Benelli sprite-barracuda, Shop Manual

Page 1: ...f__ i I _ Sprite Barracuda SHOP MANUAL 125cc 200cc 250cc FOUR AND FIVE SPEED COSMOPOLIAN MOTORS INCORPORATED JACK ONVILLE MEADOWBROOK ROADS HATBORO PA 1904 r 215 OS 2 9100 ...

Page 2: ...h battery to ensure steady supply of current to lights and horn Large 130 mm headlight Headlight 6 1 25 25 S B OVERALL DIMENSIONS Length 76 44 Width 27 Height 36 64 Weight 229 Ibs DRY Fuel tank capacity 3 5 gallons Reserve 05 gallons Maximum speed 7 MPH Fuel consumption 90 MPG MOTORCYCLE 200cc Technical data different from 125cc ENGINE Bore 66 5 mm Stroke 57 mm Cylinder displacement 197 9cc Compre...

Page 3: ...t rest Clutch lever 18 Rear light 31 Brake pedal Ii Dimmer switch 19 Rear fender 32 Oil drain plug i Damper 20 Shock absorber 33 Clutch adjuster B Handlebar 21 Chain guard 34 Frame 9 Front brake lever 22 Rear wheel 35 Horn 10 Throttle control 23 Rear hub 36 Front wheel li Gas cap 24 eh 37 Front hub 1 1 Carburetor 25 Chain adjuster 1 3 Gastank 26 Rear fork 3 ...

Page 4: ...procket wrench F Engine pinion holder G Engine pinion puller H Engine pinion puller I Flywheel magn to holder L Flywheel magneto extractor M Clutch hub holder 138 139 MB 144 nB 141 HB 140 HB 13 11MB 1431MB 146 HB 13 21MB 1371MB 1301MB N Clutch spring tool o Universal puller P Cam follower bushing extractor Q Crankshaft spacer R Kich starter spring holder S 5mm Allen wrench T Shifting drum puller U...

Page 5: ... 3 Remove electric wires from junction box 4 Unscrew fuel lines with 12mm wrench 5 Pull out engine breather tube 6 Loosen clutch cable clamp and pullout cable 7 Pullout the spark plug cap 8 Remove with pliers master link clip master link and chain 9 Unscrew foot peg bolts with 17mm wrench Remove knurled nut of brake rod 10 Remove exhaust pipe and muffer 11 Unscrew lower engine stud nut using 17mm ...

Page 6: ...e must be split will engine have to be removed By removing the left hand cover the flywheel magneto clutch adjuster and countershaft sprocket are accessible By removing the right hand cover the clutch preselector components and cam distribution gears are visible These are operated in oil bath therefore this cover must be perfectly sealed The cylinder head rocker arm and cylinder are removable from...

Page 7: ... the same time the flywheel with tool i Lock the flywheel puller L in position and with 22mm wrench loosen the flywheel from crankshaft Tap on the puller bolt slightly with a hammer if the flywheel is hard to remove Before removing the backing plate it is advisable to made a reference mark on the crankcase in order to facilitate the reassembly operation ...

Page 8: ...ws Holding kick starter spring with tool R remove with screw driver the spring fastening screw To remove countershaft sprocket it is necessary to i Lift up the safety washer loop 2 Install the special tool D 3 Remove the nut with special wrench E holding at the same time the countershaft sprocket with tool D 2 3 8 ...

Page 9: ...um gasket Before removing with 12mm socket wrench the four cylinder head nuts be certain that the piston is in compression stroke position Pull out the rocker arm support carefully in order not to damage the threads of the cylinder studs Pull out the cylinder head gasket cylinder and base gaskets ...

Page 10: ... in the tool C Install the tool C on the piston It is advisable to slightly heat the piston before removing the pin Turn the spindle until the piston pin is removed from the connecting rod NOTE It is not necessary to remove the piston rings to remove the piston 10 ...

Page 11: ...en screws with the tcol S Tapping slightly with plastic hammer pullout cover Dismantling of the clutch With the special curved tool N disconnect the five clutch springs Remove the clutch plates and the short clutch rod Lift up the loop of the safety washer bent over the nut ...

Page 12: ...t washer Pullout the preselector shaft Holding with special tool F the engine pinion gear remove the cam gear and engine pinion gear locking nuts With special puller G remove the el1 ine pinion gear NOTE If the special puller G can not be use use puller H Using extractor 0 pull out the cam gear NOTE Use special puller U with gear having two threaded holes 12 ...

Page 13: ... is ùdvisable to use a small pin in order to rotate it To install Woodruff key hold with pliers and tap slightly How to split the crankcase Remove the four oil pump bolts with 10mm wrench Use 11 mm wrench to unscrew crankcase stud nut from one side then pull out the stud Unscrew and remove the Allen bolts using tool S The screws are indicated on sketch on page 14 15 With a pin press out the crankc...

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Page 16: ...and clean thoroughly To disassemble the crankshaft from the left hand side crankcase install tightly the coarse threads protecting bu hing and proceed as per above instructions Heat the crankcase at approximately 1401 to 1800 Fahrenheit before removing bearing from it To remove the camshaft and final gear drive bearings from left hand c rankcase flywheel magneto side dismantl the two bearing cover...

Page 17: ...amshaft bearing seat No 1 seeger ring type 40JV assembled into the primary shaft bearing seat No 1 seeger ring type K assembled into the secondary shaft bearing seat NOTE This seeger most be installed after the crankcase are joined List of seeer rings assembled on 4 speed engine crankcases Left hand half crankase Flywheel magneto side No 1 seeger type 47J assembled on the main bearing seat Right h...

Page 18: ...aft external sid 1 Bearing 25x52x12 for primary shaft installation from the external side of crankcase The bearing must be even with crankcase face externally_ 1 Bearing 12x32xl0 for camshaft 1 Steel bushing for secondary shaft needle cage installed internally 1 Cam follower bushing Install the seeger rings J 47 from the external side Then install the oil seal 20x47x8 Install oil ring into the kic...

Page 19: ...te of the fìnal gear drive are assembled on the external side of crankcase The special supporting screw of the dust protecting plate must be installed on the upper side of the engine see picture alongside Install the cam shaft bearing cover with the respective gasket and lock the three screws tightly Install the fìnal drive gear internally and from the external side press in the countershaft sproc...

Page 20: ... i I I I I i i i i I I t i i Install th the final two clutch rod rive gear oil seals inte Assembl e special safety waSher Use spe I cia to I countershaft 0 s D and E Bend safty sprocket nut F o lock the washer 0 i LB 65 v r nut f ace 20 ...

Page 21: ...shing 1 Brass bushrng for preselector shaft assemble externally 1 Kick starter lever stop plate 1 Oil tube and seal rubber ring 1 Lower crankcase centering bushing 1 Breather tube list of bearings installed on right hand half crankcase 4 speed engine For 125cc 1 Bearing for crankshaft assemble externally 20x47x14 1 Bearing for crankshaft assemble inter nally 25x47x14 For 200 250cc 1 Bearing for cr...

Page 22: ...de play STD 0 010 0 020 000393 000787 STD 0 100 0 150 003937 005905 Max allow Limit 0 050 001968 Max allow Limit 0 400 01574 C piston pin play D E 20 mm 0 787 i I i I I Maximum excentricity admissible measured at the point D E indicated in the figure 0 020 000787 STD 0 015 0 020 000590 000787 Max allow Limit 0 050 001968 22 ...

Page 23: ...ar box ratio 1st 3 166 2nd 2 010 3rd 1 529 4th 1 62 5th 1 000 For 125cc Countershaft sprocket 15 T Reôir wheel sprocket 44 T Final ratio For 200250cc Countershaft sprocket 17 T Rear wheel sprocket 41 T Final ratio 1st 27 857 2nd 17 685 3rd 13 453 4th 10 224 5th 8 799 1 st 22 899 2nd 14 538 3rd 11 059 4th 8 404 5th 7 233 23 ...

Page 24: ...e gear box ratio i tal For 125cc Internal gear box ratio 1 st 2 683 2nd 1 665 3rd 1 267 4th 1 000 Countershaft sprocket 15 T Rear wheel sprocket 44 T Final ratio For 200 2S0cc Internal gear box ratio 1st 2 615 2nd 1 515 3rd 1 53 4th 1 000 Countershaft sprocket 17 T Rear wheel sprocket 41 T Final ratio 1 st 23 607 2nd 14 650 3rd 11 148 4th 8 799 1st 18 914 2nd 10 957 3rd 8 339 4th 7 233 i r i i r o...

Page 25: ...cial spacer Q in between the two half crankshafts before assembling this group Insert in the fìnal gear drive the following First needle cage Spacer Second needle cage Insert the needle cage into the steel bushing of the secondary shaft Insert the gear box assembly into the proper seats NOTE For the 4 speed gear box proceed as per above instructions ...

Page 26: ...wers and push rod This prevents noise and wear to the parts subject to constant pounding force into respective seat of the crë nkcase Protect the end of the shaft with ù layer of scotch tape NOTE Before proceeding to join the right hand crankcase be sure that the ratchet is facing towards the lower part of crankcase as shown in the picture Clean thoroughly the oil passages of thE cam follower and ...

Page 27: ...must face toward the back of the engine i J i i I i When all the shafts are partially inserted into the seats tap slightly and evenly the half crankcase and completely close Insert and tighten evenly crosswise air the screws as shown in Fig on page 14 15 Assemble the needle cage into the steel bushing of the secondary shaft and install the seeger ring Remove the adj ustable spacer Q from the crank...

Page 28: ...nd seeger Assemble Woodruff key and shifting drum nut and tighten firmly with 11 rnm socket wrench Insert the oil pump rubber ring into the oil pump seat and slide it into the cr nk case from the bottom NOTE Align the reference hole with the pin of the crankcase Use gasket cement on the oil pump gasket i nd the four screws Assemble the preselector shaft 3nd thrust washer 28 ...

Page 29: ...ing hooks are all facing the center and at the same height NOTE It is important that the clutch springs are even with the dutch hub face Slide on the primary shaft the clutch hub Install the safety washer and lock the nut at 45 50 ft lb Bend the loop of the safety washer over the locking nut ...

Page 30: ...j f G I i Il ft I Exploded view of the clutch assembly for 12Scc 4 four and 5 five spe engines 1 I lQ 1 ...

Page 31: ...rt clutch rod Assemble the pressure clutch disc with the slots corresponding to the hooks of the clutch spring Set the clutch spring retainer ring on the clutch pressure disc and attach the spring using special tool N NOTE The slot of the clutch spring retainer ring must be placed in the center of two slots of the clutch pressure disc ...

Page 32: ...r noise Procedure of distribution timing Install engine pinion gear Match mark dot of engine pinion gear with the dots of clutch crown Rotate crankshaft clockwise until the Woodruff key slot reaches 4 o clock position Turn cam shaft until the key reaches about 3 o clock position Match the dot of engine pinion gear with two dots of C2m gear NOTE When installing the cam gear be certain that Woodruff...

Page 33: ... 035 001378 A 000393 A ì 0 045 001772 I i i ì 0 010 I New 0 010 000393 B 0 025 000984 I B 0 020 000787 i 035 001378 I I 0 055 0 50 0 035 0 020 000787 0 015 000590 001278 002165 005705 C 0 030 001181 C í 025 000984 I i i I oversize 66 7 2 6259 I 11 st 66 7 2 6259 i 2nd oversize 66 9 2 6336 i As per As per As per 66 9 2 6338 I sm STD STO j3rd oversize 67 1 2 6417 67 1 2 6417 i i 250 ce I Play On ass...

Page 34: ... Install the piston rings on piston Install the piston pin into the piston hub and slide it into the special tool C Lift the connecting rod and at the same time slide the special tool through the cyilnder studs until the piston pin is in alignment with the connecting rod bushing I nsert the guiding pin B at the opposite end of the piston pin 34 ...

Page 35: ...200 Fahrenheit before the installation of the piston pin Use needle nose plier to install circlips Install one thin paper gasket special alloy gasket and a second thin paper gasket be fore assembling the cylinder Lubricate the piston and cylinder walL Assemble cylinder while pressing the rings with fingers in order to facilitate th in stallation ...

Page 36: ...1377 Max allow limits STD 125 ee 0 1 003937 Exhaust Min 0 02 000787 Max 0 045 001771 STD 200 250 cc Min 0 02 000787 Max allow limits Intake Exhaust Max 0 045 001771 0 1 003937 D Valve seat width STD 125 200 250 ce Intak ExnJust 2 1 082677 Max Hcwa le limit 3 2 125984 Inner valve spring STD FREE LENGTH 34 11 3385 FREE LENGTH 37411 724 VALVE CLOSED 2611 0236 kg 14 1b 31l VALVE CLOSED 27 511 0826 kg ...

Page 37: ...vise and using the special 45 valva seat cutter make a 0 60 wide ring for the perfect coupling with the valve Procc d to lap the valve se t with valve using fine grinding compound Nash thoro ghiy the cylinder head and with the special tool or with nut and CO JIter lock nut install the intake mani fold and exhaust pipe studs Instûll the intake manifold gaskets in se que ice as shown in the picture ...

Page 38: ...lve and valve spring it is ne ressûry to use the valve spring compressor Install the valve springs and upper spring nlate Compress the valve spring with tool until you ûre able to insert the valve keepers For valve spring tec nical data see page 36 38 ...

Page 39: ...ces NOTE The position of the intake pusn rod long push rod is to the right facing the front of the engine while the short push rod exhaust is to the left NOTE The top rocker arm intake has an oil passage hole therefore before the in stallation be certain that this opening is free of any obstruction Install the rocker arm support ...

Page 40: ...ession stroke With Hot engine Intake 005 Exhaust OOS With cold engine Intake valve 006 Exhau t valve 006 Install the rocker arm cover aiuniinum gas ket and assemble the rocker box cover Install in sequence aluminum washer steel flat washer nd tighten the A nut at 7 8 ft lb NOTE Protect all the openings of the engi ne in order to prevent any dust particles from entering 40 ...

Page 41: ...n the proper seat on right hand half crankcase Insert the cover centering bushing Spread the gasket cement on the cover contact face and assemble tightening the screw crosswise as shown on page 14 15 19 COMPONENT ASSEMBLE ON LEFT HAND SlOE flywheel magneto Assemble the kick starter spring using the special tool R I nstall the long clutch rod with the flat side facing inside ...

Page 42: ...ore assem bling the dust cover Install the clutch support lever complete with respective roller Before locking the two screws align the center of the roller with the clutch push rod Insert the electrical wire through the rub ber ring and slide the back of plate in po sition aligning the two marks made during the disassembly operation Lock the backing plate with the 3 screws as indicated on page 7 ...

Page 43: ...wly counterclo ckwise until the timing light goes on At this position the flywheel magneto mark A marked on the perimeter of flywheel must concide with the mark 0 of the crankcase To retard ignition turn the backing plate clockwise To advance ignition turn the backing plate counterclockwise For this operation it is necessary to remove the fly wheel and loosen the 3 backing plate loc king screws Th...

Page 44: ...K lOoo 9 1 R flM C i i I i L i i i A t f i FIL TAO INTERNO 11ut r filter i I 1 MOLLA J Sl rjn TAFiPO SCARICO OLIO Oil drain llJlI POMPA ouo Oil pUlip Length of spark in relation of engine R P M for all engines Voltage in relation of engine R P M measured at the bulb terminal for all engi nes Charging rate in relatk i of Engin 3 R P M Battery SAFA 3V2 8 h For all engines 22 Oil FILTER ASSEMBLY Thor...

Page 45: ...otch 3 Needle jet 260 B 260 B 260 A 4 Idle jet 40 40 45 5 Main jet 95 100 100 6 Float bowl gr 7 5 gr 7 5 gr 7 5 7 Pilot air idle screw llh turn open 1lh turn open IV2 turn open 8 Air cleaner F 35 1 F 20 F 20 NOTE With Carburetor 125cc with air horn A 200cc with air horn A 250cc with air horn B using air horn only the main jet must be changed main jet 95 main jet 105 main jet 108 45 ...

Page 46: ...he jet needle must be checked If the carburation seems to be lean the needle position must be raised If the carburation seems too rich the needle position must be lowered The needle is equipped with 5 grooves and the average position of the needle is at the third groove beginning from the top groove The 4th step corresponds to the throttle valve opening from 3 4 to fully open position Section C of...

Page 47: ...aving to disassemble the complete machine it is advisable to dismantle the front part Arst The machine can be divided in various groups depending upon the function FRAME includes the skeleton of the machine front and rear suspensions and handlebar Wheels and brakes fuel tank fenders tool boxes and chain guard compose the BODY ELECTRICAL SYSTEM Head light tail light battery horn and stop light swit...

Page 48: ...king with 11 mm wrench and pull out the axle and remove the wheel from the fork Unscrew with 10 mm wrench the 6 fender fastening bolts and slide the fender through the top to remove it Remove the cotter pin from the dampener rod and unscrew the knob Pull out the Unit from the top being careful not to drop the lower components Dismantle the handlebar clamp using 10mm wrench to remove the 3 screws a...

Page 49: ... L 49 Loosen special locking bolt with 10mm wrench Remove the two fork tubes bolts 14mm wrench Remove top fork bracket Remove the two head light bolts with 14mm wrench ...

Page 50: ...ial wrench Slide out the fork from the bottom Pullout the front bolt to remove the fuel tank Disconnect the fuel lines and unlock the plate with spring located in between the seat and the fuel tank Then using a 14 mm wrench remove the front bolt and the two rear bolts of the seat 50 ...

Page 51: ... the lower tool box fastening bolt Pull out the battery The same bolt also fastens the rear fender Remove the tail light wires from connector THE ELECTRICAL Disconnect the electrical wires from respective battery terminals Disconnect the stop switch wires Unscrew the battery strap bolt Remove the horn wires 51 ...

Page 52: ...ove master link chain and loosen the axle nuts with 22mm wrench With the same wrench unscrew the shaft Pullout the wheel tilting the motorcycle to one side 1 7 Using 14mm rench unscrew the brake lever bolt Remove the brake lever and shaft Remove the foot pegs using 17mm wrench Remove the stand using 19 mm wrench Remove the rear fender bolt and pullout fender 52 ...

Page 53: ... passage holes of the shaft on the frame Control the alignment of the shaft and thoroughly clean the grease passages Lubricate the shaft and swing arm bushing with grease Insert the shaft after aligning the swing arm with the frame and thrust washers Tignten the shaft until its shoulder is touching against the swing arm Install the locking nut on the other side and tighten at 60 ft lb NOTE The swi...

Page 54: ...AE 20 oi i G 65 oz 2 3 for each shock absorber 3 way Adjustable shock absorber Technical data 1 Kg 14 lb 31 2 Kg 34 lb 75 3 Kg 54 lb 119 Insert the two half rubber rings and steel bushings at each opening of the shock absorber and slide it on the respective shafts Tighten at 25 ft lb using 17mm wrench 54 ...

Page 55: ...en it with bolts as shown in the figure ùlongside Install the rear wheel as shown in the figure NOTE The anchor slot of the brake plate must be matched with the plate which protrudes from the right hand side of the swing arm 55 View of rear hub ...

Page 56: ... 24 3 16 ball bearings with heavy grease on each steering cap Slide the fork in position and screw on the threaded steering cone Assemble the top fork brocket and the two fork tubes bol ts Install and lock the steering nut Tighten special pinching bolt Adjust the steering mechanism by tigh tening the threaded steering cone until the teering is free but without play 56 ...

Page 57: ...p after I c I olt hùs been removed IMPORTANT NOTE To remove the hydraulic tube Turn clockwise the plug key n 14 mm to reassemble reverse the operation 1 Cl i I L i i i i i i I i i I iI i i I i i I 1 1 I ei ii Gì i 1 i i 1 IIi II ii ii I 1 ill i 9 I i Ô To remove fork tube from fork Dismantle the top bracket bolt Loosen the lower bracket bolt then pull tube out from the bottom 57 ...

Page 58: ...Install the front fender Jacking the bolts with lOmm wrench Insert the front wheel being careful to match the slot of the anchor plate with the protruding plate of the wheel support View of front hub 58 ...

Page 59: ...D LIGHT B DIMMER SWITCH C RECTIFIER 50V 14A o IMPEDENCE E BULB 6V 15W F TAIL LIGHT G TAIL LIGHT BULS 6V 3 SW H Cor NECToa BASE I IGNmON SWITCH L SWITCH FUE 10 A FUSE 15 A SPARK PLUG H TISION COIL FLYWEL MAGNETO 2S 5W BAT HORN 6V 25W STOP LIGHT SWITCH II Install the head light 33 WIRING DIAGRAM FOR 3 WIRE FLYWHEEL MAGNETO 59 ...

Page 60: ...igh tension coiL Lock the two bolts firmly Install horn using 14mm wrench to lock the bolt Hold the wiring harness in position using the special steel strap 34 BATTERY I nsert battery and attach the as on Pg 62 wire 60 ...

Page 61: ...pproximately 3 4 above plates G Let the battery rest for about two hours then bring back to the required levei by adding as much sulphuric acid as necessary Then charge at 3 4 amp rate for eight to ten hou rs 1 Once all the above operations have been completed the battery is ready to be placed in position Every month check the battery level which should always be about 3 4 of an inch above plate i...

Page 62: ...after the desired position of handlebar is set Install the dimmer switch Install the felt under fuel tank and slide the tank as shown in the picture alongside I nstall the front bolts and attach the hook to the tank Install the seat and front bolt Align the slots of the two rear seat brackets with the rear fender bolts Press the seat down and lock firmly with 14mm wrench 62 ...

Page 63: ...le 63 Vi L1lC iegi YY Jt ci IIOJII PIU II n c i IDIIUVY Remove the motorcycle from the stand Sit on bike and adyust the chain utili this has at least 5 16 to 1 2 slock moving the wheel backward of foward turning the chain tension nuts After this operation chech alignment of wheels ...

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