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ON short trips, make sure you have
the following items:
- NGK BP(R)5HS Spark Plug
with 0.5 mm gap
- Front
& Rear Bulbs
- 0.2 uF 500V DC Condenser (or 0.22 uF 1000V DC Polypropylene Capacitor)
- Tyre Pressure Gauge
- 150 mm (6") Adjustable Spanner for:
- Spark Plug (21 mm)
- Wheel Nuts (17 mm)
- Seat Bolt (14 mm)
- Engine Cover Nut (13 mm)
- Engine Protector Clamp Bolt (10 mm)
- Spark Plug HT Terminal Nut (7 mm)
- Condenser Nut (7 mm)
- Flat-Blade Screwdriver for:
- Contact Breaker fitting & adjustment
- Cross-Head Screwdriver for:
- Puncture Repair Kit
- Two Tyre Levers
- Two Tyre Valves
- Two Valve-Extracting Tyre Caps
- Inner Tube Repair Kit
- Cotton Cloth
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ON long trips, make sure you have
the following items:
- NGK BP(R)5HS Spark Plug
with 0.5 mm gap
- Magneto Rotor Extractor
- Front
& Rear Bulbs
- Filters:
- Foam Air Filter
- Fuel Tank Filter
- Carburettor Fuel Filter
- Fuel Return Pipe (Clear Tubing of 9 mm internal
diameter x 105 mm long)
- Contact Breaker
- 0.2 uF 500V DC Condenser (or 0.22 uF 1000V DC Polypropylene Capacitor)
- Tyre Pressure Gauge
- Two Front Spokes (13 gauge [2.2 mm], 225 mm
long)
- Ten Rear Spokes (13 gauge [2.2 mm], 195 mm long)
- Spoke Adjustment Tool
- Flat-Blade Screwdriver for:
- Contact Breaker fitting & adjustment
- Cross-Head Screwdriver for:
- 9 mm Ring & Open-Ended Spanner for:
- 9 mm Air Filter Housing Cover Bolt
- 9 mm Main Jet
- 10 mm Ring & Open-Ended Spanner for:
- Cylinder Nuts
- Cylinder Head Nuts
- Fuel Pipe Unions
- Carburettor Throttle Cable Assembly Bolt
- 14 mm Ring & Open-Ended Spanner for:
- Magneto Rotor Nut
- Seat Nut
- 15 mm Ring & Open-Ended Spanner for:
- Carburettor Manifold Union
- 150 mm (6") Adjustable Spanner for:
- Spark Plug (21 mm)
- Wheel Nuts (17 mm)
- Seat Bolt (14 mm)
- Engine Cover Nut (13 mm)
- Engine Protector Clamp Bolt (10 mm)
- Spark Plug HT Terminal Nut (7 mm)
- Condenser Nut (7 mm)
- Puncture Repair Kit
- Two Tyre Levers
- Two Tyre Valves
- Two Valve-Extracting Tyre Caps
- Inner Tube Repair Kit
- Analogue Multimeter with 3 (or more) Resistance
Ranges to check:
- 0.2 uF 500V DC Condenser
- Contact Breaker
- Magneto Coil
- HT Lead
- Front & Rear Bulbs
- Cotton Cloth
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TO remove the Magneto
Rotor when replacing the Contact Breaker
or Condenser, use a Magneto Rotor
Extractor.
A suitable Magneto Rotor Extractor
may be made from two M10 x 50 mm Washers (each
about 2 mm thick), one
M8 Nut, one M8 x 50 mm Bolt and three M6 x 40 mm
Bolts as shown below:
![Magneto Rotor Extractor Parts](images/Magneto Rotor Extractor Parts.jpg)
![Magneto Rotor Extractor Diagram](images/Magneto Rotor Extractor Diagram.gif)
- Braze-weld the M8 Nut to the centre of one
of the M10 x 50 mm Washers
- Braze-weld the two M10 x
50 mm Washers together
- Drill three 6 mm diameter holes through the washers, 16
mm from the centre hole and 120° apart (27.7 mm
between hole centres)
- Make the thread end of the M8 x 50 mm
Bolt conical using a flat file and screw the bolt about half-way into the M8 Nut
- Using a Permanent Marker Pen put black
marks about 7 mm from the ends of three M6 x
40 mm Bolts and insert the bolts into the M10 x
50 mm Washers
as shown below
![Magneto Rotor Extractor](images/Magneto Rotor Extractor.jpg)
To remove the Magneto Rotor:
- Prevent the Flywheel turning by using a
Flywheel
Clamp
- Remove a 14 mm Centre
Nut from the Magneto Rotor end
of the Crankshaft
- Remove a 75 mm Black
Metal Plate and Rubber
Seal
- Remove a 14 mm Centre
Nut and Washer
- Pick
up the Magneto Rotor Extractor assembly and screw the three M6 x
40 mm Bolts into the three Magneto Rotor holes
until the black marks on the threads are just reached
- Tighten the M8 x 50 mm Bolt against the centre of the Crankshaft end until you hear a sharp click and you will find that the Magneto Rotor can now be removed by hand
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TO prevent the Flywheel turning when loosening or tightening the Crank Pin (Big-End) Bolt
or when removing the Magneto
Rotor:
- Remove the M6 x
10 mm Bolt and Brass Washer beside
the Fuel Pump
(shown below)
- Look into the resulting hole with a lamp
and turn engine over slowly until flywheel is
not blocking the hole
- Screw in a M6 x 20 mm Bolt
as a Flywheel Stop Bolt
into the hole and tighten
WARNING! When you have finished
the work you wish to do, make sure you replace the original
M6 x
10 mm Bolt and Brass Washer
![Flywheel Stop Bolt](images/Flywheel Stop Bolt.jpg)
Another, perhaps stronger, way to prevent the Flywheel
turning is to make your own Flywheel Clamp.
This may be made from 20 mm x 20 mm x 105 mm
(3 mm thick) right-angled mild steel using the pictures below:
![Flywheel Clamp](images/Flywheel Clamp.jpg)
![Flywheel Clamp Diagram](images/Flywheel Clamp Diagram.gif)
Use two M6 Bolts taken from
the Crankcase Cover and
additional M6 nuts as spacers to secure the Flywheel Clamp to
the two Crankcase holes shownbelow by arrows:
![Crankcase](images/Crankcase.jpg)
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TO check that the VeloSoleX S
3800 has the correct Air-Fuel Mixture Ratio, one can use
Gunson's Colortune:
![Colortune](images/Colortune.jpg)
The Colortune adaptor fits in place of the Spark Plug and having
a clear window, one can see the Combustion
Colour inside the Combustion Chamber while
the engine is running. There are three main possible
colours:
- Yellow
- Mixture Too Rich
- Bunsen Blue
- Mixture Correct
- Whitish Blue
- Mixture Too Weak
There may also be a slight Red
tinge to any of these colours due to the presence of
oil in this 2-Stroke engine, which can normally be ignored.
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TO check that the VeloSoleX S
3800 has the correct Cranking Compression
Pressure, one can use Gunson's Hi-Gauge
Compression Tester:
![Compression Tester](images/Compression Tester.jpg)
The Hi-Gauge Compression Tester adaptor fits in place of the Spark Plug of
a fully warm engine. The throttle is kept wide open
and the VeloSoleX S
3800 is pushed for a few metres before a reading is taken. A Reset
Button, shown by the arrow above, allows
subsequent readings to be taken.
A VeloSoleX S
3800 engine with little cylinder wear, good piston rings, good
head gasket and good decompression valve seal should
show a Cranking Compression Pressure reading
of about 6.5 bars
(95 PSI or 650 kPa).
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