“WSA SERVICE SHEET No. 504 Reprinted March, W960 MODELS Di, D3, D5 and D7 ENGINE DISMANTLING FOR DECARBONISING Decarhouising shoul be carvicd ont at regular intervals of abunt three (honsane utiles (3,000 fan.) if consistent results are to be expected, ‘The symptoms indicating an xcewive deposit of carbon are undue ronghness of the engine and a leudency to pink under load, erratic runuing with excosive four : falling off in power, This latter item is particularly noticeable when the exhanst port becomes forled with carbon as it causes an obstruction to the free escape of the exhaust gas, and interferes with the correct scavenging of the cylinder which is so necusary for the (transfer of combustible mixture from the cra il cight stroking, and an appreeiat efficie cause, Fefore commencing to decarbonise the engine it is necessary Lo slacken the two bolts holding the petrol tack lo Uke steering head, ly the rear petrol tank securing bolt which pases trough the frame, and carries the earth wire of the electrical systen. Diseonneet the petrol pipe from thetank tap, after (urning fucl off at tap and raise (he rear of the tank about 1 in. to allow Ue removal of the cylinder barrel ever dhe long ancuring stds. ud to remove enti Removal of Gylinder First remove the carburettor from its stub at the rear of the cylinder by releasing: (he clip bolt by means of whieh it is attached. ‘The exhaust pipe amust also be diseonnected ing fhe union unt at the front of the cylinder barrel by means of the special "C"* spammer included in the tool kif, If this nut should prove unduly obstinate, a few drops ol penetratitig ofl slonk] he applied to the threaded portion immediately above the nut ail a little time shonkl be allowed for this to act before attempting to miscrew the mut. Discomneet (he high tension lead from she sparking plug nd unscrew the latter. hy vel aul barrel are attached to the crankease by means of leur kong stnds and when the four nuts on the top of ihe cylinder heasd are removed, the head ca easily be lifted clear, followed by the evlinder barrel. «care when removing the latter to eon of the hore im order thal iL may not be ‘The evlinder head support the piston as it emerges from damaged as it falls clear, Piston Place the eylinder heal ard barrel on one si It should not be necessury Le remaye this from the eounecting rod, fut il it should be desired to do this for any reason, first remuve the civelip Crone one ond of the ynelgeon yin pH a bench and examine the piston, sing a pair of pointed nose pliers or somw suitable instrume Then holding the piston fienly i the hand, bap tl Hit is too tight to move, if can be reased hy warming the piston by means of a rag soaked in hot water and wrung out. Application of this rag will eanse the aluminium alloy of the piston to expand men than tie stecl gudgeon pin, thus releasing the latter whieh car then be fively pushed or tapped out. Marl the inside of the piston skirt to indicate the front of the piston as originally fitted. to lever the civelip out. guilgeon pin out from the other end.B.S.A. Service Sheet No. 504 (contd.) Scrape amy carbon whiele his xecummuleted on the crown of the piston, Gaking care not to damage the relatively soft surface of the metal itself, and after removing all the carbon, polish lightly with fine cmory cloth if desired and finally wipe elean with au oily rag. Piston Rings Now examine the piston rings noting that these are located in their grooves by mies h engage in the pistoti ring gaps. If in good condition, the rings will be fowl to present a uniformly sinooth metallic surface over their entire peripheries, and if Ley are in this couchtion and obviously have a cerlain suount of “springiness' as evidenced by the fact that their fee gap is considerably greater than (he closed gap when in the bore (sce Service Short 806) they should not. be disturbed. U1, on the other hand, the rings shew signs of heat as evidenced hy brown or wore highly discoloured pateles, Whey should be replaced by new rings, and te Chis case patiodar atlention: stent be paid da (le fit of the ends of the tings on their locating pugs i and they should also be checked in the bore to ensure tha te gap. ‘Those points will not arise if genuine 9, ane already correct when the 2 spares are not obtainable, these points must feccive careful attention. First place: the ring in the eylinder bore in a position where it is clear of the ports and, making certain that it is square by pressing the skirt of the piston against ih or a suitable bar of material of the correct diameter, examine the gap which should be not less than 008 in, (2.mm,), Having satisfied yourself on this point, place the ring in its groove on the piston and make certain that it is free without perceptible up and down play. Tf i self is clean, rub the ring down on a piece of fine emery cloth laid on a dead flat surface, using a rotary motion of the arm to cosure uniform prosstire on the ring, As snort as ing is found ta be free in its groove, wipe it absolutely clean and tit it into position, ol pogs whi the piston ring grooves, they have an adequ spares are filled as the gaps on thes rings are sent oni, but if for any reason genuine 1S. not free and the groove Check alse that then: is sufficient glearance between the inner portion of (be gap and the locating peg in the groove. Do this by closing thy ring in its graove by finger pressure ‘until there is ne gap, (hus shewing that there is clearance at the peg underneath. Hf the gap will not close, indicating that the steps are binding on the peg, case the steps geutly with a dead smooth file. Lf the piston has been removed from the connecting rod refit it, first putting a smear of oil on the gudgeon pin, not forgetting a new circlip to replace the ‘one which was reitoved. Note that the pistou ring gaps slould face lowards the rear on D1 models and towards the front on D3, DS and D7 models, Then put a piece of chan jag over the piston and crankcase mouth and turn your attention ta the cylinder barrel aml head, Cylinder Head and Ports Remove all carbon deposit from the cylinder head, bearing in mind again that the ssily damaged if the decarbonising tool ix carelessly applic, and carefully wipe clean to ensure the removal of all loose particles. Most of the carbon deposit likely to have accumulated in the eylinder will be in the exlaust port, and this is most important as explained above, Scrape this out carefully, taking care not to let the tool slip into the bore and damage Uw surface of the latter. Examine the transfer and inlet ports for the presence of carbon, although this is unlikely to be heavy, and finally wipe the ports and the cylinder bore absolutely clean. aluminium is soft audB,S.A, Service Sheet No. 504 (continued) Big-end Bearing While the cylinder is off it is as well to test Lhe big-ond bearing for wear, “This is done by taking hold of the connecting rod stem and pulling it upwards until tie crank is at top dead centre. Then holding it in this position try gently hut firmiy to pull and push the cmniceting rod in the dircetion of its travel in order to feel wheiher there is any play. If the big-end inay be possible te rock the red sideways, Le. at right angles to the axis of the machine, Tt verti phty is perceptible in Uie big end it must be deeided whether the amount in evidence ix permissible or not. The asserbly is not likely to require replacement, however, provided that the machine has been carefully used ane adeqnately Iubricated, for the hig-cnd hearing is of ample dimensions for the work it las to de. But if for any reason the big-end bering has deteriorated as the result of neglect or abuso, it should be replaced ina sound condi ion there should be no play in this cnrection, althongh it Re-assembly Before altempting to repkuce the cylinder Ixurel over the piston, sinear the latter generously with cugine oil and then place it over the piston, carefully manipulating the tings into the end of te bore and secing that they enter freely withent the application of farce, As soon as the cylinder barrel is home, replace the cylinder hyad aucl put the washers and nits an (he four holding down bolts. Tighten ihe mnts in diagonal order so as Lo avoid alistortion. nine the sparking plug (sue Service Sheed 808) and eefit if sound. Before refitting, the exhaust pipe and silencer should be examined for freedom from carbon and cleaned if necessary, Refit the exhaust pipe and carburettet, lower the rear ‘of the tank into posilion and inger( Uhe long securing belt, after passing it through the earth connection tag attached to the electric wiring harness, Ensure that face of tag is ¢lean and free from dirt or corrosion 50 that it makes a good contact. Tighten up rear and frout tank seauring bolts, bs. MOTOR CYCLES LTD. Service Dept, Waverley Works, Birmingham 10. Printed in Evgland.