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HEINKEL Tourist Manual 

HEINKEL Tourist Manual Online:

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HEINKEL Tourist User Manual
HEINKEL Tourist User Guide
HEINKEL Tourist Online Manual

Text of HEINKEL Tourist User Guide:

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 16 18 Measering spring pre-tension 18.Remove Milling Tool for Inserted Valve Seats. 19. Using hand-milling tool 32 mm Ø 30.0° 16/1, mill the valve- bearing section of the valve seat. Remove guide pin. Please note: Widths of the valve-bearing sections of the valve seats Inlet valve 1.1-1.2 mm Exhaust valve 1.5 mm 20. Using a fine-grade grinding paste, grind the valves until all of the bearing sections of valves and valve seats (on cylinder head and valves) show a uniformly grey s

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 7 Special Tools for »HEINKEL-TOURIST« 2 Special Tools Key to illustration above: No . Drawing No. Description 1 401/W 22 Extractor for driven pinion 2 408/W 14 Clutch retainer 3 401/W 20 Retainer plate for piston 4 401/W 19 Guide pin for rocker arm axle 5 407.201/W 5 Ball-bearing extractor, Type 6305 6 404/W 7 Extractor for starter dynamo 7 401/W 25 Clutch compressor 8 401/W 26 Gudgeon pin extracto

  • Workshop Manual Heinkel Tourist 103 A-1 page 14 Removing and fitting connecting rod bush, reaming out the bush 13 Inserting connecting rod bush 14 Centering connecting rod bush Please note: Proceed as outlined on page 11, "dismantling cylinder head, cylinder and piston". Cover crankcase with clean rag. 1. Place and fix retaining jig

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 24 36 Taking off the armature 37 Removing the spiral 7. Replace (without tightening) screw 39/3. Screw in the extractor tool (404/W 7) 36/1 and, using forked spanner SW 27 36/2 as a counterholder, push off the armature. Remove screw 39/3, with- draw armature. 8. Undo the three hollow-headed screws (SW 6) 38/1 holding the magneto system. Remove this latter, watching out for the radial gasket. 9. Take out the three countersunk screws 37/1 and remove the spiral.

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 44 Dismantling and Fitting of Front Fork 73 Front fork, xploded view Please note: When carrying out repair work on the front fork, proceed as explained on page 43 "Removing and Refitting the front fork", paragraphs 1 to 14, being followed by: 1. Remove shock-absorbers from front fork. 2. Unscrew and remove oil drain screw (SW 14) 73/4 and take off outer tube 73/3. 3. Take off bellows portion. 4. Unscrew and undo oil filler screw 73/1 (SW 17) and remove pressure springs 73/2. 5. Screw outer pressure springs

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 9 4 Scooter frame assembly jig General Data In order to facilitate repair work on the scooter frame we recommend using an assembly jig (fig. 4, drawing on page 52) which can be made by the dealer in his own workshop. The same applies to the assembly jig for the engine (fig. 5, drawing on page 53). When carrying out any major overhaul and/or fitting work on the engine such an assembly jig and corresponding special tools should in all cases be used. Prior to carrying out repair work the vehicle should be cleaned most thoroughly. After having been cleaned, the removed componen

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 21 26 Measuring chain alignment 27 Fitting of clutch interior, clutch basket and chain Fitting the clutch 1 . Place one backing washer on the clutch spindle and one spacer on the left-hand crankshaft end. 2. Place small chain wheel on left-hand crankshaft end. (Collar facing towards spacer). 3. Lubricate clutch interior, insert into clutch basket 26/2 and to- gether put on clutch spindle. The alignment of the chain can be tested wit

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 38 69 Gears Fitting The Gears Please note: To fit the driven shaft and the drag arm cross shaft, heat the crankcase half. 1. Insert driven shaft with bearing from the gears side. 2. Insert drag arm cross shaft and secure with Seeger ring. 3. Insert drag levers. Insert the interposed abutting disc. Secure drag levers with disc and circlip. (Afterwards test for easy move- ment.) Clutch Spindle 4. Coat the needle bearing (two

  • Workshop Manual Heinkel Tourist 103 A-1 page 2 Contents Foreword .............................1, 1a Technical Data ............................ 3 Exchange Engine ........................... 6 Special Tools ............................ 7 Miscellaneous ............................ 9 Dismantling and reassembling the engine ................. 9 Dismantling

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 27 44 Adjusting the ignition Adjusting the Ignition Please note: Proceed as explained on page 9 "Dismantling the engine - Re- assembling the Engine", paragraph 1. Before screwing in the Ignition Timer (404/W 10) 2/19, by using a blunt object, clean the oil carbon from the piston top because carbon deposits of this nature can lead to inaccurate measure- ments being taken. 1. Unscrew the spark plug, and into spark plug thread scr

  • Workshop Manual Heinkel Tourist 103 A-1 page 35 63 Fitting the Seeger rings 64 Assembly jig with crankcase half Fitting Crankshaft and bearing 1 Fit Seeger ring 63/1, using special pair of forceps 63/2, into left- hand crankcase housing (clutch side). 2. Heat left-hand housing half on a hot plate (do not use a weld- ing torch or any naked flam

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 17 Check piston and cylinder 19 Testing the height play 20 Testing the gap Please note: Proceed as explained on page 11, "Dismantling Cylinder Head, Cylinder and Piston". Cover the crankcase with a clean rag. When refitting a used piston, remove all traces of oil carbon from the piston head and the cylinder, take care that the piston is fitted in the same direction as before (i.e. front to front). 1. Check piston (i.e. surface of contact) for grooves, traces of piston seizures, worn spots (li

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 23 33 Removing the fan houses 34 Locking the fan wheel Dismantling the Dynamo Please note: When repairing the dynamo, remove the engine. Proceed as explained on page 9, "Dismantling the engine, Reassembling the engine", paragraphs 1 to 13. 1. Undo hex. screw (SW 17) for bracket clamp (right-hand side) and remove clamp. 2. Take off the contact breaker cover plate. (Watch out for the gasket, as this can be used again). Undo the two slot-headed screws; take off the contac

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 6 Exchange engine: Engines to be returned to the factory under the exchange scheme must be as follows: with swinging arm, complete, carburettor, exhaustmanifold, cooling baffles, dip stick, magneto, complete, with spark plug, clutch lever with traction spring and retainer plate, rear wheel hub with brake lever, all nuts, bolts and discs, and the support for the mounting of the exhaust silencer, without air filter, exhaust silencer, air outlet tube,

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 19 22 Remove cooling air exhaust pipe and exhaust silencer 23 Clutch cover with gear an clutch levers Dismantling the clutch Please note: Repairs to the clutch can be carried out without the engine being removed. The procedure is set out on Page 9, paragraphs 1, 9 and 10. ("Dismantling the Engine, Reassembling the engine"). 1. Undo hex. screw (SE 10) 22/1 for pipe clip, turn cooling air exhaust pipe upwards by 90 degrees. 2. Undo hex. screw (SW 17) for bracket and remove bracket 23/1. 3. Drain off the engine oil at the oil drain plug (SW 17) 23/2

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 3 Engine Engine model 407 A-1 Engine cycle Four-stroke Number of cylinders 1 Arrangement of Cylinders Vertical Bore 60 mm. Ø Stroke 61.5 mm. Swept Capacity 174 cc. Clearance volume 27.5 cc. Compression ratios 1:7.4 Output 9.2 h.p. at 5500 r.p.m. Compression pressure 130 lbs per sq. inch. (When fuel valve is open and the engine is warm) Piston play 0.05–0.06 mm. Diameter of gudgeon pin 18 mm. Ø DIN 73121 (

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 49 Performance diagram Speed diagram Climbing performance diagram Fuel consumption diagram (l/100 km = litres/100 km)

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 26 41 Fitting of fan housing 42 Contact breaker 11. Insert gasket, felt holder and felt washer. 12. Check for wear the contact breaker plate 42/1 (contacts and plastic transmittor), check contact breaker cam axle 42/2 for tight fit, check contact breaker spring 43/3 for spring tension. Please note: If contacts worn, exchange contact breaker lever and contact supports. 13. Using screw-driver, unscrew fillister-head screw 42/4 and remove contact support

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 51 max permissible axle load front: 125 kg rear 240 kg Driver Pillion Passenger Luggage P-1 kg P-2 kg Front carrier Dash board hook rear luggage Distribution of Loads, max. 85 75 5 10 25 Medium Distribution of loads 75 70 5 10 20 Distribution of loads when no luggage is to be carried 110 90 – – – weight of the scooter, ready to be driven = 150 kg luggage = 40 kg driver & pillion passanger = 160 kg Admissible total weight = 350 kg Weights, as heretofore indicated, are not to be exceeded.

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 31 52 Radial gasket for driven shaft 53 Swinging arm mounting, rear collar bearing Fitting the Swinging Arm 1 . Into the groove in the rear swinging arm mounting on the engine housing fit the rubber sealing ring with grease. 2. Lay on rear collar bearing 53/4 with ball bearing 6303 and radial gasket 25x35x7. Please note: Packing lug of radial gasket 52/1 must face in the direction of ball bearing 6303, see Fig. 52. 3. Insert plate spring into driven shaft 53/5. 4. Place gasket in position on collar bearing 53/4 (for better adhesion, use grease). 5.

  • HEINKEL Tourist, Workshop Manual Heinkel Tourist 103 A-1 page 33 58 Position of bolts, on fan side Table of Bolts Fig. 58 Figure Quantity Measurements 1 3 M 8x20 2 4 404.100-003 3 1 M 6 x 150 4 1 M 8x70 5 1 M 8 x 100 6 1 M 8x92 7 1 M 6 x 105 8 2 M 6x90 Fig. 59 Figure Quantity Measurements 1 3 M 8x20 2 4 404.100-003 3 4 M 6x25 4 6 M 6x115 5 1 M 6x60 6 1 404.100-013 7 2 M 10 X 18 59 Position of bolts, on clutch side Tightening Torques For

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