Microsoft Word - Minarelli V1 Service Manual.doc
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1. 690 TABLE 7 DELL ORTO CARBURETOR PART NO QUANTITY DESCRIPTION 2200 1 Screw for Securing Clamp 5660 1 Housing for Air Filter 5880 3 Clamp for Air Filter Housing 6320 1 Cover for Mixture Chamber 6330 3 Float Bowl 6340 3 Locknut for Throttle Cable Adjuster 6350 3 Nut for Mounting Bolt 6360 3 Fuel Filter 6370 1 Float 637 1 Jet 47 for 17 6380 3 Jet 49 for 20meh 6390 1 Jet 451 for 25 30mph above 2000 feet 6400 1 Jet 452 for 25 30mph 6410 1 Gasket for Mixture Chamber 6420 1 Gasket for Air rilter 6430 1 Gasket for Float Bowl 6440 1 Gasket for Fuel Intake Screw 6450 1 Choke Lock 6460 1 Spring for Choke Lock 6470 1 Return Spring for Choke 6480 1 Return 5 ng 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 G Fuel Intake 6540 3 Gasket Insulating 6550 1 Needle valve 6560 1 Guide for Throttle Cable Old 6570 3 Choke Arm Short 6589 1 Choke Arm Long 6590 3 Slide for Throttle 6600 3 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 6650 1 Adjuster for Throttle Cable 6660 1 Housing for Air Filter Sclf supporting 6680 1 72 Guide for Throttle Cable 6690 1 Filter Element 6117 6710 1 Nut for Housing Bolt 672. 22 12 Remove snap ring 4860 washer 4850 and gear for clutch 54890 to complete clutch disassembly 18 with a l0mm socket remove the four 5550 nuts and four 5540 washers from the cylinder head 14 You can remove the cylinder head 5500 cylinder 5480 and base gasket 5460 Head gasket 5490 will stay in the 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 same thick ness as head gasket 23 15 remove the eleven 5250 6x30mm casing bolts from the magneto side 0f the engine cases 16 Install Minarelli crank shaft extractor 6930 with the three long special bolts provided with the extractor 17 Tighten the crankshaft extractor and simultancously tap the pedal shaft with a rubber mallet in order to evenly split the engine cases NOTE Tightening the crankshaft extractor tool only will result in the top end of the cases split ting at an angle to the bottom end of the cases You mist tap the pedal shaft for an even extract ion 24 18 with cases split you have access to all internal gears and shims 1 Crank should be re placed whole unit 74480 2 Idler pin 5720 can om the engine cases Spring 5770 can be removed from pedal clutch gear 5760 removes 4 Lock ring 5800 re
3. 5020 4 Pin for Securing Spring 5030 a Washer for Brake Shoe Bearing Nut 5040 1 Locknut for Brake Shoe Bearing STUB PLANE 5050 1 Cotter Pin for Nut STUB PLANE 5060 1 Cap Return Spring 5070 1 Retainer for Cap Return Spring 5089 1 Retainer Cap for Starter 5030 2 Lock Ring for Cap 5100 3 Lever for Clutch TABLE1 MINARELLI ENGINE PART NO QUANTITY DESCRIPTION 5110 1 Grommet for Clutch Lever 5120 1 Return Spring for Clutch Lever 5130 1 Set Screw for Clutch Lever 5140 3 Washer fimm CEV 5150 1 Bolt for Securing Clutch 5 A x 8nm 5160 E Bridce for Clutch Adjuster 5170 4 Clutch Lever Adjuster 5180 1 Spring Leaf Upper 5190 1 Spring Leaf Lower 5200 3 lialf Casing Clutch Side 5210 p Nalf Casing Flywheel Side for Stator f E 94 5220 1 Half Casinc Flywheel Side for tator E 80 5230 1 Gasket for lialf Casing Center 5240 3 Dowel for Crankease 10 x 40mm 5250 11 Bolt TCCE 6 MA x 30mm 5260 1 Cover Clutch Side 5270 3 Gasket for Clutch Cover 5280 3 Cap Oil Feed 5290 1 Gasket for Cap 12mm 5300 2 Bolt TCB 6 MA for Oil Level and Drain 5310 2 Gasket for Bolt 6mm 5320 3 Bolt TCCE 6 M x l5nm 5330 6 Bolt TCCE 6 M x 35mm 5340 1 Magneto Flywheel Complete 239 w External h Voltage Coil Stator 94mm CEV Model 6876 5350 1 Magneto Flywheel Complete 18 6V w Internal High Voltage Coil Stator 80mm Bosch KB6 B212 5360 1 Magneto Flywheel Comp
4. 5950 1 Voltage for Lights 5990 1 6010 1 6060 1 HHEN ORDERING MAGNETO PARTS AND MODEL NUMBER PRINTED ON YS SPECIFY THE MAKE OTOR BOSCH MODEL K86 B212 12 TABLE 5 MAGNETO A 94 MODEL 6876 23w 6v PARTNO QUANTITY DESCRIPTION 5140 4 Washer 4mm 5340 1 Magneto Complete w All Components 6030 3 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 994mm 6160 1 Stator Complete 6175 1 Coil External iigh Voltage for Ignition 6220 1 Screw for Securing Points zig TABLE 6 MAGNETO A 80mm CEV MODEL 6932 23w 6v PART NO QUANTITY DESCRIPTION 5140 4 Washer fire 5360 3 Magneto Complete w All Listed Components 6070 4 Screw for Securing Coils 6080 1 Screw for Securing Capacitor 6090 1 Capacitor 6190 3 Inductor Rotor Flywheel 6220 3 Screw for Securing Points 6230 1 Points 6240 1 Coil Primary for Ignition 6250 i Coil Low voltage for Lights 6y 23W 6260 2 Greasing Felt 6280 1 Stator 80 6290 3 Coil External High Voltage for Ignition Black 6300 3 Stator Complete 6220 6070 6249 5150 JEN ETA TABLE 7 DELL ORTO CARBURETOR 6550 6370 5880
5. 0 fr ibs Ze in housing with four phillips serews fan and fancover with three allen bolts in that order Remount engine to frame mount carburetor with intake pipe install spark plug refill engine with SAE 20 W non detergent oil only NOTE Middle phillips screw in g is correct oil level Remov Remove Remove g for conveyor 5390 hand in a clockwise direction until points check and if necessary reset point gap 015 to 018 0 35 to 0 40mm ponm NOTE 0 is top daad center A is 230 degrees before top dead center 6 Remove blue and red wires from connector located above magneto 7 Connect continuity checker buzz box bulb and battery or resistance scale of meter between red wire and case of engine NOTE Leave blue wire free Slowly move the flywheel by hand clockwise and observe the position of mark A on flywheel in relation to scribe mark on case when the points open loss of continuity indicated by checking device the timing will be correct when the two marks Line up NOTE If the opening of the points occur before advanced or after retarded the marks line up the stator plate will have to be adjusted A To adjust stator place it will be necessary to remove the flywheel Slacken the screws securing the stator plate and move the plate in the required direction advanced move stator plate counterclockw
6. 4910 1 Shim 13 x 2lmm 4920 X Bushing for Clutch 4930 3 Complete Centrifugal Clutch S P 4940 1 Bearing for Clutch S P 5030 1 Washer for Nut 5040 1 Locknut for Brake Shoe Bearing 5050 P Cotter Pin for Nut 5570 1 Shim 13 7 x 20 8 S P 6300 1 Snap Ring for Shaft CONE 6020 2 Shim 14 x 20 CONE 6040 Bushing for Clutch CONE 6180 1 Complete Centrifugal Clutch CONE 6200 1 Bearing for Clutch Shoe CONE 6270 1 Locknut for Brake Shoe Bearing CONE MOUNTING WITH STUB PLANE MOUNTING WITH CONE t 040 4460 4420 PG 4910 4940 5030 4410 TABLE 3 DEALER TOOL KIT FOR MINARELLI Vi ENGINE PART NO QUANTITY DESCRIPTION 6900 1 Point Timer 6920 1 Intermediate Sprocket Extractor 6930 1 Crankshaft Extractor 6950 1 Flywheel Puller CEV Only 6960 1 Sprocket Holding Tool 6970 1 Clutch Tool 6980 3 Clutch Puller 6990 1 Plywheel Tool 1600 1 Wrench for Cap adjuster 1610 1 Wrench for Steering Lock Nut OWNER TOOL KIT PART NO QUANTITY DESCRIPTION 1246 1 1620 1 1630 1 P 1200 13 1620 MINARELLI ELECTRICAL SYSTEM TI RY OF OPERATION The C E V Magneto used on the Minarelli engine consists of two basic components First the magneto contains a STATOR PLATE mounted on the left side engine housing This STATOR PLATE holds the primary ignition coil the lighting coil the points and the condensor Secondly there is a flywheel attached to the cr
7. MINARELLI ENGINE PARTNO QUANTITY DESCRIPTION 4240 1 Gasket for Carburetor Intake Manifold 4410 1 Crankshaft Complete STUB PLANE 4420 1 Half shaft Clutch Side STUB PLANE 4430 1 Half Shaft Flywheel Side STUB PLANE 4440 1 Connecting Pin 16 w o Hole 4450 3 Roller Bearing 016 x 22 x 12mm 4460 1 Crankshaft Assembly Complete CONE 4470 3 Bushing 12 x 13mm for Connecting Rod 4480 1 Piston Pin 12 x 31 5mm 4490 2 Stop Ring for Piston Pin Available only in complete Assembly 4410 Pistons w Parts 4480 4490 and Rings 4500 1 Standard 38 4510 Oversize 38 2mm 4520 1 Oversize 38 4 4530 1 Oversize 38 6mm 25 30 ENGINE Pistons W Parts 1480 4490 and Rings 4540 1 Standard 38 8mm o 1 Oversize 939 Omm 4560 1 Oversize 39 2mm 4570 1 Oversize 39 4mm 4580 1 Oversize 39 6 4590 1 Oversize 39 8mm RINGS l OR 20 MPH ENGINE 4600 2 Standard 38 x 2 5 x 1 5mm 4610 2 Oversize 38 2mm 4620 2 Oversize 38 4mm 4630 2 Oversize 38 6mm TABLE1 MINARELLI ENGINE PART NO QUANTITY DESCRIPTION RINGS FOR 25 30 MPH ENGT 4640 2 Standard 038 8 x 2 5 x 1 5mm 4650 2 Oversize 39 0nm 4660 2 Oversize 39 2nm 4670 2 Oversize 039 488 4680 2 039 628 690 2 939 87 NOTE Beginning January 1 1978 all Vl engines produced will 4533 4635 5475 NOTE be 49 4 cc for the 1 9 HP model apply to this new model he fo
8. and 10mm nuts Tighten cylinder head nuts in a criss cross pattern and torque them to 8 0 ft ib 32 TIMING ENGINE Rotate the flywheel bi clockwise d are fully and if gap which should 0 018in 0 35 0 40mm The correct point gap set essential before the igni ming operation can be carried Tt is better to set the points at 0 018in as the points wear together and will remain in area of correct adjustment 1662 To set timing rotate the m ywheel in a clockwise direction note arrow on flywheel until thi first line on the flywheel aligns with the arrow on easing This position is 23 degrees before top dead center The points should just start to open at this align ment Proper alignment can ba checked by removing the blue wire from any round and connecting the red wire to a continuity tester buzz box multi meter etc and to ground T33 POINTS MAGNETO To adjust the stator plate loosen e two phillips screws and move the plate counter clockwise if far advanced and clockwise if retarded Retighten screws and re check timing Note If opening occurs before the mark lines up the timing is said to be advanced The second line on the magneto flywheel top dead center Place chain sprocket_on shaft replace washer and 178 nut and tighten holding the sprocket with tool 6960 Torque to 32
9. cases in order to properly Grill the bottom two holes in the connecting red of assembly 34460 ASSEMBLY OF MINARELLI ENGINE NOTE When reassembling the Minarelli engine replace all seals and caskets All parts removed and to be reused should be thoroughly cleaned and lightly oiled 13 gaskets should be given a light coat of grease to help you seat them into place and also to insure a better scal All shims used in the Minarelli fit properly on the shafts AS 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 ring to fit on if too thick Install idler shim 5730 idler gear 5710 and shim 5730 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 EE EE side of casing with shim 5790 3 pedal clutch 5760 with spring on it pedal gear 5750 shim 45790 and snap ring 5800 which should be installed on pedal shaft previous to insertion in the case Then put on final shim 5790 on shaft next to snap ring Make sure that S or gt On piston points to exhaust sidc of cylinder If no mark appears install pis
10. on the rotor lines up with the timing mark on the engine housing While the points are closcd all current is shunted to ground and no ignition firing can occur As soon as the timing marks coincide the points crack open an current is routed through 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 hich tension coil This voltage then appears across the 0 024 inch spark plug gap The voltage is sufficient to jump this gap and the plug fires The condensor acts as the spark suppressor to keep the points from arcing when they open It acts like a short cir Guit the moment the points open but quickly becomes an open CONTINUED 10 circuit to shunt the current to the external hich tension coil The magneto as described has three outputs the light ing circuit the accessory circuit and the ignition circuit 11 the outputs are A C alternating current Any devices which require the charging of a battery off the magneto will require a rectifier to be placed in the circuit to change the current to D C 2335 TABLE 4 MAGNETO 2 80mm BOSCH MODEL KB6 B212 18w 6v PARTNO QUANTITY DESCRIPTION 5140 5 7466 5900 1 Inductor Rotor 5910 1 Screw for Securing Points 5920 3 Points 5930 4 Screw for Coils 5940 1 er 5960 1 5970 1 Voltage for Ignition
11. 1 SERVICE MANUAL MINARELLI V1 ENGINE 1978 Minarelli U S A Inc All Rights Reserved ke e No part of this work may be reproduced without the express written permission of the Copyright Holder Another shipment from M MOBILI MOON Accessories Mopeds Tal 201 438 5700 x IC MSWESTCONMERCIAL AVENUE MARINA MOBILI INC MOONACHIE 07074 USA Parts and Motors Exporters ImportersiDistributors A TABLE OF 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 SECTION 2 MAGNETOS Minarelli Electrical System Theory of Operations Table 4 Bosch Model KB6 B212 able 5 CEV Model 6876 Table 6 CEV Model 6932 SECTION 3 CARBURETOR Table 7 Dell Orto Carburetor SECTION 4 ENGINE DISMANTLING Minarelli Engine Two Stroke Dismantling Vl Minarelli Engine 5555 5 SECTION 5 ASSEMBLING V1 MINARELLI ENGINE Assembling Vl Minarelli Engine Timing Vl Minarelli Engine eene Technical Data for Vl Minarelli Engine Torque specs 10 32 13 14 16 37 39 27 35 37 38 32 8 3 TABLE1
12. 20 1 Bolt for Securing Air Filter Housing 25840 1 Carbyretor SHA 14 9 Max Jot 49 Deli Orto for 20mph 45650 1 rbyretor Dell Orto for 25 30 Multiple parts Found on engine drawing 16 Minarelli Engine Theory The Two Stroke Engine ENGINE OPERATION All Vl engines regardless of the top specd 17 20 25 30 are piston port type two strokes following cussion of each type will provide some insight into how they work and may someday prove very helpful in troubleshooting PISTON PORT TWO STROKE The piston port two stroke is the simplest of all engines commonly seen in motorcycles and moped application It has only three main movinc parts and uses ports rather than valves as in four stroke engines to requlate intake and exhaust flow These ports are all located the cylinder wall and are opened and closed by the pistons movement Their functions are intake Port Admits fresh fuel mixture from the carburetor into the crankcase Transtar Ports Provide passages for the fuel mixture between the crankcase and combustion chamber Exhaust Port Releases burat gases from the combustion chamber into the cxhaust pipe Basically with the Minarelli V1 engine this is what happens during a 360 rotation of the crank shaft beginning with the at top dead center Stroke The piston descends from the previous cycle and expose the exhaust port letting out the expanding bur
13. E Se Oi Bolt for securing spring leaves 5840 Nu Wut for securing intermediate sprocket 4840 Chi Checknut for securing centrifugal clutch LUCS 024 inches BOSCH W 145 TI Gi Marelli CW 5H Champion 186 L89CM 3 NKG 8588 cold weather 5688 warm weather t screw for cluteh lever 5130 li casing and side cover bolts take manifold bolts 5610 l level and drain screws ts for securing head 5550 ecknut for magneto flywheel 4750 with cone coupling 6270 38 KG MT 18 ER DEE EE FOES RE ERC Foot Pounds 25 7 3 o 7
14. ankshaft and aligned by means of a Woodruff key This flywheel or rotor contains four permanent magnets bonded to its outer rim These magnets are equally spaced and the exact location is determined by the engine timing The primary ignition and lighting coils consist of enameled por wire wound on a laminated iron core is laminated Core is magnetic in nature and allows for good magnetic per meability yet keeps the B dy Current losses low The enamel on the copper wire is an electrical insulator that keeps the wire from shorting to itself thereby allowing it to be wound inte 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 forced to flow 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 Proportional to the speed of rotation and the load placed on then In the Minarelli engine the lighting coil has a voltage output of approximately 6 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 The primary ignition coil supplies the power to drive the cx ternal high tension coil as its primary function As the rotor turns clockwise on the Minarelli engine the points remain closed until the timing mark
15. im for this shaft fits on outside of drive Install drive clutch 44870 shim 34850 and snap ring 54860 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 46380 washer 5030 and clutch nut 5040 on shaft 4460 Install clutch body 6180 washer 5030 and clutch nut 5040 on shaft With Minarelli clutch tool 6970 hold clutch body and torque nut to 21 7 ft 1b Install spring 5060 retainer cap for spring 5070 retainer cap 5080 press into housing lining up retainer with housing in slots Install leck ring 5090 into groove and check retaining cap for starter for proper movement which is approx imately lmm in and out 31 Install clutch cover gasket 5240 and clutch housing 5260 with the six 15 and one 6x35mm Allen bolts Torque clutch casing bolts 8 0 fr lb stall base gasket om 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 The tolerance between cylin der and piston should be 0 003in to 0 005in 080 085mm NOTE Cylinder should be lightly oiled previous tc installation Install head gasket 5490 and cyl inder head 5500 four washers
16. ise retarded move stator plate clockwise C Retighten all screws and reassemble side of engine NOTE Be sure to tighten magneto check nut securely 36 Technical Data ENGINE Model Minarelli VI Single Cylinder 2 stroke Cubic Capacity 47 6 cc 20 mph 49 4 cc 25 and 30 mph Bore 38 0 20 mph 38 8 mm 25 and 30 mph Stroke 42 0 mu Compression Ratio 8 to 1 Horsepower 4800 rpm 1 00 20 mph 1 90 25 and 30 mph Piston to wall clearance 0025 005 rebore ar 002 clearance Ring Gap 012 Ignition and Lighting Flywheel 6 volt magneto with 23 watt capacity and external 1 asion coil stop light op erated by grounding of low tension ignition coil 1 Mixture Minarelli synthetic oil 64 3 Synthetic oil 40 to 1 mixture of recomended ratio on can 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 tooth FINAL TRANSMISSION AND RATIO Driven by single row chain 1 2 x 3 16 ll tooth engine sprocket to 42 tooth wheel sprocket ratio 2 73 to 1 IGNITION TIMING 23 B T D C measure on flywheel external diameter or 079 B T D CONTACT BREAKER GAP 014 to 018 inches 35 to 40 mn 37 SPARK D a D TORQU
17. len wrench remove the six 6x35 5330mm and the one 6x15 5320mn clutch casing screws to remove clutch casing 5260 and gasket 5270 OS 6 The clutch cover_contains lever for clutch arm 5100 and two spring leafs 45180 and 45190 17 there is any noticeable wear on spring leafs replace and note wearing on starter plate bearin opposite the spring leafs NOTE Starter arm may be removed by screw This becomes necessa when the 8xl0mm cable holder is broken 7 With scrowdriver remove lock ring 5090 from hub This will allow retainer cap 15080 retainer for cap return spring 5070 and cap return spring 5060 to be removed 8 Using Minarelli clutch tool 6970 and l3nm socket remove clutch nut 6270 and washer 5030 Note new clutch 21 9 Serew Minarelli clutch puller screws into clutch body with tool 16980 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 a 13mm wrenci Observe previous note ving objects from tapered shafts 10 With a pair of snap ring pliers remove snap ring 6000 shi 14x20mm 16020 and engine sprocket with housing 4900 You can now remove the brass clutch bushing 6040 and the remaining shin 6020 on the shaft 11 with snap ring pliers remove snap ring 4860 shim 4850 and drive clutch 84870
18. lete 23W 6 w External High Voltage Coil Stator 80mm COV Model 6932 5370 1 Wire Guide on Crankcase for Internal High Voltage Coil 5380 re Guide on Crankcase for External High Voltage Coil 5390 1 Bearing for Aluminum Air conveyor only 5400 1 Bearing for Plastic Air conveyor only 5410 1 Cooling Fan 5420 4 Bolt TCS 4 MA x l0mm for securing Fan 5430 3 Air Conveyor Aluninum 5440 1 Air Conveyor Plastic 5450 3 Bolt TCCE 5 MA x 25mm 5460 1 Gasket for Cylinder Base 5470 1 Cylinder 38mm Cast Iron Mo 30km for 20mph TABLE1 MINARELLI ENGINE PART NO QUANTITY DESCRIPTION 5480 1 Cylinder 38 8 mm Cast Iron for 25 301 Engine 5490 Gasket for Cylinder Head STD 0 7mm 5500 1 Engine Head 5510 1 Spark Plug Bosch W 145 TI or Eauivalent 5520 3 Cover for Spark Plug Rubber 6 5530 4 HOLD DOWN STUD 6 MA x 136mm for Cylinder Head 5540 5 Washer Chanfered 06nm 5550 6 Nut for Stud Bolt 6 MA x 6mm 5580 D Side Carburetor Manifold 612mm for 30mph and 2 10 Engine 5590 1 Side Carburetor Manifold 8 5 mm for 25 30mph 5600 1 Side Carburetor Manifold f7 25mm for 20 mph 5630 1 Bolt 6 MA x 38 mn for Securing Cover 5620 S Wire Guide for Spark Plug Wire 3630 3 Grommet for Spark Plug Wire Rubber 5640 1 Carburetor SHA 14 9 Max Jet 49 Dcll Orto for 20mph 5650 3 Carburetor SHA 14 12 Max Jet 52 Dell Orto for 25 30mph 5660 1 Filter Housing S
19. llowing parts 1 Standard 38 7 Piston 3 Standard 38 7 Ring 3 Cylinder 38 7mm Cast Iron The oversizes for the 38 7mm Piston and Rings are 028 8 39 639 2 39 4 039 6 939 8 TABLE1 MINARELLI ENGINE PART NO QUANTITY DESCRIPTION 4700 2 Bearing fcr 11 x 40 x 12mm RIV 01 4710 2 Seal for Crankshaft 917 x 35 x Smm 5720 3 Key for Magneto Flywheel CEV 4730 3 Key for Magneto Flywheel BOSCH 4740 Screw for Securing Stator TCB 4 MA x 10mm 4750 a Check Nut for Magneto Flywheel 4750 1 Drive Shaft 4770 2 Bearing 15 x 35 x limm RIV 02A 4780 3 Shim for Bearing 35mm 4790 3 Oil Seal 25 x 24 x 5mm 4800 1 Sprocket Intermediate for 9T f 4810 1 diate for 107 4820 3 Sprocket Intermediate for 117 for 30mph 4830 1 Washer for Nut 910mm x 0 8mm thickness 4840 1 Nut for Intermediate Sprocket 4850 2 Shim 15 x 21mn 4860 2 Snap Ring for Shaft 615mm 4870 3 Drive Clutch 4880 1 Gear Set Complete w Parts 4890 amp 4900 4890 1 Gear for Clutch w Plate 2 53 4900 7 Engine Sprocket w Housing 2 15 4910 2 Shim 913 x 21mm STUB PLAN 4920 1 Bushing for Clutch STUB PLANE 4930 3 Clutch Centrifugal Complete STUB PLANE 4940 3 Bearing for Clutch Shoe STUB PLANE 4950 2 Clutch shoe 4960 2 Clutch Shoe Complete w Parts 4970 amp 4960 4970 2 Plate for Clutch Shoe 4980 2 Screw for Securing Plate TSP 4 x 12mm 4990 4 Spring for Brake Pad 5000 4 Brake Pad 5010 2 Return Spring for Clutch Shoe
20. moves shim 5790 and pedal gear 85750 from the pedal shaft 5740 18 NOTE 1 Keyed side of crank goes into magneto housing and will have shim on 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 shim 5730 on each side 20 Remove G clips from piston 4490 with needle nose pliers 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 21 Using a piston pin extractor press the piston pin 4480 about 3 4 of the way through the piston Remove tool and lift piston off of connect ing rod NOTE Rings should be removed be fore piston pin extractor is in stalled or rings should be lined up with brass pins so that they Will not break up on extraction of the pin 22 1 the brass bushing in the connect ing rod necds to be replaced you must first renove the old brass bushing 84470 install the now bush ing ream it out Imm see Technical Bulletin 004 and drill the three holes needed in the connecting roa to provide lubrication to the sleeve iston pin This step will require split ting of the
21. n bolts ar cooling fan with 4 Phillips screws to gain access to the magneto Please note that all threads on the Minarelli are right hand with the exception of the threads in the left hand crank arm Using the special Minarelli 1 wheel tool 6990 to hold the ma neto and a 1488 socket remove the nut from the center of magneto Be very careful not to ch the 2 coils They are clear enamel coated to insulate the wire and can ruined by scratching Insert the flywheel puller 6950 all y into the center of the magneto Hold the tool with a 20mm wrench and turn the extracting bolt with a l mm wrench until a popping sound is heard NOTE The magneto is on a tapered Shaft with woodruff 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 Gear puller extractor may be used to pull 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 on the engine Remove the two Phillips screws and lift out the stator plate 4 95489 the Minarelli sprocket holding tool 6960 and a l7mm wrench remove the sprocket nut and washer The sprocket can be removed with two large screwdrivers being careful not to damage the cases S prain the oil from the casing With 5mm Al
22. nt gases Simul taneously the piston s downward movement compresses the fuel mixture from the previous cycle occupying the airtight crankcase the piston continues to descend it also exposes the transfer ports The compressed mixture waiting in the crankease now rushes through the ports and fills the combustion chamber while at the same time Sweeping any remaining burnt gases oyt the exhaust port E 2 Upstroke After reaching its lowest point of travel the piston begins to ascend and closes off tne transfer ports At the same time the piston s upward 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 the combust on chamber Meanwhile the bottom of the piston exposes the intake port and a fresh fuel mixture is sucked into the crank case When the piston approaches top dead center ignition occurs and the piston once again descends to begin another cycle As described ignition occurs once every 360 or more appropriately once every two strokes of the piston one down and one up Hence the term two stroke engine Time at 23 B T D C d COMPLETE DISASSEMBLY MINARELLI V1 ENGINE Please note that all steps up to 5 can be done with the engine mounted on the bike although it is much easier to do it on your workbench Remove air conveyor 5430 with 3 6x25 5450 Alle
23. te so that pins for piston rings face exhaust port 27 In magneto side install crank 44460 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 and crank 4460 on to clutch side and press together until all shafts line up Tap together carefully with rubber mallet 28 With Smm Allen wrench draw c together slowly until snug 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 1b torque Double check all bolts with a torque wrench 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 line up Mount the flywheel 6190 making sure that Woodruff key is positioned correctly in keyway Install flywheel nut and with the flywheel holding tool 6990 and l4mm socket torque to 34 ft lb 29 Install clutch gear 4890 washer 4850 and snap ring 4860 on rear drive sprocket NOTE Larger diameter sh
24. upported by Clamp 5670 3 Gasket for Muffler 5680 1 Muffler Short below engine 5690 3 Bolt 7 MA x 20mm for Securing Muffler 5700 3 Washer Chanfered 7 5710 3 Idler 2 16 21 Teeth 5720 1 Pin 12 46mm for Idler 5730 2 Shim 22 x 17mm 5740 1 Shaft for Pedal 5750 1 Gear z 27 for Pcdal 5760 a Clutch for Pedal Sliding 835 1 8 5770 1 Spring for Sliding Clutch 5780 1 Guide Pin for Spring 08 5 x 24mm 5790 3 Shim gl6mm 5800 1 Lock Ring fl6mm for Pedal Shaft 5810 1 Crank for Right Pedal marked with a D 5820 3 Crank for Left Pedal 5830 2 Pin for Crank Complete w Nut and Washer 5840 1 Bolt 6 MA l2mm for Securing Leaves 5850 1 Cap for Pedal Shaft 5860 2 Lock Washer 96mm 5870 2 Stud 34 6 MA x 23mm for Muffler 5880 d Clamp for Securing Filter Housing 5 1 6 TABLE1 MINARELLI ENGINE PART NO QUANTITY DESCRIPTION 5890 Gasket Set Complete w 5230 5270 5460 5490 4240 and 5670 6000 2 Snap Ring for Shaft l4nm CONE 6020 2 Shim 14 x 20mm CON 6040 1 Bushing for Clutch COI 6180 Clutch Centrifugal Complete CONE 6200 1 Bearing for Clutch Shoe CONE 6270 1 Locknut for Brake Shoe Bearing CONE 7050 4 Screws for plastic air conveyor TABLE2 CLUTCH FOR MINARELLI ENGINE PART NO QUANTITY DESCRIPTION 4410 4 Complete Crankshaft Assembly S P 4420 1 Half Shaft Clutch Side S P 4460 1 Complete Crankshaft Assembly CONE
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