TABLE OF CONTENTS

DESCRIPTION PAGE BO.

M l Technical Specifications
Special Tools
Engine Schematic
Wiring Schematic
Engine emov oval & ~efitting)
Carburetor (Removal & ~ eitting
f )
Carburetor (~isassernbl~
& ~eassembl
Carburetor Schematic

Flywheel Magneto emov oval )

Countershaft Sprocket (Removal)
Transmission c isa assembly)
Cylinder head, Cylinder, Piston and
Reed Valve c isa assembly)
Crankshaft ( ~ i s a s s e m b l ~ )

)
Crankcase (~eassembly
Transmission (~eassembly)
Piston & Cylinder Matching
)
P i s t o n , C y l i n d e r and Head (~eassembly
)
Reed Valve (~eassembly
t )
Flywheel Magneto ( ~ e f i ting
Tgnit i o n Timing
Count ershaft Sprocket ( ~ ei ft t , i n g }
F i l l i n g the transmission w i t h oil
TROUBLE SHOOTING GUIDE

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 TECHNICAL SPECIFTCATIOXS

?3NGINE - Fsanco Morini MI Reed Valve

Type: Single cylinder, a i r cooled, 2-cycle, Reed Valve

Bore: 40.bMM
Stroke: 49MM
Engine Displacement : 4 9 ~ ~
Compression Ratio : 8 :1
Carburetor: Dellorto SHA 14/12
Piston: Domed head
I g n i t i o n : Flywheel Magneto 6Y-28W
I g n i t i o n P o i n t Gap: 0.35 - 0.40W
I g n i t i o n Timing: 2.1 - 2.3MM B.T.D.C.
Spark P l u g Gap: 0.5 - 0 .6y
Spark Plug Heat Range: 225 C ( ~ o s c hW7D)
Transmission Type: Automatic, in oil bath
Transmission Capacity: 1102. SAE 20 motor oil
Fuel Mixture: h o z . h i g h quality 2 cycle o i l p e r 1 U.S. gallon of
g a s o l i n e (32:1)

Transmission (primary): 52T/22T = 2.36:1

Internal Gears: 27T/10T = 2.70:l
Overall Gear R a t i o : 6 + 145 :1
 S P E C I A L SERVICE TOOLS

S P E C I A L SPANNER WRENCH
Part # 14-0506

-
~ r n W ( - = ----
--- >

SPROCKET WRENCH
Part # 14-0507

MAGNETO FLYWHEEL PULLER G E A R PULLER

(Bosch - C.E.V. - D a n s i ) Part # 14-0508
1977 Mopeds Part # 14-0501
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
 ENGINE REMOVAL

- Remove both s i d e covers from the moped.

- Disconnect t h e spark plug wire and cap from t h e engine.

- Disconnect t h e c l u t c h cable from t h e transmission housing on t h e engine.

- Unbolt the t w o nuts holding the exhaust header pipe t o the c y l i n d e r .

(8m wrench)

- Turn t h e fuel t a p to the "OFF" position and disconnect the f u e l line

from t h e c a r b u r e t o r .

- Loosen t h e clamp screw which secures the carburetor to the i n t a k e

m a n i f o l d . (screwdriver)

- Work t h e carburetor o f f the i n t a k e manifold and l e a v e the carburetor

hanging by t h e t h r o t t l e cable.

- Disconnect the magneto wire harness from t h e main harness. (If w i r e

colors do not match, mark wires)

- Remove t h e engine drive chain.

- Remove t h e t h r e e engine mount bolts holding the engine t o the frame.

(lhmm wrench)
- Remove t h e engine from t h e frame.

- Remove t h e p e d a l arms and p e d a l s from engine.

REFITTING THE ENGINE TO THE F M E

- Reverse the removal procedure.

- Replace t h e exhaust m a n i f o l d gasket w i t h a "NEW" gasket.

- Replace t h e c l u t c h cable if worn o r frayed.

- Check t h a t all wiring is r e c o n n e c t e d s o t h a t it does not l a y against

the engine or i s otherwise pinched.

- Replace c a r b u r e t o r i n t a k e manif018 bushing if worn o r cracked.

 REMOVING TKE CARBURETOR

- Turn t h e fuel t a p to t h e "OFF" position and disconnect the fuel l i n e

from t h e carburetor,

- Loosen t h e clamp screw which secures the carburetor to the intake

manifold, (screwdriver)
*
- Work t h e carburetor off the intake manifold by twisting back and forth
while pulling.

- Remove the carburetor from t h e t h r o t t l e cable by removing t h e t w o screws

which hold t h e throttle slide cover t o the c a r b u r e t o r body. (screwdriver)

- Remove the t h r o t t l e s l i d e cover, s p r i n g and t h r o t t l e s l i d e from the

carburetor as one assembly and let hang from t h e moped.

- The c a r b u r e t o r is now free a n d ready f o r service.

REINSTALLING THE CARBURETOR

- Inspect the carburetor intake manifold bushing for wear and cracks.
Replace i f necessary .
- Check t h a t the nuts securing t h e intake m a n i f o l d t o t h e crankcase are
s e c u r e l y tightened (8mm wrench), If the i n t a k e manifold has been removed,
inspect t h e reed valve assembly and replace if worn, clean the gasket
surfaces thoroughly and i n s t a l l a "new" s e t o r Intake Manifold/Reed
Valve Gaskets.

- I n s t a l l t h e t h r o t t l e s l i d e cover, spring and t h r o t t l e slide back i n t o

t h e top of the carburetor. I n s t a l l a new t h r o t t l e slide cover gasket if
gasket is deformed o r torn.

- Tighten t h e t w o screws which secure the carburetor slide cover to the

c a r b u r e t o r body. ( screwdriver)

- Activate choke lever on carburetor and check that choke releases

automatically when the throttle c o n t r o l is opened f u l l y .

- I n s t a l l carburetor back onto t h e i n t a k e manifold.

- Tighten t h e c a r b u r e t o r clamp while making certain that the carburetor is

sitting straight and not cocked t o e i t h e r side on the i n t a k e m a n i f o l d .
( screwdriver)

- Reconnect t h e fuel line securely t o the carburetor.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 DISASSEMBLING THE CARBUBETOR : ( 7 i g . 1)

DELL'ORTO CARBURETOR MODELS: SHA 14/9. 14/12 and 14/14

- Remove the a i r f i l t e r assembly by loosening t h e a i r f i l t e r cover clamp.

(screwdriver)

- Remove t h e i n n e r a i r f i l t e r element from t h e carburetor by g e n t l y prying.

- Remove the a i r f i l t e r gasket from t h e carburetor.

- Remove t h e fuel i n l e t . (screwdriver)

- Remove t h e fuel f i l t e r by prying up g e n t l y .

- Remove the float bowl by unscrewing t h e t w o screws. (screwdriver)

- Remove t h e f l o a t b o w l "0" r i n g g a s k e t .

- Remove t h e f u e l j e t . (screwdriver)

- S l i d e t h e h i n g e p i n o u t of the float carefully and remove the f l o a t .

- Remove the float needle ~ a l v e''carefully''.

Clean all c a r b u r e t o r components thoroughly by soaking in an ale01101 f r e e

solvent bath and dry thoroughly using compressed air.

REASSEMBLING T9E CARBURETOR : ( ~ i g .1)

- Reverse dismantling procedure and replace a l l filter, gaskets.

- Replace float if warped o r pourous.

- Replace float needle valve if worn.

 DELL'ORTO CARBURETOR
MODELS: SKA 14 / 9
SHA 14 / 12
SHA 14 / 14

Fig. #I

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 ENGINE DISASSEMBLY

Having removed t h e engine from t h e frame, you are now ready to begin
6iszssembling t h e engine.

The following is a s t e p by s t e p guide covering complete disassembly

f o l l o w e d by a reassembly guide s t e p by s t e p .

FLYWHEEL MAGNETO REMOVAL :

- Remove t h e left engine cover by unscrewing t h e two allen head b o l t s .

(5mm allen wrench)
- I n s e r t the special spanner wrench ( p a r t #14-0506) i n t o t h e s l o t s of
t h e magneto flywheel t o prevent r o t a t i o n and loosen t h e flywheel nut
.
(l5mm wrench). ( ~ i g #2 )

F i g . #2

NOTE: If t h e flywheel n u t is difficult to loosen, a l l o w the spanner

wench to rest a g a i n s t t h e pedal s h a f t for better leverage.
 ENGINE DISASSEMBLY

- Thread t h e flywheel puller (part #lh-0501) i n t o t h e flywheel and

tighten (2% wrench), (Fig. #3)

- Tighten the flywheel puller c e n t e r bolt (lplm wrench ) , ( ~ i#3).

~ .

- The flywheel will break free from t h e crankshaft,

Fig.

- Remove t h e s t a t o r p l a t e assembly from t h e engine by unscrewing t h e t w o

stator p l a t e mount screws ( P h i l l i p s screwdriver) , ( ~ i #~4 .
).

Fig.

1977 Mopeds
248 N. Kalamazoo Mall
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1.800.965.1977
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 - S l i d e the rubber wire guide off the engine case while removing the
F s t a t o r p l a t e assembly,

- Place the stator plate assembly back into the magneto flywheel to
prevent a l t e r i n g t h e magnetic f i e l d s .

- Remove t h e flywheel key from t h e c r a n k s h a f t using a p a i r of needle

nose p l i e r s .

COUNTERSI-WT SPROCKET REMOVAL :

- Remove the countershaft sprocket n u t using a 17mm wrench and the special
s p r o c k e t wrench (part #14-0504). Allow the s p r o c k e t wrench to come to
r e s t a g a i n s t the pedal s h a f t t o ease the removal of the sprocket n u t ,
(Fig. fS5E

/'--

Fig. #5
 ENGINE DISASSmBLY

- Remove the countershaft sprocket from the shaft by using a u n i v e r s a l

gear puller as shown in Figure #6.

F i g . #6

TRANSMISSIO%I DISASSEMBLY:

- Remove t h e carburetor if not already done. ( s e e page 6)

- Drain transmission o i l by removing o i l drain plug at l o w e r rear s e c t i o n
o f the clutch cover. (screw&iver)

- Remove t h e pedal arm and pedal from t h e pedal shaft i f not already
removed. (10mm wrench)

- Remove t h e c l u t c h cover by unscrewing t h e s i x A l l e n head b o l t s (5m

Allen wrench). A rubber m a l l e t m a y be needed to f r e e t h e c l u t c h cover
f r o m t h e pedal s h a f t .

- Remove tde clutch cover gasket.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 EBGINE DISASSEMBLY

- 9ernove the starting c l u t c h d i s c r e t a i n i n g clip by pushing in on t h e

c l u t c h d i s c and using a screwdriver to work the r e t a i n i n g clip out
of t h e c l u t c h drum, ( F i g . # 7 )

Fig. #7

- Remove the starting c l u t c h d i s c and s p r i n g .

- Hold the c l u t c h assembly from r o t a t i n g by using the s p e c i a l s p a n n e r

wrench ( p a r t #lb-0506) and unscrew the c l u t c h r e t a i n i n g nut and
washer, (17mm wrench), ( ~ i g .#8)

Fig. #8
 ENGINE DISASSENBLY

- I n s t a l l the special gear puller (part #14-0508) using two c l u t c h

cover Allen head b o l t s and remove the clu-tch assemble, (5mm A l l e n
wrench and L T m wrench), ( ~ i# 9~ ) .

F i g . #9

- Rmove t h e clutch drum assembly and bushing t a k i n g special care to note

t h e exact placement of t h e shims on the c r a n k s h a f t on both the foward
s i d e and b a c k s i d e of t h e clutch drum. These shims will have to be
reused in the exact placement when reassembling the c l u t c h and
transmission, ( F i g . #lo)

Fig.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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r - Hold t h e transmission gear s t a t i o n a r y by using t h e s p e c i a l spanner
wrench ( p a r t $14-0506). Allow t h e spanner wrench t o rest against
t h e pedal shaft for b e t t e r leverage, ( ~ i g .#11).

- Unscrew t h e transmission gear n u t and remove the washer (17m wrench),

( ~ i g #ll).
.

Fig. #ll

- I n s t a l l t h e special g e a r puller ( p a r t #1b-0508) using t w o of t h e

c l u t c h cover Allen head b o l t s and remove t h e transmission gear,
(17m wrench), ( F i g . #12).

Fig.
 FJTGIRE DISASSEMBLY

- Remove s p a r k plug (13/16 spark plug wrench).

- Progressively loosen t h e four n u t s securing the c y l i n d e r head t o

the c y l i n d e r and remove n u t s (lorn s o c k e t ) , ( ~ i g .#13).

- Remove t h e f l a t washers from t h e c y l i n d e r head.

- Remove t h e c y l i n d e r head.

- Remove the c y l i n d e r head gasket.

Fig.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 ETTGTME DISASSEMBLY

- Remove the c y l i n d e r assembly carefully so as to avoid damaging t h e

piston, ( ~ i#14). ~ .

- Remove the c y l i n d e r base g a s k e t .

Fig.

- Remove t h e t w o intake m a n i f o l d n u t s a n d washers (lOmrn wrench), (Fig. #15) .

Fig. 815
 EBGINE DISASSEMBLY

- Remove t h e i n t a k e manifold.

- Remove t h e reed valve assembly as well as the t o p and bottom

gasket. Take s p e c i a l care in handeling t h e r e e d valve to prevent
dmage, ( ~ i g .#16).

Fig. #16

- Place a rag i n s i d e the crankcase beneath t h e p i s t o n to avoid dropping

the p i s t o n p i n r e t a i n i n g c l i p s into the crankcase,

- Remove t h e t w o p i s t o n p i n r e t a i n i n g c l i p s from t h e piston using a p a i r

of needle nose p l i e r s , (Fig. #17).

Fig. #17

1977 Mopeds
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 ENGINE DISASSEMBLY

r - Remove t h e two piston rings by gently prying t h e ends apart and

l i f t i n g off the t o p of t h e piston.

- Extract t h e p i s t o n pin using t h e s p e c i a l p i s t o n p i n Extractor/Installer

( p a r t # F10025) to press t h e p i s t o n p i n out of t h e p i s t o n , (Fig. #18).

- Remove t h e piston a n d p i s t o n p i n bearing.

Fig. #18
 ENGINE DISASSFMBLP

- Support the crankcase so t h a t t h e magneto side i s f a c i n g downward.

- Drive the crankcase j o i n i n g dowels out through t h e magneto s i d e of
t h e crankcase (hammer and d r i f t punch), ( F i g . #l9)

Fig. #19

1977 Mopeds
248 N. Kalamazoo Mall
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1.800.965.1977
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 ETTGITE DISASSEMBLY

- Turn the crankcase over so that the magneto s i d e i s facing upward and
r remove the A l l e n head b o l t s holding t h e c r a n k c a s e halves t o g e t h e r ,
(5m Allen wrench).
- S p l i t the crankcase halves by using t h e special case s p l i t t e r tool
( p a r t #14-0511). If t h e special c a s e s p l i t t e r is n o t accessable, hold
the crankcase above t h e bench and t a p lightly on the c f a n k s h a f t and p e d a l
s h a f t alternately u n t i l 1 the crankcase halves separate, ( ~ i g .#21 and # 2 1 ) .

F i g . #20

Fig. #21 - 24
 ENGINE DISASSEMBLY

- Remove t h e crankcase gasket and c l e a n t h e gasket mating surfaces

thoroughly.

- Remove t h e primary and secondary s h a f t s from t h e crankcase. Take

s p e c i a l care t o note the exact placement of t h e shims on the respective
s h a f t s . These shims w i l l have to be r e i n s t a l l e d in the exact placement
they were in when reassembling t h e engine ( F i g . # 2 2 ) .

- Remove the c r a n k s h a r t by g e n t l y t a p p i n g w i t h a rubber mallet.

F i g . #22

To replace any bearings mounted in t h e crankcase, slightly h e a t t h e

crankcase surface around the bearing being replaced and g e n t l y t a p the
bearing out. I n s t a l l t h e new bearing by Lightly h e a t i n g t h e crankcase
and g e n t l y t a p t h e bearing fully i n t o place.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 ENGINE REASSEMBLY

P r i o r to reassembling t h e engine, i n s p e c t all bearings and bushings

a n d replace if worn. Never re-use gaskets, oil seals o r p i s t o n r i n g s
when r e b u i l d i n g t h e engine.

CRANKCASE RMSSEMBLY

- I n s t a l l t h e pedal s h a f t and secondary s h a f t coupled t o g e t h e r by the

chain i n t o t h e clutch s i d e of the crankcase. Make c e r t a i n the proper
s p a c i n g shims are i n s t a l l e d at the same t i m e ( F i g . #23)

Secondary Shaft Shim -

Pedal Shaft Shim = 0.8MM
0.3MM

Fig. #23

, ,
I
 ENGINE REASSEMBLY

- I n s t a l l the primary gear s h a f t and c r a n k s h a f t i n t o t h e crankcase

by g n e t l y tapping with a rubber m a l l e t . Make c e r t a i n t h e crankshaft
is i n s t a l l e d w i t h t h e propper end facing the c o r r e c t d i r e c t i o n as
it is possible to i n s t a l l t h e crankshaft backwards. (Fig. # 2 4 ) .

c
-
. ,.U* .,A^.

F i g . #24

- O i l all moving p a d s .

- I n s t a l l a new crankcase gasket.

- I n s t a l l t h e other crankcase half and t a p into place w i t h a rubber

m a l l e t , ( ~ i# 2~
5)..

*'.,&
.-
-#,
i&-:TT
.-* , ,

., ,
:"P
,;

' .
,
, ,-$
,
.---

?;a*
"

F i g . #25

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 ENGINE REASSBCBLY

/" - Drive the crankcase dowel p i n s back i n t o t h e position ( d r i f t punch

and hammer 1.

- I n s t a l l t h e nine A l l e n b o l t s and t i g h t e n t o a t o r q u e of 1-1.2 Kgm

( 7 . 2 - 8 , 5 F t / L b s ) , ( ~ o r q u ewrench and 5mm Allen wrench a t t a c h m e n t ) ,
(Fig. #26). -

Fig.
 ENGINE REASSEMBLY

- Apply some oil to t h e new crankcase seals and drive i n t o place by using 1
a piece of tube and gently t a p p i n g i n t o place w i t h a, hammer, (Fig. #27 1.

- Check t h a t a11 moving p a r t s r o t a t e f ~ e e l yimparticular t h e pedal s h a f t .

- T r i m any excess protruding crankcase gasket around t h e area. of t h e
reed valve and cylinder mount.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 ENGINE REASSEMBLY

TRANSMISSION REASSEMBLY

- I n s t a l l t h e transmission gear making c e r t a i n that t h e tapered s h a f t

i s completely c l e a n .

- I n s t a l l t h e washer and l o c k nut and t i g h t e n t h e n u t to a torque of

3.5 - 4 Kgm. (25.3 - 28.9 F ~ / L G S ) , ( ~ i g .#28).

Fig. #28

- I n s t a l l the crankshaft shim onto t h e c r a n k s h a f t , ( F i g . # 2 9 ) .

- I n s t a l l the c l u t c h drum and bushing onto the c r a n k s h a f t , ( F i g . # 2 9 ) .

- I n s t a l l t h e f i n a l crankshaft shim onto t h e c r a n k s h a f t , (Fig. # 2 9 ) .

Fig.
 - I n s t a l l t h e c l u t c h assembly making c e r t a i n the c o n i c a l surface of
t h e c r a n k s h a f t is c l e a n , ( ~ i# 3~
0)..

Fig,

C4
- I n s t a l l t h e clu-tch locknut and washer and t i g h t e n to a t o r q u e o f 3.5 Kgm,
( 2 5 Ft /~bs), (17m socket and torque wrench) .
- Check t h a t the clutch d m turns freely w i t h a minimum of lateral play.

- I n s t a l l t h e s t a r t i n g c l u t c h spring and disc, (l?ig. #31).

- I n s t a l l s t a r t i n g clutch l o c k clip i n t o clutch drum, (screwdriver, ( ~ i g .#31).

Fig.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
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 ENGINE REASSEMBLY

- I n s t a l l a new c l u t c h cover g a s k e t , ( ~ i g .# 3 2 ) .

Fig.

- R e i n s t a l l t h e c l u t c h cover c a r e f u l l y s o t h a t
t h e new pedal s h a f t seal
does not tear. -
Tighten the clutch cover screws k o a t o r q u e o f 1.1
1.3 Kgm, (7.9 - 9.4 ~ t / ~ b s (Fig.
) , #33).

Fig.
 ENGINE REASSEMBLY

- Install t h e cylinder base gasket onto the engine crankcase.

PISTON CYLTBDER MATCHING

Piston and c y l i n d e r matching is very important! Each cylinder
and each piston has a color reference painted o n t o it a t the f a c t o r y .
The four c o l o r s i n ascending s i z e a r e g r e e n , n e u t r a l (no color), yellow
and red. The d i f f e r e n c e in aiameter between each c o l o r is .005MM.
The best possible match between a cylinder and p i s t o n would be to have
both the same color. However, pistons and c y l i n d e r s c a n be matched in
the f o l l o w i n g manner.

Piston Color "To Be Used With" Cylinder Color

Green o r Neutral Green

Green, Neutral or Y e l l o w Neutral
N e u t r a l , Yellow or Red Yellow
Y e l l o w or Red Red

IMPORTANT: Whichever piston c y l i n d e r assembly i s f i n a l l y chosen, t h e

piston t o c y l i n d e r clearance must be:

- Smear the wrist p i n needle bearing w i t h oil and i n s e r t it i n t o t h e

connecting rod.

- I n s e r t the wrist pin in t h e connecting rod and bearing and check for
excessive play.

-
NOTE: If excessive play i s present t h e problem is one o f t h e three
components o r a combinakion of t h e components are worn. (EE.
piston p i n , bearing, connecting r o d ) .

- I n s t a l l t h e piston so that t h e piston ring l o c a t i n g pins face upward

and away from t h e exhaust p o r t .

1977 Mopeds
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Kalamazoo, Mi 49007

1.800.965.1977
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 ENGINE REXSSENELY

P - I n s t a l l t h e p i s t o n pin using t h e s p e c i a l pin e x ' t r a c t o r / i n s t a l l e r tool,

( p a r t # ~ 1 0 0 0 2 5 ) , ( ~ i g .#34).

Fig. #34

- I n s t a l l a "new" s e t of p i s t o n p i n c l i p s using tlie appropriate

pliers.

- Without the p i s t o n r i n g s mounted on t h e piston, s l i d e t h e c y l i n d e r

dawn over t h e piston.

IMPORTANT: Check piston/cylinder clearance by using a feeler guage.

Minimum piston/cylinder clearance = .055MM
Maximum piston/cylinder clearance .065MM
- R e m o v e the cylinder and i n s t a l l a "new" s e t o f piston r i n g s .

- I n s t a l l a "newt' c y l i n d e r base gasket making c e r t a i n that it i s

a l i g n e d c o r r e c t l y w i t h the crankcase t r a n s f e r p o r t s .

- Check that t h e c y l i n d e r w a l l is n e i t h e r scuffed nor scored.

 ENGINE RFASSEMBLY

- Oil t h e cylinder walk and i n s t a l l t h e c y l i n d e r onto the p i s t o n while

making c e r t a i n that t h e p i s t o n r i n g s are p r o p e r l y a l i g h n e d w i t h
their l o c a t i o n pins in the ring groove, ( ~ i g .# 3 5 ) .

Fig.

- I n s t a l l a new cylinder head g a s k e t ensuring t h a t t h e thin edged

copper s i d e is facing towards t h e cylinder head.

- Install t h e four c y l i n d e r head washers and nuts and t i g h t e n uniformly

in a cross pattern -to a torque of 1.5 Kgm, (10.8 F t / L b s ) , ( ~ o r q u e
wrench and 1 h n s o c k e t , it. #36).

F i g . #36

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
1977mopeds.com
 ENGINE REASSEMBLY

7' REED VALVE A S S W L Y

- I n s t a l l t h e reed valve assembly a f t e r having made c e r k a i n that the

reeds are in perfect condition. A "new" upper and l o w e r reed valve
gasket must.be used to prevent any a i r leaks. Refer back t o Fig. #16
in the engine disassembly s e c t i o n .

- Install t h e i n t a k e m a n i f o l d and t i g h t e n t h e nuts to a torque of 1.5 Kgm,

(10.8 F t / ~ b s ) , (Torque wrench and lOMM socket).

REFITTING THE FL-L MAGNETO

- Thoroughly clean t h e tapered end o f t h e crankshaft t o remove any

0i3 or grease.

- I n s t a l l t h e flywheel key back into t h e crankshaft.

- P o s i t i o n t h e s t a t o r p l a t e assembly onto t h e engine c a s e , ( ~ i g .#37).
- I n s t a l l the t w o phillips and t i g h t e n so that t h e stator p l a t e is
i--. secured w i t h the two screws m i d w a y in the elongated holes.

- Slide the coil wise rubber guide i n t o itsv s l o t ensuring t h a t t h e wires

do not i n t e r f e r e w i t h t h e f r e e movement of - t h e flywheel, ( ~ i g #37).
.

Fig.
 - Instal1 t h e flywheel onto t h e crankshaft to check and a d j u s t , if
1

necessary, t h e i g n i t i o n point gap. The i g n i t i o n point gap should be

0.35MM to 0.40MM. If t h e point gap is incorrect loosen the
i g n i t i o n p o i n t holddown screw and adJust to t h e correct gap s e t t i n g ,
(~ig.#38).

Fig. #38

The precise moment of i g n i t i o n timing can be checked by using a

d i a l i n d i c a t o r and a t e s t L i g h t , Ohm meter or buzzy box. ( ~ i g ,#39).

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
1977mopeds.com
 IGNITION TIMING

Viewing t h e engine from the magneto side, t h e crankshaft r o t a t e s

counter-clockwise when running. The magneto f l y w h e e l has two reference
l i n e s scribed into it.

The first reference line when r o t a t i n g the flywheel counter-

clockwise represents the ignition f i r i n g mark o r t h e precise moment
the i g n i t i o n points should just begin to open, (2.1 - 2.3MM B.T.D.C.).

The second reference l i n e when r o t a t i n g t h e flywheel counter-

clockwise represents t o p dead c e n t e r , ( T . D . C . ) .

Both reference lines on the flywheel have a fixed reference

p o i n t in the shape of a "V" which is l o c a t e d on t h e engine crankcase,
(Fig. #40).

F i g . #40
 To check t h e i g n i t i o n t i m i n g , perform the following s t e p s in
order.

- S e t t h e i g n i t i o n point gap to 0.35 - O.~OMM, (feeler guage), ( ~ i#38).

~ .

- Connect an ohn meter , t i m i n g light or buzzy box to t h e red magneto

wire and to ground, (l?ig. # 3 9 ) .

- Ratate t h e magneto counter-clockwise while watching your tester.

When t h e firing reference mark on the f l y w h e e l a l i g n s with t h e fixed
"V'hrefesence p o i n t on t h e engine case t h e p o i n t s should Just begin
to break c o n t a c t . Your ohm meter, timing l i g h t o r buzzy box should
verify t h i s by r e g i s t e r i n g an open circuit.

- It is recommended that a d i a l i n d i c a t o r be used to verify the

NOTE:
exact p o s i t i o n o f t h e p i s t o n i n r e l a t i o n s h i p t o top dead
center, ( F i g . # 3 9 ) .

ADJUSTING IGNITION PIMING

To a d j u s t t h e ignition timing, perform the following steps i n

order.

- Set t h e i g n i t i o n p o i n t gap to 0.35 - O.~OMM, (feeler guage).

- Connect an ohm meter, timing l i g h t or buzzy box t o t h e r e d magneto

w i r e and t o ground.

- A l i g n t h e flywheel f i r i n g mark w i t h the f i x e d "V" reference p o i n t on

t h e engine c a s e .

- Loosen, but do not remove, t h e two screws holding the stator place t o
the engine, ( I ? h i l l i p s scr,ewdriver).

- Using your f i n g e r s , reach through the flywheel and r o t a t e t h e s t a t o r

p l a t e u n t i l your meter i n d i c a t e s -the p o i n t s are jusk opening while
t h e firing m a r k and t h e f i x e d "V" reference mark a r e aligned.

NOTE : T o r e t a r d the t i m i n g r o t a t e t h e stator place i n t h e d i r e c t i o n

o f flywheel r o t a t i o n . To advance t h e t i m i n g r o t a t e the stator
p l a t e o p p o s i t e flywheel r o t a t i o n .

- Tighten the t w o screws holding the s t a t o r plate t o the engine taking

care not to shift the stator plate while tightening.

- Recheck t h e engine t i m i n g by r o t a t i n g t h e flywheel one full t u r n

counter-clockwise. A s t h e firing m a s k on t h e flywheel a l i g n s w i t h t h e
f i x e d "V" reference mark on the engine t h e i g n i t i o n p o i n t s shoula
just begin t o open.
1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
1977mopeds.com
 - Reinstall the l e f t engine cover and gasket and t i g h t e n the two Allen

- head b o l t s , (5MM Allen wrench).

SPARK PLUG

Spark Plug Gap: 0.5 0.6y-

Spark Plug Heat Range: 225 G ,
Spark Plug Type: A u t o l i t e AG32A -
Chmpion N-9Y -
Bosch -
W7D
AC -G3XLS
-
NGK BP6ES

COUNTERSWT SPROCKET INSTALLATION

- I n s t a l T t h e countershaft sprocket onto t h e countershaft.

- Hold t h e countershaft sprocket stationary by using t h e special tool

(part #14-0507) , ( F i g . #h1).

- F i t t h e washer and nut and t i g h t e n to a torque of 3.5 - 4.0 K g n ,

( 2 5 . 3 - 28.9 ~ t / ~ b s (Fig.
) , #41).

Fig. $41

REFILLING .THE TmSMISSION

- R e i n s t a l l t h e oil d r a i n p l u g and gasket.

- Refill transmission w i t h a 20 weight SAE non synthetic oil. "DO MOT

USE AUTOMOTIVE TRPLNSMISSION OIL".
P Transmission c a p a c i t y = 11 o z .
 TROUBLE SHOOTING GUIDE

Ml - REED VALVE

HELPFUL HINTS :

When t r o u b l e shooting e l e c t r i c a l components, t h e quickest and easiest

method i s s u b s t i t u t i o n .

A) Make s u r e t h a t the part b e i n g used i n the substitution i s known to be

good.

B) When a parts s u b s t i t u t i o n i s made and t h e problem is not solved. leave

t h e newly substituted p a r t i n the system u n t i l the problem is found.
Then, back t r a c k one component a t a t i m e . This method will enable
you to more effectively trouble shoot a machine which may have
multiple problems.

I. ENGINE WILL NOT START

A) Check f o r spark at spark plug.

B) Check for flow r e s t r i c t i o n s in t h e fuel system.
C) Check engine compression with the spark plug i n s t a l l - e d .
D) Check to see if the engine stop switch is i n the "run" p o s i t i o n .
E) Check Reed Valve. T

IT. IT0 SPARK

A) F a d - t y spark p l u g .
B) F a u l t y r a d i o suppressor (spark plug cover).
C) Faulty high t e n s i o n coil.
D) Faulty ignition p o i n t s a n d condenser.
E ) I g n i t i o n p o i n t s not opening.
F) Grouding wire i n s i d e the magneto.
) Magneto wiring harness burnt or broken.
B) Poor magnetism present in rotor.
I) Faulty exciter coil inside magneto.
J) Wiring or ground problem in brake light circuit.
111. GOOD IGNITION SPARK, BUT THE ENGINE WILL NOT START

A) Restriction of fuel flow (Ex. f'uel t a p , fuel t a n k , f u e l line,

carburetor).
B) Faulty head gasket.
C) I g n i t i o n t i m i n g incorrectly set.
D) Faulty i n t a k e m a n i f o l d gasket.
E) Exhaust part and exhaust pipe clogged.
F) Fiorn Reed Valve

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
1977mopeds.com
 TROUBLE SHOOTING GUIDE

Ml - REED VALVE

IT. ENGINE RUNS, BUT HAS A HIGH SPEED MISS

Faulty or worn spark plug.
Improper i g n i t i o n timing.
F a u l t y radio suppressor.
Faulty high tension coil.
Faulty or worn i g n i t i o n points and condenser.
F a u l t y head gasket.
Air leak between i n t a k e manifold and crankcase.
Exhaust system clogged.

V. ENGINE RUNS, BUT HbS LOW SPEED MISS

A) Improper spark plm.

B) Improper ignition t i m i n g .
C) Faulty or worn out ignition p o i n t s and condenser.
D) Faulty r a d i o suppressor ( s p a r k - p l u g cover).
E) Magneto r o t o r subbing on i n t e r n a l c o i l s .
VI. E3!GINE POPS AND BACKFIRES WHEN TRYING TO START

A) Ignition t i m i n g improperly s e t .
B) Faulty c y l i n d e r head gasket.
C) Faulty i g n i t i o n points or condenser.
VII. DIFFICULT TO STAXT WHEN COLD

A) Carburetor choke p l a t e not f u n c t i o n i n g sufficientlp.

B) Improper ignition timing.

'3111. DIFFICULT TO START WHEN WART4

A) Improper i g n i t i o n timing.
B) Worn out spark plug.
c) Exhaust system clogged.
D) Faulty i g n i t i o n p o i n t s and condenser.
IX. EXCESSIVE FLEL CONSUMPTION

A) Engine is not broken in ( 6 0 0 miles).

B) Carburetor choke plate stuck in closed position.
C) Carburetor flooding ( s t i c e float).
D) Leakage in fuel line.
 TROUBLE SHOOTING GUIDE

M1 - REED VALVE

X. ENGINE KRS NO POWER

A) Improper ignition timing.

B) Clogged exhaust port or p i p e .
C) Fuel R e s t r i c t i o n .
D) Worn out piston r i n g s o r engine seals.
E) Engine p a r t i a l l y seized.
F) Moped chain a d j u s t e d t o o t i g h t .
G) Brakes adjusted too t i g h t .
H) Worn Reed Valve
XI. THE EDTGINE WILL RUN ONLY IF T I E CHOKE IS USED
A) Clogged f u e l j e t in carburetor.
B) Clogged f u e l l i n e .
C ) Clogged f u e l f i l t e r i n c a r b u r e t o r o r gas t a n k .
D) Clogged f i l l e r cap vent h o l e .
E) Loose o r cracked i n t a k e manifold and gasket.
F) Loose carburetor.
G ) Worn e n g i n e seals .
XII. E2lGINE WILL RUN BUT WON'T IDLE
A) Idle c i r c u i t i n c a r b u r e t o r clogged.
B) Idle screw not adJusted c o r r e c t l y .
C) Air l e a k at c a r b u r e t o r o r intake manifold mounts.
D) Worn engine seals.

XZII. ENGINE SEIZED OR STARTS KNOCKING

A) Insufficient o i l in fuel mixture.

B) Connecting rod looseness on crankshaft.
6 ) Loose magnet in fJywhee1.
D) Piston s e i z e d to c y l i n d e r .

POOR EXGINE PERFORMANCE

V e r y o f t e n poor engine performance may not be r e l a t e d t o t h e engine

i t s e l f , but t o one o r several frequently unsuspected secondary causes.

In such case, we suggest the following:

1977 Mopeds
2481.
N. Kalamazoo
Check Mall t h e t h r o t t l e s l i d e opens f u l l y . Quite o f t e n the c o n t r o l
that
Kalamazoo, Mi 49007
is badly adjusted and t h e engine i s starved even at full t h r o t t l e
position.
1.800.965.1977
1977mopeds.com
 TROUBLE SHOOTING GUIDE

Ml - REED VALVE

2. Check that t h e r e is no braking action due to chain being too

t i g h t . Tension adjustment must be performed in the m i n g
p o s i t i o n , the machine loaded w i t h a r i d e r weighing about
165 Ibs.
3. Make sure t h e brakes are not a d j u s t e d t o o tightly.

4. Check that the fuel cap vent hole i s not clogged as t h i s m a y

bring about poor f i e 1 supply.

5. Check that t h e spark plug is in accordance w i t h t h e manufacturer's

specifications.

6. Check t h a t the exhaust is n e i t h e r p a r t i a l l y blocked n o r

blocked. If this is the case, clean out t h e comple-te exhaust
system.

7. V e r y important n o t e : Quite o f t e n poor engine performance may be

caused by o v e r t i g h t e n i n g t h e cylinder head
n u t s and thereby d i s t o r t i n g t h e cylinder.

LIGHTING CIRCUTT

LIGHTS AT ALL

A) Faulty headlamp switch.

B) Faulty lighting coil or coil ground.
C) Magneto harness burnt or grounding behind engine.
D) Wiring harness connector disconnected.
E ) Improper wire connections.
F) Blown bulbs.

11. NO BRAKE LIGHTS

A) F a u l t y brake l i g h t switch.
B) Faulty ground at rear fender.
C ) Blown bulb.

111. DIM LIGHTS AND NO HORN WHEN HFADLAMP SWITCH IS ON

A) Faulty lighting coil.

B) Incorrect bulbs.
 TROUBLE SHOOTING GUIDE

MI - REEE VALVE

TV. EXCESSIVE LIGET CAUSING LAMP BURNOUT

A) Tncorrect bulbs.
B) F a u l t y lighting coil.

A) Faulty horn unit.

B) Faulty horn switch.
C) Faulty horn wires or connections.

1977 Mopeds
248 N. Kalamazoo Mall
Kalamazoo, Mi 49007

1.800.965.1977
1977mopeds.com