HEINKEL-TOURIST 103 A-1 Technical Data Manual
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HEINKEL-TOURIST 103 A-1 Technical Data Manual

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Summary of Contents for HEINKEL-TOURIST 103 A-1

  • Page 1 https://www.motorcycle-manual.com/...
  • Page 2 Guarantee becomes invalid. Our Customers' After-sale Service Department will always welcome any hints and suggestions which you may care to give us for the enlargement and improvement of this Manual. ERNST HEINKEL AKTIENGESELSCHAFT STUTTGART-ZUFFENHAUSEN Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 3 For example, 10/2 : 10 is the number of the illustration and the figure 2 after the oblique stroke refers to the part number in the illustration in question. ERNST HEINKEL AKTIENGESELSCHAFT STUTTGART-ZUFFENHAUSEN Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 4: Table Of Contents

    Drawing of Assembly Jig for Scooter Engine ....Table for Service, Maintenance and Greasing ....54 Workshop Manual Heinkel Tourist 103 A-1 page...

  • Page 5: Technical Data

    Jet needle, conical 15 x 1.95 Ø number 3 Mixture screw 2½ x turns open 1½ turns open adjust to best idling Air filter "Knecht" micronic air filter *) see pteng (www.pteng.de) Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 6 26 psi driver and passenger 18 psi 29 psi driver with sidecar passenger 22 psi 29 psi 22 psi driver with pillion passenger 22 psi 36 psi 29 psi and sidecar passenger Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 7 *) Hint in year 2004: because of difficulties with the clutch, never use modern HD-oil or synthetic oil. Only use classic oil for the engine. See pteng (www.pteng.de) In the interests of technical development, we reserve the right to make modifications. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 8: Exchange Engine

    Carburettor Bowden cable. Note: Owing to import restrictions, import duties and for other reasons it has not, unfortunately, been possible for the Factory to apply the German Engine Exchange Scheme to foreign countries. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 9: Special Tools

    5 mm. key for starter dynamo 407/W 30 Assembly sleeve for radial gasket 407/W 29 Assembly sleeve for sealing cap commercial type Tension wrench (Torque-metering spanner) 0-6 mkg. 404/W 10 Ignition timer Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 10 Milling cutter 32 mm diam. 45.0° commercial type Milling cutter 32 mm diam. 30.0° commercial type Cutter for adjusting valve seating commercial type Guide for cutter for adjusting valve seating Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 11: Miscellaneous

    4. Close the fuel cock, disconnect the fuel line at the carburettor; remove fuel tank. (Also remove rubber cushions beneath fuel tank.) 5. Undo air filter locking screw and remove air filter, take off car- burettor. Assembly jig for scooter engine Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 12 50. When fitting Genuine HEINKEL Exchange Engine, check oil level. If necessary, fill in oil of well-known brand, such as e.g. Mobil Oil Special. Prior to operating, change Micronic filter insert. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 13: Dismantling The Cylinder Head, Cylinder And Piston

    Please note: To avoid bending the connecting rod, on no account knock the gudgeon pin out. 5. To strip the engine completely, undo nuts 7/5 and take off the bracket. Dismantling the piston Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 14: Reassembling The Cylinder Head, Cylinder And Piston

    Fit cooling baffles and air outlet hose. 13. For further assembly, reverse the procedure as outlined, under "Dismantling the Engine - Reassembling the Engine", page 9, paragraphs 6, 5,4 and 1. Fitting rocker arm shafts Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 15: Adjusting The Valves

    The valve tappet clearances are: Inlet valve 12/1 0.15 mm. Exhaust valve 12/2 0.20 mm. 4. Once adjusted, lock the setscrews with nuts. 5. For assembly, the reverse procedure is to be applied. Adjusting the valves Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 16: Dismantle, Ream But And Assemble Connecting Rod Bush

    Ø hole for piston piston connecting gudgeon gudgeon rod bush White + 0.003 + 0.0005 - 0.0025 + 0.0425 Black + 0.0005 - 0,0025 + 0.0275 - 0.002 - 0.005 + 0.0450 Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 17: Dismantle And Assemble Cylinder Head, Grind In Valves

    (smooth surface!), proceed to finish-mill. For this purpose, leave milling operator in same position. Only operate rapid-action regulator 17/7 and 17/8 (see paragraph 14) and repeat procedure as outlined in paragraph 13. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 18 + 0.028 mm. and/or if valve seat rings are very worn. 27. For further assembly, reverse the procedure as explained under "Reassembling the Cylinder Head, Cylinder and Piston", page 12, paragraphs 7, 8 etc. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 19: Check Piston And Cylinder

    (See Table of Original and Oversize groups on page 18). Should Measuring the cylinder the wear exceed the adjusted ORIGINAL size by 0.15 mm. or more, the cylinder and the piston have to be exchanged. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 20: Table Of Measurements And Oversizes (Cylinder And Piston)

    60.46 Ø + 0.020 + 0.020 60.47 Ø + 0.030 60.94 Ø - 0.010 60.95 Ø + 0.010 61.0 Ø + 0.010 60.96 Ø + 0.020 + 0.020 60.97 Ø + 0.030 Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 21: Dismantling The Clutch

    Remove wire snap ring from clutch insert by applying screw driver (watch out!) and take off end separator clutch plate. Remove control segment 24/2. Clutch cover with gear an clutch levers Removing clutch by using compression tool Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 22 25/5 into the bore (fixing for spring leg) on the swinging arm. Fasten rear wheel hub by fixing jig claw to bolt. Using socket spanner (SW 24), undo castle nut and remove hub. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 23: Fitting The Clutch

    Remove fitting tool and compression jig. 11. Fit the shift segment 30/2. See that the mark 30/5 conforms to the two lines on the control roller 30/4. Fitting the clutch Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 24 12. Clean the face surface of the crankcase, smear it with grease to encourage better adhesion of the gasket for the clutch cover, then fit gasket. 29/3. 13. Fit assembly sleeve (407/W 29) 29/1 over the clutch pin, and assembly sleeve (407/W 30) 29/2 over the shift segment, fit the clutch cover with built-in radial gasket for shift segment, and rubber cap fitted for clutch pin.

  • Page 25: Dismantling The Dynamo

    6 Apply the retaining arm of jig (401/W 9) 34/1 or jig (407/W 21) 2/10 (using the two bores on the armature) and undo screw (SW17)39/3. Remove disc and spring washer. Locking the fan wheel Centrifugal governor Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 26 Remove this latter, watching out for the radial gasket. 9. Take out the three countersunk screws 37/1 and remove the spiral. 10. Remove spring from shaft. Taking off the armature Removing the spiral Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 27: Assembling The Dynamo

    10. Fit fan housing, secure it with three screws (SW 14) 41/2 and spring washers, nut (SW 10) 41/1 and spring washers, lock nut 41/3 with sealing ring (smear threads with sealing compound). Armature, Screw 10 K Centrifugal governor Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 28 22. Fit clamp bracket with hex. screw (SW 17). 23. For further assembly, reverse procedure as explained on page 9 "Dismantling engine - Reassembling engine", paragraphs 1 to Check contact breaker for short-circuit to earth Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 29: Adjusting The Ignition

    For coarse adjustment purposes, there are three lines marked on the fan wheel and an integrally cast arrow on the fan housing. Top dead centre Mark: OT 44/1 = retarded ignition SP 44/2 = advanced ignition FP 44/3 = Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 30: Measuring Voltage And Current On Dynamo And Governor Switch

    It is recommended to have this work carried out by a local BOSCH Service station having at its disposal all the necessary Checking the charging current spare parts. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 31: Dismantling The Swinging Arm

    9. Remove swinging arm, take off small chain wheel. Small chain wheel with retaining plate and nut Removing the chain wheel Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 32 14. Remove Woodruff key 51/5 from driven shaft. 15. Take off rear collar bearing 51/4 with ball bearing 6303 and radial gasket (oil seal). 16. Remove rubber ring. Swinging arm mounting, rear collar bearing Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 33: Fitting The Swinging Arm

    15. Fix nut 54/5 (SW 10) in position between swinging arm and crankcase. Put sealing compound on gasket and nut. 16. Lock fan wheel by means of retaining jig (401/W 9); Put in gear. Swinging arm mounting, rear collar bearing Fitting swinging arm Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 34 Swinging arm mounting 26. Fit rubber protecting cap. 27. For further assembly, proceed as explained on page 25, "As- sembling the Dynamo", paragraphs 10, 20, 21, 22 and 23. Fitting fan housing Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 35: Table Of Bolts

    Kilogram-meter (mkg) : 1 mkg = 9.807 Nm. Kilogram-meter (mkg) : 1 mkg = 7.246 lb-ft. Newton meter (Nm) : 1 Nm = 0.738 lb -ft. Pound-foot (lb-ft): 1 lb-ft = 1.356 Nm. Workshop Manual Heinkel Tourist 103 A-1 page...

  • Page 36: Dismantling Crankshaft And Bearing

    6305. Please note: To avoid damaging the crankshaft, use only the necessary spe- cial tools, thus safeguarding the exchangeability of the former. Do not place crankshaft into a vice. Extracting ball bearing Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 37: Fitting Crankshaft And Bearing

    9. On the inside of the crankcase half, above the bore for the bearing, insert a metal strip 65/1 (180x25x0.3 mm). 10. Fit crankshaft 65/1. Assembly jig with crankcase half Fitting the crankshaft Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 38 1 to 26; page 12, "Reassembling the Cylinder Head, Cy- linder and Piston", paragraphs 1 to 12. Reverse procedure of "Dismantling the engine - reassembling the engine" page 9, paragraphs 1 to 13. Right hand half of crankcase housing Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 39: Dismantling The Gears

    9. Before removing the drag arm cross shaft, remove the Seeger ring on the outside of the right-hand half of the crankcase. Please note: To remove drag arm cross shaft, heat crankcase half. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 40: Fitting The Gears

    21 "Fitting the clutch", paragraphs 1 to 26, and page 12 "Reassembling the Cylinder Head, Cylinder and Piston", pa- ragraphs 1 to 12. Reverse procedure as per "Dismantling the engine; Reassembl- ing the engine", page9, paragraphs 1 to 13. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 41: Removing, Dismantling And Refitting Of Carburettor

    11. Replace defective gaskets. For reassembly, reverse above procedure. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 42 Float chamber cover Adjusting screw Valve plate Sealing disk Float Spring Idling jet Float needle Gas piston Pump jet needle Air adjusting scew Banjo connection Gas piston spring G 1 Clamp bracket Spring Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 43: Removing, Dismantling And Refitting Of Pallas Carburettor

    10. Remove defective gaskets. For reassembly, reverse above procedure. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...
  • Page 44 Pallas-Carburettor 20/14P Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 45: Removing And Fitting The Front Fork

    The Chassis with front fork brake lever on the handlebar must show resistance when the first quarter of its overall movement has been travelled. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 46: Disassembling And Fitting Of The Front Fork

    4. If necessary, remove burr from front piece (race support). 5. Using a tube, press fork race onto front fork, or use a light hammer. 6. Fit front fork as explained on page 43, paragraph 14. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 47: Removing And Fitting Of Front Wheel Hub

    4. Adjust the front wheel brake so that the wheel still turns smooth- ly. The brake lever on the handle bar must offer some resistance after having travelled first quarter of its overall path. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 48: Adjusting The Gear Shift Arrangement

    2. Screw in or screw off respectively the setting screw 77/5 on the clutch cover until the clutch lever on the handlebar can be moved by about 20 mm (outer tip of l ever), with the clutch being fully engaged. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 49: Adjusting The Headlamp

    5. If headlamp setting is to be adjusted, loosen the countersunk fillister-head screws on the support ring of the headlamp. 6. Adjust headlamp and check again as explained in paragraphs 3 and 4. Tighten the countersunk screws again. Adjusting the headlamp Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 50: Removing And Fitting Of Frame

    When fitting the control cables 79/1 and electric leads, these have to be placed on both sides of the frame as shown in figure 79, and secured with cable strings 72/2. Leads and cables Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 51: Power Curve

    H E I N K E L – T O U R I S T 1 0 3 A - 1 » « Performance diagram Speed diagram Climbing performance diagram Fuel consumption diagram (l/100 km = litres/100 km) Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 52: Wiring Diagram

    Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 53: Table Of Loads

    150 kg luggage 40 kg driver & pillion passanger 160 kg Admissible total weight 350 kg Weights, as heretofore indicated, are not to be exceeded. Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 54: Drawing Of Assembly Jig For Scooter

    Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

  • Page 55: Drawing Of Assembly Jig For Scooter Engine

    Workshop Manual Heinkel Tourist 103 A-1 page https://www.motorcycle-manual.com/...

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