$1.

50

COSMOPOLITAN MOTORS, INCORPORATED

JACKSONVILLE & MEAOOVVBROOK ROADS, HATBORO, PA.19040 (215) OS 2-9100
SOLE US IMPORTERS ANO OISTRIBUTORS OF BEN£L.LI MOTOR'CYCLEB / PIPEl..t..l TIAE. / AOV ANO COaMO HELM&T•
 1

Technical characteristics ENGINE

Type 4 stroke

Number of Cylinders 2

Cyli\-.der layout Parallel

Bore 84mm

Stroke S8mr1
------ -------
Displacement 642 .8 cc
- - - - - - -- - - - - - - · - - --
Compres.sion Ratio 9.1

Maximum H.P. 57 at 7400 A.P.M.

Crankcase Aluminum alloy divided horizontally.

Cylinders Special aluminum alloy with special

cast iron sleeves .

Cylinder Head Special aluminum alloy with valve guide

and valve seat of special Bronze.

Crankshaft Assemb led on four (4) large supports

two 121 large double race bearings
and two (2) large needle cages .

Connacting Rod Needle bearing at the upper and lower

end .

Pistons Special aluminum alloy and special

steel band inserts.

VALVE TRAIN Overhead valve of larger diameter at

a 58° angle . .
Cam shaft assembly Is on four (4)
supports . Cam followers are made of
special steel alloy stelllte .
Push rods are constructed of high
quality aluminum alloy and steel. The
va lve train is f orce lubricated by a
gear type oil pump.

CARBURETOR Two (2) Dellorto type VHB 29mm with

concent ric float bowl and supplemen-
tary starter device .
Gravity fuel supply 98 to 100 octane.
Fuel tank capacity is 3 ~~ gallons.

LUBRICATION Forced lubrication type .

The engine supports of the crankshaft,
connectiong rods. cam shaft. cam fol-
lowers . push rods , and rocker arm are
force lubricated by a gear type oil
pump, driven from the shaft by gears.
The pump sucks t he oil through a ,
replacable oil filter, automotive type.
Oil in crankcase is 2.66 quarts.
The crankcase is equipped with an oil
level window.

BATTERY 12 V 12 AH D. C. current Ignition system.

Bosch type with centrifugal automatic
advance, driven by the cam shaft.
Fixed advance SO • 60
Total advance 35<> · 360
Spark plug Marelli CW 240 L
Two [2) High Tension Coils Bosch type

STARTING SYSTEM Start by pedal, located on the right

hand side of the vehicle.
TRANSMISSION Primary transmission by helical gear.
Ratio 1 . 3.210.

CLUTCH Multiple discs. wet type.

GEAR BOX Five (5) speed. constant mesh. The

gear box is incorporated with the en-
gine . Th e foot shift pedal is located
on the R.H. side

GEAR BOX RATIO 1st gear 1 : 2.499

2nd gear 1 : 1.383
3rd gear 1 1.000
4th gear 1 : 0.860
5th gear 1 : 0.749

SECONDARY TRANSMISSION By chain 5/ 8" X 9/16" .

Countershaft sprocket has 17 teeth .
rear wheel sprocket 36 teeth. Ratio
1 : 2.117

FINAL RATIO 1St gear 1 : 16.986

2nd gear 1 : 9.405
Jrd gear 1 6.797
4th gear 1 : 5.845
5th gear 1 : 5.097

FRAME Tubu lar. double cradle type.

- -- --------~-----------------

FRONT FORK Rear swing arm with adjustable hy-

draulic shock absorbers.

WHEELS Front 2 ' 2' X 18" Rim

Rear 3" X 18" Rim

TIRES Pirelli - Front 350 x 18 RIB

Rear 400 x 18 UNIVERSAL

BRAKES Expclnding type br~kes .

Front 230mm diameter. four ( 4) le-
ading shoes.
Rear 200 mm diameter with foot brake
lever . located on the L.H . side.

OVERALL DIMENSIONS Length 81"

Width 32"
Wheelbase 56"
Seat height 31"
Maximum height 46"
Ground clearance 8.5"
Handlebar width 32"
Weight 407 lbs.
- - -·- --·- - - -- - -
SPEED 1st gear 36 M.P.H .
2nd gear 65.5 M.P.H.
Jrd gear 92 M.P.H.
4th gear 104.6 M.P.H.
5th gear 118.5 M.P.H .
- - - - -- -- ·- · - -- - - - -- - -
FUEL CONSUMPTION 2 ' • gallons x 100 miles.
 3

cv
HP OIN

I CV-H~

. BI
50

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45

40 Kg m

_ 5.5
= 5. 3
35 . .
_ 5.1
= 4. 9
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15
) 250
225
10
j_ 200

1000 2000 3000 4000 5000 6000 7000 II lr 1/mln

Vehicle identification
The serial numbers are stamped on the w1th two (2) ignition keys A and two
frame and the engine . When ordering [2) anti-theft keys B.
parts. it is necessary to give such For replacement keys, order by the
numbers. Every vehicle is supplied number stamped on the key.

A B

~~ I
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~
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 -- - - - - - - - - -- - - - - - -

Controls
1 - Rear brake pedal
2 - Horn
3 - Light switch
4 - Clutch lever
5 - Steering damper
6 - Tachometer
7 - Green light (generator charging indicator)
8 - Red light (electrical system)
9 - Speedometer
10 - Starter lever (choke)
11 -Front brake lever
12 - Throttle twist grip
13 - S.1ifting lever
14 - Ignition key
15 - Kick starter
 5

Operating instructions Before using the motorcycle, check the sity requires, by turning the lever at
following: the lower part of the shock absorber.
Battery as per instructions on page 28 . Adjust both shock absorbers at the u-
Engine oil as per instructions on page ml! position.
19.
Tire pressure - front tire 22 lbs. Rear
tire 28 lbs.
Fill fuel tank with 98-100 octane fuel.
Brake ad ustment, front and rear su- Starting
spensions. Put m neutral position , the gear box.
Adjust steering damper which must be half-way between 1st and 2 nd gear.
free for smooth road surface, and tight Open the two fuel petcocks (no. 1 po-
for rough road . sttion . close - 2. open - 3 reserve) .
Adjust rear shock absorber as neces- Pul l the starter lever (only when en·

gtne is cold) and push forward as soon with the toe. Release the clutch lever To stop
as the engine is warm . slowly and the same time, rotate the
Rotate the ignition key to the 2 posi- throttle gradually. Retard the throttle, depress the clutch
lever. and put the foot shift lever in
tion. The red light Indicator will light
up (note : the light Indicator will go neutral position, apply both brakes
gradually. tum the Ignition key to
out as the engine Increases R.P.M .)
position marked • 0 • .
kick the starter pedal keeping the
Close both fuel petcocks.
throttle at idle position . (When engine
is hot. open slightly _the throttle).
It is important to run the engine at
idle speed tor a few seconds to allow Changing gears
the oil to reach all the lubricated To change into higher gears . repeat
components. the same procedure and each time.
Depress the clutch lever and engage depress the shifting lever with your
the first gear. I ifting the shifting lever toe.

--- - --· -- - --------

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 6

Light switches Anti-theft lock

Turning the ignition key to position n. 3 The lock is located on the L.H . side
(see fig. • A • on page 15) , you turn of the steering tube. To lock, turn the
on the main lights, the panel lights lock cover and insert the key. Press
and red indicator light. in the key and at the same time rotate
from right to leh.
The dimmer switch is located on the
L.H . side of handlebar . The n. 1 button Rotate the handlebar to the right, util
operates the high and low beams the steering is locked . Pul l the key
while the n. 2 buttons Is for the horn. from the lock.

Break-in period Your cycle IS made to a very close Do not maintain the specified speeds
tole rance . Because of its precision fit- for a long period of time and as soon
ting components . a break-in period of
as the engine decreases in R.P.M ., re-
1600 miles. is recommended .
duce the speed.
To obtain the beat performance and
longer life for the engine. the following
instructions are recommended.
IMPORTANT
Do not operate your engine at a high Aher the first 300 miles. change the
R.P.M. until it is sufficiently hot. engine oil, preceding as indicated on
Do not e)(cede the prescnbe d speed . page 19.

R.P.M. 1st 2nd 3rd 4th 5th

A · first 450 miles 4500 25 37 so 62 68

B - 450 to 1000 miles 5500 31 43 56 74 90

C - 1 000 to 1600 m•les 6000 37 47 62 B4 99

 7

Maintenr~nce Periodic maintenance is important to

the efficiency of the engine and frame
components.

After the break-in period (1600 miles] . Lubrication and the majority of the
Tighten , with engine cold . the cylinder remaining maintenance operations r.an
head nut to 25 ft . lbs . be made with the tool supply with your
motorcycle (see page 32) .
Tighter: the intake manifold . exhaust
pipe flange nuts and all the frame However. we suggest always to see
bolts , particularly the engine bolt, your dealer. where you will receive the
front and rear wheel axel , shock absor- best and accurate assistance.
ber nuts and the swing arm bolt.

Check point gap .016 ".

Check spark plug gap .024".

Check and adjust if necessary. valve

clearance (as Indicated on page 20) .

Check generator bolt tension (see pa-

ge 19) change oil and replace the oil
paper filter . Note - the oil must be
changed every 1600 miles while ~he
oil paper filter must be replaced every
3rd oil change.

It is necessary to check frequently. the •

oil level which must be at the specified
level

Check battery electrolite level as

shown on page 28.

Every 1600 miles . change the oil as NOTE CARBURETOR ADJUSTMENT

follows : change oil with engine hot
To facilita te the oil draining. it is advi- Your carburetor is equipped with two
1) Remove nuts that fasten the cove r sable to remove the plastic plug of the (2) 29mm concentric Dell'orto type
of the oil pump filter . filling hole . carburetors.
2) Be careful not to damage the gasket The normal adjustment of the idle
The oil . paper filter , must be changed
screw • C • is 1' 2 turn open from
3) Remove oil filter and clean it with every 3rd oil change .
focked position while the screw • B ,
gasoline and compressed air. Remove the special nut with 12 mm adjusts the idle speed (the slide) .
4] Reassemble . after the oil is comple- wrench . Pull out the filter element and To obtain an equal opening of the car-
tely drained .the filter gasket and the respective washers and gaskets . buretor slides ,adjust the throttle cable
cover. as shown . It is important When reassembling , follow accurately with the adjusters located on the
that the hole with the rubber ring the sequence shown below cables .
IS facmg the left hand side of th e
motorcycle

I
 8

Check. and if it is necessary, adjust pulley locking nuts and tighten alter· crankshaft and the driven pulley disas-
the generator belt tension. nately . sembled.
NOTE Follow the ssme above instructions to
Applying a normal pressure . the belt
should have a play greater than 5/ 16" align belt .
Before locking the nuts . turn the en·
or 3/8 ". To adjust generator belt. gine over. using a 19 mm wrench. to After the cover is reinstalled. readjust
loosen the rear brake rod and remove prevent the belt from fitting in without the rear brake rod .
the L.H cover being locked between the two half
Remove the three (3) pulley fastening pulleys.
nuts with an 8mm wrench .
Remove the necessary spacer washers IMPO r f ANT
from the mternal half of pulley and NOTE
relocate the spacer equally. in order The valve clearance must be chec;kitd
to mamtain the perfect alignment of To replace the generator belt. the dri· and adjusted when the engine Is cold.
the two (2] pulleys . Reassemble the ving pulley must be removed from the R"move seat. fuel lines. and fuel tank .
Remove valve cover.
Turn engine to T. D. C. In compression
stroke . Check valve clearance using a
feeler gauge - exhaust valve .005" -
intake valve .004".
And procede to adjust If necessary. as

jlbPI) IIIIII { follows :

Loosen with 12mm wrench .the ad-
JU Sting screw locking nut.
With 5mm allen wrench, turn adjusting
screw and tighten at same time. the
locking nut.
After valve of one cylinder is adjusted,
turn the engine one (1) turn and
adjust valve of second.
Check if rubber gasket properly fits
the seat and reassemble the cover.
Tighten nut • A • 5 kgm .

ADJUSTMENT OF SPARK PLUG GAP · refers to the L.H . cylinder) IS comple- pulley must coincide with the line
IGNITION POINTS • IGNITION TIMING tely open. Check with a feeler gauge mark of the crankcase • rib • .
0.16" the point gap. To adjust. loosen To time the felt hand cylinder:
Check spark plug gap 024" then retighten. slightly, screw • A • Connect the timing light to the lower
Check pomts gap .016 " with a screw driver. Apply leverage ignition point.
In the event that the engine has signs (see figure) to obtain correct gap. Re·
of effic1ency loss 1f not caused by tighten firmly. the screw • A • . Repeat Turn the crankshaft clockwise a com-
other malfunctions. procede to check operation. turning the engine clockwise plete turn (3600) and repeat the same
the ignition as follows . a complete turn (36o:>) . to adjust upper operation as per right hand cylinder.
Loosen the rear brake rod and remove ignition points (right hand cylinder) . Check and lubricate the automatic ad·
the L.H . cover. Turn engine until the vance components and check the
After the points gap is adjusted, pro- spring tension .
piston of the LH cylinder reaches the
cede to check the ignition timing.
T.D.C. pos1t1on . The • 0 • mark of the Every 6000 miles. it is necessary t.o
driven pulley will align with the line Connect timing light to upper ign1tion fill the grove of the automatic advance
mark on the case • rib •. Usmg a 19mm points of right hand cylinder and turn shaft. and impregnate the grease point
wrench . turn the engine clockwise engine to compression stroke until the felt with grease type bosch 5200·
until the lower ignition point (which light goes out . The line mark of the 005000.
Lubrication Every 1600 miles . grease (using a grease pump) the
Change oil as indicated on page 19. swing atm shaft (fig. C) until the
Lubricate all the controls as shown grease will surge around the trusts
(fig . B-0-G) with multipurpose grease parts of the shaft.
• Shell retinax A •. Lubricate the wheel bearing with be-
Throughly clean the chain and lubri- aring grease • Shell Retinax A • (fig.
cate with chain lube. These operations I & F).
are of maximum importance and must Lubricate the ftont brake and the choke
be repeated periodically . cable controls (fig. A).
Every 60JO miles or as needed, replace Lubricate battery terminal with vasoline
the oil of the front fork tubes (fig. L) as indicated on page 28.
proceeding as follows : Unscrew the Lubricate the brake shoe cams (fig. H) .
fork tube top plugs and fill each tube Be careful that the oil does not enter
with 210 C.C. of • Shell Donax A1 • inside the brake hubs.
hydraulic oil (see fig. C) . Lubricate the shaft and grease the felt
Lubricate with • Shell Retinax A • as indicated on page 21.
 10

Adjustment Adjust front and rear brakes frequent iy . the stand and loosen axel. and anchor
leaving some play at the controls . rod nuts . Sit on motorcycle and adjust
The front brake can be adjusted at the turning the chain tensioner bolts. Lock
handlebar lever [fig. A) or if necessary. axel nuts and check wheel alignment.
with the two adjusters shown 8t fig. G. If needed. adjust rear swing arm as
Adjust evenly. The rear brake system follows: Loosen with 22mm wrench.
•s equipped with a simple adjustment the nut on the R.H. side and with 30mm
on the brake rod (fig . D) . wrench. loosen the nut on the other
Figure B. shows the adjuster of the stde of the swing arm shaft. Using a
clutch lever on the handlebar. If ne- 16mm wrench. tighten swing arm bolt
cessity requires. adjust the clutch until :· ;e swing arm turns freely
with screw on clutch lever (ftg. F). witho .Jt side play. Lock the two (2)
To adjust chain. remove cycle from sh aft ~u ts at 25 ft. lb.,
 ll

Fuel system Clean. with compressed air, fuel lines. Readjust screw • B • to obtain the Idle
petcock and carburetor filters , if ne- speed desired and same exhaust pres-
cessary. sure.
Replace fuel lines if hardened . Different temperature and altitude may
Every 6000 miles. it is necessary to result in change of carburetor, If the ::
clean carburetor passage and float idle screw Is completely closed.
bowls. In order to obtain the proper mixture,
It is necessary to replace the existing
NOTE: DO NOT USE STEEL WIRE TO Idle jet with a larger size. Viceveraa,
CLEAN CARBURETOR PASSAGE. USE if the screw Ia open more than normal.
ONLY COMPRESSED AIR. a smaller jet Is required.

CARBURETOR ADJUSTMENT MAIN JET ADJUSTMENT

The carburetor adjustments must be If when running the engine at full
made when engine is hot (normally, throttle the engine will not reach the
running temperature) . proper R.P.M ., or backfires. and when
closing the choke lever. the engine
IDLE SPEED ADJUSTMENT increases its performance, this Indi-
Check if both screws are 1 1 2 turns . cates that the mixture Is too lean. The
opened from lock position . Adjust original jet must be replaced with a
equally. the two (2) throttle cables larger size.
with cable adjuster on throttle cables. If when running the engine at full
Start engine and with engine running throttle. black smoke Is emitted from
at idle speed. adjust screw B. until the exhaust pipe and closing the choke
the two (2) cylinders have equally lever . the abnormality increases, this
exhaust pressure . Adjust screw • C • indicates that the mixture Is too rich .
to obtain best fuel air mixture. Replace the jet with a smaller size .

Tuning specifications

~-

©-- - .------
I

A - Slide (size 60)

B - Slide screw
C - Idle adjusting screw (open 1' •
@--
@- ---
t
@
--

turn)
0 - Float bowl
E - Needle jet
F - Main jet
G - Starter jet
®- -
H - Idle jet
- Needle
 12

Electrical components BATTERIES (BOSCH 0.180.001 .213) for 8 to 15 hours at a rate of one·
tenth of battery capacity (1 .2AHJ .
The 650cc Benelil IS equ1pped with two
( 2] 6v batteries connected m series. NOTE: The temperature of the plates
which are located under the seat during the battery charge , must not
Jo serv1ce the battenes after the seat exceed 81c F. lnterupt the charge if
is removed . dismantle the two (2) s1de the temperature exceeds such tempe-
covers. using a screw driver. rature.
Remove the wing bolt located unde r After two (2) hours the battery is
the seat and pull out batteries . completely charged.
1) Fill the battery to approximately Bring the solution level back to the
.080" above the plates with pure sui· proner level, over the plates.
furic acid having a specific gravity of Pe·o0d1cally check battery level adding
1280 at 36° F. on , 1f necessary, chemically distilled
2) Let the battery rest for two [2) V~.~ter.
hours and bring back to the required Every 6000 miles , clean the battery
level by adding sulfunc acid. as much ter m1nals and lubricate with pure va-
as required . Then charge the battery soline.

GENERATOR (BOSCH EH (R) 14V. 11A. HIGH TENSION COli- 2 TYPE (BOSCH 1s Important that wires are re-assem-
19) TJ 12/ 3 0.222.003.003.000) bled in their original position.

Every 6000 miles clean accurately. the Regulator type . TAIL LIGHT TYPE (CEV 127 SAE STLB
generator armature . at the contact Note ; The regulator is sealed. there- 66)
fore, if damaged .it must be replaced
po int of the brushes. with a clean with another of the same type . STOP LIGHT SWITCHES (CEV 9343)
cloth Impregnated with gasoline.
Front brake switches are located on
Check the generator brushes wear. HORN TYPE 12V (BOSCH 0.320.023.001 ) the handlebar. Front brake lever (right
::md 1f necessary replace hand side) . The rear brake stop light
HEADLIGHT (CEV 137 SAE M66)
switch is attached to the frame on
Note : Adapt new brushes to the a-· To replace sealed beam. unscrew lo we ~ the right hand side, next to the front
mature rim fastening screw. Remove clips It of the rear wheel.
Electrical system

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To remove .front wheel To remove rear wheel

Remove the cotter pins and pins of Disconnect the rear brake rod adjusting
the brake cables (fig. 1) . knob (fig. 1) and remove the chain
Unscrew the brake plate anchor arm master link (fig. 2) .
fastening nuts (fig . 2) . Unscrew the anchor plate arm at the
Disconnect speedometer cable from swing arm aide (fig. 3}.
speedometer.
Unscrew the axel nut (fig . 3) and pull Remove one axel nut and pull out axel
out the shaft after the axel pinching (fig. 4).
bolt is loosened . To reassemble, reverse operation in·
Pull the two (2) anchor plate arms stalling the master link clip as shown
from the bolt and remove wheel. in the sketch.
To reassemble. reverse operation.
The anchor arms must be fitted on the
even threaded parts of the fastening
bolts.
Remember to refit all the cotter pins.

------, r-----------------------

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 14

Tool kit components A) Smm allen wrench

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B) Screw driver c-:..,,_;;;_.oJr=>
-.

CJ Tube wrench type 10/ 12mm

c - ~" ::0
D -~
OJ Spark plug wrench 21mm

E) Pin for tube type wrenc h

F - - - ---9 ...,._.........,
1 he tool kit 1s located under the dri-
G ---~fJ30iiii!i~~§)~
vflrs seat.
F) Open wrench 5.5 and 7mm (for ~ ~ 6
Ignition points)
t~g;iiiii~:S
G) Open wrench 8-10mm

HJ Open wrench 12-13mm

I) Open wrench 17-19mm

L) Open wrench 22-24mm

'- N) Tool container

Trouble chart DIFFICULTY CAUSE & CORRECTION

Engine will not start or stop as soon, Clean fuel lines. f ilters, and carburetor
after running. jets .

Irregular flow of gas-carburetor flooded . Close petcocks . Remove and clean

spark plugs. Kick over, the engine. a
few t imes . Re-assemble the spark plug.
- - - - - - - -- - - -
Ignition. Re-place spark plug . Check ignition
points gap , ignition circuit. Battery ,
low charge. Switches .

Pre-ignition. Replace fuel with higher octane . Check

proper spark plug heat range . Carbon
deposit on pistons and cylinder head
chambers . Check ignition timing, car-
buretor mixture (see page 18 & 27) .
------- ------- --
Engine misses. Check spark plug gap. Check ignition
po in t gap. Flow of gas line through
fuel lines and carburetor.
--------- - - - - -·- ------
Loss of efficiency Check carbon deposit on piston and
cylinder heads. Spark plugs. Check
valve adjustment. Cylinder head bolt
torque, piston & piston ring wear. Valve
leakage. Improper carburetor mixture.
Check ignition timing .
----------
Back firing from carburetor. Carburetor mixture too lean. Close air
adjusting screw . Check air leaks at
intake manifold and at carburetor
clamp. (See instructions page 27) .
Oil circulation

The most important requirement for

an engme. to obtain the best results,
is the oil circulation .
On the 650cc tornado engine, the most
modern technical knowledge is adop-
ted. All the major and essential compo-
nents are force lubricated with a gear
type oil pump. driven by a cam shaft .
From the crankcases the oil is forced
to all the crankshaft supports and the
lower ends of connecting rods, through
the cam followers and push rods, it
reaches the roker arms, consequently
lubricating the valves.
Also. the oil lubrication system is
equipped with an automotive type oil
filter .
It is most Important to observe the
lubrication instructions, changing the
oil and oil filters as prescribed .

• Sae 40 in summer
* Sae 30 in winter

Cleaning All the painted parts must be cleaned

with water using a sponge and dried .
and storage preparations bo not wet carburetors .
The engine and all other parts of
motorcycle must be cleaned with pe-
troleum giving maximum attention not
to impregnate the brake shoes. Lubri-
cate all the controls .
To store for an extended peraod of time
it is advisable that the tires should not
touch the ground . This reduces the tire
pressure . Remove batteries and store
in a cool dry place. Recharge the ba!-
tery every month .
Drain all the gasoline from the fuel
tank and wash it with a mixture of oil
and gasoline. Introduce a small quan-
tity of motor oil into the cylinder
through the spark plug hole and turn
the engine over a few times.
Protect all the chromed parts with a ·1
solution to prevent rust .