Minarelli V1 Service Manual
Contents
1. Cov Model 6932 5370 1 Wire Guide on Crankcase for Internal High Voltage Coil Coil Stator 5300 ire Guide on Crankease for External High voltage Coll 5390 1 Bearing for Aluminum ALY conveyor only 5400 1 Bearing for Plastic Air conveyor only 5410 1 Cooling Fan 5420 4 Bolt TGS 4 x 10mm for securing Fan 5430 1 Air Conveyor Aluminum 5440 1 Air Conveyor Plastic 5450 3 Bolt 6 x 25mm 5460 1 Gasket for Cylinder Base 5470 1 Cylinder B38nm Cast Iron Model 30km for 20aph TABLE1 MINARELLI ENGINE PARTNO quantity DESCRIPTION 5480 1 Cylinder 838 8 mm Cast Iron for 25 30 and 2 10 Engine 5490 1 Gasket for Cylinder Head STD 0 7rm 5500 Engine Head 5510 1 Spark Plug Bosch W 145 TI or Pcuivalent 5520 1 Cover for Spark Plug Rubber B 5530 4 HOLD DOWN STUD 6 M x 136m for Cylinder Head 5540 5 Washer Chanfered 06mm 5550 6 Nut for Stud Bolt 6 MA x 6mm 5580 1 Side Carburetor Manifold 6l2mm for 30roh Z 10 Engine 5590 1 Side Carburetor Manifold 08 5 mm for 25 30mph 5600 1 Side Carburetor manifold f7 25mm for 20 mph 5610 1 Bolt 6 MA x 16 mm for Securing Cover 5620 1 Wire Guide for Spark Plug Wire 5630 1 Grommet for Spark Plug Wire Rubber 5640 1 Carburetor SHA 14 9 Max Jot 49 Dell Orto for 20mph 5650 1 carburetor SHA 14 12 Max Jet 52 Dell Orto for 25 30nph 5660 1 Filter Housing Supported2. 5650 1 Adjuster for Throttle Cable 6660 1 for Air Filter Self supportin 5680 1 2 Guide for Throttle Cable 6690 1 Filter Element 6117 5710 1 Nut for Housing Bolt 6720 1 Bolt for Securing Air Filter Housing 1 pretor 14 9 Max Jet 49 Dell orto for Carbyretor Del or Multiple parts Pound on engine drawing m Minarelli Engine Theory The stroke Engine ENGINE OPERATION All Vl engines regardless of tha top spocd 17 20 25 30 are piston port type two strokes The following discussion of each type will provide sore insight into how they work and may someday prove very helpful in troubleshooting PISTON PORT TWO STROKE The piston port two stroke is the simplast of all anginos commonly Suen in motorcycles and moped application 1t has only three main moving parte and uses ports rather than valves as in four stroke engines to regulate intake and exhaust flow These ports are all located y and opened and closed by the pistons movement Their functions are Intake Port Admits fresh fuel mixture from the carburetor into the crankcase Transfer Ports Provide passages for the fuel mixture between the crankcase and combustion chambar Exhaust Port Releases burat gases ror the combustion chamber into the exhaust pipe Basically with the Minaralli Vl engine this is what happens s 360 rotation cf the crank shaft beginning w
3. _SERVICE MANUAL a MINARELLI V1 ENGINE 1978 Minarelli U S A Inc All Rights Reserved No part of this work may be reproduced without the express written permission of the Copyright Holder Tolaz 133196 MMOBIL MOON Accessories Mopeds 201 438 5700 S MARINA MOBILIINC 149 WEST COMMERCIAL AVENUE Exportorsimportersibistibutors MOONACHIE J 07074 Parts and Motors 2 lt gt TABLE CONTENTS Service Manual for MINARELLI Vl Engines SECTION 1 Minarelli V 1 Engine All Models Table 1 Minarelli Vl Engine Table 2 Clutches for Minarelli Vl Engine Table 3 Dealer Tool Kits for Minarelli Engines SECHON 2 NAGNETOS Minarelli Electrical System Theory of Operations Table 4 bosch Model kB6 8212 Table 5 CEV Model 8876 Table 6 Model 6932 SECTION 3 CARBURETOR Table 7 Dell Orto Carburetor ENGINE DISMANTLING MON 4 Minarelli Encino Two Stroke Theory Dismantling Vl Minarelli Engine SECTION 5 ASSEMBLING Vl MINARELLI ENGINE Assembling Vl Minarelli Engine Timing Vl Minarelli Engine Tech Data for Vl Minarelli Engine Torque Specs 10 12 1 16 17 19 27 as 37 38 Se 05 lt 2 TABLE1 MINARELLI ENGINE PARTNO QUANTITY DESCRIPTION 4240 1 Gaske
4. cold weather B amp BS warm weather TORQUE KG T Foot Pounds t screw for clutch lever 5130 slf casing and side cover bolts Intake manifold bolts 3610 1 0il level amd drain screws 3 5 Bole for securing spring leaves 5840 10 Nuts for securing head 5550 1 0 pn 3 0 2 1 5 2 5 8 Nut for securing intermediate sprocket 4840 Checknut for magneto flywheel 4750 Checknut for securing centrifugal clutch with cone coupling 6270 38
5. by Clamp 5670 n Gasket for Muffler 5680 1 Muffler Type Short below engine 5690 1 Bolt 7 MA x 20mm for Securing Muffler 5700 1 Washer Chamfered Tnm 5710 Idler 2 16 21 Teeth 5720 n Pin 12 x 46mm for Idler 5730 2 Shim 12 x 1m 5740 1 Shaft for Pedal 5750 1 Gear 2 27 for 1 5760 1 Clutch for Pedal Sliding Hgt linm 5770 1 Spring for Sliding Clutch 5780 1 Guide Pin for Spring 8 5 x 24mm 5790 3 Shim 916mm 5600 1 Lock Ming flomm for Pedal Shaft 5810 1 Crank for Right Pedal marked with a D 5520 1 Crank for Loft Pedal 5830 2 Pin for Crank Complete w Nut and Washer 5840 1 Bolt 6 x 12mm for Securing Leaves 5850 1 Cap for Pedal Shaft 5860 2 Lock Washer 95mm 5870 2 Stud Bolt 6 x 23mm for Muffler 5880 1 Clamp for Securing Filter Housing S TABLE 1 MINARELLI ENGINE PARTNO DESCRIPTION 5890 1 Gasket set Complete 5230 5270 5460 5490 4230 and 5670 6000 2 snap Ring for shaft Plann CONE 6020 2 shim 14 x 20mm CONE 6040 1 Bushing for Clutch CONE 6180 Clutch Centrifugal Complete CONE 6200 1 Bearing for Clutch Shoe CONE 6270 1 Locknut for Brake Shoe Bearing CONE 7050 Screws for plastic air conveyor TABLE2 CLUTCH FOR MINARELLI ENGINE PARTNO QUANTITY DESCRIPTION 4410 1 Complete crankshaft Assembly S P 4420 1 Half Shaft Clutch Side S P 4460 1 Complete Cr
6. 0mm nuts Tighten cylinder head nuts in a criss cross pattern and torque them to 8 0 ft lb 3 TIMING ENGINE h should be 0 014in 9 35 0 49am The correct point gap set essential before the igni timing operation can be carried It is better to set the olgin as the points t together and will remain in area of correct adjustment longar To set timing rotate yuheel in a clockwise di note arrow on Flywheel the arrow on the casing position is 23 degrees bel ad center The tart to open at ti Proper alignment can be checked by renoving the blue wire from any muity tester c meter etc Ground and connecting the wire to a co buzz box mu MAGNETO To adjust the stator plate loosen the two phillips serewe and move the plate counter clockwise if Fo far advanced and clockwise if s and re eck timing Note 1f opening occurs before the mark lines up the timing is said to be advanced Note The second line the magneto flywheel 1 top dead center Place chain sprocket on shaft replace washar and 17mm nut and hLen holding the sprocket with tool 6360 Torque 32 0 ft ibs ace fan housing wi screws fan and fanc allen bolts in that order engine to frane mount carburetor with intake pipe install spark plug refill engine with SAE 20 V non detergent
7. AYS Si KAKE AND MODEL NUMBER PRINTED Oi IV MODEL 6932 5190 6240 dye TABLE 7 DELL ORTO CARBURETOR 6619 4 6460 eu 640 TABLE 7 DELL ORTO CARBURETOR PART NO QUANTITY DESCRIPTION 2200 1 Screw tor Securing 1 5660 1 Mousing for Air Filter 5880 1 Clamp for Air Filter Housing 6320 1 Cover for Mixture Chambar 6330 i Float Bowl 6340 1 Locknut for Throttle Cable Adjuster 6350 i Mut for Mounting Bolt 6360 i Fuel Filter 6370 1 Float 6379 2 Jet 47 6380 1 Jet 49 6390 1 Jet 51 for 25 30mph above 2000 foot 6400 1 Jet 452 for 25 30mph 6410 1 Gasket for Mixture Chamber 6420 1 Gasket for Air Filter 6430 id Gasket for Float Bowl 6440 1 Gasket for Puel Intake 6450 Choke Lock 6460 1 Spring for choke Lock 6470 i Return Spring for Choke 6480 1 Return Spring for Throttle Slide 6490 1 Spring for Idler Screw 6500 1 Pin for Float 6510 1 Pin for Choke Lock 6520 1 Screw for Securing Choke Arm 6530 1 Fuel Intake 6540 1 Gasket Insulating 6550 1 Needle valve 6560 Guide for Throttle Cable Old 6570 1 Choke Arn Short 6580 1 Chexe Arm Long 6590 1 Slide for Throttle 6600 1 Bolt for Securing Carburetor to Manifold 6610 2 Screw for Securing Mixture Chamber Cover 6620 1 Screw for Securing Fuel Intake 6630 2 Screw for Float Bowl 6640 1 Screw for Adjusting Idler
8. E This step will require split ting of the cases in order tc properly drill the bottom two holes in the Connecting red of assembly 44480 26 ASSEMBLY OF MINARELLI ENGINE When reassembling the Minarelli engine replace ali seals and caskets All parts removed and to be reused should be thoroughly cleaned and lightly oiled A11 gaskets should be given light coat of grease to help you seat them into place and also to insure a batter seal NOTE All shims used in the Minarelli fit properly on the shafts i5 Shafts are of different diameters a loose fitting shim is improperly placed Placing the wrong thickness shim on shaft will either allow a loose fit if too thin or not allow snap ying to fit on if too thick install idler shim 5730 idler gear 5710 and shin 25730 on to idler shaft which should be on the clutch side 1f piston was extracted from connect ing rod reassemble at this time Install one G clip and push in pis ton with piston pin extractor In stall second G clip making sure there is sufficient clearance install pedal shaft into clutch Side of casing with shim 5790 ES pedal clutch 85760 with spring 4 Gn it pedal gear 5750 shin 35790 and snap ring 45800 which should be installed on pedal shaft previous to insertion in the case Then Put on final chim 5790 on shaft mext to snap ring NOTE Make sure that S or gt Gn piston points to exhaus
9. ankshaft Assembly CONE 4910 1 Shim 13 x 21mm 4920 1 Bushing for Clutch 3930 1 Complete Centrifugal Clutch S P 4940 x for Clutch S P 5030 1 Washer for Nut 5040 Locknut for Brake Shoe Bearing 5050 1 Cotter Pin for Nut 5570 Shin 13 7 x 20 9 S P 6000 n Snap Ring for Shaft CON 6020 H Shim l4 x 20 CONE 6040 1 for Clutch CONE 6180 1 Complete Centrifugal Clutch CONE 6200 l Bearing for Clutch Shoe CONE 6270 n Locknut for Brake Shoe Bearing CONE MOUNTING WITH STUB PLANE MOUNTING WITH CONE P H 4920 8 1 5040 446 4910 4940 5030 mmm his 6020 6200 iso 6006 TABLE 3 DEALER TOOL KIT FOR MINARELLI VI ENGINE PART NO QUANTITY DESCRIPTION 6900 1 Point Tiner 6920 1 Intermediate Sprocket Extractor 6330 n Crankshaft Extractor 6950 I Flywheel Puller CEV Only 6950 Sprocket Holding Tool 6970 1 Clutch Tool 6930 1 Clutch Puller 6930 1 Flywheel Tool 1600 1 1616 1 C9 1619 6990 1600 7 Rp 960 OWNER TOOL KIT PART NO QUANTITY DESCRIPTION 1240 1 spark Plue wrench 1620 1 Double 1630 1 Allen w 228 1630 MINARELLI ELECTRICAL SYSTEM THEORY OF OPERATION Tho Magneto usad on tha Minarelli angina consists o two basic components First the magneto contains a STATOR PLATE mounted on the left side engine housing This STATOR PLATE holds the primary ignition coi
10. ar drive sprocket NOTE Larger diameter shim for this shaft fits on outside of drive Install drive clutch 4870 shim 34850 and snap ring 44860 on shaft All parts should fit on shafts with virtually no play Install shim 6020 bushing 46040 clutch housing 4900 shim 36020 and snap ring 6000 cluster body 36180 washer 5020 and clutch nut 5040 on shaft 4460 To Install clutch body 46180 washer 15030 clutch nut 5040 on shaft With Minarelli clutch tool 6970 hold clutch body and torque nut to 21 7 ft lb install spring 5060 retainer cap for spring 5070 retainer cap 5080 and press into housing lining up retainer with housing in slots Install lock ring 5090 into groove heck retaining cap for starter for proper movement which is approx imately lam in and out sket 5210 clutch housing 5260 with the six 6x15mm and one 6x35mm Allen bolts Torque clutch casing bolts 8 0 fe lb Install base gasket on engine casing Line up rings with pins on piston so that the cylinder can be in stalled over piston Rings can be compressed by hand to enter the cylinder Turn magneto to observe smooth and even movement of the piston NOTE The tolerance between cylin Ger and piston should be 0 003in to 0 0051 NOTE Cylinder should Be Lightly oiled previous to installation d gasket 5490 and cy inder head 5500 four washers and 1
11. e 38 7zm Piston and Rings are 38 8 939 639 2 229 4 039 6 939 8 TABLE1 MINARELLI ENGINE PARTNO QUANTITY DESCRIPTION 4700 2 Bearing for 11 x 40 12mm RIV 01 4710 2 Seal for Crankshaft 917 x 35 x 4720 1 Key for Magneto Flywheel 3730 1 Key for Magneto Flywheel BOSCH 2740 Screw for Smeuring Stator 4 MA x 10mm 4259 1 Check Nut for Magneto Flywheel 4760 1 Drive Shaft 4770 2 Bearing 15 x 35 limm RIV 028 4780 1 Shim for Bearing B35mm 4790 3 O11 Seal 15 x 24 x Smm 3800 1 Sprocket Intormodiate for for 20mph 4810 1 Sprocket Intermediate for 10T for 25moh 2 10 Engine 3820 1 Sprocket Intermediate for 117 for 30mph 3830 1 Washer for Nut 10 x 0 8mm thickness 1840 1 Nut for Intermediate Sprocket 3850 2 Shim 15 x 21nn 1860 3 Snap Ring for Shaft 615mm 3870 t Drive Clutch 4880 1 Gear Set Completo w Parts 4890 amp 4900 3890 n Gear for Clwtch w Plata 2 53 1900 z Engine Sprocket w Housing 2 4910 2 Shim x 21mm STUB PLANE 4920 1 Bushing for Clutch STUB PLANE 4930 1 Clutch Centrifugal Completo STUB PLANE 4940 1 Bearing for Clutch Shoe STUB PLANE 1950 2 Clutch Shoe 1950 E Clutch Shoe Complete w Parts 4970 amp 4980 1970 2 Plato for Clutch Shoe 4980 2 Screw for Securing Plate TSP 4 MA x 12mm 1990 4 Spring for Brake Pad 5000 4 Brake Pad 5019 2 Return Spring for Clutch Shoe 3020 4 Pin for Securing spring 5030 1 Was
12. ews end reassemble side of engine NOTE Be sure tighten magneto check nut securely 6 Technical Data ENGINE Model Minarelli VI Single Cy 2 stroke Cuble Cap 47 6 cc 20 mph 49 4 ce 25 and 30 mph Bore 38 0 ma 20 roh 38 8 on 25 and 30 mph Stroke 42 0 ma f Compression Ratio 8 to 1 Horsepower 4500 cpm 1 00 20 mph 1190 25 and 30 mph Piston to wall clearance 0025 005 zebore at 002 clearance Ring Gap 012 ignicion and Lighting Flywheel 6 volt magneto with 23 wart capacity and external high tension coil stop light op erated by grounding of low tension ignition coil uel Mixture Minarelli synthetie oil 64 ro 1 Syathecic oil 40 to 1 mixture of recomended ratio on cam or Starting Pedal and Clutch Clutch Automatic centrifugal expanding running in oil Lubrication Clutch and Gears Capacity 1 pint SAE 20 oil PRIMARY TRANSMISSION Final reduction of 3 533 to 1 clutch gear 15 tooth Secondary gear 52 Looth PINAL TRANSMISSION AND RATIO ven by single row chain 1 2 x 3 16 ll tooth angine Sprocket to 42 tooth wheel sprocket ratio 2 73 to 1 IGNITION TIMING 23 B T D C measure on flywheel externa or 079 diameter CONTACT BREAKER GAP 014 to 018 inches 35 to 40 mm 7 SPARK PLUCS BOSCH W 145 TI 024 inches Marelli 5H Champion L86 L89CH NKG BSHS
13. her for Brake Shoe Bearing Nut 5040 1 Locknut for Brake Shoe Bearing STUB PLANE 5050 1 Cotter Pin for Nut STUB PLANE 5050 1 Return Spring 5070 1 Retainer for Cap Return Spring 5080 1 Retainer Cap for Starter 3090 1 Lock Ring for 5100 1 Lever for Clutch TABLE1 MINARELLI ENGINE PARTNO QUANTITY DESCRIPTION silo 1 Grommet for Clutch Lever 5120 1 Return Spring for Clutch Lever 5130 1 Set Screw for Clutch Lover 5140 1 Washer Maret CEV 5150 1 Bolt for Securing Clutch 5 x 8mm 5180 1 Bridge for Clutch Adjuster 5170 1 Clutch Lever Adjuster 5180 1 Spring Lea Upper 5199 1 Spring Lea Lower 5200 1 Nalf Casing Clutch Side 5210 1 Walf Casing Flywheal Side for Stator p 94 5220 1 Malf Casins Flywheel Side for Stator J 80 5230 1 Gasket for ialf Casinc Center 5240 3 Dowel for Crankease 10 x 10am 5250 ii Bolt TCCE 6 MA x 30mm 5260 1 Cover Clutch Side 5270 1 Gasket for Clutch Cover 5280 Cap Oil Feed 5290 1 Gasket for Cap l2nm 3300 2 Bolt TCB 6 for Oil Level and 5310 2 Gasket for Bolt f nm 5320 3 Bolt 6 x 15a 5320 6 Bolt 6 MA x 35mm 5340 Magneto Flywheel Complete 239 6V w External High Volta posam CEV Model 6876 5350 1 Magneto Fiywheel Complete 18 6V W Internal High Voltage Coil stator 080 Bosch Ra6 E2121 d Magneto Flywheel Complete 23 6V w External High Voltage Coil stator
14. ith the nat top dead cen l Down Stroke The piston from thc previous cycle and cxposes the exhaust port letting ont the expanding burnt gases Simul taneously the plscon s downward movemant compresses the fuel mixture from the previous cycle orcupying the airtight erankease As the piston continues to descend it also oxpeses the transfor ports The compressed mixture waiting in the crankease vow rushes through the ports and filla the combustion chamber while at the same tine sweeping any remaining burnt gases out the exhaust port 2 upstroke After reaching its lowest point of travel the piston begins to ascend und closes off the transfer ports At the same tine the piston s vpward movement creates a partial Vacuum in the crankcase AS the piston continues to ascend it closes off the ex haust port and begins to compress the mixture in tha combust ion chamber Meanwhile the bottom of the piston exposes the intake port and a fresh fual mixture is sucked into tho crank casc When the piston approaches top dead center ignition occurs and the piston once again descends to begin another cle As described ignition occurs once every 360 or more appropriately once every two strokes of Lhe piston one down aad one up Hence the term two stroke engine Time at 23 B T D COMPLETE DISASSEMBLY MINARELLI V1 ENGINE Please noto that al
15. l the lighting coil the points and the condensor Secondly there is a flywheel attached to the crankshaft and aligned hy means of a Woodruff key This flywheel or rotor contains four permanent magnets bonded to its outer These maqnets are equally spaced and the exact location is determined by the engine timing The primary ignition and lighting coils consist of enameled copper wire wound on a laminated iron core his laminated core is magnetic in nature and allows for good magnetic per meability yet keeps the Eddy Current losses low The enamel the copper wire is an electrical insulator that keeps the wire from shorting to itself thereby allowing it to be wound into many turns over itself When a copper wire known as a conductor is cut by mag netic lines of force a voltage is impressed in the conductor and current is for flew In order that the conductors are cut by the lines of force the magnets are mounted on the rotating Flywheel The voltage output of the coils is directly prozortional to the speed of rotation and the load placed on them Im the Minarelli engine the lighting coil has a voltage output of approximately volts at 25 watts max load The primary ignition coil puts out 12 volts at approximately 20 Watts to be used for accessories such as a stop light circuit Tbe primary ignition coil supplies the power to drive the ex ternal high tension coil as its primai A
16. l steps up to 15 can be done with the engine mounted on tho bike although it is much easier to do ton your workbench Remove air conveyor 55430 with 3 6x25 5450 Allen bolts and cooling fan with 4 Phillips screws to gain access to the magneto Please note that all threads on tho Minarelli are hand with the exception of the threads in the left han Using tho special Minarelli fly wheel tool 46990 to hold the mag neto and 14mm socket remove Aut from the center of Be very careful not to Scratch tne 2 coils They are cloar enamel coated to insulate tha wire and can be ruined by Insert the flywheel puller 6950 ali the way into the center of the magnato Hold the tool with a 200m wrench and turn the extracting boit with a 17mm wrench until popping sound is heard NOTE The magneto is on a tapered Shaft with wocdruff key If the extractor bolt is extremely hard to turn remove socket and rap extractor bolt smartly with plastic mallet No other tool such as a puller extractor may be used 11 the magneto It must be extracted only from the center threads or it will be warped 19 3 scribe a line on the stator plate and the engine casing marking it s position oa the engine Remove the two Phillips screws and lift out the stator plate 4 Using the Minarelli sprocket holding tool 6960 and a 174m wrench remove the sprocket nut and
17. oil only NO Middle phillips screw in Sing is correct oil level 1 Engine L left foorre 2 Remove air conveyor 3 Remove fan 5410 4 For convenience renove bearing for conveyor 5390 5 Rotate flywheel by hand in a clockwise direction until points are fully open check gap and ecessary reset point gap which should be 014 to 018 0 35 to O 40mm NOTE The correct point gap set al before the ignition timing operation be carried out NOTE 0 is top dead center A is 23 degrees before top 6 Remove blue and wires fron connector located above magneto 7 Connect resistence scale of meter NOTE Leave blue wire f 1b and battery or ond case of engine 3 Slowly move the flywheel by hand clockwise and observe the position of mark on flywheel in relation to scribe mark case when the points open loss of continuity Indicated by checking device the timing will be correct when the ivo marks line up NOTE IE the opening of the points occur before advanced or after retarded the marks line up the stator plate will have to be adjusced A To adjust stator place it will be necessary to remove the flywheel Slacken the screws securing the stator plate and nove the plate in the required direction if advanced move stator plate counterclockwise 1f retarded move stator plate clockwise Retighten all scr
18. or Securing Points 5920 1 nts 5930 4 cw for Securing Coils 5940 1 tor Condensor 5960 1 3970 1 5980 1 Coil Low voltage for 5990 1 Stat r 980mm 6010 1 Stator Com 6060 1 if 5920 5940 3140 soso 5890 5930 TABLE 5 MAGNETO 94mm MODEL 6876 23w s050 5140 6110 PART NO QUANTITY DESCRIPTION 5149 a Washer fma 5348 1 Magneto Complete w All Components 6030 1 Inductor Rotor 6050 1 Cam Adjusting for Points 6060 1 Points 6070 4 Screw for Securing Coils 6080 1 Screw for Securing Capacitor 6090 1 Capacitor 6110 1 Coil High Voltage for Ignition 6120 1 Greasing Felt 6130 1 Coil Low Voltage for Lights 6140 1 Holder for Felt 6150 1 Stator f94nm 6160 1 Stator Complete 6175 1 Coil External High Voltage for Ignition 8220 1 Screw for Securing Points 13 TABLE 6 MAGNETO 80mm CEV MODEL 6932 23w 6v PART NO QUANTITY DESCRIPTION 5140 4 Washer g nm 5360 1 Magneto Complete w All Listed Components 6070 4 Serew for Securing Coils 1 Screw for Securing Capacitor 6090 1 Capacitor 6190 1 Inductor Rotor Flywheel 6220 Screw for Securing Points 6230 1 Points 6240 1 Coil Primary for Ignition 6250 1 Coil Low voltage for Lights Gv 23 6260 i creasing Felt 6280 Stator 880 6290 1 Coil External High Voltage for Ignition Black 6300 1 Stater Complete ORDERING MAGNETO PARTS ALW
19. pedal clutch gear 5760 i Lock ring 5800 re moves shin 85790 and pedal cear 5750 from the pedal shaft 15740 TE 1 Kcyed side of crank goes magneto housing and will have shim it 2 The flat side of the drive gears goes toward the mag neto side and may have a shim on it also 3 The small gear of the idler gear 5710 faces the magneto Side of the engine cases with shin 5730 on each wide i a Renove G clips from piston 44490 with needle nose pliers NOTE When not expecting to split Case e g decarbonization always put a rag or paper towel in the top end of the cases under the piston to avoid dropping any clips dirt or broken ring parts into the cases of the engine which would force an unneccessary split ting of the cases 25 21 Using a piston pin extractor pre the piston pin 4480 about 3 4 of the way through the piston Remove icol and lift piston off of connect ould be removed he fore piston pin extractor is in stalled or rincs should be lined WD with brass pins so that they l not break up extraction of the pin 22 13 the brass bushing in the connect ing rod needs to be replaced you must first remove the old brass bushing 4470 install the now bush ing ream it out lnm see Technical Bulletin 004 end drill the three holes needed iz the connecting rod to provide lubrication to the slecve and piston pin NOT
20. s the rotor turns clockwise on the Hinarelli engine the points remain closed until the timing mark om the rotor lines up with the timine mark on the engine housing While the points are closed ail current is shunted to ground and mo ignition firing can occur As soon as the timing marks coincide the points crack open and current is routed throuch the primary winding of the external high voltage coil to the ground this causes a high voltage approximately 15 000 volts to be induced in the secondary winding of the external high tension coil This voltage shea appears across the 0 024 inch spark plug gap The voltage is sufficient gap and the plug fire The condensor acts as the spark suppressor to keep the points from arcing when they open It acts like a short cir Cuit the moment the points open but quickly becomes an open CONTINUED 10 Circuit to shunt the current to the cxternal high tension coil magneto as described has three outputs the light ing circuit tho accessory circuit and the ignition circuit All the outputs are A C alternating current Any devices which require the charging of a battery off the nagneto will require a rectifier to be placed in the circuit to change the current to D C TABLE 4 MAGNETO 80mm BOSCH MODEL KB6 8212 18w 6v PARTNO QUANTITY DESCRIPTION 5140 5 Washor 5900 1 Inductor Rotor 5910 i Screw f
21. shim 6020 the shaft with snap ring pliers renove snap ring 4860 shim 4850 and drive clutch 84870 Taz 12 Remove snap ring 4860 washer 4850 and gear for clutch 4890 to complete clutch disassembly 13 With a lon socket remove the four 5550 nuts and four 5540 washers from the cylinder head 4 You can remove the cylinder head 5500 cylinder 5480 and base gasket 5460 Head gasket 5490 will stay in tho cylinder head and may appear not to exist It can be removed with a small screw driver but generally need not be replaced or removed IF replaced be sure to replace with sane thick mess as head gasket 23 15 Renove the eleven 5250 6x30mm casing bolts from the magneto side of the engine cases 16 Instal1 Minarelli crank shaft extractor 26930 with the three long special bolts provided with the extractor d Tighech the crankshaft extractor and simultaneously tap the pedal shaft with a rubber mallet in order so evenly split the engine cases NOTE Tightening the crankshaft Gxtractar tool only will result tha top end of the cases split ting at an angle to the bottom cmi of the cases You must tap the pedal shaft for an even extract ion 24 19 With cases split you have access to aii internal qears and shins 1 Crank should be re unit 1480 pin 5720 can be 3 Spring 5770 can be removed from
22. t for Carburetor Intake Manifold 4410 1 Crankshaft Complete STUB PLANE 4420 1 Half shafz Clutch Side STUB PLANE 4430 1 Half Shaft Flywheel Side STUB PLANE 4440 i Connecting Pin 916mm w o Hole 4450 1 Roller Bearing 916 x 22 x l2mm 4460 1 Crankshaft Acsecbly Complete CONE 4470 1 Bushing 12 x 13mm for Connecting Rod 4480 1 Piston Pin 012 x 31 5mm 4490 2 Stop Ring for Piston Pin Available only in complete Assembly 4410 4500 4510 4520 4530 20 ENGINE Pistons w Parts 4480 4490 and Rings Standard 38 0mm Oversize 938 2mm Oversize 38 4mm Oversize 38 6mm 25 30 MPH ENGINE Pistons u Parts 1180 4490 and Rings Standard 938 2mm Oversize 239 0mm Oversize 939 2mm oversize 939 amm Oversize 939 6mm Oversize 839 8mm 4600 4610 4620 4630 RINGS FOR 20 MPH ENGINE Standard 38 x 2 5 x 1 5m Oversize 38 2mm Oversize 538 4mm Oversize 38 6mm TABLE1 MINARELLI ENGINE PARTNO QUANTITY DESCRIPTION RINGS FOR 25 30 MPH ENGINE 4640 2 Standard 238 8 x 2 5 x 1 5mm 4650 2 Oversize 039 07 4660 2 Oversize 839 20 4670 2 Oversize 039 4rm 4680 2 Oversize 39 6rm 4690 2 oversize 939 8mm NOTE Beginning January 1 1978 all Vl engines produced will be 49 4 cc for the 1 9 HP model The following parts apply to this new model 4535 1 standard 38 7 Piston 4635 1 Standard 38 7 Ring 5475 1 cylinder 38 7mm Cast Iron NOTE The cversizes for th
23. t side of cylinder I no mark appears install piste so that pins for piston rings face exhaust port 27 In magneto side install crank 34460 shim goes between crank and cases on this side Install drive shaft 4760 with shim shafted side first into magneto side These two shafts should hold their position in cases Place gasket and casing on clutch side placing clutch side up Place magneto side with drive shaft 4760 an crank 44460 on to clutch side and press together until all shafts line up together carefully with rubber mallet 28 With Srm Allen wrench draw cases together slowly until snug Tighten the six bolts in the magneto housing in a criss cross fashion first Then tighten the five remaining Casing bolts starting from the lower part of the engine Torque to 8 0 ft lb torque Double check all bolts with a torque wrench At this point make sure all shafts spin freely There should be no play in any shaft at all Place Woodruff key in its position on Magneto side of crankshaft Install stator plate using the two Phillips head screws 4740 making sure that scribe marks ling Mount the flywheel 6190 making sure that Woodruff key is positioned correctly in keyway Install flywheel nut and with the flywheel holding tool 16990 and limn socket torque to 34 ft lb 2 Install clutch gear 4890 washer 44850 and snap ring 4860 on re
24. washer The sprocket can be removed with two large screwdrivers being careful not to damage the cases oil from the casing wich a Smm Allen vronch remove the six 6x35 5330mm and che one 6x15 5320ms clutch casing screws to remove clutch casing 5260 and gasket 85270 20 6 The clutch cover contains lever for clutch arm 45100 and two spring leafs 45180 and 45190 there is any noticeable wear on spring leafs replace and note wearing on starter plate beari he spring leafs Starter arm may be removed by Screw This becones necessary when the 8xlOmm cable holder is broken 7 With a screwdriver remove lock ring 5090 from hub his allow retainer cap 5080 retainer for cap return spring 5070 and cap return spring t 060 to be removed 8 Using Minarelli clutch tool 6970 und linn socket remove clutch mut 6270 and washer 5030 new clutch 10 Screw 111 clutch puller screws into clutch body with tool 6980 making sure that they are all the way in Insert long screwdriver through tool resting it against the pedal shaft and tighten the extracting bolt with Lamm wrench NOTE Observe previous not Fenoving objects With a pair of snap ring pliers remove snap ring 6000 shim 14x20nm 16020 and engine sprocket with how 4900 You can now remove the brass clutch bushing 6040 and the remaining
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