ENGINE S6 / E

INDEX

TECHNICAL SPECIFICATIONS SPECIAL TOOLS PERIODIC MAINTENANCE LUBRICANTS TROUBLESHOOTING TIGHTENING TORQUE TABLE ENGINE DISASSEMBLY ENGINE REASSEMBLY OIL MIXER PUMP UNIT ENGINE COMPONENT INSPECTION AND SERVICE PARTS CATALOGUE

2 3-4 5 6 7 - 14 15 16 - 24 23 - 33 34 35 - 37 xx

Page 1

ENGINE S6 / E

TECHNICAL SPECIFICATIONS
SPECIFICATIONS
CYCLE ......................................................... Nr. of CYLINDERS ....................................... DISPLACEMENT .......................................... BORE AND STROKE mm. ................... CYLINDER MATERIAL .................................. COMPRESSION RATIO ................................ SPARK PLUG ............................................... TIMING SYSTEM .......................................... ..................................................................... MAX. R.P.M. .................................................. CARBURETOR ............................................ INTAKE MANIFOLD ..................................... FUEL ............................................................
...........................................................................

- 2 stroke -1 - 49.908 cc. - 39 X 41.8 - Special cast iron - (11 0.6) : 1 - CHAMPION L78 C - Reed valve in crankcase with 3 metal flaps - 9000 - 12 mm diameter or equivalent - Fixed - EURO UNLEADED NC 623/02 - R.O.N. 95 plus 2% oil - AGIP 2T CITY - automatic oil mixer pump (on request) - (on request) - Inductive electronic - Straight-tooth gears Z 14/59 with safety coupling - Sprocket Z 10 or Z11 chain type 1/2 x 3/16 roller 7.75 - Automatic centrifugal 2-shoe clutch in oil bath - AGIP RADULA 68 type SAE 20 W quantity 200 cc - Kick starter - Air cooled

LUBRICATION MIXER OIL TYPE ................. LUBRICATION SYSTEM .............................. GENERATOR ............................................... IGNITION ...................................................... PRIMARY DRIVE GEAR ................................ ..................................................................... SECONDARY DRIVE GEAR ......................... ..................................................................... CLUTCH ...................................................... ..................................................................... TRANSMISSION GEAR OIL ......................... ..................................................................... STARTER ...................................................... COOLING ......................................................

Page 2

ENGINE S6 / E

SPECIAL TOOLS

Figure

Code

Description

143176

BEARING INSTALLER output shaft

143154

BEARING INSTALLER crankshaft

143156

BEARING INSTALLER output shaft

143179

OIL SEAL INSTALLER output shaft

143180

OIL SEAL INSTALLER crankshaft (flywheel + clutch)

143181

OIL SEAL MOUNTING PROTECTION crankshaft (flywheel + clutch)

Page 3

ENGINE S6 / E

SPECIAL TOOLS

Figure

Code

Description

143155

OIL PUMP SHAFT INSTALLER (pre-assembled)

140558

FLYWHEEL REMOVER

143162

CRANKCASE PULLER

Page 4

ENGINE S6 / E

PERIODIC MAINTENANCE

RUNNING-IN RECOMMENDATIONS: During the running-in period, i.e. for approx. the first 500 km on the road, please note as follows: - Do never run the engine at maximum revolutions. - Do never keep the vehicle at maximum speed. - Do not keep the engine at idle speed for longer time.

FIRST MAINTENANCE SERVICE: to be carried out after 500 - 600 km. - Replace the engine oil - Check the carburation and adjust if necessary - Check the tightness of nuts and bolts (See table tightening torques page 15)

Page 5

ENGINE S6 / E

LUBRICANTS

N.B. Use original MORINI FRANCO MOTORI spare parts only

RECOMMENDED LUBRICANTS / ADHESIVES DESCRIPTION Transmission oil Assembly of various parts Special assembly Thread-locking glue Clamping glue CHARACTERISTICS AGIP RADULA 68 SAE 20W GR/SM2 GREASE GRAPHITISED MOLYCOTE type GREASE LOXEAL 82-21 LOXEAL 83-54

N.B. TRANSMISSION OIL LEVEL CHECK Remove the oil filler cap on the clutch cover and check the transmission oil level through window.

Page 6

ENGINE S6 / E

TROUBLESHOOTING

The following flow charts give a general outline of the causes and effects when the engine is not running correctly. Descriptions of solutions for a specific cause are general; for more details the reader should consult the disassembly-reassembly manual.

LEGEND OF SYMBOLS

EFFECT (fault noticed by the user)

Possible CAUSE of the fault

Possible general SOLUTION to the fault

Page 7

ENGINE S6 / E

Starting problems

Faulty spark plug or wrong spark plug heat rating

YES

Check spark plug and replace if necessary.

NO Start the engine with the throttle fully open.

Engine flooded

YES

NO

Remove the spark plug, rev the engine, install a dry spark plug and restart the engine.

NO

The engine starts

Sparking starts at a high r.p.m.

YES

Replace the ignition coil

Page 8

ENGINE S6 / E

Maximum indicated running speed cannot be reached

Soiled or clogged filter

YES

Disassemble, wash sponge with a 50:50 solution of petrol and 2T oil; leave to dry. Clean the filter box using compressed air; re-assemble.

NO
Silencer obstructed

YES

Check the silencer for clogging. Replace if necessary.

NO
Disassemble the cylinder and check that the exhaust pipe is clean. If the exhaust pipe is partly obstructed by carbon deposits, clean it thoroughly using a scraper.

Cylinder exhaust port soiled with carbon deposits

YES

NO
Disassemble the cylinder head, cylinder and piston. Remove the piston rings, place them in the cylinder liner and check the amount of wear. Replace if excessively worn.

Poor compression

YES

Page 9

ENGINE S6 / E

Poor acceleration/pickup

Clutch

YES

Check the clutch shoe thickness and the clutch springs for stretching. If either is excessively worn they should be replaced.

NO

Irregular acceleration

YES

Check the exact number of turns of the air adjusting screw on the carburetor.

Page 10

ENGINE S6 / E

Incorrect idling speed

Idling speed too high or too low

YES

Adjust the RPM of the idling speed (with engine warm) by adjusting the screw on the throttle valve of the carburetor. Disassemble the carburetor and clean all the parts (nozzles, throttle valve, jet needle, float chamber and casing) with solvent and dry using compressed air.

YES NO

False air intake from carburetor manifold

YES

Check the integrity of the carburetor manifold gaskets.

YES NO

Check the integrity of the rubber coupling sleeve that connects carburetor and air filter box.

YES

Check the reed valve gasket

False air intake from engine crankshaft oil seals

YES

Check the integrity of the crankshaft oil seals. Replace even if only slightly damaged.

Page 11

ENGINE S6 / E

Noisy engine

Incorrect transmission gears assembly

YES

Check the assembly of all gears and parts of the transmission.

NO

Loose transmission nut

YES

Check the tightening torque of the clutch nut.

NO
Transmission noise and rear wheel drag at idling speed.

YES

Check the clutch unit

Page 12

ENGINE S6 / E

Noisy engine

Noisy gears

YES

Check the oil level. Refill if necessary.

YES NO

Check the teeth of the drive gears visually. Replace if signs of damage or wear are evident.

Noisy cylinder unit

YES

Check the clearance between the piston and the cylinder. If it does not correspond to the prescribed value, grind the cylinder and assemble 1st oversize piston.

NO

Noisy crankshaft bearings

YES

BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are mounted in the crankcase. Replace the bearing if anything unsual is found.

Page 13

ENGINE S6 / E

Smokey exhaust

Percentage of mixer oil

YES

Replace the fuel in the tank with new fuel mixed with 2% of the type of oil indicated in the handbook.

NO

Mixer oil

YES

Check that the oil is 100% synthetic for separate oil mixer pump use.

NO
Disassemble the cylinder and remove any carbon deposits; check the silencer for clogging.

Carbon deposits

YES

NO

Oil mixer pump

YES

Disassemble the oil mixer pump and check the flow rate.

Page 14

ENGINE S6 / E

TIGHTENING TORQUE TABLE

DENOMINATION Crankcase bolts Clutch cover bolts Flywheel cover bolts Carburetor manifold bolts Ignition coil clamping screws Oil mixer pump clamping screws (for model with mixer only) Carburetor clamping screw Starter lever bolt Oil drain plug Clutch nut Flywheel nut Head nuts Spark plug

TORQUE (Nm) 10 - 12 10 - 12 3-4 7-8 6-8 5-6 4-5 8 - 10 8 - 10 50 - 55 25 - 30 12 - 14 20 - 25

Page 15

ENGINE S6 / E

ENGINE DISASSEMBLY

CARBURETOR - CYLINDER HEAD - CYLINDER - PISTON

DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Disassemble the CARBURETOR

Remove the SPARK PLUG

Loosen the SCREWS and remove the CARBURETOR MANIFOLD including the REED VALVE.

Disassemble the CYLINDER HEAD and remove the HEAD-CYLINDER GASKET

Remove the CYLINDER

Page 16

ENGINE S6 / E
DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Disassembly the CIRCLIPS and the PISTON PIN. Remove the PISTON and the ROLLER CAGE.

Remove the CYLINDER BASE GASKET

FLYWHEEL SIDE
DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Loosen the clamping BOLTS and remove the FLYWHEEL COVER

MIND THE BRACKET INSIDE THE COVER

Disassemble the SPARK COIL

Page 17

ENGINE S6 / E
DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Disassemble the FLYWHEEL ROTOR (compass tool + flywheel remover)

140558

Disassemble the SNAP RING

Remove the SPROCKET from the OUTPUT SHAFT

Page 18

ENGINE S6 / E CLUTCH SIDE

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Remove the OIL DRAIN PLUG (cross-headed)

MAKE SURE TO DRAIN THE ENGINE COMPLETELY

Loosen the clamping BOLTS on the cover and remove the CLUTCH COVER

Remove the SPECIAL FRONTCLUTCH NUT and the BELLEVILLE WASHER

Compass tool

CLAMPED WITH LOXEAL

Page 19

ENGINE S6 / E

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Disassemble the CLUTCH and the 2.5mm SPACER RING

Remove the CLUTCH BELL and SPACER RING

Page 20

ENGINE S6 / E

CRANKCASE OPENING

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Remove the cylinder STUD BOLTS if necessary

BLOCKED WITH LOXEAL

Remove the 8 CRANKCASE BOLTS

Open the CRANKCASE

143162

THE CRANKSHAFT IS DRIVEN ONTO THE BEARINGS. OPEN THE CRANKCASE FROM FLYWHEEL SIDE USING THE PULLER TOOL

Remove the DOWEL PINS and the CRANKCASE GASKET. Remove the crankshaft if necessary

Page 21

ENGINE S6 / E

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Remove the OUTPUT SHAFT SNAP RING.

Remove the OUTPUT SHAFT.

Inspect the OUTPUT SHAFT BEARING for abnormal play and noise. Replace the bearing if anything unusual occurs. Remove the SNAP RING.

Remove the BEARING by using a standard bearing remover set.

THE BEARING IS DRIVEN INTO THE BEARING HOUSING

To replace the CRANKSHAFT BEARING and the OUTPUT SHAFT ROLLER CAGE (flywheel side) follow the same procedure as described above.

Page 22

ENGINE S6 / E

ENGINE REASSEMBLY
CRANKCASE PREASSEMBLY
DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Drive the OUTPUT SHAFT BEARING into the half crankcase clutch side and secure with the snap ring

143176

LUBRICATE THE HOUSING LEAVE THE PRINT ON THE BEARING VISIBLE

LUBRICATE THE HOUSING Drive the CRANKSHAFT BEARINGS into the half crankcase clutch side and into the half crankcase flywheel side. 143154 LEAVE THE PRINT ON THE BEARING VISIBLE

LUBRICATE THE HOUSING Drive the ROLLER CAGE OUTPUT SHAFT into the half crankcase flywheel side. 143156 LEAVE THE PRINT ON THE BEARING VISIBLE

Page 23

ENGINE S6 / E

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Insert the DRIVE SHAFT in the half crankcase clucth side

Insert the SNAP RING onto the second output shaft slot (near transmission gear)

Insert the OUTPUT SHAFT into the half crankcase clutch side and secure with SNAP RING

CRANKCASE CLOSING
DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Insert the DOWEL PINS

Page 24

ENGINE S6 / E

DIAGRAM

DESCRIPTION
Lubricate the CRANKCASE GASKET on both sides. Apply the CRANKCASE GASKET on the half crankcase clutch side using the 2 dowel pins for centering.

TOOL CODE

NOTES

Assembly the HALF CRANKCASES

Fix 1 x BOLT M6X60 in the postion between the stud bolts and the reed valve zone.

DO NOT TIGHTEN

Fix the remaining 7 X BOLTS M6X50. Cross-tighten the bolts using a tightening torque of 10-12 Nm. Check to make sure that the crankshaft and output shaft rotate smootly.

Grease the oil seal housing and the oil seal lip carefully. Install the CRANKSHAFT OIL SEAL RINGS and the OUTPUT SHAFT OIL SEAL RING. Trim the crankcase gasket (cylinder zone and carburetor zone.) 143179 143180 143181

GREASE TYPE GR/SM2

Page 25

ENGINE S6 / E

FLYWHEEL SIDE
DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Mount the SPROCKET and secure with the SNAP RING

Caulk the key seat on the crankshaft and insert the FLYWHEEL KEY.

Clean and remove all traces of grease from the rotor cone and the drive shaft cone. Compass tool Assemble the flywheel rotor using the key as reference. Assemble the FLYWHEEL NUT and tighten. Assemble the IGNITION COIL and fit the 2 BOLTS without tightening them. Check the clearance between the ignition coil and the flywheel rotor using a thickness gauge: CLEARANCE = 0.35 - 0.45 mm. Tighten the bolts. Tightening torque 25 - 30 Nm DO NOT TIGHTEN

Tightening torque 6 - 8 Nm

Page 26

ENGINE S6 / E

FLYWHEEL COVER
DIAGRAM DESCRIPTION
Drive in the 2 elastic dowel pins in the cover. and make sure that they do NOT INTERFERE with the bracket mounting face. Assemble the BRACKET on the flywheel cover.
TOOL CODE

NOTES

Assemble the FLYWHEEL COVER placing the rubber fairleads in their seats on the cover.

Secure the FLYWHEEL COVER using: 3 SCREWS M5X50 + WASHER. Tightening torque 3-4 N.m. 1 SCREW M5X20 + WASHER. Tightening torque 3-4 N.m.

Page 27

ENGINE S6 / E

CYLINDER - PISTON - CYLINDER HEAD

DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Insert the CYLINDER BASE GASKET

Assemble the ROLLER CAGE, PISTON and PISTON PIN and secure with CIRCLIPS. ALWAYS ASSEMBLE ROLLER CAGE SIZE - 2 - 4 OIL THE PISTON.

WHEN INSTALLING THE PISTON TURN THE ARROW MARK ON THE HEAD OF THE PISTON TO THE EXHAUST SIDE

Assemble the CYLINDER

BEFORE ASSEMBLY CHECK THE SIZE CODE OF THE CYLINDER AND THE PISTON

Insert the CYLINDER HEAD GASKET

Page 28

ENGINE S6 / E

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Fit the 4 CYLINDER HEAD NUTS and cross tighten.

Tightening torque 12 - 14 Nm

Install the SPARK PLUG and tighten

Tightening torque 20 - 25 Nm

CARBURETOR UNIT

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Insert the CARBURETOR MANIFOLD BASE including the REED VALVE.

Assemble the CARBURETOR MANIFOLD on the base and secure with 4 BOLTS M6X20.

Tightening torque 7 - 8 Nm.

Assemble the CARBURETOR and tighten the CLAMP SCREW.

Tightening torque 3 - 4 Nm.

Page 29

ENGINE S6 / E

CLUTCH COVER
DIAGRAM DESCRIPTION
TOOL CODE

NOTES

Assemble the SPRING on the sliding gear as shown on the figure. Lubricate the inside of the spring using GR MU/3 grease.

143167

Assemble the SLIDING GEAR on the cover and secure the SPRING between the two stops.

Assemble the SPACER RING and O-RING on the KICK STARTER SHAFT. Lubricate the O-ring area using GR MU/3 grease.

Lubricate the KICK STARTER SHAFT in the clutch cover operating zone using grease type MOLYCOTE. Install KICK STARTER SHAFT in the clutch cover and make sure that the gear section is engaged properly with the sliding gear. After assembly check that the spring of the sliding gear is correctly

Page 30

ENGINE S6 / E

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Install and load the RETURN SPRING on the kick starter shaft. Secure the spring on the backstop in the clutch cover.

Assemble the SPRING WASHER and secure with the SNAP RING.

Place the SPACER on the kick starter shaft and secure with the snap ring.

Assemble the KICK STARTER LEVER and fasten by using the bolt M7x25. KICK STARTER LEVER POSITION *Steel lever = 109 *Aluminium lever = 96 Check axial clearance: 0.1 - 0.3 mm

Tightening torque 8-10 N.m.

KICK STARTER LEVER POSITION *Steel lever = 109

*Aluminium lever = 96

Page 31

ENGINE S6 / E

CLUTCH SIDE

DIAGRAM

DESCRIPTION
Insert the 0.8mm SPACER RING on the crankshaft clutch side. Lubricate the clutch bell operating zone of the crankshaft using the grease type ROCOL ASP MOLYCOTE. Install the CLUTCH BELL

TOOL CODE

NOTES

Insert the 2.5 mm SPACER RING

CAUTION
Install the CLUTCH on the crankshaft THE PRINT ON THE CLUTCH SHOE AND THE REFERENCE MARK ON THE HUB MUST BE ON THE SAME SIDE AND LEFT VISIBLE

Insert the BELLEVILLE WASHER and clamp the clutch using the SPECIAL FRONT CLUTCH NUT. (LEFT HAND THREAD) Add LOXEAL 83-54 to the clutch nut and tighten Tightening torque 50-55 N.m. Check the axial clearance of the clutch bell: 0.3 - 0.5 mm Assemble the clutch cover gasket.

CAUTION
In order to avoid Compass tool any clutch hub jamming on the spline shaft and to ensure any future disassembly operation of the clutch unit, make sure to apply LOXEAL 83-54 exclusively on the cluth nut and NOT on shaft end.

Page 32

ENGINE S6 / E

DIAGRAM

DESCRIPTION

TOOL CODE

NOTES

Mount the clutch cover and secure with 6 BOLTS M6 x 30.

Tightening torque 10-12 N.m.

Insert the OIL DRAIN PLUG + WASHER and tighten.

Tightening torque 8 - 10 N.m.

Pour 200 cc of oil type AGIP RADULA 68 SAE 20W and fit the OIL FILLER CAP + GASKET. AFTER COMPLETED ASSEMBLY CHECK THAT THE ENGINE ROTATES SMOOTHLY

Recommended Oil type: AGIP RADULA 68 SAE 20W

Page 33

ENGINE S6 / E

S6 OIL MIXER PUMP

DIAGRAM

DESCRIPTION
Preassemble the 2 BEARINGS and SPACER on the OIL MIXER PUMP DRIVE SHAFT and secure with 2 SNAP RINGS. The print on the bearings should face the drive end of the shaft.

TOOL CODE

NOTES

Lubricate the bearing housing. Drive the OIL MIXER PUMP DRIVE SHAFT UNIT into the half crankcase flywheel side. Insert the CLEARANCE SPACER. Assemble the BEARING SNAP RING.

143155

143342

Insert the DRIVE BELT onto the DRIVEN PULLEY. Install the pulley on the oil mixer pump shaft and the drive belt onto the splined part of the crankshaft.

Assemble the oil mixer pump on the support bracket and tighten the screw M5x12. In order to simplify the assembly operation of the oil mixer pump, make sure that the timing of the driven pulley and the oil mixer pump shaft do match. Install the BRACKET with OIL MIXER PUMP into the housing of the half crankcase flywheel side.

Tightening torque 5 - 6 Nm

Page 34

ENGINE S6/E

ENGINE COMPONENT INSPECTION AND SERVICE

CYLINDER - PISTON TABLE

Value (mm) Part 50cc
Cylinder Piston Piston rings : 1)Piston ring 1st slot 2)Piston ring 2nd slot 39 39 39 x 2 - 0.01 - 0.025 39 x 1.25 - 0.01 - 0.025

Page 35

ENGINE S6/E

CYLINDER - PISTON ASSEMBLY SELECTION TABLE

SIZE CODE
(stamped on part)

CYLINDER - PISTON DIMENSIONS

CYLINDER
+ 0,026

ASSEMBLY CLEARANCE

PISTON
- 0,036 - 0,040 - 0,041 - 0,046 - 0,047

A (RED) B (YELLOW) C (NEUTRAL) D (GREEN)

39 + 0,021 39 + 0,016 39 + 0,010 39 + 0,004

+ 0,009 + 0,015 + 0,020

39 39 39 39

0.050-0.067 mm

- 0,052

- 0,053 - 0,058

CHECK POSITION For correct dimension control

Page 36

ENGINE S6/E
CYLINDER CHECK -Check the internal surface of the cylinder for signs of seizure or abnormal wear. -Measure the internal diameter of the cylinder using a bore gauge. -Wear limit: Minimum indicated cylinder selection diameter + 0.03mm. -Take measurements in three different positions along the axis of the cylinder. -In each position take two measurements, one parallel with and the other perpendicular to the crankshaft axis. PISTON CHECK -Remove the piston rings and check the piston for abnormal signs and wear.

N.B. The piston rings are fragile, handle with care. RING-TO-GROOVE MEASUREMENT. Wear limit: 0,08 mm max.

PISTON BORE MEASUREMENT. -Maximum permitted diameter:12 + 0,18 mm -Measure the piston outside diameter in the direction perpendicular to the piston axis at 14,5 mm from the skirt.
+0,18

Page 37