United States. War Department

“ High Speed Tips. Only experienced riders should indulge in high‐speed riding. A motorcycle operated for long distances at high speed must be given closer than ordinary attention to avoid serious engine overheating with consequent damage. For better motorcycle service, apply the following suggestions:
(1) Develop habit of frequently snapping throttle shut for an instant when running at high speed. This draws additional lubrication to piston and cylinder and assists in cooling engine. ”

“ While vehicle is in motion, listen for any sounds such as rattles, knocks, squeals, or hums that may indicate trouble. Be alert to detect any odor of overheated components or units such as generator, brakes, or clutch, fuel vapor from a leak in fuel system, exhaust gas, or other signs of trouble. ”

“ When installing generator, the important point to consider is correct shimming of generator in its cradle to provide correct mesh of driving gear with intermediate timing gear. Make sure same number of paper shims are used in reassembling as were found underneath generator when it was removed. After an engine has been run a considerable length of time and gears have worn to some extent, they have possibly developed sufficient lash or play to safely remove one or more of the original shims, and thus affect closer meshing and quieter operation. ”

“ If light fails to go out after engine is warm, or after 1 minute of operation, further checks must be made to locate trouble, as indication points to faulty engine lubrication system, or fault in signal circuit. Eliminate the signal system first.
(2) Test oil pressure signal switch to panel signal light circuit. Remove wire from oil pressure switch terminal by turning on ignition and light switch and observing red signal light. If light burns, short circuit in wiring exists. If light does not burn, it indicates normal condition, leaving oil pressure switch of the signal circuit to be tested. ”

“ Start engine as follows: After choke lever has been moved to normal open running position and engine is normally hot, correct adjustment of needle valve by turning needle valve down (to right) one notch at a time until mixture becomes so lean that engine misses, and is inclined to stop: then back out (to left) needle valve 5 to 10 notches, or until engine fires regularly with spark advanced and throttle closed (or as nearly closed as it can be set and still have engine running at idling speed) . ”

“ A correctly adjusted front chain has 1⁄2–inch, or slightly more, free up‐and‐down movement midway between sprockets, at inspection hole. Chain must never be run taut (no slack at tightest point) . Chain must never be allowed to run loose enough to cause jerky, noisy action and/or strike the chain guard.
d. Adjustment of front chain is made by shifting transmission on its mounting base. This will affect adjustment of gear shifter control linkage, clutch control linkage, and rear chain. ”

“ When starting and warming up in cold weather, considerable vapor getting into crankcase condenses to water before crankcase is hot enough to exhaust the vapor, without inside condensation, through outside breather. If engine is driven enough to get crankcase thoroughly warmed up frequently, most of this water is again vaporized33 and blown out through outside breather. However, a moderately driven engine, making only short runs now and then, and seldom thoroughly warmed up, is likely to accumulate an increasing amount of water in oil tank. ”

“ If motorcycle is run unusually long distances, inspect more frequently. Motorcycle must be on rear stand in straight upright position when checking oil level or filling transmission case. Use same grade of oil used in engine, summer, and winter. If gear shifting difficulty is caused by oil congealing in extremely cold weather, thin oil with small amount of kerosene or dry‐cleaning solvent. Every 1,000 miles, drain and refill transmission to level of transmission filler plug opening with specified grade of engine oil. ”

“ When switch is turned on, immediately after engine has been primed by cranking, red (oil pressure) signal light may not light at once, but will light after a few seconds, due to oil pressure built up by cranking, and is most likely to be noticed in cold weather. ”

“ All brake, transmission, and clutch control points not fitted with grease connections should be lubricated with engine oil. Front brake control cable, spark, and throttle control wires must be oiled at the ends of their respective housings, especially after washing vehicle, or after operating it in wet weather. Keep battery terminal felt washers saturated with engine oil to prevent corrosion of connections. ”

“ If clutch adjustment is correctly maintained, clutch will cause very little trouble. Ease of gear shifting and service life of transmission gear shifter clutch dogs depend largely upon full disengagement of the clutch. Clutch adjustment is in two parts; namely, control linkage and spring tension. Do not adjust clutch spring tension before correcting control adjustment.
b. Clutch Control Linkage (fig. 22) . Operation of foot pedal, control cable, and clutch release lever actuates the push rod through hollow transmission shaft, disengaging or engaging clutch at will. ”

“ If engine has been shut off for only a brief period and is near normal operating temperature, it is not necessary to use carburetor choke lever. With some engines, depending upon carburetor condition and adjustment, hot starting is easier and more dependable if foot starter crank is operated one stroke before turning ignition switch on. ”

“ If the battery runs down again after a short period of operation, have the generator output increased (refer to a higher echelon) .
c. Lights Exceed Normal Brilliancy When Accelerating Engine. Examine battery: if defective, replace (par. 113) . Remedy faulty wiring and connections (fig. 73) . Do not forget the ground connection of the lamp body.
d. Blackout Stop Lamp and/or Service Stop Lamp Fail to Light. If the unit is burned out, replace it (par. 115) . If the brake pedal is not operating switch, remedy the faulty operation. Remedy all faulty wiring and connections (fig. 73) . ”

“ If standing on an incline or in loose, heavy ground, more engine power will be required to start vehicle without stalling engine.
(2) It may be necessary to keep vehicle from rolling by keeping pressure on front brake hand lever. Brake pressure is released after vehicle starts in forward motion.
(3) Open throttle and engage clutch at same time to provide power needed for starting, without racing engine unnecessarily.
(4) Motorcycle starts should be made without excessive application of power, with consequent unnecessary spinning of rear wheel. ”

“ Length of control cable must be adjusted to obtain 1⁄16–inch clutch release lever and sprocket cover stud and/or nut clearance. To lengthen or shorten clutch control cable, cable adjustable end must be removed from foot pedal stud (figs. 23 and 24) . With foot pedal in forward (toe down) position, remove cotter pin and washer retaining cable end. Release other end of cable from notch in clutch release lever by pressing release lever inward and lifting cable end out of notch. Rock the foot pedal to rear (heel down) position and work cable adjustable end off foot pedal stud. ”

“ Both front and rear chains are automatically lubricated by engine oil pumps. Chain oilers are adjustable and may need occasional readjustment to meet lubrication requirements of varied operating conditions. Chains under most operating conditions require a very small amount of oil; therefore, chain oilers require very fine adjustment to supply just enough oil without waste. ”

“ Practice will enable a rider to judge at what rate of speed the motorcycle should be moving before he shifts from a lower to higher17 gear, and engine should never be permitted to labor unduly, when a shift of gears, higher to lower, would improve operation.
(1) Operator must not look down at gear shifter when shifting gears, but keep his eyes on the road ahead. Do not ride the clutch. The operator’s foot should rest on clutch foot pedal only when he is operating it. When shifting gears, disengage clutch fully to avoid gear damage and shifting difficulties. ”

“ Test steering head bearing adjustment by exerting strong upward pull at handle bar grips, and observing whether or not there is any noticeable play in bearing. Operate steering damper lever and observe that damper is compressed before lever reaches right‐side position, and is fully released with lever in left‐side position. Test handle bar grip controls for full, free action; also test for complete opening and closing of throttle, and full advance and retard of timer. ”

“ Before attempting to adjust carburetor to correct faulty engine performance, attention should be given other items which have a direct bearing on and can affect carburetor adjustment as well as engine performance. ”

“ Spark and Throttle Control Grips. These grips require disassembly. Twice a year, or whenever grips do not turn freely, indicating need of lubrication, remove grips, clean parts, apply grease, and reassemble (par. 101) .
(5) Air Cleaner. Examine oil cup daily for excessive dirt and correct oil level. Under extremely dusty or sandy conditions it may be necessary to clean and refill the air cleaner more than once daily. Refill oil cup to indicated level with engine oil. Drain, clean, and refill oil cup every 250 miles, depending upon operating conditions. ”

“ Auxiliary front wheel brake, when used in conjunction with service brake, must be applied with caution, especially on wet, muddy, or slippery roads.
(2) After passing through water, the brakes should be set slightly, and the vehicle operated for a short distance, until sufficient heat has been generated to dry the brakes.
c. Avoid Low Gear Operation. Always operate vehicle in highest gear possible, consistent with tactical situation, speed required, power required, and kind and nature of road substance, to prevent overheating of engine. ”

“ To insure mechanical efficiency it is necessary that the vehicle be systematically inspected at intervals each day it is operated and weekly, so that defects may be discovered and corrected before they result in serious damage or failure. ”

“ Light is located on left side of light mounting bracket. Top unit is used for service stop and taillight (double filament lamp) . Taillight filament is controlled by ignition and light switch; stop lamp filament is controlled by brake‐operated stop light switch. Stop light does not operate in daytime when ignition only is turned on. Bottom unit serves as a spare blackout taillight. ”

“ Connect spark control wire to circuit breaker lever and secure control wire housing clamp under cylinder base nut. Make sure that spark advances fully (lever inward) when control grip (left handle bar) is turned inward, and that spark retards fully when control grip is turned outward. Make needed adjustment at control wire and lever connection.
(18) Remove nipple cap from tank oil pipe nipple (if one was used) and connect oil feed pipe, securely tightening union nuts at tank and oil pump.
(19) Position exhaust pipe and muffler assembly and attach rear hanger frame bolt, washer, and nut. ”

“ No clearance or insufficient clearance at valve tappets; valves sticking in guides; valves seating poorly; cylinder heads leaking; spark plugs loose in heads; piston rings badly worn and/or broken; cylinder and pistons badly worn, or lack of lubrication could cause the above condition. Make external checks first: See that oil is in tank, that spark plugs are tight, and examine around cylinder heads for signs of leaking oil deposits. In extremely cold weather, resistance to the starter crank is increased by “stiff” oil in engine and transmission. ”

“ When the circuit breaker timer shaft and base assembly must be replaced due to excessive wear in timer shaft bearing, sheared worm gear pin, and/or worn or damaged worm gear, engine ignition must be retimed. Ignition timing for the V‐type twin engine is difficult and should be attempted only by experienced personnel. ”

“ Exhaust System. The exhaust system consists of muffler and tailpiece assembly, front exhaust pipe assembly, and rear exhaust pipe. Exhaust pipe ends are a slip fit in cylinder exhaust ports.
76. AIR CLEANER (figs. 46 and 47) . a. General. Air cleaner should not be submerged in water, nor should high‐pressure stream be directed into cleaner louvers (where air enters on rear of body) when cleaning vehicle. Either water or dirt entering air cleaner in excessive quantities will raise the oil level in oil cup and choke off proper air supply to carburetor. ”

“ The foot starter crank is located on right side of motorcycle. Gear shifter lever must be in neutral position, and clutch foot pedal in forward engaged position, before using foot starter crank. Starter crank normally is in upward position. Straddle motorcycle, place right foot on starter crank, and shift weight of body for forceful downward crank operation to start engine. ”

“ To remove rear brake rod, disconnect clevis from brake lever, and free front end of rod at brake shaft bell crank.
(3) Remove rear chain guard (par. 102) .
(4) Remove tool box and bracket in one piece (par. 106) .
(5) Remove nut and bolt securing left side lower battery box mounting to mudguard bracket. Remove nut and bolt securing battery front mounting to frame saddle post tube bracket.
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(6) Remove the two nuts securing rear safety guard center connection to mounting studs. Unscrew mounting studs to free the plate nut which clamps the battery box bracket to frame cross member. ”

“ Even though all ignition timing marks are in perfect alinement, as when engine was originally timed, ignition timing may change somewhat after engine has been in service for a while, due to normal wear and seating of the various moving parts that can affect ignition timing. ”

“ This 2‐cylinder solo motorcycle is powered by a V‐type, air‐cooled gasoline engine, operating on conventional 4‐stroke, 4‐cycle principles. Air‐cooled engines rely upon movement of air over cylinder and head radiating fins, and upon circulation of oil for dissipation of excessive heat. Motorcycle engines, therefore, under no conditions should be operated for more than 1 minute when motorcycle is not in motion. ”

“ Pass generator drive gear end through gear case hole, lifting generator so that oil slinger clears intermediate timing gear. Turn generator in its cradle so that end holes line up with long mounting screws which pass through gear case cover. Tighten mounting screws securely.
(2) Install curved washer, lock washer, and nut on end of clamp strap; tighten nut securely.
(3) Connect red‐black wire to generator terminal marked RELAY, and green wire to generator terminal marked SWITCH. Refer to wiring diagram (fig. 55) . ”