I

DISMANTLING AND REASSEMBLY INSTRUCTIONS

VERTICAL CYLINDER ENGINES

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TABLE OF CONTENTS

. page 2

TECHNICAL SPECIFICATIONS

SPECIAL TOOLS AND TOAOUE SPECIFICATIONS

ENGINE REMOVAL

ENGINE DISASSEMBLY (common

CLUTCH DISMr\NTLING. SINGLE SPEED . . . . . . . .

CLUTCJ-1 DISMANTLING. 2 SPEED AUTOMATIC

CLUTCH AND PRIMARY DRIVE DISMANTLING. 3+ 5 SPEED

GEARBO X A I~ OSE CO N D~\R Y DR IVE DI SMAN TLI NG .

GEARBOX AND SECONDARY DRIVE DISMANTLING, 15 SPEED . . . . . .

ENGINE REASSEMBLY. SINGLE SPEED. 2 SPEED AUTOMATIC . .. .

REASSEMBLY OF DRIVEN GEAR AND CLUTCH, SINGLE SPEED .. . . . .. _. . . . .

. ...page 19

REASSEMBLY OF DRIVEN GEARS . FREEWHEEL AND CLUTC H. 2 SPEED AUTOMATIC

. . . . page 20 .,. 21

REASSEMBLY OF PISTON. CYLINDER AND CYLINDER HEAD. SINGLE SPEED. 2 SPEED AUTOMATIC.3 SPEEO

ENGINE REASSEMBLY. 3 SPEED

ENG INE REASSEMBLY. 4 SPEED

ENGINE REASSEMBLY. 5 SPEED

REASSEMBLY OF ?RIM/a.RY DRIVE AND CLUTCH. 3-45 SPEED

PISTON, CYL INDER. CYLINDER HEAD . . . .

- ... .. page 3
.page 4 "' 5

..
op e r:~tH:ms

. page 6

to all modelsJ

11

. . . .. .. . . . . . .. . . .. .pJga 9
. . . . . . . . . . . . .. . ... .page 10

. .page 12 -;- 13

SING LE SPEED. 2 SPEEIJ AUTOM.AJ IC. 3 SPEED

.. .. page 14

. . . . . . page 15
.p;:ge 16 - 18

page 22

.. . _ . _. . _ . __ . _. _. .. .. . . .. . . . . . . .. . . . . . . . . . . page 23 ~ 25
.pa~e

26 "'- 27

.. page 28 -:- 29

. , . . . . ..

.page 30

. .page 32

31

TECHNICAL SPECIFICATIONS
GARELLI

E NGI ~I E

SmgiE' cyhr!ler 2 stroke

Displacement

cc.
CIJ.IO_

Bore

m~

In

StriJke

mm.
1n

Pollltl'. IJ&P

3 SPEED

4 SPEED

5 SPEED

::J

49
2,989

49
2.989

119
2.989

3.026

40
1.574

40
1.574

40

40

40

1,574

1,574

1,57.!

39

:)9
1,535

39

39

39, 5

1,535

1.535

1,555

0,35~0.45

0.35 0,45

o.:.5-:-0.45

.014+ .0 18

.014-r,018

SINGLE
SPEED

AUTOMATIC

Cl

49
2.989

1 535

mm. 0,35+ 0,45

1n.

.01 4+ .018

2 SPEED

0,35 +0,45
.014 +.0 T8

49.6

.014+ .018
I

lgnil1on hnllng
correspona1ng to

26~

23'

23"

mm

1, 60

1.80

1,80

.070

.070

.070

1,60
.070

2,30

1n.

[!

[I

S':utmg: pedats

ktcKstarter
-

23.

23

.090

ClulCIY
c~nl11 1 ugill

.:tutomatu. 111 011bat11

h1ed mult1disc 10 oll ll<tth

[1

- Geartox:
s ogle :>peed
2 speed automat1r.

0
0

3 spe&d ~1andsr ifl

4 speed taotsl1ift
5 speed lootsh1rt

lJ

u
0

Pnm<ll)' reduction

18/6 7

~ 81 67

16167

16/67

18167

14139

14{39

14{39

25158
-

Secondary reduction. 1st speecf

Secondary rodt ct10n 2nd speed

20133

20/33

1B/35

Seconaa1) rt:tkCtlull, 311 ~peed

24129

24129

22131

Secorda rv radoction . 4:h speed

Seconda1y reduction. ~lh sprrd

Cl rburellor . Deii'Or!o lypc

Gt:JI tJO:>' 011 Cn j.J:~c:11y l!'"tJ FIAT VS~ 'JO

(Sl\E 30)
cc.
cu in

14139

141S9

27 26

24129

26127
SHA 14i1 2

350
21.35

SHA 14112

.'350
21,35

SHA 14112

450

27,46

SHB 18112

SHB 18/12
SHB 19/198

SHB 191198

450
27.46

1150
27,46

I
I

SPECIAL TOOLS

TORQUE SPECIFICATIONS FOR

SCREWS & NUTS

TOOLS
M . 7~2

Er.trar:ror tool lor CEV

and DUCATI flywheels

SINGLE

2 SPEED

SPEED

AUTOMATIC

[j

IJ

SPE.ED

5 SPEED

6J 753 l lolding tool fw orirnaro,

driving sprocket

3 SPE.EO

64 756 Ho rirn~ tOol to cranotShaft

drr\rng soro:kel

64 751 AOJu~tiio e 6-xlr2C!Or :aol

Cl

r-

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64 759 Dnit i or gudgeon prr

[1

l1

64 766 Too-l for 11ub body

[l

64 7G7 Holding tool for clulclr hLb

6.; .7li8 CIUch

~ll<iC!O I

64.777 CheckrliQ tool lor gears

location
64 779 Extractor tool to Bosth
llywh(!els

61 781 l lolding laol for flywiHtel

~ nd drrven oe<Jrs

6" 784

--

Cl

I.J

Holding tool ior lreew:1eer

catches

61.785 011seat prottclion too

bcconr1arv ; ~all ,

6L 786 Oilseflt protectron roo

tdr ve s de)

1)4

I~)

6..!1 ":'5(-

' ~ .-.

~--

SINGLE

TORQUE SPECIFICATIONS

--

CYLINDER HEAD NUT

FLYWHEEL MAGNETO NUT

CLUTCH 1\IUT

K9n1
IO .Jil.

CHAI N SPROCKET NUT

CRANKCASE SCREW

n
,.47b

MJ}; FI.

.....

SPEE:D

2 SPEED
AIJTOMATrC

3
SPEED

4
SPEED

5
SPEED

1'.5-o-1.6
0,084-o-0.10

1,5+1 .8

1 .5 ~ 1,S
0,084-;-0, 10

1,5-o-1.8

1,5+ 1,8

O,OB4+ 0,10

0,084+0.10

0,084+ 0, 10

rrr 'lb.

3+ 3,5
3+3,5
37 3,5
3+3.5
3+3,5
0,168.:..0,196 0,168+ 0,196 0.168+ 0. 196 0, 168+0, , 96 0 ,168+ 0,196

Kgm

3-o-3.5
4,5+5
4,5-;-5
a.~+4 1 4.~~5
0. 168-;-0.196 0.196..,..0,224 0,252-;-0,280 0,252+0.280 0.252+ 0,280

Kam

in b

DRIVEN GEAR NUT

rn IO.

4+4,5
8 6,5
0.2'24-'-0,252 0,448+ 0,476

Kgm
in. lb.

6+6,5
0,336+0,364

Kym

Kgm

0.8

rn lb.

0.044
I

6H>.5

0 . 335 + 0 ,36~

0,8
0,044

6+ 6,5
6+6.5
&+6, 5
0,336+ 0 ,364 01,33-6+ 0,364 0,336+ 0,364
0,8
0,044

0,8

(l3

0.044

0.044

ENGINE REMOVAL
After removing engine covers. if any, the chain cover, the star1ing and gcarchange pedals , tor whicl1 no special toois or
procedures are required. proceed as follows:

Remove tt1e silencer us1ng spec:1al tool 64753 (for

single Sl}eed. 2 speed <iulomatic. 3 speed models) .
For the other models simply loosen the two nuts with
an 11 mm 1.433" ) open end wrench.

Disconnect the starting cable using a 17 mm !.669' ')

open end wrench as illustrated .

With a screwd river remove carburettor from the engme but leave it CQnnected to the frame

ENGINE REMOVAL

Disconnectthe wires from the terminal block. as well

as the spark plug and the engme cut-off wires.

Break tne chain by removing 111aster link

Remove the engine by loosening the 3 "B '' mount1r1g

bolls. using a 13 mm ( 511") socket.

ENGINE DISASSEMBLy -

COMMON OPERATIONS TO ALL MODELS

Remove the 4 nuts holding the cylmder head usmg

one 11 mm 1.433..) box spanner L1f1 the head and
:he barrel over the 4 studs and remove the cylinder
base gasket.

Remove the two gudgeon pin reta111111g e~rc l ips with

the pliers.

Remove the oiston gudgeon p1n us1ng t11e extractor

64759 and a mallet , berng carelul to support the
p1ston on Ire oopos:te side.

ENGINE DISASSEMBLy -

COMMON OPERATIONS TO ALL MODELS

Using the toot 64781 to 11otd the llywhe-el. unscrew

tile flywl1eel retaining nut with a 14 mm (. 551'' )
socket.
Remove the spring washer.

-CAUTION
Befon! usmg the extractor. the external Hmads and
those cf the center bolt sMulct be 11glltty greased
Screw the extractor 64 779 (ior Bosch flywheelsi or
64752 (lor the othersi into Ule threads of the flyNheel, then turn tile e>~t racto r center bolt in a clockwise
d irec~ion to pull the flywheel off tile laper: keep holding the rota r with the tool 64 781

l'vl2ke a scriber mark S" across tile bottom of the

stator plate and the crankcase in order to facilitate

re-tirning on assembly_ Remove the screws uV1
holding the stator pl2te to the crankcase . Remove tile
Wood ruff key from the cranksl1aft .

ENGINE DISASSEMBLY -

Using the tool 6H53 and 22 m'Tl t 866"1 wrench

remove the nut and the lock wash er. then pull the
sprocket lrom the sr aft.

Dra1n oil 'rom the gearbox and clutch by removmg the

drain plug on th:: boitom of the eng ne

Renw;e the lett s1decover and its gasket by tak1ng out

the s1x screws that hold 1! to t11e crankcase

COMMON OPERATIONS TO ALL MODELS

CLUTCH DISMANTLING -

SINGLE SPEED

Using the needlenose pliers remove tl1e circlip and

the spring from lhe clutch assembly.

Using 1he 1ool 64767 and a 17 rnm (.669") socket

remove the nut locking the clutch hub. Then slide the
clutch hub and housing from ths crankshaft.

Holding the gear with the lool 64 781, unscrew1he nut

with a 17 mm (.669") socket.

Use extractor tool 64757 and a 19 mm (.748")

wrench to remove the gear.

CLUTCH DISMANRING -

2 SPEED AUTOMATIC

Remove witl1 the screwdriver the pressure plate from

the 4 rubbers.

Holding the clutch body witn the tool 64756, usc a 17

mm (.669"') socket to unscrew the nut. then remove
the washer.

Take the assembty ot two clutches comple1e with

gears and slide il from the crankshaft.

CLUTCH DISMANTLING -

2 SPEED AUTOMATIC

Hold the gear with the tool 64781 wh1le unscrewing

the nut with a toque wrench.

Remove the 2nd ~ peed gear and then the 1st', .,,.hi le
holding the catc h~s with t11e tool 64784.
Then slide the clutch hub o:nd washers.

'11

CLUTCH AND PRIMARY DRIVE DISMANTLING

Take off the lock nut and unscrew the clutch rod . Take
the extractor 64758. act on its screw first. then
tigl1ten the nut " D" with a 22 mm (.866--} socket to
make the spring group pack together.

With the pliers remove the ci rclip . the spring plate

and Lhe clutch discs.

12

Hold the clutch hub with a 30 mm t 1.181.. ) wrench,

unscrew the lock nut with a 17 mm 1.669") socket ,
slide tile washers , the nut and Lhe hexagonal body.

3-4-5 SPEED

CLUTCH AND PRIMARY DRIVE DISMANTLING

3-4-5 SPEED

Hold the gear with tl)e tool 64756. remove ttle nut
with a 14 mrn (_551 " ) ~olygona l wrench_ remove Lh e
spring washer.

Hold the gear with the tool 64 757 operate ils centra

sCt"ew and slide tile gear fromt he crankshaft with ii 19

mm (.748" ) wrench .

COMMON OPERATION TO ALL MODELS

Remove the 10 crankcase screws from !he nglll hand
crankc.ase . Slnke the ends of the crankshall "A" 2ncl
of the primary shaft " p,. alternately with a mallet until
the two halves or Lhe crankcase separate.

13

GEARBOX AND SECONDARY DRIVE DISMANTLING

SINGLE SPEED - 2 SPEED AUTOMATIC

-

Remove t he crankshait. the pri mary shaft, and the

secondary shaft ana the pedal shaft together.

3 SPEEO
-

Slide the starling assembly ,, p1>-_ the gears " h tram

t11e secondary shaft. tile primary shaft ,.p,. and the
crankshaft A" from the crankcase , using a mallet if
necess.:ry. Making use of a magnet. remove the 7
pips from their housings in the second;;rv shaft

Unscrew the nut "N" that secu res theselector " o ~ to

the shaft "H". slide out tile sllatt complete and the
serondary shaft. To make this operation easier. secure in the open position the catct1 .,s))

14

GEARBOX AND SECONDARY DRIVE DISMANTLING 4-s sPEED

Slide the stllrting assembly "P1" , the gears " I" from

the secondary shall. the primary shaft " P" and the
crankshaft "A" from the crankcasB. using a mallet if
necessary
For tile 4 speed engines only: making use of a magnet
remove the 9 pips from their housings in the secondary shaft.
Remove the seconda1y shaft "Sl" together with tt1e
selector assembly. taking care to remove first the 2
hexagonal screws ~ F2 and the top spindle P3.

Secure in a vice the secondary shaft of the 5 speed

engine, draw back and slide ott tile slider taking care
not to lose the sp rings and locating balls.

'

'

1S

ENGINE REASSEMBLy ..

SINGLE SPEED, 2 SPEED AUTOMATIC

Before s ~arting to ilssemblc the: unit. carefully olean and sligh tly oil all the parts _

Using the Lool 64785msert in tile nght !land crankcase the secondary shaft along Nith the pedals shaft
with the cha1n. the starting spring and tt1e starting
assembly. Then fit the primary shall and sh11n VIasiler_

Insert ttle crankshatt into the crankWJse. lightly tapping it w1th a mallet.

16

ENGINE REASSEMBLy ..

SINGLE SPEED, 2 SPEED AUTOMATIC

Before starting to assemble tt1e unil. carefully ()ean and slightly oil all the parts

t..lsing tile lool64785 msert in the nght hand crankcase the secondary shaft along with the pedals sh<!ft
'.vith the chain. the starting spring and tile starting
assembly. Then fit the primary shall and sh1111 '.Va-

slw .

Insert the crankshatt into the crankcase. lightly tapping i t w1th a mallet.

16

ENGINE REASSEMBLy -

SINGLE SPEED, 2 SPEED AUTOMATIC

Join the left crankcase w1th the rigtlt one acting as

follows:

a) Make sure that the faces of the cases are clean and
b)

c)
d)

e)

free from burrs and that the dowels are 111 posi
lion.
Slightly grf.'.ase a new gasket on botl1sides , ',~J h i ch
is lo to be insertcd between tt1e two crankcase
halves.
Using the tool 64786, press the two crankcases
by hand and then tap them together w1th a mallet
Fit and tig hten 1he 10 screws joimng the cases.
Check Ulat the crankshafl, the primary shaft. the
secondary shaf1 and the pedal shaft tu rn freely.

Willi the excepti on of the Bosch flywheel, Jnsert Ule

distance piece under the stator plate, fit t11e plate so
that the scriber mark " S" previously mr~de is in line.
tighLen the mounting screws Vl "

Fit thewoodruti key in position on the crankshaft. slip

111~ fi)'Wheel r~nd rotate 11 until it is felt that the key is

correctly seated.

ENGINE REASSEMBLy -

SINGLE SPEED, 2 SPEED AUTOMATIC

Rotate the f1ywheel by hand in the clockwise directiOn

until the points gap is in the .vi des! position ..At this
instant clleck lhe gap with a feeler gauge. reselLing if
necessary to 0.35 : 0.~5 mm (.014'. :- 018"i
Check the timmg, which is correctly set when the
poinls begin to open at 23 B. T.D.C. (for 5 SfJCCd
only: 2G' B.T.D.C.) {see owners manual) .
To check the timing rotate the flywheel m the clockwise dtrection so as to line up the arrow " F3 on the
flywheel and the mark <d 3" on the crankcase: in this

position U)e poims should just begin to open. If they

do not. sl ip off tt1e fi)1Wheel. loosen the stator p l~te
lstening screws. rotate tile plate in the ap~roprit~te
direction, lightly refit tile screws. refit the flywheel,
check the gap.

Wilen satis1ied 1hat the gap is set c.orrectly. fit the

washiH and tighten the fastening nul, using the tool
64781 and the 14 mrn (.551'.) socket previously
used when disrn;mtling.

F1t the cha in ge2r and the two shim washers on the
secondary silaft. using the tool 64 753 and a torque
wrench t1 g ~l!Bn the nut to 6+ 6,5 kp m. (in. lb.
0.336-;. 0. 364}.

1S

REASSEMBLY OF DRIVEN GEAR AND CLUTCH

Turn the engine the opposite side, place on the primary shaft the gear, the washer and the nut and.
us1ng the lool64781. tighten il to 4 : 4.5 kpm (in. lb.
0.224 + 0.252) with the torque wrench_

c
,1

Fit the clutch assembly and hub following tile illustration.

Before mounting the plate ..s,. the elaStiC body C"

and the circlip "A'' . with the tool 64767 and torque
wrench tighten to 3+ 3 ,5 kpm (in. lb. 0, 168+ 0 , 196)
the nul fi x111g the clutch hub to the crankshaft

,./

SINGLE SPEED

REASSEMBLY OF DRIVEN GEARS FREEWHEEL AND CLUTCH

2 SPEEO AUTOMATIC

Place gears and freewheel 011 the primary sl1aft as per

rllustratrorL Use t he tool 64 784 to l1 old in place
sprtngs and catches wllen sl it:ling ttle 1st speeo gear.

CAU TION: 111e freew'leel hub shall be fitted so as to

illlow th:: 1sr spe~d gear to turn free w11en rotatea 'n
!he counter-clockwrse directiOn.

With the tool fiJ7R1 an d torque wrench tighten to

8-'-8 .5 kplll (ln.lb. D.44S~0 . 476 r the nul fixmg tne
gears on ll1e prim<lrf shaft.

_'0

REASSEMBLY OF DRIVEN GEARS FREEWHEEL AND CLUTCH

2 SPEED AUTOMATIC

Reassemble the clutch assembly as illustrated.

When at the disc "0". place the 4 rubbers ,,G., in the

correspondig holes. The rubbers ends should iace
towards the Duler side of the engine and the thicker
lined lace of the dtsc towards the inner side.

Hold lhe 2nd speed housing ,, c ~ wtth the tool 64 766

8nd tighten the nut to 3+ 4 kpm (in.lb.
0.168 + 0 ,224) with the torque wrench.

Sitde the cross shaped plate "S" with t11e pliers on t11e
4 rubbers G as illustrated . then cut the 4 rttbbe rs
ends.

:11

ENGINE REASSEMBLy - PISTON, CYLINDER. CYLINDER HEAD

SINGLE SPEED, 2 SPEED AUTOMATIC , 3 SPEED
Once the mentioned opera lions are acco m plis ~1ed . before fittlllg the cover make sure the two rubber bodies 1urn free on the
hubs.
Make sure that the faces of the left hand crankcase and of the cover ilre clean and tree from burrs. slightly grease a new
gasket and place 11 on !he crankcase face. Make ce11a111that the cover fits the 011plug and washer. Place 111c cover on the
crankcase and lig hten the 6 JOining screws

Ref1t p1ston w1th needlebeanng. gudgeon pin and

circ11ps as i ii Us l r<J t ~d and rnake cer1a1n that the circlips are ~rope rly inserted in their grooves.
Make sure tilat .. s,. on the piston 1s towards th e
exhausl port .

Check that the crankcase upper face and ltle cylmder

base are clean and free from burrs . L1ghtly grease a
new gasket on both sides and lay it on the crankcase
face. Oil the cylinder bore and lhe p1ston sk1rt.
Lower t~m cyl inder ontu :he p1slon Wilh f1ngers cornpressing tt1e rings into n e bo re . Make sure that : he
ends of tne piston rings are properly filled in pos1t10n
against the pegs oi the ring grooves Slide tte cylinder along the a studs and itt it 1n place

Check that the top of the cylinder and U1e face of the
head are clean and undamaged . Fit tile head over Ihe
studs and place tt1e 4''lashers and nuts on the stuas.
T1ghten the nuts gradually in a cross palletn.
The final torq ue shou ld be 1.5: 1 .8 kpm (in.lb;
0,084 ""' 0, 10)'
Ret11 the spark plug.
Thro11gh tl1 f. hole on the left hand cover fill the crankcase wittl abt. 350 cc. 1cu .m. 21 .35.1of FIAT VS-'30 !SAE 301 oi l.

ENGINE REASSEMBLy

3 SPEED

Fit as illustrated the clutch le11er with return spring

and tighten the sere:. on the opposi te sid e of the
crankuse_(Th1s operat1on also applies to the 4 speed
and 5 speed engines) _

Fit n1e selector S~ . tl1c pm " p" and tighten the nut
inside the crankcase.

Mount tl1e pin " P". the spring ''M" and the gears
locating lever. screw but do not tighten the locknut.

Slide the seconda ry shaft in the support and then m

me bearing. using the tool 64 785.

ENGINE REASSEMBLy

3 SPEED

Put the gea rchange in the <( ne utra l ~ position and

adjust it actin~ with a scre'Ndriver on the pin ,.p, until
when the protrusion on the sirding axle is in the centre
between t11e hole of the lsi speed and that of the 2nd
speed.

Pi a~ the balls in ttle respective

holes on the seconda-

ry shall and hold them m place with some grease.

Mount lhe primary shaft and then the gears on the

secondary shaft. Make sure that the toofhm gs are in
line_

-24

ENGINE REASSEMBLy

3 SPEED

Mount the distance piece, the shatt. the engagement

for starting with gear as shown in the illustration.

Slide lile crankshaft. lightly tapping 1t With c. m2llet.

a)
b)
c)
d)
e)

Join the lelt crankcase with lhe right one acting as fol lows:
Make sure that the faces of tl1e cases are clean and free from burrs and that the dowels are in place.
Slightly grease a new gasket on both sides. t.~hich is to be inserted between tl1e two crankcase halves.
Press the t,vo crankcases. b~/ h~ n d then tap them together with a mallet.
Fit ;md tighten tt1e 10 screws joining the cases
Check that the crakshah. the rima1y shaft. the secondary shaft tum freel~ -

.,..;:..:J

ENGINE REASSEMBLy

4 SPEED

To mount t.ne sleeve and slider on the seconaary

sl1att. hold the assembly in a vice as illw;tri!ted .
The slee1e side having the hole at 4 mm e1should be
up.
Slide the dowel " S lull~ in with a 3 mm 0 center
ounch , which should engage also into the transverse
hole or 111e slider , c, _
Wilh a calk,ing tool make <1 cross mark on the hole to
avoid 1hat ttle dO'ilel may get out.
Note: Check that the mark 1s such as to hold Ihe dowel
in place.

Assemble the selector group as illustrated

\\

Once thegroup is assembled. the spring " M" should

be engaged with tile plate "p,. and anchor A as
illustrated

Slide the selector group into the right hand crankcase. lightly tighten the 2 hexagonal screws .

:!.(1

ENGINE REASSEMBLY

4 SPEED

Fit the: clutch lever ilnd spring and tighten the scre1v
on the opposite side of the crankcase.

Fit the gearchange lever "C" slrpping the gears operating slider into the slee've 0 placed on the secondary shaft
Insert the secondary shalt in place makrng sure that
the grub screw <F on the lever .,c,, is properly
seated in the slide of tre selector drum "G " .
Then trghten the screw "P3.

To ch ~ck and adjust if necessary tile gears position,

act as lollows:
a) Ope rate the gearchange lever to drive tt)e sliding
axle protrusion rn the 2nd or 3 rd speed posrtion
and make sure that the slider sideway swivel (bott1
up and down) is steady and not excessive or
defective.
b) To regulate tl'iis. rotate the gear selector quadrant
.. o.. in the appropriate drrection untrl adjustment
is got, th en tighten tile 2 screws <<V.

Slide the crankshaft A in the right hand crankcase

and the primary shaft .. p, in place.
Slide the gears group .. ,. on the secondary stlalt "S"
taking care that the balls previously fitted do not get
out from the shaft.
Fit tile starting assem bly G in the selector group.
Make sure thai the spring M is correctly sealed.

27

ENGINE REASSEMBly

5 SPEED

Hold the secondary sl1afl in a vice. Slide the sleeve tar

enough to leave the hole F2" exposed . Place in the
hole the springs and Ihe 3;' 16" balls .. 53 .. (one eact1
sidel

Using two punches press tile balls inward towards

oneanorhe1and at til! same tune push thesleeve over
!hem

Assemble the selector group as illustrated

To have the group assembleu correctl\1. the spring

" M should be engaged with the plate " P" and Lhe
anchor A as per illustration.

Fit the gearch;:mge lever "C'' sliding the control fork

o.. , then place H1e slee-ve in place
using the tool 517B5

111to ihe sleeve ..

ENGINE REASSEMBLy

5 SPEED

Fit the clutch lever and spring and tighten the screw
on the opposite side ol the crankcase.

lnser1 the selector group in Ihe right hand crankcase .

making surethat the grub screw" f,. on the lever"
is properly seated 1n the sltde of the selector drum
G. Tighten the 2 hexagon<ll screws ~ V .
Then tighten the screw .,p3,, and nut. The more the
screw 1s Light, U1e more accu rate is the speed passage.

Using the tool6477 7, operate the gearchangelever to

drive tl1e sleeve nibs " N" 1n the 2nd and then in the
3rd speed position. and make sure that the slider
sideway swivel (both up and down) 1s steady.
To regulate this, rotate the gear selector quadrant
D in the appropriate direction until adjustment is
got. tllen lighten the 2 screws V~.

Slide tlle crankshatt "A" in the right hand crankcase

and the primary shaft . p. in place.
Slide the gears group,, I on the secondary shaft S.
as wel l as lhe shim washer ana the starting group

c..

~G ~.

Check that at each pull tl1e sleeve nib is in the oentre

of ti1e gears marks.
Make sure that the spring <M is correctly seated.

2'1

REASSEMBLv OF CLUTCH .. 3-4-5 SPEED

Place Ihegear and tl1e elastic washer on the end of the

crankshaft With the tool 64756 and torque wrench
tigl1ten to 3,5-7 4 kpm . (in.lb. 0.1957 0.224).

Assemble the clutch as illustrated

Place on the pnmaf)' shaft the slwn washer R . the

clutch housing C. the oH' er shim washer << R.fit
t11e clutch hub "M'' , the washer " D" and the nut "G".
Hold the clutch hub with a 30 mm socket and tighten
the nut G)> to 4.57 5 k~m (in.lb. 0,252~0.280) with
the torque wrenc11.

30

REASSEMBly OF CLUTCH -

Place the clutch discs " F-H taking care that the H)
discs mbs face outwards
Mount the springs holder plate, following the inverse

procedure as when dismantling.

With alo mm (.393''} socket and screwdriver adjust

the play (6-'-8 rnm) (.236" -'- .314") of the clutch
discs control rod.

3-4-5 SPEED

ENGINE REASSEMBLy -

PISTON, CYLINDER, CYLINDER HEAlD 4-5 SPEED

Grease the bore of the s.mall end and the 21 needles

2 x 11.s. insert them in the small end eye l1oldmg
them in place w1th the drill pin bust1 64759.
Slide the piston over the connecting rod making sure
that the "S"' on the piston IS towards the exhaust

port.
Place the gudgeon pin on th e dri ft pin 64759. insert it
through the piston and the small end bDre forcing out
liHJ bush. then slide 1t out.. Fit in place the two gudgeon pin rings and the piston rings into tl1eir grooves.

Check that the crankcase upper face and the cylinder

base are clean and free from burrs. Lighlly grease a
new gasket on bon1 sides and lay it on tl1e crankcase
face. Oil the cylinder bore and ttle piston skirt.
Lowe r the cylinder ontJ the piston with fingers cornpressing tl1e rings imc the bore . Make sure that t11e
ends of the piston rings ue properly fitted 1n position
agamst the pegs ot the rings grooves. Slide the
cylinder along the 4 studs and fi t it 1n place .

Check that the top ot the cyl inder and the face of the
head are clean and undamaged. Frl the gasket and the
studs and place Ihe '1 washers and nuts on the studs.
Tighten the nuts gradually in a cross pattern.
Ttle linal torque should oe 1,5~ 1 .8 kpm. (in.tb .
0.084 :- 0, 10).

Th en refit the gea rchange and starting pedals , tile

carbu rel1or and rhe spark plug.
Til rough the hole on tiH left hand cover ti ll n1e cr~nk
casevvil h abl. 450CC. ICU.in 27 L6 ) of FIATVS + 30
(SAE 30) oil.

for reassembly ol tlywheel magneto and cl1ain gear follow the same procedure as illustrat;;d at pages 17 13
No special instructions are needed to mount tile complete engines on th e frames. but follo'N the inverse procooure as
shown at pages 4-5.
31

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s.p.a . monticello brianza (Como)

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SINGLE SPEED - 2 SPEED AUTOMATIC PEDALS STARTING AND KICKSTARTING

TABLE OF CONTENTS

fE.CHNICAL SPECIFICA fiONS

SPECIAL TOOLS ANO TORQUE SPECIFICATIONS ... ........ .. ....... .... ... . ................. page 3

ENGINE REMOVAL . . ..... .. .. . .. . ... .. . . . .. . . . .. . . . ...... . .... . .... . .. .... .. .. . . . . page 4..;.5

ENGINE DISASSEMBLY (common operations to all models)

CLUTCH DISMANTLING. SINGLE SPEED

CLUTCH DISMANTLING. 2 SPEED AUTOMATIC

ENGINE DISMANTLING (common operaltons to all models)

. -

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2

. .... page 6+ 8

.. . . . . . . . . . . .. . . . . . . . .. . . .... . . . . ....

.page 9

p2ge 10 <- 11

. . . . . .. . .... . . . . . .

ENGINE REASSEMBLY. SINGLE SPEED, 2 SPEED AUTOMATIC

.. .

. .... .. . .page 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13-:. ts

REASSEMBLY OF DRIVEN GEAR AND CLUTCH. SINGLE SPEED . . . . . . ... .. . . . .. . ... .. . . .. ... . .. .page 16+ 17

REASSEMBLY OF DRIVEN GEARS. FREEWHEEL, CLUTCH, AND STARTING /J.SSY. 2 SPED AUTOMATIC . .. . .page 18+ 20

ASSEMBLY OF PISTON . CYLINDER AND CYLINDER HEAD. SINGLE SPEED. 2 SPEED AUTOMATIC ... page 21

TECHNICAL SPECIFICATIONS
GARELLI ENGINE

SINGLE SPEED

SINGLE SPEED

AUTOMATIC

AUTOMATIC

PEDALS

KII<STARTER

PEDALS

KICK

lJ

Single cyl nder. 2 Stroke

Otspl;;cement

0
e<;_
CU. In .

Bore

mrn.
tn.

Stroke

mm.
10.

mm.

Potnls gap

10,

Ignition trming
correspondig to

mm_
Ill

49

49

49

2,989

2.989

2,989

49
2.989

4[}

40

40

40

1,5741

1,574

1,574

1.574

39

39

39

39

1,535

1.535

1,535

1,535

0,35+ 0,45
.01 4-i- .018

0,35 f-0,45

0,35+ 0,45

.OH-r.018

.014+.018

0,35+ 0.45
.014-:-.018

18"

18
1,2

18~

18"

1,2

.047

.047

1,2
.047

1,2
.047

SmMg:
pedals

kiCkstarter
-

Clutcllc-entmugal automauc

1n oil balh

Cl

[!

']

Ge;~rb o>::

single

sp~d

2 speed automatic
-

Pnmary reductton

"15171

Carlwrellor. Oeii'Orto type

Gearb,Jx o I caoaciry,
tSAE 30j

ty:~e

SHA 14112

16171

SHA 14/ 12.

1617i

16.171

23f64

23164

SHA 14112

SHA 14112

FIAT VS--'-30
cc.
CU _tn _

350

350

350

350

21,35

21 ,35

21,35

21 .35

SPECIAL TOOLS

TORQUE SPECIFICATIONS FOR

SCREWS & NUTS
SINGLE SPEED SINGLE SPEED
PEDALS
KICKSTARTER

TOOLS

AUTOMATIC
PEDAlS

AUTOMAllC
KICK

6.1752 Extractor tool tor CEV

an DUCATl flywheels
64753 Holding tool for pnmary
dnving sprocket

Cl

64782 Tool for clutch hub

::1

64757 AdJUStable extractor tool

64.759 Dri ft for gudgeor1 pm

64.766 Tool for 11ub body

54.767 Holdmg tool for clu tch hub

54.783 Tool lor starltllg

as~y.

nut

64.779 Extractor tool for Bosch

flywheels

[l

AUTOMATIC
PEDALS

AUTOMATIC
KICK

1,5+ 1,8
0,084+0.1 0

1.5+1.8
0,084-=-0,10

0.084+ 0,1 D

64.781 Holdin9 tool for flyvvheel

and dnven gears

64 784 Holding tool lor fr eewheel

catches

6L.786 Oilseal protectiOn tool

(dnve s1de. crankshaft. pnmary shaft}

TORQUE SPECIFICATIONS
CYLINDER HEAD NUT
FlYWHEEL MAGNETO NUT

SINGLE SPEED SINGLE SPEED

PEDALS
KICKSl ARTER

Kgm I 1,5-:- l ,B
Hl.lb.
0,084..;-Q,10

1.5-:-1 ;8

3+ 3,5

3-:-3,5

lrl.lb.

0.168-:-0.196

0.1 68+0.196

3+ 3.5
0.168 +0,196

37 3.5
0,168-:-Q, 196

CLUTCH NUT

t<:gm
tn lb.

3..;-3.5
0.168-:-0.196

3+3.5
0.1 68+0.196

3.574
0,196+ 0,224

3,574
0,196-:-0,224

DRIVEN GEAR NUT

Kgm
m.lb.

4-:-4,5

4+4 ,5

0,2.24...;-0 ,252

0,224-:-0.252

8+8,5
0,448-:-0.476

8-:-8,5
0.44870,476

CHAIN SPROCKET NUT

Kgm
ln.lb.

6-=-6,5
0.336-:-0. 364

6+6,5
0.336+0.364

6+6.5
0,336+0,364

6+ 6,5
0,336+0,364

CRANKCASE SCREW

Kgrn
m.lb.

0,8

0 ,8

0,8

0,8

0,044

0,044

0 ,044

0.044

Kgm
tn.lb.

0,044

SIDE COVE.RS SCREW

Kgm

0.8

0,8

O,.S

0,044

0,044

0,8
0,044
3

ENGINE REMOVAL
Aftt!r removing engine covers tf any the cham cover. the star1in g and gearcha nge De dais. ior WhiCil no soec1al to{)IS or
proced ures are requ tred , proceeds as follows:

Remove the silencer loosening the three nuts and

screws with an 11 mm (. 433") open end wrenc11 .
Take oti the gasket_

On the pedals model only. disconnect the starting

cable using a 17 mm (.669") open end wrencl1 as.
ill ustraled.

With a screwdriver remove carburettor from the en

gine but leave it connected to the l 1ame.

ENGINE REMOVAL

Disconnect the wires from theterminal block. as well

as the spark plug and the engine cut-off wites.

Break the chain by removing master link

Remove the engine by loosening the 3 ,,5,, rnountmg

bolts . using a 13 mm (. 551'') socket.

ENGINE DISASSEMBLy -

COMMON OPERATIONS TO ALL MOOELS

Remove the 4 nuts holding ttle cylinder head using

one 11 mrn (.433 ") box spanner. Lit! the 11ead and
the barrel over the 4 studs and remove the cylinder
base gasket.

Remove the two gudgeon pin retaining circlips with

the pliers.

Remo\le the ptston gudgeon pin usrng the extractor

64759 and a mallet. being careful to support the
piston on the opposite s1de.

ENGINE DISASSEMBLY -

COMMON OPERATIONS TO ALL MODELS

Using the tool 6478 1 to hold the flywheel. unscrew

the ltywt1ee l relammg nut wtth a 12 mm (_L72'' )
socket. Remove the sp ring washer.

Before using th e extractor. the external tiHeads .and

those of the cef'lter bolt should be lightly greased.
Screw the exi:ractor 64779 (for Bosch flywheelsj or
64752 (lor the others) into tl1e threads of the flywheel. then turn the extractor center bolt in a clockwise
direction to pull the fl ywheel oti !'he taper: keep holdtng the rotor with the tool 64781.

-CAUTION

s, across t11 e oottcm of t11e

stator plate and the crankcase in order to IJcllltate
re-tim1ng on assembly. Remote the screws Vl "
Make a scriber mark ..

ho-lding the slato r plate to the crankcase. Remove the

Woodruff key from the crankshaft.

/~NGINE

DISASSEMBLY -

COMMON OPERATIONS TO ALL MODELS

Using the tool 64753 and a 17 mm ( .669" ) wrench

remove the nut and the loCk. washer then pull the
sprocket from the shaft

Dram 0 11 from the gearbox and clutch by removing the

drain plug on the t>ottom of the eng rne

Removethe lett sideco11er ana its gasket by taki ng out

the six screws that hold it to the crankcase.
On the kickstarter models only: remove the starting
assy. from the left hand cover takmg oft the 3 screws
f1XJ11 Q the plate. !hen remove the variot.s parts.

1\

CLUTCH DISMANTLING -

SINGLE SPEED

On the pedals models only.

Usmg the needlenose plie1 s remove the wclip and
the spring from the clutch assembly.

On the pedals models: Using the tool 64767 and 17

mm (.669"1 socket remove the nutlockmg the clu tch
hub. Then slide the clutch hub and housmg ' rom the
cranksllaft.

On t11e klckstarter models: follow the same procedure

usmg the tools 64782 and 6~ 783 .

Holding the gear wil h Ihe tool 6478 1, unscrew tile nut
with a 17 mm (.669''} socket .

Use extractor roo I 64757 and a 19 mm

wrench to remove the gear

i.748" 1

CLUTCH DISMANTLING -

2 SPEED AUTOMATIC

On the pedals models only; remove w1th a screwdnver the pressure plate from the 4 rubbers.

On the kickstarier models: holding tile cl utch

bod~~

with tool 64 766 . use the tool 64 783 to unscrew H1e

nut. then remove the w2sl1er.
-

On the pedr~ls models: follow the same procedu re

using a 17 mrn (.669''} socket.

Take the assembly of two clutches complete with

gears ilnd slide it from the crankshaft.

CLUTCH DISMANTLING -

2 SPEED AUTOMATIC

Hold ttle gear Y.'ith t11e tool 64781 wh1le unscrewing

the nut W1!t1 a torque wrcnc11.

Remove the 2nd speed gea r and Ihen the 1sl' . whi le

holding the catches wi!l1 the tool 64784.

Then slide H1e clutch hub and .... aslle rs.

11

ENGINE DISASSEMBLy -

COMMON OPERATIONS TO ALL MODELS

Remove the 10 cr;mkcase scre,.vs from the right hand

crankcase_ Slnke tt1e ends of the crankshaft " A'~ and
of the primary st1aH .. pu a lte rnative l ~1 wiHl a mallet
until the two hal,es of the crankcase separate.

On the oedals models: remove l11e crankshaft, the

primaryshaft and the ped;1ls shaft togethe r.

-

12

On the kickslarter models: remove tl1e crankshaft and

then simply take or: the primary shaft.

ENGINE REASSEMBLy

-SINGLE SPEED. 2 SPEED AUTOMATIC

Berore starting to assemble the un1t. carefully clean and shglnly 011 all the parts_

On the pedals models: Using tile tool 6 ~7 85mse rt in

Ihe nght hand crankcase the p11mary shaft along with
the pedals shaft w1th lhe chain. lhe starting spnng
and the starting assembly.

On the kickstarter models: simply slide the primary

shaft 111 place.

Insert the crankshalt into the c1ankcase . lightly tap pmg it with a mallet.

13

ENGINE REASSEMBLY

-SINGLE SPEED, 2 SPEED AUTOMATIC

Join t11e left crankcase w ith tile right one acting as

follows:
a) Make sure1hatthe faces of the cases are clean and
tree from burrs and that the dowels are in posilion.
b) Sligh tly 9rease a new gasket on both sides. which
is to be mserted between the two crankcase hal-

'les.
c) Using the tool 64786. press the two crankcases
by hand and then tap them together w11t1 a mallet.
d) Fit and tighten the 10 screws j01m ng the cases.
e) Check that the cra nkshaft . the primary shaft. and
the pedal shaft turn freely.

Caution
Fit the plate so that mescriber mark "s.. previously
made is in line. tighten the mouting screws .. v 1 ~ .

Frl the woodruff key in position on the crankshaft. slip

the flywheel and rotate it until 1l is fell that the key is
correctly seated.

14

ENGINE REASSEMBLY -SINGLE SPEED, 2 SPEED AUTOMATIC

Before starting to assemble the unit. carefully clean and slightly oil all the parts.

On the pedals models: Using the tool 64785 insert m

the right 11and crankcase theprimary shaft along with
the pedals shaft wllh the cham. the starti ng spring
and the starting assem bly.

On the kickstarter models: simply slide the primary

shaft 1n place.

Insert the crankshaft ill!O the crankcase. lightly tap

ping it with a mallet.

ENGINE REASSEMBLy

-SINGLE SPEfD. 2 SPEED AUTOMATIC

Rotate the flywheel by hand In the counter clockwise

direc~ o n until the points gap is in the w1dest position.
At this instant cl1 eck the gap with a feeler gauge.
resetting 11 necessary to 0.35 7 0.45 mm_
(.0 14"" 7 .018"').
Check the timing. which is correctly set when the
points begin to o!)en at 18" B L D.C.
To check the lirntng rotate the llywheel in the
counter-clvckwtse direction so as to lineup the arrow
,,f3) on the flywheel and the mark ... 13,. on the crankcase. in this position the pornts should just begin to
open. If they do not. slip off the flywheel. loosen tl1e
stator plate fastening screws . rotate the plate in tile
appropriate direction. lightly refit the screws. refit H1e
flywheel. ooeck the gap.

When satisfie\1 that the gap is set correctlr. tit the

washer ami tighten the fastening nut , using the tool
64781 and the 12 rn m (-472"') socket prev,ously
used when dismantling.

Fit the chain gear and t11e tvvo sllim washers on the
primary shal l. using the tool 54753 and a torque
wrench tighten the nut to 6+ 6.5 Kpm. (in.lb.
0,336-'-0 .364).

15

REASSEMBLY OF DRIVEN GEAR AND CLUTCH

SINGLE SPEED, PEDALS

Turn the engine the opposile side , pl<lce on the pri

mary sh<Jfl the gear. the wasMr and the nut and.
usinQt11c tool 64781. tiohten it to 4 -o- 4,5 kom l in.lb.

0,2i4 + 0.252) with the torque wrench.

R M

I
-

Fit the clutch ~sse m bly and I1Ub following the i ll u st r~

lion.

Before mounting the plate "S" the elast1c body .. c..

and the circlip ,,A. with the tool 64767 and torque
wrencl1 t1gl1ten to 3-7- 3,5 kpm (in.lb. 0, 158+0 , 196)
the nut Dl> and the washer ,,A, fixmo the clutch hub

"M,, to lhe crankshaft .

16

' ,

c
'

REASSEMBLY OF DRIVEN GEAR AND CLUTCH

SINGLE SPEED , KICKSTARTER

Turn the engine the opposite side. place on the primary shaft the gear. tl1e washe r and the nut an d,
using the toot 64781 . tigl1ten 1t to 4--;- 4.5 Kpm \.in .lb.
0,224 -;- 0,252j w1th the torque wrench.

D R
I
-

Fit the clutch assembly and t1ub followmg the illustration.

Witt1the tool 64782 11old the clutch hub and lighten

witl1 the tool 64783 tl1e nut "o ~ an d washer " R"
tix1ng 1t to the crankshaft.

I
I

17

REASSEMBLY OF DRIVEN GEARS FREEWHEEL AND CLUTCH

2 SPEED AUTOMATIC

'

Place gears 1,. and freewheel A" on 1he primary

shaft "P" as per illus tration. Use the tool 64784 to
hold in place the springs ,<f\1 and catclles Sr. 'Nhcn
sliding the 1st speed gear on.

CAUTION: the freewheel hub shall be fitted so as to

allo.v the 1st speed gear to turn free when rotated in

tile clockwise dtrecti\ltl.

With the tool 64 781 and torque wrench tigh ten to

8+ 8,5 kpm [i n.lb. 0. 448 + 0.476) the nut fixing 111e
gears on the primaf)l shalt.

"1

REASSEMBlY OF DRIVEN GEARS FREEWHEEL AND CLUTCH

2 SPEED AUTOMATI C. PEDALS

i
-

Reassemble the clutcl1 assembly as Illustrated.

When at the disc .. o. place the J rubbers G in the

corresponding holes. The rubbers ends shoLid lace
towards the outu s1de ot !he engme and the ttucl\er
lined face of the disc towards the mner side of engine.

Hold the 2nd speed llousmg C w1lh the tool 64766

and tighten the nul to 3+4 kprn (in.lb.
0,168+0.224) with torque wrencll .

Slide the cross shaped p!ate S With the pliers on th e

4 rubbers G., as illustrt~ted . then cut the 4 rubbers
ends.

,..

~~~ ~

_..,". . \ ' I.Q;- . . (.)

REASSEMBLY OF DRIVEN GEARS FREEWHEEL AND CLUTCH

2 SPEED AUTOMATIC. KICKSTARTER

Reassemble the clutch assy. as illustrated.

Hold the 2nd speed llousmg wilh the tool 64766 and
ttghten the nut wit1 the tool 6L783.

Assernbte the stariing assy. as 1llustrated. (Tilts operation also applies to the smgle speed

ki ck s ~arte r

modelsJ

When rerit11ng the start1ng assy . make sure that the

return spring t-.-1 15 correctly in place as illustrated.

(thts ope ratton also applies to lhe smgle speed lack-

startcr models)

20

REASSEMBLY OF PISTON, CYLINDER AND CYLINDER HEAD

SINGLE SPEED , 2 SPEED AUTOMATIC

Once the mentioned operatrons are accomphshed. before fitting the cover make sure the two rubber bodres turn tree on
tl1e hubs
Make sure that the faces of the lett hand crankcase and of the cover are clean and free from burrs. slightly grease a new
gasket and place it on the crankcase face. Make certain that the left hand crankcase fits the oil plug and washer. Place the
cover on tile crankti!se and trghten thl' 6 jornmq screws.

Rehl prston wrth needlebearrng. gudgeon prn and

circltps as rllustrated and make cenam that thewcl rps are properly mserted rn their grooves
Make sure lhat the " S" on the prston is towards the
exhaust polt.

Check that the crankcase upper iace and the cylinder

base are clean and iree from burr s. Lrg11tly grease a
new gasket on both sides and lay it on the crankcase
face Orl the cylinder bore and the prston ski rt.
Lower the cylinder onto the p1ston wrth ftngers c.ompressing the rings into the bore. Make sure that the
ends of the oiston rings are properly fitted in position
agarnst the pegs of the ring grooves Slide the cyhn
der along the 4 studs and fit it in place

Check tnat the top of the cylinder and the face of the
head are clean and undamaged. Fit the gasket and the
head over the studs and place tile 4 washers ;:nd nuts
on the s1uds. Tighten the nuts gradually in a cross

pao:ern.

The rinal torque should be 1.5+ 1.8 kpm. (in.lb.

0.084..:..0, 10) ,
Refrt the spark ol ug.
Tl1rouQh tile hole on the left hand cover hll the crankcase with abt. 350 cc (cu.in. 21 ,35) of FIAT VS + 30
(SAE 30) Otl.

No spccial rnstrucllons are needed to mount the complete engines on tile frames. but follow the inverse procedure as
shown at pages 4-5
.!1