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BSA Manuals
Motorcycle
B25SS Gold Star 1971
Workshop manual
BSA B25SS Gold Star 1971 Workshop Manual
250 cm3 & 500 cm3
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Introduction
Engine and Frame Numbers
Factory Service Arrangements
Replacement Parts
Repairs
Technical Advice
Proprietary Parts
Service Arrangements
Battery
To Fill and Charge the Battery
Dilute Sulphuric Solution
Contents
General Data
Index
Weights
Gear Ratio Calculation
Lubrication
Recommended Lubricants
Approved Lubricants
General Engine Lubrication Diagram
Engine Lubrication
Changing the Oil and Cleaning the Filters
Oil Pressure and Non-Return Valves
External Oil Filter
Non-Return Valve
Sump Filter
Contact Breaker
Low Oil Pressure
Crankcase Oil Pipes
Crankcase Breather
Gearbox Lubrication
Primary Drive
Gearbox Oil Level
Swinging Arm
Wheel Bearings
Primary Drive Lubrication
Control Cables
Rear Chain
Engine
B25 Engine Exploded
B50 Engine Exploded
Description
Decarbonising
Preparing to Decarbonise
Removing the Cylinder Head and Rocker Box
Pushrods
Removing the Valve Springs
Valve Rockers
Valve Guides
Valves
Pocketed Valve
Removing Carbon Deposits
Reassembling the Cylinder Head
Valve Grinding
Cylinder Barrel
Grinding in Valve
Removing Cylinder Barrel
Removing the Piston
Piston Rings
Checking Piston Ring Grooves
Small-End Bush
Reassembly after Decarbonising
Replacing Cylinder Barrel
Checking Valve Clearances
Location of Pushords
Removal and Replacement of the Engine Unit
Valve Rocker Adjustment
Transmission
Removing Engine Unit
Removing Primary Drive Cover
Clutch Dismantling
Generator Removal
Clutch Centre and Cush Drive
Clutch Chainwheel
Gearbox Sprocket
Inspecting the Clutch
Primary Chain Alignment
Primary Case Back Plate
Checking Alignment of the Primary Drive
Reassembling the Primary Drive
Fitting Primary Drive
Contact Breaker Points
Ignition Timing
Piston Position
Removing the Contact Breaker and Auto-Advance Unit
Setting the Ignition Timing Statically
Ignition Timing Light
Checking Ignition Timing with a Stroboscope
Using Pliers to Set the Cam
Oil Pump Removal
Timing Gears
Tappets
Removing Inner Cover
Dismantling the Oil Pump
Rebuilding the Oil Pump
Oil Pump Exploded
Refitting the Oil Pump
Timing Marks
Tachometer Drive
Correct Fitting of Tappets
Gearbox Dismantling
Gearchange Mechanism
Kickstart Ratchet Assembly
Selector Forks
Gearbox Reassembly
Gear Cluster Exploded
Fitting the Gearchange Return Spring
Fitting the Plunger Quadrant
Gearchange Spring Adjustment
Sequence of Gearchanging
Neutral Gear Position
First Gear Position
Second Gear Position
Third Gear Position
Fourth Gear Position
Splitting the Crankcase Halves
Parting the Crankcase Halves
Main Bearings
Big End and Flywheel Assembly
Flywheel Balancing
Refitting the Connecting Rod
Knife-Edge Roller
Flywheel Truing
Checking the Flywheels
Reassembling the Crankcase
Box for Supporting Crankcase
Carburettor
The Amal Concentric Carburettor Exploded
Dismantling and Rebuilding the Carburetor
Inspecting Carburetor Components
Hints and Tips
Throttle Cable
Fuel Feed
Tracing Faults
Banging in Exhaust
Excessive Fuel Consumption
Air Cleaner
To Cure Richness
To Cure Weakness
Variable Settings and Parts
Sequence of Tuning
Tuning the Carburetor
Pilot Air Screw
Main Jet
Needle and Needle Jet
Carburetor Air Cleaner
3Rd Throttle Cut-Away
4Th Needle
Frame and Fittings
Frame Dimensions
Frame Alignments
Testing for Oil Leakage
Steering Head Mandrel
Setting up the Frame
Refitting the Bearings
Removing the Bearings
Front Mudguard
Checking Alignment of the Swinging Arm
Trail and MX Models
Street Scrambler Models
Seat
Chainguard
Battery Carrier and Tool Tray
Rear Shock Absorbers
Prop Stand
Replacing the Prop Stand Spring
Cam Ring Positions
Centre Stand
Crankcase Shield
Rear Brake Pedal
Fuel Tank
Front Brake Cable
Fitting a Clutch Cable
Clutch Cable
Exhaust Valve Lifter Cable
Front Forks
Adjusting Steering Head Bearings
Testing the Steering Head for Play
Steering Head Adjustment
Renewing Steering Head Bearings
Reassembling the Steering Head
Dismantling the Steering Head
Fitting New Steering Head Races
Dismantling the Fork Legs
Changing the Fork Springs
Dismantling the Damping Assembly
Damper Valve Retaining Screw
The Oil Seals
Fork Leg Explained
Rebuilding the Fork Legs
Removing Oil Seal
Fork Alignment
Alternative Method
Bottom Yoke Twisted
Offset Steering Column
Wheels, Brakes and Tyres
Front Wheel with 6 Brake
Brake Shoes
Wheel Removal
Wheel Replacement
Brake Shoe Adjustment
Front Wheel Replacement
Front Brake Shoe Adjustment
Front Hub Dismantling
Rear Wheel
Removal of Rear Wheel
Rear Hub
Rear Chain Adjustment
Rear Wheel Sprocket
Renewing Brake Linings
Peening-Over Rivets
Chopping out the Rivets
Wheel Building
Wheel Balancing
Security Bolts
Balance Weights
Tyre Creeping
Security Bolt
Wheel Alignment
Removing and Refitting Tyres
Tyre Removal
Checking Alignment
Removing the First Bead
Removing the Tyre
Tyre Replacement
Commencing to Fit the Tyre
Tyre and Tube Assembled Ready for Fitting
Fitting the First Bead
Tyre Maintenance
Completing Fitting of the Second Bead
Completing Fitting of the First Bead
Front Tyre
Rear Tyre
Electrical System
Electrical Box
Battery Inspection and Maintenance
Alternator
The Ignition System
Charging the Battery
Routine Maintenance
Checking the Low Tension Circuit for Continuity
Ignition Coil
Bench Testing Ignition Coil
Ignition Coil Test Rig
2 MC Electrolytic Capacitor
Checking the High-Tension Circuit
Terminal Identification
Sparking Plug
Periodic Check
Efficiency Check
Service Notes
Sparking Plug Diagnosis
Charging System
Checking Alternator Output
Rectifier Maintenance and Testing
Testing the Rectifier on the Machine
Bench Testing the Rectifier
Refitting the Rectifier
Checking the Charging Circuit for Continuity
Rectifier Test Sequence
Constructing a 1 Ohm Load Resistor
Zener Diode Charge Control
Electric Horn
Direction Indicator Lamps
Maintenance
Checking Performance of the Zener Diode
The Master Ignition Switch
Handlebar Switch Functions
The Left Handlebar Switch Connections
The Right Handlebar Switch Connections
Headlamp
Tail and Stop Lamp Unit
Beam Adjustment
Right Handlebar Switch Connections
Other Light Units
Stop and Tail Lamp Dismantled
Wiring Diagram
Chains
Primary Chain
Chain Measurement
Measuring Chain Wear
Chain Alterations and Renewals
Chain and Sprocket Inspection
Worn Sprocket
Chain Alterations
Correct Fitting of the Connecting Link
Torque Wrench Settings
Abbreviations
How to Calculate the Revised Torque Setting
Torque Wrench Extension
Service Tools
Useful Tables
Inches to Millimeters
Decimal Fractions of an Inch to Millimeters
Fractions of an Inch to Decimals and Millimeters
Millimeters to Inches
Decimal Fractions of a Millimetre to Inches
Drill Sizes
Letter Drills
Number Drills
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Quick Links
1
B50 Engine Exploded
2
Ignition Timing
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This manual is also suitable for:
B50ss gold star 1971
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