Allstate 50cc and 60cc Models Basic Information

Allstate 50cc and 60cc Models Basic Information
Allstate 50 and 60cc
MOTORCYCLE
ALLSTATE
SEARS, ROEBUCK AND CO.
U.S.A.
SIMPSONS-SEARS, LTD.
CANADA
50 AND 60CC MODELS
MODEL
Mo-Ped
Displacement-cc ........... . ............. 49
Bore-MM ......... ......... .. . . .. .. ..... 38
Stroke-MM .................. . .. • ... • .... 43
Number of cylinders ..... . ... . ....... ... .. I
Oil-fuel ratio .............. ... . . ..... ... .. I to 25
Plug gap-inch ...... .......... • ...... •. ... 0.020
Point gap-inch .. .. ... .... ................ O.Dl6
Ignition timing- Advance .. ............... Fixed
Inches BTDC .. ... ..... ...... . .......... 0.071
Electrical system voltage ................. 6
Tire size ........ . .. ..... ....... .. ....... . 2.25 X 23
Tire pressure psi·front. ................... 25
rear . .. . .............................. 32
Chain free play-inch. . . . . . . . .. . . . . . . . . . . . 1h
Number of speeds ............. .. .... . . . . . 2
Weight lbs. (approx.) ..................... 115
'32 psi with two riders
Campus 50
Saber
49
38
43
49
38
43
1
1 to 25
0.020
0.016
Fixed
0.071
6
2.25 X 23
25
32
I
1 to 25
0.020
O.D16
Fixed
0.071
6
2.25 X 23
25
32
'h
3
118
'h
3
140
Sport 60.
Cheyenne
Motor
Scooter
59.6
42
43
1
I to 25
0.020
0.016
Fixed
0.039
6
2.25 X 23
25
32
'h
3
141
59.6
42
43
I
I to 25
0.020
0.016
Fixed
0.043
6
3.00 X 12
20
25 "
V2
3
150
MAINTENANCE
SPARK PLUG. Spark plug electrode gap is 0.5 MM (0.020 i n.) for all
models. Refer to the following chart
for correct type of plug.
?~
1
Model
2
~3
a.
Washer
4. Clip
5. Needle
valve
6. Throttle
s lide
i. Main jet
8. Lock nut
9. Idle ad·
~·
Justlng
screw
10. Plug
11 . Gasket
12. Needle
val\·e
~
•
12---m
11--o
\
~8
Jet
13. Float
14. Float
needle
15. Gasket
16. Float
cover
7
9
to--e
Fig. Al -l-Exploded view of Bing 1/12
carburetor.
14
Fig. A 1·2-Exploded view of Bing 1 / 17
carburetor.
1. Idle speed adjusting scr ew
Choke thrus t pin
Clip
Choke slide
Fuel s trainer
Float needle valve
Float
4.
5.
6.
7.
8.
10.
11. Cover
12. Main jet
13. Needle Jet
14.
15.
16.
17.
Th r ottle slide
Nee dle valve
Clip
W asher
Allstate
C h a mpion
Mo-Ped
60410
L-7
Motor Scooter 60400
L-7
Other Models 902.0727
L-5
CARBURETOR. Mo-Ped 50 models
use a Bing 1/ 12 carburetor shown in
Fig. Al-l. Main jet (7) is usually size
62; however, for better fuel economy,
size 60 main jet may be installed.
Needle valve clip (4) should be installed in second groove from top of
needle (5). Make certain washer (3)
is installed. Idle speed screw (9)
should be locked by nut (8).
All models except Mo-Ped 50 use
Bing 1/17 carburetor shown in Fig.
A1-2. Main jet (12) size is normally
No. 90 for Sport Mo-Ped and 84 for
Motor Scooters; however, other sizes
may be used for better fuel economy
or slightly better performance. Clip
( 16) should be installed in third
groove from top of needle (15). Make
certain washer ( 17) is installed. Idle
speed screw (1) is on right side.
Allstate 50 and 60cc
SERVICE
IGNITION AND ELECTRICAL. A
flywheel type magneto is used and
consists of three systems. The ignition
primary coil (5-Fig, A1-3 }, head and
tail light coil ( 10}, stop light coil ( 11}
and ignition points (12) are located
on left side of engine under the flywheel (18}. Ignition points should be
set to 0.4 MM (0.016 in.} fully open.
With ignition point gap correctly set,
ignition timing should occur with piston 1.8 MM (0.07087 in.} BTDC on
50cc models; 1.0 MM (0.03937 in.} on
Sport 60 and Cheyenne and 1.1 MM
(0.04331 in.) on Motor Scooter. If timing is incorrect, the coil stator plate
can be moved in the elongated holes
after loosening the three mounting
screws (9}.
LUBRICATION. Engine is lubricated by mixing SAE50 two stroke
motor oil with the fuel. Normal ratio
is 1:25. The gear box is lubricated
with SAE40 or 50 oil (in cold weather
use SAE 20 or 30} . Gear box oil should
be maintained at oil level plug (PFig. A1-5}. Oil should be drained
every 4000 miles.
Fig. A 1-6-Exploded view
of clutch used on all
models except Mo-Ped 50.
Mo-Ped 50cc model is
similar.
1.
3.
4.
5.
Snap ring
Cap
Rubber washer
Return spring
CLUTCH. The clutch, located on
right side of engine, is of the multiple·
disc, wet type. The clutch lever (2Fig. Al-6) should not have less than
10 MM (0.3937 in.} free play with
cable disconnected. If adjustment is
required, remove plug (9} and lock
wire ( 11}. Turn ball nut ( 12) as required and install lock wire. Adjustment of the cable will take up excessive play in controls.
1
2~.J.
3~
;:-d w
4___.:; 10 9
1~
k ""12
4A
0. Rubber washer
i. Clutch shaft
10. Gasket
12. BaH nut
13. Snap ring
14A . Bearing shell
1-tB. Set bolt
HC. Snap ring
15. Nut
16.
17.
16.
19.
20.
21.
22.
23,
24.
L o c k washer
Spring cup
Clutch spring
Spring cage
Steel clut ch disc
Clutch friction plates
Clutch hub
Thrust washer
Clutch housing
25. Bushing
26. Thrust washer
Fig. A 1-3-View of the flywheel electrical
system typical of all models. On some early
models, ignition coil may be at 10 instead
of location 5.
5 . Ignition coil
i'. Condenser
10. H ead a nd tailligh t coil
11. Stop light coil
12. Ignition points
H . Lul)ricator
15. \\'asher
16. Shims
10
17. C li p
18 . Flywheel
19. Roller
20. 'Vasher
21. :'\'ut
24. I nsulating w ashers
9.
10.
11.
12.
13.
14.
15.
16 .
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Bumper
Couplings
Spring
Spring bolt
Bottom joint
Nuts
Sealing Washer
Washer
Nut
Sliding tube
Bottom guide
Top guide bushing
Seal
Felt \Vasher
Sealer shell
Felt strip
Nut
Dust cap
Bearing balls (42 used)
Bearing seat
Bearing seat
30. Bearing cones
Fig. A1-5-Gear box oil should be maintained at level of plug (P), All models are
similar.
~
Fig. A 1-7-Exploded view
of Mo-Ped and Campus
50 front suspension assembly.
i-10
12
!7;14
....-15
-16
0......17
15
Allstate 50 and 60cc
MOTORCYCLE
Fig. A 1-8-Exploded view
of Sport 60, Saber and
Che yenne front sus pension
assembly.
11. P lug
13. Screw
H. P lug
15 . Dust cove r
16. Bearing cones
17.
18.
20.
24.
Beari ng balls (42 u sed )
Dea ring cups
I•..ork bridge
Sliding tube
30. llumner
31. Co\·cr
32, Rubber spacer
~- Centering ring
34. Headlight bracket
36. Couplings
37. Spring
38. I01ner fork tube
Sport 60, Sab er and Chey e nne telescopic front fo rks sh ould be drained
and refilled wi th SAE 30 or 40 motor
oil every 3700 to 5000 m iles. Oil is
drai ned and refilled at pl ug (26-Fig.
A 1-8). Capacity for each side is 100cc.
S uspension u nits for Motor Scooters
and rear u nits for Mo- Ped and Campus 50 is sh own i n Fig. A1-9.
Rear suspension units on Sport 60,
Saber and Cheyenne should be drained
and refilled with shock absorber fluid
every 3700 to 5000 miles. Capacity is
65cc for each uni t. The un its must be
r emoved and 22 MM nut (3-Fig. A1-10} loosene d before ser vicing cyl inder.
39. Felt washer
40. Felt scraper ring
41. Sealer shell
42. Rubber collar
43. Upper bushing
44.
45 .
46.
4j.
Lower bushing
Pisto n
Piston ring
Spring bolt
REPAIRS
48. W asher
49. S pring w ash er
GO.
51.
G2.
53.
Vat ..·e
L ower union
Nuts
Seal
\Vasher
55. Nu t
~4.
SUSPENSION. The front fork on
Mo-P ed and Campus 50 is shown in
Fig. A1-7. Oil in the telescopic fo r k
should be drained every 6000 miles.
Service with oil a t screw (37}. Capacity is 40cc for each sid e.
39fl()
38~~~
43.---a
PISTON, RINGS A ND CY LINDER .
The p iston can be removed after first
removing cow ling, exhaust pipe, carburetor, cylinder head and cylinder.
R ing end gap should be 0.1 -0.8 MM
(0.00394-0.03150 inch}. Piston should
h ave 0.12- 0.15 MM (0.00 4 7-0.0059
i nch) clearan ce in cyli n d er bore .
Standard cylinder bore diam e te r is
38 MM (1.4961 in.} for 50cc models,
42 MM ( 1.6535 in.} for 60cc models.
P iston and rings are ava i lab l e i n
standard size and 0.5 MM oversize.
P iston should be installed with both
ring groove p ins toward fr ont of engine. Piston p in is f ull floating type
and is held in place with snap r ings
Fins on cylinder head should run from
side to side.
47- - 0
44~
48~
73
16
n--::::-0
~
fFl4t,.
4~
74 ,
49
IS.
#$)~ 17
~
12
13
51
f J - -12
Fig. A1·9- Exploded view of suspe nsion
unit typical of type used on rear of MoPed and Campus 50 and both front and
rear of 60cc Motor Scooter.
39. Bushing
44. Bumper
47. Plastic guide bushlnss
48. Felt
49. Felt washer
16
Fig. A 1-1 0-Exploded view of rear suspe nsion unit typical of Sport 60, Saber and
Cheyenne.
2. Bumper
3. Sealing screw
4. Seal
Spring c up
G. S p r ing
U.
50. Lower sliding tube
51. Stop ring
7. " ' asher
8. Guide bush ins
73. Spring
74. U p per s liding tube
9. Spacer
10. Spring washer
11. Valve
0"-17
o=-n
14. Spring washer
15. Screw
Fig. A 1·12-Crankshaft, bearin<JS and piston typical of all models. Crankshaft and
connec:tirtg rad are available anly as a
complete unit.
16. Cylinder
17. End cap
18. Bushing
20. Spring
21. Cover
6.
11.
12.
13.
12. Piston
13. Ring
Piston pin bushing
Seals
Bearings
Shim (0.05,
0.1 & 0.2 MM)
15. Snap ring
16. Bearing
17. ' Vasher
SERVICE
Allstate 50 and 60cc
CONNECTING ROD AND CRANKSHAFT. The crankshaft is supported
in three ball type main bearings.
B earings and/or crankshaft can be re-
2
moved after disassembling crankcase
as outlined in CRANKCASE AND
GEAR BOX. The connecting rod and
crankshaft are available only as a
complete unit and should NOT be disassembled. Crankshaft end play is adjusted to 0.0 (DO NOT PRELOAD
BEARINGS) by adding shims ( 13Fig. Al-12) .
CRANKCASE AND GEAR BOX. To
disassemble the crankcase a nd gear
box, the e ngine must first be removed. Remove the cowling, cylinder
head, cylinder, piston, flywheel,
clutch cover and clutch. Remove the
Fig. Al-13-Exploded view of two speed
transmission.
1. Nut
2, Lock plc\te
3 , Driven gea r
4. Uearlng race
5. Dearing rollers
(1 4 for each race)
6. First speed g ear
GA. S 1>a cer ( 1.6,
1.8, 2.0 & 2.5 MM )
t.
Outpu t shaft
8. Second speed gear
9 . T h rust washer
10. Seal
11. Spacer
12. S procl<et
13. Lock p la t e
14, Nut
15. Hearing race
16. Dearing r ollers
C18 u sed )
1j .
18.
19.
20 .
21.
Thrust washer
lnt>ut shaft
Bear ing
Snap rinJ::
Genrshift yoke
blower baseplate and gear shift as-
1. S hifter for k
2. Shifter yoke
3. Shltter rail
4. \Va sher
5. Snap ring's
G.
7.
8.
9.
10.
t 1.
sembly (Fig. Al-18). Remove screws
that attach crankcase halves together
Spr ing washer
Gea r s hifter lever
Detent plug
S pring
Seal
and carefully se parate the halves.
Dowel pins are installed between
Gui de plug
halves. Be careful not to damage seal-
12. Seal washer
13. ~'asher
ing s urfaces of crankcase. The trans-
14. Shifter s haft
15. Disc
mission gears are shown in Figs. Al-
Fig. Al-l 5-View of Mo-Ped two speed
gear shift mechanism.
13 and Al-16.
9·~j!
456,1\
t~
~~b
1lrnJ
~~26
~13
22
2021
I . Starter co untershaft
and gear s
2. Thrust washer s
(1.9, 2.0. 2.1 &
2.4 MM)
3. Bushings
4. S tarter gea r
5. Driver
6, S pring ring
7 . Cla w colla r
8. Ped a l shalt
Fig. Al-14- View
of Mo-Ped starting
and pedaling asIWIIIbly.
9. T hrust washer and
shims (0.1 , 0.2 &
0.5MM)
10. Seals
11. Bushings
12. " ;asher
13. Brake le\'er
H. CleYis
15. Sr.ap ring
16. D ri\'e r brake s vrt ng
17'. Thrust was her
18 . Snap rlng
19. Catc h r ing
20. Snap ring
1211
j ?. I~~~~
1
~~ ~
25
20
21
10 15 16
Fig. A1-16-Exploded view of typical three speed transmission.
4 . Benr ing rnces
;:;, Bear ing rollers
(14 tor each race)
6. Shims (1.6. 1,8, 2.0 &
2.5 M'M)
10. Oil seal
11. Spacer
12. Sprocket
13. Lock pla t es
14. Nuts
15. Bearing race
16. Bearing rollers (18 u sed)
19. Bearing
20. Snap r ing
21. Driven gear
22.
25.
26.
27.
28.
Input shaft a nd gears
Firs t spee d gear
Seeond speed sear
Output shaft
T hird speed g ear
17
Allstate 50 and 60cc
MOTORCYCLE
Fig. A1·17-View of starter assembly typical of all models except Mo-Ped.
2. Thrus t washers
(1.9, 2.0, 2 .1 and 2.4 MM)
10. O il seal
11. Bushing
3. Bushings
16. Driver brake spring
9. Thrust w asher and shims
(0.1. 0.2 and 0 .5 MM)
18. Snap rin g
19. Catch ring
20.
28.
29.
31.
17 . Thrus t w asher
Snap ring
Starter gear
Drl\·er
Starter !~haft
36.
3i.
;;o,
51.
Starter countershatt
Driver cap
S pring hub
Retur n spring
02. Washer
54. Hub
Fig. A1·18-Exploded view of shifter mechanism used on three speed transmissions.
1. Housing
3. Oil seal
4. Selector s h a ft
5. Geo.rshlft lever
5A. Thrust washer
li. Lever
7. Ratchet
8. Lifting p la te
18
D.
10.
11.
12.
13.
17.
18.
Support plate
Selector spring
Washer
Spring washer
Sn a p-ring
Shifte r d og
Pin
19. Spring
20. Shift fork
21. Snap ring
22. Spr ing
23. Detent
24. Guide p lug
25. Seal
35. Exterior shift lever
40. Control rod
59.
Gl.
62.
64.
65.
Starter c rank
S!)ring
Detent pin
Stop
Seal
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