- - SERVICE MANUAL
Contents
1. e 945 peu en s HOLIMS N Ig 1 H313WOQ33dS E 23 OL3NOVW 133HMA14 MO G eniq dWVl 3Xvu8 1lvi dWV10V3H dWV1 ua13woq33aas1J 5 HOLIMS 440 NNY ES a gt N 2 2 N z 52 LLi nd Lad HOLIMS NHOH 1H911 S3HOLIMS 4016 13 ELECTRICAL IGNITION SYSTEM FLYWHEEL MAGNETO SYSTEM 1 Stator plate assembly low tension L T coil lighting coil contact points adjusting screw condenser mooOu2 2 High tension H T coil 3 Flywheel i 1 u o z Se IE 1 9 5 512 COIL ice 2 gis 9 RUN OFF i Bejaan NE SWITCH TO SPARKPLUG SWITCH STOP LIGHT RIGHT LEFT BRAKE LAMP Voltage is generated by the low tension coil LT coil This voltage charges the condenser allowing when the contact points open a pulse of voltage to the high tension coil HT coil This voltage is magnified by the HT coil to provide an arc across the spark plug The current of the ground side of the LT coil is routed through either the stop lamp filament or the stop lamp switches depending on the state of the switches 25 13 ELECTRICAL IGNITION SYSTEM l J TAILLAMP SPEEDOMETER LAMP vx GHTING COIL La cos a2. HEAD LAMP The 25 watt lighting coil generated alternating current A C which supplies the running lights and horn The lamps are connected in parallel with the speedometer lamp in the deluxe unit only 26 13 ELECTRICAL IGNITION SYSTEM SPARK PLUG MAINTENANCE miles the spark plug should be carefully cleaned and gapped The spark plug gap tolerance is 020 to 024 5 to 6 mm Since the gap will widen under normal use it is best to set it at its lower setting of 020 5 mm The plug heat value greatly depends on how the engine is employed It may be necessary to use a value other than that suggested LYWHEEL MAGNETO MAINTENANCE Premature wear on the rubbing block causes the contact points gap to narrow It is therefore very important to perform the proper maintenance to the magneto If the flywheel cam is properly cleaned and greased the rubbing block on the points will suffer very little wear dowever if dust or dirt is allowed to mix with the grease it will create an abrasive substance which will cause dremature rubbing block wear Also if not enough lubrication is provided the surfaces will become dry creating friction causing the rubbing block to burn A Contact points B Cam rider C Grease this surface luring normal operation burns and pits may develop on the contact points As a general rule this does not interfere with operation However if the ignition should m
3. When the points just begin to open the timing marks on the flywheel and the crankcase should line up If they do not the stator plate may be rotated by loosening the 2 fastening screws see illustration This can be done through the windows of the flywheel so that it is not necessary to remove the flywheel After obtaining the correct timing retighten the 2 fastening screws 28 14 CARBURETTOR Jet Idle adjustmen screw Float Fuel filter AIR FILTER The air filter system is designed to regulate the amount of air that flows into the carburetor It is therefore im perative that the filter and entire filter cover be installed to insure proper air fuel mixture CHOKE This is a mechanical choke which is mechanically engaged to reduce the throat size so as to restrict the amount of air flowing into the carburetor This results in an increase in the amount of fuel flowing through the jet IDLE ADJUSTMENT The idle adjustment operates mechanically so as to control how far the carburetor slide will close when in the throttle off state The throttle cable should have about 1 8 of slack when turned all the way off If the cable is adjusted too tight it will interfere with the operation of the idle adjustment JET The carburetor jet vaporizes the fuel in order to get the air fuel mixture To insure proper engine performance the jet must be clear of any foreign particles Carburetor jet sizes FLOAT NEEDLE AND SEAT Th
4. amp VERIFICATIONS Piston to cylinder clearance Minimum 0016 04mm Piston to cylinder clearance Minimum 0016 04mm Maximum 002 05mm Limit 004 1mm Piston ring end gap Minimum 012 3mm Maximum 039 1mm All Garelli cylinders have a dot of paint at the base of the intake port The color of the dot of paint on the top of the piston should be the same as the color dot on the cylinder 16 12 ENGINE REASSEMBLY Insert the crankshaft A into the right hand crank case CAUTION Make certain that the tapered end of the crankshaft is toward the flywheel side Fit the primary shaft B along with the pedal shaft with the chain and the starting assembly taking care that the spring D fits in its seat CAUTION Make certain that the spring D remains in the seat TOOLS Mallet Join the left crankcase with the right one acting as follows A Make sure that the faces of the cases are clean and free from burrs and that the dowels are in position B Slightly grease a new gasket on both sides which is to be inserted between the two crank case halves C Press the two crankcases by hand and then lightly tap them together with a mallet D Insert the 6 short screws in the inner holes and the 4 longer screws in the outer holes Slowly tighten the screws in the order indicated in the illustration E Check that the crankshaft the primary shaft and the peda
5. direction to pull the flywheel off the taper Remove the Woodruff key from the crankshaft CAUTION Make certain that the external thread of the extractor is screwed fully into the flywheel TOOLS Special tool 1050 flywheel extractor 14mm open end wrench adjustable wrench Make a scriber mark s across the bottom of the stator plate and the crankcase boss in order to facili tate re timing on assembly Remove the 2 screws v holding the stator plate to the crankcase Lift the stator assembly from the engine TOOLS Screwdriver 11 10 ENGINE DISASSEMBLY Remove the nut from the countershaft sprocket then pull the sprocket from the shaft NOTE Note the order of the 2 spline washers and the spring washer TOOLS Special tool 1060 17mm wrench Drain oil from the gearbox and clutch by removing the drain plug on the bottom of the engine TOOLS 17mm wrench Remove the left sidecover and its gasket TOOLS Screwdriver 12 10 ENGINE DISASSEMBLY After removing the circlip the pressure plate and the spring from the clutch assembly remove the nut and washer TOOLS Special tool 1090 17mm socket circlip pliers Slide the clutch hub spline washer and clutch housing from the crankshaft Arrange the screws in tool 1040 to fit the driving gear Use this tool to hold the gear while unscrewing the nut Remove the spring washer TOOLS Special tool 1040 17mm
6. socket 13 10 DISASSEMBLY Use extractor tool 1070 to remove the driving gear NOTE This gear is on a tapered shaft therefore it will have a tendency to snap off If any difficulty is encountered a rubber mallet may be used to lightly tap around the edge of the driving gear while pressure is being exerted by the puller TOOLS Special tool 1070 19mm wrench Remove the 4 nuts holding the cylinder head Lift the head and cylinder over the 4 studs and remove the cylinder base gasket NOTE If the cylinder is stuck to the crankcase a mallet may be used to lightly tap around the cylinder to break it loose TOOLS 11mm socket Remove the 2 circlips from the piston TOOLS Needlenose or circlip pliers 14 10 ENGINE DISASSEMBLY Remove the piston gudgeon pin the piston and the needle bearing TOOLS Gudgeon pin extractor mallet Remove the plastic protectors from the pedal shaft Remove the 10 crankcase screws from the right hand crankcase Strike the ends of the crankshaft A the primary shaft B and the pedal shaft C alternately with a mallet until the two halves of the crankcase separate TOOLS Screwdriver mallet The gearbox components and crankshaft will slide out or may be tapped out The pedal shaft C and the primary shaft B are connected by an endless chain so both shafts will have to be slid out together TOOLS Mallet 15 11 CHECKS
7. 2 155 9 ENGINE REMOVAL Remove rubber mat and top cover held by 4 bolts TOOLS 8mm socket Disconnect the clutch cable TOOLS Screwdriver or needlenose pliers 17mm open end wrench Remove the 2 exhaust manifold bolts TOOLS 5mm Allen wrench 9 ENGINE REMOVAL Disconnect the blue yellow and black engine wires from the terminal block Disconnect the spark plug wire TOOLS Small blade screwdriver Remove carburetor by loosening the clamp screw and sliding off manifold TOOLS Screwdriver Remove the right chain guard by removing rear shock absorber bolt and the swingarm nut and washer TOOLS 17mm open end wrench 17mm socket 19mm socket 9 ENGINE REMOVAL Break chain by removing master link Remove the 2 rear and one front engine mounting bolts TOOLS 13mm open end wrench 13mm socket Drop engine forward and down to remove 10 10 ENGINE DISASSEMBLY After removing the spark plug carburetor and pedals for which no special tools or procedures are required proceed as follows to dismantle the engine After removing the right side cover remove the fly wheel retaining nut and spring washer using special tool 1040 to hold the flywheel CAUTION Do not scratch the coils with tool TOOLS Special tool 1040 12mm socket Screw the fiywheel extractor into the threads of the flywheel then turn the extractor center bolt in a clockwise
8. AMERICAN GARELLI SERVICE MANUAL A guide to servicing the Garelli 49cc moped engine prepared for use by American Garelli dealers and technicians TABLE CONTENTS 1 Specifications 1 2 Vehicle Identification 2 3 Pre Delivery Servicing 3 4 Oil Injector 4 5 Maintenance Servicing 5 6 Decarbonization 6 7 Special Tools 7 8 Torque Specifications 7 9 Engine Removal 8 10 Engine Disassembly 11 11 Checks and Verifications 16 12 Engine Reassembly 17 13 Electrical Ignition System 23 14 Carburetor 29 15 Trouble Shooting 30 DIMENSIONS AND WEIGHT Tire front and rear Weight dry Overall Length Overall Width Overall Height Wheel Base LIQUID CAPACITIES Gas Tank Gearbox ENGINE Type Bore Stroke Displacement Weight dry ELECTRICAL Ignition System Ignition Timing Spark Plug Head Lamp Tail Stop Bulb 1 SPECIFICATIONS 2 25 x 16 in 46 kg 101 Ibs 1 65 m 65 in 0 70 m 27 6 in 1 060 m 41 7 in 1 10 m 43 3 in 3 liters 0 8 gals 400 cc 13 5 ozs 2 cycle single cylinder air cooled piston valve 40 mm 39 mm 49 cc 8 10 kg 18 Ibs C E V Mechanical Point 1 3 mm B T D C 18 degrees B T D C 0 5 mm 0 020 in Sealed beam 6v 18w 6v 5 8w 2 VEHICLE IDENTIFICATION The frame number can be found on the left side of the frame head The engine number can be found on the right side of the engine below the pedal shaft 3 PRE DELIVERY SERVIC
9. ING 1 Install handlebars leaving expander bolt loose NOTE The expander device may require slight lubrication if rusted 2 Install engine stop switch on right side of handlebars NOTE Twist handlebars to the right to install switch 3 Install gas control throttle assembly on right side of handlebars leaving control loose 4 Install horn light switch on left side of handlebars NOTE Twist handlebars to the left to install switch 5 Install clutch control lever assembly on left side of handlebars 6 Set levers and switches in correct position and secure 7 Adjust handlebars for correct position and tighten expander bolt CAUTION Make sure at least 2 of stem is in headset before securing expander bolt 8 Install and secure seat 9 Install taillight and corresponding wires NOTE Blue wire to S terminal Black wire to terminal Grey wire to T terminal CAUTION If these wires are not connected to the proper terminals engine failure will occur 10 Install crankarms and pedals NOTE Install crank with D mark on right side of bike 11 Tighten reflector screw on both pedals NOTE Certain models do not have these screws 12 Tap both crankarm pins and tighten 13 Check tire pressure NOTE Front tire 18 psi Rear tire 28 psi 14 Check tightness of all bolts and screws NOTE This is IMPORTANT and special attention should be given to the following LOCATION QUANTITY SIZE Wheel nuts 4 17mm
10. Shock abs nuts 4 17mm Swingarm nuts 2 19mm Motor mount nuts 3 13 mm Muffler mount bolts 2 8mm Left side cover 6 screw Carburettor mount 1 screw 15 Check chain tightness and rear wheel alignment 16 Check all cable and control adjustments 17 Check for correct amount of gear box oil NOTE Oil should be level with oil level plug located on the left side of engine This is determined when oil shows by leaning bike about 10 degrees to the left side If additional oil is needed add 30 wt non detergent oil The total amount of gear box oil is 13 5 ounces 400 cc 18 For models with oil injector refer to oil injector section 4 For models without oil injector pour gas oil mixture in tank NOTE Normally use 5 ounces of 2 cycle oil to 1 gallon of regular gasoline If American Garelli oil is used mix 3 ounces of oil to 1 gallon of regular gasoline This mixture is used for break in of engine only 19 Check that spark plug gap is set at 020 5 mm 20 Start engine and set carburetor idle adjustment on the left side of carburetor 21 Test ride for general inspection again checking all controis 22 Adjust and check all lights 4 OIL INJECTOR Oil inlet fitting Left side Activator rod Filler cap Minimum oil level feeder line Fill the oil injector reservoir with the proper oil Garelli 2 stroke engine lubricant or Golden Spectro Do not connect oil feeder line Place end of oil fee
11. alfunction as a result of more seriously burned con tacts the contact points must be replaced 27 13 ELECTRICAL IGNITION SYSTEM SETTING IGNITION CONTACT POINTS AND TIMING The points and timing are adjusted through the flywheel windows with the flywheel remaining on the engine Rotate the flywheel until the points gap is in the widest position At this point measure the points gap Points 014 018 35 45 mm To change the point setting loosen the set screw see illustration Wedge a small bladed screwdriver between the notch on the points and the pins on the stator plate Turning the screwdriver clockwise will open the points gap and turning counter clockwise will close it When satisfied that the gap is set correctly tighten setscrew and check the gap once again NOTE It is helpful to have the bike at the comfortable working level with good lighting To check the timing rotate the flywheel in the counter clockwise direction until the contact points just begin to open This position may be more closely determined with a test light buzzer or ohm meter Connect one lead to the low tension wire that connects to the high tension coil and the other lead to ground Be certain the run off switch is in the run position Rotate the flywheel by hand The points will be closed when the test light brightens or the buzzer gets louder or the ohm meter needle deflects to zero Otherwise the points are in the open position
12. der line into empty oil bottle or can to catch any oil as feeder line is bled Slowly operate the oil injector activator rod until all air bubbles disappear from the feeder line Connect feeder line to fuel tank oil inlet fitting located on left front of fuel tank Recheck feeder line to insure that no air bubbles are present in the line Fill the fuel tank with regular leaded gas Seven tenths 70 of a gallon will fill the tank to capacity leaving room for the oil This amount is slightly less than 3 4 gallon or slightly less than 3 quarts Operate the activator rod through the complete cycle of pulls one cycle is one complete pull and one com plete push to inject the required amount of oil into the fuel tank Screw the knob down to secure 5 MAINTENANCE SERVICING Each Garelli moped should be checked at these intervals with a thorough inspection to include the following points Every 300 miles 500 Km clean gap spark plug drain and replace gearbox oil 13 5 oz 400 cc use SAE 30 non detergent oil CAUTION Do not use detergent oil inspect tires lubricate and adjust chain clean carburetor adjust contact points adjust and lubricate all cables and controls check the tightness of all screws and nuts Every 1200 miles 2000 Km repeat the operations performed in the 300 mile check clean carburetor main jet fuel filter screen float chamber etc remove clean and lubricate dri
13. e float is factory set for the proper fuel level and is not adjustable When cleaning the carburetor the needle and seat should be cleaned and checked for proper seating 29 15 TROUBLE SHOOTING What is trouble shooting Trouble shooting is an organized way of determining the cause of malfunction This diagram illustrates how a gas engine performs If there is a problem with an engine it must be in one of these sections IGNITION LT COIL HT COIL POINTS CONDENSER SPARK PLUG plug gap gt Insufficient difficult spark in point gap starting combustion chamber HT coil bad connection of plug wire to plug cap When trouble shooting an engine it should always be thought of in this perspective If the section that the trouble lies is not known then steps of elimina tion must be taken For example when you pull out the spark plug to see if it has fire you are taking an elimination process Here you will find out if the ignition process is performing If the ignition is performing then you know to check another section If the ignition section is not performing properly then further steps of elimination must be taken to determine which part of the ignition section is failing The same is true if another section is found to be malfunctioning FUEL AIR CARBURETOR CRANK SEALS CYLINDER GASKET Symptom Problem Reason carburetor clogged jet engine bogs low
14. it the stator plate so that the scribed mark S pre viously made is in line and lightly tighten the 2 mounting screws 3lip the flywheel onto the crankshaft taking care that the Woodruff key is still correctly seated The spring washer and flywheel nut may now be inserted and ightened to 12 ft Ibs 3 kgm TOOLS Special tool 1040 12mm socket torque wrench 3otate the flywheel until the points gap is the widest position At this position check the gap with a feeler gauge resetting if necessary to 014 018 35 45mm NOTE For more detail see Electrical System section 13 21 12 ENGINE REASSEMBLY To check the timing rotate the flywheel in the counterclockwise direction until the contact points just begin to open At this instant the timing marks on the flywheel and crankcase should line up If they do not the stator plate may be rotated by loosening the 2 fastening screws This can be done through the windows of the flywheel so that it is not necessary to remove the flywheel After obtaining correct timing retighten the 2 fastening screws Replace the right side cover 22 id gt 2 e 2 S N lt 2 od OLANDVW 133 on1axuvas E WOOD HOLIMS AR dip UM XV 7 ang V 7 enig SAHOLIMS 4015 enig dWVv1 e
15. l shaft turn freely Insert needlebearing and gudgeon pin in crankshaft and refit piston making certain that the 5 on the piston is toward the exhaust port or downward CAUTION The piston circlips should be properly inserted and fully expanded in their grooves TOOLS Circlip pliers or needlenose pliers 17 12 ENGINE REASSEMBLY Check that the crankcase upper face and the cylinder base are clean and free from burrs Lightly grease a new gasket on both sides and lay it on the crankcase face Oil the cylinder bore and the piston skirt Lower the cylinder onto the piston with fingers com pressing the rings into the bore CAUTION Make sure the ends of the piston rings are properly fitted in position against the pegs of the ring grooves Check that the top of the cylinder and the face of the head are clean and undamaged Fit the head over the studs and place the 4 washers and nuts on the studs Tighten the nuts gradually in a cross pattern The final torque should be 12 ft Ibs 1 6 kgm TOOLS 11mm socket torque wrench Refit the driving gear to the tapered shaft placing the washer and nut Tighten the nut to 35 ft Ibs 5 kgm TOOLS Special tool 1040 torque wrench 17mm socket 18 12 ENGINE REASSEMBLY Center punch the shaft to lock the nut into place TOOLS Hammer center punch Place washer and spring washer on the crankshaft Slide the clutch housing and
16. spline washer onto the crankshaft CAUTION The flat side of the spline washer should face toward the center of the engine Mount the clutch hub with the spring washer and nut Tighten to 23 ft Ibs 3 kgm TOOLS Special tool 1090 17mm socket torque wrench 19 12 ENGINE REASSEMBLY Check to see that the clutch housing turns inde pendently of the clutch hub and crankshaft The axial play of the clutch assembly should be as little as possible taking care however that it will still turn free from the crankshaft To reduce possible excessive play the spline washer part 2350 may be fitted with the chamfer side towards the engine center line Insert the spring over the clutch hub nut NOTE The spring will fit only in one direction Place clutch body and pressure plate over clutch hub Insert clutch circlip while maintaining pressure on the pressure plate CAUTION Tap the circlip to make certain that it is well seated TOOLS Needlenose or circlip pliers 20 12 ENGINE REASSEMBLY heck that the surfaces of the left side cover and the srankcase are clean Lightly grease both sides of the cover gasket and insert gt AUTION The gasket has an identation to clear the pedal shaft Screw the side cover down TOOLS Screwdriver rit the Woodruff key in position on the tapered end of the crankshaft NOTE A small amount of grease may be used to hold the Woodruff key in place
17. vacuum left or right crank shaft seal base gasket COMBUSTION CHAMBER RINGS CYLINDER HEAD GASKET HEAD worn rings low power low compression scarred cylinder walls leaking head gasket overall poor performance cracked head EXHAUST EXHAUST PORT BAFFLE low power clogged exhaust restricted exhaust port clogged baffle low top speed 30 15 TROUBLE SHOOTING The following is an actual example of how the problem of no starting or difficult starting should be approached If engine is hard to start or does not start Does fuel into carburetor Fuel tank petcock clogged Check carburetor for restricted fuel flow Fuel strainer clogged Gas cap vent clogged Check for spark at the spark plug at cranking speed Weak spark No spark Bad spark plug Shorted or fouled spark plug Incorrect spark plug gap Incorrect point gap Bad connection of plug wire to plug cap Shorted Run Off switch Incorrect point gap Stop lamp system shorted Bad HT coil Disconnected wire Dirty contact points HT coil failure Bad LT coil LT coil failure Bad condenser Contact points wire rubbing crankshaft Contact points wire rubbing crankshaft 31 f 1 f 3 r 1 f f 1 3 r 4 r4 ry 14 4 4
18. ve chain Every 2000 miles 3200 Km repeat principle operations of 300 mile check check clutch for wear decarbonize engine see Decarbonization section 6 check for brake wear remove and oil all control cables 6 DECARBONIZATION Remove muffler Remove carbon from the mouth of exhaust pipe Check exhaust baffle for carbon deposit TOOLS 5mm Allen wrench Remove cylinder head Remove carbon TOOLS 11 mm socket Remove cylinder block Remove carbon from exhaust port after scraping out carbon taking care not to damage cylinder walls smooth exhaust port with emery cloth Remove the piston rings and carefully scrape any carbon deposit from ring grooves Replace components following cylinder portion of engine re assembly section 12 fom exhaust port 7 SPECIAL TOOLS I2 ONS Tool Number 4 Holding Tool for Flywheel and Driven Gear 1040 2 Flywheel Extractor Tool 1050 3 Holding Tool for Primary Driving Sprocket 1060 4 Driven Gear Extractor Tool 1070 5 Holding Tool for Clutch Hub 1090 6 Clutch Hub Extractor 1100 8 TORQUE SPECIFICATIONS Torque Torque kpm ft Ib Cylinder Head Nut 11 mm 1 5 2 0 11 14 Flywheel Magneto Nut 12mm 3 0 3 5 22 25 Clutch Nut 17 mm 3 0 3 5 22 25 Driving Gear Nut 17 mm 4 5 5 0 32 36 Chain Sprocket Nut 17 mm 6 0 6 5 43 47 Crankcase Screw slothead 1 0 7 Left Side Cover Screw slothead 1 0 7 Flywheel Side Cover Screw slothead 0
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