Sears Free spirit 8080 Betriebsanleitung

drepair

Sears

SEARSMOPEDS

MODELNO'S

80808084

80818085

80828086

8083

PART

NO.

80848

www.1977mopeds.com

1.800.965.1977

CONTENTS

PART1

SECTION

PAGENUMBER

RoutineMaintenanceChart3

RecommendedLubricants4

LubricationandMaintenanceProcedures5

SECTIONII- ENGINE,CLUTCH,REDUCTIONGEAR

SpecialTools

Specifications18

TechnicalData19

Dismantling23

Re-Assembly28

Installation32

TroubleShooting33

SECTION

III

- FUELSYSTEMANDCARBURETION

Operation/Adjustments36

ExhaustSystem40

TroubleShooting40

SECTIONIV- IGNITIONSYSTEM

IgnitionTiming42

TroubleShooting44

SECTIONV - FRAMEANDFORKASSEMBLY

Frame46

RearFork46

ShockAbsorbers46

FrontFork47

SteeringHead47

TroubleShooting49

SECTIONVI- WHEELHUBSANDBRAKES

Brakes52

FrontandRearHubs52

TroubleShooting54

SECTIONVII- ELECTRICALSYSTEM

GeneralDescription' 56

TroubleShooting57

WiringDiagram58

SECTIONVIII- TECHNICALDATA

TorqueReading& Specifications60

AssemblyTolerances62

MetricConversionTable63

INDEX

PART

PartsManual67

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1.800.965.1977

SECTION

LUBRICATIONANDMAINTENANCE

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1.800.965.1977

LUBRICATIONANDMAINTENANCE

ROUTINEMAINTENANCESCHEDULE:

ThegeneralandperiodicmaintenancerequiredforFREESPIRITMopedsisclearlydescribedin

thefollowingpages,andshouldbeperformedatthemileageintervalsshowninthefollowing

chart.

LUBRICATION& MAINTENANCECHART

OPERATIONSTOPERFORM

Tirewearandcondition

Throttlecableadjustment

Checktirepressure

Checkgearboxoillevel

Cleanandlubricatechain

Cleanairfilter

Changegearboxoil

Checksparkplug

Decarbonizeengine

Cleanexhaustbaffle

Retightenscrews,nuts(inc.headnuts)

Cleanfuelvalveandlines

Cleancarburetor

Idlespeedadjustment

Checkignitiontiming

Adjustclutch

Checkbrakes/linings

Check/lubricatehubbearings

Steeringbearingadjust/lubrication

Lubricatecontrolcables

Adjustchaintension

Lubricatefrontfork

First

300

Frequencyinmiles

Every

600

900

1,800

3,600

7,200

NOTE:

Abovetimescheduleappliestomopeduseondrypavedsurfaces.Ifmopedisusedin

wet,muddyorsandyareas,maintenanceshouldbemorefrequent.Alwayscheck

con-

trolsandlightingbeforeanytrip.

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1.800.965.1977

LUBRICATIONANDMAINTENANCE

RECOMMENDEDLUBRICANTS

GASOLINE-OILMIX

1)Mixtureofregulargasoline

2)Mixtureratio50: 1 withspecialtwostrokeoil

GEARBOXFLUID

1)5.74

(170cc)AutomaticTransmissionFluid,Type"F

MACHINELUBRICATION

GREASE(TYPE)LUBRICATION

1)Lithiumbasegrease

OIL(TYPE)LUBRICATION

1)SAE90

2)SAE30

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1.800.965.1977

LUBRICATIONANDMAINTENANCE

LUBRICATION

Changinggearboxoil

1)Warmuptheengine./ Stopengine.

2)Removetheoilfillingplug(figure1/1)andoildrain

plug(figure1/2).

3)Drainoil.

4)Replacedrain

plug.

5)Fillwithfreshautomatictransmission

fluid-TYPE

ONLY-(approx.170cc)tobottomoffillingscrew

hole.

6)Replaceoilfilling

plug.

Fig.

Cleaningandoilingthechains

CAUTION:

ENGINESHOULDNOTBERUNNING.

Thelonglifeofchainsdependstoa greatextenton

careandmaintenance.Chainsshouldalwaysbe

cleanedandlubricatedregulary.Whenrefittingthe

chains,takecarethatthetensioniscorrectandthe

connectinglinksareproperlyplaced- withtheclosed

endpointinginthedirectionofchaintravel(figure2).

Fig.

Greasingcycleparts

Bymeansoflubricatinggrease

(forqualityseelubricationchart)(page4)

Speedometerdrivelubrication(Notmodel8080)

1)Atthelubricationnipple(figure3/1)oneortwo

strokesoutofthegreasegun.

Kickstandbearing

1)Removethestandspring.Remove3 hexagonbolts.

Removestand.Greasebothhalvesofthestand

pivot.

Fig.

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1.800.965.1977

LUBRICATIONANDMAINTENANCE

Fig.

Bymeansofoil

1)Brakeadjustingscrewonfrontandrearwheel.

2)Adjustingscrewforstartingclutchcable.

3)Chaintensioningscrews.

4)Workingsurfacesofbothbrakelevers.

5)Bowdencables.

Lubricatingtheignitioncam:

Lubricatethegreasefelt.Thelubricantmustnotreach

thebreakerpointsasthiswouldcauseprematureand

excessivewear.

MAINTENANCE

PleasecontactanauthorizedSearsAutoCenterfor

workyoudonotwishtocarryoutyourself.Theagent

willbepleasedtoadviseandhelp.

Checkingsparkplugs

Unscrewspark

plug,

connecttohightensionleadand

placeplugbodytoearth,forinstanceonthecylinder

head.

A strongsparkmustbevisiblebetweenthespark

plugelectrodeswhenoperatingthestarter.Oiledup

plugsordirtyelectrodesdonotsparkandmustbe

cleanedfirstwitha pieceofwoodora steelwirebrush.

Fitonlyreplacementplugshavinga heatvaluein

accordancewiththeenclosedchart(page18).The

electrodegapshouldbefrom( .016-.020in)0.4to

0.5mm,iflarger,adjustbybendingtheearthelectrode.

Whenreplacingthesparkplugensurethreadmatches

properlyandtheplugcanbescrewedineasily.Never

applyforce.Screwinplugbyhandfor2 to3 turns

beforeusingthesparkplugspanner.

Appearanceoftheplugtipcantellyouhowyour

enginehasbeenrunning.

MAINTENANCE

Decarbonizingtheengine(figure4)

Carbondepositsonthecylinderhead,pistoncrown

andintheexhaustportsarenormalwithalltwo-stroke

enginesandcaneventuallyleadtotroubleifnot

removedintime.Combustiondepositsfromoilaswell

asfromfuelmustthereforeberemovedregularly.

Cylinderheadandpistonhead

Carbondepositsonthecylinderheadandpiston

crownshouldberemovedonlywitha soft,bluntedged

instrumenttoavoiddamagetothelightalloycasting.

Scratchingshouldbeavoidedsinceeverynewscratch

willharbourmorecarboninfutureuse.

Onlyscallydepositsneedberemovedfromthepiston

crown,

thereisnoneedtodisturbthepistonifitis

coveredonlybya uniformlayerofoilcarbon.Before

refittingthecylinderhead,thoroughlyremoveall

carbondepositsandscrapingsfromthecylinderwall

witha nonfrayingsoftclothandsmearthesurface

lightlywithmotoroil.Beforeassembly,turnoverthe

enginea fewtimestomakesureitrunseasily.Then

cleanthejointingsurfaceswitha cleanrag.Tighten

thefourcylinderheadnutscrosswise(7ft/lb)(10

Nm).

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1.800.965.1977

LUBRICATIONANDMAINTENANCE

Exhaustport

Inordertocleantheexhaustport,removetheexhaust

pipe.

Bycranking,turntheengineover(withthespark

plugremovedtoreducecompression)untilthepiston

reachesitslowestpoint.Removetheoilcarbonfrom

theexhaustport.Cautiouslytakecarenottodamage

thepistonorcylinderworkingsurfaces.Whencleaning

theexhaustport,itisalsoa goodideatocleanoutthe

muffler.

Cleaningthemuffler(figure5)

Unscrewandpullofftheexhaustendpiece.Remove

oil-carbondepositsfromtheinsideofthemufflerusing

ascraper.Alsoremovecarefullytheoildepositsfrom

thefasteningdeviceandfromthepipesoftheexhaust

endpiece.Replacethegasketsifnecessary.The

machinehasbeenstandardizedwithoriginalmufflers

only.

NOTE:

Forfurtherbreak-downofexhaustsystemrefer

todiagramonpage40

©fl

;

©•

Fig.

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1.800.965.1977

LUBRICATIONANDMAINTENANCE

-^|M

-—1

jfl

H^S

j^MB

iQf

Fig.

Cleaningtheaircleaner

Removethelefthandchainguard.Loosenscrew

(figure6/1and6/2)oftheclipontheintakesilencer

andpullaircleanerassemblyfromthecarburetor.

Removefrontpartoftheaircleanerusinga drift,

carefullypushoutfilterscreen.Washfilterscreenin

gasolineorsolventandallowittodrythoroghlybefore

replacing.

Fitagaindamperpipe,filterscreen,andair

cleanerassembly.

Cleaningthefuelpipesandlines

Emptyfueltank.

Pullthefuelpipefromthefuelvalveandcarburetor

andblowitclear.Unscrewthefuelvalve.

Cleanthevalveandstrainerbymeansofgasoline.

Cleaningthecarburetor

Maintenanceoperationsonthecarburetorareoutlined

inSection

III,

FUEL SYSTEMANDCARBURETION.

Cleaningthemainjet,needlejetandfloatchamber.

10)

11)

12)

Closethefuelvalve.

Removethelefthandsidecovering.

Removetheintakesilencer.

Loosencarburetorclampingscrew(figure7/1).

Pullthefuelpipefromthecarburetor.

Turnthecarburetorwithitsfloatschamber

(bottom)towardstheclutchsideandpulloff.

Undoscrewsandpulloutthetoppartswith

throttlepistonandchoke(figure7/2).

Screwoffthefloatchamber.

Unscrewthemainjet(figure8/5)beingscrewedin

theneedlejet(figure8/4)andcleanbyblowing

throughorbyusinga stiffbristle.Neverusea

pieceofwire.Also,unscrewneedlejetandclean.

Cleanthefloatchamber(figure8/8)withgasoline.

Washcarburetorbodyandblowthrough.Make

surethattheboresarenotcloggedwithdirt.

Whenrefittingthejets,tightenthemproperly.

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1.800.965.1977

LUBRICATIONANDMAINTENANCE

Adjustingtheidlingspeed

1)Warmuptheengine.

2)Completelyclosethetwistgrip(throttledown).

3)Iftheenginethreatensto

stall,

screwintheadjuster

(figure7/3)untiltheengine,inwarmcondition,

regainsitseventickover.

Now,withtheidlingadjusted,adjusttheplayofthe

throttlecontrolcable.

1)Loosencounternutofthecableadjuster(figure

7/4).

2)Screwcounternutofthecableadjuster(figure7/5)

untilthereisa playonboththethrottlecableand

thethrottletwistgrip.Thecoverofthethrottlecable

canbepulledoutfromthecableadjusterbyappr.

.08in.(2mm),beforethethrottleslideislifted,i.e.

beforetheenginestartsrunningfaster.

3)Maintainpositionoftheadjusterandtightenthe

counternut.

Fig.

Explodedviewofthecarburetor(seefig.8)

1Inletmanifold

2Carburetorbody

3Throttleslidestopscrew

4Needlejet

5Mainjet

6Floatneedle

7Float

8Floathousing

9Hoseswivelconnector

10Throttleslider

11Jet-needle

12Chokevalve

13Chokelever

14Topcover

15Slidespring

<?5r©-^

Fig.

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