Checking of Tire Pressure and Balance The 350 GTR has excellent acceleration and high speed performance so correct tire pressure should always be maintained Make a thorough check weekly Recommended tire pressure Front tire 2 0kg cm 28 30 psi Rear tire 2 2kg cm 30 32 psi Balance 1 Tire balance is very important to minimize vibration at high speeds 2 When replacing tires or repairing punctures check carefully the yellow spot on the side wall of the tire The tube valv
3. 6 Remove right crank case cover by unscrewing nine screws of right crank case cover 7 m Fig 18 Removing ring nut 7 Remove the left hand threaded pinion gear nut with the driven gear stopper and 28mm nut wrench special tool and then remove the pinion gear Fig 21 Then remove timing gear fitting bolt timing gear driven gear and kick idler gear 8 Remove over run stopper plate by unscrewing the screw shown by the arrow A in Fig 22 Fig 22 To do this shift into any gear by installing the change Fis 19 Removing clutch h housing pedal Then pull out the change shaft 9 Remove guide plate and ratchet comp by unscrewing the two 6 x 12 screws shown by the arrow B of the ratchet guide plate Fig 22 Fig 21 Removing Po gear left hand thread Drum m guide i6 plat 4 e ZAC A E Fig 22 Removing o overrun stopper amp guide plate 10 11 12 13 14 15 16 Engine 11 E Remove rotary valve cover by unscrewing the six 6 x 16 screws Fig 23 Remove rotary valve cover drive sprocket and neutral switch from the left side of engine Fig 24 Take off eight cylinder head nuts and remove cylinder heads gaskets and cylinders Fig 23 Removing rotary valve cover Remove piston pin circlips and then piston pins pistons and needle hearings Fig 25 Remove screw 5 x 30 of AC Dynamo and hexagonal nut of set band Then remove AC generator
4. at 5000 Engine rpm K Frame 1 Caster 63 2 Trail 105 mm 4 13 inches 3 Fuel tank capacity 15 litre 3 4 5 US gal Including 3 2 litre 4 5 US gal reserve 4 Oil tank capacity 2 5 litre 3 5 US gal 5 Brake lining thickness 4 5mm 0 1772 inches 2 mm 0 079 inches 6 Brake shoes thickness 179 6 179 9mm 7 07 7 08 inches 177mm 6 97 inches 7 Brake drum inside diameter 180 180 2mm 7 09 7 095mm 181mm 7 13 inches L Suspension 1 Front fork Stroke 120mm 4 716 inches Oil capacity 220cc 1 2 pint Oil surface 405mm 15 92 inches 435mm 17 09 inches 2 Rear suspension Stroke 80 mm 3 14 inches M Lighting equipment Battery Capacity 12V 6AH Acid capacity 390cc 4 5 pint Specific gravity 1 280 at 20 C 68 F 1 220 2 Main switch Insulation resistance over 1 MO 3 Selenium rectifier Capacity 2 7Amp 10mm Amp 4 Head lamp 12V 35 30W 5 5th gear indicator lamp 12V 3W 6 Speedometer lamp 12V 3W 7 Stop lamp 12V 23W 8 Tail lamp 12V 7W 9 Horn volume 95 115 phone 10 Fuse 10A 11 Speedometer error 10 0 14 TOLERANCE AND FITS N Adjusting Torque Size Stud 8x50 Exhaust Stud 6x40 Dynamo Stud 8x156 Cylinder 5 mm Hexagon bolt A 6 mm Hexagon bolt A 8 mm Hexagon bolt A 6 mm Clutch set bolt 8 mm Drum guide bolt 8 mm Change arm stopper pin 6 mm Tachometer bushing bolt 5 mm Cross pan head screw 6 mm Cross pan head screw 6 mm Cross flat head screw 40mm Ring nut clutch 8 mm Cylinder head nut 20mm Left thre
5. The internal stinger reduces noise levels significantly but for street use a canister type silencer is still recommended D 105mm 10 329 deg S 15deg D 58mm E 19 deg 40mm 28mm l 00mm 200mm 230mm 260mm 80mm Note Internal stinger L 30 5mm ID 28mm Fhush wath large dia of exhaust cone Expansion chamber
6. adjustment Worn clutch facings Flats worn on clutch facings Carburetor starter lever left raised Air cleaner clogged Flow of gasoline bad Hole of tank cap clogged Muffler clogged Ignition timing zee EE Kick and check compression Use compression gauge red mm o oo n Stiff piston ring Gas leakage from gasket Plug loosely fitted Dirt in fuel tank Dirt in fuel cock and bowl Not cleaned 2 Unsuitable plug Too much oil Trouble shooting 69 mmm rm ee pm Check whether engine overheats 1 Carbon accumulated in the verheats combustion chamber Does not Overheat ERA Es 2 Mixture ratio too lean 3 Clutch slips 13 3 Unsatisfactory R P M Trouble Inspection Investigation Causes of Trouble Inspect point gap at ignition timing 1 Point gap is too wide 2 Ignition timing is too advanced f Adjust air screw of carburetor s e M H l Gas is lean Screw outi 2 Gas is rich Screw in Satisfactory adjustment Unsatsfactory adjustment Check if air is coming in from carburetor attachment 1 Bad carburetor insulation 2 Unsatisfactory attachment of carburetor 3 Unsatisfactory rotary valve adjustment 4 Damaged O ring valve cover Remove plug kick and check condition of sparking 1 Plug bad or dirty 2 Point of
7. passing in back of the rotary disc valves Labyrinth parking 305 40 3 shim The oil sprayed from the crank shaft lubricates the cylinder walls the small end of the crankshaft and the ball bearings of the crankshaft Fig 44 Diech valve Check v lv Fig 44 Lubrication of crankshaft D Lubrication of transmission gears Oil stored in the gear box lubricates gears as shown Caution Oil filler plug 1 When refilling with new transmission oil take off oil cock and fill with 1 5 litre 3 5 U S gal SAE No 20W 40 in all seasons or SAE No 20 in winter 2 Check the oil level through the peephole only when the oil has settled in the transmission case 3 Change the oil periodically as follows Ist oiling after break in 2nd oiling every 2 000 miles gt Driven gear Transmission gear Fig 45 Lubrication of transmission gears 20 Crankshaft pistons cylinders and Rotary Disc Valves 5 2 CYLINDERS AND PISTONS A Construction The cylinders of the Bridgestone 350 GTR are made of aluminum alloy Cylinder walls are honed after hard chromium plating and then porous treated Therefore this engine has excellent cooling efficiency and since the heat expansion coefficients of the cylinder and piston are the same the piston cylinder clearance can be kept to a minimum and the engine operates quietly Moreover the aluminum alloy cylinders reduce t
8. 1 0 759 Secondary Chain 1 2 40 Total Gear Ratio p 1 18 27 2e 1 12 23 3 1 9 29 4n 1 7 43 5s 1 6 33 6 1 5 64 2 110 mm 83 1 inches 825mm 32 5 inches 1 115 mm 43 9 inches 810mm 31 9 inches 1 375 mm 54 1 inches 145 mm 5 7 inches 3 25 19 4 ply 3 25 19 4 ply 2 0kg cm 28 30 Ibs in 2 2 kg cm 30 32 Ibs in 63 105 mm 4 15 inches 46 165 kg 363 Ibs 15 litre 3 4 5 US gal Including 3 2 litre 4 5 US gal reserve 2 5 litre 3 5 US gal 12V 35 30W 12V 7W 12V 23W 12V 3W 12V 3W 12V 3W 12V 3W 12V 3W 12V 6AH 2 FRONT and SIDE VIEWS of BRIDGESTONE 350 GTR Dimensions in millimeters inches Front and Side Views of BS350GTR 810 31 9 1115 43 9 825 32 5 1375 54 1 2110 83 1 4 3 Performance 40 35 30 25 N c Output HP 3 000 Performance Output iHPj Torque kg m Fuel Comsumption gr HP h 4 000 5 000 6 000 7 000 Crankshatt R P M 4 8 4 0 3 0 600 500 400 300 8 000 Torque ikg mj Fuel Comsumption gr HP hi 8 000 4 2 000 Speed km h Speed M P H 6 Engine 4 ENGINE 4 1 Removing Engine A Notes of Caution 1 Becareful not to damage the insulation of the various wires 2 Becareful not to get oil on the clutch parts of the dry type racing clutch that is fitted to the 350 GTR B Tools necessary for dismounting and mounting the engine 1 Standard Tools
9. 4 WW N 28 Transmission 2 Stopper pin 37 Ratchet pole Change arm E ES b Change pedal ET oe e a if RT en Drum shifter A Nu 1 Se Fig 62 Neutral gear position L H i ch d ca z X y ET lt 3 wes Nempe 70 070 7 C SE D Gear shift mechanism C l Neutral gear position Fig 62 Fig 65 1 Stopper plate Change arm Stopper plate C 2 Operation of shift pedal pushed down Fig 63 C 3 Operation of shift pedal lifted up Fig 64 C 4 Operation of change arm stopper plate Fig 65 1 2 X i t IN d D KR DN d F sje e B Drum shifter Stopper plate The 350 GTR is equipped with a change arm over run stopper mechanism that prevents improper or excessive turning of the shift drum This design makes it impossible to miss gears when shifting Change arm Fig 65 2 Operation of charge arm stopper plate VD 00 1 DN PWN e LA e e e ken ben ben ben Fe Fe ke O vw GJ Oh Lh E D H r c Driven gear Clutch housing 40 lock washer Counter shaft Counter shaft spacer Needle bearing 20 thrust washer 3x15 Woodruff key N ra Li ra BWR Fa Fa Fe Fa Fan Fa Fa N Fe bei Fe Fe Transmission 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 17 oil seal 17 thrust washer 22 thrust washer Kick starter gear A Drive shaft Ist gear B 2nd gear B 3rd gear B 4th gear B 5th gear B 6th
10. 5 1 CRANKSHAFT AND ROTARY DISC VALVES A Construction Dual cylinders dual carburetors and dual rotary disc valves are incorporated in the Bridgestone 350 GTR engine Rotary disc valves are spline fitted at each end of the crankshaft of this parallel twin Fig 42 Right crankshaft A Right crankshaft B Left crankshaft A Left crankshaft B T y DEE OST e 1 S BRB Seow ja BE Be END med V S p A 25x0 3 shim X 09049 109 MV 30 x 0 3 shim 09049 1608 E Kee Z 222 toua MET 15 25x0 3 shim 09049 109 Left rotary valve Fig 42 Construction B Inspection I Measure crankshaft play with a dial gauge for tolerance and fit Fig 43 2 Inspect the crankshaft for wear and excess play where bearings are fitted If abnormal noise is produced or there is excessive play replace the crankshaft 3 If the connecting rod big end bearing is worn or damaged replace the crankshaft assembly 4 Ifadisc valve is damaged replace it 5 Ifan O ring is damaged or worn replace it Fig 43 Measuring crankshaft play Crankshaft pistons cylinders and Rotary Disc Valves 19 C Lubrication of the crankshaft Crankshaft bearings are lubricated automatically and correctly with oil fed from the oil pump through oil tubes B and C and the union bolt O Ring The oil which lubricates bearings is sprayed to crank chamber after lubricating vg oi seal the big end of the connecting rod or
11. BOLT 2216 9000 Outer Plate Not Used HOUSING 2218 9000 Clutch Spring 6 2219 9000 Set Bolt 6 2221 9000 Clutch Hub 1 2216 9010 Special Outer Plate 1 CLUTCH 2195 9010 Grommet 1 CLUTCH HUB ppt FIELD MODIFICATION 2 USING n SPECIAL OUTER PLATE 2216 9010 AFTER SERIAL NO 21501022 P PRESSURE et PLATE FRICTION x PART NO NAME OTY PLATE 2211 9001 Pressure Plate 1 2214 9000 Friction Plate 7 INNER PLATE 2215 9000 Inner Plate 6 HEX BOLT 2218 9001 Clutch Spring 6 Er 0113 0616 Hex Bolt 6 2221 9001 Clutch Hub 1 09040 112 Plain Washer 6 GA 2216 9010 Special Outer Plate 1 CLUTCH HUB 2195 9010 Grommet 1 FACTORY MODIFICATION USING SPECIAL OUTER PLATE 2216 9001 PRESSURE AFTER SERIAL NO 21V04022 H FRICTION PLATE PLATE GT MIEL PART NO NAME QTY INNER PLATE 2211 9001 Pressure Plate 1 2214 9000 Friction Plate 7 CLUTCH pr pas Tt HEX B 2215 9000 Inner Plate 6 HOUSING 3 SCH 2218 9001 Clutch Spring 6 2218 9002 Hex Bolt 6 2221 9002 Clutch Hub 1 Se 6 SHER 1 1 22 eee de Clutch 6 CLUTCH A Construction The 350 GTR has racing type dry discs instead of conventional wet discs to ensure quick and powerful action for better performance by eliminating resistance of oil film DEER FAR RANG eegen BERG DRE SOP TELET Fig 50 General view of clutch B Operation 1 Transmitting Engine Power Engine power is transmitted through the drive pinion on the crankshaft and the driven gear The driven
12. Engine Speed Adjustment 1 8 3 4 throttle opening 1 The gasoline air mixture can be adjusted by raising or lowering the jet needle at Ye 34 throttle opening for medium engine speed Therefore adjust the jet needle within the range where acceleration is not adversely affected 2 Trouble shooting Possible causes Remedies 1 Clogged main jet or needle jet Clean 2 Loose fitting of needle jet or main jet Screw in securely 3 Worn needle jet Replace it with a new one 4 Incorrect adjustment of needle jet position Raise the jet needle when mixture is too lean and lower it when mixture is too rich Standard jet needle position is in the third groove E High Engine Speed Adjustment 1 The gasoline air mixture can be adjusted by the main jet at 3 4 full throttle opening 2 Trouble shooting Possible causes Remedies 1 Clogged needle jet hole Clean 2 Loose fitting of needle jet or main jet Screw in securely 3 Incorrect main jet size Use a bigger main jet when mixture is too lean and a small one when mixture is too rich Standard main jet is No 130 Caution The main jet size should be decided according to the climate or temperature 38 Fig 79 Measuring float level Carburetors F Adjustment of Carburetor Float Level 1 The float level affects the gas air mixture ratio and should be checked as follows Gas air mixture becomes rich at high floating level and lean at low level 2 Adjustment Dismoun
13. Fig 14 Exhausting oil bubbles Fig 13 Checking oil level Engine 9 4 3 Disassembling and Assembling Engine A Special precautions 1 When removing or installing the engine use a wooden or plastic hammer and tap it lightly and uniformly so as not to strain any parts 2 When disassembling take careful note of the position of the meshing gears and location of the many washers and lay the parts out in an orderly manner so that they are not mislaid or confused when assembling 3 The parts should be carefully cleaned except the clutch parts This machine is equipped with dry racing type clutch which must be kept free from oil to ensure efficient action 4 Bolt tightness of the clutch set bolt is 70 90kg cm 61 78 Ibs in B Dismounting Engine 1 Disconnect oil tubes from the connector instead of disconnecting them from the check valves to avoid air leakage Fig 15 F t Check vatve 2 Pull out oil pump assembly by removing the two pump screws Fig 16 3 Remove clutch springs and clutch facings and all related parts by pulling out diagonally and evenly the six hexagonal bolts of the clutch set plate Fig 16 4 Remove clutch hub nut 23mm with clutch hub stopper special tool Fig 17 Wo j Clutch hub stopper U Fig 17 Removing clutch hub 10 Engine 5 Remove ring nut with the clutch housing stopper and the ring nut wrench special tools and then remove clutch housing Fig 18 19
14. SAR UC P2 Throttle valve spring Mixing chamber top Mixing chamber cap Cable adjuster Adjuster lock nut Throttle stop rod Throttle stop screw Stop screw spring Split pin Pilot air screw Air screw spring 140 main jet HA HA LA HAHAHAHA E d HAHAHAHA HA AHA BD Carburetors 24 25 26 27 28 29 30 130 main jet Needle jet Pilot jet Washer Starter plunger Plunger spring Plunger cap Float valve assy before 21H Float valve assy after 21H Valve seat gasket Float Float pin Float chamber body Float chamber gasket Clamp screw Hexagon nut A Set screw OO HAHAHAHA HA HAHA LAHA b2 LA HA LA HA LA BD 35 36 Carburetors 9 CARBURETORS A Synchronizing Carburetors ei c For best performance the carburetor throttle valves should be adjusted so they operate together To adjust open the throttle slowly until the O mark on one of the throttle valves is at the top of the air intake hole While holding in this position adjust the throttle cable adjuster of the other carburetor so the mark on its throttle valve is also at the top of the air intake hole Fig 76 Adjusting throttle valve Now close the throttle and check cable clearance Each cable must have at least 1 32 free cable before carburetor opens or readjustment will be necessary Fig 76 4 Z B Indication of trouble at various engine speeds Mixture Too Rich Mixture Too Lean minn C Idling Adju
15. by pulling it out in direction A Fig 26 Remove rotary disc valves Remove four hexagonal bolts one 8 x 80 one 8 x 90 and two 6 x 65 of upper crankcase Fig 27 Fig 26 Removing AC generator 12 Engine 17 Remove thirteen hexagonal bolts one 8 x 114 three 8 x Sx 4 Eg T IC 90 two 8 x 62 five 6 x 62 one 8 x 100 and one 6 x 90 8x 114 N 8400 of lower crankcase Fig 28 T 6x90 2 890 E x Ge em rar this bolt 18 Remove upper crank case cover Fig 29 shows the gear Drum guide be box after taking off the upper cover 19 Remove crankshaft comp counter shaft drive shaft Fig 28 Removing bolts of lower crankcase and kickshaft from lower case Shift drum and forks need not be removed from the case The previous 19 steps are generally all that will be necessary for most repairs If it is necessary to remove the shift drum or forks proceed as follows a Toremove shift drum take off guide bolt drum stopper and guide stopper plate Then pull out two guide pins in the direction of right crank case cover Fig 30 31 32 b Take off split pin of fork guide remove fork guide pins and the shift drum Fig 32 Removing guide shafts Fig 33 Crankcase fitting VD 00 10 tA E L H e See ee ben ka QN Lh P UN C Crank case assembly Dynamo spacer Dynamo set band Dynamo set pin Set band washer Cross recd pan head screw 8 x 156 Stud 8 fiber gasket Hex
16. gasoline and oil injects lubricating oil directly to the crankshaft bearings and other parts Fig 80 570 oil seal O Ring 576 i oil sea Labyrinth packing 25 x0 3 shim ll NS ME 3000 3 shim PM Dowel 6x10 Check valve Check valve Fig 80 Oil injection system A Operation The worm wheel of the oil pump is driven through the Crankshaft Driven Pinion Pump gear B The worm wheel the boss of which is cam shaped is pushed in direction A by the plunger spring and contacts the rod c as shown in Fig 81 EZ O outlet port Qit distributor The worm wheel plunger slides both ways following the cam height Oil pump chamber Oil intake port Worm wheel Fig 81 Operation Oil outlet port Oil distributor Oil pump Worm wheel Fig 82 1 Oil intake To Left To Right check valve check valve mor EUR H Ep pb q Bobo Fig 82 2 Rotation of distributor Fig 82 3 S Oil outlet port Fig 83 Oil outlet Left check valve Fig 84 1 Oil distribution left valve Fig 84 2 Right valve Oil Injection System 41 B Oil Intake When the worm wheel contacts the rod at the highest point of the cam the volume of the pump chamber increases and the pressure in the chamber decreases The inlet port opens and oil is sucked into the oil pump chamber Fig 82 1 2 3 C Oil Outlet When the worm wheel plunger slides
17. gears on the countershaft remaining in position the 3 gear B on the drive shaft slides to the right and the drive dogs on this gear engage with 1 gear B Engine power is transmitted in the following order driven gear clutch counter shaft First gear A First gear B 3 gear B driveshaft and drive sprocket Fig 67 With the 2 gear A remaining in position the 3 gear B slides to the left and the drive dogs on this gear engage with 2 gear B Engine power is transmitted in the following order driven gear clutch countershaft 2 gear A 2 gear B 3 gear B driveshaft and drive sprocket Fig 68 3rd gear With the 3 gear B on the drive shaft remaining in position the 2 gear A slides to the right and the drive dogs on this gear engage with drive dogs on 3 gear A Engine power is transmitted in the following order driven gear clutch countershaft 2 gear A 3 gear A 3 gear B driveshaft and drive sprocket Fig 69 4th gear With the 4 gear A remaining in position the 5 gear B slides to the right and the drive dogs on this gear engage with 4 gear B DETO Engine power is transmitted in the following order driven gear clutch countershaft 4 gear A 4 gear B 5 gear B driveshaft and drive sprocket Fig 70 Fig 70 In 4 gear position 32 Transmission
18. in the direction and contacts the rod at the lowest point of the cam the pump chamber volume decreases therefore oil is forced into the outlet port Fig 83 D Distribution of oil to both cylinders The rotation of the distributor shaft is one half that of the worm wheel plunger The distributor shaft has oil passage holes as shown in Fig 84 Therefore oil flows to each cylinder alternately Fig 84 1 2 42 E Operation of worm wheel plunger in relation to the throttle grip Oil Injection System Engine Idling at slow speed When the throttle grip is in zero position closed the rod contacts the control lever at its lowest position The worm wheel plunger slides to the right by spring tension and the plunger contacts the adjust screw before it contacts the rod When the cam height is at the lowest point the plunger contacts the rod instead of the adjust screw Fir QE Nil intaka Garn thenttla The distance of the shaft of the plunger to the adjust screw D is shortened to less than the height of the worm wheel cam thereby reducing the volume of oil Fig 85 86 High Speed wide open throttle When the throttle grip is wide open the cam of the control lever contacts the rod c at its highest point thereby shifting the rod c to the left so that the distance of shift of the plunger is lengthened and the volume of oil is increased Fig 87 88 ele g S EE 765 ise H fH H P t
19. of fork oil Do not use hydraulic brake fluid Fig 100 The oil level is checked with an oil gauge Correct level depths are 45mm 1 77 inches D Removing the steering damper 1 The steering damper is disassembled by taking off the split pin at the bottom of the steering damper knob Then loosen the steering damper knob and remove the special nut friction plate tension spring and damper guide plate Fig 101 Upper bridge ES Damper facing Fricti n plate Steering damper spring Damper spring guide T rt pin Fig 101 Component parts of steering damper 50 Rear Suspension 11 3 Rear suspension A Construction The rear suspension of the 350 GTR is adjustable for land or road conditions by changing the mounting position at the top end of the shock absorber as shown in Fig 102 The vertical position is stiffer B Operation Fig 103 Fig 102 Adjustment of rear suspension When depressed by shock or load When the unit receives shock or load the spring is compressed and the damping oil chamber becomes smaller Oil enters the oil passage pushes open the valve and flows into the oil control chamber Oil flows through the oil hole on the inner tube into the gap between the inner tube and the outer tube Shocks are absorbed by this spring action and oil flow m Jaqqni sedueg siou 19101 HO giou ino 110 18Qwoy gt 0410023 PO
20. plug fouled or in poor condition 2 Contact breaker points fouled or out of adjustment 3 Bad condenser 4 Weak ignition coil 5 Ignition timing incorrect 6 Cable disconnected between spark plug cap and high tension wire of ignition coil 7 Damaged or short circuited wiring B Possible causes of fuel failure 1 Throttle valves not opening synchronously 2 Clogged fuel line fuel pipe fuel cock bowl tank cap etc 3 Improperly adjusted air screw of carburetors 4 Clogged jet holes of carburetors C Possible causes of mechanical failure 1 Worn cylinder piston or piston rings 2 Air leak around carburetor 3 Cracked rotary disc valve A Electrical failure Possible causes Spark plug fouled or in poor condition 2 Weak ignition coil 3 Incorrect contact breaker point gap Breaker points dirty oxidized or burned 4 Excessive contact firing or badly burned contacts due to defective condenser 5 Checking ignition timing Remedies Remove spark plug and ground it to the cylinder fin and crank engine Spark must then flash If spark plug is fouled replace it with the plug of the other cylinder and recheck Defective ignition should be checked carefully with an electrotester Before this test remove spark plug pull ignition cable out of spark plug adapter hold cable at a distance of about 6 mm 0 236 inches from the cylinder fin If no sparks flash between cable and fin the failure may
21. plunger gear with the distributor gear 45 FRAME PE 46 IST WE EENEG 47 Removing Handlebar SEENEN eco ese p e NEE eer hr er erre ks cede 47 LU 201 10 EES 47 Inspection vinsretasanetenagererener que Eae peus pes tuner Goa He T Rire dee re her ae Hane dois oa E het E 47 From DT 48 Operatore eaa e E E a E E O EA A E E A E E E E EE 49 IK LEET EENEG 50 Assembling and Inspection 50 Removing the steering damper renn ene renn e n rre 50 Rear suspension Ae ENEE EE EENS EENS Pra at Construction EE 51 IER at Adjustment of rear suspension 2 2 0 2 0c een e e n rn 32 Wheels 1 eue prRUPEPERECUPPPUPCOeFTP e pU que ME E be do bee NR EE 53 TEEN SEET 53 Checking of Tire Pressure and Balance 33 Front Wheel EE 54 Rear Wheel 2 2k e fos tee Re Re TeDRTSERFG PERSEREKORQTe Re esPEs PYTe fgsbkerPker eQy d r4ereqsseex 55 ELECTRICAL EQUIPMENT 2225355525252935229229225925253532225 9359259359225 52554235925 5352525553 57 A C Generator EES 58 Description 24 606cerete ere bCRRO ROTE EEE EE EE EEE EE OE ERTEN OP EC OF EE RR ERER EN POE ENEN OREA Oe ea 58 Charping current 222 oux peas oer EA RE RPERRURERENERUREREXER REBECERTSRU epee REB erase apes ed 58 Voltage Regulator e 58 Ignition system 66 6 feeb ie a EE EE ELE NL EEE EEE OEE SCORE OT ET EE OE EERE EE EERE REE ERAR ERAR GE bek PE RE eS 59 Contact Breakers Se NEE EELER ere DEEA ESET OTENE RIOT EE EE GC EE EERE EO Ce PE REM 59 Adjusting the game ced
22. reputation because it eliminates the need for finding neutral thus allowing quick starting of the engine In conventional kick starters the kick gear engages with one of the transmission gears But with the primary type kick starter three kick starter gears are installed independently in the transmission gear box Fig 73 Je eege Fig 73 Construction 34 Kick Starter 8 KICK STARTER B Operation B 1 To start 1 The kick shaft and ratchet arm turn counter clockwise as shown in Fig 74 The pressure of the ratchet spring meshes the ratchet with the kick gear Fig 74 2 When the kick starter is operated the ratchet turns the kick gear 3 Since the kick gear is always in mesh with the kick idle gear the l force created by turning the kick shaft is transmitted from the Fig 74 In kicking position kick starter gear B kick starter gear A driven gear and pinion gear to the crankshaft and starts the engine 4 When the kick shaft is released it is returned to its original position by the return spring the ratchet is released automatically from the kick gear and the kick gear rotates freely B 2 In cruising The Ratchet arm is turned counterclockwise by the kick return spring and ratchet and kick gear are held apart Fig 75 C Inspection Fig 75 In cruising position Check for worn or damaged gears kick return spring and ratchet Index No e vm Ah E La Hr ken C
23. sets of contact breakers are installed One contact breaker opens every 180 1 2 turn of cam rotation and high voltage current is induced in the ignition coil Maintenance Contact breaker points should be kept bright and smooth If point surfaces are rough or pitted polish surfaces of both points with a point file If point surfaces are excessively rough or pitted polish lightly and evenly on an oil stone until the surfaces are smooth After polishing wash the point surfaces with gasoline or thinner and wipe dry with a clean cloth B Adjusting the gap T Turn the engine over until the point cam is holding Lett se the point at its widest position Loosen the two lock screws of the breaker and adjust the gap to 0 3 0 4mm 0 012 0 016 inches with a thickness gauge by sliding breaker base slowly Fig 109 Repeat for other points Fig 109 Contact breakers C Checking and Adjusting Ignition Timing Checking Remove the 8x12 hexagonal bolt on the front of the crank case and install timing bolt and pin Same as 175 Connect a continuity light to the points Put the transmission in gear and rotate the rear wheel forward If the continuity light goes out when the timing button snaps into the hole in the crankshaft the ignition timing is correct 58 Ignition Timing Selenium Rectifier Adjustment Timing is adjusted by a point plate that moves both right and left points at the same time The point gap sett
24. 1 Wrench 10 x 12mm 14 x 17mm 19 x 21mm 2 Screw driver amp No 3 No 2 3 Screw driver o 4 Side cutting plier 5 Combination plier 6 T Type wrenches 10 12 14 23mm 2 Special Tools Fig 1 Box wrench bar 28mm nut wrench 40mm ring nut wrench Driven gear stopper Clutch housing puller Clutch housing stopper Clutch hub stopper MPO Lh ROC LA C Removing the Engine Remove left side cover and dual seat 2 Disconnect mainswitch wires and A C Generator wires from the terminals Fig 2 3 Remove both exhaust pipes by pulling out the four bolts Fig 3 4 Disconnect tachometer cable at the end of engine case then remove high tension terminal plug caps from spark plugs Fig 3 Removing exhaust pipes Engine 7 5 Disconnect oil tube C from union connector on oil tank and plug the connector as shown in Fig 4 Take off the rubber cap of the tube valve on the tire and plug it to the union connector 6 Remove carburetor cover R by unscrewing the six screws one 6 x 40 one 6 x 30 three 60 x 20 one 6 x 8 and take off rubber plug then pull out carburetor Fig 5 7 Remove left carburetor following the same procedure as for the right carburetor Remove change pedal and kick arm after taking off footrest L 9 Remove dust cover by unscrewing the three screws and remove the crankcase cover by removing the six screws Fig 6 10 Disconnect chain and lift the front sect
25. 53 0 8258 inches 0 1 0 3 mm 0 004 0 012 inches 24 004 25 009 mm 0 9434 0 9829 inches 16 90mm 0 6288 inches 1 0 mm 0 0393 inches 1 1812 inches 21 053 mm 0 8274 inches 4 2 mm 0 1654 inches 23 98 mm 0 9424 inches 74 Tolerances and Fits Standard Permissible Limit 6 Outside diameter of right 21 99 22 005 mm 21 97 mm crankshaft B 0 8642 0 8648 inches 0 8634 inches mm mm 11 024 inches 1 181 inches 7 Up and down play of crankshaft Less than 0 02 mm 0 15 mm 0 0008 inches 0 0059 inch 8 Thickness of rotary disc valve 3 95 4 00 mm 0 1552 0 1572 inches E Clutch 1 Type Multiple discs seven facings dry type 2 Distortion of clutch friction plate Less than 0 1 mm 0 2 mm 0 0039 inches 0 0078 inches 3 Thickness of friction plate 2 95 3 00 mm 0 1161 0 1181 inches 4 Width of teeth of friction plate 581 5 Distortion of inner plate Less than 0 2 mm 0 0078 inches 6 Distortion of outer plate Less than 0 2 mm 0 0078 inches 7 Free length of clutch spring 30 3 30 9 mm 29 mm 1 1908 1 2144 inches 1 1397 inches F Number of teeth Inspecting width of teeth Inspecting distortion of friction plate of inner plate 1 Drive pinion gear 21 11 3rd gear B 25 2 Driven gear 65 12 4th gear B 23 3 Ist gear A 13 13 5th gear B 23 4 2nd gear A 17 14 6th gear B 22 5 3rd gear A 20 15 Drive sprocket 15 6 4th gear A 23 16 Driven sprocket 36 7 5th gear
26. 6 57 Left engine bracket Right engine bracket Engine cushion rubber B Left engine hanger Right engine hanger 10 plane washer 8 plane washer Hexagon bolt A Hexagon bolt A Spring washer Spring washer Spring washer 10 x 38 hexagon bolt Main switch bracket Spacer A Battery band Battery pad Battery seat OH bb REE br o Kat jai ken e fiak ra H L 45 46 Frame 11 1 Handlebar A Removing Handlebar l B Assembling Assembling is done in the reverse order of removing Loosen clutch cable to the limit of the adjusting nut and remove from clutch lever Remove the adjusting nut of the front brake and pull the cable out of the brake lever Take off the 6 x 45 hexagonal nut of the starter lever Fig 95 Removing headlight rim and remove the starter cable from the lever Unscrew the head light rim fitting screws at the bottom of the rim and disconnect the wiring harness connections from the terminals Fig 95 Take off the four handle holder fitting bolts 8 x 36 and remove the handlebar assembly from the front fork C Inspection 1 Brake lever Clutch lever Adjust clutch and brake levers periodically Front brake lever should be adjusted to allow a play of 15 30mm 3 8 1 1 8 before the brake acts Fig 96 When properly adjusted there will be approximately Se ce 15 20mm 3 8 3 4 free play in the clutch control Fig 97 Adjustment of clutch lever bef
27. A 27 17 Kick gear 22 8 6th gear A 29 18 Kick starter gear A 15 9 Ist gear B 32 19 Kick starter gear B 30 10 2nd gear B 28 20 Oil pump gear B 25 Correct pattern o teeth Re OL Uncorract m Correct G Fork guide 1 Thickness of fork guide H A C Generator amp Ignition coil 1 Rated output of A C Generator 2 Ignition timing 3 Contact breaker point gap 4 Condenser capacity 5 Ignition coil Type Sparks Insulation resistance 6 Spark plug Type Plug gap I Carburetor 1 Type 2 Throttle valve cut away 3 Main jet 4 Jet needle 5 Pilotjet 6 Air screw turn back 7 Float level Tolerances and Fits 75 Standard Permissible Limit 5 35 5 45 mm 5 1 mm 0 2103 0 2142 inches 0 2004 inches Measuring thickness of fork guide 62 Watt 2000 Engine rpm 88 Watt 5000 Engine rpm 98 Watt 8000 Engine rpm 23 26 Before Top Dead Center B T D C 0 3 0 4 mm 0 012 0 016 inches 0 22 0 28 micro Farad uF HS 12B Over 9 mm at 1 500 Engine rpm Over than 500 Meg Ohm MQ B 8H or B 9H 0 5 0 6 mm 0 020 0 024 inches MikuniVM26SC 2 0 mm No 130 4D 3 2 5 No 22 5 2 24 1 0mm 0 98 0 91 inches 76 Tolerances and Fits J Oil pump Standard Permissible Limit 1 Min plunger stroke 0 40 0 45 mm 0 016 0 018inches Plunger stroke is measured 60cc h 68cc h with a dial gauge at 5000 Engine rpm 2 Max plunger stroke 3 6 3 73 mm 0 142 0 147 inches 600cc h 626cc h
28. BRIDGESTONE BRIDGESTONE 350 GIR CFO SERVICE MANUAL FORWARD The ever increasing demand for larger more sophisticated motorcycles is the reason Bridgestone developed the 350GTR the most advanced motorcycle in the industry The increasing knowledgeability of your customers and complexity of their motorcycles make satisfactory maintenance service even more important This manual outlines the most efficient maintenance procedures To give your customers the best possible service have a clean well organized repair shop equipped with all the necessary special tools and keep this manual always at hand for every service man s use BRIDGESTONE TIRE CO LTD MOTORCYCLE SECTION Table of Contents Ie TECHNICAL 5 9 KEEN 1 2 FRONT and SIDE VIEWS of BRIDGESTONE 350 GIRA 3 3 Performance sv 26 54 6 66 GTA BSG 4 J ENGINE EE 6 Removing Engine 2e keleeeceee CORE ER OE MEE HALON EE HH EE EEE EEE EE OEE ONE peor er CPRerT eres exe p eR Creed 6 Notes of Caution ees eee ere eee bbe OT eee be ibe ODORE e ECT P EC HOT e CO EES eI e EY 6 Tools necessary sess bcd ec ere ene heh ROPA PRO eed ode ee OUO P dE OE bee ET IPRC OF EOS OT eU PEE 6 Removing the Engine ENEE ENEE EE rer EEN dende eee ere EE epe Ope E He e Y dd 6 Mounting Engine on Fame 0c eee nee eben ereere rererere 8 Disassembling and Assembling Engine renn eet m e n 9 Special precautions eppoi pea veered gor ca eee eae nied w TRERERTEZERRERUSTIURURERTEPSERTCRETAIBS
29. ECT pue 83 Port Time Atea e555 jose pr rintt A ERU PpYETEPUECTQURUPTE TEE PEUT IV Y EEUU ERRERA KARER EONI RV Ew FRE ques 83 Cylinder Exh st 2 oec IRL RUR pU pU PUPEPUHEPURTPTUPIPEPROTRPEPERIPRUEPDOT PU I Ene RU p 83 Head Pipe iones eee b RR un d heb dekk did EE Y kode de ho Ge be DURS dr deb does de CT ORET OUI ERR DUE EE 83 Squish Band Clearance EENEG 84 ROAY tu EET 84 IS dt TEEN 84 Expansion Chamber ee e ness pe e p ph ERRE EELER EELER REESEN seer we gees 84 1 TECHNICAL DATA Engine 1 Type 2 Piston Displacement 3 Bore amp Stroke 4 Compression Ratio 5 Max Brake Horse Power 6 Max Torque 7 AirIntake System 8 Starting System 9 Charging System 10 Ignition System 11 Ignition Timing 12 Spark Plug 13 Carburetor 14 Engine Lubrication 15 Fuel 16 Transmission Oil Performance 1 Max Speed 2 Climbing Ability 3 Fuel Consumption 4 Min Turning Radius 5 Acceleration Standing Start 1 4 mile Zero to 60 mph 6 Braking Distance Frame and Suspension 1 Frame 2 Front Suspension 3 Rear Suspension Technical Data 2 stroke Dual Cylinders 344 9cc 21 5 cu inches 61 mm x 59 mm 2 40 x 2 32 inches 9 31 1 40 HP 7500 rpm 4 0 kg m 7000 rpm Rotary disc valve Kick Starter A C Generator Contact breaker gap 0 3 0 4 mm 0 012 0 016 inches Battery 25 1 2 degrees before T D C N G K B 8H Electrode g
30. ETPICTPIGEE 9 Dismounting Engine 9 Component parts of crankcase 13 Assembling Engine 14 CRANK SHAFT PISTON ROTARY VALVE ss ss sss eee 17 CRANKSHAFT AND ROTARY DISC VALVES hh e e hh 18 Construction s evereseserernserersearee beer d der bd bb OVEN aar EEEE EOE drar EE EE NEES ea 18 Inspection 2e eceeceteceteter eseee rere hr er HEMEL EEE EEE E EOE ORC OE OE OUO AE EOE EME OE ERRA 18 Lubrication of the crankshaft avavuavvrrv vr nnn nee ren 19 Lubrication of transmission gears 19 CYLINDERS AND PISTONS 20 Construction s ceed oboe EOE EERE OPE EOE ere AE EERE EE ORT OP OE EEE CPU OeOPATERPE EE PE HE ds 20 Notes of Caution ces ele erer ececete EE ere been er CO CERO RE ERER bee d der CERE CY Pr eg en 20 Inspection sve a Re ie BER e eR ORT OO ATO eERCRTOURTOPOTO RC OPETOUCE OPER aar EE HE OPEL HEHE Gu 20 Disassembling ii 6c cee cece eee EE et p RR OEE EEE EE EEN NEEN ENEE AE NEEN EE ENEE AS E 20 CLUTCH W 21 Construction eee esetreerereeseetececeseteceorerecosereeeeoreremesevenprorereeonarees EE SEAN 22 EE 22 Clutch Adjustment 222 g 23 Disassembling Clutch 23 Inspection EERSTEN 24 TRANSMISSION WEEN 25 CONSU ON 6 65 priti r ESIA EER Met EERE A EE EE AE E EE beer REENEN 26 IER 26 Component parts of gear change pedal amp shift dum av eee m 27 Gear shift mechanism 4 6 66 6 teris pt EELER EEE Ore TO E HEHEHE de EE EE OC E EERE ENEE EE EEN d 28 Gear operation and gea
31. H 2 B a E K SEER Fig 88 Oil outlet full throttle Oil Injection System 43 F Adjustment of oil pump control wire Open the throttle grip slightly until the O mark of the throttle valve matches the top center of the air intake of the carburetor At the same time the edge of the control lever of the oil pump should meet the protecting end of the oil pump body Fig 89 1 89 2 e Fig 89 1 Adjustment of oil pump wire Caution Caution the customer not to touch the adjusting er body di throttle gt valve screw because it is adjusted accurately at the factory es The control lever is adjusted by turning the cable adjuster Turning the cable adjuster to the left lifts the lever up farther G Special Attention 1 Assemble the union connectors to the pump body as shown on Fig 90 2 Do not unscrew the union bolts to avoid bending the 6mm aluminum gasket of the union bolts 3 To exhaust air bubbles between the oil tank and the oil tube disconnect the tube from the oil pump and let oil flow freely Then connect the tube to the pump and hold the control lever wide open while running the engine at idle for about one minute Fig 91 4 Be sure to use only check valve bolts to connect oil lines to the crankcase Fig 91 Exhausting air bubbles 44 Frame H Meshing the plunger gear with the distributor gear Fig 92 Mark o Plunger 1 When the oil pump is disassembled be care
32. ION See page 34 Transmission 25 26 Transmission A Construction The 350 GTR has a 6 speed return change transmission Fig 60 61 lS Front pedal tread o Fig 61 Return change transmission B Operation When the gear shift pedal is depressed the shift drum is turned by the arm fixed on the gear change shaft Three shifting forks are fitted to the shift drum and travel along three grooves on the drum when it turns The gear shifting forks move the gears on the countershaft and drive shaft The operating angle of the gear shift pedal is 12 degrees and the gear shift drum turns 51 5 degrees for each gear change Transmission C Component part 18 Cross recd pan head screw 19 Drum stopper gasket 20 Shift fork Change arm complete 1 2 Ratchet spring 2 21 Fork guide M o om SE Dos S s ds 23 Fork guide pin 6 od Nes odd pin 1 24 Fork guide stopper AME esp DE 25 Cross recd pan head screw 7 Shift drum complete 1 e pp 1 26 Drum guide plate Des S E 27 Cross recd pan head screw 9 Drum shifter shaft 1 10 D SE 1 28 12 B snap ring ii Des E em 1 29 12 thrust washer aummun gastel 30 Cross flat head screw 12 Stopper plate l 31 Gear change pedal 13 Brun stopper arm 1 32 Change pedal rubber 14 Drum stopper roller 1 33 Hexagon bolt A 15 Drum stopper boss 1 34 Spring washer 16 Drum stopper spring 1 35 Drum shifter 17 4 x 8 A dowel 1 36 Ratchet LA a Fa Fa Fa ra e Ne NNN
33. Ko nm A U N A C dynamo assembly Contact breaker cam O ring Contact breaker cover gasket Contact breaker cover Contact breaker base Left contact breaker assy Condenser Right contact breaker assy Pan head screw Pan head screw Pan head screw Plane washer B Spring washer 4 plane washer A C Generator Voltage Regulator No QN A U e e e ben ken gt Fe Fe Fe KA 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Hexagon bolt A Plane washer A Timing gear 3x13 woodruff key 6 plane washer External toothed washer Hexagon bolt A Neutral switch case Neutral switch contact plate Neutral switch gasket Cross rec d pan head screw Cross rec d pan head screw Neutral switch wire grommet Spark plug NGK B8HS LA Re RB DR be Fe be Fe be Fe Fa Fe Fe 55 56 A C Generator Voltage Regulator 12 1 A C Generator A Description The generator fitted to the 350 GTR is a six pole magnetic inner rotor type A C dynamo The dynamo consists of a rotor into which magnets are cast and a stator with an iron core and wires wound around the iron core The timing gear is fitted on one end of the rotor and a cam which operates the contact breakers is fitted at the other end A six pole permanent magnet is contained in the center of the rotor Its rated output of 88 watts is produced at an engine speed of 5000 r p m and the peak output of 98 watts at 8000 r p m The rated output therefore is obta
34. Sth gear With the 5 gear B remaining in position 4 gear A slides to the left and the drive dogs on this gear engage with 5 gear A Engine power is transmitted in the following order driven gear clutch countershaft 4 gear A 5 gear A 5 gear B driveshaft and drive sprocket Fig 71 Hx wee wee SE JB ee DEE EE 6th gear With the 6 gear A remaining in position 5 gear B slides to the left and engages with the Drive dogs on 6 gear B Engine power is transmitted in the following order driven gear clutch countershaft 6 gear A 6 gear B 5 gear B driveshaft and drive sprocket Fig 72 F Inspection Fig 72 In 6 gear position 1 Check for worn or damaged gears splines bearings and shafts 2 Inspect shift fork and drum grooves 3 Check for wear on the change arm ratchet and drum shifter spring Kick Starter 33 8 KICK STARTER 6 Kick starterratchet stopper LL 8 Return spring spacer 9 Fick starter shat bushing 2 Kick starter arm ass y G 7 E 20 Ball A Construction A primary kick starter system similar to other Bridgestone models is used on the Bridgestone 350 GTR Since the kick starter does not operate through the clutch the engine can be started even when the transmission gears are engaged by simply pulling in the clutch lever This very convenient system has earned a good
35. ad nut Pinion gear 8 mm Hexagon nut C worm shaft 16mm Hexagon nut Counter shaft Spark plug 8 mm Check valve ass y 16mm Drain plug 17mm Hexagonal nut 10mm Hexagonal nut Tolerances and Fits Kg cm 250 300 100 120 350 400 40 50 60 90 140 200 70 90 150 200 200 250 70 90 35 45 60 90 60 80 400 500 250 300 700 800 150 200 400 500 200 300 60 80 400 500 500 700 200 350 Lbs inch 217 260 86 104 304 345 35 43 52 78 122 174 61 78 130 174 174 217 61 78 30 39 52 78 52 69 347 434 217 260 608 694 130 174 347 434 174 260 52 69 347 434 434 610 174 304 77 Wiring Diagram 78 STH SWITCH NE i NEUTRAL LAMP NEUTRAL SWITCH 12V 3W 9 5TH LAMP Wi HORN ASSY AM L AM I 12V 3W C OU i v too i HEAD LAMP A Y WIRE HARNESS 12V 35 30 W af Bed 5 E E k E d TAIL LAMP JH III 19 e e e peeraa mea mak White om E cc ee 12V 23 7W I K LEK ae d d Ve Ls PR E c Blue E l ER Brown 9 STOP SWITCH R BS Yello p DEA 15 WIRING DIAGRAM E ge D AOUR A U2227 HIGH BEAM LAMP 12V 3W t Black IV ID d Op N C z ds E o rean Stud Nr p Black White 12V6AH Performance Information 16 PERFORMANCE 16 1 Port Timing Exhaust Open Period 89 to 272 Exhaust Open Duration 183 Boost Port Open Period 115 to 250 L Boost Port Ope
36. agon bolt A 4 x 8 A dowel Oil baffle plate Cross recd pan head screw 16 drain plug 16 aluminum gasket See WO bh RB k 0 ki Ln FE EFE n 09090 101 2122 9000 2123 9000 2125 9000 09056 105 09057 102 09511 113 09011 102 0113 0890 0113 0880 0113 0862 09011 106 0113 0662 0411 0818 0411 0613 09056 111 2137 9000 2139 9000 12 oil seal Bearing retainer A Bearing retainer B Bearing retainer C 6 x 10 A dowel 8x 12 x 14 B dowel 8x114 hexagon bolt 8x100 hexagon bolt Hexagon bolt A Hexagon bolt A Hexagon bolt A 6x70 hexagon bolt Hexagon bolt A Plane washer A Plane washer A 5 x 10 A dowel 8 rubber plug 8 plug l2 FN DOONAN ra H ra BRR ra NY WK NY KK 13 14 Engine D Assembling Engine to Fig 33 Fig 36 2 Fitting kick shaft stopper 2 The engine should be assembled in the reverse order of disassembling l 2 E Be careful to set gears and thrust washers correctly Be careful to insert knock pin and knock ring of bearings correctly Grease shafts and gears with heavy oil Caution Be sure both crankcase halves are cleaned properly and no old sealer is left on the mating surfaces Apply liquid sealer evenly and generously to the mating surfaces of both crankcase halves We recommend a Goodyear product Pliobond Hexagonal bolts of the cases should be fitted according Set the over run stopper as shown in Fig 34 35 To fit kick shaft stopper a
37. ap 0 6 mm 0 024 inches Type AMAL VM 26 SC Venturi 26 mm Main Jet No 130 Throttle Valve Cut Away 2 0 Air Jet 2 0 Adjustment of Needle Jet 0 6 Pilot Jet 22 5 Pilot Air Screw Position 2 turns out Needle Position 3 2 cycle oil Regular Gasoline 1 5 liter 2 5 US gal in transmission case SAE No 10W 30 in all seasons or SAE No 30 in summer and SAE No 20 in winter 100 110 mph lin2 94 mpg 25 mph 40 km litre at 40 km h 2 25 m 7 38 feet 13 7 sec 5 2 sec Less than 12m at 50 km h 39 feet at 30 mph Pipe Frame Cradle Type Telescopic Fork with Hydraulic Damper Swinging Arm with Hydraulic Damper 2 Transmission 1 Clutch 2 Transmission 3 Gear Ratio Dimensions and Weight 1 Overall Length 2 Overall Width 3 Overall Height 4 Saddle Height 5 Wheelbase 6 Road Clearance 7 Tire Size Front Rear 8 Tire Pressure Front Rear 9 Caster 10 Trail 11 Banking Angle 12 Net Weight 13 Fuel Tank Capacity 14 Oil Tank Capacity Electrical Equipment 1 Head Light 2 Tail Light 3 Stop Light 4 Speedometer Lamp 5 Tachometer Lamp 6 Neutral Indicator Lamp 7 5th Gear Indicator Lamp 8 Headlight High Beam Lamp Technical Data 9 Battery Manual Multiple discs Dry type Constant mesh 6 speeds Primary Helical Gear 1 3 095 Gear Box p 1 2 46 25 1 1 647 3 1 1 25 44 1 1 00 5 1 0 852 6
38. be due to other causes including ignition coil Correct gap is 0 3 0 4 mm 0 012 0 016 inches Clean both points with a fine file Check capacity of condenser with tester replace it with new one when necessary Correct capacity 0 25 0 3 uF micro Farad Insulation resistance Over 5 MO Meg ohm The main cause of failure is incorrect ignition timing To adjust ignition timing refer to page 57 72 Trouble shooting B Failures in fuel system Engine does not run smoothly at low and middle speeds Possible causes Remedies 1 Clogged fuel line sien ees Check the fuel flow from fuel tank to carburetor 2 Improperly adjusted pilot air screw Correct adjustment is 2 turns out 3 Throttle valves not opening synchronously Adjust both slow adjuster screws and then open the throttle grip slightly until the O mark of throttle valve matches the upper line of ventilator 4 Defective carburetor Air blast all passages and jets and reassemble parts properly Replace gasket with a new one Engine does not run smoothly at high speeds 1 Fuel tank air vent hole plugged Air blast the hole 2 Coggedmamiet nunn Air blast the hole 3 Loosely fitting carburetor to engine Tighten C Mechanical failures 1 Insufficient compression Check the compression Standard 8 5 9 5 kg cm 121 135 Ibs in Permissible Limit 6 3 kg cm 90 Ibs in 2 Damaged rotary disc valve
39. contact rough 3 Condenser bad Bad or irregular sparking Constant satisfactory sparking 4 Bad ignition coil 70 Trouble shooting 13 TROUBLE SHOOTING 13 4 Irregular Revolutions At medium and high speeds Trouble Inspection Investigation Causes of Trouble Bad adjustment Remove fuel pipe to the side of the carburetor and check the flow of gasoline 1 Dirty fuel tank 2 Dirty fuel cock 3 Clogged fuel pipe 4 Clogged tank cap hole Does not flow sufficiently Flow unsatisfactory 5 Insufficient amount of ne ee Check by substituting a gasoline m smaller size main jet e Ma jet tm lig Km Check by substituting jet of larger size a 13 5 Unsatisfactory gear shifting Trouble Causes of Trouble Gears cannot be shifted smoothly 1 Defective gear shift drum 2 Bent shift fork 3 Defective clutch 4 Worn claws of drum shifter Change pedal does not return smoothly 1 Broken change return spring I 2 Drum shifter touching some part 3 Bent change shaft Gears disengage 1 Bent and worn out shift fork 32 Worn out claws of drum shifter 3 Worn out drum stopper Trouble shooting 71 13 6 Common Failures Their Causes and Correction One cylinder goes dead This is generally due to electrical fuel or mechanical failure A Possible causes of electrical failure Spark
40. e stem should be lined up with this mark When this yellow mark is not recognizable mark the position of the tube valve on the tire before removing the tire 3 Balance weights clamped to the spokes should be Fig 105 Balance weights attached to their original position Fig 105 4 To check the wheel balance spin the wheel several times A balanced wheel will stop in any position If the wheel regularly stops in the same position clamp a balancing weight to the top spoke the lightest part in the stopped position Fig 106 Be sure to check the wear and air pressure of tires bent or deformed rims looseness of spokes and wear of shafts or bearings before balancing tire 5 There are two balancing weights of 10 and 30 gram 6 To fit the weights tap them lightly onto the nipples by hand Wheel axle Fig 106 Wheel balancing Front Wheel Index No OMANI Ch Lh E UC LA Front brake drum Front drum collar Collar supporter Front spoke assembly Front wheel rim Front wheel tire Wheel balancing weight A Wheel balancing weight B Front panel complete 48 oil seal Brake shoe complete Brake shoe spring 14 thrust washer Speedometer gear Front brake cam Cam dust seal NN ra BN NR RRR Fei Fe Fa Re Fa ra FA EA Eech Wheels 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Brake arm A Brake arm B Rod end A Rod end B Brake arm rod Front arm return s
41. ectrolyte has dropped add more electrolyte until the proper level is reached 3 Charge at the proper rate as given below until all cells are gassing freely and cell voltage and specific gravity stop rising and remain constant The total charging time will be 10 hours During charging battery temperature should be kept below 45 C 113 F If the temperature exceeds 45 C stop charging for a time until the temperature falls below 45 C Proper charging 0 6 Ampere x 12 hour Quick charging 3 Ampere x 1 hour 12 9 Lights A Head lamp Tail lamp Index No G Ge m A Eh uU E La H ken e e Fe VD 00 10 Lh E GA LA Head lamp body Head lamp grommet Cross oval head screw Head lamp assembly Head lamp rim assy Head lamp lens comp Socket complete Shield rubber Head lamp bulb Quick acting nut Adjuster spring Square nut Adjuster screw Holder screw Socket set ring Split pin Neutral lamp assembly Speedometer bulb High beam lamp assy No Req d 1 NOR EA Fa ND RR RN RRR Fe Fe RK NR H ead lam Tail lam 23 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 Hexagon bolt A Spring washer Tail lamp assembly Tail lamp lens Tail lamp bulb Tail lamp gasket Cross oval head screw Hexagon bolt A Spring washer Hexagon bolt A Hexagon nut A Spring washer External toothed washer Plane washer A Wire harness Wire harness High beam wire Body ea
42. ed ee ete ee e YE EERE ETER ORC OPETOTOE EEE EERE AT VEO OT P RT ea 39 Checking and Adjusting Ignition Timing 59 Selemum Rectifier isc cc tertiis eb oO dE AE aber t CROP er ORO OUR OE OE OIE Ob bt AE dE E AEN 60 Special E e EE 61 Inspection EE 61 RTE 61 Inspection 2 sceecereveteser esesereee49PereRe e RREKO SENET EE EERE OPER OEE AE bb dar Eb de MEE er ea d 61 Ignition con pei eee bbe bee EE EERE EE OS EROFRREUEROTER E CROT EE NE CT BE EE OEE EE TO CC OE e LA 61 inspection sevetecereretererecesebeee 4 ERAT HE EEE EEE EERE Ob EE EERE OE OE AERE CORPORE VO er EE HERS 61 Spark CEET 62 Deseriptton EEN 62 Inspection and Adjustment 62 Table of Contents Inspection of Specific Gravity 63 Storage of dry charged batter 64 Ital Charging Rate s siekcRte b bU EPVUTIPURERUETDPUOTRURREUPUPUHORPUCEPHRRPUPEPTSREUeIXCIPres 64 Head lamp Tail l mp 5 sc z 6 re z pe e pie pYORPERER ER PPOTRFRRETREREEREURTERYRRAURGUENRER NU E ds 65 Speedometer Ignition Coil e Main Switch I e 66 Bulbs oiv ts 64 va Ba eh Gh Ge Pv GW Md Gok wad Ree GG psu GFN EPA qoe Xue ggg rang gorda t gore XR E epus 67 Adjustment of head light beam e me nn 67 EENEG 68 HOL SPES ARNAR Ged Taek te ER TRAKEAL EAA we GARG HRS GWE Gee ES EAS EOE HRD BR TS GEE ER 68 TROUBLE SHOOTING eege RE EELER EELER EE Ee 69 Engin is hard to statt s osessevsseserersrenensenses EEE EE redere EES EEN EERE e E ROOF P E E ea 69 High engine revolution cannot be obta
43. f 0 035 0 005 Soft copper can be used for material with copper gasket sealer during final assembly If the thinnest material available will not bring clearance below A 0 040 then planing and lapping of the head will be necessary Milling may also be required initially to achieve the Milling head proper combustion chamber contour 16 7 Rotary Valve No modification of rotary valves is recommended Stock intake timing is optimal for street use Cutting the disk will result in increased blowback during all but very high rpm causing reduced cylinder charging and enrichening of the fuel air mixture over most of the normal operating range This is due to part of the air stream then actually entering the carburetor twice drawing extra fuel 16 8 Ignition Timing 25 0 2 23 1 for racing Point gap 0 012 Spark plug NGK B 8HV Add a ground strap from the engine to the frame This is typically a braided non insulated ribbon cable with lugs at each end 16 8 Expansion Chamber Intake valve The chamber below will slip fit on the stock headpipe The first segment straight pipe can be made long to start with then cut shorter to move the power peak higher in the rpm band until the desired point is reached The length below should cause power to roll off beyond redline but is sensitive to actual exhaust port height An adjustable slotted mount is recommended to allow tailoring to riding preference
44. f front fork When load is applied to the front fork the load is received by the fork springs At the same time oil in the chamber flows into the oil control chamber The load is held by resistance from the compressed oil and air and the shock is absorbed Oil lock bars dampers are installed inside the bottom of the lower fork tubes to prevent the fork from bottoming when receiving severe shocks When oil moves through the gap between the piston oil hole and the oil lock bar shock is absorbed by resistance of the oil The oil lock bar is tapered so that oil resistance increases as the front fork comes to the end of the stroke When the fork lengthens rebound is damped by oil resistance generated by the oil flow from the oil control chamber through the gap between the oil lock bar and piston ol hole Fig 98 Rear Suspension 49 B Disassembling 1 Putthe cycle on the mainstand and place a supporting block under the engine before disassembling the front fork and front wheel 2 Take off the front fender by loosening four hexagonal bolts 8x12 and then turning the outer tube of the fender Air holes 3 The front fork is removed separately by removing upper bracket bolts and lower bracket bolts C Assembling and Inspection 1 Assembling is done in the reverse order of removing 2 Place the air holes on the rubber boot facing back to prevent dust entering as shown in Fig 99 3 Fill each fork tube with 220cc
45. ful to mesh the plunger Shatt here gear with the distributor gear Because the distributor gear has three oil l passage holes Refer to Fig 84 one hole is for oil intake the others Se for lubrication of both cylinders it is necessary to match the holes of the distributor with the plunger cam slot Fig 2 Disassembled oil pump Worm wheel 1 5 2 mm 2 How to mesh both gears 1 Match the timing pin mark on the distributor gear with the center of the plunger shaft hole Fig 92 2 Insert the plunger shaft by placing the end of the cam over the center of the distributor gear Fig 94 Fig 94 Place the end of the cam over the center of the distributor 11 FRAME Rear fender complete Hexagon bolt A Hexagon bolt A Hexagon nut A Plane washer A Plane washer A Spring washer Rear fender clamp Fender mounting rubber 14 hexagon slotted nut 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Frame 15 plane washer Split pin Front tank cushion rubber Rear tank cushion rubber Tank mounting bolt 18 plane washer Frame handle Hexagon bolt A Plane washer A Cover pad Tank cushion rubber Number plate supporter Supporter pad Hexagon bolt Engine cushion rubber A Engine mounting bolt Rear fender grommet 10 x 145 hexagon bolt Hexagon nut A Hexagon nut D rn rn H H Lu en RP RP Ree RR rs H rn ri 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 5
46. g 41 No timing is necessary HET tase M Sg E a 4 Fig 41 Meshing oil pump gear 16 Engine 15 Be careful when fitting the oil tubes Color Length Remarks Oil tube A Transparent 340 mm 13 4 inches Left check valve Oil tube B Transparent 370 mm 14 6 inches Right check valve Oil tube C Black 530 mm 20 9 inches Oil tank 16 Adjust contact breaker point gap and ignition timing Contact breaker gap 0 3 0 4 mm 0 012 0 016 inches Ignition timing 25 1 2 Ignition timing should be checked carefully Refer to page 57 1301 9000 1321 9000 1325 9000 1331 9000 1337 9000 Crank shaft complete Crank pin Needle bearing Connecting rod 1333 9000 09075 106 1341 9000 1305 9000 1381 9000 Piston ring set Piston pin Engine HA HA LA HA HAHAHAHAHA a NRBR 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 1382 9000 1385 9000 09045 103 09029 104 1412 9000 1413 9000 09056 102 09059 101 1430 9000 09090 118 1441 9000 1423 9000 09066 121 09066 122 0311 0616 Piston pin circlip Drive pinion 20 external toothed 20 left thread nut Rotary valve Valve guide 4x8 A dowel 4 x 18 spring pin Valve cover complete 32 Oil seal Left valve cover Left valve guide 125 O ring 33 O ring Cross recd pan head N e Fe Feat Fe be Fe ra EA Fe ben Fe A N 17 18 Crankshaft pistons cylinders and Rotary Disc Valves
47. gear B 25 thrust washer Drive shaft bushing 2nd gear B bushing 25 oil seal Kick starter gear B 20 B snap ring 20x0 3 Shim Drive sprocket Sprocket set plate Hexagon bolt A Needle bearing spacer a a en ren bn bb be en bo o ben ro on re be on a Ve ww WD 29 30 Transmission E Gear operation and gear ratios 5th 3rd 4th gear A 6th gear 5th gear 2nd gear A 3rd gear A g lst gear A 10 305 N SN PH Ball bearing 6203 Bail bearing etc Oil seal 17 6 xi Counter shaft Clutch rod 6305 N Ball bearing Oi seal 25 Drive mae Needle bearing 6th 5th 4th and rd lU ET Kick starter gear B gear B gear B gear Blgear 8 Ast gear R m ies gear B 6th 4th 2nd ist Transmission Mechanism in Neutral Gear Fig 66 2 Gear ratios Number of teeth ME Gears A Gears Countershaft B Gears Driveshaft Transmission Gear Ratio EE 3 Operation The counter shaft and Ist gear A act as a unit Second gear A and 4th gear A act as a unit and are spline fitted on the countershaft and slide both ways on the countershaft spline 3rd gear A and 5th gear A turn freely on the countershaft 6th gear A is locked with a woodruff key on the countershaft Transmission 31 1 gear B 2 gear B 4 gear B and 6 gear B turn freely on the driveshaft 3 gear B and 5 gear B are spline fitted on the driveshaft Ist gear With the
48. gear is fitted to the clutch housing and clutch friction plates are fitted inside the clutch housing with teeth so that they turn together with the clutch housing and driven gear Clutch friction plates and inner plates are fitted alternately with the inner plates fitted to the clutch hub with teeth The clutch hub friction plates and inner plates all fit inside the clutch housing and are pressed together tightly by the clutch springs The clutch hub is spline fitted to the transmission countershaft which turns the transmission gears Effective Serial No 21 S 01021 After No 21 S 01022 Clutch Friction Plate lee 7 In erPlate 3 eh Eeer D Ee 7 Outer Plate 2595 8 E E none Clutch Spring 2 21 qose yx dr RIP 6 Spring tension seen 100kg 220 Ibs 100kg 220 Ibs Clutch Disengaged When the clutch lever is pulled the clutch wire turns the clutch release arm so that the adjusting screw pushes the dowel 6x10 rod 6x236 and push rod and presses against the clutch pressure plate The clutch springs are then compressed so that they do not hold the clutch friction plates against the inner plates As the friction plates and inner plates separate the inner plates cease to turn so that engine power is cut off from the clutch hub and transmission countershaft Clutch 23 C Clutch Adjustment 1 Adjustment is easily carried out with the cable adjuster and cable adjust screw Fig 51 52 2 Whe
49. he weight of the engine B Notes of Caution 1 Do not use chromium plated piston rings Always use the ferox treated piston rings Cast iron 2 Keep the air cleaner element clean 3 Be careful to set the piston identification mark EX forward Fig 46 C Inspection Measure piston ring gaps as shown in Fig 47 Replace rings with new ones when gaps exceed 1mm 0 04 inches 2 Check cylinder head gasket for damage Replace with a new one if necessary 3 Remove carbon deposit on cylinder ports and cylinder head with cleaning solvent or gasoline 4 Replace the cylinder base packing with a new one D Disassembling 1 The cylinders and pistons can be removed without removing the engine from the frame by removing the dual seat fuel tank horn and ignition coil Fig 48 2 Before removing pistons remove the cylinders and cover the crankcase with a cloth to prevent the piston circlips from entering the crankcase Fig 49 b DA Fig 49 Removing piston pin circlip Clutch 21 PARTS LISTS AND SECTIONAL VIEWS OF THE 3 TYPES OF MODIFIED CLUTCHES ARE SHOWN BELOW FIELD MODIFICATION 1 USING SPECIAL OUTER PLATE 2216 9010 BEFORE SERIAL NO 21501022 09040 112 Plain Washer 2216 9001 Special Outer Plate 2195 9010 Grommet PRESS UTP T PARTNO NAME QTY EN PLATE 2211 9000 Pressure Plate 1 2213 9000 Spring Washer 6 INNER PLATE 2214 9000 Friction Plate 7 2215 9000 Inner Plate 6 erre SET
50. heels about 33 feet 10 meters from the wall and be loaded by the rider Switch on the high beam and set the headlamp so that the beam strikes the center of the cross Switch to the low beam the upper edge of the illuminated area should be about 3 5 inches 9 cm below the cross Adjust as required Fig 118 To adjust beam left and right screw in or out the screw at the left side of the head light rim 9 cm 13 5 inches Dan Le T Ei 2339 m Sep Fig 118 Adjustment of headlight beam 66 Main Switch e Horn 12 10 Main Switch The ignition switch is combined with the lighting and horn switches and divided into four positions and operated as follows Combination Table Battery Ignition Head Tail Horn Stop 5thgear Neutral High Parking coil light light light Indicator beam 1 O O O O O O 2 O O O O O O O O O O 3 O O Position of key 0 For parking Key can be pulled out Entire electric circuit is switched off 1 For daytime driving Engine can be started Key cannot be pulled out and horn stop light neutral lamp 5th gear indicator lamp are in circuit 2 For nighttime driving Headlight tail Key cannot be pulled out light stop light neutral lamp high beam lamp 5th gear indicator lamp speedometer lamp horn are in circuit 3 For parking Parking light is in circuit Key can be pulled out 12 11 Horn Adjust horn volume by screwing the adjusting screw Fig 119 When horn does not work correct
51. ined e Hh e 70 Wnsatisfactory R P M ENEE NEEN NEE EEN OE RELA LREN CREN GE EYE RE EXE de deer EY YE 71 Irregular R volutions ees ob et irit itin er ete e Rr EE Oe EEE EEN EMRE LEONE OBE OO CCO e GR dE E C EA 12 Unsatisfactory gear shifting 1 eritin iKi RER R hh I He mee 72 Common 2222 vv dE cone ae rer ERR RUPPEReRERESERERERMPERPTOPEE bee ARA B Electrical failure eege EE EELER aber dies RREN OAKA CREA been ARER EAKA done ES 73 F ilures in fuel system see ZR ete p p RI RREK USEAN KREE RUN UN KAR EROR ER OREN CAKA NERA OEE EES PE Mechanical failures 2 0 hh e e en 75 TOLERANCES AND FITS ss s s s x s oi cane ed bind win ied sa eb ed aa ee ee ow a ee 76 EE EE 76 E ele 76 LN EE 76 Crankshaft amp Rotary Disc Valve 76 endum 78 Number of EE 78 Fork E EE 79 A C Generator amp Ignition COU 1 vere rv ear hh He Ih ee 79 ET e GEERT EE ed 79 OW DID EE 80 Frame p reeeo ieee E EE EAEE OE A L EE EE EE EE 80 ele EE 80 Lighting equipment oecpeefPeetpUePprTeteUeRe Ce EES fT PIT EE 80 Adjusting Torque 42er e ee ie RR RR TO RIO EEE MEE RTI EE OE OEE ES EVENE TES ERENER ENERE ETETE EE P E Pa doa 81 WIRING DIAGRAM 5 5 54449444444 445 4444 ENEE EELER EE ENEE a 82 PERFORMANCE 52545322252535229222522924594592593235343532324245593534933 SAXSAUESASERSAA ENSE 83 Port Timing 1 222 RR EE bee ege ODIO e p OTPEOCOROer EEEE 83 Port Dimensions enr Re PURI D OPSPDTCTC Re ELINE VRNE PRR pU PRECEPIT PIER HR HH AeA OE PT
52. ined at the following speeds m p h B Charging current The following table shows the engine speed which charges the battery Operation of Engine Speed M P H K M H SR ight ing Day time Upper beam Lower beam 12 2 Voltage Regulator The 350 GTR is equipped with a voltage regulator Fig 107 The charging current generated by A C dynamo is regulated by the voltage regulator and the regulated current is shown below Fig 108 1 EE T EEE ED EEA tOO 1 S A ER TT EE wortage TT NER Sg Sad Ga SSES Fig 108 2 Nighttime driving upper beam 108 1 Daytime driving no lights Contact Breakers Ignition Timing 57 12 3 Ignition system A Contact Breakers 1 Description Two contact breakers are fitted on the A C dynamo The A C dynamo is turned through the pinion gear the driven gear and a timing gear The timing gear turns one complete revolution when the crankshaft turns one full revolution The timing gear and point cam are fixed on the dynamo shaft and turn with it The engine of the 350 GTR is a two stroke twin cylinder engine so two explosions occur every time the crankshaft makes one full revolution Because the speed of the A C dynamo is the same as the crankshaft contact points must supply two sparks for each revolution of the dynamo Therefore two
53. ings are the same as on the Bridgestone 175 012 016 but the generator does not turn for adjusting the timing Use the same timing bolt and pin used on Bridgestone 175 s to locate the firing mark Turn the point plate until Z the right point breaks at the timing mark Check the left Fig 110 Checking ignition timing points which should also now be in time If not turn the point plate approximately half the distance it is off of the timing mark to balance both the left and right sides as close as possible to the two timing marks To equalize for precision timing open the gap slightly on the retarded side to speed it up close the gap slightly on the advanced side to slow it down Caution After adjustment the point gaps must be within the 012 016 inch tolerances Fig 111 Finding ignition timing Note B T D C 232 24 25 267 Piston distance m m 2 82 3 07 3 33 3 60 inches 0 11 0 12 0 13 0 14 12 4 Selenium Rectifier The selenium rectifier converts A C current generated by the generator into D C current and charges the battery Fig 112 113 i Fig 113 Key position 2 Fig 112 Key position I When is positive cycle 2 changes into When is positive cycle or changes into negative cycle and vice versa negative cycle is positive cycle D or negative is positive cycle D or negative Condenser Ignition Coil 59 A Special Attention Take care not
54. ion of chain case by taking out the hexagonal bolt 6 x 48 Fig 7 11 Take out four engine mounting bolts one 8 x 265 one 8 x 145 two 10 x 38 and then remove engine mounting bracket L Fig 8 12 Remove six screws 5 x 25 of air cleaner cover and lift engine from left side Fig 7 Disconnecting chain Fig 8 Unscrewing engine mounting bolts 8 Engine 4 2 Mounting Engine on Frame The engine should be installed in the reverse order of its removal Be careful of the following points 9 2 Seethat the wires work correctly and especially match the marks on the throttle valve and the projecting end of the control lever of the oil pump Fig 10 11 3 Connect electric wires securely Fig 10 Adjusting throttle valve 4 The chain connector should be linked with the open end pointing in the reverse direction of the moving chain Fig 12 Chain adjustment is correct when chain slack is approximately 10mm 3 8 up or down when the rear wheel is on the ground 5 See that the transmission is filled with the proper amount of oil 1 5 litre 2 5 US gal and check the oil level through the peep hole only when the oil has settled in the transmission case Fig 13 6 After starting the engine exhaust air bubbles in the oil tubes A B and C by manually opening the control lever of the oil pump with the engine at idling speed Fig 14 7 Fit carburetor cover R after checking the oil pump
55. ly the trouble may be disconnected wires damaged contact points or a short circuited coil in the horn Improper operation can also be caused by a defective horn switch or a defective horn Trouble shooting 67 13 TROUBLE SHOOTING 13 1 Engine is hard to start Trouble Inspection Investigation Causes of trouble ISI E Gasoline flowing into carburetor r 1 No gasoline in tank SC z di je 2 Fuel pipe clogged between tank and carburetor Gasoline filled Clogged gasoline strainer Disconnect plug Check for spark between Clogged hole of tank cap ignition wire and cylinder head by kicking pedal Bad plug Plug very dirty Contact points dirty Sparks BM S Unsatistactory adjustment of d point clearance Kick and check compression Bad condenser iMeasure with compression gauge Disconnected or short citcuited ignition coil Weak or no compression 7 Disconnected or short circuited ignition coil B Unsatisfactory adjustment of 1 ignition timing 1 Good compression Repeat starting procedure Ka Gas leakage at cylinder gasket 2 Plug insufficiently tightened 3 Stiff ring Does not Sign of 4 Cylinder ring worn start although explosion DM ee there is sign of explosion l 1 Open throttle grip when starter lever is pulled Steg ee e Remove plug once more 2 Air screw of carburet
56. n Duration 135 Transfer Port Open Period 120 to 245 Transfer 2 Transfer Port Open Duration 125 Rotary Valve Open Period 242 to 62 Rotary Valve Open Duration 180 Connecting Rod length 4 9 16 Piston Crown Height 1 5 16 2 Port Dimensions Exhaust W 1 4 H 1 06 Distance from top of cylinder 1 3 to 2 36 Mean Area 150mm Transfer W 1 12 H 0 5 Distance from top of cylinder 1 88 to 2 4 Mean Area 56mm x 2 Boost W 1 08 H 0 76 Distance from top of cylinder 1 82 to 2 58 Mean Area 64mm 16 3 Port Time Area Ec Exhaust 3 4E 4 sec cm cm Transfer 8 67E 5 sec cm cm Boost 1 07E 4 sec cm cm 16 4 Cylinder Exhaust Tract Length 2 25 center Actual size 16 5 Head Pipe Length 12 75 inside 14 625 center 16 5 outside 80 Performance Information 16 6 Squish Band Clearance 0 035 0 005 Squish band not to scale Measure by setting four pieces of solder into grease radially at each diagonal edge of the piston with the piston about a half inch before TDC Bolt the head into place torqued properly with the head gasket installed and rotate the engine past TDC Remove the head and measure the thickness of the solder noting where each piece came from If the four pieces in a cylinder do not measure the same thickness it indicates the head is not properly centered on the cylinder Adjust the head gasket material thickness to achieve the desired squish band clearance o
57. n satisfactory adjustment cannot be made in this way remove rubber cap from left crankcase cover loosen locknut and adjust by holding the lock nut and turning adjustment screw The play of the lever is lessened by turning the screw right and increased by turning left Fig 53 D Disassembling Clutch Remove carburetor cover by unscrewing the six screws in the right carburetor cover one 60x40 one 60x30 three Fig 52 Clutch cable adjust screw 6x20 and one 6x8 screws 2 Remove clutch springs and clutch facings and related parts by removing diagonally and evenly the hexagonal bolts of the clutch set plate Fig 54 3 Remove clutch hub nut 23mm with clutch hub stopper special tool Fig 55 Fig 55 Re x moving clutch hub 24 Clutch 6 CLUTCH 4 Remove the ring nut with the clutch housing stopper and ring nut fitting tool special tools and then remove the clutch housing Fig 56 57 Fig 56 Removing ring nut with clutch housing stopper Fig 57 Removing ring nut with ring nut fitting E Inspection el 1 See if there is any damage such as serrations on the inner plate and worn or uneven plates 2 Check for damaged worn or uneven arms on friction plates Fig 58 59 3 Check release arm release screw release push screw dowel and rod for wear Replace where necessary Fig 58 Checking friction plate E mmm Fig 59 Checking friction plate 7 TRANSMISS
58. or opened too wide D Plug is wet Kick once more after pulling starter lever 3 Air taken in from carburetor adapter Plug is dry me 1 Carburetor overflowing Fuel spark and compression are basic points for engine operation To locate engine trouble first check these points 68 Trouble shooting 13 2 High engine revolution cannot be obtained Insufficient power Trouble Turns lightly Correct Air pressure Engine speed drops when clutch is released Increase speed Speed does not m increase sufficiently Ignition timing correct Not clogged Not dirty or discolored Correct amount of oil Inspection Investigation Raise front and rear wheel i and turn by hand Turns stiffly ELLE SEET Check tire pressure Geet Speed drops for a short period even when clutch is released ecce wem up the engine SES Check ignition timing e tim h ET Use timing light EM timing TUE a if carburetor is clogged C C Clogged m e m a mae eos Remove plug and check Dirty and discolored Remove oil cap of transmission case for amount and condition p w nm Ka Causes of trouble Unsatisfactory brake adjustment Damaged wheel bearings Needs bearing gteasing Drive chain too tight Resistance on road surface tuo great Slips due to unsatisfactory clutch
59. ore the clutch disengages Fig 97 Check for damaged or cracked wires in the grip holders dimmer switch and horn switch and replace if necessary 11 2 Front Fork Index No GO JA Ch tn E LQ LA ra Front fork assembly Outer tube B Outer tube A 8 x 26 hexagon bolt 4 x 7 cross pan head screw Drain plug gasket Outer tube nut 34 oil seal 40 O ring Cushion slide metal Inner tube A Upper bridge bolt 9 O ring Upper bridge washer Front main cushion spring Dust seal Main spring seat Front fork boot Upper boot holder Fork cover guide Lower bridge 10 x 32 hexagon bolt HLA AAA HA LA HA HAHAHAHA HAHA HAHAHAH rar Front Fork 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Upper bridge Handle holder Hexagon bolt C Plane washer B Steering head nut Steering head washer Left fork cover Right fork cover Cable clip Spring washer Cross rec d pan head screw Steering damper knob Damper knob guide Damper lock spring Steering damper spring Damper spring guide Friction plate Damper facing Damper guide plate 6x18 hexagon bolt Split pin ka N e ben ke bet Fe Fe bet Fei ben be Fe Fe Fa Fe Fa EG E ON 47 Front Fork A Operation Inner tube Front tork boot Main Spring 32 Oil seal Outer tube nuts Oi contro chamber 9 Qil hole Cushion slide metal Outer tube A Compression stroke Fig 98 Operation o
60. park gap should be 0 5 0 6mm 0 020 0 024 inches B Inspection and Adjustment e d Poimgep E T 0 5 0 mm Q 024 0 027 Check the spark plug every 3 000km 2 000 miles Fig 116 Spark plug When the electrode becomes worn or coated with carbon clean or replace it A worn or dirty plug produces weak sparks or none and causes hard starting low output irregular engine power etc When too cold a plug is used Oil will foul the electrode or heavy carbon deposits will form Change to a hotter type plug Lower number 2 When a correct plug is used The plug remains nearly white or light brown sometimes greyish deposits form 3 When too hot a plug is used Absence of deposits bleached appearance of the insulator and sometimes blisters indicate too hot a plug is being used Change to a colder plug Higher number 4 Seechart below for plugs recommended BRAND STANDARD IF PLUG FOULS EASILY IF PLUG OVERHEATS EASILY Slow Speed High Speed BOSCH W310T16 W240T W340T16 LODGE R47 3HN R49 Battery 61 12 8 Battery The capacity of the battery is 12V 6AH The battery should be checked periodically Check the level of the electrolyte and the specific gravity Specific gravity of the solution should be 1 260 1 280 at 20 centigrade 68 F when the battery is fully charged A Inspection of Specific Gravity The condition of the battery can be determined by measuring the specific gravity of the electrol
61. pring Brake arm pin 14 A snap ring 5 D snap ring Hexagon bolt A Hexagon nut A Plane washer A Hexagon nut C Front torque link Front link bolt Internal toothed washer Front wheel axle Front axle collar 14 slotted hexagon nut 14 plane washer Split pin e e e ee e e N FA FA FA EA EA e RR e e 53 54 Rear Wheel CG SS vw o A eh E ut LA N H ra Fa Fa Fa Fa Fa Fa Fa HA ro OO GJ Ch Lh E Ut LA Rear brake drum Rear drum collar Driven sprocket 10x35 hexagon bolt Hexagon nut C Spring washer 78 B snap ring Front spoke assembly Front wheel rim Rear wheel tire Wheel tube Tire flap Wheel balancing weight A Wheel balancing weight B Rear panel complete Brake shoe complete N be Fe Fe bei Fe ran Ch Ch Ch ben O be Fe Fe ben Fe Wheels 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 Brake shoe spring 14 thrust washer Rear brake cam Cam dust seal Brake arm C Rear arm return spring 14 A snap ring Hexagon bolt A Spring washer Rear torque link Rear link bolt Latch clip Hexagon nut A Plane washer A Spring washer Rear wheel axle Rear axle collar Oil seal collar 14 slotted hexagon nut 14 plane washer Split pin Roller chain assembly Chain joint complete e bet bet ben ben ben Fe ben Fe bei Fei Fei Fa Fa FA Fe SG FA 12 ELECTRICAL EQUIPMENT Dynamo and neutral switch G Gw e A Oh E LM Hr
62. r ratios varer rear hh eh he e e Al Inspection P eee Be EEE EEE EE EEE EEE EERE EEE EE EEE EEEEE EEE EEEEEEEEEEEE EEE E EERE LER EEERE EERE REEL HELE OS 33 KICK STARTER 5452242232252352352225323922293229225325552323535535939 455933555355 38923258424 2325 34 COnStr ctlOf ssneeseseteterereebeetececeveteeeorer chsereeeeoreremesevenrprerereeonerevesevec vereoee een 34 EE 35 Inspection EE 35 CARBURETORS 5 422122255532935399229478231235224 EE 8488 ERR AUR CURA EROR bebe 37 Synchronizing Carburetors 37 Indication of trouble at various engine speeds 37 Table of Contents Idling Adjustment de p e het ov be RH EE EE OA EES SERA ke TOT CU ee eee 37 Medium Engine Speed Adjustment 38 High Engine Speed Adjustment seseeeeeeeeeeeeee ee hh he mee 38 Adjustment of Carburetor Float Level 39 Trouble Shooting of Gasoline Leaks from Carburetor a9 OIL INJECTION SYSTEM 2452255355335358393322333533952253 4892352 335 amp 21099352 23952A935923 492 2 52454 37 40 Operation pee 24 pe aeons MPXTQEETERTERCRURERTPXTUPUSDEERURERUERNPREREPRCORTRESTRUPRE bee eee Gees Ree ee 41 IRC 42 Oil Outlet EE 42 Distribution of oil to both cylinders 42 Operation of worm wheel plunger in relation to the throttle ep 43 Engine Idling at slow speed e n eran 43 High Speed wide open rot 43 Adjustment of oil pump control Wire 44 Special Attention 0 R 9 9 9 e cee R 99 it R LELENE RREA RRR R ERKA LEYA RRR RRR RRR RR EY Ex 44 Meshing the
63. rth wire Cover tube ka ra Fa ra ra GO LA FA LM A L L LA ra ra ra ra NEN 6 3 64 Speedometer e Ignition Coil e Main Switch i B Speedometer Ignition Coil Main Switch Index No No Req d 18 Spring washer 4 1 Speedometer assembly 1 19 Main switch assy 1 2 Speedometer bulb 3 20 Stop switch complete 1 3 Tachometer assembly 1 21 Stop switch spring 1 4 Left meter holder 1 22 Batter y 1 5 Right meter holder 1 23 Rectifier assembly 1 6 Speedometer washer 2 24 Pan head screw 5 H Speedometer set spring 2 25 Plane washer A 5 8 Meter cushion rubber 2 26 Plane washer A 2 9 4 27 Spring washer 5 10 4 28 Spring washer 1 11 1 29 Hexagon nut C 1 12 2 30 Regulator assembly 1 13 Spring washer 2 31 Hexagon bolt A 2 14 Left ignition coil assy 1 32 Spring washer 9 15 Right ignition coil assy 1 33 Fuse assembly 1 16 Plug cap complete 2 34 Fuse 2 17 Hexagon bolt A 4 C Bulbs Lamps Wattage Head lamp 12V 35 30W Speedometer lamp 12V 3W Tachometer lamp 12V 3W Neutral Indicator lamp 12V 3W D Adjustment of head light beam Lights Lamps Wattage 5th Gear Indicator lamp 12V 3W Headlight Beam lamp 12V 3W Tail lamp 12V 7W Stop lamp 12V 23W 65 The headlight setting for high and low beams is important This should be kept in proper adjustment For this purpose a cross should be drawn on a light colored wall at the same height as the center of headlamp The motorcycle should stand on its w
64. ssemble upper and lower crank case covers first and fit kick pedal temporarily to the kick shaft by cranking the engine Fig 36 1 2 3 Position of kick shaft stopper MIDP Gfittne Rick sh ttistopped ve l LE rachel position Li p ka e 4 R 7 Le y e KC shaft stopper A Z lt Fig 36 3 Fitting kick shaft stopper 3 amp change ratchets ks 4 me 4 MEN e K e ES Adjusting Pay Pressure plate Noni DESSE Pressure plate Clutch Hub _ Fig 40 Matching the 4mm hole Engine 15 8 Fit kick ratchet and change ratchets as shown in Fig 37 Set the gears in neutral when fitting the ratchets 9 Match the key position of rotary valve collar with the mark on the rotary valve Fig 38 10 Set the timing marks on the timing gear driven gear and pinion gear as shown in Fig 39 11 Be careful in assembling clutch inner plates and clutch outer plate as they are of different thicknesses The outer plate 3mm thick should be installed first Effective Serial No After Serial No Upto 21801021 21 S 01022 thickness Q ty thickness Q ty Inner plate 1 6mm 6 1 6 mm H Outer plate 3 0mm 1 none 12 Grease the top of the push rod when assembling 13 Match the mark on the clutch hub with the 4mm hole on the pressure plate when assembling clutch pressure plate Fig 40 14 Mesh the oil pump gear with pinion gear by turning the worm shaft outside of right crankcase Fi
65. stment 0 1 8 Throttle opening 1 When the engine stops at engine idling speed control the engine speed with the throttle grip and turn the idle speed adjuster on both carburetors until the engine runs smoothly Fig 77 2 Turn the pilot air screws on the carburetors alternately Both screws must be turned an equal amount Set the screws at the point where the engine runs the most smoothly Fig 77 Idling adjustment When the pilot air screw is turned clockwise the gasoline air mixture becomes richer and when it is turned counterclockwise the mixture becomes leaner Correct adjustment is approximately 2 turns out Fig 78 Fig 78 Pilot air screw adjustment Carburetors 37 3 To set the pilot air screw a fairly satisfactory method is to detach one spark plug and set the air screw on the carburetor of the other cylinder Reverse the process for the other cylinder If when both spark plugs are reconnected the engine runs slightly faster than desired a slight readjustment of the throttle screw will put this right 4 Trouble shooting Possible causes Remedies 1 Pilot air hole or breather hole of pilot jet is Clean and blow these holes plugged 2 Loose pilot jet Set pilot jet securely 3 Starter plunger does not close when starter Adjust starter cable to set plunger completely closed lever is closed 4 Improper pilot air screw adjustment Adjust the air screw Correct adjustment is 2 turns out D Medium
66. t carburetor remove float chamber and hold mixing body upside down so the float arm is resting on the float needle valve Measure the float adjustment as shown From gasket seat to top of float Correct float setting is 15 16 1 Adjustment is made by carefully bending the float valve tab G Trouble Shooting of Gasoline Leaks from Carburetor Possible causes Gas leaks from carburetor Gas overflows at any time even cruising or stopping Gas leakage occasionally Main causes of trouble Inadequate contact between needle valve and valve seat Punctured or deformed float 1 Operation of float or needle spring is not correct 2 Clogged needle valve and valve seat with dirt Remedies Replace needle valve and valve seat with a new one Replace the float with a new one Adjust float or replace needle valve with a new one Clean needle valve or valve seat Clean fuel cock bowl Oil Injection System 10 OIL INJECTION SYSTEM 17 Component parts of oil injection system Index No 1 Oil pump assembly 1 2 Check valve assembly 2 3 Union connection C 2 4 8 Aluminum gasket 4 5 Worm shaft bush B 1 6 1 7 1 8 3 x 24 A dowel 1 9 External toothed washer 1 10 1 11 1 12 1 13 1 14 Oil tube grommet 1 15 Cross recd pan head screw 2 16 Wire bracket 1 17 Cross recd pan head screw 2 39 A0 Oil Injection System On the 350 GTR the oil injection mechanism which eliminates the necessity of pre mixing
67. to wet the rectifier when washing the motorcycle or run the engine without the rectifier connected B Inspection 1 Inspection is carried out easily by flowing 12 volt current in the reverse OE direction as shown in Fig 114 If the bulb lights in the circuit the rectifier is defective K 2 Insulation resistance should be more than 10Meg ohm with a 500V 3W Bulb tester Rectifier Fig 114 Inspection of rectifier 12 5 Condenser A Inspection Condenser EEN The capacity and insulation resistance of the condenser should be checked with an electric tester but it can also be checked easily in the following manner Pass the current to the condenser by connecting the wire of the battery and then ground the condenser wire Grounding Fig 115 Inspection of condenser If there is a sharp spark between the wire and the ground the condenser is in good condition Fig 115 Condenser capacity 0 2 0 3 uF Insulation resistance more than SMQ 12 6 Ignition coil inspection The ignition coil requires no maintenance When testing the ignition coil perform with an electro tester If the spark jumps 9mm or more the coil is in good condition Checking Standard figure Sparking Over 9mm at 1500 rpm Insulate resistance 500 MQ Resistance of secondary coil 1 MQ 60 Spark Plug 12 7 Spark plug A Description The standard spark plug used is N G K B 8H whose sectional structure is shown in Fig 116 The s
68. yte solution If the gravity is below 1 220 the battery should be charged without delay Specific gravity at 20 C 68 F Amount of charge Solution Temperature 1 260 10096 1 220 75 1 160 50 1 105 25 1 050 None Caution Take care of the following points when checking the specific gravity 1 Do not let the hydrometer float touch the side of wall 2 Read the hydrometer at A upper level of contact instead of B lower level as shown in Fig 117 3 As specific gravity varies according to the temperature of the solution apply the following conversion table based on standard 20 C 68 F for the different temperatures wal Float A correct B incorrect Fig 117 Hydrometer 62 Battery Relation between specific gravity and temperature of solution 0 C 5 C 10 C 15 C 20 C 25 C 30 C 35 C 40 C 45 C 30 F 42 F 50 F 59 F 68 F 71 F 86 F 95 F 104 F 113 F B Storage of dry charged battery Dry charged batteries if stored in a relatively dry place will remain in good condition for a considerable period but if the cells absorb moisture during storage the negative plates will discharge slowly and the charging rate will be longer as shown in the following table Storage period Decreased Capacity Charging Rate 0 100 0 6Ampere x 10Hour C Initial Charging Rate 1 Fill the battery with sulfuric acid 2 Wait from 2 to 12 hours after filling before charging When the level of el

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