Sears 788.94360, Assembly, Operating Instructions And Parts List

Page 1: ...ive selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed accordingly WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOW ING INFORMATION AS SHOWN IN THIS LIST 1 The PART NUMBER 3 The MODEL NUMBER 788 94360 2 The PART NAME 4 The NAME of item Motor scooter COAST TO COAST NATION WIDE SERVICE FROM SEARS FOR YOUR SEARS MOTOR SCOOTER SEARS ROEBUC...

Page 2: ...od big end in this way the bearings are so efficiently lubricated as to permit a reduction of the percentage oil con ten in the gasoline 2 The improvement which the rotary alve brings to the thermo dynamic performance of the e gine can be appreciated by considering the at ness of the power curve this as is well know renders the engine capable or functioning over a wide rpm range and of adjusting i...

Page 3: ...amount prescribed in this booklet Ethyl gasoline should never be used Do not use Allstate compounded motor oil or other Praemium Heavy Duty Oil with detergents The inexperienced operator should exercise caution in applying front wheel brake to avoid locking 1 Gear chllnge tWtStgrip with clutch control lever 2 Front brake lever 3 Throttle con trol grip 4 Light and dim mer switch 5 Front br ke jaws ...

Page 4: ... er 6 Sparkplug 7 En gine cut out an switch Fig 5 Ignition diagram transmission ratios 14 46 10 28 7 31 5 36 J 1 5 Engine to wheel Fi rst Second Third Fourth J t coil Clutch Wet type multi plate with facings of cork composition applied to the driving discs Ignition By flywheel magneto and external ignition Gear box 4 speed drive with mesh gears in oil bath Its two cable control is coupled with tha...

Page 5: ...nt wheel swinging hub pivoted at its bottom end through a stub axle Lighting and horn By flywheel magneto feeding bot ead lamp wo bea tail lamp horn and stop light see fig 9 Brakes Expanding type Font brake co trol lever on right hand side of a dlebars REar brake con rol pedal on right hand side of floo board The rear brake jaws are hinged on indepen de t pivots Wheels Of pressed steel sheet inter...

Page 6: ...meter has its housing in the middle of the handlebars and adds to the perfor mance and appearance of the scooter Accessories see specific table of Parts ist On request the Sears scooter can be equipped with the spare wheel and bracket ELECTRIC WIRING DIAGRAM Note he installatior diagram here carried out and the position of the various units correspond to those which are really mounted on the vehic...

Page 7: ... Fig 10 Feeding circuit 1 Fu 1 cock lever A eserve B Open C Closed 2 Float 3 Air c1eane and carburenor 3 1 Air ilter 4 Stoner iet 5 Set screw or thronle slide 6 Throltle slide 7 Air ven for moin iel 8 Hole on mixer top 9 Mixer 10 Main iet 11 Idling iet 12 Air vent for idling iet 13 Plug ior inlet hole for oil ror laying up 14 Idling odj Sler 15 Stoner valve 16 Intake port 17 Transfer ports 1a Exha...

Page 8: ...en proceed as follows Fig 12 Engine bonnet removal 1 Engine bonnet locking lever 2 Front pivot 3 Fixing hook 4 Hooked pivot Fig 13 Drive system 1 Gear change twistgrip 2 Clutch control lever 3 Ge change control cables 4 Gear shifter S Selector stem 6 Selector 7 1st gear 8 2nd gear 9 3rd ge 10 4th gear 11 Mainshal 12 Cush gear 13 Clutch N B Positions 1 2 3 4 01 the gear change twistgrip corresoond ...

Page 9: ...ont wheel a ohe screw spri g loaded see Fig 10 No 14 This screw controls the flow of carburated air through he duc from the idling jet and consequently the idling evs We recommend that customers refrain from re setti g this screw unless absolutely necessary or during dismantling and re assembling operations that should anyway be entrusted to a Sears Store Stopping the engine Push the earthing butt...

Page 10: ...keep your fingers off reflector surface Before setting the machine in motion if it has been delivered di rectly to the customer by the Factory check oil level in gear box by unscrewing the level screw marked OLIO from the cranckase see Fig 21 The scooter standing upright oil should just be about to flow out After the first 600 miles Replace oil in the gear box by the procedure as explained in the ...

Page 11: ... and the points should begin to open when the current in the primary ig i ion circui has attained its peak value 2 Grease he control cables 3 Change the oil in the gear box as stated on page 13 4 Grease the felt which lubricates the cam of flywheel magneto In case of shock absorber troubles overhaul or simply clean the assembly and change oil These operations should be carried out by you r SEARS s...

Page 12: ... miles Front wheel hub I Speedometer Lubricate with grease gun Every 2500 miles High Pressure Chassis flex drive and i i pinion Joints on brake Grease Every 2500 miles Allstate all purpose controls Gear Lubricator SAE 140 Ratchet qua Grease Every 2500 miles Allstate all purpose drant of gear Gear Lubricator SAE 140 shifter i Control cables Clean and lubricate i Every 5000 miles Allstate all purpos...

Page 13: ...l or lever too long Brake linings oily or worn down Brake drums and lininit SCrlltcned Top race of lop ball bearing too light Bottom races of the two bearings pitted 5 Gear pinion di engage of own ccord a Clutch snotches Gear pinions not lubricated pro perly b Clutch slips Springs feeble Plates worn or burnt c Clutch does not disengage com pletely Excessive play on control cable mm gap to 0 6 Repl...

Page 14: ...TABLE I PARTS LIST 2 15 27 I 10 16 17 18 21 2C 1 2 3 22 14 9 ...

Page 15: ...6 90819 Piston 3rd oversize with wrist pin witf figs 24 25 9 14 49290 Seal spring loaded for crank case clutch side 26 90820 Piston 4th oversize with wrist pin with figs 24 25 9 15 16 17 S 12485 S 521 49502 Bolt short securing crankcase halves Stud for fixing carburettor Gasket crankcase 27 97453 Crankcase assy Figs n 6 22 17 10 1 3 2 4 15 16 T I i 27 28 30 9 10 31 32 26 T II i 1 4 26 24 25 3 2 23...

Page 16: ...of con Roller cage end 20375 22313 I I I I FOR ENGINE PARTS LIST Clutch Crankshaft I I Figure ISpare Part Number I I I 5 I 93233 i I 97 6 I C RIPTION DES __ f for nut shake proo Washer flywheel securing for cra nkshaft woodruff Key he l side flyw 93233 th part n Crankshaft WI fig 5 fl wheel securing y Nut S 1544 I 2 1 6861 3 I 267 I Fi jure I Spare Parr i Number I 91060 16 ...

Page 17: ...with inserts 34 94760 Driving disc external of clutch 18 16821 Plate clutch centralizing 35 94425 Plate smooth of clutch 19 14457 Spring for fixing clutch cen tralizing plate 36 94743 Plate clutch with linings 20 89858 Thruster cl utch 37 59109 Washer spacer 21 83806 Lever inner clutch 38 150103 Gear clutch 22 50100 Cover clutch with inserts 39 94379 Plate spring of clutch 23 S 6708 Packing betwee...

Page 18: ... 2 3 4 5 S 1108 S 3108 87714 S 12787 S 2314 Nut for securing wheel Washer spring for nut secu ring wheel Washer plain for nut securing wheel Split pin for locking castle nut Nut castle for securing wheel 6 7 8 9 10 85914 Stud for joining brake drum to wheel 78480 Drum 92517 Plug for drum 46699 Seal spring loaded of main shaft 46700 Circlip 18 ...

Page 19: ... 20321 a 20322 Washer shoulder 1st oversize thickness 2 2 mm 0 086 Washer shoulder 2nd oversize thickness 2 35 mm 0 092 Washer shoulder 3rd oversize thickness 2 50 mm 0 098 Washer shoulder 4th oversize thickness 2 65 mm 0 104 a 20324 a 20323 38 38 Link brake Link brake Pin for rear brake links 42047 25 24 23 22 a 94975 I Mainshaft 903061 I I 94779 i 26 27 28 29 i i I I a I I S 426 5 6939 78821 001...

Page 20: ...ing of main shaft 2 82086 I Cage roller bearing I 3 81842 Roller 47 61 Washer shoulder roller bea ring Figu e I P N b Spare ar um er I DESCRIPTION I Figure Numoer 5 6 7 8 Spare Part I I 47218 1 77413 1 46631 150003 DeSCRIPTION Spring return of kickstarter Sector starting Plug Kickstarter g a Figs n 9 10 11 12 13 20 ...

Page 21: ...sector 14 15 16 7 S 672 46742 89229 S 5765 Packing Buffer for starting sec or Gear starting Rivet for sec plate washer 26 27 28 29 I I 48000 I 5141 I i 2457 1 I 94419 Blade short for starting sector Circlip for locking multiple gear ball bearing Roller for multiple gear layshaft 18 77370 I 77371 Washers plate ext and into of cush drive springs 30 97718 Ball bearing of multiple gear 19 78853 Spring...

Page 22: ...ESCRIPTION IFigure I I Number Spare Part DESCRIPTION 2 14501 Terminal 6 5 3055 3 662 Terminal 7 5 3105 4 S 5981 Cirdipi for f1ywheel extraction 97935 Cable earth with terminal 5 101119 Stator g a Figs n 23 33 22 34 36 24 30 32 37 1 38 6 35 7 31 28 29 15 Washer plain for screws se curing stator and coils Washerl spring for screw se curing stator 22 ...

Page 23: ...oil low tension N 2 with figs n 2 3 Condenser with fig n 2 Coil feeding H T ext coil with fig n 2 15 16 17 18 19 20 21 22 23 87646 2946 5 3056 2856 47577 5 3106 5 12554 625 622 Stator with fig n 36 Screw short for securing fan casing cover and dust cover Washer spring Screw long for securing fan casing cover Cover fan casing Washer spring Washer shake proof Fork spring Washer shim of breaker 31 32...

Page 24: ...3 58364 I i I Packing air cleaner 4 84797 5 S 4436 I Screw for air cleaner body 6 5 3105 Washer spring I Fig re ISpare Part Numoer I I I 7 5 14743 i 8 90926 9 90928 NFumber I Spare Par Igure DESCRIPTION 10 11 12 24 49542 5 3109 5 13762 DESCRIPTION Screw for air cleaner bod Air filter body Air cleaner g a Figs n 3 16 8 4 1 6 5 19 Screw for securing carbure Washer spring Washer plain ...

Page 25: ... for air cleaner 44 92712 Starter jet 20 21 82932 92410 Packing mixture filter Washer 45 46 85293 150045 Float Valve needle 22 150048 Jet idling 85297 Mixer 49 85295 Pipe 23 24 150049 Air hole on mixer top 47 48 150031 85291 Packing f float chamb cove Needle of float 25 150047 Jet main 50 85288 Pecking for pipe fig 49 26 27 28 29 30 31 32 33 34 85299 26018 92774 i 2613 i i 2612 I 58246 85298 i 852...

Page 26: ...ABLE VII 27 25 I 2 t PARTS LIST FOR ENGINE Geu shifter Low tension lOcket 8 tJl a B 7 Table VII tI U r ISpare Part I 70403 2 S 8230 3 70405 4 S 14402 5 70404 DESCRIPTION I r I Spare ParI I 26 DESCRIPTION ...

Page 27: ...carrying of gear shifter Spring of roller carr stirrup Adjuster Support g a Figs n 18 16 15 19 14 13 12 Nut Support gear shifter Nut Washer spring for gear shifter support Washer plain Gasket between support and crankcase 25 26 27 28 29 30 31 32 33 34 35 397 5 11288 90613 90372 90611 5 15120 I 557251 292 5 3105 5 1205 84737 Packing oil filling and drai ning holes Stud securing gear shifter sup por...

Page 28: ...ION DESCRIPTION 90740 Dual saddle Figs 2 3 46 47 40 39 41 42 43 44 451 2 97227 Cover saddle 3 94029 Grip on saddle 4 94146 T nk fuel with filling cap Figs n 9 10 7 6 8 5 11 5 6 7 8 85247 16724 4435 92217 Transfer indicating gas ratio of fuel Cap filler of fuel tank inserts Screw tie of filler cap Knob for filler cap j 28 ...

Page 29: ...1 Bolt securing saddle 39 84224 13835 56730 Rod tap fuel Flange tap fuel Buffer 40 Strap pipe f astening Washer plain sec saddle pin 17 18 19 S 3057 3221 I I 87467 Pipe plastic from fuel tap to carburettor 41 42 98834 S 14417 S 13880 Support central Screw Washer plain securing spring 20 84262 Grommet 43 S 1106 Nut securing spring 21 9641 Sediment bowl tie rod 44 90731 Spring central R H 22 9640 Se...

Page 30: ...CRIPTION S 10781 Rivet for model number 7 87019 Cover chassis 2 150898 Plate model number 8 S 12112 Nut self locking 3 72271 Beading windshield 9 60201 Washer plain 4 73111 Spring for sec lock tool box 10 83115 Spring grip cowl 11 83111 Grommet grip 5 S 14564 Plug Chassis of motor scooter Figs 12 83113 Grip 6 150760 n 1 2 13 85457 Hook o ...

Page 31: ... Grommet on chassis Tool box g a with Figs n 28 29 Locking clip Security lock tool box cowl with Figs 26 2B 29 30 31 32 33 34 35 36 37 3B 39 40 2944 10020B 5 12263 90523 90522 93122 I 5 12542 5 12118 5 3056 5 3106 5 1106 5 3054 151124 Split pin of tool box shutter Shutter tool box with inserts Screw securing licence plate Ornamental strip with attach tool box cowl With Figs 33 34 35 Ornamental str...

Page 32: ...PTION 2 3 4 5 3109 70646 70649 60536 Washer spring for shock absorber anchoring pin Spring rear suspension Shock absorber hydraulic rear g a Figs n 28 29 24 8 25 26 20 22 23 27 7 21 35 Bracket elastic 5 6 7 8 9 5 3108 5 12109 70642 70635 70641 Washer spring Nut securing bracket to frame Spacer for upper attachment Tube protection of shock abo sorber Stem of shock absorber 32 ...

Page 33: ...pport spring 28 2 22832 Valve discharge g a Figs n 18 17 19 16 17122 Ring lock of piston 29 70638 Body shock absorber 17 22828 Valve discharging with inserts 18 17385 I Washer seal 30 5 1214 Nut for securing engine to chassis 19 84603 Spring of seal washer 31 5 3114 Washer spring 20 70640 Tube inner of hydraulic shock absorber 32 5 14689 Bolt securing shock absorber bottom 21 5 6721 Packrng 33 818...

Page 34: ... DESCRIPTION 2 3 73405 S 10869 S 10868 S 10881 Cap strip Rivet securing inner strips cap of floorboard Rivet securing outer strips cap of floorboa rd Rivet securing outer strips of floorboard 5 6 7 8 73403 73404 73400 S 3110 Strip short of floorboard R H Strip short of floorboard L H Channel L H outer Washer spring for securing muffler to engine 34 ...

Page 35: ...H outer Washer spring for securing muffler to cylinder Nut for securing muffler to cylinder Washer plain Channel L H inner Screw self locking Strip R H mat retainer Strip L H mat retainer Mat rubber 23 24 24 25 26 27 27 28 29 30 5 12281 59188 59189 5 3106 5 1006 54146 54147 91047 5 12306 5 3060 Bolt securing stand R H clip of centre stand L H clip of centre stand Washer spring for center stand att...

Page 36: ...securing wheel Washer spring for nut secu ring wheel Drum front brake Stud securing wheel Nut for bolt securing mud guard Washer spring under nut se curing mudguard I 7 I I 8 I 9 10 11 Spare Part I 60201 57401 2957 S 3055 92714 DESCRIPTION Washer plain for bolt securir mudguard Bolt securing mudguard Bolt for securing mudguard t steering column Washer plain for securing mudguard Crest with fig 12 ...

Page 37: ...nd plate Washer lock Nut Lubricator stauffer Washer plain for stauffer lu bricator Ball bearing for front wheel axle R H side 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 I I I 2007 2443 78743 78738 90533 5141 5 8722 267 15982 99474 5 12528 78735 78737 78736 5 6716 75604 5 815 5 13879 5 2314 S 12787 92517 79227 83880 83883 S 13863 98652 S 13862 91621 Washer l...

Page 38: ...n of steering steer colum top ball bearing column bottom ball bearing 2 3751 Washer lock of steering co B 55986 Seat upper of steering column lumn to ball bearing top ball bearing 3 30566 Tube for upper buffer 9 77024 Ball cage for steering column 4 92667 Seat upper of steering column top ball bearing bottom ball bearing 10 56641 Seat lower of steering column 5 77023 Ball cage for steering column ...

Page 39: ...ink front brake R H Pinr for security lock Coverr security lock Packing KeYr for security lock Shock absorber front g a Figs 3 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 84603 97247 82585 S 13816 93468 17285 32812 S 13768 17122 26108 26101 90151 31443 31444 17118 93188 30567 15020 15019 9141 S 3111...

Page 40: ...SCRIPTION I Figure I Number Spare Part DESCRIPTION 70578 2 17492 3 97734 4 97733 5 S 14629 Lever clutch and front brake 6 70568 Washer plain control 7 60565 Washer spring Washer spring for securing control levers 8 101192 Gear change crank Washer 9 97356 Clip Washer 10 71039 Spring Screw secu ri ng control levers 11 70583 Screw sec speedo 40 ...

Page 41: ...n Washer plain for speedo Plate anchor Tube with inserts for geur change control Speedometer miles Washer spring Lever throttle control Screw Handlebars g a Figs n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 22 23 24 26 27 28 22 23 24 25 26 27 28 29 41 70589 70577 S 12136 100618 100586 70620 100617 S 12113 Tube for throttle control Rubber twistgrip Nut for screw securing control levers Packing...

Page 42: ...mcer DESCRIPTION IFigure I I Number Spare ParI DESCRIPTION 2 3 90512 14657 a 94 7 Wire gear change control g a Figs n 6 5 4 Nipple Ferrule 6 7 90513 S 11510 Sheath for gear change con trol cable with ferrull with Fig 3 Pin locking for rear brake pedal 90419 Cable gear change control with nipple fig 2 8 94451 Rear brake pedal g a witl Fig 9 5 26249 Terminal 9 93100 Rubber sleeve brake pedal 42 ...

Page 43: ...92796 Pin for brake links 28 90529 Strap for gear change sheats 16 S 1426 I Nut for bolt securing cable to brake links 29 94048 Washer for speedometer cable 17 90541 Tube protection 30 99011 Flex drive Fig n 29 18 82385 Clip gear change control 31 97112 Cable flex drive with washer 19 57321 Protective bellows 32 80279 Cap 20 15395 Nipple threaded 33 15718 Ring biconical 2 S 10 16 Screw clamp for g...

Page 44: ... with fig 4 Cable clutch with fig 9 Nipple Nipple on front brake and clutch control ca bles Nipple handlebars side Cable throttle with fig 11 Nipple carburettor side 15 16 17 18 19 20 21 22 23 24 25 90416 90420 I 90426 90422 90425 48171 92370 26249 S 10016 15395 90417 a 94171 Sheath fro brake with fig 4 Cable fro brake with fig 9 Wire throttle control g a Figs n 7 13 21 12 Wire front brake Figs 14...

Page 45: ... a Figs n 8 7 6 5 Nut Washer spring Flange with fig 9 Rim Bolt Roll tool complete Figs n 11 12 13 14 15 16 Spanner box 11 14 21 and 22 mm Spanner double open end 11 14 13 17856 14 84829 15 3204 16 11469 17 51199 18 5 12258 19 S 12277 20 S 3058 21 85083 22 S 1108 23 85097 24 85058 25 91999 DESCRIPTION Spanner single open end 8 mm Spanner double open end 10 7 Screwdriver Roll tool Buffer Bolt long B...

Page 46: ...TABLE XVIII II 0 I i 20 46 AP 8 1 1 1 1 33 tTiJ q V I J 17 34 6 ...

Page 47: ...cer tail lamp 101059 Gasket between chassis and tail lamp 18425 Stud for tail lamp attachment to chassis 24 25 26 27 28 29 30 31 32 150555 92184 70557 S 1003 S 3053 S 3103 55327 S 14555 55316 Packing for glass Bulb tail lamp Red reflector Nut Washer plain Washer spring Gasket STOP switch Screw securing STOP switch Switch STOP 20 21 22 16583 S 8431 97827 Bulb WQ beam for head lamp Screw secu ri ng ...

Page 48: ...ble fro head lamp to swHch 7 9 20 15 18 1 16 6 92372 Cable from switch to low ten 13 10 12 21 22 sian socket 18 55064 Cable from low tension socket 93257 Cable fro switch to head lamp to STOP switch 7 Cable fro switch to head lamp 19 92366 Cable from tail lamp B 93256 9 93487 Cable from switch to horn 20 92848 Tube insulating 10 84348 Tube insul for STOP switch 21 26930 Terminal 11 90644 Tube insu...

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