S6 / E ENGINE
Contents
1. Idling speed YES too high or too low YES False air intake from YES carburetor manifold YES YES False air intake YES from engine crankshaft oil seals Page 11 Adjust the RPM of the idling speed with engine warm by adjusting the screw on the throttle valve of the carburetor Disassemble the carburetor and clean all the parts nozzles throttle valve jet needle float chamber and casing with solvent and dry using compressed air Check the integrity of the carburetor manifold gaskets Check the integrity of the rubber coupling sleeve that connects carburetor and air filter box Check the reed valve gasket Check the integrity of the crankshaft oil seals Replace even if only slightly damaged MORINI FRANCO MOTORI ENGINE S6 Noisy engine Incorrect transmission gears assembly Loose transmission nut ransmission noise and rear wheel drag at idling speed YES Check the assembly of all gears and parts of the transmission YES Check the tightening torque of the gt clutch nut NES 9 Check the clutch unit Page 12 gt MORINI FRANCO MOTORI ENGINE S6 E Noisy engine YES Noisy gears YES gt NO Noisy YES cylinder unit Noisy crankshaft YES bearings Page 13 Check the oil level Refill if necessary Check the te2. FIRST MAINTENANCE SERVICE to be carried out after 500 600 km Replace the engine oil Check the carburation and adjust if necessary Check the tightness of nuts and bolts See table tightening torques page 15 Page 5 MORINI ENGINE lt FRANCO 6 E MOTORI LUBRICANTS N B Use original MORINI FRANCO MOTORI spare parts onl RECOMMENDED LUBRICANTS ADHESIVES DESCRIPTION CHARACTERISTICS Transmission oil AGIP RADULA 68 SAE 20W N B TRANSMISSION OIL LEVEL CHECK Remove the oil filler cap on the clutch cover and check the transmission oil level through window Page 6 MORINI ENGINE lt FRANCO S6 E MOTORI TROUBLESHOOTING The following flow charts give a general outline of the causes and effects when the engine is not running correctly Descriptions of solutions for a specific cause are general for more details the reader should consult the disassembly reassembly manual LEGEND OF SYMBOLS EFFECT fault noticed by the user Possible CAUSE of the fault Possible general SOLUTION to the fault Page 7 e MORINI ENGINE lt FRANCO S6 E MOTORI Starting problems Check spark plug and replace if necessary Faulty spark plug or wrong spark plug heat rating Start the engine with the YES throttle fully open Engine flooded Remove the spark plug rev the engine install a dry spark
3. plug and restart the engine The engine starts YES Sparking starts ata high r p m Replace the ignition coil Page 8 MORINI FRANCO MOTORI ENGINE S6 E Maximum indicated running speed cannot be reached Soiled or clogged YES filter Silencer obstructed YES Cylinder exhaust port soiled with carbon YES deposits Poor compression YES Page 9 Disassemble wash sponge with a 50 50 solution of petrol and 2T oil leave to dry Clean the filter box using compressed air re assemble Check the silencer for clogging Replace if necessary Disassemble the cylinder and check that the exhaust pipe is clean If the exhaust pipe is partly obstructed by carbon deposits clean it thoroughly using a scraper Disassemble the cylinder head cylinder and piston Remove the piston rings place them in the cylinder liner and check the amount of wear Replace if excessively worn MORINI ENGINE lt FRANCO S6 E Poor acceleration pickup YES Check the clutch shoe thickness and the clutch springs for stretching If either is excessively worn they should be replaced Check the exact number of turns YES gt of the air adjusting screw on the carburetor Irregular acceleration Page 10 MORINI FRANCO MOTORI ENGINE S6 E Incorrect idling speed
4. de vedic beds ee ee ee ee ce bath TRANSMISSION GEAR OIL AGIP RADULA 68 type SAE 20 W quantity 200 AR TER Kick starter eau Air cooled e MORINI ENGINE lt FRANCO S6 E MOTORI SPECIAL TOOLS Description BEARING INSTALLER 143176 output shaft BEARING INSTALLER 143154 crankshaft 143156 BEARING INSTALLER output shaft 143179 OIL SEAL INSTALLER output shaft OIL SEAL INSTALLER crankshaft flywheel clutch 143180 OIL SEAL MOUNTING PROTECTION crankshaft flywheel clutch 143181 Page 3 e MORINI ENGINE FRANCO S6 E MOTORI SPECIAL TOOLS Description 143155 OIL PUMP SHAFT INSTALLER pre assembled 140558 FLYWHEEL REMOVER 143162 CRANKCASE PULLER Page 4 e MORINI ENGINE lt FRANCO S6 E MOTORI PERIODIC MAINTENANCE RUNNING IN RECOMMENDATIONS During the running in period i e for approx the first 500 km on the road please note as follows Do never run the engine at maximum revolutions Do never keep the vehicle at maximum speed Do not keep the engine at idle speed for longer time
5. e MORINI ENGINE lt FRANCO S6 E MOTORI INDEX Fee soma Je Gros CE ES uses TORQUE ARE f DEE fa fe 1 e MORINI ENGINE lt FRANCO S6 E MOTORI SPECIFICATIONS ace an TE 2 stroke Nr of CYLINDERS sssssssnuncccnseeannenansonnens 1 DISPLACEMENT 49 908 AND STROKE PP PEN 39 X 41 8 CYLINDER MATERIAL Special cast iron COMPRESSION RATIO 11 0 6 1 SPARK PLUG sscucessreannnenuseuns CHAMPION L78 C TIMING S Reed valve crankcase with metal gees flaps es 9000 CARBURETOR _ 12 mm diameter or equivalent INTAKE MANIFOLD Fixed FUEL ts EURO UNLEADED NC 623 02 R O N 95 TE plus 2 oil LUBRICATION MIXER OIL AGIP 2T CITY LUBRICATION SYSTEM automatic oil mixer pump on request GENERATOR ssssssicssr cnnenneunenusuns on request LOIN E Inductive electronic PRIMARY DRIVE GEAR Straight tooth gears Z 14 59 with safety coupling SECONDARY DRIVE GEAR Sprocket Z 10 711 EE chain type 1 2 x 3 16 roller 7 75 CLUTGH RE Automatic centrifugal 2 shoe clutch oil ee ee
6. eth of the drive gears visually Replace if signs of damage or wear are evident Check the clearance between the piston and the cylinder If it does not correspond to the prescribed value grind the cylinder and assemble 1st oversize piston BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are mounted in the crankcase Replace the bearing if anything unsual is found e MORINI ENGINE lt FRANCO S6 E MOTORI Smokey exhaust Replace the fuel in the tank with gt new fuel mixed with 2 of the type of oil indicated in the handbook YES Percentage of mixer oil YES Check that the oil is 100 synthetic for separate oil mixer pump use NO Disassemble the cylinder and YES remove any carbon deposits Carbon deposits check the silencer for clogging YES Disassemble the oil mixer pump Oil mixer pump and check the flow rate Page 14 e MORINI ENGINE lt FRANCO S6 E MOTORI TIGHTENING TORQUE TABLE DENOMINATION Lis Nm Crankcase bolts Clutch cover bolts Flywheel cover bolts Carburetor manifold bolts Ignition coil clamping screws 6 8 Oil mixer pump clamping screws 5 6 for model with mixer only Starter lever bolt Oil drain plug Clutch nut Flywheel nut Page 15
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