1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.

com

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

TABLE 3
PART NO.
L

MINARELLI ENGINE
-.

QUANTITY

DBCRWTIOH

Standard 2 3 3 . 8 x 2.5 x 1 . b Ovexsiaa p39. O m Ovetxniae fl39=Duersfze fl39,Bm W e r r i e 939.-

mesaim 039,8rmR

NOTE:

Beginning Jawary 1, 1978 a l l Vl engines praduced will be 49.4 cc Ear 1 9 HP mdel. The fallatrS.ng parts .
apply ta t h i ~e rnd&l+ nw

Standard 33-7 Pinton Standard 33-7 Ring Cylinder 3 8 - 7 m C a ~ Iran t

NOTE:

The owtsizcir for the 3 8 - 7 m Pistm and Rings are 838.8 - $39 - P139.2 - 939.4 - 839.6 - I J 9 . B

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

--

PART NO.

W m
-

W R IWION
Cr-k

5110
5120

far Clutch Lever

1
1 ,

5136
5144

5150
5160 $170

f 1
1 ,

Return Sprlny for Clutch Lever S e t Screw far ~ l u k c h l v o w ~ Washer, gdmm, CEV Bolt for Securing Clutch, 5 ?.dA x 8mm
Rri,dge fur ClutEh Adjuster Clutch Lwer Adjuster

1
1 1 1

5180 5190 5200 5210

5220

1 1

Spxing Leaf, Upper Spring Leaf, Laver iralt-Casing , Clutch side ~falf-Casing, Fl.ywhea1 Side, for

P E-84 Half-Casing, PlyPohael Stator B E-80

stator

Side, for

Oaoket far Half-Casing, Center Dowel for Crankcaser #I0 x 4 O m B o l t , TCXE 6 PlIA X 3 0 m Cover, Clutch Side Casket for Clutch Cover C a p F O i l Fmd Gasket 101 Capl J f l h n 901t, TCB 6 HA for Oil Level end D r a i n

Gasket for Bolt, p 6 m -It, TCCE 6 YA x l5m B n l t r TCCE 6 MA x 3mqnets Flywheel, Complete, 23W 6% G/External High Voltage C o i l # Stator j394mm (CEV Mad01 68761 Wqnsto Flywheel, Cmslate, 18W 6Y, w/Internsl High Voltage cail,srator

88(hPnr [Rnsch KBb-B212)

mgneto FZph-1,

5374 5300
53 90 5400 54 10

Cmpletr, 2P 3F 6Vr w/ExtermaL High Voltage Coil, Stator j380mm [ G D I Cbdc3 6332) Wire Guide on Crarrkcaso for Internal High Voltage Coil W i r e Guide on Crankcase for External High Voltage Cnil Bearinp, f a r Alumfnum A i r conveyor only Bearing, for P l a s t i c Air conveyor only

Cooling Fan

5420 54 30 5440 54 50 546 0

547 0

~ l t TGS, 4 , x LOmm for securing Psa l i r Conveyor, Aluminum Air Conveyox, P l a s t i c Bnltr TCCE, 6 HA x 2 S m G a s k e t Ear Cylinde~B ~ w Cylinder, P38nm, Cast Iron, mdel 30km for 2Ornph
-5. _

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

S a t # Complete W/ 5230, $ 2 7 0 , 5960, 5490, 4240, &nB 5670 Snap R i n g for Shaft: $ l d m , CONE

shiaa, p14 x 2 O m , CONE Bu~hingfor clutch. CONE Clutch, Centrifugal, C m p ht a C W E Ilearing fur Clutch m a , CWSE L o @ b t for Brake Shos Bearing, CONE

Screws for plaetic air conveyor

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

TABLE 3 -DEALER T'OOL KIT FOR MINARELtl VI ENGINE

Point: Timer

I n t e m ~ d i a t eSprocket ExWactor crankshaft Exkrackor P l y w h e e l Puller tCsV Only) Sptackot BXding n o 1

Clutch Wt clv*h Puller Flywheel 1

Wronch for Cap ~ M j w t e r Wrench for Btecring mck mut

6970

OWNER TOOL KIT

PART NO.
QUAMm

MSCRWlbN
-

S p a r k Plw Wrench

Allen Wrencb 5 m

Double Enti Wrench 10117 m~

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

olroult kt~ &hunt the currant t o r a external U g h tonaim h

4mil.

The magmeto. aa deecribed. has three outputsr the l5ghting circuit, the acceoeory circuit, and t h e ignition u h u i t . A l l the Outputs a m L C - (alternating current). Any devices whshleh reqmlrc the charging o f a battexy o f f the mgnmtu w 5 l X require a r e e f i e r to ba placed in t h circuit to change the curzent t LC. a

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

TABLE 5 -MAGNETO & 94mm-CEV MOOEL 6676 2 3 ~ W

PAFn NO.

Q U A M

OSCRIPW6N

Washer, # U r n Hagncto, Complete njhll Components Inductor 4IWt~orl Can, Adjusting f o r Points

Pointa

Screw for Securing C o i l s S c r w l o x Securing Capacitor

Capacitor Coil, B i q h V o l t a g e Ear Xgnitkon Greasing Felt

Coil, Law Voltage for Light8 d far F e l t Stator* P94m

Stator.

mmpl#ta Coil Zxtemal lfigb Mltage for I g n i t i o n Screw far Securing Points

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

TABLE 7 DCLL'ORrO CARBURETOR

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

All V 1 engf nea rogarflloss o f the top apeod (17,20r25,301 a r e pirton-port type tmr-strokes. The f a l l w i n g d i s a u e ~ i o nof each type will p r w i d e rerne insight Anto how they work a d may someday prove very helpful in troubleshnnt.i.ng.
PISTUN PORT TWO-STROKE
The pickan-part --stroke is the simplest crf a11 engines. convlnarly seen in matorcycles and mpad aqal;lcaEion. I t has a n l ~ three m a i n moving parts and u r r s mrts rather than valves, an in four stroke engines, t o regulate intake and exhaust flun. T h e s e ports a n a l l located in the cylinder wall and are OFOM and closed by t h e pistans movement. TheSr functions are:

Intaka Port

* -.its

fresh fuel d x t t l r s from the carburemr tha crankcase.

Transfer Parts

Provide prrssaq~sfor t h e fuel mixture between the crankcase and combustion

~hmber:.

Exhaust

P r at

Releasea burnt gases from t h e cdbuarion

i n t o tbc exhaust pipe.

Basically with the Hinarelli V 1 enginr this is what happen6 during a 360* natation of the crank s M E t bnginni.nq with tha piston a t top dead mnter:

Ulc p r e v i w s cycle an8 exposes the ~xhaurrtport l e t t i n g n i ~ t the expanding burnt gases. Sianrltnnoously, khe pistan's damwar4 m m r m n t canpresses tha f u e l mixture from the p r e v i u s cycle or~upyingthe a i r t b h t c r a n k c a s e .
froln

1, Down Stroke Phe pSsmn descends

the p i a w n r o o t i n w s MI descendr it also r x . p s s e rhe transfer parts. The c c n a p o o d n I x t u r ~ waiting in t h e crankcase non ruahes khmugh the ports and fills the oombostion chamber while a t the same time m e p i n g any remaining burnt gases oyt
Aa

rn

Ule exhaust port,

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

COMPLETE MSASSEYBLY

MINARELLI W ENGINE

Please note that a l l steps up ta e l 5 can be &no wZth the engine mount& on the bike, although tt 5s mch esslcr t o 8 6 i t on your workbench,
~ e m o v eair cenvcyar t543D with 3 6x25 )5450 Allen bolts, and cooling fan with I Phillips aexeure ta gain access t o the magneto.

Plcaso note that a l l threads ba the N i ~ e l l are r i g h t i hand, w i t h the exception of the thr-d* in the left b n d
axad.

1 U s i n g tho specgal Minarelli f l y . wheel tool 86990 t o hold khs mgmaqneto. t NOTE: BE w r y careful m t o scratch the 2 coils. They are clear enamel m a t e d t i n s u i a h o We wLril, an8 can be mined by

meto# and a 14- qocket, remove the nut, frcm the center OE the

scratching.

2. mrcrt t h e Elywhecl puller $6950 a11 the way into : h -- ~ a l d o centerhof the the 1 wit a 2 magneto. wrench and turn the axtxactibg bolt with a l?m w ~ e n c huntil a -ping swnd I s hezwd. NOTE: T ~ G magneto i s on a 4 trd x- . -k with woodruff keyy. If the axtractar blt is extremely hard ta turn, r-ve -Met: an8 rap extractor b o l t smartly w i t h plastle mirXlct& -&I bDo othar W o l , such as a gear p u l l e r extractor* m y be used rn ~ l l a a q ~ t o . It must: be
m x t t a c t ~ d n l y - f m a the aentcr o thrsa8s or .it will be w a r p e d .

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

8*

clutch aver contains lever far cZutch arm I5100 and Wu w i n g leafs 85180 and d5190. If there i s m y noticeable wear on spring leafs, raplacs and note maring on starter plate bearing oppasfte the sprinp h a f a . N Starter a r m may be rcmowd byrerew. % i s bpcama necessary when the 8xlElm c a b h holdex i s
broken.

7. with a f i m i d r i v a r , rclaovo lock ring i5090 from huh. ~ h i o i l l w allow retainex cap Y5080r xefniner fox cap wstura spring t5070, and cap r e u r n s p t h g #SO60 ta be
Y~M~M*

%.Using Winrrslti clutch toof 16970 and a 13- s o c k e t * r-e clutch nut Q B Z ~ O and washer #503Qi

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

12. Ramve &nap ring 14860, washer 14850 and gear for clutch P4890 C a m p l e k c cllltch disaslrembly. o

with a s o c k e t , remove ihe four #555Q auks a d four 45540 washers iron the cylindcx head.

14. You can

45500.

cylinder 115480 and base gasket t S 4 6 0 . H e a d gasket #5490 w L l l #tap i n the cylinder head an8 m y appear m tro m t i e t P X t can t be remvCa w i t h a -11 scxdriver, but pencrully need not be rrplaed ar removed. IF *cplaced, be sure +o replace w i t h e m Chicknerr; as head gasket.

+emwe the cylinder head

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

*.with

caaes s p l i t yau have m e s s to ell internal gears a m shbs. W E : 1 Crank ahoultl be replaced a6 a whole unit t t 4 4 6 0 ) 2 . Idfar pin #5710 can be rmnovd from the engine Cares, 3, Spring #5770 can m m w d from pedal clutch geur 85360. 4 , Lack ring #SBOO m moves shim #5790 and pedal gear #5350 Exan t.ha 1 shaft $5740,

lols.Nm:

1 Keyed aide af crank gees . magneu, h w a i n g and w i 1 . l have a &im m it* 2 m a f h t side of tha rlrive gmrc goes bowad tho mag-

an ft also,

nate sf &, and may have a s h i m i

3, The - 1 1 gmr af the idler pear 65710 faces the magncta side of the engine cases w 3 t h shtm # S f 3a an each side.

#). Renwvo G
_ 0 .:

clips from piston 114490 w i t h nrmdls nos* p l i e r s .

case (a-g., decarbanircation) i almy8 put: 4 rag or paper tawel
whm not expecting Eo

split

the piston lo a w i d dropping any c l i g ~ , i r t , or brokon ring W r t s d into the casca o f the engine, pphieh would force on unn-essary splitting of the wserr-

in th6 C o p clrrd of the c&sea unbr

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

ASSEMBLY OF MlNARELLl ENGINE

When teasiw&ling the ninarelli engine, replace all seals a d s ar t . All parts n w k l ea and to be r e ~ ~ o d nhauld be th~xoughlycleaned and l i g h t l y oiled. All gaskets s h w l d be given a light coat of greaoe to help yeu seat thcm i n t a place and axso to inrurr a b e t t e r - . 1
NOTB:

A l l shiru ussd i n the i h a r e l l i f i t properly on kh& shafts. ~s e f t are of different diameters, a looae f i t t z n q shim i r inproperly placed, Placing the wrong thickness shim on shaft will either a l h r a looset fit i f taa thin, or not allmi r m p ring to f i t on i f 600 t h i c k .
NmE:

Imtall idler shin #5730, ldler gear #57lOs and 4 h h %9?38on to idler e h a f k which should be on clutch sideX f piston was r*trectrd from carmeeting xodr reassemble at this t . Inatall one G-clip and push in pieton w i t h piston i n extcacmr. Inskall ascond C;c ip,'maU.ng sure there i s sufficient cl4~;ramo.

ti&

'-'d'

f~stallpedal s h a f t i n t o elutch . side af c a s h w i t h sham #5?90 pedal clutch 5760, wf* sgrlng on i t r pedal gear # 5 7 5 b , - ~ h U85790, and snap ring a5800. &ich should be installed on pedpl s h a f t p r w h u n

t o iasation in t)rs.curs* 'Phtn put: an i-1 shim #5790 bn shmft next co sndp ring. HOTE: m e sure that ' w ~ uor m i a t o n painta to exhaust s i d e of cylinder. t f .nomark appears, install p i a t - so that p h o for piston r i n g 6 f*ca Pxhauot port.

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

ahaft*

Install clutch body 46180, w 4 a W #5030# artd clukch nut: #SO40 an

With Minarelll clutch 1 hold c l u t c h bady a d Car-

#6970, nut t~

21.9 Et.*lb,

lnseall spring 15060. retalnei cap for o ~ r i n g111090, ietaiaer cap #SO80 and pzeec into hausing, Lining up rotairrcrr w i t h houoinp i n alots.
I n s t a l l lock zing 15090 into - w e r and cheek rettaining cap for tarter POP proper mvenrmt, which is appro* h t e l y h m f n and out.

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

TIMING ENGINE
Ratate the flywheel by hand in a clockwioe direction u n t i l points
are f u l l y open. Check p o i n t gap and, if neceossary, reset p i n t gap, whZch a b u l d be O.Ol4in. t o

is better ta srt thr ms a t O.Olflln, as thc point9 t wear together a d will remain in area of correct adjustment lorsger.
NQTE:
Xtr

m,: t.

0.010itt Ib.35-Oa4a#rm]. The carrect point gap setting i s e o o a n t h l before the ignit i o n tinf ng operation can be carr3ed

To s e t timing., rotate the magnetu flysrheel i n a clockwise d i r e t i o n ( n ~ t m a r m on flywheel) until the , first lane cm the fXyvhoal aligns w i t h the arrow on the ca#lw. This poeitian i s 23 degrees h h r c tap dead center. The points shauld j u s t etart to open a t thitr alfgnmenL

tr.,

Proper alignment cafi k chccksd by k removing the blue wlrt Irm any ground and oonneoting thewire t o a oontiauity tester te. g. bum box1# multi-meter, etc. ) and to

gxoud.

MAGNETO

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

Tr 3w the Mtnarelli V 1 Engine in .

1, 2.
RemCwe lefz Emtrest. lkmw a i r cmwyor (5430). 3. Immue fan 5410) 4. For cbnvenidnes remove bearing f o r conveyor 5380). 5, Rotate klywhr.1 b hand in a elo~ktuiecdircctim until points are fully wen; o eck gap end if necersnr rsrrot point w p which s W d be .014 to .618 (0.35 t o 0 .

. E

&.

)IOTE;

Tlse corract poLnt s e t r i n g is essential before rhc &nitLan r l e g operarim can be catrfod out.

w p

(0) &ad cmkirr.

cop dead center

(A)

i s 230 degrees befare top

6.
7.

Renovc bllra and red wixcs fxam connector locatad above magnoco.

Connect c o n t l a u i t y checker (buzz box, bulb w d battery or rcsiatance scale of meter) betred wire and case of m g i a t . NOTE: Leave blue usre free,

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com

Technical Data

* Model - mmre1lL VI: * Sfn Le Cylinder 2 stroke * CubPc: Ca c i r y : * Bog@:

5 . 6 cc 49.4 cc

- 20 mph 30 mph - 25 and

26 m h p 25 and 30 mph

* * eDqression Ratio: 8 t o * Horsepower'@ 4800 rpm:

l.00

38.0 arn 38,8 m Strake: 12.0 mm

* Piston t o waLl

= Rt f a Z
*

coil, FWl Mgxture: HinarellL aynrhrtLc o i l , 66 t o I Synthetic 051 - 40 t o I mixture, of recamended a 0 m . or

running Ln

clmeraner .[1025" .005" rebore SlE ,002'' elsaranc& - 012" ani ti httng: Plywhee 6-mlt: magneto wLth 23 watt capacity and external high t m s i o n c o i l s t o p light operated by grounding of low tension f-ftion

- 25 mph 30 w h 20 1.90 and

* Startinet Padel and Clutch * Clutch t Automatic centrifugal expanding, 051 * tubrication (Clutch and care^) Cspaclty : * FTnal reduction
of 3.593 t o 1 clutch gear: secondary gear: 52 toorh

1 pint M E 20 oil
15

- touth;

FINAL TRANsp4ISSII)N A P RATIO W

* brim by

s i n le xm? chain 1/2 x 3/16; 11-tooth engine s p m c c t to &&tooth wheel sprocket ratio: 2.73 t o 1

1977 Mopeds 248 N. Kalamazoo Mall Kalamazoo, Mi 49007 1.800.965.1977 1977mopeds.com