1969 DATSUN 610 check oil

IgnItIon
System

DESCRII
TION

IGNITION
TIMING

IGNITION
DISTRIBUTOR
Maintenance

ADJUSTING
THE
CONTACT
BREAKER
GAP

CENTRIFUGAL
ADVANCE
MECHANISM

VACUUM
ADVANCE
MECHANISM

IGNITION
DISTRIBUTOR
Removal
and

Dismantling

IGNITION
DISTRIBUTOR

Assembling
and
Installation

SPARKING

PLUGS

DESCRII
TION

The

ignition
circuit

comprises
the
distributor

ignition
coil

ignition
switch

spark
plugs
high
tension
lead
and
the

battery

See
Fig
C
1

The
Hitachi
distributor
is
shown
in

exploded
form
in

Fig

C
2

19niton

timing
is

automatically
regulated
by
the
distributor

centrifugal
advance
mechanism
or
vacuum
advance
mechanism

depending
upon
the

demand
made
on

the
engine

The
vacuum
advance
mechanism

operates
under
part

throttle

only
and
uses
intake
manifold

depression
to
advance
the

ignition
timing
When
the

engine
speed
is
increased
the
vacuum

is

inoperative
and
ignition
timing
is

regulated
by
the

centrifugal

advance
mechanism

The

centrifugal
advance
mechanism
uses
a

system
of

governor
weights
and

springs
which
turn
the
carn

assembly
in
on

anti
clockwise
direction
to

advance
the

ignition
timing
As
the

engine
speed
is
decreased
the

weights
move
back
and
allow
the

cam
to
return

thereby
retarding
the

ignition
timing

The

ignition
coil
is
an
oil
filled
unit

comprising
a
coil

around
which
is
wound
the

secondary
and

primary
windings
The

number
of
turns
in
the

primary
winding
provide
a

high
secondary

voltage
throughout
the

speed
range
The
resistor
is
automatically

by
passed
at
the
moment
of

starting
and
allows
the

ignition

coil
to

be

directly
connected
to

the

battery
This
applies
the

full

battery
voltage
to
the

coil
to

give
the

necessary
staTting

boost

When
the
starter
switch
is
released
the
current
flows
through

the
resistor
and
the

voltage
through
the
coil
is

dropped
for

normal

running
purposes

IGNITION
TIMING

The

ignition
timing
can

be

accurately
checked

using
a

stroboscopic
timing
light
which
should
be
connected
in
accor

dance
with
the
manufacturers
instructions

Make
sure
that
the

timing
marks
on
the
crankshaft

pulley

are
visible
if

they
are
not
visible
mark

them
with
chalk

or

white

paint
Each
mark

represents
a
50
division
of
the
crank

angle

Disconnect
the
distributor
vacuum

line
start

the

engine

and
allow
it
to
run
at
normal

idling
speed
or

slightly
below

Point
the

timing
light
at
the

timing
pointer
on
the
front
cover

Fig
C
3
The
crankshaft

pulley
groove
should

appear

to

be

stationery
and

aligned
with
the

pointer
on
the
front
cover

The

top
dead
centre
mark
is
located
at
the
extreme

right
as

shown
in
the
illustration
If
the

setting
requires
adjustment
the

distributor

flange
bolts
must
be
slackened
and
the
distributor

body
turned
clockwise
to
advance
or
anti
clockwise
to
retard

the

timing
See
Technical
Data
for

timing
settings

After

adjusting
the

timing
tighten
the
distributor

flange

bolts
and
recheck
the

timing

IGNITION
DISTRIBUTOR
Maintenance

Remove
the
distributor

cap
by
easing
away
the
two

clamps

and
examine
the

points
for

signs
of

burning
or

pitting
The

points
can
be
cleaned
if

necessary
using
a
fine

grade
of
oilstone

or
file
The
faces
of
the

points
must
be

completely
flat
and

parallel
and
all
abrasive
dust
removed
with

compressed
air
If

the

points
are

excessively
pitted
they
must

be
renewed
and

grease

applied
to
the

moving
contact

pivot
and
the
surface
of

the
cam

Ensure
that
the
distributor

cap
is

thoroughly
clean
both
inside

and
outside
A

contaminated

cap
will

promote
tracking

indicated

by
black
lines
and
caused

by
electrical

leakage
between

the

segments
on
the
inside
of

the

cap
Make
sure
that
the

carbon

button
is
not
worn
Both
the
distributor

cap
and
rotor

must
be
renewed
if

they
are
cracked
or

damaged

IGNITION
DISTRIBUTOR

Adjusting
the
contact

breaker

gap

To

adjust
the
contact
breaker

points
remove
the
distributor

cap
and

pull
the
rotor
off

the
cam

spindle

Turn
the

engine
until

the
heel
of
the
contact
breaker
arm

is

positioned
on
the
cam

lobe
the
contact

breaker

gap
is
set
to

the
maximum
in
this

position

Slacken
the

adjusting
screw

Fig
CA
insert
a
feeler

gauge

between
the

points
and

adjust
the
breaker

plate
until
the
re

quired
gap
of
0
45
0
55
mm
0
0177
0
0217
in

is
obtained

Tighten
the

adjusting
screw
and
recheck
the

setting
After

the
contact
breaker

gap
has
been

adjusted
check
the

ignition

timing
as

previously
described

The
tension
of
the
contact
breaker
should
be
0
5
0
65

kg

I
I
I
4
lb
Measure
the
tension
with
a

gauge
and
at
900
to

the
contact
breaker
arm

29

CENTRIFUGAL
ADVANCE
MECHANISM

Special
equipment
is

required
to
check
the
advance

characteristics
It
is

possible
however
to

carry
out
an
exam

ination
of

the
caffi

assembly
and
the

weights
and

springs
to

ensure
that
the
earn
is
not

seizing

Lift
off
the
distributor

cap
and
turn
the
rotor
anti
clock

wise
When

the
rotor

is
released
is
should
return
to

the
fully

retarded

position
without

sticking
If
it

does
not
return
to
the

fully
retarded

position
it
will
be

necessary
to
check
for

dirt

and
weak

springs

It
should
be
noted
that

any
wear
in
the

mechanism
or

lose
of

spring
tension
will

upset
the
advance
characteristics
and

cause

unsatisfactory
engine
running
performance
over
the

speed

range

VACUUM
ADVANCE
MECHANISM

The

diaphragm
of
the
vacuum
advance

mechanism
is

mechanically
connected
to
the
contact
breaker

plate
The
rise

and
fall
of
inlet
manifold

depression
causes

the

diaphragm
to

move

the
contact
breaker

plate
to

advance
or

retard
the

ignition

If
the
vacuum

control
unit
fails
to

function

correctly
a

check
can
be
carried
out
to
ensure
that
the
contact
breaker

plate

is

moving
freely
and
that
the

three
steel

balls
at

the

top
and

oottom
of
the

plate
are

adequately
lubricated

Also
make
sure
that
the
vacuum
inlet

pipe
is
not
blocked

or

leaking
and
is

securely
tightened

Leakage
may
be
due
to
a

defective

diaphragm
which

should

be
renewed

along
with

any
other

faulty
part
of
the
mechanism

IGNITION
DlSTRffiUTOR
Removal

and

Dismantling

Disconnect
the

battery
leads

2
Disconnect
the

high
tension
lead
at

the
coil

3
Withdraw

the
high
tension
leads
from
the
distributor

cap

4
Detach
the
suction

pipe
from
the
vacuum
control
unit

5
Mark
the

position
of
the
distributor
and
rotor
remove
the

flange
mounting
bolts

and
withdraw
the
distributor

To
dismantle
the
distributor

proceed
as

follows

Take
off
the
distributor

cap
and
remove

the
rotor

Slacken

the
two
set
screws

holding
the
contact
breaker

upper
plate

Remove
the

primary
cable
terminals
and
withdraw
the
contact

set
from

the
distributor
Fig
C
S
Remove
the
vacuum
control

unit

c
Remove
the
two
screws
and
lift
out
the
contact

breaker

plate
detach
the

clamp
the
terminal
and
the
lead

To
remove
the
cam
take
out
the
centre
screw
as

shown
in

Fig
e
6
Drive
out

the
drive

pinion
retaining
pin
with
a
drift

and
hammer
Fig
e
and
remove
the

pinion
and
washer
Take

care
not
to
stretch
or
deform
the

governor
springs
when

detaching

them
from
the

weights

IGNITION
DISTRIBUTOR

Assembling
and

Installing

Assembly
is
a
reversal
of
the

dismantling
procedure

Lubricate
the

moving
contact

pivot
and
smear
the
lobes
of
the

cam
with
multi

purpose
grease

If

the
centrifugal
advance
mechanism
has
been
dismantled

the

governor
springs
and
cams
must
be
refitted
as

shown
in

Fig
e
8
The

governor
weight

pin
6
should
be
fitted
into

the

longer
of
the
two
slots

leaving
a
certain
amount
of

clearance

for
the
start

and
end
of
the

centrifugal
advance
movement

When

installing
the
distributor
take
care
to

align
the

body

and
rotor

with
the
marks
made
during
removal
The
rotor
must

be

positioned
in
its

original
location
it
will
turn

slightly
when

the
distributor
is
inserted
and
the

gear
teeth
mesh
Remove
and

replace
the
distributor
if

the
rotor
does
not

point
to
the

align

ment

mark
until
both
distributor

body
and
rotor
are
correctly

aligned

SPARKING
PLUGS

The

sparking
plugs
should
be

inspected
and
cleaned
at

regular
intervals
not

exceeding

every
10
000
km
6000
miles

New

sparking
plugs
should
be
fitted
at

approximately
20
000

km
12
000
miles

Remove
the

plugs
and
check
the
amount
of
electrode

wear
and

type
of

deposits
Brown
to

greyish
tan

deposits
with

slight
electrode
wear

indicate
that
the

plugs
are

satisfactory
and

working
in

the
correct
heat

range

Dry
fluffy
carbon

deposits
are
caused

by
too

rich
a
mixture

dirty
air
cleaner
excessive
idling
or

faulty
ignition
In
this

case

it
is
advisable
to

replace
the

plugs
with

plugs
having
a

higher
heat

range
Oily
wet
black

deposits
are
an

indication

of

oil
in

the
combustion
chambers

through
worn

pistons
and

rings
or
excessive
clearance
between
valve

guides
and
stems

The

engine
should
be
overhauled
and
hotter

plugs
installed
A

white
or

light
grey
centre

electrode
and
bluish
burned
side

electrode
indicates

engine
overheating
incorrect

ignition
timing

loose

plugs
low
fuel

pump
pressure
or
incorrect

grade
of
fuel

Colder

sparking
plugs
should
be
fitted

The

plugs
should
be
cleaned
on
a

blasting
machine
and

tested
Dress
the
electrodes
with
a
small
file
so
that
the
surfaces

of
both
electrodes
are
flat
and

parallel
Adjust
the
spark
plug

gap
to
0
8
0
9
mm
0
031
0
035
in

by
bending
the
earth

electrode
Refit
the

plugs
and

tighten
them
to
a

torque
reading

of
1
5
2
5

kgm
II
15Ib
ft

31

and
seats
or
a
weak

diaphragm
return

spring

A

pressure
above
the

specified
figure
may
be
due
to

an

excessively
strong
and
tight
diaphragm

Capacity
test

The

capacity
test
can
be

carried
out
when
the
static

pressure
has
been
tested
and
conforms
with
the

specified
figure

of
0
18

kg
sq
cm
2
6Ib

sq
inJ

Disconnect
the
fuel
line
at

the
carburettor

and

place
a

container
under
the
end
of
the

pipe
to
act
as
a
fuel

sump

Start
the

engine
and
run
it
at
a

speed
of
1000

Lp
m
The

amount

of
fuel
delivered
from
the

pump
in
one
minutc
should

be

1000
cc
2
1
US

pt

If

petrol
does
not
flow
from
the

opcned
end
of

the
pipe

at
the
correct
rate
then
either
the
fuel

pipe
is

clogged
or

the

pump
is
not

operating
correctly

If
the
latter
cause
is

suspected
the

pump
must
be
removed

and

inspected
as
described
below

FUEL
PUMP

Removing
and

Dismantling

Before

removing
the
pump
take
off
the

petrol
tank

cap

and
disconnect
the

pump
inlet
and
outlet

pipes
Blow

through

the

pipes
with

compressed
air
to

make
sure

that

they
are
not

clogged

Remove
the

pump
retaining
nuts

withdraw
the

pump
and

dismantle
it
in
the

following
order

Referring
to

Fig
D
l

Take
out
the
screws

holding
the
two

body
halves

together

and

scparate
the

upper
body
from

the
lower

body

2
Remove
the

cap
and

cap
gasket

3
Unscrew
the
eI
bow
and
connector

4
Take
off

the
valve
retainer
and
remove
the
two
valves

5
To
remove
the

diaphragm
diaphragm
spring
and
lower

body
sealing
washer

press
the

diaphragm
down

against

the
force
of
the

spring
and
tilt
the

diaphragm
at
the
same

time
so
that
the

pull
rod
can
be
unhooked
from
the
rocker

arm

link

Fig
D
7

The
rocker
arm

pin
can

be
driven
out
with
a
suitable

drift

FUEL
PUMP

Inspection
and

Assembly

Check
the

uppcr
and

lower

body
halves
for
cracks

Inspect

the
valve
and
valve

spring
assembly
for

signs
of
wear
and
make

sure
that
the

diaphragm
is
not

holed
or

cracked
also
make
sure

that
the
rocker
arm
is
not
worn
at
the

point
of
contact
with

the

camshaft

The
rocker
arm

pin
may
cause

oil

leakage
if
worn

and

should
be
renewed
Assembly
is
a
reversal
of
the
dismantling
procedure

noting
the

following
points

Fit
new

gaskets
and
lubricate
the
rocker
arm
link
and
the

rocker
arm

pin
before

installing

The

pump
can
be
tested

by
holding
it
approximately
I

metre
3

feet
above

the
level
of
fuel

and
with
a

pipe
connected

between
the
pump
and
fuel
strainer

Operate
the
rocker
ann

by
hand
the

pump
is

operating

correctly
if
fuel
is
drawn

up
soon
after

the
rocker
ann
is

released

CARBURETTOR
IDLING
ADJUSTMENT

The

idling
speed
cannot
be

adjusted
satisfactorily
if
the

ignition
timing
is
incorrect

if
the
spark
plugs
are

dirty
or
if

the
valve
clearances
are
not

correctly
adjusted

Before

adjusting
the

idling
speed
set
the
hot
valve

clearances

t
o
0
25
mm
0
0098
in
for
the
intake
valves

and

0
30
mm
0
0118
in
for
the
exhaust
valves
as
described
in

the
ENGINE

section

Idling
adjustment
is
carried
out

with
the
throttle

stop

screw
in

conjunction
with
the

idling
adjustment
screw

See

Fig
D
8

Run
the

engine
until
it
attains
its
normal

operating

temperature
and
then
switch
off

Starting
from
the
fully
closed

position
unscrew
the

idling
adjustment
screw

by
approximately
three
turns

Screw
the
throttle

stop
screw
in

by
two
or
tftr
e
turns
and

start

th
engine

Unscrew
the
throttle

stop
screw
until
the

engine
commences

to
run

unevenly
then
screw
in
the

idling
adjustment
screw
so

that
the
engine
runs

smoothly
at
the

highest
speed

Readjust
the
throttle

stop
screw
to

drop
the

engine
speed

of

approximately
600
r

p
m
is
obtained

WARNING
Do
not

attempt
to
screw

the

idling
adjustment

screw

down
completely
or
the

tip
of
the
screw

may
be

damaged

FAST
IDLE
OPENING
ADJUSTMENT

The
choke
valve
is

synchronized
with
the
throttle
valve

and
connected
to
it

by
levers
as
shown
in

Fig
D
9
The
fast

idle
opening
can
be
check

by
fully
closing
the
choke
valve
and

measuring
the
clearance
between
the

primary
throttle
valve
and

the
wall
of

the
throttle
chamber
This
clearance

being
shown

as
A

in
the
illustration
The
clearance
for

the
carburettor

types
is
as
follows

Carburettor

type
Throttle

opening

angle

180

180

190
Dimension
A

213304
361

13304
4
I

13282
331
1
55mm
0
06lin

1
55mm
0
06Iin

1
3
mm
0
051
in

35

FLOAT
LEVEL

Adjustment

A
constant
fuel

level
in
the
float

chamber
is
maintained

by

the
float
and
ball
valve

Fig
D
12
If
the
fuel
level
is
not

in

accordance
with
the
level

gauge
line
it
will
be

necessary
to
care

fully
bend

the
float
seat
until
the
float

upper
position
is

correctly

set

Fig
D
13

The
clearance
H
between
the
valve
stem

and
float
seat

should
be
1
0
mm
0
039
in
with
the
float

fully
lifted
as
shown

Adjustment
can

be
carried
out

by
carefully
bending
the
float

stopper
Fig
D
14
until
the

required
clearance
is
obtained

SU
TWIN
CARBURETTORS

Adjustments

It
is
essential
that
the
two

carburettors
are

correctly
adjusted

if

peak
m3l1ce
and
economical
fuel

consumption
is
to
be

realized
Incorrect
carburettor

a
ljustment
will
have
an
adverse

affect

during
idling
and
on

acceleration
etc

Carburettor

synchronization
and

idling
adjustment

Run
the

engine
until
it
reaches
its
normal

operating

temperature
remove
the
air
cleaner
and
slacken

the
front

and

rear
throttle

adjusting
screws
the
balance
screw
and
the
fast

idling
setting
screw
Make
sure
that
the
front
and
rear
throttle

shafts
are
not
connected

Fully
tighten
the

idling
adjustment

nuts
of

the
front

and
rear

carburettors

Fig
D
15

the
back

off
each
nut

by
an

equal
amount
and

by
one
and
a
half
to
two

tUrns

Screw
in
the
front
and
rear
throttle

adjusting
screws

by
a

few
turns
and
start
the

engine
Allow
the

engine
to
reach
its

normal

operating
temperature
before

proceding
to

the
next

stage

Adjust
the
front
and
rear
throttle

adjusting
screws
until

the

engine
speed
is
reduced
to

approximately
600
700
r

p
m

The

engine
should
turn
over

smoothly
and

consistently
Apply

a

flow
meter
to
the
front
carburettor
air
cleaner

flange
and
turn

the

adjustment
screw
on
the
flow
meter
so
that
the

upper
end

of
the
float
in
the

glass
tube
is
in

line
with
the
scale
Uft
off
the

flow
meter

and
apply
it
to

the
rear
carburettor
air
cleaner

flange

without

altering
the

setting
of
the
flow
meter

adjusting
screw

If

the

position
of
the
flow

meter
float
is
not

aligned
with
the

scale

adjust
the
rear
carburettor

throttle
adjusting
screw
to

align
the
float
with
the
mark
on
the
scale

With
the
carburettor
flow

correctly
adjusted
turn
the

idling
adjustment
nuts

of
both
carburettors

approximately
1
8

of

a
turn

either
way
to
obtain

a
fast

and
stable

engine
speed

Both
nuts
must

be
turned

by
an

equal
amount

Back
off
the
front
and
rear
throttle

adjusting
screws
and

adjust
the

engine
speed
to

the

specified
value
of

650
r

p
m

for

the
standard

engine
or
700
r

p
m
with
vehicles
fitted
with

automatic
transmission
Make
sure

that
the
air
flow
of

both

carburettors
remains

unchanged
Screw
in
the
balance
screw

until
the
screw
head
contacts
the

throttle
shafts
without

changing
the

idling

speed
setting

Move
the
throttle

connecting
shaft
and
accelerate
the

engine
a
few
times
then
check
that
the

idling
speed
is

unchanged

Turn
the
fast
idle

setting
screw

to
increase
the

engine
speed

to

approximately
1500

r

p
m
and
recheck
with
the
flow
meter
that
the
air
flow
for
both
carburettors
is

correctly
matched
If

the
air
flow
is
uneven

it
will
be

necessary
to

readjust
the
balance

screw

Finally
back
off

the
fast
idle

setting
screw

Fig
D
16

and
decrease
the

engine
speed
Apply
the
flow
meter
to

the

carburettors
to
confirm
that
the
float

positions
are
even
Re

adjust
if

necessary
by
means
of

the
throttle

adjusting
screws

Stop
the

engine
and
fit
the
air
cleaner

SU
TWIN
CARBURETTOR

Dismantling

Piston
and
suction
chamber

Dismantling

Unscrew
the
plug
and
withdraw
the

piston
damper
Fig
D

17
Remove
the
four
set
screws

and
lift
out

the
suction

chamber
withdraw
the

spring
nylon
washer
and
the

piston

Take
care
not
the

damage
the

jet
needle
and
the
interior
of

the

suction
chamber

Do
not
remove
the

jet
needle
from
the

piston
unless

absolutely
necessary
If
a

replacement
is
to
be
fitted
ensure
that

the
shoulder
of
the
needle
is
flush
with
the
lower
face
of

the

piston
This

operation
can

be
accomplished
by
holding
a
strai

edge
over
the
shoulder
of
the
needle
and
then

tightening
the

set
screw
as
shown
in
Fig
D
18

Wash
the
suction
chamber
and

piston
with
dean
solvent

and

dry
with

compressed
air
Lubricate
the
piston
rod
with
a

light
oil
Do

NOT
lubricate
the

large
end
of
the

piston
or
the

interior
of
the
suction
chamber

NOZZLE

Dismantling

The
nozzle
See
Fig
D
19
can
be
removed

quite
easily

but
should
not
be
dismantled
unless

absolutely
necessary
as

reassembly
of

the
nozzle
sleeve
washer
and
nozzle
sleeve

set
screw
is
an

extremely
intricate

operation

To
remove
the
nozzle
detach
the

connecting
plate
from

the
nozzle
head

pulling
lightly
on

the
starter
lever
to
ease
the

operation
Loosen
the

retaining
clip
take
off
the
fuel
line
and

remove
the
nozzle
Be
careful
not
to

damage
either
the
jet

needle
oc

the
nozzle
Remove
the
idle

adjusting
nut
and

spring

The
nozzle
sleeve
can
be
removed
if

necessary
by
taking
out

the
set
screw
but
as
previously
stated
should
not
be
dismantled

unless

absolutely
necessary

SU
TWIN
CARBUREfTOR

Assembly

Assemble
the

piston
assembly
into

position
but
do
not

fill
with

damper
oil

Assemble
the
nozzle
sleeve
washec
and
set
screw

by

temporarily
tightening
the
set
screw

Set
the
piston
to
its

fully

closed

position
and
insert
the
nozzle
until
it
contacts

the
nozzle

sleeve
When

the
nozzle

jet
contacts
the

jet
needle
the
nozzle

sleeve
must
be

slightly
adjusted
so

that
it
is
at

right
angles
to
the

centre
axis

and
positioned
to
leave
the
nozzle

jet
clear
of

the

jet
needle
Raise
the

piston
without

disturbing
the
setting
and

allow
it
to

drop
The

piston
should

drop
smoothly
until
the

stop
pin
strikes
the
venturi
with
a

liaht
metallic
click
See
below

under

Centering
the

jet
Tighten
the
nozzle
sleeve
set
screw

remove
the

nozzle
install
the
idle

adjustinJ
spring
and

adjusting

nut
on
the
nozzle
sleeve
and
refit
the
nozzle

39

1

Oil
cap
nut

2
Suction

chomber

3
Suction

piston

4

Li

tingpin

S

Stop
pin

6
Oil

dDmper

7

Plunger
3

j

I

r

L
2

1

Fig
0
17

Inspecting
the

suction

piston

STlq
O

OO

Fig
D
20

Checking
the
float
level
SU

twin
carburettors

q
J

iT

j

I

@

@

J
1
Conn

ctingrod

2

Wi
guard

3
Choke

lever

4

Connecting
plate

7
S
Thrott

adjusting
SC
Tt
W

6
Fast
id
lever

7

Throttle

adjusting
p1at

8
Throttle

valv

9

Throttlevalv
cletlran

B

Fig
D
22

Adjusting
the

starting
interlock

opening
inteN
lli
i

D

U
I

i

n

1
Jet
n
edle

2
Set
screw

Fig
D
18

Installing
the

jet
needle

1
Nozzle
sleeve

2
Wa
sher

3
Nozz
det
V
d
C1e
W

4

Ad
u
ting
him

5

dlingadjustment
spring

6

Idling
adjustment
nut

Z
Nozz
c
J

Fig
D
l9

Dismantling
the
nozzle

assembly

3

I
Float
lever

2
Bend
here

loadju5t

dimension
H

3
Va
veslem
r

F

Fig
D
21

Adjusting
the
float

level
SU

twin
carburettors

Fig
D
23

Checking
the

damper
oil

41

Connect
the
fuel
line
from
the
float

chamber
to
the
nozzle

nipple
and

tighten
the

retaining
clip
Pull
out

the
choke
lever

and

place
the

connecting
plaie
betw
n
the
washer
and
sleeve

collar
Screw
the

plate
to
the

nozzle
head
and
check
that
the

collar
is
installed
in
the
hole
in

the

plate
by
mo

ing
the
choke

lever
as

necessary

Recheck
the

piston
to
make

sure
that
it
falls

freely
without

binding

SU
TWIN
CARBURETTOR

Centering
the

jet

Remove
the

damper
oil

cap
nut

and
gradually
raise
the

lifter

pin
4
in

Fig
D
17

Continue
to
raise
the
lifter

pin
until
the
head
of
the

pin

raises
the

piston
by
approximately
8
mm
0
31
in
When
the

lifter

pin
is
released
the

piston
should

drop
freely
and
strike

the
venturi
with
a

light
metallic
click
If

the

pi
ston
does
not

fall

freely
it
will
be

necessary
to
dismantle
the

carburettor
in

the
manner

previously
described

SU

TWIN
CARBURETTOR

FLOAT
LEVEL

Inspection
and

Adjustment

The
fuel
level
in
the
float
chamber
can

be
checked

using

the

special

gauge
ST
19200000
Remove
the
float
chamber

drain

plug
and
install
the

special

gauge
as
shown
in

Fig
D
20

Start
the

engine
and
allow
it
to
run
at

idling
speed
The

fuel
level
is
conect
if
it
is

indicated
on

the

glass
tu

be
at
a

distance
of
22
24
mm
0
866
0
945
in
below
the

top
of
the

float
chamber

The
level
of
the
fuel
can

be
corrected
if

necessary
by

adjusting
the
float
level
in
the

following
manner
Take
out
the
float
chamber
coveT

securing
screws
and

lift
off
the
cover
and
attached
float

lever
Hold
the
cover
so
that

the
float
lev
r
is

facing
upwards
Lift
the
float
lever
and
then

lower
it
until
the
float
lever
seat

just
contacts

the
valve
stem

The
dimension
uH
in

Fig
D
1
should
be
11
12
mm
0
43

0
47
in

and
can

be
corrected

by
bending
the
float
lever
at
the

point
indicated

SU
TWIN
CARBURETTOR

Starting
interlock
valve

opening
adjustment

To

adjust
the
starting
interlock

opening
the

connecting

rod
4
in

Fig
D
22
1
must
be
bent

using
a
suitable

pair
of

pliers
The
throttle

opening
can

be
increased

by
lengthening

the

connecting
rod
or
reduced

by
shortening
the
rod

The
throttle

opening
is
correctly

adjusted
when
the

clearance
8

between
the
throttle
valve
and
throttle
chamber

is
set
to
0
6
mm
0
023
in
with
the
choke
lever
half

completely

out

HYDRAULIC
DAMPER

The

damper
oil

should
be
checked

approximately
every

5000
km
3000
miles
To
check
the
oil
level
remove
the
oil

cap
nut
as
shown

in

Fig
D
23
and
check
the
level
of
oil

against

the
two

grooves
on
the

plunger
rod

Top

up
with
SAE
20

engine
oil
if

the
oil
level
is
below
the
lower
of
the
two

grooves

Take
care

not
to
bend
the

plunger
rod
when

removing
and

replacing
the
oil

cap
nut

and
make
sure
that
the
nut
is

sufficiently

tightened
by
hand

TechnIcal
Data

Engine
Model
Ll4

I400cc

Primary
Secondary

28mm
32mm

21x7mrn
28xlOmm

96

165

60
60

I
Omm

220
100

1
6
Outlet
diameter

Venturi
diameter

Main

jet

Main
air
bleed

1
st

slow
air
bleed

2nd
slow
air
bleed

Economizer

Power

jet

Float

level

Fuel

pressure

Main
nozzle
55

22mm

0
24

kg

sq
cm
3
41b

sq
in

2
2mm

2
Smm

SU
Twin
Carburettors

Type

Bore
diameter

Piston
lift

Jet
needle

Nozzle

jet
diameter

Suction

spring
IUL
38
W6

38mm

1
4961
in

29mm

1417
in

M
76

2
34
mm

0
0921
in

No
23

Float
needle
valve

inner
diameter

Float

level
1
5mm
0

059
in

23mm
0
9055
in

42
Ll6
1600cc

Primary

Secondary

28mm
32mm

22x7mm

29xlOmm

102
165

60

60

1
0mm

180
100

1
6
Ll8

l80Occ

Primary
Secondary

30mm

34mm

23x14x7mm
30xlOmm

102
170

60
60

I
Omm

210
100

1
6

55

22mm
55

22m

2
3mm
2
5mm
2
3mm
2
8mm

Throttle

clearance
at
full

throttle

Position
at
full
throttle
0
6mm
0
0236
in

6
50

FUEL
PUMP

Type

Delivery
amount
Mechanical

1000cc
minute
at
1000

r

p
m

0
18
0
24

kg

sq
cm

2
5
3
41b

sq
in

from
eccentric
on
cam

shaft
Delivery

pressure

Drive

Clutch

DESCRIPTION

CLUTCH
Removal
and

Dismantling

CLUTCH
Inspection
and

Adjustment

CLUTCH
Installation

CLUTCH
PEDAL
Removal
and
Installation

DESCRIPTION

Either
a

diaphragm
spring
or

coil

spring
type
clutch

is

fitted
to

the
vehicle
The

component
parts
of
the

diaphragm

spring
clutch
are
shown
in

Fig
E
l
and
the

component
parts

of
the
coil

spring
clutch
are
shown
in

Fig
E
2

The
clutch
is
of
the

single
dry
plate
type
consisting
of

the
drive

plate
clutch
coveT
and

pressure
plate
and
release

bearing

The
driven

plate
comprises
a

flexible
disc
and

splined
hub

which
slides
on
the

clutch
shaft
Friction
linings
are

rivetted
to

both

sides
of
the
disc

The
clutch
cover

and

pressure
plate
are
combined

by
nine

spring
setting
bolts
The

diaphragm
is
dished
to

maintain
a

constant

pressure
on
the

pressure
plate
which
in
turn
holds

the
driven

plate
in
contact
with
the

flywheel
The
release

bearing

is
a
sealed

type
ball

bearing
mounted
on
a

bearing
sleeve
Both

bearing
and
sleeve
are
operated

by
the
withdrawalleveT
when

the
clutch

pedal
is

operated

The
clutch

pedal
actuates
a
master

cylinder
which
transmits

fluid

under

pressure
to
a
slave

cylinder
The
movement
of

the

slave

cylinder
piston
operates
the
clutch
withdrawal
lever
via

a

push
rod
See

Fig
E
14

CLUTCH
Removal
and

Dismantling

The

gearbox
must

be
removed
from
the
vehicle
before

the
clutch
can

be
withdrawn
The

procedures
for

removing
the

gearbox
can
be
found
in
the
section
GEARBOX

If
a

diaphragm
clutch
is
fitted
insert
a

spare
clutch
shaft

or
a

special
alignment
tool
ST20600000
into
the

splines
of

the
driven

plate
So
that
the
dutch
is

supported
Slacken
the

six
bolts

securing
the
clutch
cover
to
the

flywheel
by
a
single

turn
at
a
time
and
in
a
diagonal

pattern
until
the

spring

pressure

is
relieved
Remove
the
bolts

completely
and
lift

away
the

clutch

assembly

When

removing
the
coil

spring
type
clutch
it
will

be

necessary
to
insert
suitable
hooks

under
the
release
levers
to

restrain
the
tension
of
the
clutch

spring
before

removing
the

clutch
cover
lx
llts

Ensure
that
the
friction

linings
of
the
driven

plate
do
not

become
comtaminated
with
oil
or

grease
when
removing
the

plate
from
the

splined
shaft

Diaphragm
clutch

The
clutch
cover
and

pressure
plate
assembly
should
not

be
dismantled
and
must
be

replaced
if
wear
or

damage
has

occurred
Make
sure
that
the
friction
face
of

the

pressure
plate
CLUTCH
PEDAL
Adjusting

CLUTCH
MASTER
CYLINDER

CLUTCH
SLAVE
CYLINDER

CLUTCH
WITHDRAWAL
LEVER

Adjusting

CLUTCH
SYSTEM

Bleeding

is
perfectly
flat
and
smooth

Coil

spring
clutch

A

special
tool
No
ST200S0000
is
available
to
ensure

that

the
clutch
can
be
dismantled
and

accurately
reassembled
The

tool
shown
in

Fig
E
3
consists
of
a
Base

plate
I
Centre

spigot
2
Distance

pieces
3

Height
gauge
4
Operating
lever

5

Securing
bolts
6

A
chart
is
included
to
indicate
the
various

parts
to
be
used

for
each

type
of
clutch

To
dismantle
the
clutch
place
the
distance

pieces
on

the

base
plate
as
shown
and

arrange
the
clutch
cover
on
the
base

plate
so
that
the
cover
holes
coincide
with
the
threaded
holes

in
the
base

plate
Insert

the

securing
bolts
provided
in
the
kit

and

tighten
them
gradually
and

evenly
in
a

diagonal
pattern

until
the
cover
is

firmly
attached
to
the
base

plate
Mark
the

clutch
cover

the

pressure
plate
lugs
and
the
release
levers
with

a

centre

punch
so
that

they
can

be
reassembled
in
their
original

positions

Remove
the

restraining
hooks
from
the
release
levers
and

unscrew
the
three
nuts
from
the

eye
bolts
Slowly
release
the

pressure
on
the
clutch
coil

springs
by
unscrewing
the
bolts

securing
the
cover
to
the
base

plate
and
lift
off
the
cover

springs

and

pressure
plate

CLUTCH

Inspection
and
Adjustment

Use
a
solvent
to
clean
the
dismantled

parts
with
the

exception
of
the
disc

linings
and
the
release

bearing

Check
the
clutch
cover

diaphragm
spring
and

pressure

plate
assembly
for
wear
or

damage
and
renew
the

complete

assembly
if

necessary
The

pressure
plate
on
the
coil

spring

clutch
can
be

lapped
if
necessary
as
described
below
Ensure

that
the
disc
rivets
are
not
loosened
and

inspect
the

linings
for

contamination
Grease
or
oil
should
be
removed
and
the

linings

dressed

using
a
wire

brush

Check
the
disc
for

run
ut

using
a
dial

gauge
as
shown
in

Fig
E
4
Position
the
dial

gauge
at
a

point
approximately
9Smm

3
74
in
from
the
centre
of
the
disc
and
check
that
the
run

out
does
not

exceed
the
permissible
limit
of
0
5
mm

0
02in

A
slight
deflection
can
be
corrected

by
hand

pressure
with

the
disc
mounted
on
the

gearbox
shaft

The
disc
must
be
renewed
or
relined
if
the
height
of
the

linings
above
the
rivets
is
less

than
0
3mm
0
012
in

Replace

the
bearing
sleeve
if
it
shows

signs
of
wear
at

the
point
of

contact
with
the
withdrawal
lever

Replace
the
release

bearing

if

grease
is

leaking
from
it
or
if
it
is

noisy
when
turned

43

The
coil

spring
clutch

pressure
plate
can

be

lapped
with
a

surface

grinder
to
remove

dents
or

scratches

only
the
minimum

amount
of
metal
should
be
removed
to
restore
the
surface

Check
the

plate
for
distortion

by
placing
it

on
a
surface

plate
with

the
friction
face
towards
the
surface

plate
Press

the
pressure

plate
down
and
insert
a
feeler

gauge
of
1
0mm

0
0039
in

between
the

pressure
plate
and
surface

plate
If
it

is

possible
to
insert
the
feeler

gauge
then
the

pressure
plate
must

be

repaired
or

replaced
The

plate
can
be
skimmed
but
the

maximum
amount
of
metal
that
can
be
removed
is
1
0mm

0
0039in

CLUTCH
SPRING

Diaphragm
clutch

With
the

diaphragm
spring
assembled
to
the

pressure
plate

inspect
the

spring
height
and
load
in
the

following
manner

Place
distance

pieces
of
7
8
mm

0
307
in
on
the
base

plate
as

shown
in

Fig
E
3
and
bolt
down
the
clutch
cover

using
the

special
bolts

provided
with
the
kit
Meas
Jre
the

height
B
in

Fig
E
5

at
a
diameter
of
44mm
1

732
in
The
release

fingers

should
not

exceed
a

height
of
43
45
mm
1
693
1
772
in

from
the
base

plate
Replace
the

spring
if

the

height
is
in
excess

of
the

figures

quoted

Press
the
dutch
down
as

shown
in
Fig
E
6
to
a

depth
of

7
8mm
0
307
in
or
until
the
clutch
driven

plate

upper
surface

lines

up
with
the
clutch
cover

mounting
face
If

the
load

applied

is
less
than
350

kg
770
lbs
it
will
be

necessary
to
renew
the

diaphragm
spring
Do
not

press
the
clutch
disc
down

by
more

than
9mm
0
35
in
or
the

diaphragm
spring
may
be
broken

CLUTCH
SPRINGS
Coil

spring
clutch

The
clutch

springs
must
be

replaced
as
a

set
if

any
of
the

springs
are
found
to
be
defective
Specifications
for
the

springs

are

given
in
Technical
Data
at
the
end
of
this
section

Generally

a

spring
may
be
considered
faulty
if
when
assembled
the
load
is

reduced

by
more
than
15
or
if
the
free

length
has
altered

by

more
than
1
5mm
0
0590
in
or
if
the
deflection
B
to
A

in

Fig
E

7
exceeds
5mm

per
100mm
0
2
in

per
3
94
in

Release

Bearing

The
release

bearing
should
be
renewed
if

excessively
worn

or
if

roughness
can
be
felt
when
the

bearing
is
turned

by
hand

The

bearing
should
also
be
renewed
if
the

grease
has

leaked

away
or
if
the
clearance

between
the
clutch
cover
and
inner

diameter
of

the
sleeve
is
more
than
0
5
mm
0
0197
in

The

bearing
can
be

removed

using
a
conventional

puller

as
shown
in

Fig
E
8
Two

types
of
release

bearings
are

available

and
care
must
be
taken
when

fitting
onto

the
bearing
sleeve

The
release
bearing
should
be

pressed
into

place
on
the

diaphragm

spring
type
of
clutch
with
a
force
of
400

kg
880
lbs

applied

at
the
outer
race
as
shown

in

Fig
E
9
On
the
coil

spring
clutch

the
same

force
must

be

applied
at

the
inner
race
as
shown
in

Fig
E
IO
It
should
be

possible
to
turn
the

bearing
freely
and

smoothly
when
it
is

pressed
into

place
CLUTCH

Assembly

Coil

spring
type

Press
the

pin
into
the

eyebolt
and

through
the

lug
on

the

pressure
plate
Place
the
three
distance

pieces
on
the
surface

of
the
base
plate
of
the

special
tool
ST20050000
and

position

the

pressure
plate

pressure
springs
and
retainers

on
the

plate

Set
the

retracting
springs
on
the
cover

and
insert
the

release
levers

through
the

spring
Place

the
clutch
cover
over

the

pressure
plate
and

springs
making
sure
that
the

retracting

springs
do
not

become
dislodged
or
distorted

Compress
the

pressure
springs
by
screwing
the

special
set

bolts
into
the
holes
in

the
cover

Tighten
the
bolts

gradually

in
a

diagonal

pattern
to
avoid

distorting
the
cover
Place
the

release
levers
on

the

eye
bolts
and
screw
OR
the

securing
nuts

Place

retaining
hooks
under
the
release
levers
and
remove
the

clutch
assembly
from
the
base

plate
slackening
the
set
bolts
in

a

diagonal
pattern

COIL
SPRING
CLUTCH

Adjusting

Screw
the
centre

pillar
into
the
base

plate
and

place
the

high
finger
over
the

pillar
The
height
of
the
release
levers
must

be

adjusted
by
turning
the
eye
bolt
nuts
until
the

tops
of

the

release
levers
are

just
touching
the

tip
of
the
gauge
See
Fig
E

11
Remove
the
centre

pillar
when
the
release
levers
are

correctly
adjusted
and
screw
in
the

actuating
lever
Fig
E
12

Turn
the

actuating
mechanism
several
times
to
bed
down
the

parts
and
then
recheck
the

height
of
the
release
levers
Check

for
run
out
as
near
to
the

edge
as
possible
and

readjust
if
the

deviation
is
more

than
0
5
mrn
0
020
in

CLUTCH
InsWlation

Ensure
that
the
friction
faces
are

free
from

oil
and

grease

and
place
the
driven

plate
on
the

flywheel
The

longer
chamfered

splined
end
of
the

assembly
should
face

the

gearbox
Use
a

spare
drive
shaft
to

align
the
driven

plate
The
shaft
must

be

inserted

through
the
splined
hub
of
the
driven

plate
and
into

the

pilot
bearing
of
the

flywheel

Place
the
clutch
cover
into

position
on

the
flywheel
and

tighten
the
dutch
bolts

gradually
in
a

diagonal

pattern
to
a

torque
reading
of
1
5
2
2

kgm
11
16Ib
ft

Remove
the

dummy
shaft
and
the

restraining
hooks
from
the
release
levers

Refit
the
release

bearing
and
the
bell

housing

CLUTCH
PEDAL
Removal
and
Installation

Remove
the
clevis

pin
from
the
end
of
the
master

cylinder
pushrod
and
disconnect
the
pushrod
Remove
the

return

spring
Remove
the

pushrod
after

slackening
the

pushrod

adjuster
Coil

spring
clutch

only
Remove
the

pedal
lever

securing
bolt
slacken
the
handbrake
bracket
bolts
and
lift
out

the

pedal

Clean
all

parts
thoroughly
and
check
them
for
wear
or

damage
paying
particular
attention
to
the
rubber

parts
return

spring
and

pedal
lever
bush

Installation
of
the
clutch

pedal
is
a
reversal
of

the

removal

procedures

45