Benelli Sprite-barracuda Installationsanleitung

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Sprite - Barracuda SHOP MANUAL

125cc 200cc 250cc FOUR AND FIVE SPEED

COSMOPOLIAN MOTORS. .INCORPORATED

JACK~ONVILLE & MEADOWBROOK ROADS, HATBORO. PA. 1904

.r (215) OS 2.9100

t:NulNt: - ::ingle cyiinaer 4 strOKe - uver lledO vaives - oore :J4 rnm. - .:truKe ::"l mill. - \..yiiiiuei

displacement 123,7cc. - Compression ratio 9,5 to 1 - CV. 16 at 8.800 R.P.M. - Distribution with

stand3rd cam - Intake open 30° BTDC - Intake close 75° ABCD - Exhaust open 75° BBDC - Exhaust

close 30° ATDC - Valve clearance with hot motor 0.006" - Forced lubrication by gear pump

60 L/H Oil capacity 2 qts - Gravity fuel supply 98 to 100 octane - Carburetor UB 22 BS - Ignition

by alternator flywheel magneto with external H.T. coil - Ignition advance 19° - Plus automatic

advance of 25° - Point gap 0.016" - Marell¡ Plug CW 260 L - Champion plug N. 3 - With multiplate

clutch - Costant mesh gear box - Foot shift pedal - Primary transmission by helicoidal gears -

Secondary transmission by chain 1/2" x 5/16".

FRAME . Combination of pressed steel and tubular " Double action hydraulic front fork -

Rear swing arm with adjustable hydraulic shock absorbers.

TIRES - Pirelli 2.75 x 18" (rib.) front wheel - 3.00 x 18" (univ.) rear wheel - Expanding type

brakes.

LIGHTING EQUIPMENT - Alternating current 6V 7 amp equipped with battery to ensure

steady supply of current to lights and horn - Large 130 mm. headlight - Headlight: 6\1 25/25

S. B.

OVERALL DIMENSIONS - Length 76.44" - Width 27" - Height 36.64" Weight 229 Ibs. (DRY) -

Fuel tank capacity 3,5 gallons - Reserve .05 gallons . Maximum speed 7~ MPH - Fuel

consumption 90 MPG.

MOTORCYCLE 200cc. (Technical data different from 125cc.)

ENGINE. Bore 66,5 mm. - Stroke 57 mm. - Cylinder displacement 197,9cc. - Compression

ratio 8,8 to 1 - CV. 19,5 at 8.600 R.P.M. -Carburetor UB 22 B5 - Ignition advance 9" 30' -

Plus automatic advance of 29" with flywheel magneto ADP 791 AN.

. (Note: with flywheel magneto ADP 54/2ANB ignition advance 17' - plus automatic advance

of 25").

TIRES - Pirelli 3.00 x 18" rib. front whee! - 3.00 x 18" univ. rear wheeL.

OVERALL DIMENSIONS. Weight 231 Ibs. (DRY) - Maximum speed 90 MPH - Fuel consum-

ption 85 MPG.

MOTORCYCLE 250cc. (Technical data different -from-1-25cc.)--------------------

ENGINE. Bore 74 mm - Stroke 57 mm - Cylinder displacement 245.1cc. - Compresskin ratio

8,5 to 1 - CV. 24 at 8.500 R.P.M. - Carburetor US 24 B5 2 - Ignition advance 9'" 30' - Plus

automatic advance of 29° with flywheel magneto ADP 79/AN and ADP 78/2ANB.

TIRES. Pirelli 3.00 x 18" univ. front wheel - 3.25 x 18" univ. rear wheeL. .

OVERALL DIMENSIONS. Weight 232 Ibs. (DRY) - Maximum speed 95 MPH - Fuel cons'Jmption

80 MPG.

, 2:

\ \.,

\14 15

30 i

29 \

1Front fork 14 Petcock 27 Rear foot rest

2Front fender 15 Tool box 28 Stand

:i Headlamp 16 Strap 29 Kickstart

4Switch key 17 Seat 30 Foot rest

,. Clutch lever 18 Rear light 31 Brake pedal

Ii Dimmer switch 19 Rear fender 32 Oil drain plug

i' Damper 20 Shock absorber 33 Clutch adjuster

BHandlebar 21 Chain guard 34 Frame

9Front brake lever 22 Rear wheel 35 Horn

10 Throttle control 23 Rear hub 36 Front wheel

li Gas cap 24 eh ¡¡ 37 Front hub

1:1 Carburetor 25 Chain adjuster

1 :3 Gastank 26 Rear fork

Special tools are made in order to facilitate disassembly and reassembly operations, and used

with metric wrenches, will enable you to perform all necessary operations.

A B~

~~ ~

A Thread protecting bushings

B Piston pin shaft extractor -l

C Piston extractor .J

o Countershaft sprocket holder

E Countershaft sprocket wrench

F Engine pinion holder

G Engine pinion puller

H Engine pinion puller

I Flywheel magn~to holder

L Flywheel magneto extractor

M Clutch hub holder

138&139/MB

144/nB

141/HB

140/HB

13 11MB

1431MB

146/HB

13 21MB

1371MB

1301MB

N Clutch spring tool

o Universal puller

P Cam follower bushing extractor

Q Crankshaft spacer

R Kich starter spring holder

S 5mm Allen wrench

T Shifting drum puller

U Cam gear extractor

V Engine support

i 3 SIHB

133/HB

134/HB

G 276

1421MB

G 262

136/1113

147/HB

1451MB

Before performing any operation, it is advisable to thoroughly clean the machine, in order to

prevent any dust particles from accumulating on engine components.

1 ) Remove engine oil, using 27mm wrench to unscrew oil plug. Then remove oil filter

assembly.

2) Loosen carburetor clamp with 8mm wrench and pull out carburetor after air fìlter has

been removed.

-:3) Remove electric wires from junction box.

4) Unscrew fuel lines with 12mm wrench.

5) Pull out engine breather tube.

6) Loosen clutch cable clamp and pullout cable.

7) Pullout the spark plug cap.

8) Remove with pliers, master link clip, master link and chain.

9) Unscrew foot peg bolts with 17mm wrench. Remove knurled nut of brake rod.

10) Remove exhaust pipe and muffer.

11) Unscrew lower engine stud nut using 17mm wrench - press out stud.

12) Remove upper engine studs nuts with. 14mm wrench, also studs and engine from frame.

To reassemble, reverse above instructions.

Engine view flywheel magneto side

~--

Engine yiew clutch s.ide

NOTE:

Due to the unique characteristics of the engine, most of the operations shown in this book

can be made with the engine on the frame. Only if the crankcase must be split, will engine have

to be removed.

By removing the left hand cover, the flywheel magneto, clutch adjuster and countershaft

sprocket are accessible.

By removing the right hand cover, the clutch, preselector components and cam distribution

gears are visible. These are operated in oil bath, therefore, this cover must be perfectly sealed.

The cylinder head, rocker arm and cylinder are removable from the front side.

i-;:

iiuiiu ..VYC;I \JIYVVIICC¡ I(la~I'taU ~IU~J Wltrt

tool Sf removing the three fastening

screws.

Remove the flywheel magneto nut, using

19mm wrench, holding at the same time,

the flywheel with tool i.

Lock the flywheel puller L in position and

with 22mm wrench, loosen the flywheel

from crankshaft. Tap on the puller bolt

slightly with a hammer if the flywheel is

hard to remove.

Before removing the backing plate, it is

advisable to made a reference mark on the

crankcase in order to facilitate the

reassembly operation.

Remove clutch lever support screws using

tool S. With screw driver, unscrew flywheel

protection cover fastening screws.

Holding kick starter spring with tool R,

remove with screw driver the spring

fastening screw.

To remove countershaft sprocket it is necessary to:

i) Lift up the safety washer loop.

2) Install the special tool D.

3) Remove the nut with special wrench E, holding at the same time the countershaft sprocket

with tool D.

Wi th lOmm socket wrench, remove the 4

rocker cover fastening screws. Pull out

cover and aluminum gasket.

Before removing with 12mm socket wrench:

the four cylinder head nuts, be certain

that the piston is in compression stroke

position. Pull out the rocker arm support

carefully in order. not to damage the

threads of the cylinder studs.

Pull out the cylinder head, gasket, cylinder

and base gaskets.

Remove with plyers the two piston pin

circlips.

Insert the pin B in the tool C. Install the

tool C on the piston. (It is advisable to

slightly heat the piston before removing

the pin).

Turn the spindle until the piston pin is

removed from the connecting rod.

NOTE: It is not necessary to remove the piston rings, to remove the piston.

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