Bridgestone 350 GTR Bedienungsanleitung
SERVICE MANUAL
Classic Cycles Technical Resources
1. TECHNICAL DATA ...................................................................... 1
2. FRONT and SIDE VIEWS of BRIDGESTONE 350 GTR ...................................... 3
3. Performance ............................................................................. 4
4. ENGINE ................................................................................. 6
Removing Engine ........................................................................................ 6
Notes of Caution ................................................................................. 6
Tools necessary .................................................................................. 6
Removing the Engine ............................................................................. 6
Mounting Engine on Frame ................................................................................ 8
Disassembling and Assembling Engine ....................................................................... 9
Special precautions ............................................................................... 9
Dismounting Engine .............................................................................. 9
Component parts of crankcase .....................................................................13
Assembling Engine ..............................................................................14
CRANK SHAFT • PISTON • ROTARY VALVE ............................................... 17
CRANKSHAFT AND ROTARY DISC VALVES .............................................................18
Construction ...................................................................................18
Inspection ......................................................................................18
Lubrication of the crankshaft ......................................................................19
Lubrication of transmission gears ..................................................................19
CYLINDERS AND PISTONS ............................................................................20
Construction ...................................................................................20
Notes of Caution ................................................................................20
Inspection ......................................................................................20
Disassembling ..................................................................................20
CLUTCH ................................................................................. 21
Construction ...........................................................................................22
Operation .............................................................................................22
Clutch Adjustment ......................................................................................23
Disassembling Clutch ...................................................................................23
Inspection .............................................................................................24
TRANSMISSION .......................................................................... 25
Construction ...........................................................................................26
Operation .............................................................................................26
Component parts of gear change pedal & shift drum ...........................................................27
Gear shift mechanism ....................................................................................28
Gear operation and gear ratios .............................................................................31
Inspection .............................................................................................33
KICK STARTER .......................................................................... 34
Construction ...........................................................................................34
Operation .............................................................................................35
Inspection .............................................................................................35
CARBURETORS .......................................................................... 37
Synchronizing Carburetors ...............................................................................37
Indication of trouble at various engine speeds ................................................................37
Table of Contents
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Table of Contents
Idling Adjustment .......................................................................................37
Medium Engine Speed Adjustment .........................................................................38
High Engine Speed Adjustment ............................................................................38
Adjustment of Carburetor Float Level ......................................................................39
Trouble Shooting of Gasoline Leaks from Carburetor .........................................................39
OIL INJECTION SYSTEM ................................................................. 40
Operation .............................................................................................41
Oil Intake .............................................................................................42
Oil Outlet .............................................................................................42
Distribution of oil to both cylinders ........................................................................42
Operation of worm wheel plunger in relation to the throttle grip .................................................43
Engine Idling at slow speed .......................................................................43
High Speed, wide open throttle ....................................................................43
Adjustment of oil pump control wire .......................................................................44
Special Attention .......................................................................................44
Meshing the plunger gear with the distributor gear ............................................................45
FRAME .................................................................................. 46
Handlebar .............................................................................................47
Removing Handlebar ............................................................................47
Assembling ............................................................................................47
Inspection .............................................................................................47
Front Fork ............................................................................................48
Operation ......................................................................................49
Disassembling ..................................................................................50
Assembling and Inspection ........................................................................50
Removing the steering damper .....................................................................50
Rear suspension ........................................................................................51
Construction ...................................................................................51
Operation ......................................................................................51
Adjustment of rear suspension .....................................................................52
Wheels ...............................................................................................53
Construction ...................................................................................53
Checking of Tire Pressure and Balance ..............................................................53
Front Wheel ....................................................................................54
Rear Wheel ....................................................................................55
ELECTRICAL EQUIPMENT ............................................................... 57
A.C. Generator .........................................................................................58
Description ....................................................................................58
Charging current ................................................................................58
Voltage Regulator ......................................................................................58
Ignition system .........................................................................................59
Contact Breakers ................................................................................59
Adjusting the gap ................................................................................59
Checking and Adjusting Ignition Timing .............................................................59
Selenium Rectifier ......................................................................................60
Special Attention ................................................................................61
Inspection ......................................................................................61
Condenser .............................................................................................61
Inspection ......................................................................................61
Ignition coil ...........................................................................................61
inspection ......................................................................................61
Spark plug .............................................................................................62
Description ....................................................................................62
Inspection and Adjustment ........................................................................62
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Table of Contents
Battery................................................................................................63
Inspection of Specific Gravity .....................................................................63
Storage of dry charged battery .....................................................................64
Initial Charging Rate .............................................................................64
Lights ................................................................................................65
Head lamp • Tail lamp ............................................................................65
Speedometer • Ignition Coil • Main Switch ...........................................................66
Bulbs .........................................................................................67
Adjustment of head light beam .....................................................................67
Main Switch ...........................................................................................68
Horn .................................................................................................68
TROUBLE SHOOTING .................................................................... 69
Engine is hard to start ...................................................................................69
High engine revolution cannot be obtained ..................................................................70
Unsatisfactory R.P.M. ...................................................................................71
Irregular Revolutions ....................................................................................72
Unsatisfactory gear shifting ...............................................................................72
Common Failures ......................................................................................73
Electrical failure ................................................................................73
Failures in fuel system ...........................................................................75
Mechanical failures ..............................................................................75
TOLERANCES AND FITS .................................................................. 76
Engine ................................................................................................76
Cylinder ..............................................................................................76
Piston ................................................................................................76
Crankshaft & Rotary Disc Valve ...........................................................................76
Clutch ................................................................................................78
Number of teeth ........................................................................................78
Fork guide ............................................................................................79
A.C. Generator & Ignition coil ............................................................................79
Carburetor ............................................................................................79
Oil pump ..............................................................................................80
Frame ................................................................................................80
Suspension ............................................................................................80
Lighting equipment .....................................................................................80
Adjusting Torque .......................................................................................81
WIRING DIAGRAM ....................................................................... 82
PERFORMANCE .......................................................................... 83
Port Timing ...........................................................................................83
Port Dimensions ........................................................................................83
Port Time/Area .........................................................................................83
Cylinder Exhaust .......................................................................................83
Head Pipe .............................................................................................83
Squish Band Clearance ..................................................................................84
Rotary Valve ...........................................................................................84
Ignition ...............................................................................................84
Expansion Chamber .....................................................................................84
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1. TECHNICAL DATA
* Engine
( 1 ) Type :
( 2 ) Piston Displacement :
( 3 ) Bore & Stroke :
( 4 ) Compression Ratio :
( 5 ) Max. Brake Horse Power
( 6 ) Max. Torque :
( 7 ) Air Intake System :
( 8 ) Starting System :
( 9 ) Charging System :
(10) Ignition System:
(11) Ignition Timing:
(12) Spark Plug:
(13) Carburetor:
(14) Engine Lubrication:
(15) Fuel:
(16) Transmission Oil:
Performance
( 1 ) Max. Speed :
( 2 ) Climbing Ability :
( 3 ) Fuel Consumption :
( 4 ) Min. Turning Radius :
( 5 ) Acceleration :
(Standing Start 1/4 mile)
(Zero to 60 mph) :
( 6 ) Braking Distance :
Frame and Suspension
(1) Frame:
(2) Front Suspension:
(3) Rear Suspension:
2-stroke, Dual Cylinders
344.9cc (21.5 cu-inches)
61 mm × 59 mm (2.40 × 2.32 inches)
9.31:1
40 HP/7500 rpm
4.0 kg-m/7000 rpm
Rotary disc valve
Kick Starter
A. C. Generator
Contact breaker gap : 0.3 - 0.4 mm (0.012 - 0.016 inches)
Battery
(25+1-2) degrees before T.D.C.
N.G.K. B-8H, Electrode gap : 0.6 mm (0.024 inches)
Type AMAL VM 26 SC
Venturi: 26 mm
Main Jet No.: 130 Throttle Valve Cut Away: 2.0
Air Jet : 2.0 Adjustment of Needle Jet : 0.6
Pilot Jet: 22.5 Pilot Air Screw Position: 2 turns out
Needle Position: 3
2 cycle oil
Regular Gasoline
1.5 liter (2/5 US gal.) in transmission case
SAE No. 10W/30 in all seasons or
SAE No. 30 in summer and SAE No. 20 in winter
100-110 mph
1 in 2
94 mpg/25 mph (40 km/litre at 40 km/h)
2.25 m (7.38 feet)
13.7 sec
5.2 sec
(Less than 12m at 50 km/h)
39 feet, at 30 mph
Pipe Frame, Cradle Type
Telescopic Fork with Hydraulic Damper
Swinging Arm with Hydraulic Damper
Technical Data 1
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Technical Data2
Transmission
( 1 ) Clutch :
( 2 ) Transmission :
( 3 ) Gear Ratio :
Dimensions and Weight
( 1 ) Overall Length :
( 2 ) Overall Width :
( 3 ) Overall Height:
( 4 ) Saddle Height :
( 5 ) Wheelbase:
( 6 ) Road Clearance :
( 7 ) Tire Size (Front) :
(Rear):
( 8 ) Tire Pressure (Front) :
(Rear):
( 9 ) Caster :
(10) Trail:
(11) Banking Angle:
(12) Net Weight:
(13) Fuel Tank Capacity:
(14) Oil Tank Capacity :
Electrical Equipment
( 1 ) Head Light :
( 2 ) Tail Light :
( 3 ) Stop Light :
( 4 ) Speedometer Lamp :
( 5 ) Tachometer Lamp :
( 6 ) Neutral Indicator Lamp :
( 7 ) 5th Gear Indicator Lamp :
( 8 ) Headlight High Beam Lamp :
( 9 ) Battery :
Manual, Multiple discs, Dry type
Constant mesh 6-speeds
Primary (Helical Gear) 1:3.095
Gear Box: 1st 1:2.46
2nd 1:1.647
3rd 1:1.25
4th 1:1.00
5th 1:0.852
6th 1:0.759
Secondary (Chain) : 1:2.40
Total Gear Ratio : 1st 1:18.27
2nd 1:12.23
3rd 1:9.29
4th 1:7.43
5th 1:6.33
6th 1:5.64
2,110 mm (83.1 inches)
825mm (32.5 inches)
1,115 mm (43.9 inches)
810mm (31.9 inches)
1,375 mm (54.1 inches)
145 mm (5.7 inches)
3.25-19 4 ply
3.25-19 4 ply
2.0kg/cm2(28-30 lbs/in2)
2.2 kg/cm2(30-32 lbs/in2)
63°
105 mm (4.15 inches)
46°
165 kg (363 lbs)
15 litre (3-4/5 US gal.)
Including 3.2 litre (4/5 US gal.) reserve
2.5 litre (3/5 US gal.)
12V-35/30W
12V-7W
12V-23W
12V-3W
12V-3W
12V-3W
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12V-3W
12V-3W
12V-6AH
2. FRONT and SIDE VIEWS of
BRIDGESTONE 350 GTR
Dimensions in millimeters (inches)
Front and Side Views of BS350GTR 3
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3. Performance
4Performance
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Performance 5
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Fig. 1 Special Tools
Fig. 2 Disconnecting wires
Fig. 3 Removing exhaust pipes
4. ENGINE
4-1 Removing Engine
A. Notes of Caution:
1. Be careful not to damage the insulation of the various wires.
2. Be careful not to get oil on the clutch parts of the dry type racing clutch that is fitted to the 350
GTR.
B. Tools necessary for dismounting and mounting the engine:
1. Standard Tools:
1. Wrench 10 × 12mm
14 × 17mm
19 × 21mm
2. Screw driver rNo. 3, No. 2
3. Screw driver s
4. Side cutting plier
5. Combination plier
6. T Type wrenches: 10, 12, 14, 23mm
2. Special Tools: (Fig. 1)
1. Box wrench bar
2. 28mm nut wrench
3. 40mm ring nut wrench
4. Driven gear stopper
5. Clutch housing puller
6. Clutch housing stopper
7. Clutch hub stopper
C. Removing the Engine:
1. Remove left side cover and dual seat.
2. Disconnect mainswitch wires and A.C. Generator
wires from the terminals. (Fig. 2)
3. Remove both exhaust pipes by pulling out the four
bolts. (Fig. 3)
4. Disconnect tachometer cable at the end of engine case,
then remove high-tension terminal plug caps from
spark plugs.
6Engine
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