BSA Gold Star (DB / DBD) — Example photo: Ronald Saunders, CC BY-SA 2.0, Wikimedia Commons

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BSA · British pre-unit single, telescopic fork (1946-1966)

Gold Star (DB / DBD)

Library entry covers 1949-1963

32 factory 50 guideline

Published source

B.S.A. Instruction Manual for Models 1946-1955 B31, B32, B33, B34 incl. B32/B34 Gold Star, Part No. 00-4010 (B.S.A. Motor Cycles Ltd, reprint July 1961)

Factory owner's handbook. Covers 1946-1955 B32/B34 Gold Star (book covers B31-B34 incl. Gold Star), reprinted July 1961.

82 items for a 1954 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead valve, pushrods, adjustable tappets
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: DC generator with regulator
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Chain in oil-bath case with its own oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1954 BSA Gold Star (DB / DBD)

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Guideline

Old machines shake things loose: exhaust nuts, mudguard stays, footrests, tank mounts, battery strap.

On the road: every 1,600 km

2 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Chains: check primary and rear chain up-and-down movement. Factory: Every 1,000 miles, p.18.
Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: no interval set

2 items

Check engine oil level

Pre-ride / on the road

Factory

Manual: Oil tank: inspect level, top up. Factory: Periodical Maintenance, Weekly, p.16; Weekly Lubrication table p.37.
Check tire pressures

Pre-ride / on the road

Factory

Manual: Tires: examine, check pressures. Factory: Weekly, p.16.

Every 1,500 km

1 item

Inspect, clean and gap spark plugs

Engine

Factory

Manual: Sparking plug: remove for inspection. Factory: Every 1,000 miles (1,500 km) or so, p.33.

Every 1,600 km or 6 months

5 items

Grease swingarm pivot

Rear suspension and frame

Guideline
Adjust front drum brake

Brakes

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 1,600 km

6 items

Check and adjust valve clearances

Engine

Factory

Manual: Tappet adjustment: check when engine cold. Factory: Every 1,000 miles list, p.18; Gold Star see p.50.
Check engine breather and oil return

Engine

Factory

Manual: Engine pressure valve: examine. Factory: Special Notes, at 1,000 miles, p.37.
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: grease control arm, check free play. Factory: Every 1,000 miles, p.18.
Check steering head bearing adjustment

Front end

Factory

Manual: Steering head: test for play, adjust. Factory: Every 1,000 miles, p.17.
Lubricate brake cam spindles, check linings and drums

Brakes

Factory

Manual: Brake cam spindles: few drops of oil (8 in. front: grease). Factory: Every 1,000 miles, p.18 and p.37.
Repack / replace wheel bearings

Wheels and tires

Factory

Manual: Hubs: inject grease through nipple. Factory: Every 1,000 miles, three or four strokes, p.17 and p.37.

Every 2,500 km or 6 months

1 item

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.

Every 3,000 km or 12 months

1 item

Check / adjust primary chain

Primary and gearbox

Guideline

Every 3,000 km

9 items

Change engine oil

Engine

Factory

Manual: Oil tank: drain, flush and refill, wash filter. Factory: Every 2,000 miles, p.18 and p.37. New machines also after 500 and 1,000.
Clean oil strainers / mesh screens

Engine

Factory

Manual: Oil pump filter and crankcase filter: wash mesh screen. Factory: Every 2,000 miles, p.18; Special Notes p.37.
EVERY 2,000 MILES: Magdyno Fixing. Slacken off the magdyno strap and pull the magdyno towards the nearside of the machine ... re-tighten the magdyno strap bolt.

Engine

Factory

Factory: As printed: EVERY 2,000 MILES
EVERY 2,000 MILES: Generator and Magneto. See Electrical Section pages 63, 64.

Ignition and electrics

Factory

Factory: As printed: EVERY 2,000 MILES (note only: See Electrical Section pages 63, 64.)
Change gearbox oil

Primary and gearbox

Factory

Manual: Gearbox: drain, flush, refill to filler plug level. Factory: Every 2,000 miles, p.19 and p.37.
Change primary chaincase oil

Primary and gearbox

Factory

Manual: Primary chain oilbath: drain and replenish. Factory: Every 2,000 miles, p.18.
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Chains: remove, clean, warm in grease and graphite. Factory: Every 2,000 miles, both chains, p.19.
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Central stand fulcrum: grease. Factory: Every 2,000 miles, p.19 and p.37.
EVERY 2,000 MILES: Brake Fulcrum Pin. (7" brakes only). Check tightness of locking nut on brake cover plate.

Brakes

Factory

Factory: As printed: EVERY 2,000 MILES

Every 5,000 km or 12 months

12 items

Check engine mounting bolts and plates

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Oil / check generator bearings (where an oiler is fitted)

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 5,000 km

1 item

Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Factory

Manual: Magneto: clean and adjust contact breaker, lubricate wick. Factory: About every 3,000 miles, Electrical section p.64.

Every 6,500 km or 12 months

1 item

Replace spark plugs

Engine

Guideline

Every 8,000 km or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 9,500 km or 12 months

6 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Inspect generator brushes and commutator

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 9,500 km or 2 years

2 items

Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 16,000 km

2 items

Replace chain and sprockets (wear based)

Final drive

Guideline
Change fork oil

Front end

Factory

Manual: Front fork: check oil level. Factory: Special Notes, at 10,000 miles, p.37.

Every 19,500 km or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 19,500 km or 4 years

1 item

Decarbonize head, grind / lap valves (top-end decoke)

Engine

Guideline

Period practice. Leaded-era valve seats may need hardened seats for unleaded fuel.

Every 24,000 km or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

11 items

WEEKLY: Cleaning. Obviously regular and thorough cleaning will keep your machine looking smart ...

Engine

Factory

Factory: As printed: WEEKLY (weekly interval, no month value)
WEEKLY: Oil Tank. In the case of new machines, drain the tank after the first 500 and 1,000 miles as explained on page 18.

Engine

Factory

Factory: As printed: after the first 500 and 1,000 miles (new machines)
WEEKLY: On Iron engines an occasional coating of the cylinder head and fins with cylinder paint prevents rust formation and also helps heat radiation.

Engine

Factory

Factory: As printed: occasional (printed under WEEKLY)
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: top up with distilled water. Factory: Weekly list, p.17, as often as necessary.
Check gearbox oil level

Primary and gearbox

Factory

Manual: Gearbox: examine oil level, top up. Factory: Weekly, p.17. New machines: drain after first 500 miles.
WEEKLY: Gearbox. In the case of new machines, drain the gearbox after the first 500 miles as explained on page 19.

Primary and gearbox

Factory

Factory: As printed: after the first 500 miles (new machines)
Repack / replace steering head bearings

Front end

Factory

Manual: Steering head: two or three strokes of grease gun. Factory: Weekly, p.17; Weekly Lubrication table p.37.
Grease plunger rear suspension, check springs and bushes

Rear suspension and frame

Factory

Manual: Rear suspension (plunger type): few strokes of grease gun. Factory: Weekly, plunger models only, p.17 and p.37.
Grease saddle pivot, check saddle springs / seat post

Rear suspension and frame

Factory

Manual: Saddle nose bolt: grease. Factory: Weekly, except dual seat, p.17 and p.37.
WEEKLY: Brake Pedal. Give two or three drops of oil occasionally.

Brakes

Factory

Factory: As printed: WEEKLY (weekly interval, no month value); 'occasionally'
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control joints and exposed cables: few drops of oil. Factory: Weekly, p.17 and p.37.

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.