BMW - Isetta - Owners Manual - 1961 - 1961

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Cbco;k ~ICo ••.huM tin;i~Gok ...... ,.aLe, .. - ~ ....... .. ................ . . .....,... ..almlll ~-- ~ ... pnf--tu ,~ " .-• , BRITISH OWNER ' S • HANDBOOK • I CONTENTS Page Alphabetical index - 4-5 Introduction 6 Technical data 7-9 Instrumentation and Control layout 10-11 Registration for police and customs authorities, data for filling stations and workshops Controls and running-in instructions 12-16 Care of coachwork - 16-17 T echnicaJ. mainrt:enance PRINTED IN GREAT BRITAIN 12 - 18-28 M:inor inspecltiions and adjustments - 29-35 Maintenance survey 35-36 Maintenance chart - Pull out 3 ' ALPHAB~~[ICAL INDEX Pedal shaft Polishing '!-.¥$;, Adjuster plate, chain Adjuster bolt, brake Air cleaner Axle construction Battery maintenance Blower wheel Bore Brakes Brake adjustment Brake drum Brake fluid Brake master cylinder Brake pedal Brake shoes Page 33 34 ;24 8 ·22/23 30/31 7 8, 33/34 34 33/34 34 34 34 34 Figure 70 76 42/43 Feeler gauge Fill-up data Float chamber Folding hood front rail Front wheel bearings Fuel consumption Fuel line control tap Fuel tank Fuses 38/39 74/76 75/76 74 74 75/76 Canvas hood Canvas hood maintenance Capacity Carburettor Carburettor adjustment Care of coachwork Care of glass Carrying capacity Chain Chain case Cliiunois leathering Chassis frame Choke lever Cteaning, light metal parts Climbing ability';..,;, , Clutch ""'·'~" Clutch adjustment Clutch pedal clearance Compression ratio Contact breaker gap Contact gauge Contact plate Contact point lock screw Control layout Cylinder head 15 17 7 31/32 31/32 16/17 17 8 32/33 33 16 8 13 17 8 7, 33 33 33 7 31 31 31 31 Dipper Directional signal switch Door Hinge pins 13,25 13, 25 19 10 11 37 Eccentric adjusting screw Electrical equipment Electrode gap Engine position Engine power Exhaust valve 31 7, 21/28 29 7 7 29/30 63 16 27 66/69 66/68 23/26 28 70/72 24 7 26 4 6 4 47 8 8 33/37 Headlamps Height, overall Horn 26 8 27 48/49 Ignition 30/31 Ignition capacitor 27 Ignition coil 27 Ignition key 13 Ignition switch 13 Ignition test lamp 31 Ignition timing 31 Ignition warning light 27 Instrumentation and control layout 10/11 29 Intake valve 62/65 Jack Jets 20/21 Main dimensions Maximum speed 57 69 16 44 13 13 19 Lamps Length, overall Lighting switch Locating pins Lubrication Lucas electrics 62/63 62 64/65 64 1 Figure 58 Gear changing Gear lever Greasing Kerb weight King pins 73 73 Page 30 9 32 15 24 8, 15/16 13 9, 12 25/26 15 50 7 7 65 Page 19 17 Rear wheels Reflectors Road performance Rocker arm Rocker-box cover-gasket Running-in Running-in speeds 8 27 8/9 30 30 14 14 Seat adjustment Seat removal Sparking plugs Speed limits Starter Starter choke lever Starter switch Starting Steering Steering lubrication Stop-tail lamps Stroke Suspension Swing arm 13 17 29 9, 14 7 13 13 13 8 19 28 7 8 19 Tail lamp Technical data Technical maintenance Terminal block Three-way fuel tap 28 7/9 18/23 27 13 Figure 36R 25/26 59 60 13 29 54/56 7 7 7 52 52 30/44 6 Page 16 19 8 8 7 18 8 23 23 Universal joint, steering 19 '~6L Valves Valve adjustment Valve adjusting screw Valve checking Valve clearance Valve stem Ventilation Volume control screw 29/31 29/31 29/31 29/30 29 30 14/15 32 58/61 58/61 59 59 58/59 59 14/15 67 Washing Weight Wheelbase Wheel changing Wheel cover plate Wheel spare Width, overall Windscreen wiper Wire brush Wiring diagram 16/17 8 8 15 15 15 8 13, 28 29 28 23/28 31/32 8 19 25/28 8 13 30 7/9, 18/24 21/23, 25/28 45/52 9 61 30/37 8 8 Number plate lamp 27 Oil capacity Oil change Oil dipstick Oil drain plug Oil1evel, chain drive 9 18 12 18 18 Figure 22 35.,, Tool kit Torque arm Track (tread) front Track (tread) rear Transmission Transmission oil change Tyres Tyre pressure Tyre wear 51 30/32 5 ~0 32 5 3t: --;: 4,0'' 41 17/21 18 17 12, 53 56 Pull out SERVICING INTRODUCTION Isetta Service Stations art' organised in the form of a wide net of Isetta Agencies. They are always at your service. At these Service Stations you will find technicians wh9 have been specially trained at the Isetta factory or by factory representatives. Each' of these Service Stations is equipped with proper tools and has a complete stock of genuine spare parts. Technical data : J3MW single-cylinder, four stroke engine, blower cooled 300 c.c. engine Engine: In the following pages you will find described in non-technical language everything. the Isetta driver needs to ·know about his vehicle. Where technical details do occur, such as on the succeeding two pages, they are included mainly for service stations and for the more technically-minded Isetta . owner. The British-manufactured I~etta is a new solution to motoring problems. Its manoeuvrability in dense traffic; the ab. solute weather-protection which at the same time permits draught-free oren-alf driving by means of the folding sun roof; its comfortable interior dimensions; its quick acceleration and considerable top· speed given by a high performance aircooled engine unit; and above all its tremendous mileage; these are advantages that will certainly suit new trends in motoring. "' You will find the J~S~J:~ .:;tri,.easy-to-handle runahout, suitablw;~~~B;~,:~:l.ity and toi.Intrry driving, for field-tra2k ahd modern higpway alike. Furthermore, excellem road · holding and a brake s)i;stem of r~f?arkable efficiency ensure a maximum 6f driving >.4~~;·;~:;:~iJ~/n;~ safety. Bore 72 mm (2.83 in.) Stroke 73 mm (2.87 in.) Capacity 295 c.c. (18.30 cu. in.) Compression 6.8 to 1 Power 13 bhp at 5,200 rpm Overhead, in V -arrangement Valve timing measured at .08 in. in valve clearance : Intake opens 6° before T.D.C . Intake closes 34 o after B.D.C. Exhaust opens 34 ° before B.D.C. Exhaust closes 6° after T.D.C. Valves Lubricating system Single plate dry clutch Right hand side, transverse equipment Sparking plug 6 Force feed lubrication .... 1tth~:iseat 12 volt dynamo starter Noris, LA:'i~/BO;~: 12 volt/130 watt generator with voltage regulator ". ~~~¥-ucas 12 volt/32 amps battery and lighting equipment ./'Lodge CC14 L 9' 0 ... . Carburettor Bing starter carburettor 1/22 Transmission : Gearbox four forward speeds and re-&erse Gear ratios : , ., Overall gear ratios : 1st 10.05 23.21 2nd 5.17 ;.. 12.14 3rd 3.54 8.17 4th 2.70 6.1 Reverse 12.15 30.0 7 Transmission continued Final drive Final drive 2.31 (13/30 teeth) through transverse resilient mounted drive shaft and totally enclosed fully adjustable chain drive in oil bath. Chassis frame: Rigid tubular chassis frame constructed by Rubery Owen & Co. Limited. Axle layout and suspension : Front wheels Independent front wheel suspension, swingmg arms, coil springs and shock absorbers. Camber 1t deg. King pin inclination 5', in castor 12 o, toe-in 4 to 5 mm = 5/32 in. to 3/16 in., measured on the rim borders, front and rear. Rear Wheels Suspension by quarter elliptic telescopic shock absorbers. leaf Wheels: St~el disc wheels by Dunlop. Rim size 3.50 in. X 10 in. Tyres: Four Wheels and Three Wheels Tubeless tyres, size 4.80 in. X 10 in. Steering gear : Worm and nut, turning circle approx. 24 feet. Brakes: HydTaulic braking to all four wheels. Brake diameter 7 in. Total brake lining area 50.25 sq. in. Dimensions : Track (tread), front Track (tread), rear (four wheeled Isetta) Wheelbase Overall length Overall ··width Overall height (unladen) and 2.8 Imp. gal. = 3.4 U.S. gal. with reserve fuel supply of .65 Imp. gal. (.8 U.S. gal.) 3.1 Imp. pints = 3.6 U.S. pints Oil capacity, engine 1 Imp. pint = 1.2 U.S. pints Oil capacity, gearbox Oil capacity, chain drive .44 Imp. pints = .55 U.S. pints Tyre Pressure: Four Wheels 16 lbs. Front and Rear Three Wheels Front: 16 lbs. Rear: 28 lbs. Fuels and lubricants: Fuel Lubricant Recommended Speeds,: During running in (Permissible cruising speeds after running in period) Maximum speeds Regular or Premium grade See lubrication chart (m ph) 1st 2nd 18 9 3rd 28 4th 12 15 37 40 50 52 25 28 37 Fuel Consumption Curves 20.4 in. 58 in. 89.9 in. 54.3 in. 52.6 in Kerb weight approx. 770 lbs. Kerb weight approx. 750 lbs. Carrying capacity 507 lbs. (N.B. Carrying Capacity refers to both) Maximum speed : 52 mph Climbing ability : First gear 1 in 3 Average fuel consumption : 76 miles/Imp. gal. Oil consumption : Approx. 3.5 Imp. pints per 1,000 miles 8 300 c.c. 47.2 in. Weight: Four Wheels Three Wheels \ springs Fill-up data : Fuel tank 25 9 30 35 40 45 50 55 INSTRUMENTATION & CONTROL LAYOUT Right hand Drive Left hand Drive 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Clutch pedal. Brake vedal. Accelerator pedal. Hand brake. Gear lever. Choke lever. Lighting switch. Ignition and starter switch. 13. 14. 15. 16. 10 Directional signal switch. Headlamp dipper switch. Heater. Ignition control light. Headlamp main beam warning light. Speedometer. Horn button. Windscreen wiper motor. 1. 2. 3. 4. 5. 6. 7. 8. Clutch pedal. Brake pedal. Accelerator pedal. Hand brake. Gear lever. Choke lever. Lighting switch. Ignition and starter switch. 9. 10. 11. 12. 13. 14. 15. 16. 11 Directional signal switch. Headlamp dipper switch. Heater. Ignition control light. Headlamp main beam warning light. Speedometer. Horn button. Windscreen wiper motor. 2 For police and customs authorities Serial plate : Inside ail: the (figure 2) r~ight in front of tt:he seat Chassis number : On front cross member of frame, below the right-hand door corner (figure 3, left, number 1) Engine number : On engine housing to the right of blower case (figure 3, right, number 2) 3 For filling stations and workshops Fuel tank: In the rear end of vehicle, access from outside Capacity 2.8 Imp. gal. = 3.4 U.S. gal. with reserve fuel supply of .65 Imp. gal. = .8 U.S. gal. (figure 4) 4 Engine oil filler : Oil filler and dipstick on right-hand bottom side of engine. Maintain oil level up to the mark on dipstick (figure S). Oil capacity 3.1 Imp. pints=3.6 U.S. pints. Branded oil SAE 40 for summer use and SAE 20 for winter. Multigrade lOW /30 for overseas. ~ The new Isetta owner will probably have had experience as a driver or, at any rate, wiU have had tuition from a driving school. It is, therefore, unnecessary to include within the scope of this manual details about how to use clutch, accelerator and other controls. With the British5 12 1 f I I manufactur.ed lsetta these controls are accommodated in a convenient arrangement that makes for easy handling. The lever for the three-way fuel line control tap, situated behind the seat squab, is easily reached with your right or left hand (figure 6). When starting from cold, pull choke lever full back (figure 7); at the same time turn the ignition key with the other hand (thereby switching on the ignition) and push same in with a further short clockwise rotation to- operate rthe starter motor. As soon as possible after the engine 1fires, reset the choke lever into its foremost position. The gear change mechanism works smoothly especially if you get into the habit of pulling the gear lever with the fingers and pushing it with the palm of your hand (figure 8) instead of grasping it with your whole hand. If first gear does not engage at once, release the clutch a little or clutch and declutch again for an instant. The heating for the interior, which is an optional extra, is hand-controlled by moving the larger lever situated just beneath the choke lever. The lighting switch located below the ~teering wheel is also within reach (figure 9.) The switch for dipping and raising the headlamp beams is situated below the sliding windows and just above the gear lever (figure 10). The directional signal switch is mounted in the centre of the door below the windscreen (figur(\ 11). To bring the windscreen wiper into operation, push the switch of the motor unit which is !fitted to the door (figure 12). To adjust seating, slacken the two screws underneath the seat and adapt the seat position to your requirements (figure 13). For the o1ther controls and instruments see pages 10 and 11. 6 13 9 7 8 10 11 12 13 Your friends may have told you about running in a new vehicle. On the other hand you may well already have had experience of it yourself. In any case, it is not a complicated operation. Do not be afraid to give your Isetta plenty of work to do, even in the first weeks-continuous development has made its engine a marvel of precision and robustness. Correct use of the gear box will avoid engine overloading during the first 600 miles and provided the recommended running i~ speeds are strictly observed the engine will respond with long service and good performance. For the first weeks of the running-in period, that is for the first 600 miles, we recommend the following speed limits:1st gear : not over 10 mph 2nd gear : not over 18.5 mph 3rd gear : not over 28 mph 4th gear : not over 37 mph These speed indications correspond with an engine rate of 4,000 to 4,500 rpm, whereas the speeds mentioned under 'Technical data' will be reached at a rate of about 5,200 rpm. After the first 600 miles you may on occasions use your BMW engine's full power output. After 2,000 miles you may consider the engine as being completely run in. You may then use the cruising speeds indicated on page 9. The red markings I, 11, Ill on the speedometer dial show the cruising speeds for first, second and third gear. In fourth, the speed range available within the redcoloured section should only be used for the purpose of passing other vehicles. The British-manufactured Isetta has many other advantageous features not so far mentioned. For instance, the two sliding windows have stop spring catches 14 to prevent opening from outside while the vehicle is parked. To open a window, press the button of the locking device and simultaneously push the window to the desired position. All windows are made of toughened safety glass (figures 14/15). The folding sun roof is opened by operating the lever situated on the middle of the front rail. After rain, do not open the roof until it is completely dry. To close the canvas hood, draw the front rail forward and lock with the lever (figure 14 16). 1 .~ In the case of wheel changes, removal of the spare wheel (an optional extra) is achieved by pulling the rear of the seat forward and lifting the spare wheel from behind (figure 17). Wheel-changing, which should be carried out not only in the event of a damaged tyre, but in any case at regular intervals (see also page 23 and 24, figures 40 and 41) does not involve any trouble, though it should be done with care. The jack is stowed beneath the seat. Figures 18, 19, 20 and 21 show the method of wheel removal and jacking positions front and rear. The way in which you drive considerably influences the fuel consumption. You will profit by the economy of the BMW engine provided that you use accelerator and brake-pedal in a careful manner. Every vigorous movement of vour righit foot, every full depression. of the accelerator pedal or brake pedal, costs fuel. Therefore, try to adopt modern methods of changing gear. If, for instance, you drop from a higher speed to 25 mph in city traffic, and then want to accelerate you should shift from 4th into 3rd and only change up again when you have regained the higher speed. If the traffic · speed is 25 mph stay in third gear a.t 15 15 16 17 18 half-throttle opening. ln this way you will spare your engine and you will save fuel. BMW engine is designed for high revolutions and it will not suffer if you raise the revolution rate in the lower gears in traffic so as to get away quickly. With the remarkable acceleration and manoeuvrability of the British Isetta you can easily wind through narrow spaces and always keep up with the flow of traffic. Care of coachwork 19 20 21 The tool-kit (figure 22) contains all the items you need for maintenance and minor repairs. Washing your Isetta requires some care; the following procedure should be adopted. First flush the chassis and lower part of the body with water from a low pressure open-end hose, to soak off dirt. Afterwards a brush should be used. Washing of the varnished areas to remove injurious dirt-accumulations and dust should be done when the body is cold; never wash or polish your Isetta in the direct rays of the sun or while the body is still hot from having been exposed to sunshine. Apply an even spray of clear water on the exterior finish until the dirt is removed. Do not allow a strong jet of water to hit the varnished surface. Using plenty of water, dirt should be removed with a clean sponge (figure 23). Clean the sponge at short intervals. Next use the wrung-out sponge to wipe off all drops of water and then rub the lacquer dry with a clean, soft chamois to avoid water spots (figure 24). If water alone does not do the job the varnished areas may be given a second wash with lukewarm water, soapy water (1 to 2 per cent) or shampoos. Do not, however, use 16 soap or shampoo too strong or the varnish will become brittle. After soapy water or shampoo treatment wash the body thoroughly with clear water and polish with a good quality wax (figure 25). Wax polish should be applied with a soft polishing cloth or polishing cotton in small quantities upon the completely dry finish, doing only a small area at a time. Remove the wax, using a clean polishing cloth, until the original brilliance is restored. Light metal parts, such as bumpers, window frames, etc., which have become opaque or spotted, should be coated with a chromium-nickel polish and then rubbed with a clean, soft linen cloth or wad until the original brilliance is restored (figure 26). Maintenance of the canvas hood is easily carried out. Dust should be removed with a soft brush. From time to time clean the canvas hood with a washing-brush, using plenty of water (figure 27). Never try to remove spots with gasoline or other chemical products, but rather use a good textile cleaner as you would use it for removing spots from clothes. Care should be taken in the maintenance of the window panels. In order to avoid scratches on the safety glass surface, the adherent dust should be removed with a duster, or, better, with plenty of flowing water by means of a hose and sponge (figure 28). It should never be rubbed off with a linen cloth. Should you wish to remove the seat of your vehicle in order to carry out interior maintenance, first remove the spare wheel in the manner already described and then fold the seat and turn it into the gap which contained the spare wheel. Finally draw the seat on its left corner forward and raise and remove in an upward direction (figure 28). 22 17 25 23 24 Technical maintenance 27 28 29 'Dhe following items can well be dealt with by the owner:(a) Changes of oil in the engine should be carried out after the first 300 miles, thereafter every 1,000 miles. To achieve this unscrew the drain plug at the bottom of the crankcase (figure 30). After the last traces of old oil have drained, replace and tighten the drain plug before filling with the new oil up to the height of the level mark on the dipstick. The oil capacity is 3.1 Imp. pints = 3.6 U.S. pints. Draining should :rake place with the oil still warm. On no account use flushing oil to flush the engine. (b) Similarly the oil while still warm should be drained from transmission and chain drive. The transmission drain plug is reached from the side opposite the engine, at the bottom of the gearbox case (figure 31, left). The transmission 'filler plug is located below the air filter in front of the mudguard of the right-hand rear wheel (figure 31, right). Having drained the transmission oil and thoroughly tightened the drain plug, fill up with transmission oil througb the filler orifice until it can be seen in the filler hole. The topping up should be done in the same manner. Oil capacity approx .. 96 Imp. pint = 1.1 U.S. pints. The oil level of the chain ca·se and rear axle assembly is checked through the filler orifice in the rear axle unit (figure 32). The oil sheuld reach the lower threads of the plug hole. The drain plug is situated just beneath the 'filler orifice and is marked by an arrow in figure 32. The oil capacity 18 of this unit is about .5 Imp. pint= .6 U.S. pint. The simplified design of 1Jhe British [setta features only eight grease points, four on the front suspension (figures 33, 34 and 35), two in the cabin on the steering and pedal controls (figure 36) one on the handbrake cable and one on steering arm shaft. Each of the front suspension units features two grease nipples and one oil filler plug. The grease nipples serve to lubricate top and bottom bearings of each steering knuckle king pin. The grease gun should be applied to them every 1,000 miles at Service A. The oil filler plug gives access to a small oil reservoir that lubricates the fulcrum bearings of the swing arm and the newly introduced torque arm (figure 35). Use engine oil SAE 40 for this lubrication point. Refill initially at 300 miles and subsequently every 2000 miles at Service B. Top up to about the middle of the filler hole thread. The remaining two grease points are the universal joint at the lower end of the steering column, accessible by opening the door (figure 36 left), and the shaft for the foot pedals (figure 36 right). The old, emerged grease should be properly removed on these two latter points as they are located within the body and do not get splashed by dirt and moisture. Joints lacking grease nipples, such as the door-hinge pins, the yoke pins on the. linkage mechanism of the pedal shaft (see lubrication chart at the end of the booklet) and all other parts causing friction should be given a few drops of oil from time to time (see lubrication chart) by means of an oil can (figure 37). For greasing use a lubricating-grease (all makers' recommended lubricants) which should incidentally always be stored in its securely closed container in order to prevent the ingress of dust and dirt. 19 30 31 32 33 HEADLAMPS for Three-Wheel Isetta for Plus model only Each headlamp contains a Lucas Light Wheel Change for Three-Wheel lsetta Unit secured by five W-shaped wire clips to the front rim. The Light Unit con- sists of an aluminised reflector permanJack up rear wheel placing jack under ently attached to the front glass which 1s the near, i.e., left-hand side, rear spring lensed to form an optical system of flutes eye adjacent to axle. and prisms. The bulb has two filaments, i=IIM through the dipper switch to provide remove the four wheel nuts and backing double-dipping of the headlamps. plate. Now remove wheel to the right (offside) until clear of bolts, and then HEADLAMP SETTING The Headlamps should be set so that when the vehicle carries its normal load the main beams are projected straight ahead, parallel with each other and with the road. The setting should be rechecked after replacing a defective bulb. The lamp bodies are secured to the vehicle by four set screws access to which is gained by removing the interior trim panels. These screws nius~t be slackened when it will be found ·rhar,.the lamp bodies can be adjusted to give the correct setting. The filaments are fed through a Lucas adaptor (554691). Lucas Bulb No. 355 12-volt 42/36 watt, B.P.F. cap. lower to ground (Fig. 2). HOW TO REPLACE BULB When replacing the wheel, it must be Slacken the screw at the bottom of the pushed through the aperture between front rim and withdraw the rim and Light wheel studs and swing arm (Fig. 2), and Unit assembly. Access to the bulb is gained by releasing the bayonet-fixed the side of wheel on which the inflating adaptor with a press-in anti-clockwise valve is fixed should be next to the brake motion. It should be noted that a notch drum. Note that the distance pieces must in the flange of the bulb is arranged to be replaced so that the tapered side is locate with a ridge in the bulbholder to ensure that the bulb is non-reversible. nearest the wheel. The bulb is of a prefocus' pattern. 20 SCREW Headlamp Bulb Replacement. main and dip, and these are connected With box spanner or brace (Fig. 1), SE:CURIN~ 21 . :;~~~~- hyd;~ineter readings fro' time to time, but, to avoid low misleading r~adings, Lucas electrics Battery such measurements should nqt be made immediately after topp' p~3(figure 39). The readings shown be for ambient temperatures and above 90°F. Climates bebw 90°F '(i) 1.270-1.290 1.200-1.220 (ii) 1.190-1.210 1.120-1.140 (iii) 1.110-1.130 1.040-1.060 The indications ,givfrl by these readings are as follows : ';;'~ (i) Cell fully charged (ii) Cell about haif discharged (iii) Cell completely discharged The readings for all cells should be approximately the same. If widely varying readings are obtained the battery should be examined at a Lucas Service Depot or by an official Lucas Agent. Storage : Never leave the battery in a discharged condition. If the vehicle is to be out of use for an appreciable period, the battery should first be fully charged and, subsequently, should receive a short refresher charge every fortnight. Model H07A/8; Type, Lead-A~id; 12 volt; 7 plates per cell. Capacity, 32 ampere-hours at the 10-hour rate and 31 ampere-hours at the 20-hour rate; first charge current 2 amperes; recharge current 3 amperes. Access to battery for topping up (see figure 29 page 18). Every 1,000 miles or monthly, whichever is the lesser, remove the ·filler plugs from the battery and inspect the electrolyte level with the top e:(f'~es of the inter-plate separators. This 35' addition will replace water lost by evaporation. The use of a Lucas Battery Filler enables the correct electrolyte level to be obtained automatically (figure 38). Use only distilled water. Never overfill the cells. Never hold a naked light near the cell tops. TAKE READING AT EYE LEVEL Keep the cell tops dry. 36 Run the vehicle immediately after topping up in cold weather. This will help to mix the distilled water and electrolyte and so prevent freezing and possible damage to the battery. General care : Keep the cell tops clean. Keep the electrical connections and fixing bolts tight. Hydrometer readings : Hydrometer readings indicate the condition and state of charge of the' battery. Good cells wi11 yield clear electrolyte free of particles in suspension and will produce high specific gravity readings. It is advisable to take 37 22 ~· Technical Maintenance (cont.) Tyre pressures should be checked (figure 40) at frequent intervals and at least once a week. If you use your own tyre gauge, check it from time to time with a calibrated tyre gauge at a filiing station .. The tyre pressures should be adjusted to 16 lbs.fsq. in. (front and rear) and 16 lbs. front and 28 lbs. rear on three wheelers. In order that tyre wear should be uniform with the spare wheel tyre, you should change the wheels round from time to time. The manner of rotating the wheels is shown by figure 41. Periodical maintenance should also include care of the air cleaner. This filter 23 39 40 HOLD TUBE VERTICALLY 41 rt~zt'-~<,' 42 43 44 is of the dry 'element type and should be cleaned every 2,000 miles. To do this unscrew the rubber hose-clip on the carburettor with a, screwdriver. Push the rubber tube away from the carburettor (figure 42 left). Next loosen the toggleabtion dips on the filter. On gripping th~ 'air cleaner let the toggle-action clips snap back. Tap the filter gently on wooden block to expel dust (figure 42, right). The filter element should be replaced every 7,500 miles (see Service C). To carry out this replacement slacken the fixing screw with a 9 mm spanner, remove the cleaning element and fit a new element (figure 43). The transmission of movement from clutch pedal to clutch unit, from accelerator pedal to carburettor and from air lever to carburettor is achieved by Bowden cables. These cables should be checked from lt'ime to time if necessary and lubricated. These jobs, however, are best done by a service station. They should be performed at intervals of about once a year or every 7,500 miles as indicated in the maintenance chart, and therefore belong to the maintenance items of Service C (page 33 and appendix). There is a 'final maintenance job which should be carried out every 7,500 miles (also see lubrication chart on last page). The grease loads in the ball-bearings diminish at a very slow rate, so that the grease in the front-wheel bearings needs to be renewed only occasionally. For this purpose remove the wheel-cover plates and with a clean finger press the fresh ball-bearing grease into the bearings. Under no circumstances fill the dust cap completely and replace because this may inject grease into' the brake linings (figure 44). ·? 24 For the detailed indication of the pre- ing the ;jlgle lens s~g{iring screw arid scribed maintenance jobs and the corre- withdrawing the lens. The bulb is Lucas '" ·.~ sponding service periods see mainte11ance ~No. 382, 1,2-volt 21 watt s.c.c. cap. chart. 'i' 6. 63 64 ignition key to switch off test lamp, reconnect er lead to "terminal 1 of igrutwn, detach test lamp, reconnect wheel, replace spark plug and push high-tension lead connector over the sparking plug. Carburettor The arrangement of jets and burettor adjustment have been the' factory in order to obtain performance and a maximum of 31 the cartested at the best economy 65 i~{'\herefore, from time to tim6:·~~~Jhe striking of the chain against its case will tell you when the chain has lengthened and needs adjustment. This is done by -means of a perforated adjuster plate on the chain case (figure 70), which is accessible from the si4e opposite the engine. Remove the adjuster pla;te locating-screw with an appropriate spanner (figure 70). Then raise it with a screwdriver from the bottom upwards until strong resistance prevents further movement (figure 71). This re-establishes the proper tension of chain. The next problem is to get the drill holes in the adjuster plate corresponding with one of the two screw holes in the chain case. This cannot be done by forcibly lifting the plate until the holes _meet one another (figure 72) because this would result in excessive chain tension. If the hole in the chain case happens to stay between two adjuster plate holes, slacken off in order to get the locating screw into its hole. in consumption. lt' pointless to try and increase performance or to lower fuel consumption by altering the carburettor adjustment or by fitting jets of other sizes. It is possible to lower the fuel consumption by using smaller j·ets, but this will immediately cause an appreciable loss of power; there is the risk of the engine overheating and of the valves burning. In short, major repairs will become necessary. Consequently this chapter includes only those jobs which can be done for the maintenance and servicing of the carburettor. The carburettor is regulated by means of two screws (figure 67) and the idling adjusting screw (figure 66). The volume control screw is best left with its original adjustment as set at the factory. If this adjustment has been altered by some cause, slacken lock nut of the volume control screw, turn the screw fully in with a screw driver, and then back it off by 1t-2 turns. This is best done with a special tool and, therefore, you should leave the job to an expert (figure 68). The regulating and adjusting described above is all that can be done on the car-burettor, by either layman or expert. To clean the carburettor, open the drain plug on the bottom of the float chamber (figure 69) having first set the fuel tap (figure 6) into its " OFF " position. Should it become necessary to remove' the top of the carburettor ensure th~t the gasket sealing is replaced correctly. Clutch The free movement of the clutch peda:l pad should be about .48 in. to .6 in. The readjustment of clutch pedal clearance takes place on the clutch actuatinolever at the transmission case and, lik~ the cha:in adjustment, is achieved from the side oppos•ite the engine. This can be done with the vehicle supported at the rear, errtel'ing the spanner fr():m behind. Turning the adjuster screw clock-wise increases clutch pedal clearance and contrary adjustment decreases it (figure . n~ Chain ' The power output of the engine is transmitted to the rear wheels by means of a ch~in running in an oil bath. Since it is completely protected this chain has a long life. It .8hould, however, be adjusted Brakes The foot brake is hydraulic. It affects all four wheels, since the two rear wheels 33 32 ..~· 'II 74 75 76 are mounted on a rigid scale. Maintenance of the brake includes checking the brake: fluid level. The brake-master cylinder with the fluid reservoir is situated below the seat bench and is accessible simply by unscrewing the filler plug. When removing it take care to avoid getting dirt into the brake fluid. Use only Girling crimson fluid from the original can (figure 74). If the brake pedal travels too freely, it is an indication that air has entered the hydraulic system; the fluid line must then be bled. This can best be done by a service station as it requires special devices and knowledge. Running adjustments Girling brakes are adjusted for lining wear only at the brakes themselves and on no account should any alteration be made to the handbrake cable for this purpose. Front brakes (figures 75 and 76) A separate snail cam adjuster is provided for each shoe. Jack up the vehicle until the front wheel to be adjusted is clear of the ground, then fully release both adjuster bolts on outside of the backplate by Fuming anti-clockwise. Turn one' of the adjuster bolts clockwise until the brake shoe concerned touches the brake drum then release the adjuster until the shoe is just free of the drum. Repeat the process for the second adjuster and shoe. Spin the wheel to ensure that the brake shoes are quite free of the drum. Repeat the whole procedure for the second front wheel. Rear brake (figure 77) One common adjuster is provided for both shoes. Release the handbrake and jack up the 77 34 I I car. Turn the square end of the adjuster on the outside of the rear brake ba~k­ plate in a clockwise direction until a resistance is felt, slacken two clicks, when the drum should rotate freely. Immediately after fitting replacement shoes it 1:> advisable to slacken one further click to allow for possible lining expansion, reverting to normal adjustment afterwards. ~aintenance 00 01 509, us,ing a 12 mm. flat ring spanner. (Note: Free Service, but oil is chargeable.) (b) At 600 miles:1. Change oil in gearbox, rear drive and eng:ine. Oil and grease chassis points, oil all hinges and joint. 2. Check front suspension mounttings. 3. Check and tighten all nuts and bolts, including transmiss10n, universal coupling bolts and wheel nuts. 4. Check electrolyte level of battery, add distilled water, give posts and terminals a grease coatJing. 5. Remove valve rocker covers and tighten the four cylinder head holding down bolts to a torque loading of 32 lbs. ft. This operation should, of course, be carried out diagonally. Re-adjust tappets with engine cold (see "Valves," page 29) and refit rocker covers. 6. Che'ck and· re-tighten if necessary cylinder base nuts, Part No. 00 01 509, using a 12 mm. flat ring spanner. , 7. Clean sparking. plug and adjust gap. 8. Check ignition po~nts, read)ust if necessary. 9. Remove carburettor, clean out jets and . petrol filter, clean throttle slide and ensure needle is in correct slot, ensure correct clearance; on throttle and choke cables. 10. Adjust slow running, clean out air intake filter. survey All jobs mentioned in the preceding chapters for the proper maintenance and servicing of your vehicle are arranged in the following service groups and in the maintenance chart. The most frequent jobs form Service A, to be performed every 1,000 miles. The more complicated jobs to be done at longer intervals form Service B and Service C. The ex~perienced mechanic will on a " C " Service check the entire chassis, brake and steering assemblies as well as all stationary and movable parts, and eventually provide them with the necessary paint /and anti-corrosion coatings. In addition to Services A, B and C the following jobs should be done: (a) After the first 300 miles:~ 1. Drain engine oil, remove oil sump, clean it and wash the oil screen, refit sump and refill with fresh oil. 2. Remove valve rocker covers and tighten the four cylinder head holding down bolts to a torque loading of 32 lbs. ft. This operation should, of course, be carried out diagonally. Re-adjust tappets wirh engine cold (see "Valves", page 29) and refit rocker covers. 3. Check and re-tighten if necessary cylinder base nuts, Part No. 35 This document was downloaded free from www.iw1axr.eu/carmanual.htm Questo documento è stato scaricato gratuitamente da www.iw1axr.eu/auto.htm