BMW R71 Instruction
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BMW R71 Instruction

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BMW R71 Sidecar Replica Instruction for Motorcycle
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  • Page 1: Table Of Contents

    BMW R71 Sidecar Replica Instruction for Motorcycle CONTENTS 1 MAIN STRUCTURAL AND PERFORMANCE DATA 2 RUNNING-IN OF MOTORCYCLE 3 OPERATION OF MOTORCYCLE 4 MOTORCYCLE COMPONENTS CHECKING AND ADJUSTING 5 MOTORCYCLE ELECTRIC SYSTEM 6 MOTORCYCLE LUBRICATING 7 LONG TERM STORAGE OF MOTORCYCLE...

  • Page 2: Main Structural And Performance Data

    1. MAIN STRUCTURAL AND PERFORMANCE DATA Components 1.2 Main Dimensional Data...
  • Page 3 1.3 Main Weight Data 1.4 Main Performance Data 1.5 Modes and Technical Data of Main Parts...

  • Page 4: Running-In Of Motorcycle

    RUNNING-IN OF MOTORCYCLE In initial operation period of engine, improper operation will speed up wering of parts because the parts have not been completely run in. Therefore running-in must be done for new motorcycle. Running-in period is divided into two phases: The first phase is from 0 to 1000 km and the second one is from 1000 to 2000 km.

  • Page 5: Operation Of Motorcycle

    OPERATION OF MOTORCYCLE 3.1 Preparation Before Start 3.1.1 Gasoline filling Before start, check gasoline and oil quantity first . Refill it if gasoline or oil is insufficient . Fill gasoline directly through the filter to gasoline tank . The gasoline level should be 15-20mm below the edge of filler port.
  • Page 6 3.2.2 Set the hand gear shift lever or foot gear shift lever to neutral gear position between gear positions No.1 and No.2 (see Figs 4 and 5). Check to see whether the gear lever is at neutral positicn by stepping lightly the kickstarter . If the wheels wouldn't move, the neutral gear position is properly set.
  • Page 7 3.2.7 Cut-in the ignition switch by use of key (turn the key counterclockwise for daytime driving and vice versa). 3.2.8 Press down the kickstarter slightly by foot to make the brake block insert into the ratchet wheel of the starting gear (No idle travel is felt). Then starting can be realized by stepping the kickstarter forcefully.
  • Page 8 3.5.1 Before parking, set the gasoline control knob to OFF and press down the float button to make all gasoline remaired in the carburetter burnt out. 3.5.2 Remove the battery to prevent it from being damaged by frost. NOTE : If starting motor is to be used due to engine flameout caused by improper operation to the motorcycle, hold the clutch lever to disengage the clutch, then start the engine with motor.

  • Page 9: Motorcycle Components Checking And Adjusting

    MOTORCYCLE COMPONENTS CHECKING AND ADJUSTING As the motorcycle had been adjused and tested before delivery, there is no need to make any readjustment. In case there is any fault with the motorcycle, trouble shooting should be performed as the following: 4.1 Spark Plug Gap Adjusting When new spark Plug is used or after the motorcycle has been driven for1000 km, spark plug gap should be checked with feeler gauge.
  • Page 10 NOTE: The mixture valve opening for engine CJ-750D can be checked and adjusted as follows: a. Open the valve chamber cover ( Fig.7) remove rubber block (Fig.10) from observation hole in crankcase, apply kickstarter to operate the crank shaft. When inlet valve of left cylinder opens, apply gently kickstarter to make the "O"...
  • Page 11 4.3.1.4 Loosen the securing screw, adjust platinum contact gap to 0.4-0.45mm by turning the platinum contact adjusting screw, and then tighten the securing screw. 4.3.1.5 Turn cam 180 more by applying kickstarter and check contact gap at the other end to see whether it meets requirement. 4.3.2 The distributor of engine CJ-750D is of FDQ-5 type, which is an automatic and centrifugal ignition advance distributor.
  • Page 12 4.4.1.2 Operate the crankshaft by applying kickstarter to make piston be in upper limit position of compression stroke, measure distance from piston top to cylinder end face and write down the value. Then operate the crankshaft again to make the piston be 0.5-1 mm to the upper limit position.
  • Page 13 4.4.2.3 CJ-750D engine ignition angle adjusting (see Figs 9 and 10). a. Remove the rubber block from observation hole in crankcase, apply gently kickstarter to make mark "6" on flywheel be in the center of observation hole (see Fig. 10) . Loosen distributor pressing nut (Item 1 in Fig.9 ) and turn the installation plate to make the scale align with the center scale on front crankcase and then tighten the pressing nut.
  • Page 14 varies 2 of ignition angle) . If it is felt in operation that ignition is in delay too much. rotate the distributor clockwise, and tighten the pressing nut after adjustment. 4.5 Carburetter Adjusting Two carburetters are used on left and right cylinders (one for each) in operation . Since two carburetters are used in operation simultanously they must operate in same state.
  • Page 15 4.5.1.6 Repeat the steps of para .4.5.1.4 and 4.5.1.5 to make the engine operate at min. stable RPM. 4.5.1.7 Tighten lock nuts (Item 4 in Fig.11 ) of the two screws. 4.5.1.8 Adjust the other cylinder at idle speed by using the above methods. Improper adjustment at idling will result in uneasy starting , unstable operation, even if it is started and single cylinder operation is impossible when a high tension cable is removed from the other cylinder and checking its operation.
  • Page 16 If acceleration is not satisfactory when two cylinders are operating in same state . In this case, lean mixture or rich mixture can be checked by closing the air valve narrower or opening the air valve wider . If its power performance becomes better after closing the air valve narrower, it is the lean mixture eausing the problem , which can be solved by checking fuel line for being unimpeded or by raising needle in throttle, valve for 1-2 grids .
  • Page 17 15mm before brake begins to function. The steel cable free stroke can be adjusted by adjusting hollow screw in front hub cap and the rocker position. The rear wheel brake is applied by foot. Its suitable free stroke is so adjusted that front end of foot brake pedal goes down 25 mm before brake begins to function.

  • Page 18: Motorcycle Electric System

    MOTOCYCLE ELECTRIC SYSTEM 5.1 Ciruitry 5.1.1 Generator complemented with engin CJ-750 is a positively grounded DC generator MZF-12, whose rated power is 65w, rated voltage is 6v. The motorcycle circuitry is given in Fig 14.
  • Page 19 5.1.2 Generator MJF-280B complemented with engine CJ-750MIM is a negatively grounded AC generator, whose rated power is 280w, rated voltage is 12v. The motorcycle circuitry is shown in Fig 15. 5.2 Control Switeh Operating 5.2.1 Ignition switch For daytime operation, insert a key into the switch and turn it counter clockwise to cut in switch contacts 1and 3.
  • Page 20 When it is pressed down, the horn operates and when it is released, the horn stops operating. 5.2.2.4 Turn light switch-when it is turned to left, left turn light comes on and to rights, right turn light comes on. 5.2.3 Electric starting pushbutton -press down this button is to conduct electric starting.
  • Page 21 5.3.8 The battery should be kept at dry and well-ventilated place, Fall, impact and upside-down store of the battery are strictly forbidden. 5.3.9 The battery plate should be cleaned frequently as it is corrode easily, the battery wires after being secured should be coated with vaseline or grease. 5.3.10 The dry storage battery can keep its dry charg within half a year.

  • Page 22: Motorcycle Lubricating

    MOTORCYCLE LUBRICATING The motorcycle should be lubricated according to Fig. 16 and periodic lubrication table. Standard lubes for the motorcycle are: Oil: HQ-6, HQ-10, HQ-15, and GB485-72 Calcium grease: ZG-1, ZG-2, ZG-3, ZG-4, ZG-5, andGB491-65 Sodium-base grease: ZN-2, ZN-3, ZN-4 and GB492-65 The shock absorber oil, which can be substituted by oil HQ-10, is made up of 25# transformer oil and 20# turbine oil each in 50% by volume.

  • Page 24: Long Term Storage Of Motorcycle

    LONG TERM STORAGE OF MOTORCYCLE To avoid corrosion and surface damage, the following should be done for long term stored motorcycle. 7.1 Remove spark plug, fill 30ml engine oil to each cylinder through funnel screen filter, refit the spark plug, apply gently kickstarter to rotate engine crank shaft for 3-4 times.

  • Page 25: Motorcycle Periodic Maintenance

    8 MOTORCYCLE PERIODIC MAINTENANCE The motorcycle should be periodically maintained as described in the following table :...

  • Page 26: Motorcycle Troubleshooting

    9 MOTORCYCLE TROBLESHOOTING Trobleshoot the motorcycle according to the following charts. NOTE: Smoking is prohibitted and fire is not allowed nearby in checking fuel system.
  • Page 27 140 MOTORCYCLE ELECTRICAL DIAGRAM...

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