CONTROLS AND OPERATION
Paragraph
Controls 5
Engine prestarting instructions 6
Starting the engine 7
Stopping the engine 8
Operation of vehicle 9
Driving precautions 10
Stopping and parking vehicle 11
Towing vehicle to start engine 12
Running‐in new engine (or vehicle) 13
[Illustration: RA PD 310201
_Figure 4—Controls_]
5. CONTROLS (fig. 4).
=a.= Controls are peculiar to the motorcycle. The rider must become
thoroughly familiar with the location and use of all control devices
before attempting to operate vehicle.
=b. Gasoline Valve= (figs. 5 and 6). Gasoline valve is located in left
tank, forward. Valve is closed by turning to the right, finger tight.
Turning to left opens valve. Valve is in normal operating position
when turned to left, with valve head down. Lifting valve head releases
emergency supply of fuel (3 quarts).
[Illustration: RA PD 310202
_Figure 5—Fuel Supply Valve_]
[Illustration: RA PD 310293
_Figure 6—Fuel Supply Valve Positions_]
=c. Throttle.= The throttle is controlled by right handle bar grip.
Turning grip inward opens throttle, turning it outward closes throttle.
=d. Spark.= Spark is controlled by left handle bar grip. Turning grip
inward advances spark, turning it outward retards spark.
=e. Clutch= (fig. 7). Clutch is operated by left foot (rocker‐type)
pedal, connecting with steel cable, which actuates clutch release
lever. Pedal is located on left side of motorcycle above footboard.
Forward downward (toe) position of pedal engages clutch. Rear downward
(heel) position of pedal disengages clutch. Foot pedal provided with
friction device to retain it in either engaged or disengaged position.
[Illustration: RA PD 310204
_Figure 7—Clutch Pedal Positions_]
[Illustration: RA PD 310205
_Figure 8—Gear Shifter Lever Positions_]
=f. Service Brake (Rear Wheel).= Foot pedal is located on right side
of motorcycle at forward end of footboard.
=g. Auxiliary Brake (Front Wheel).= Auxiliary brake is operated by
hand lever located on left handle bar. It is used in conjunction with
service brake, as an emergency brake, or for holding vehicle while
starting engine on grade. CAUTION: _Brake is to be applied lightly and
cautiously on wet and slippery roads._
=h. Gear Shifter= (fig. 8). Shifter lever is located on left tank,
forward position, and operates within a guide. Shifter lever guide is
notched for positive location of gears and each position is identified,
front to rear: “1”—low gear; “N”—neutral; “2”—second gear; “3”—direct
high gear.
[Illustration: RA PD 310206
_Figure 9—Carburetor Choke Lever Positions_]
=i. Steering Damper.= Steering damper is an adjustable friction
device to damper turning action of forks, steady front wheel, and
prevent wobble in rough terrain or at high speeds, and is located on
top of steering head in center of handle bars. Move handle to right to
apply desired friction.
=j. Foot Starter Crank= (fig. 1). The foot starter crank is located
on right side of motorcycle. Gear shifter lever must be in neutral
position, and clutch foot pedal in forward engaged position, before
using foot starter crank. Starter crank normally is in upward position.
Straddle motorcycle, place right foot on starter crank, and shift
weight of body for forceful downward crank operation to start engine.
=k. Ignition and Light Switch.= Earlier models are provided
with switch lock, later models are nonlocking. Switch is off in
straight‐forward position. First position to right is for engine
ignition only. Second position to right is for ignition and blackout
lights. To use vehicle service lights, depress button to turn switch to
third right position.
=l. Instrument Panel Signal Lights.= Instead of an ammeter and oil
pressure gage, signal lights indicate generator charging, and engine
oil pressure.
(1) Green light is located on left side of instrument panel. When
engine is running, and light is out, it indicates generator is charging.
(2) Red light is located on right side of instrument panel. When engine
is running, and light is out, it indicates engine oil is circulating.
=m. Carburetor Choke= (fig. 9). Choke lever is in full prime position
when all the way up, and in normal running position when all the way
down.
6. ENGINE PRESTARTING INSTRUCTIONS.
=a.= Before the engine is started, perform the Before‐operation Service
outlined in paragraph 15. Special care must be taken during starting
and warming‐up period to avoid unnecessary engine wear.
=b.= The rider must acquire correct motorcycle engine starting habits,
and learn to do the job the quickest, easiest, and most dependable way.
The following pointers will be helpful to the beginner as well as to a
seasoned rider:
(1) Mount (straddle) motorcycle to obtain firm grip on handle bars.
(2) Leave side stand (jiffy stand) outward to support vehicle while
operating foot starter crank with right foot.
(3) Engine starting will be benefited by use of front wheel,
hand‐operated brake, to prevent vehicle from rolling or shifting during
starting kicks. This is especially helpful if vehicle is parked on an
incline or on soft, uneven surface.
=c.= The procedure outlined below is preparatory to starting either
cold, warm, or hot engine:
(1) Place gear shifter lever in “N” (neutral) position (fig. 8).
(2) See that gasoline shut‐off valve is open (fig. 5).
(3) Engage clutch (fig. 7).
(4) Spark control (left) grip must be turned inward to fully advanced
position, or nearly so.
(5) Foot starter crank may travel 1/2 way downward before starting
engine. See that a full vigorous starter stroke is used. A vigorous
kick, using a full swing (not a jab) of right leg and hip, is correct
engine starting practice.
7. STARTING THE ENGINE.
=a.= Procedure for starting cold, warm, or hot motorcycle engines
differs. Therefore, following instructions are used with paragraph 6 c
to cover correct procedure in all three cases.
=b. Starting Cold Engine.= When vehicle has not been operated for
some time, and engine is normally cold, follow progressive procedure
for easiest starting.
(1) Set carburetor choke lever in full upward (closed) position.
(2) Open throttle wide by turning right grip inward as far as it will
go.
(3) Prime cylinders by operating foot starter crank one or two strokes.
(4) Set carburetor choke lever in 1/4 to 1/2 closed position for mild
weather starting: 3/4 closed (or leave fully choked) for extremely cold
weather starting. CAUTION: _It is only in extremely cold weather
that engine may start best with choke fully closed, and even then it
will have to be moved from this position immediately after engine is
started._
(5) Set throttle (right) grip to slightly open position.
(6) Turn ignition switch on, first right position.
(7) Start engine with vigorous strokes of foot starter crank.
(8) When engine starts, set throttle for moderate idling speed for
warming up, or until ready to set vehicle in motion. Do not race engine
unnecessarily.
(9) After engine warms up, and misfires due to an overrich mixture,
gradually move choke lever downward. After engine has thoroughly warmed
up, move choke lever to fully open (downward) position.
=c. Starting Warm Engine.= Following instructions apply to engine
when halfway between hot and cold. With engine in this condition,
carburetor choking must be handled cautiously.
(1) Lift choke lever to first upward position from normal (1/4 closed).
(2) Set throttle (right) grip to fully closed (outward) position.
(3) Operate foot starter crank one or two strokes.
(4) Set throttle grip to between 1/4 and 1/3 open position.
(5) Turn ignition switch on.
(6) Start engine with vigorous strokes of foot starter crank.
(7) Soon after engine starts, choke lever must be moved to fully open
(downward) position.
(8) Turn throttle grip to control idling speed of engine.
=d. Starting Hot Engine.= If engine has been shut off for only a
brief period and is near normal operating temperature, it is not
necessary to use carburetor choke lever. With some engines, depending
upon carburetor condition and adjustment, hot starting is easier and
more dependable if foot starter crank is operated one stroke before
turning ignition switch on.
(1) Close throttle grip by turning fully outward.
(2) Turn ignition switch on.
(3) Operate foot starter crank to start engine.
(4) When hot engine does not start readily after two or three strokes
of the foot starter crank, it is usually due to an overrich (flooded)
condition, and the proper procedure then is to open throttle wide so
that more air can enter: close throttle quickly after engine starts.
CAUTION: _After engine has warmed up to a normal operating temperature,
do not allow engine to stand idling for longer than a 1 minute
interval._
=e. Starting Engine with Dead Battery.= See paragraph 12.
=f. Behavior of Instrument Panel Signal Lights.= Function of
generator (green) signal light depends upon action of cut‐out
relay; engine oil pressure (red) signal light depends upon action
of oil feed pump. Rider must, therefore, thoroughly understand
operating characteristics of both signal lights to judge condition of
generator‐battery circuit and pressure in engine oil circulating system.
(1) When ignition light switch is turned to first (right) position,
preparatory to starting engine, both green and red signal lights should
go on. CAUTION: _When switch is turned on, immediately after engine has
been primed by cranking, red (oil pressure) signal light may not light
at once, but will light after a few seconds, due to oil pressure built
up by cranking, and is most likely to be noticed in cold weather._
(2) With engine started and running at medium idling speed, both signal
lights should go off. CAUTION: _Should oil pressure (red) signal light
fail to go off at speeds above idling, conditions must be brought to
attention of unit mechanic._
(3) At slow idle speed, or under approximately 20 miles per hour road
speed (in high gear), generator (green) signal light will normally
flash on and off, because at that speed generator voltage output is
very low and unsteady. CAUTION: _Should generator (green) signal
light fail to go off at speed above approximately 20 miles per hour,
generator is either not charging at all, or its current output is not
up to normal, and generator should be given attention at once._
8. STOPPING THE ENGINE.
=a.= Stop engine only by turning ignition and light switch to off
(straight‐ahead) position, to prevent discharge of battery through
spark coil primary circuit.
9. OPERATION OF VEHICLE.
=a. Starting on Level Ground.= The engine having been warmed up and
checked for satisfactory operation, the vehicle (with operator in
riding position) is put in motion as follows:
(1) Transfer body weight to right leg.
(2) Fold back side stand (jiffy stand).
(3) Disengage clutch by depressing clutch foot pedal with heel of left
foot.
(4) Shift gear shifter lever into “1” (low) gear position.
(5) Slowly engage clutch by depressing clutch foot pedal with toe of
left foot.
(6) When clutch starts to “take hold,” open throttle sufficiently to
maintain engine speed.
(7) Accelerate gradually to between 12 and 15 miles per hour in low
gear.
(8) Close throttle quickly.
(9) Disengage clutch.
(10) Shift through “N” (neutral) position into “2” (second) gear.
(11) Reengage clutch and accelerate to about 25 miles per hour.
(12) Close throttle quickly.
(13) Disengage clutch.
(14) Shift into “3” (high) gear.
(15) Reengage clutch and accelerate to desired speed.
=b. Starting on Uneven or Soft Ground.=
(1) If standing on an incline or in loose, heavy ground, more engine
power will be required to start vehicle without stalling engine.
(2) It may be necessary to keep vehicle from rolling by keeping
pressure on front brake hand lever. Brake pressure is released after
vehicle starts in forward motion.
(3) Open throttle and engage clutch at same time to provide power
needed for starting, without racing engine unnecessarily.
(4) Motorcycle starts should be made without excessive application of
power, with consequent unnecessary spinning of rear wheel.
10. DRIVING PRECAUTIONS.
=a.= Practice will enable a rider to judge at what rate of speed the
motorcycle should be moving before he shifts from a lower to higher
gear, and engine should never be permitted to labor unduly, when a
shift of gears, higher to lower, would improve operation.
(1) Operator must not look down at gear shifter when shifting gears,
but keep his eyes on the road ahead. Do not ride the clutch. The
operator’s foot should rest on clutch foot pedal only when he is
operating it. When shifting gears, disengage clutch fully to avoid gear
damage and shifting difficulties. CAUTION: _Many transmissions are
ruined through failure to disengage clutch fully when shifting gears._
=b. Braking.= Rear wheel service brake must be in such condition that
medium‐hard application will cause rear wheel to lock. Application of
service brake should be gradual, with just enough force to accomplish
desired result.
(1) Auxiliary front wheel brake, when used in conjunction with service
brake, must be applied with caution, especially on wet, muddy, or
slippery roads.
(2) After passing through water, the brakes should be set slightly, and
the vehicle operated for a short distance, until sufficient heat has
been generated to dry the brakes.
=c. Avoid Low Gear Operation.= Always operate vehicle in highest gear
possible, consistent with tactical situation, speed required, power
required, and kind and nature of road substance, to prevent overheating
of engine.
=d. High Speed Tips.= Only experienced riders should indulge in
high‐speed riding. A motorcycle operated for long distances at high
speed must be given closer than ordinary attention to avoid serious
engine overheating with consequent damage. For better motorcycle
service, apply the following suggestions:
(1) Develop habit of frequently snapping throttle shut for an instant
when running at high speed. This draws additional lubrication to piston
and cylinder and assists in cooling engine.
(2) In cool weather, operate engine slowly until it is thoroughly
warmed up, to avoid damage to pistons, rings, cylinders, and other
parts before oil is warm enough to circulate freely.
(3) If handle bar windshield and leg shields are used, engine is
more likely to overheat with continued high‐speed riding. Watch this
carefully.
(4) Adjust “steering damper” for best control of motorcycle consistent
with riding speed and condition and nature of road.
11. STOPPING AND PARKING VEHICLE.
=a. Stopping Vehicle.= Rider will make a “restart” easier and quicker
if he will apply the following instructions upon stopping vehicle:
(1) Close throttle.
(2) Disengage clutch.
(3) Apply brake (or brakes) to slow vehicle without sliding rear tire.
(4) Just before coming to a complete stop, shift into “N” (neutral)
position and engage clutch. CAUTION: _If immediate restart is to be
made, shift into “1” (low) gear and allow clutch foot pedal to remain
in disengaged position. (Rider will be mounted on motorcycle with
engine running.)_
(5) Continue brake application to complete stop.
(6) After vehicle slows to point where it can no longer be balanced by
steering, place left foot on ground to maintain balance until right
foot can be removed from brake operating pedal. CAUTION: _Do not idle
engine longer than 1 minute._
(7) Stop engine by turning ignition switch off.
=b. Parking Vehicle.=
(1) Lean motorcycle on side (jiffy) stand.
(2) Shift into “1” (low) gear.
(3) Engage clutch so vehicle cannot roll.
(4) Shut off gasoline supply by turning valve (to right) finger‐tight
against its seat.
12. TOWING VEHICLE TO START ENGINE.
=a.= In emergencies when engine cannot be started with foot starter
crank, it can be started by towing the motorcycle.
(1) Set gear shifter lever in “2” (second) gear position.
(2) Disengage clutch.
(3) Choke carburetor.
(4) Turn ignition switch on.
(5) After momentum of the towed motorcycle reaches between 10 and 15
miles per hour, engage clutch, and continue procedure until engine
starts.
=b. Engine Starting with Dead Battery.= Emergency engine starting
with dead battery can be effected by making use of freshly charged
battery, or by towing as outlined above. If vehicle with dead battery
is to be towed for engine starting, proceed as follows:
(1) Disconnect battery negative wire from ground on right side of
motorcycle.
(2) Tow motorcycle for engine starting.
(3) After engine is started, reconnect battery ground wire to frame to
prevent damage to electrical system.
13. RUNNING‐IN NEW ENGINE (OR VEHICLE).
=a.= A new motorcycle engine or newly overhauled engine must be given
proper “break‐in” consideration for at least the first 1,000 to 1,200
miles of service. Failure to do this may result in damage that will put
engine out of active service within a short period of time.
=b.= At the first 250 miles, check front and rear drive chains to make
sure they are receiving required amount of oil for ample lubrication.
If necessary, have chain oilers adjusted by unit mechanic. Drive chains
must be inspected for correct adjustment, and be given attention by
unit mechanic as needed.
=c.= At first 500 miles, drain oil tank and refill with fresh oil.
Check front and rear chains (step b above). Thereafter, follow
instructions in Maintenance Operation section.
=d.= After a new motorcycle has been run 500 to 1,000 miles it needs
to be thoroughly checked over and any loose screws and nuts tightened.
Particular attention must be given engine and transmission mounting
bolts and nuts, and to rear wheel mounting socket screws.
=e.= Following pointers must be observed when running‐in new engine or
newly overhauled engine:
(1) Do not exceed 30 miles per hour during first 100 miles.
(2) Do not exceed 35 miles per hour during next 200 miles.
(3) Do not exceed 40 miles per hour during next 400 miles.
(4) Do not exceed 50 miles per hour during next 500 miles.
(5) Avoid use of low gears during break‐in operation as much as
possible.