; SERVICE MANUAL MINARELLI V1 ENGINE s§ © 1978 inaredls U-s-. Ine. pe reproduced without the express written permission of the Copyright Holder. Another shipment from, Telex: 132486, M.MOBILLMOON Accessories, Mopeds Tel: 201-438-5700 anna ic Petecouaecn eens pli ~ MARINA MOBILIING. iooNacHiE, N.J.07074 © USA Parts and MotorsTABLE OF CONTENTS Service Manual for MINARELLI V1 Engines secTIOy 1 ' Minarelli V 1 Engine All Models Table 1 - Minarelli V1 Bngine - zs Table 2 - Clutches for Minarelli V1 Engine ---+-++.++ Table 3 - Dealex Tool Kits for Minarelli Sngines - secrion 2 MAGNETOS Minarelli Electrical Systen Theory of Operations Table 4 - bosch Model KB6-B212 « able 3 = CEV Model 6876 . Table 6 - CEV Model 6932 --22ee eee eeee reece eect eee eee SECTION 3 - CAREURETOR Table 7 - Dell'orto Carburetor SECTION 4 ENGINE DISMANTLING Minarelli Engine~Two-Stroke Theory «+++ Dismantling V1 Minayelli Engine SECTION 5 ~ ASSEMBLING V1 MINARELLI ENGINE Assembling VL nazelli Engine - ‘Timing VL Mina: 11i Engine ++ Technical Duta for Vl Minarelli Bngine ++ Torque specs 20 12 a wu 16 uv 19 27 as 37 382, F0748059, S155 AE =O) po oO =| < =TABLE1 MINARELLI ENGINE PART NO. QUANTITY DESCRIPTION 4240 1 Gasket for Carburetor Intake Manifold 4410 1 Crankshaft, Complete, STUB PLANE 44208 1 Half-sheft, Clutch Side, STUB PLANE 4430" 1 Half Shoft, Plywhee! Side, STUB PLANE 4410 1 Connecting Pin, BL6mm w/o Hole 4450, 1 Roller Searing $16 x 22 x 12mm 4460 1 Crankshaft Assembly, Complete, CONE 4470 1 Bushing, $12 x 13mm for Connecting Rod 4480 1 Piston Pin, g12 x 31.5mm 4490 2 Stop Ring for Piston Pin * Available only in complete Assembly (#4410) 20 NPH_RNGINE Pistons w/Parts 4480, 4490 and Rings 4500 1 Standard 938. 0mm 4510 1 Oversize 938. 2mm 4520 1 Oversize 938. 4mn 4530 1 Oversize 938. 6mm 25/30 MPH ENGINE Pistons w/Parts 480, 1490 and Rings 4540 1 Standard 938. 9mm 4550 1 Oversize 939. Omn 4560 2 Oversize 939. 2mm 4570 1 Oversize 939. 4mm 4580 1 Oversize 939. 6mm 4590 1 Oversize 939.8mm RINGS COR 20 MPH ENGINE 4600 2 Standard 938 x 2.5 x 1.5mm 4610 2 Oversize $38. 2mm 4620 2 Oversize #28.4mm 4630 2 Oversize §38.6mmTABLE1 MINARELLI ENGINE PART NO. Quantity DESCRIPTION GIN 4640 2 Standard 38.8 x 2.5 x 1. 4650 2 Oversize §39.0mn 4660 2 Oversize £39. 4670 2 Oversize 939.4mi 4680 2 Oversize 939. 6m: 4690 2 Dversize 939. 8nm Beginning January 1, 1978 all V1 engines produced will be 49.4 cc for the 1.9 HP model. ‘he following parts apply to this new model. 4535 2 Standard 38.7 Piston 4635 x Stanéard 38.7 Ring 5475 1 Cylinder 38.7mm Cast Iron Phe oversizas for the 38.7nm Piston and Rings are 938.8 - $39 - $39.2 - 939.4 - 939.6 - 939.8TABLE 1 MINARELLI ENGINE PARTNO. QUANTITY DESCRIPTION 4700 2 Bearing for #11 x 40 x 12mm, RIV 01 4710 2 Seal for Crankehaf=, $17 x 35 x 8mm 4720 L Key for Magneto Flywheel (CHY) 4730 L Key for Magneto Flywheel (BoscH) 4740 3 Screw for Securing Stator, TCB 4HA x 10mm 4750 1 check wv Magneto Flywheel 4760 1 Drive Shaft 4770 2 Bearing #15 x 35 x linn 02: 4780 1 Shim for Bearing, 635mm 4790 3 Oil Seal, B15 x 24 x 5mm 4800 1 Sprocket, Intermediate for 9T for 20mph 4610 1 Intermediate fer 10% Zor 25mph 2-10 Engine 4820 1 Sprocket, Intermediate for 117 Zor 30mph 4830 1 Washer for Nut £10mm x 0.8mm thickness 4840 1 Nut for Intermediate Sprocket. 4850 2 Shim, 615 x 21m 4860 2 Snap Ring for Shaft, 915mm 4870 2 Drive Clutch 4800 1 Gear Set, Complete w/ Parts 4890 & 4900 4890 1 Gear for Clutch w/Plate, 2-53 4900 a Engine Sprocket w/Housing, 2-15 4910 2 shin, 913 x 2inm, STUB PLAN 4920 1 Bushing for Clutch, STUB PLANE 4930 1 Clutch, Centrifugal, Complete, STUB PLANE 4940 1 Bearing for Clutch Shoe, STUB PLANE 4950 2 Clutch shoe 4960 2 Clutch Shoe, Complete w/Parts 4970 & 4980 4970 2 Plate for Clutch shoe 4980 2 Screw for Securing Plate, TSP 4 MR x 12m 4990 4 Spring for Brake Pad 5000 4 Brake Pad 3010 2 Return Spring for Clutch Shoe 5020 4 Pin for Securing Spring 5030 L Washer for Brake Shoe Bearing Nut 5040 1 Loeknut for Brake Shoe Bearing, STU3 PLANE 5050 L Cotter Pin for Nut, STUB PLANE 5060 a Cap Return Spring 5070 L Ret fox Cap Return Spring 5080 Z Retainer Cap for Starter 5090 L Lock Ring for Cap 5100 L Lever for ClutchTABLE1 MINARELLI ENGINE PART NO. QUANTITY DESCRIPTION silo 2 Grommet for Clutch Lever 5120 1 Return Spring for Clutch Lever 5130 2 Set Screw 5140 2 Washer, 5150 1 Bolt 5160 1 Bridoe ich Adjuster 5170 1 latch F Adjuster 5180 1 Spring 5190 av ing 5200 1 Walf-Gasing, Clutch Side 520 4. Walf-Casing, Flywhael Side, for Stator B R.94 5220 1 alf-Casing, Flywheel Side, for Stator § B.80 5230 1 Gasket for ialf-Casing, Center 5240 3 Dowel for Crankcase, flo x 4 5250 1 Bolt, TCCE 6 MA x 30mm 5260 1 Cover, Clutch Side 5270 1 Gasket for Clutch Cover 5280 1 Cay, O1L Feed 5290 2 Gasket for Cap, Lamm 5300 2 Bolt, TCB 6 MA’ for Oil Level and Drain 5310 2 Gasket for Bolt, B6nm 5320 3 Bolt, TCCE 6 MA x 15mm 5330 6 PCCE 6 MA x 35mm 5340 1 co. 1, Complete, 230 - 6V, ternal High Yoltace Coil, Stator 994mm (CEV Model 6876) 5350 1 ‘iywheel, Complete, 18% - 6V, fh Yoltace Coil,stator 880mm (Bosch KB6-B212) 5360 a Magneto Flywheel, Complete, 238 - 6V, w/External High Yoltace Coil, Stator p8Omm (CoV Hodel 6932} 5370 1 Wire Cuide on Crankeace for Internal High Voltage Coil 5380 2 2 Guide on Crankcase for Bxternal i voltage 5390 i Bearing, for m Aix conveyor only 5400 1 Bearing, for r conveyor only 5410 1 Cooling Fan 5420 4 Bolt, TCS, ¢ MA x 10mm for securing Fan 5430 1 54e0 L 5450 3 Bolt, TCCE, 5460 1 Gasket for Cylinder Base $470 2 Cylinder, 638mm, Cast 30km for 20mphTABLE1 MINARELLI ENGINE PART NO. QUANTITY DESCRIPTION 5480 cylinder, £38.8 mm, Cast Iron, for 25/30mch and 2-10 Engine 5490 1 Gasket for Cylinder Head STD 0.7mm 5500 1 Engine Head 5510 x Spark Plug, Bosch W 145 Tr or Bavivelent 3520 2 Cover for Spark Plug, Rubber 86 5530 4 HOLD DOWN STUD, 6 HA’ 136mm for cylinder Head 5540 5 Washer, Chanfered oGnm 5550 6 Nut for Stud Bolt, 6 MA x 6mm 5580 1 Side Carburator Manifold 612mm for 30nph and 2-10 Engine 3590 2 Side Carburetor Manifold $8.5 nm for 25/30meh 5600 a Sido Carburetor uanifola 97.25mm for 20 mph 5610 1 Bolt, 6 MA x 26 mm for Securing Cover 5620 2 Wire Guide for Spark Plug Wire 5630 1 Grommet for Spark Plug Wire, Rubber 5640 1 Carburetor, SHA 14-3, Max. Jet 449 Dell'Orto for 20mph 5650 aL carburctor, SHA 14-12, Max. Jot #52 Dell'orte for 25/30mp 5660 1 Filter Housing Supported by Clamp 5670 z Gasket for Muffler 5680 2 Muffler, flype "M* Short (balow engine) 56s0 a Bolt, 7'Mi x 20mm, for Securing Muffler 5700 Z washer, Chemfered, 7m 5710 a! Idler, 2-16, 21 ‘Teeth 5720 Z Pin, 12x 4énn, Zor Taler 5730 a Shim, 922 x 17mm 5740 2 Shaft for Pedal 5750 2 Gear, 2-27, for Pedal 5760 1 Clutch fer Pedal, Sliding (ligt. linn) 5770 1 Spring for Sliding Clutch 5780 1 Guide Pin for Spring, $8.5 x 2énm 5790 3 Shim, 916mm 5600 2: Lock Ring, 16mm, for Padal Shaft 5810 i Crank for Richt Pedal (marked with 2 "D") 5820 L for Left Pedal 5830 2 nk, Complete w/Nut and 5£40 1 Roit, 6 MA x 12mm, For Securing Leaves 5850 i Cap for Pedal shaft 5e60 2 Lock washer, sémm 5870 2 Stad Bolt, 6 MA x 23mm, for Muffler 580 ai Clanp for Securing Filter Housing "S-L" 6~TABLE1 MINARELLI ENGINE PART NO. QuaNrity DESCRIPTION 5890 L Gasket Set, Complete w/ 5230, 5270, 5460, 5490, 4240, and 5670 6000 2 Snap Ring for shaft Flamm, CONE 6020 2 Shin, #14 x 20nm, COW 6040 1 Bushing for Clutch, CONE 6180 Clutch, Centrifugal, Complete, CONE 6200 1 Rearing for Clutch Shoe, CONE 6270 i Locknut for Brake Shoe Bearing, CONE 7050 4 Screws for plastic air conveyorTABLE 2 CLUTCH FOR MINARELLI ENGINE PARTNO. QuanriTy DESCRIPTION 4410 z Complete Crankshaft Assembly, S.P. 4420 2 Half shaft Clutch Side, 5.P. 4460 1 Complete Crankshaft Assembly, CONE 4910 1 Shim 13 x 21mm 4920 2 Bushing for Clutch 4930 2 Complete Centrifugal Clutch, $-P. 4940 2 Bearing for Clutch, §.P. 5030 1 Washer for Nut 5040 i Locknut for Brake Shoe Bearing 5050 1 Cotter Pin for Nut 5570 L Shim 13.7 x 20.8 S.P. 6000 1 Snap Ring for Shaft - Cone 6020 2 Shim 14 x 20 - CONE 6040 2 Bushing for Clutch - CONE 6160 1 Complete Centrifugal Clutch - CONE 6200 y Bearing for Clutch Shoe = CONE 6270 2 Locknut for Brake Shoe Bearing ~ CONE MOUNTING WITH STUB PLANE MOUNTING WITH CONE 6180.TABLE 3 —DEALER TOOL KIT FOR MINARELLI VI ENGINE PARTNO. ‘Quantity DESCRIPTION 6300 1 Point Timer 6920 1 Intextiediate Sprocket Extractor 6930 i Crankshaft Extractor 6950 i Flywhee! Puller (CEV Only) 5960 1 Sprocket Holding Tool 6970 1 Clutch Tool 6930 i Gluteh Pullez ceeo i Plyshee! Tool 1600 1 french for Cap Agjuster i610 i Wrench for Steering Lock Nut OWNER TOOL KIT PART NO. QUANTITY 1240 1520 1530 3 1200 Cc 1630MINARELLI: ELECTRICAL SYSTEM THEORY OF OPERATION ‘the ¢.2.¥. Magnoto unad on cha Minaralli engine consists of two basic components. First, the magneto contains a STATOR PLATE mounted on the lezt side engine housing. ‘This STATOR PLATE holds the primary ignition coil, the lighting coil, the pointe, and the condeneor. Secondly, there is a flywheel attached 40 the crankshaft and aligned hy means of a Woodruff key. This flywheel or retor contains four permanent magnets bonded to its outer rim. these magnets are equally spaced and the exact location is determined by the engine timinc. The primary ignition and lighting coils consist of enamel copper wire wound on a laminated iron core. ‘this laminated core is magnetic in nature and allows for cood magnetic per- meability, yet Keeps the Eddy ent losses low. The enamel on the copper wire is an electrical insulater that keeps the ire from shorting to itself, thereby allowing it to be wound inte many turns over itself When a copver wire, kaown as a conductor, is cut by mag- natic lines of Fores, 2 voltage is impressed in the conductor and current is forced to flow 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 lead placed on them. Tm the Minarelli engine the lighting coil has a voltage outpul of approximately 6 volts at 25 watts max load. The primary ignition coil puts out 12 volts at approximately 20 such as a stop light Circuit. the primary ignition coil supplies the power to drive the ex- ternal high tension coil as its primary ction. watts to be used for accessorics As the rotor turns, clockwise on the Minarelli engine, the points remain closed until the timing mark on the rocor lines up vith the timing mark on the encine housing. While the points are closed all current is shunted to ground, and no ignition firing can oceur. As soon as the timing marks coincide, the points crack open, and current is routed through the primary windine of the external high voltage coil to the ground is causes a high voltage, approximately 15,000 volts, fo 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 keap 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-¢ircuit to shunt the current to the external high tension coil. The magneto, as described, has three outputs: the light- ing circuit, the 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 magneto will require a rectifier to be placed in the circuit to change the current to D.C. -ll-TABLE 4 MAGNETO ¢ 80mm—BOSCH MODEL KB6-B212 18w év PART NO. QuaNTiTY DESCRIPTION 5140 Washer, 4m 5900 uctor, (Rotor) 5910 Screw for Securing Points 5920 Points 5930 Serow for Securing Coils 5940 Capacitor (Condenser) Geeasing Felt Coil, High Voltage for Ignition oil, Low voltage for Lights Stator, 880) tor, Con gneto, Comlete Pep HEN ORDERING TO PARTS, ALWAYS SPECIFY THE MAKE AND MODEL HUMBER PRINTED ON THE ROTOR. BOSCH MODEL K86-B212 1 iif if 5920 59401 5140 sog0 5990 5930 -12-TABLE § —MAGNETO ¢ 94mm—CEV MODEL 6876 23~ bv 6060 60: 5140 6110 PART NO. ‘QUANTITY DESCRIPTION 5140 4 Washer, finn 5240 1 Magneto, Complete w/AL1 Components 6030 a Inductor (Rotor) 6050 1 Cam, Adjusting Tor Points 6060 1 Points 6070 4 Sexew for Securing Coils 6080 i Screw for Securing Capacitor 6090 1 Capacitor 6110 2 Coil, High Voltage 6120 2 Greasing Felt 6130 2 Coil, Low Voltage for Lights 6140 2 Folder for Falt 6150 1 Stator, B94nm 6160 1 Stator, Complete 6175 1 Coil External iligh Voltage for Ignition 6220 1 Screw for Securing Points -1a-TABLE 6 —MAGNETO ¢ 80mm—CEV MODEL 6932 23w 6v PARTNO. QUANTITY DESCRIPTION 5140 4 Washer, g4mm 5360 1 Magneto, Complete w/All Listed Components 6070 a Serew for Securing Coils 6080 1 Screw for Securing Capacitor 6090 a Capacitor 6190 a Inductor (Rotor Flywheel) 6220 aL Screw for Securing Points 6230 a Points 6240, 1 Coil, Primary for Ignition 6250, 1 Coil, Low Voltage for Lighte 6v - 230 6260, 1 Greasing Felt 6280 1 Stator, 980 6290 aL Ceil, External High Voltage for Ignition (Black) 6300 1 Stator, Conplete WHEN ORDERING MAGNETO PARTS, ALWAYS SPECIFY THE MAKE AND MODEL NUMBER PRINTED ON THE ROTOR. CEY MODEL 6932 6220 6070 5240 / Jf Ss 6260 Lh /s L ~14TABLE 7 DELL'ORTO CARBURETOR 6550 6560 \T bad x 6680 6320. 6410. 6480.TABLE 7 DELL‘ORTO CARBURETOR PART NO. uantiry DESCRIPTION 2200 L Screw for Securing Clamp 5660 ZL Housing for Air Filter EEO ef Clamp for Air Pilter Housing 6320 1 Cover for Mixture Chamber 6330 2 Float Bowl 6340 1 Locknut for Throttle Cable Adjuster 6350 i Mut for Mounting Bolt 6360 1 Fuel rilter 6370 2 6375, 1 x np 380% 1 20mph 6390 1 /30mph above 2000 feet 6400 1 Yet #52 for 25/30mph 6410 1 Gaskat for Mixture Chamber 6420, 1 Gasket for air rilver 6130 1 Gasket for Ploat Bowt 6440 1 Gasket fer fuel Intake Serew 6450 I Choke Lock 6460 1 Spring for Choke Lock 6470 z Return Spring for Choke 6480 1 Return Spring for Throttle Slide 6490 1 Spring for idler sere 6500 1 Pin tor Float 6510 2 Pin Zor Choke Lock 6520 z Screw for Securing Choke Arm 6530, i Fuel Intake 6540 1 Gasket, Insulating 6550 2 Needle valve 6560 z Guide for Throttle Cable, Old 6570" 1 Choke Arm, Short 6380 1 Choke Arn, Long 6590 1 Slide for throttle 6600 1 Bole for Securing Carburetor to Manifold 6610 2 Serew 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 i Ho|sing for air Filter, self-supporting 6680 1 72° Guide for Throttle Cable 6690 1 Filter Element, #6117 6710 1 Nut for Housing Bolt 6720 1 Bolt for Securing Air Filter Housing 25640 1 yretor, SHA 11-9 oe beli'orto for 85650 1 Corbyretor, ~ _ Deli orto for 25/30meh ~16- * Multiple parts a2 Pound on engine drawingMinarelli Engine Theor ‘The Teo-Seroke Ergire ENGINE OPERATION AlL Vl engines regardicss of the top speed (17,20,25,30) are piston-vort type two-strokes. The following discussion of each type will provide sone insigh < they work and way st of all angines plication. Tt has rather than valve: in intake and exhaust flow. These ports are all located in the cylinder wall and are opened and closed by the pistong movenent. Tacir functions are: intake Port = Admizs A fuel mixture from the carburetor into the crankcase. Tranter Ports - Provide passages for the fuel mixture between the crankcase and combustion chamber . Bxhaust Port ~ Releases burnt gases from the combusvion chamber into the exhaust pipe. Basically with marelli Vi engine this i ta ing a 360° rotation of tha crank shaft baginning with piston ut tep dead center: 1. Down Stroke The piston descends from the previous cycle and expose: the exhaust port letting out the expanding burnt gases, Simul- tancously, the pistoa's downward movement. compresses the fuel mixture from the previous eycle occupying the airticht = crankcase. As the piston continues to descend, it alse exposes Sransfor ports. The compressed mixture waiting in the crankcase how rushes through the ports and fills combustion chamber while at the same tine sweazing any remaining burnt gases oyt the exhaust port. -17-2, Upstroke After reaching its lowest point of travel, the piston begins to ascend and closes eff the transfer ports. At the same tine, the piston's upwaré movement creates a partial n the crankcase. As the piston continues to ascend, it closes off the ex- haust port and begins to compress the mixture in the combus ion chamber. Meanwhile, the bottom of the piston exposes the intake port and a fresh fuel mixture is sucked inte the crank- case. When the piston appreaches top dead center, ignition occurs and the piston once again descends to hegin another cycle. As described, ignition occurs once every 360° ox more priately, once every two strokes of the piston (one down and one up). Hence, the term two-stroke engine. (Time at 23° B.E.D.C.)COMPLETE DISASSEMBLY MINARELLI V1 ENGINE 15 can be done with the s mich casier to do Please note that all steps up to engine mounted on the bike, although it on your workbench, Remove air conveyor #5430 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 the Minarelli are right Mth the exception of the threads in left hand crank hand, arm. Using the special Minarelli fly- wheel tool #6990 to hold the mac neto, and a Idnm socket, remove hut from the center of the magneto. NOTE: Be very careful not to Scratch the 2 coils. They are ear enamel coated to insulate wire, and can be ruined by scratching. Insert the flywheel puller #6950 all inte the center of the jagnets. Hold the tool with a 20mm wrench and turn the extracting bolt with a limm wrench until a popping sound is heard. NOTE: “The magneto is on a tapered Raft with woodruff key. If the extractor bolt is extremely hard o turn, ranove socket and rap extractor bolt smartly with plastic mallet. NOTE: No other tool, such as a gear puller extractor, may be used =o pull the magneto. It must be extracted only fron 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.Using the Minarelli sprocket holding tonl #6960 and a 17am wrench, remove the sprecket nut and washer.’ The sprocket can be renoved with two large screwdsivers being careful net to damage the cases. S.prain the oil Srom the easing. th a Smn Allen wrench, renove the six 6x35 25330mn and the one 6x15 $5320nm clutch casing screws to remove clutch casil 260 and gasket #5270.6. The clutch cover contains lever for clutch arm £5100 and two spring leafs #5180 and #5190. 1f there is any noticeable wear on spring leafs, replace and note wearing on starter plate bearing osite the spring leafs. NOTE: Starter arm may be removed Screw. This becomes necessary when the 8xl0nm cable holder is roken. 7. With a screwdriver, remove Inck ring #5090 from hub. This wilt allow retainer cap £5080, retainer for cap return spring #5070, and eap return spring £5060 £0 be removed. 8 Using Minarelli clutch tool #6970 and a L3mm socket, remove clutch mut #62/0 and washer #5030. Note new clutch. -21-9. Screw Minarelli clutch puller screws Into cluteh body with teol 46980, making sure that they are all the way in, Insert Long screwériver, through tool, resting it against the pedal shaft, and tighten the extracting bolt with a l3mn Observe previous note on renoving objects fron tazered shafts. 10. With a pair of snap ring pliers, remove snap ring #6000, shim 14x20mm $6020, and engine sprocket with housing #4900. You caa now remove the brass clutch bashing #6040 and the remaining shin #6020 on the shaft. 41. with snap ring pliers, renove snap ring #4860, shim #4850, and drive clutch 44870. -22-12. Remove snap ring $4860, washer #4950 and gear for clutch #4890 to complete clutch disassembly. 13. With a lomm socket, remove the four #5550 auts 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 oxist. It can be removed with a small screw- river, but generally need not be replaced or removed. IF replaced, be sure to replace with eame thick- ness as head gaske!. TH15.Remove the eleven #5250 6x30mm casing bolts from the magneto of the engine cases. 6. Install Minarelli crank shaft extractor #6930 with the three long special bolts provided with the extractor. ghten the crankshaft oxtra and simaltancously tap the shaft with a rubber nallet in order to evenly split the engine cases. Tightening the crunkshal tor tee] only will result in the top end of the cases split- ting at an angle to the boctem end of the cases. You must tap the pedal shaft for an even extract~ ion. -24-18. With cases split you hava access to ail internal qears and shims. NOTE: 2. Crank should be re~ placed es a whole unit (#4460). 2. Idler pin 25720 can be om the engine cases. 3, Spring #5779 can be om pedal clutch gear 35760. 4, Lock ring #5800 re- moves shin #5790 and pedal gear #5750 from the pedal shaft 75740. 19. NOTE: 1. xeyed side of srank gous Tnto magneto housing and will have a shim on it. 2. The flat side of the @sive gears goes tevard the mag- neto side, and nay have a shim on it also. 3. The emall gear of the idler gear #5710 faces the magneto side of the engine cases with shim 5730 on each side. Remove G clips from piston #4490 h needle nose pliers E+ hen not expecting to split (e.g., decarbonization) , always puta rag or paper towel the cases under Wy in the lop end o: the piston Lo avoid dropping an clips, dirt, or broken ring par into the cases of the enginc, which would force an unneccessary split- ting of the cases. ~25-21. Using a piston pin extractor, press the piston pin #4480 shout 3/4 of the way through the piston. Remove tool and lift piston off of connect- ing rod. Rings should be removed he- ston pin extrector is in- stalled, or rings should be lined up with brass pins, so that they will not break up on extraction of the pin. 22.15 the brass bushing in the connee+- ing rod needs te be replaced, you must first remove the old brass bushing #4470, install the new busk- ing, ream it out Inn (see echnical Builetin #004), and eril1 the three holes nceded ia the connecting rod to provide lubrication to the sleeve and piston pi NOTE: This step will require split- ting of the cases in order to properly drill the bottom two noles in the connecting red of assembly #4460. -26-ASSEMBLY OF MINARELLI ENGINE NOTR: When reagsembling the Minarelli engine, r seals and gaskets. All parts removed and to be reused thoroaghly cleaned and Lightly oiled. All gaskets should be given a light coat of grease to help you seat them inte place and also to insure a better seal. NOTE: AL1 shims used in t as shafts are of differe: @ Minarelli fit properly on the shafts. diameters, a loose fitting shin is improperly placed. Placing the wrong thickness shim on shaft will either allow a loose ring to fit on iz too thick. € if teo thin, or not allow snap nstall idler shim $3730, idler gear #5710, and shim #5730 on to idler shaft which should be on the clutch ston 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 i side of casing with si pedal clutch #5760, w: on it, pedal cear $5750, shim $5790, and snap ring #5800, wndcn should be installed on pedal shaft previous to insertion in the case. Then put on final shin #5790 on shaft hext to snap ring. NOTE: Make sure that "Ss" or > on piston points to exhaust side of cylinder. I£ no mark appears, install piste. so that pins for piston ring: face exhaust port. a7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 cn to clutch side and press together until all shi line up. Tap together carefully with rubber mallet. ~28-With Smm Allen wrench, draw cases together slowly until snug. Tighten the six bolts in the magneto housing in @ criss-cross fashion first. Then tighten the five remaining casing bolts starting from the lower part of the engine. Torque to 3.0 #t.1b. 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 crankshaf 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 nat, and with the flywheel holding tool #6990 and 14mm socket, torque to 34 ft.1b. =28-Install clutch gear #4890, washer #4850, and snap ring #4860 on rear drive sprocket. NOTE: Larger diameter shim for this shaft fits on outside of drive. Install drive clutch 24870, shim 34850, and snap ring 24860 on shaft, all parts should fit on shafts with virtually no play. Install shim #6020, bushing #6040, clutch housing #4900, shim 96020, and snap ring #6000, cluster body #6180, washer #5030, and clutch nut #5049 on shaft #4460. =30-Install clutch body #6180, washer #5030, and clutch mut #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 and press into heusiag, lining up retainer with housing in slots. Install lock ring #5099 into groove, and check retaining cap for starter fox proper movement, which is approx- imately 1mm in and out. =31-Install eluteh cover gasket #5240 ¢ clutch housing #5260 with the six 6xl5nn and one 6x35mm Alien bolts, Torque clucch casing boles to 8.0 #z.1b. Install base gasket on engine casing. Line up rings with pins on piston, so chat 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 movenent of the piston. NOTE: The tolerance becween eylin- Ger and piston should he 0.003in to 0.005in. (.080-085mm.), NOTE: Cylinder should ‘be lightly © installation. Tngtell head gasket #5490 and cy inder head #5500, four washers end 10mm nuts. Tighten cylinder head nucs in a criss-cross pattern and torque then to 8.0 Ft,Ib, =32-TIMING ENGINE Rotate the flywheel by hand in a until points eck point gap jeceessa eset point h should be 0.014in. to 018in (0 40mm) . ect point gap set~ is essential before the igni- timing operation can be carried gap, 5 better to set the at Q.018in, as the » together an oF set timing, rotate the yeheel in a clockwise ai. (note arrow on flywheel) w: first line on the flywheel alicns with the arrow on the casiag. position is 23 degrees before top Gead center. ‘The points should just start to open at this align- nt. Proper alignment can be checked dy removing the blue wire any ground and connecting the red ize ko a continuity tester (e.g., buzz box, multi-meter, ete.) and to ground. poms MAGNETOTo adjust, the stator plate loosen the two phillips serews and move the plate counter-clockwise if to far advanced and clockwise if retarded. Retighten screws and re- occurs before the mark lines up. th @ is said to be advanced. on the top dead center. Place chain sprocker_on shaft, replace washer and 17mm nut, and tighten, holding the sprocket with tool #6960, Torque co 32.0 £t.lbs. Replace fan housing with four phillips screws, fan, and fancover with three allen bolts, in that order, Rerount ngine to frei cunt 6; plug chgine with Ae 20 non-detergent oil only. HOTE: Tiddle phillips screw in casing is correct oil level. =34-TECHNICAL BULJ Timing the enove bearing for conveyor (5390). 1 by hand in a Clockwise direction uci! points y opun; check gap aad if necessary, reset point gap hould be .014 to .0L8 (0.35 to 0.40nm). orrect po timing opera tial before the NOTE: (0) is top dead center - (A) is 23° degrees before top dead eonter. Remove blue and red wires from connector located above magneto. 7. Connect continuity checker (buzz box, bulb and battery or vesistance seale of meter) between red sire and case of engine. NOTE: Leave blue wire free. =35-8. Slowly move the flywheel by hand clockwise and observe the position of mark (A) on £ly el 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 Lwo marks line up. NOTE: Tf the opening o£ 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 serews securing che stator plate and move che plate in the required direction If advanced move stator plate counterclockwise. If retarded move stator plate clockwise. ¢. Retighten all screws and reassenble side of engi NOTE: Be sure to tighten magneto check nut securely. -36-Technical Data ENGINE, * Model - Minarelli VI * Single Cylinder 2 stroke Cubic Capacity: 47,6 ce - 20 mph * 49/4 ce - 25 and 30 mph * Bore: 38.0 mm - 20 mph 38.3 mm - 25 and 30 mph * Stroke: 42.0. nm Compression Ratio: 8 to 1 Horsepower @ 4800 zpx 1.00 - 20 mph 1190 - 25 and 30 ph * Piston to wall clearance - .002: xebore at .002" clearance Ring Gep - .01 * Ignicion and 1. Flyvhe > .005" ating: 6-volt magneto with 23 wact capacity and external high Lension coil stop light op- erated coil, by grounding of lew tension ignition * Minarelli synthetic ofl, 64 co 1 etic oil - 40 to 1 mixture, of recomended on can. oF Fuel * Starting: Pedal and Clucch * Clutch: Automatic centrifugal expanding, running in gil * Lubrication (Clutch and Gears) Capacity: 1 pint SAE 20 oil PRIMARY TRANSHISS1ON * Final reduction of 3,533 to 1 clucch gear: 15 - tooth; secondary gear: §2 - tooth FINAL TRANSMISSION AND RATIO 1/2 x 3/16; 11-tooth engine th wheel sprocket zatio: 2.73 to 1 ngle row cl sprocket to 42. IGNITION TIMING * 23° B.T.N.C. (measure on flywheel external diameter) or 1079 3.T.D.C. CONTACT BREAKER GAP % .014 to .019 inches (.35 to .40 mm) -37-SPARK PLUGS BOSCH W145 TI Gap: .024 inches Marelli cw 5H Champion 186, Lacy NKG = B5HS -'cold weather, BENS - warm weather Reem TORQUE, Set serew for cluteh lever (5130) -1B-. 2 Half-casing and side cover bolts Intake manifold bolts (5610) Oil Leve? and drain screws Bolt for securing spring leaves (5840) Nuts for seeuring head (5550) Wut for securing intermediate sprocket (4840) Cnecknut for magneto flywheel (4750) Cheeknut for securing centrifugal clutch with cone coupling (6270) 5 a a Buwreornd & bRoDuSCS =38-