Badger

June 15, 2015

Welcome. Badger mopeds were made by Tovarna Rog, in the city of Ljubljana, Slovenia, formerly Yugoslavia.

 

 

Info Badger

There are many things the same as Batavus (Holland). 

You have to admire the 120 year history, from http://www.secondchanceproject.eu/wp/?page_id=16

Tovarna Rog in 2000's

Tovarna Rog in 2000’s

The long history of the Rog Factory (Tovarna Rog)

The industrial use of the area and the building started in the year 1871 when the Janesch (Janež) tannery started to operate. After 1900, the tannery was bought by Carl Pollak who renovated and extended the factory building, and expanded the production. The rebuilt factory is the first example of (visible) iron-concrete skeleton construction in Ljubljana. The Pollack factory worked successfully until the economic crisis in the 1930s, when the company was placed under compulsory administration of the Municipal Savings Bank, because it was insolvent. The industrial building was in use during and after the Second World War, when the Rog factory started manufacturing bicycles and typewriting machines on site (1952). The last big renovations of the building and the construction of auxiliary facilities were carried out in 1953 and 1963. The Rog factory operated on location until the early 1990s when the bicycle production was closed.

Part of the story that is not verified, was an earthquake struck the bicycle factory not long after the production of mopeds began, in the mid to late 1970’s. The earthquake destroyed most of the moped making equipment, and it was never replaced. So Rog moped production was brief. That is why Badgers are so rare in the US, because they were only made one year, pretty much. 

The abandoned 7000 square meter Rog factory was revitalized as a arts and cultural center in the 2000’s.

Info Badger photo 1

A rare photo of a US model Rog Badger moped.

 

 

Flandria Bermuda

June 14, 2015

Bermuda mopeds are made in Belgium by Flandria. They are called Flandria in Europe. In 1976-77 they were imported into the USA by Bermuda Bikes, Inc. first at 606 Ocean Ave, Point Pleasant, NJ 08742, then at 301 Locust Av Oakdale, Long Island, NY 11769, and then at 68 Bay Rd Brookhaven NY 11719. Many were sold on the island of Bermuda, where they replaced the Motobecanes that ruled there in the 50’s and 60’s.

In 1978-79 Bermuda mopeds were distributed on the west coast by ZSN, at 351 S Raymond Av Fullerton CA 92631. ZSN also distributed Demm mopeds, only 2 miles from Myrons Mopeds.

Mopeds
by Paul Dupre

Here is an article about Bermuda mopeds from the 1977 book “Mopeds” by Paul Dupre.

1952 Flandria

About 150 years ago a Flemish blacksmith named Alexander Claeys, in Zedelgem, Belgium, was busy doing his thing when suddenly he became quite ambitious and founded a company known as A. Claeys Flandria. The family firm repaired, renovated and built a wide range of metal products. In 1896 the company went into the bicycle manufacturing business and after World War II added motorized bicycles to it’s line. The company produced 25,000 mopeds in 1950 – it’s first year of moped production. The plant’s assembly line now has a capacity of 300 motorized bicycles a day. The firm has stayed a family concern – the president is now Mr. Paul Claeys.

In addition to their popularity in Europe, Bermuda mopeds are familiar to tourists to that island paradise and for many years these handsome and economical vehicles have been praised as the best, most leisurely, least exhausting way to see and feel the charm of Bermuda. The moped makes Bermuda’s many scenic hills and dales child’s play to people who couldn’t tackle them on an ordinary pedal bicycle. The cost of renting a moped and buying fuel for it in Bermuda makes this by far the most economical way of seeing the island, as well as the most pleasurable.

The Robert Bosch people have provided a magneto with sufficient generating capacity to meet the needs of the NHTSA-required sealed beam head-light, the stop light, tail light, electric horn, and ignition system on units imported into the USA.

The 49cc engine, made by the Belgian company, Flandria, is a single-cylinder two stroke motor with a cast iron cylinder, chrome alloy piston, and carefully balanced roller bearing crankshaft. The engine is mounted ahead of the pedal crank and provides a very low center of gravity. As with most mopeds, you use the pedals to get the engine started and to give it a little extra help on hills. The engine drives the unit through a dual centrifugal clutch – the inner clutch is connected to the rear wheel and is thus activated by forward motion, while the outer clutch is connected to the engine and is brought into action by engine rpm’s. As you pedal to get started (either by moving along or while the vehicle is still on the stand) the inner clutch pads expand and transfer rotary motion to the outer clutch attached to the engine. With the decompressor open, there is sufficient drag to turn over the engine. Closing the decompressor permits the engine to fire on compression and start up. When the engine is idling, there is not enough centrifugal force being generated to activate the outer clutch so there is no forward movement.

To start off your Bermuda (as with most other mopeds) after pedaling a short distance, you open the handlebar throttle and the increased rpm causes the outer clutch to become engaged. As  you slow down to stop, the outer clutch automatically disengages as wheel revolutions slow down and the engine is back to the idling mode.

 

1976 Bermuda Hampton
(US model of Flandria 147 F-A)

’73 Flandria 137 AF-A (Euro model)

’77 Flandria Carina (Euro model)

 

 

 

 

 

 

 

See more Flandria models in the Flandria Club of Belgium Museum:

http://users.telenet.be/flandriaclub/pages/Museum70.html

 

Bermuda Models

Bermuda is a marketing name for Flandria mopeds originally sold in the USA. Bermuda models are named after places in Bermuda.

1976-77 Bermuda Hamilton

1976-77 Bermuda Hamilton (Flandria Carina) 2-cycle engine, 49.7cc, with a 7.5:1 compression ratio. Maximum speed: 25mph and the machine is designed to climb an 11.7 percent grade without pedaling. Transmission is one-speed dry centrifugal clutch and v-belt. The engine delivers approximately 133 miles per gallon and produces 1.4 maximum horsepower at 5500 rpm. Carburetor is Encarwi S33. The tank holds one US gallon. Fuel is regular gasoline and oil mixture (4 percent oil). Frame is pressed steel, and the unit has telescopic front forks and rigid rear forks, a “hard tail”. Wheelbase 43.3 inch. The wheels have drum brakes front and rear. Tires are size 2.00-17.  Net weight of the Hamilton is 92 lbs. Equipment includes Bosch magneto-generator, sealed beam adjustable headlight, 10 watt stoplight, 5 watt tail light, electric horn, Bosch W145T1 spark plug (NGK B6HS), tool kit, safety flag. Color is blue with white trim.

 

Info Flandria Bermuda color 2

1976-77 Bermuda Hampton

1976-79 Bermuda Hampton (Flandria 147FA): All specifications and equipment for the Hampton model are the same as for the Hamilton with the exception of an added speedometer/odometer, a swinging-arm type rear suspension with shock absorbers, steering column lock, wheelbase 44.0 inch, a 97 lb net weight, and tires 2.25-17. Both the Hamilton and the Hampton are available in lower power and lower speed versions where required by state laws.

Flandria dry clutch engine

1976-77 color is aqua blue with white trim.

1977 color is aqua or dark  blue with white and black trim.  

1978-79 colors are aqua blue, silver, cinnamon, green, orange.

 

 

1978-79 Bermuda Hampton

Info Flandria Bermuda color 1

’77 Bermuda Hampton

’77 Bermuda

’76 Bermuda Hampton

 

 

 

 

 

’78 Bermuda Hampton

1976-77 had white rear fender, white metal covers, gray pulley.

1977 had white rear fender, black plastic covers, gray pulley

1978-79 had painted rear fender, black plastic covers, black pulley.

 

 

1977 Flandria Bermuda

 

 

 

 

 

 

 

 

 

 

 

1978-79 Bermuda Somerset (Flandria 147FVA): Same as Hampton but with a dry clutch variator v-belt transmission.

 

 

1978-79 Bermuda Pembroke

1978-79 Bermuda Pembroke (Flandria 147AFA): Same as Hampton except for different engine with one speed oil bath centrifugal clutch transmission, kick-back starting (like Tomos). Same Encarwi S33 carb, but different Dansi magneto 6V 30/18W, same 2.25-17 tires, more weight 100 lbs.

Flandria wet clutch engine

 

 

 

 

 

 

 

 

Flandria Pembroke engine

1978 Bermuda Pembroke

 

 

 

 

 

 

 

 

 

 

 

Bermuda Components

Bermuda controls 1) decompression, 2) engine stop, 3) horn, 4) rear brake, 5) lights, 6) throttle, 7) choke, 8) front brake

Bermuda speedometer

 

 

 

 

 

 

 

Magura (made in Germany) controls 1970’s wrap-around throttle, choke trigger on right thumb, decompression trigger on left thumb.

VDO (made in Germany) small type speedometer. VDO left side driver. VDO cable 2.0mm square inner, M10x1 thread on both end caps. The bikes only go 25 (or 20) mph on level ground, but the speedometer goes up to 40 or 45.

Bermuda fuel tap positions

 

Gas valve: is a vertical type used in the sideways position, a Karcoma (made in Germany) 1970’s “early” style petcock, 12×1 spigot right. It had no reserve.

 

Cables same brake cables as 1977-79 Sachs (Hercules) double pear-end. Brake plate arms have the clevis piece riveted on, like 77-79 Sachs. The rear brake plate is anchored by a welded post, like Sachs (unlike KTM which is clamp-on). 

Grimeca (made in Italy) hubs with 90mm brake drums, 2-chain rear, like Sachs.

Grimeca Rear Double Chain Hubs, Bermuda (Flandria) is the same as Sachs (Hercules)

ULO (made in Germany) “early” type 2-bulb tail light. Top 6V10W brake light, bottom 6V5W tail light.

 

 

Flandria piston

Flandria engine, dry clutch, belt drive, bore 40.0mm. Rings 40 x 2.0 FG.

     Bosch (made in Germany) magneto (right side) 90mm 0212-115-023  6V 18-10-5W 4 coils, 5 wires,
1) blue: ignition, 2) yellow: 18W head light, 3) green: 10W brake light, 4) green/black: ground, 5) gray: 5W tail light  

     Encarwi (made in Holland) S33 carburetor with #52 Bing 3.5mm jet.

Both engine versions have the same top end (piston, cylinder, and head). The design is unique and unusual. The upward fresh intake flows from the crankcase, through the middle of the piston, and then out through short transfer ports and back in above the piston. Most two strokes have long transfer tunnels that go around the sides of the cylinder, like the long handle of a beer mug, to get from below the piston to above it.

 

 

Flandria engine, wet clutch, gear drive, bore 40.0mm.

Dansi flywheel

     Dansi (made in Italy) magneto left side) 80mm 101414 6V 30-18W 3 wires, 2 coils,
1) red: ignition, 2) black: 30W head and tail light, 3) green: 18W brake light

     Encarwi S33 carburetor.

 

Flandria rims: All three Flandria models have 17 inch spoke wheels. The hubs and brakes are same as on Sachs-Hercules mopeds, Grimeca 2-chain stamped steel. The Hamilton has steel rims. But the Hampton and Pembroke have aluminum rims, made in Switzerland by Wienmann. These are the only US-model mopeds with aluminum spoke-type rims. Too bad. 

Motor chain: It’s a #41 made by Sedis. It has thinner pins than all other mopeds.

Puch Korado

June 14, 2015

1959 Manet ad

1950 Manet M90 ad

Manet

Manet is a division of Povážské Engineering Works, National Corporation, Povážská Bystrica, Czechoslovakia. Manet motorcycle history began in 1947 with the production of the M90. It was a 93cc two-stroke single cylinder but it had two pistons. It produced 2.6kW at 4500 rpm. By the year 1951, when production ended, 37,630 M90s were produced.

The Jawa-Manet alliance is shown in this 1959 advert for the US-model Manet scooter, “The scooter for all occasions”. It has a 100cc two-stroke 3-speed grip-shift engine. “Fast enough for the highway”.

Red star is where ’94-06 Manet and pre-’86 Jawa mopeds were made.
Green star is where 1986-1995 Jawa (Babetta) mopeds were made.

All through the 1960’s, 70’s, 80’s the Jawa and Babetta names were used for Czech mopeds instead of Manet. See myrons jawa info

Before the 1990’s, all Czechoslovakian companies were nationally owned, and so their names appear together in ads, like CZ, Jawa, Babetta, Manet and others. Starting with the fall of socialist economies in 1990, and the privatization of industries, many companies faced increasing costs, and decreasing market demand, as Slovakians were free to purchase from outside the country. In 1993 Czechoslovakia was split into Czech Republic (now called Czechia) at the northwest side, and Slovakia at the southeast side. The brand name Manet was revived in the privatization and restructuring. 

 

 

Manet Korado

1995 Manet Korado ad

The Manet Korado was made in Slovakia by PS Motor Manet from 1994 to 2008, and sold in the US as Puch Korado from 1995 to 1999. It was made in the same factory that pre-1986 Jawa Babetta mopeds were made at, Povážské Strojárne (PS) (Povážské Engineering Works) near the city of Povážské Bystrica in north-central Slovakia.

At the same time the first Manet mopeds were made, in 1994-95, the last Jawa mopeds were made in the small agricultural town of Kolárovó, in southern Slovakia near the Hungarian border. While the Manet Puch Korado was made with Piaggio top notch equipment and modern methods, the last few years of Jawa’s were made using obsolete, worn-out equipment with not enough expertise and concern for quality.

Here is the story of the end of Puch summarized from http://www.jawamoped.com/html/manet_korado.html

After Puch closed it’s doors in 1987, the moped production equipment was sold to Maxwell, in Turkey, Piaggio, in Italy, and Hero, in India. Puch had developed the Super Maxi, with a catalytic exhaust, an improved right-side air filter, and an improved cylinder with 4 transfer ports and a boost port. Maxwell in Turkey produced Puch Super Maxi remakes, but they had quality issues, and were not successful. Puch had developed the advanced Maxi Plus (Austro-Daimler), with help from Ferdinand Porsche. Hero produced Maxi Plus remakes into the 2000’s. Piaggio produced Puch Super Maxi remakes in Italy until 1997. Piaggio then sold the Puch rights and engine production equipment to Manet in Slovakia. In 1998 Piaggio destroyed the molds and equipment for making the Maxi.

Manet bought the engine production line in 1994, and moved it to Povážská Bystrica in Slovakia. They developed their own frame and moped, called Manet Korado. The first engines were of low quality, but they learned quickly. Here is a translation from http://mpkorado.cz/en/ They are currently an accredited importer of mpKorado scooters, electric bicycles and VCAN helmets for the Czech Republic, since 1994.

MP KORADO CZ, s.r.o. imported over 16,500 Manet Puch Korado mopeds, made in Povážské Bystrica, Slovakia, to the Czech Republic from 1994 to 2006. In 1994 the Korado immediately became a very popular means of transport for Czech customers, and disrupted the sales of Babetta (Jawa) mopeds made in Kolarova, Slovakia. It was the best selling machine in it’s category, and contributed the end of Jawa Babetta moped production. Manet Korados were produced in four motor versions, all with one-speed automatic transmissions: Puch Maxi or Super Maxi, pedal-start or kick-start. The mopeds were supplied in six basic colors.

By 2006 the factory at Povážská Bystrica stopped moped production completely. Povážské Strojárne Motor Manet transformed into VVED, and produced agricultural light equipment.

 

Manet Korado US Models

1995 Puch Korado ad

The flyer at right is screaming the logos and word PUCH, while not mentioning the true maker Manet. The US models were called Puch Korados. They were imported and distributed by American Jawa Ltd. 185 Express St, Plainview NY 11803. In the late 1970’s Puch was the best selling moped in America. American Jawa knew that many Americans knew the name Puch, or they had one and liked it.

1995 American Jawa Price List

 

 

 

 

 

 

 

 

 

 

Local history: The 1995 suggested retail price for the “Puch” was $1099. That was slightly more than a comparable 1995 Tomos Sprint for $999. Some of the Puch Korado dealers were Steves Mopeds in Dumont NJ and Mr. Moped in Sarasota FL. But there were no Puch Korado dealers in California. So there are no Korado-specific parts at Myrons Mopeds. Even though Shaun was actively servicing one or two hundred Southern California mopeds each year, at Royal Cyclery and later at Myrons Mopeds, he did not see a Puch Korado in person until 2009, 14 years after they came out. And that one Korado was brought into California only because the internet, that allowed people to easily buy things from far away places.

Specifications: The Korado Owners Manual lists specifications. Power 2.0kw (2.6hp), speed 40km/h (26 mph), weight 57.5kg (126 lb) 20lb heavier than a Puch.

Korado 1.5kW (2.0hp)
8-side-fin cylinder

Korado 2.0kW (2.6hp)
9-side-fin cylinder

Speed Versions: Korado engines (cylinders, heads, pistons and cases actually) have two speed versions. Both are 38mm bore, 49cc displacement.

Most US and European models have the 2.0kW (2.6hp) cylinder Super Maxi. It can be identified from a distance by the 9 side fins. It is like a 1979 Puch Magnum, but the piston has transfer port holes, and the cylinder has way more transfer ports. So it “gulps” more air and fuel with each stroke.

Some US and European models have the 1.5kW (2.0hp) cylinder called Maxi. It can be identified from a distance by the 8 side fins. It is exactly like a 1979 Puch Maxi Luxe cylinder.

16 inch 90×20 V-spring
Bernardi Mozzi Motors wheels on Puch Korado

Wheels: The drum brake specified in the owners manual is 85 x 20mm, and tires 2.25 – 16″, like Jawa spoke wheels. From the owners manual photos, the brake arms look like Jawa ones. But none of the 100 or so Manet Korado photos on Google Images have spoke wheels. 97 out of 100 have white Bernardi 3-ray mag wheels, and the rest have other mags. So only the prototype Korado had 16″ Jawa-type spoke wheels. Almost all others have 16″ 3-ray Bernardi wheels, that take Bernardi 90×20 or Grimeca 90×18 brakes. The cast aluminum front brake plate in the photo at right is identical to Puch-made ones for the Grimeca “snowflake” wheels with 90×18 brake drums. So much of the owners manual is out-dated, because things on the bike changed, but the manual did not.

There are pedal and non-pedal (kick) versions offered. By the mid 1990’s many European countries followed Germany and dropped the requirement for pedals on mopeds. Many US states followed Europe and allowed “no-peds” to be classified as mopeds (motorized bicycles).

System 4, for all US-models and some Euro

Electrical: There are four Korado electrical systems. System #1 and #2 are for European models with a ring-ring bell and no brake light. System #3 is for Euro models with an electric wrong-answer buzzer and no brake light. Electrical system #4 is the deluxe pizza with all the toppings, for all US models and some Euro models.

1.  6 volt 20 watt generator with points-and-condenser ignition
1.  6V 15W head light, 6V 5W tail light

2. 12 volt 40 watt generator with point-less electronic ignition
2. 12V 15W head light, 12V 5W tail light, 12V 1.2W speedo light

3. 12 volt 40 watt generator with point-less electronic ignition
2. 12V 15W head light, 12V 5W tail light, 12V 1.2W speedo light
3. 12V AC horn 

4. 12 volt 40 watt generator with point-less electronic ignition 
4.. 12V 21W head light, 12V 4W tail light, 12V 1.2W speedo light
 4. 12V AC horn, 10W brake light, optional 12V 10W turn lights

Owners Manual: Here is a link to the Manet Korado owners manual: http://projectmopedmanual.info/Manuals/Puch/Puch-Korado-owners-manual.pdf

Identification: US models said Korado, or nothing, on the gas tank. Some European models also said nothing on the tank, but most Euro models said Manet Korado. US models all had wiring system #4, with a engine stop button operated by the right thumb. Some Euro models also had that. But only US models have a US-DOT-compliant ID plate, that says “This vehicle conforms to all US safety standards in effect on the date of manufacture above”. And only Euro models have bells and engine stop buttons operated by the left thumb. Euro models with electrical systems 1, 2, and 3 have a different shaped headlight. If you see that, and no red button on the right thumb, it is a Euro model. Compare the 1995 blue with the 1999 blue below. 

You can tell the speed version from a photo, by the number of engine side fins. Maxi is 8-fin, Super Maxi is 9-fin.

1995 Puch Korado blue
pedal-start, Euro-model
9-side-fins Super Maxi

1996 Puch Korado red
pedal-start, Euro-model
8-side-fins Maxi

1996 Puch Korado white
pedal-start, US-model
9-side-fins Super Maxi

1999 Puch Korado blue
pedal-start, US-model
9-side-fins Super Maxi

 

 

 

 

 

 

 

1999 Manet Korado red
kick-start, Euro-model
9-side-fins Super Maxi

Euro and USA version Korado tank decals

Korado engine case
Super Maxi version

 

 

 

 

 

 

 

 

Spare Parts

Spare parts for the Manet Korado moped can be obtained from MP KORADO CZ, s.r.o. http://mpkorado.cz/en/ They are an accredited importer of mpKorado scooters, electric bicycles and VCAN helmets for the Czech Republic. On the Czech market since 1994.

Spare parts for Korado and Jawa can be obtained from JawaParts.com, since 1992. https://www.jawaparts.com/  But they won’t ship to customers in the USA, for some reason.

Much more info and photos of parts are here http://www.mopedarmy.com/wiki/Puch_Korado

 

Myrons Mopeds does not have actual Korado parts, but has many things for other mopeds that are the same.

Gas cap: screw-on

Gas valve: M22-1.0 thread, like Jawa but with long shaft, round knob, see Gas Valves

Speedometer

Speedometer: made by Facomsa

Front Wheel: 16″ Bernardi 3-ray, white, sealed bearings, 90×20 drum
Front Wheel: 90 x 20 Bernardi or 90 x 18 Grimeca V-spring brake shoes, see Brakes

Rear Wheel: 16″ Bernardi 3-ray, white, sealed bearings, 90×20 drum
Rear Wheel: 90 x 20 Bernardi or 90 x 18 Grimeca V-spring brake shoes, see Brakes
Rear Wheel: 18 tooth freewheel with standard threads, see Pedal Parts

Front Axle: 12mm smooth, M12-1.5 thread (same as Jawa) see Jawa Parts
Rear Axle: 12mm smooth, M12-1.5 thread (same as Jawa) see Jawa Parts

Sprocket 45T 5-hole

Front Sprocket: 14 or 15T (same as Puch)

Rear Sprocket: 45T 5-hole (different than Puch)

Tires: both 2.25 – 16, see Tires and Tubes

Engine: Puch 1-speed, two different cases, cylinders, heads, and pistons:
Engine: 1.5kw (2.0hp) Maxi version 8-side-fins
Engine: 2.0kw (2.6hp)  Super Maxi  9-side-fins, piston has transfer holes

Crankshaft: needle bearing rod, upper and lower (same as 1984-86 Puch)

Gears: Korado helical-cut gears are “reverse cut” opposite of Puch original

Puch and Korado gears

Helical-cut means the gear teeth are slanted. The benefit of helical-cut gears is much less noise or “whine”. The drawback is some of the driving force is diverted to the side. The Korado gears are forced to the opposite side as Puch gears.

Clutch:

 

 

Bing 18-14-180

Carburetor: 14mm Bing 18/14/180, “1990’s square Bing”
Carburetor: bigger than Maxi Plus (Austro Daimler) 18/12/107 or 18/12/106
Carburetor: see Bing Carburetor scroll down to Bing Austro Daimler

Jet:

Air filter:

Gasoline:

 

Right Control: Domino 1990’s all black, sliding block with pinch bolt
Right Control: Electrical system 1, 2, 3, plain, no switch mount
Right Control: Electrical system 4, with rectangular switch mount

Euro model with bell, wiring system 1 or 2

Wiring system 4

 

 

 

 

 

 

Left Control: Domino 1990’s all black,
Left Control: pedal versions have a start lever, kick versions do not
Left Control: Electrical system (all), with rectangular switch mount

Cables: The double-ended brake cables are not the same as Puch,
Cables: because the Domino controls do not use Magura adjusters
Cables: 19
Cables: 20
Cables: 21
Cables: 22
Cables: 22

 

 

 

Odyssey Parts

June 13, 2015

For identification see Odyssey Models

Regular Transmission Models
32/1-R  32kph (20mph) 11 x 53T Solo 254, thin exhaust
40/1-R  40kph (25mph) 14 x 53T Solo 255 engine
40/2-R  47kph (29mph) 15 x 50T Solo 255 engine

2-speed Transmission Models
32/1-2  32kph (20mph) 11 x 53T Solo 254, thin exhaust
40/1-2  40kph (25mph) 14 x 53T Solo 255 engine
40/2-2  47kph (29mph) 15 x 50T Solo 255 engine

 

 

Odyssey Parts Manual

 

Odyssey Parts Manual, first edition, April 1977


xx qty R is Regular, 2 is 2-speed
fig R2  Odyssey# price  Crank and Cylinder Parts
01 22 00 50 102 $10.0 crank bearing 6202 C3
02 10 22 00 641 none  disk clutch crankshaft
02 01 22 00 657 none  shoe clutch crankshaft
04 22 00 31 375 $0.00 crank washer 15.3 x 22 x 0.5
06 11 00 75 101 $2.00 flywheel key M85 3 x 3.7
08 11 00 30 144 $0.00 flywheel washer 8.4 10
09 11 00 20 161 $4.00 flywheel nut M8 left M10-1.0 x 6 hex17
10 11 00 34 115 $0.00 star washer 8 10
11 11 22 00 593 $0.00 piston complete N
11 11 22 00 600 $0.00 piston complete U
12 22 20 48 227 $0.00 piston ring N
12 22 20 48 249 $0.00 piston ring U
13 11 20 31 238 $10.0 piston pin 10 x 32
14 22 00 55 144 $1.50 piston clip
15 22 00 15 201 $0.00 exhaust stud
16 22 00 30 100 $0.00 washer 6.4
17 22 00 28 100 $0.00 nut M6 thermac
18 11 22 00 595 none  cylinder N for 32/1
18 11 22 00 594 $0.00 cylinder N
18 11 22 00 603 none  cylinder U for 32/1
18 11 22 00 604 $0.00 cylinder U
19 11 20 00 601 none  head for 32/1
19 11 20 00 602 $0.00 head
20 11 20 61 337 $0.00 head gasket
21 11 20 61 346 $9.00 base gasket
23 11 00 31 336 $0.00 “friction” washer 15 x 25.6 x 0.5
24 10 00 35 134 $9.00 disk clutch tab washer
25 10 00 20 107 $4.00 disk clutch nut M10-1.0×6
26 11 00 52 186 $0.00 needle bearing 10 x 14 x 13
27 11 00 61 255 $1.50 seal washer 5 x 9 x 1
28 11 00 10 266 $0.50 drain screw M5 x 15 (16) slot
29 11 00 62 159 $0.00 o-ring 101.3 x 2.6
30 22 00 55 106 none  inner retaining ring 35
31 11 00 16 126 $0.00 fill plug M10-1.0
32 11 00 61 210 $0.00 seal washer 10×14

 


xx qty R is Regular, 2 is 2-speed
fig R2  Odyssey# price  Crankcase Parts
01 10 21 00 300 none  disk clutch crankcase for 32/1-R
01 01 21 00 321 none  shoe clutch crankcase for 32/1-2
01 10 21 00 301 none  disk clutch crankcase
01 01 21 00 322 none  shoe clutch crankcase
02 11 00 42 208 $0.00 crankcase pin
03 66 00 10 161 $0.80 case screw M6 x 50 slot
05 11 00 54 203 $12.0 left crank seal 26 x 35 x 7
06 11 00 66 217 $0.00 wires grommet
07 11 00 62 112 $0.00 intake o-ring
08 11 20 61 334 none   case gasket
09 66 00 34 107 $0.25 lock washer 6
11 44 00 20 169 $0.30 head nut M6
15 10 20 45 460 $0.00 clutch cover
15 01 00 45 455 $0.00 clutch cover
17 11 00 45 455 $0.00 magneto cover
21 44 00 15 158 $0.00 stud M5 x 15
22 44 00 34 103 $0.25 lock washer 5
23 44 00 20 101 $0.40 nut M5
26 44 00 31 292 $0.20 head washer M6
27 11 20 12 448 $0.00 intake manifold
28 11 20 61 284 $0.00 intake gasket
29 11 20 74 525 $0.00 reed housing
30 22 20 42 000 $0.00 reed petal
31 11 20 63 000 $0.00 reed petal holder
32 44 00 15 226 $0.00 cylinder stud
33 11 00 54 128 $7.00 right crank seal 15 x 35 x 7

 


xx qty R is Regular, 2 is 2-speed
fig R2 Odyssey# Batavus# price  Disk Clutch Regular Trans. 
01 10  30 23 313 000000 $32.0 start lever
05 10  35 00 286 000000 none  clutch drum complete
06 20  00 52 104 000000 none  needle bearing HK1512 15 x 21 x 12
07 20  00 54 195 000000 $6.00 seal ring 15 x 21 x 3
08 10  00 72 124 480887 $8.00 saucer spring 28 x 12.2 x 1
09 10  35 00 220 480881 none  alum. hub with steel saucer
09 10  35 00 220 480881 $35.0 steel saucer only
10 10  35 00 232 480886 $30,0 weight-spring ring
11 10  30 41 322 000000 $20.0 steel plate
12 10  30 76 123 480889 $32.0 friction plate
13 10  00 70 194 480883 $8.00 start spring
14 10  35 00 219 000000 $60.0 start plate
15 10  30 42 315 480890 $12.0 end plate
16 60  00 34 103 843500 $1.00 wave washer 5
17 60  00 20 101 827500 $0.40 nut M5
18 40  00 73 230 000000 $6.00 dampening leaf spring
19 10  70 43 856 000000 $12.0 start lever plate
21 20  00 12 164 000000 $1.00 screw M5 x 18 hex
22 20  00 34 147 000000 $0.25 lock washer 5
23 20  00 30 108 000000 $0.20 washer 5

Much of this clutch assembly is the same as the clutch on a Laura M48 engine used on Batavus mopeds. Those items that are the same have Batavus part numbers listed.

 


xx qty R is Regular, 2 is 2-speed
fig R2 Odyssey#  price  Shoe Clutch 2-speed Trans. 
01 01 00 00 000 none  x
02 01 00 00 000 none  x
03 06 00 00 000 none  x
04 03 00 00 000 none  x
05 03 00 00 000 none  x
06 03 00 00 000 none  x
07 01 00 00 000 none  x
08 01 00 00 000 none  x
09 02 00 00 000 none  x
10 01 00 00 000 none  x
11 02 00 00 000 none  x
12 02 00 00 000 none  x
13 02 00 00 000 none  x
14 01 00 54 202 none  clutch seal 12 x 22 x 7
15 01 00 52 193 $13.0 needle bearing 15 x 21 x 22
16 01 35 00 258 none  clutch drum complete
18 11 00 31 336 none “friction” washer 15 x 25.6 x 0.5
19 11 00 54 203 $12.0 left crank seal 26 x 35 x 7
20 01 00 31 385 none  washer
21 01 00 31 386 none  washer

 

 

 

 

 

See Carburetor/Bing-Solo

 

Odyssey Parts Manual, first edition, April 1977
Odyssey Parts Manual, first edition, April 1977, non-engine section

 

Link to Project Moped Manual for the Odyssey Service Manual, for more info.

 

 

 

 

Steering

May 14, 2015

Bicycles are external, motorcycles are internal.

Welcome. Steering bearings on most bicycles are external type, where the bearings lie outside the frame head tube (which is “not stepped”). Steering bearings on most motorcycles are internal type, where the bearings lie inside the frame head tube (which is “stepped”). All mopeds have the bicycle type steering bearings, except Derbi, which has motorcycle type.

Balls Up or Balls Down is the famous question faced when installing retainer (caged) ball bearings. The lower bearing always faces balls down, but the top bearing is sometimes facing up, and sometimes facing down. When it is installed wrong the cage gets crushed. The answer is: the balls always face the “cone” and not the “cup”, regardless of “up” or “down”. Sometimes the upper frame race is a “cone”, sometimes it is a “cup”.

Any bearing, when pushed together lightly with your fingers, should feel like the balls are rolling. Nothing should feel like it’s scraping or sliding. When you see the balls rolling at half the rotation speed, and the feel is solid and smooth like an ice cube on a smooth table, then the bearing is correct and good. 

Caged Balls or Loose Balls can be interchanged. The cage/retainer is a convenience, that keeps the balls from falling out during installation. If the retainers are the wrong size, or bent, but the balls are correct, the balls can be popped out, and installed using grease to hold them. When the cage is eliminated, almost twice as many balls are required, enough to fill the circle with a half to one ball gap. This has another big benefit on worn out races that have dents where each ball was at. When the number of balls changes, say from 14 to 26, the dents do not line up anymore. So it’s almost like having a new race.

Bicycle headset threads and dimensions, from Sutherlands

Bicycle headset threads and dimensions, from Sutherlands Handbook

Slight Differences in steering threads have frustrated many bicycle and moped mechanics trying to substitute steering parts from one machine to another. At right is a chart of bicycle headset threads and sizes. Basically the whole world uses ISO threads, one inch with 24 threads per inch (25.4 x 1.06), except France (25.0 x 1.00), Austria (26.0 x 1.00), Raleigh (25.4 x 1.02), and motorcycles (24.0 x 1.00). None of these thread sizes interchange. They either won’t screw on, or they will screw on loosely, and later slip around and “strip”. 

Slight Differences in “30mm” frame cups, from 30.0 to 30.2 millimeters, turn out to not matter, ordinarily. Only when the fit is already too loose on a 30.2, or too tight on a 30.0, would it matter.

30.0 replacing 30.2: Take a moped frame that has 30.2 cups and pound one cup out with a hammer and punch, alternating sides. Then take a 30.0 cup and hammer it in. You will only have to strike it about half as hard, because it has a looser press fit. It will hammer out easier.

30.2 replacing 30.0: Take a moped frame that has 30.0 cups and pound one cup out with a hammer and punch, alternating sides. Then take a 30.2 cup and hammer it in. You will have to strike it about twice as hard, because it has a tighter press fit. It will hammer out less easy.

There is much confusion about what is 30mm, the cup outer, or the frame inner. A frame for 30.0 cups can be 29.7 to 29.9 mm inner diameter (id). A frame for 30.2 cups can be 29.9 to 30.1. Some cups are made in between, 30.1 mm. The cups for sale below are classified as “30.0 cups” if they measure 29.9 to 30.15 mm. They are classified as “30.2 cups” if they measure 30.16 to 30.25 mm.

Slight Differences in “32.5mm” frame cups, from 32.5 to 32.7 millimeters, turn out to not matter, ordinarily. They range from 32.5 to 32.7, with most around 32.6. 

 

 

1. #52     2. #65     3. #73     4. “Euro”

Bearing Retainers

1   #52 retainer, 15 – 3/16″ balls  31.5 id      $5.00
For traditional American bicycles, AMF, Colombia, etc.

2   #65 retainer, 15 – 3/16″ balls  28.5 id      $2.00
For traditional Schwinn bicycles, BMX, and low-end ATB.

3   #73 retainer, 16 – 5/32″ balls  29.0 id      $1.50
For traditional ten-speed bicycles, standard bikes, childrens.
A good substitute for the European 14 – 5/32″ ball retainer.

4   “Euro” retainer, 14 – 5/32″ balls 27.0 id    $8.00
This is like a #73 retainer with an inner lip for stiffness.

Loose Balls

1   5/32 inch (#5) balls (3.97mm), pack of 26        $2   26 loose 5/32″ balls can replace a “Euro” 14-ball retainer. 
For light duty moped and bicycle headsets.                 26 loose 5/32″ balls can replace a #73 16-ball retainer.

2   3/16 inch balls (4.76mm), package of 26          $2   22 loose 3/16″ balls can replace a #65 15-ball retainer. 
For heavy duty headsets, and some wheels.                22 loose 3/16″ balls can replace 21 loose 5mm balls

3   5 millimeter balls (5.00mm),  pack of 21           $5   21 loose 5mm balls can replace 22 loose 3/16″ balls
For Puch Magnum, Sears Free Spirit, and Tomos.          More balls, or bigger balls, can carry more weight.

 

 

Headsets and PartsMyrons Shirt green

In ascending order of thread size (fork), then cup size (frame).

After years of ignorance and misunderstanding, moped headset items have been identified, measured, verified, and presented below. With these measurements and specifications, it is possible to find correct replacements by measuring their sizes precisely with a calipers or a micrometer, and then matching it with the pictures and or brand names below, hopefully. These things have to be somewhat precise. If something is too tight it might not go on. If it’s too loose, or mismatched, the bike might be difficult to control, or be unpleasant to ride.

 

24.0 x 1.00 mm thread

 

Left: External Bearings Right: Internal Bearings

Derbi           24.0 x 1.00 (0.94″- 25.4 tpi), internal

Derbi mopeds have internal steering bearings, like motorcycles have. You can see on the Derbi at the right, the bearings are not visible. But on the Sparta Foxi on the left, the steering bearings are visible above and below the frame head tube. The Sparta has external steering bearings, as do all other mopeds.

Japanese motorcycles usually have this 24×1 thread on the top nut, but further down the steering tube steps up to 25×1 or 26×1 or bigger, where the bearings go.

 

 

25.0 x 1.00 mm thread

 

Peugeot Headset, 25-1.0 thread, 30.0 cups

Peugeot headset, 25-1.0 thread, 30.0 cups

Peugeot       25.0 x 1.00 (0.98″- 25.4 tpi), 30.0 cups

1         51974  complete set #2-10                   $40
2         48684  top chrome cap, press fit            $10-$18
3         51646  lock nut, 5 tall, 32 hex                 $5-$7
4         56118  lock washer serrated                   N/A
5         91783  adjustable cone chrome               $4-$6
5a  This little “nub”, from Peugeot bicycles, must be ground off.
5a  It goes into a ring of holes, a special “holey” washer, not #4.
6         91778  upper frame cup chrome 30.0 od  $8
7        91502a upper balls, 26 – 5/32″ 3.97mm   $2 or use #73
8         91502  lower “Euro” retainer 14-5/32″    $8 or use #73
9         46840  lower frame cup chrome 30.0 od  $8
10       14512  lower cone (crown race)  26.7 id  $5-$8
30.0 cups will replace 30.2 ones. They just press in easier.

Motobecane headset, 25-1.0 thread, 30.2 cups

Motobecane 25.0 x 1.00 (0.98″- 25.4 tpi), 30.2 cups

1         23312  partial set #3,5,6,7,8,9              N/A
2         15528  top plastic cap, press fit            $10–$18
3         15526  lock nut, 32 octagonal                $6
4         00000  plain washer 25x35x1                 $2
5        23016a adjustable cone, zinc plated       $8-$12
6        23016b upper frame cup, zinc   30.2 od  $7
7         00005  upper balls, 26 – 5/32″           $2/26 or use #73
8         00005  lower balls, 26 – 5/32″           $2/26 or use #73
9         14208  lower frame cup, zinc   30.2 od  $7
10       19859  steering tube with lower race       N/A
11       14606  lock plate/washer                       $4
12       14605  pivot bolt M20-1.0, 32 oct          $15

 

Vespa Grande set, 25- 1.0 thread, 33.0 cups

Vespa Grande set, 25- 1.0 thread, 33.0 cups

Vespa Grande 25.0 x 1.00 (0.98″- 25.4 tpi), 33.0 cups

Vespa Grande headset is unique, heavy duty, French thread.
3       G68856  chrome cap nut, 32 hex, 25×1    $12-18
3a     000000  Piaggio emblem pressed-in           N/A
4       306912  thin washer for nut                        $3
5       G21316  adjustable cone, 25×1, notched    $15
6       G22937  upper frame cup, zinc    33.0 od   $7.00
7       G21317  upper balls, 27 – 5/32″ 3.97mm    $2/27
8       G21317  lower balls, 27 – 5/32″ 3.97mm    $2/27
9       G22937  lower frame cup, zinc    33.0 od   $7.00
10     G21315  lower cone (crown race)  25.6 id   $7.00
The Grande crown race is only 25.6 id, and the fork is 25.7.

 

25.4 x 1.06 mm thread

 

Honda PA50 set, 1"-24 thread, 30.0 cups

Honda PA50 headset, 1″-24 thread, 30.0 cups

Honda PA50  25.4 x 1.06 (1.00″- 24.0 tpi), 30.0 cups

The Honda PA50 Hobbit (Camino) is made in Belgium.
It is mostly European in design and components.
3     00000000 chrome cap nut, original              N/A  use bicycle
4     00000000 washer 26x32x1.5                       $3
5     00000000 adjustable cone chrome              N/A  use bicycle
6+9 00000000 frame cup chrome, each 30.0 od $5 2.0 thin wall
7+8 00000000 orig. retainer 14-5/32″ each        $8   
7+8 JB-1909    #73 retainer, 16-5/32″ each        $1.50
10   00000000 lower cone (crown race) 25.7 id N/A
10
This is the original crown race size. It was loose on the fork.
Three samples of Honda PA50 original forks were like this.
The fork steering tube is a straight 25.4mm all the way down.
So there needs to be a 0.15mm hard steel strap under the race.

General headset, 1"-24 thread, 30.0 cups

General headset, 1″-24 thread, 30.0 cups

General            25.4 x 1.06 (1.00″- 24.0 tpi), 30.0 cups

2    1150-5860 chrome cap nut, original             $20  use bicycle
3    1150-5895 stepped notched nut, 31.8 lip      $15
The bottom side of nut #3 has a lip that fits inside #4a.
That’s why the holes in #4 and #4a are big, 32 not 26.
This lip carries the side loads through the nut threads,
instead of the fork top pressing on the threads directly.
1960’s small Honda motorcycles had this design.
4    1150-5894 plain washer 32x44x0.5               $5
4a  3150-5885 fork top plate, 31.8 hole             N/A
4b  1150-5886 spacer tube  26x41x8                  $7
5    1150-5893 adjustable cone chrome             $15
6    1150-5892 upper frame cup chrome 30.0 od $15
7+8 1150-5890 loose balls, 23 – 3/16″ 4.76mm   $2/26
9    1150-5891 lower frame cup chrome 30.0 od $15
10   JB-2742    lower cone (crown race)  27.0 id   $7
Asian mopeds use the Japan Industry Standard (JIS). General, Lazer, Grycner, Clinton, Jui Li, AMS, Tas, Tym, etc.

Tange Levin CDS Headset

Tange Levin CDS sealed precision headset

Bicycle (JIS)  25.4 x 1.06 (1.00″- 24.0 tpi), 30.0 cups

JB-35496  EC30/27 Tange Levin sealed headset $30
0000000   upper frame cone black  30.0 od        N/A
0000000   lower frame cup chrome 30.0 od        N/A
0000000   lower cone (crown race) 27.0 id        N/A
JIS stands for Japan Industry Standards.
JIS crown races are 27.0 id, for a 27.1 fork.
JIS frame cups are 30.0, for a 29.9 frame.

 

Bicycle (ISO)  25.4 x 1.06 (1.00″- 24.0 tpi), 30.2 cups

Headset PartsJB-35495  EC30/26 Tange Levin sealed headset $30
0000000   upper frame cone black  30.2 od        N/A
0000000   lower frame cup chrome 30.2 od        N/A
0000000   lower cone (crown race) 26.35 id       N/A
ISO stands for International Standards Organization. 
ISO cups are 30.2 mm o.d, for a 30.1 mm i.d frame.
ISO crown races are 26.4 id, for a fork crown 26.5 od.

Nuts and Washers:
A   0000000  thin lock nut, for spacing, 1″-24, oct     $2.00
B   JB-35705  Origin8 black open top nut, 1″-24, oct  $2.00
C   JB-3510    Wald 220 chrome open nut 1″-24, oct  $5.00
D   0000000  keyed thick washer 26x34x3                 $1.00
E   0000000  plain thin washer 26x32x1.5                 $1.50
F   0000000  plain thick washer 26x33x2.5                $2.00

Batavus headset, 1"-24 thread, 30.0 cups

Batavus headset, 1″-24 thread, 30.1 cups

Batavus  25.4 x 1.06 (1.00″- 24.0 tpi), 30.1 cups

Batavus mopeds are made in Holland.
1     47.043.00 partial headset #3-10               N/A
2     46.306.00 plastic plug for nut                     N/A
3     02.059.00 chrome open nut, original     $5-10  use bicycle
4     06.055.00 washer 26x34x1.5                      $3
5     47.043.04 adjustable cone chrome             N/A  use bicycle
6     47.043.03 upper frame cup, zinc 30.1 od  N/A use Peugeot
7+8 47.096.00 orig. retainer 14-5/32″ each       $8   
7+8 JB-1909   #73 retainer, 16-5/32″ each        $1.50
9     47.043.02 lower frame cup, zinc 30.1 od  N/A use Peugeot
10   47.043.01 fork cone (crown race) 26.5 id $12 use bicycle
11   46.117.00 spring strap/sleeve 1.0/0.35      N/A
The fork steering tube is a straight 25.5mm all the way down.
The strap crushes to 0.5 mm, so it adds up, 26.5 = 25.5 + 2*0.5.
The ideal spring strap for Batavus would be 0.5mm.

Trac headset, 1"-24, 30.0 & 30.2

Trac headset, 1″-24, 30.0 and 30.2 cups

Trac          25.4 x 1.06 (1.00″- 24.0 tpi), 30.2 cups

Trac mopeds are made in Korea by Kia and Dae Lim (DMC).
This example is for the early Tracs 1982-85 with M56 engines.
3  90305-M56-8900 chrome cap nut, orig. hex  N/A use bicycle
4  90503-M56-8900 washer 26 x 37 x 1            $3
4a 90304-M56-8900 notched thin nut               N/A use octag.
5  53211-M56-8900 adjustable cone chrome     N/A use bicycle
6  50301-M56-8900 upper cup chrome 30.2 od  N/A
7  96211-05000      upper balls, 26- 5/32″ #5  $2/26 or use #73 
8  96211-05000      lower balls, 26- 5/32″ #5  $2/26 or use #73 
9  50302-M56-8900 lower cup chrome 30.0 od  N/A
10 53212-M56-8900 cone (crown race) 25.5 id  N/A
This is the original crown race size, but it was loose on the fork.
The fork steering tube is a straight 25.4 mm all the way down.
The looseness had caused a 25.3 mm wear groove on the tube.
To be tight it needs a spring strap and a bigger race, like Batavus.

Cimatti set, 1"-24 thread, 30.2 cups

Cimatti headset, 1″-24 thread, 30.2 cups

Cimatti         25.4 x 1.06 (1.00″- 24.0 tpi), 30.2 cups

Cimatti’s are Italian, and use Italian headset standards.
Cups are 30.2, for a 30.1 frame. Same as bicycle.
3     18-00-51  chrome cap nut, 32 octagon        $20
4     18-01-18  plain washer, 26x30x1.5                $3
4a    xx-xx-xx  spacer tube, 26x29x9                   N/A
5     12-00-65  adjustable cup chrome                $12
6     12-00-62  upper frame cone, zinc   30.2 od    $8
7+8 10-00-39   orig. retainer 14-5/32″ each         $8 
7+8 JB-1909    #73 retainer, 16-5/32″ each         $1.50
9     12-00-63  lower frame cup chrome  30.2 od $20
10   12-00-64  fork cone (crown race)    26.5 id  $12
11
Italian crown race is 26.5 id, for a fork crown 26.6 od.
ISO (International Standards Org.) threads are 1″- 24 tpi.

Garelli headset, 1"-24 thread, 30.2 cups

Garelli headset, 1″-24 thread, 30.2 cups

Garelli          25.4 x 1.06 (1.00″- 24.0 tpi), 30.2 cups

Garelli’s are Italian, and use Italian headset standards.
1  507607.2100 complete original set #3-10       $65
1a    000.0000  set with chrome hexagonal nut   $45
2      206.3067  chrome open nut, 32 octagonal    $6
3      000.3086  chrome cap nut, 32 octagonal    $20
4      000.3085  plain washer, 26x30x1.5              $3
5      207.3078  adjustable cup chrome              $12
6      000.3062  upper frame cone zinc   30.2 od  $8
7+8  10-00-39  orig. retainer 14-5/32″ each         $8 
7+8  JB-1909   #73 retainer, 16-5/32″ each         $1.50
9      201.3064  lower frame cup chrome 30.2 od $20
10    000.3065  lower cone (crown race) 26.5 id  $12
One German-made moped, Kynast, uses this headset,
because Kynast (Flying Dutchman) has an Italian fork.

Vespa Ciao set, 1"- 24 thread, 30.2 cups

Vespa Ciao or Bravo, 1″- 24 tpi, 30.2 cups

Vespa Ciao/Bravo  25.4 x 1.06 (1″- 24 tpi), 30.2 cups

Vespa mopeds are made in Italy by Piaggio.
1       135977 partial original set #5-10              $25
3a     145608  chrome cap nut, 32 oct (Bravo)    $20
3       137609  chrome open nut, 32 oct (Ciao)    $18 use bicycle
4a     145607  locking plate, 32 octagon (Bravo)  N/A
5       136258  adjustable cup chrome decagon    $12
6       123315  upper frame cone zinc   30.2 od    $8
7+8 10-00-39  orig. retainer 14-5/32″ each         $8 
7+8 JB-1909   #73 retainer, 16-5/32″ each         $1.50
9       123316  lower frame cup chrome  30.2 od  $12
10     123317  lower cone (crown race)  26.5 id  $10
11   Vespa uses Italian headset standards, 26.5 and 30.2.
12

Schwinn set, 1"- 24 thread, 32.5 cups 1960's rechromed

Schwinn headset
1″- 24, 32.5 cups
1960’s re-chromed

1968 Schwinn Stingray equipped for BMX

1968 Schwinn
BMX equipped

Bicycle, Schwinn 25.4 x 1.06 (1″- 24 tpi), 32.5 cups

In the 50’s – 60’s USA this was a Schwinn-only head set size.In the late 1960’s BMX (bicycle moto cross) began. The first BMX bikes were 20″ kids bikes with off road tires, MX handlebars and seat. The Schwinn Stingray was preferred, because of it’s heavy duty construction and high quality. In the 70’s BMX equipment became Schwinn-compatible, including frames with 32.5 mm headset cups. BMX became very popular, as did the headset. In the 80’s it became the mountain bike (ATB) standard. In the 1990’s bigger 1-1/8″ steering tubes came out on high-end ATB’s, with 34.0 frame cups. Soon 34mm frames became the new ATB standard. Then bigger 1-1/4″ steering tubes and 37mm frames followed. Now this historic headset is almost obsolete.

BMX Headset, 1"-24 thread, 32.5 cups

BMX Headset, 1″-24 thread, 32.5 cups

This is a 1980’s-90’s BMX or ATB headset, 32.5 cups.
The cups fit Puch Magnum, Tomos and Sears Free Spirit.
1   JB-35334-0  EC32/26 Sunlite chrome headset $10
3   JB-35334-3  Sunlite chrome open nut, 32 hex   $5
4   JB-35334-4  keyed washer 26x34x1.5              $1
5   JB-35334-5  adjustable cone chrome               $3
6   JB-35334-6  upper frame cup chrome 32.5 od  $4
7   JB-35334-7  special retainer, 16-5/32″ each     $3
8   JB-35334-7  special retainer, 16-5/32″ each     $3
For 50 years these had #65 retainers, with 3/16″ balls.
9   JB-35334-9  lower frame cup chrome 32.5 od   $6
10 JB-35334-1  lower cone (crown race)  26.4 id   $8
The fit, roundness and finish are surprisingly good.

 

AMF headset, 1″-24 thread, 33.6 cups

Bicycle, American 25.4 x 1.06 (1″- 24.0 tpi), 33.6 cups

1      MP-0014    AMF original headset #3-10        $40
1a   JB-3512       Wald 4080 headset 3a-10 below $15
3     MP-0014-1  chrome AMF open nut, hex         $18
3a   JB-3510       Wald #220 chrome nut, 32 oct     $5
4     MP-0014-1a tab/lock washer                        $2
4a   JB-3503       1 inch keyed washer                  $1
5     MP-0014-2   adjustable cone, zinc                $8
6+9  MP-0014-4  frame cup zinc, each  33.6 od   $15
6a+9a JB-3513    Wald #410 cup, each 33/34 od  $6
7+8  MP-0014-3  #52 retainer 15 – 3/16″, each     $5
10    MP-0014-5  lower cone (crown race) 25.7 id  $7
10a  JB-35345     lower cone (crown race) 26.4 id  $8

Wald headset, 1"-24, 30/33 cups

Wald headset, 1″-24, 32.9/34.3 cups

This standard is on AMF, Colombia mopeds and bicycles.
Also traditional American bicycles, Murray, Huffy, etc.
Wald 4080 headset is for traditional or vintage American.
The Wald 410 replacement frame cups have 3 “bumps”.
The diameter is 32.9 mm, but 34.3 mm at the bumps.
Grind them down to fit any frame from 32.8 to 34.2 mm.

Colombia Fork Crown Race

American Crown Race: Unlike other fork crowns that have a small step at the base of the steering tube, American type bicycles have a smooth flare. The race #10 only touches at the top of the flare, and at the bottom floor of the fork. You can see in the right photo the crown race is cone shaped inside. All other crown races are cylindrical shaped inside. 

If an American type conical crown race is not available, then a 26.4 mm id standard crown race will substitute (at least it did on this fork), thanks to the bottom having enough straight section that is 26.5 mm outer diameter. It sounds crazy that a 26.4 race will substitute for a 25.5 one. That is why this explanation and pictures are needed here.

 

 

 

26.0 x 1.00 mm thread

 

Puch Maxi set, 26 -1.0 thread, 30.8 cups

Puch Maxi   26.0 x 1.00 (1.02″- 25.4 tpi), 30.8 cups

The Puch Maxi headset is the same as Sachs (Hercules).
1   0000000000 partial headset #5-10    see treatland.tv
2   3491300181 chrome open nut                     $7-$15
3   3491305181 chrome cap nut                      $8-$20
4   0009013935 plain washer 26x32x2               $3
5   6001330071 adjustable cone chrome            $3-$5
6+9 6002330051 frame cup, zinc each  30.8 od N/A  2.0 thin wall
7+8 0003298    orig. retainer 14-5/32″ each      $8 
7+8 JB-1909    #73 retainer, 16-5/32″ each      $1.50
10 6002330061 lower cone (crown race) 26.7 id $5-$8
11 3491300151 spring strap/sleeve 1.0/0.35 mm  N/A
Installed, the sleeve becomes 0.35 mm. So 26.7 = 26.0 + 2*0.35
These sizes are the traditional Austrian bicycle headset standard.
The 1984-86 Puch Cobra, was a “Magnum”, but it had this Maxi headset.

Sachs headset, 26-1.0 thread, 30.8 cups

Sachs/Hercules  26.0 x 1.00 (1.02″- 25.4 tpi), 30.8 cups

The Sachs headset is the same as a Puch Maxi headset.
1   5041009701 partial headset #5-10    see treatland.tv
2   9271013516 chrome open nut                     N/A  use Puch Maxi
3   9271013519 chrome cap nut                      N/A  use Puch Maxi
4   9279920817 plain washer 27x37x1.25        N/A
4a 9279919606  spacer ring 27x32x6           N/A
5   000000000 adjustable cone chrome          N/A  use Puch Maxi
6+9 00000000   frame cup, zinc each  30.8 od N/A  2.0 thin wall
7+8 00000000   orig. retainer 14-5/32″ each      $8 
7+8 JB-1909    #73 retainer, 16-5/32″ each      $1.50
10 000000000 lower cone (crown race) 26.7 id $5-$8
11 9219769501 spring strap/sleeve 1.0/0.35 thick N/A
Installed, the sleeve becomes 0.35 mm. So 26.7 = 26.0 + 2*0.35
These sizes are the traditional Austrian bicycle headset standard.

Sparta, KTM 26x1.0 32.0 cups

Sparta, KTM,  26-1.0 thread, 32.0 cups

Sparta/KTM   26.0 x 1.00 (1.02″- 25.4 tpi), 32.0 cups

1     00000000  complete headset #3-10            $35
2     335.01.01  chrome cap nut (Kreidler & KTM)  $10-$18
3     00000000  chrome cap-lug nut (for Sparta) $10-$20
This nut bottom is cone shaped, for centering, like a lug nut.
4     235.01.10  plain washer (for Kreidler & KTM)  $2
5     00000000  adjustable cup, bright zinc          $5-$8
6     235.01.02  adjustable cup chrome (Kreidler) $15
6     00000000  upper frame cone, zinc   32.0 od  $5-$8
7+8 JB-1908    #65 retainer, 15 – 3/16″ each      $2
7+8 00.69.27    22 – 3/16″ balls (Kreidler) each    $2/26
9     00000000  lower frame cup zinc    32.0 od   $5-$8
10   00000000  lower cone (crown race) 26.7 id  $5-$8
New crown races range from 26.65 to 26.74 mm id.

Puch Magnum set, 26-1.0 thread, 32.6 cups

Puch Magnum set, 26-1.0 thread, 32.6 cups

Puch Magnum   26.0 x 1.00 (1.02″- 25.4 tpi), 32.6 cups

Puch Magnum MkII, Sears Free Spirit 8084, 8085, 8086 silver:
3a 3211308181 chrome cap nut (zinc on Sears)  N/A
4b 3211308191 washer 29x35x.75             N/A  above plate
4a 3211308511 spacer 26x32x13.5             $8  below plate
Magnum XK, Sears Free Spirit 8080 blue, 8081,8082,8083 red:
3   3491305181 chrome cap nut                 $8-$20
4        9013935  washer 26x32x2.5              $3 below plate
All Puch Magnums (except Cobra) and Sears Free Spirits:
5   3211307081 adjustable cone zinc 51 od    $15-$20
6+9  25221  frame cup, zinc, each  32.6 od    $25  3.3 thick wall
7+8  25226  loose balls 5mm qty 21 each        $5/21 or use 3/16
10    25220  lower cone (crown race) 26.7 id   $5-$8
11    00000  early Schwinn cup, chrome 32.5  $12  2.0 thin wall
12    02016  Sears Free Spirit cup, zinc  32.6   $15  2.8 thick wall
13    00000  Schwinn/BMX cup, chrome 32.7   $20  2.6 thick wall

Tomos A3 and A35, 26-1.0 thread, 32.6 cups

Tomos 1975-2006  26.0 x 1.0 (1.02″-25.4 tpi) 32.6 cups

Tomos made Puchs, under license, from 1955 to 1974. 
That is why the steering parts also fit Puch Magnum.
3        200718  chrome open nut 32 hex           $8-$12
3a      219349  chrome cap nut 32 hex             $8-$15
4        206701  plain washer 26x36x1.5            $3
5a      200717  notched adjustment nut            $5
5b      200715  dust shield 26x47x9mm             $5
5c      200714  upper cone, no threads 26.0 id   $8
6       200558  upper frame cup, zinc  32.6 od $15  2.6 thick wall
7       044535  upper balls 5mm qty 21            $5
8       044535  lower balls 5mm qty 21            $5
9       200471  lower frame cup, zinc   32.6 od $20  2.6 thick wall
10     200714  lower cone (crown race)  26.0 id $8
11
The 1987-06 Tomos fork has M26-1.0 rolled threads 25.8 od, then smooth 25.1 od, flaring to 26.1 at arrow.
The 1975-86 Tomos fork has M26-1.0  cut  threads 25.8 od, then smooth 26.0 od, flaring to 26.1 at arrow.

Tomos A55 headset, 26-1.0 thread, 32.5 cups

Tomos 2007-2013  26.0 x 1.0 (1.02″-25.4 tpi) 32.5 cups

1        230741  partial headset #4-11               $40
The 2007-12 Parts Catalogs only have the older fork items.
So the 07-on EBR fork items, 10 and 11, are not available.
3       219349  chrome cap nut 32 hex               $8-$15
4       222848  chrome washer 26x36x2             $3
5a     200717  notched adjustment nut              $5
5b     200715  dust shield 26x47x9mm                $5
5c     200714  upper cone, no threads  26.0 id    $8
6      223155  upper frame cup, zinc   32.5 od   $15  2.6 thick wall
7      044535  upper balls 5mm qty 21               $5
8      044535  lower balls 5mm qty 21               $5
9      223157  lower frame cup, zinc   32.5 od   $18  2.6 thick wall
10     00000  lower cone (crown race)  27.4 id  N/A use 26.7-27.0
11     00000  spring strap/sleeve 1.0/0.4 thick   $10 for 27.4 race
The strap crushes down from 1.0 to 0.7 when installed.
So 27.4 = 26.0 + 2*0.7. Ideal strap is 0.7mm thick.
The 2007-13 Tomos fork has M26-1.0 cut threads 25.8 od, then smooth 26.0 od, with no flare.
Instead of a flare or step, it has a #11 spring strap, the same one that a Puch Maxi has.

 

 

28.0 x 1.00 mm thread

 

Vespa Si          28.0 x 1.00 (1.10″- 25.4 tpi)  41.2 cups

This futuristic early 1980’s moped has a bigger steering tube and bearings.
This size was also for an old French tandem, according to http://sheldonbrown.com/cribsheet-headsets.html

3      212152  chrome cap nut 36 oct               $20
4      000000
5      000000
6      000000  upper frame cup, zinc   41.2 od   $15  4.0 thick wall
7      000000  upper balls
8      000000  lower balls
9      000000  lower frame cup, zinc    41.2 od   N/A  4.0 thick wall
10     000000  lower cone (crown race)

 

28.6 x 0.98 mm thread

 

Bicycle (1-1/8″)  28.6 x 0.98 (1.125″- 26 tpi)  34.0 cups

EC34/30. This (1.125″) was the first oversize for 1990’s mountain bikes (ATB), 34.0 cups, 30.0 crown race.

 

 

31.8 x 0.98 thread

 

Bicycle (1-1/4″)  31.8 x 0.98 (1.25″- 26 tpi)  37.0 cups

EC37/33. This (1.25 inch) is the biggest external cup (EC) threaded bicycle headset, 37.0 cups, 33.0 crown race.

 

Dellorto SHA 14/xx, 15/xx

December 24, 2014

 

Dellorto SHA is a family of Italian moped or mini-bike carburetors. SHA’s have flat throttle slides and no jet needles. They all have the same outer size and main body appearance, with a 59mm round flange for an air filter. They have been produced for in Italy from the 1960’s to the 2000’s. In particular the Dellorto SHA 14/12 and 14/9 carburetors were on tens of thousands of US mopeds from 1976 to 1985.

Carburetor Size: The venturi is where the air mixes with gasoline. It is also where the air passage gets narrower, to cause a higher air speed in order to atomize or break up the liquid fuel into smaller droplets. With Dellorto SHA carburetors, two numbers are used to describe the size of the venturi. The first number is the venturi exit, and the second number is the venturi entrance. So looking at an SHA 14/12 from the front you see a 12mm hole, and from the back (engine side) you see a 14mm hole.

Choke Type: The choke is a lever you push or pull, “on” for cold starting, or “off” for normal running. There are three types used on Dellorto SHA carburetors:

A  direct lever  push down lever on carb to put choke “on”, give full throttle to release it “off”
B  linkage lever  same operation as direct lever
C  cable choke  cable goes to a handlebar thumb lever, pull to put choke “on”, let go for “off”  

 

Cable choke is needed when the carburetor choke lever cannot be reached by hand.

Arbeo-Dellorto SHA carbs were made in Spain under license for the Spanish moped Derbi. They were more goldish colored, and tended to leak fuel past the float seat.

Generic SHA: Since the 2000’s there are China made remakes. Most have different screw threads, not Italian-metric. Many have M5-0.80 jet threads, different from Dellorto M5-0.75. The Runtong remake carb has M5-0.75 jet threads. So it can take any Dellorto M5 jet, but many other generics cannot.

 

Original Carburetors

’60-85 Dellorto SHA 14/9 has a lever choke,
20 mm clamp, 16 or 18 sleeve, jet 44, 46 or 48.
Original on 20-25 mph models.

’60-85 Dellorto SHA 14/12 has a lever choke,
20 mm clamp, 16 or 18 sleeve, jet 48, 50 or 52.
Original on 25-30 mph models.

’85-06 Dellorto SHA 14/12P has a linkage choke,
21 mm clamp, 18 sleeve, jet 51 or 53.
Original on 25-30 mph ’85-06 Tomos.

’75-86 Arbeo SHA 12/12 has a lever choke,
20 mm clamp, 18 sleeve, jet 52. Spain 14/12
Original on ’75-86 Derbi models.

’86-90 Arbeo SHA 12/12C has a cable choke,
20 mm clamp, 18 sleeve, jet 54. Spain 14/12C
Original on ’86-90 Derbi models.

 

Replacement Carburetors for Sale


Dellorto SHA 14/12L has a lever choke,
21 mm clamp, 18 sleeve, jet 57, air cover #39
Genuine replacement for SHA 14/12.
Can replace carbs that clamp to 16-19 mm intakes.
$73.0 with 16, 17, or 19 sleeve,  $70.0 with 18 sleeve


Dellorto SHA 14/14R has a cable choke,
19 mm clamp, no sleeve, jet 54, air cover #38d
Replaces Gurtner Motobecane AR2 side-mount.
$90 with choke and throttle cable inner wires


Dellorto SHA 15/15C has a cable choke,
21 mm clamp, 18 sleeve, jet 70, air cover #39
Can replace carbs that clamp to 16-19 mm intakes.
$73 with 16, 17, or 19 sleeve,  $70 with 18 sleeve

 

Clamp size: These new replacement carburetors only clamp tight when the intake pipe is exactly the right size. Many intakes are made slightly smaller or become smaller from wear. When the clamp screw is tightened fully, the carburetor can still move, and eventually slip off. For a 18 sleeve, a 18.00 to 18.10 pipe would clamp tight, but 17.95 or less pipe would not clamp tight. That is not very much forgiveness.

Cut up a can: A strip cut out from an aluminum can, with scissors, can be placed under the sleeve. Thickness is 0.1mm. Either a 1/3 circle or a full circle can be used, as needed. A full circle adds 0.2 to the clamp diameter, for a 17.80 to become 18.00. A 1/3 circle adds 0.1 mm, for a 17.90 to become 18.00. A thin aluminum baking pan is thinner than a can. A thinner full circle is better for when only a little is needed.

Most brand new original Garelli, Minarelli, and Tomos intake manifolds (pipes) are 18.00. But some are 17.95, and actually need a 1/3 strip of aluminum can inserted in order to clamp tight and proper, with new original carburetors.

Cable pipes are for redirecting the throttle cable. Pipe thread is M6-0.75. Adjuster thread is M5-0.75. A throttle cable end can pass through, except 2d. Bikes with front carburetors don’t need them, because the cable goes straight up. Others have gas tanks or floor boards that the cable must go under or around.

a
Although some are shown with adjusters, cable pipes do not include #3a pipe adjuster and #3 pipe lock nut.

 

                 P A R T S    L I S T

price colors mean used  new  new
part# colors mean Dellorto, Minarelli, Tomos, other

pic#  price  part#    description
1    $2.00 1476   rubber boot long
1a  $2.00 1476A 219624 rubber boot short
2    $5.00 1104   top adjuster with nut A13 M6-0.75
2a  $13.0 7423   cable pipe Vespa   22×30 90º use 2ar
2ar $6.00 7423r  cable pipe Vespa   22×30 90º 
2b  none  3698   cable pipe 6560    20×28 90º use 2br
2br $16.0 3698r  cable pipe xxxx    20×30 90º
2c  $13.0 3600   cable pipe 6680    long 70º use 2cr
2cr $8.00 243152 cab. pipe Tomos  long 70º 
2d  $7.00 pipe2d cable pipe Derbi   long 70º no adj.
2e  $7.00 80210400 c. pipe Garelli  medium 35º 
2f    $15.0 163515835  pipe GarVIP short 45º
2g  $5.00 pipe2g cable pipe xxxxx  30×27 90º
2h  $5.00 219623 cab. pipe T. A35  med. 70º 
2j   $5.00 pipe2j cable pipe xxxx    med. 32º
2k  none  10854 cable pipe  xxxx    long 50º
2n  none  pipe2n cable pipe xxxx    long 40º
2as $9.00 53036 cable pipe set 1+2ar+a
2cs $14.0 53037 cable pipe set 1+2h+2cr+3a
2ks none  53038 cable pipe set 1+2k+3a 
2js  none  53073 cable pipe set 1a+2j+3a  
2gs $9.00 53040 11630cu   set 1+2g+3a
2fs  none  265146 Malossi   set 1a+2fr     
2ns none  53058 cable pipe set 2n+3b      
3    $3.00 1691   cable pipe nut M6-0.75  special     
3a  $6.00 219625 pipe adjuster with nut M5-0.75
3b  $3.00 1692   pipe adjuster lock nut M5-0.75

pic# part#  price   description
4   3318    $2.00 top screw M4-0.75 x 14 slot not M4-0.7
5   5011    $1.50 narrow washer M4 
6   6110M  $5.00 6320 top bare metal
6a 6110    $5.00 top bare white plastic
6b 6110    none  top bare black plastic
6c 219596 $21.0 top assy black angled 30° 85-06 Tomos
6d top6d   $15.0 top assy metal   6+7+8+9+10
6e top6e   $15.0 top assy white  6a+7+8+9+10
6f  13662  none  top assy black  6b+7+8+9+10
7   6115    $2.00 6510 hinge pin (in top)
8   6259    $2.00 6460 spring choke (in top)
9   6112    $5.00 6450 lever choke trigger


10   6111 00 $4.00 6410 gasket for carb top
11   3346 00 $10.0 6480 spring throttle return
12   6108/64 $12.0 6590 slide throttle #1 metal 219580 25mph
12a 6108/2x $8.00 slide throttle #2 metal 20mph
12b 6108 00 none  slide throttle #12 plastic


13   4190 0  $5.00 6620 screw M5-0.75 x 15 not regular metric
14   3385 0  $1.50 seal washer 5 x 9 for metal banjo not plastic
15   6106 0  $8.00 6530 banjo metal angled out 3/16″
15a 219584 $9.00 banjo inlet metal straight 3/16″
15b 9249 0  $7.00 6535 banjo plastic angled out 3/16″
15c Der15c  none  banjo inlet thick 1/4″ put a thin hose over 15a
16   6109 0  $5.00 6360 filter fuel plastic mesh
17   6304 0  $2.50 6350 nut M6 teardrop most have regular nut
18   6159 0  $3.00 6420 gasket for air filter
19   6105 0  $3.00 6470 spring for choke plate


20   6112    $7.00 choke plate-lever short  type A lever choke
20a 6114    $7.00 choke plate-lever short
20b 7406    none  6580 choke plate-lever long-bent
20c 8026    $7.00 6570 choke plate-lever long   Cimatti type
21   5417    $3.00 6520 pivot step-bolt choke
22   8773    $2.00 hinge pin 6500 Ø2.0 x 16.5 
23a 14148  $7.00 21-16 sleeve, inner lip for 16.00 mm intakes
23b 12914  $7.00 21-17 sleeve, inner lip for 17.00 MB (some)
23c 10811  $7.00 21-18 sleeve, inner lip for 18.00 mm intakes
23d 11362  $7.00 21-18 sleeve, outer lip for 18.00 mm intakes
23e 227324 $5.00 rubber ring,  for 23d  21 x 16 x 3.5 angled
23e 227324 $0.00 only for carbs that have sleeve 23d Tomos
23f  10146  $7.00 21-19 sleeve, inner lip for 19.00 Peugeot, MB
23g 2300    $7.00 21-19 sleeve, outer lip for 19.00 Peugeot, MB
23h 6124    $5.00 20-16 sleeve, inner lip for 16.00 Morini MO1,
23h cont     Demm, Benelli G2, Tomos ’74-85, Batavus M48
23i  6448    $7.00 20-18 sleeve, inner lip for 18.00 Minarelli V1,
23i  cont     Garelli, Tomos ’85-06, Morini M1
23j    19-17 $22.0 19-17 sleeve, inner lip for Motobecane (some)
23k 114482 $12.0 18-16 sleeve, inner lip for Vespa type SHA
24   6305    $2.00 clamp bolt M6-1.00
25   6140    $4.00 idle screw M4-0.70 x 25 regular metric !
26   3606    $2.00 spring idle Ø4 Ø6 x 12


27   2838    $10.0 float needle valve L=17.0

28 jet M5-0.75 thread
Left is genuine, right is aftermarket. The sizes do not agree.
See Dellorto Jets. These are all genuine jets with the INC logo.
28 1486/42 $5.00 jet 42 0.0178″=0.451
28 1486/43 none   jet 43 0.0182″=0.462 pre-78 Ciao & Bravo
28 1486/44 $5.00 jet 44 0.0186″=0.472
28 1486/45 none   jet 45 0.0190″=0.483 78-on Ciao & Bravo
28 1486/46 $5.00 jet 46 0.0194″=0.493
28 1486/47 $7.00 jet 47 0.0198″=0.503
28 1486/48 $5.00 jet 48 0.0202″=0.513 most 20mph mopeds
28 1486/49 $7.00 jet 49 0.0207″=0.525 78-on Vespa Grande
28 1486/50 $5.00 jet 50 0.0210″=0.533 76-80 Garelli (some)
28 1486/51 $7.00 jet 51 0.0215″=0.546 85-91 Tomos late A3
28 1486/52 $5.00 jet 52 0.0219″=0.556 most 30mph mopeds
28 1486/53 $7.00 jet 53 0.0223″=0.566 92-95 Tomos early A35
28 1486/54 $5.00 jet 54 0.0227″=0.577 86-90 Derbi (flat reed)
28 1486/55 none   jet 55 0.0231″=0.587
28 1486/56 $5.00 jet 56 0.0235″=0.597 96-06 Tomos late A35
28 1486/58 $5.00 jet 58 0.0242″=0.615
28 1486/60 $5.00 jet 60 0.0247″=0.627 96-06 Tomos+exhaust
29 6122-80 $18.0  float all white plastic
30 6123-00 $2.00 float gasket ring all new ones are round
31 6107-96 $5.00 float bowl metal
31 13412 0 $5.00 float bowl plastic          
32 3598-36 $4.00 float bowl screw M4-0.75 x 18  not regular metric


33 4611-50 $4.00 cover clamp ∅60 replica with screw
34 4617-36 none  clamp screw M4-0.75 re-thread nut to use #8-32
35   6117   $9.00 air filter metal screen
00x 0 ∅58 id air covers  TL# bare says   color  holes
36   7758   none  cover #0 assy 00 000 black 2-∅10 with #40 tubes
36   7204   none  cover #0 bare 00 000 black 2-∅10, no tubes
36   9887   $10.0 cover #1 bare 00 000 black 2-∅12, no tubes
37   8602   none  cover #7 bare S33 00 black 2-∅12, no tubes
37   0000   none  cover #0 bare S33 00 grey  2-∅12, no tubes
37a 8603   $11.0 cover #5 bare S3 F44 black 2-∅12, no tubes
37a 0000   none  cover #0 bare S3 F44 grey  2-∅12, no tubes
37a 10574 none  cover #0  bare 00 000 black 3-∅12, no tubes
37b 8632   none  cover #0  bare 00 000 black 2-∅12, no tubes
38   5660   $32.0 cover #0  bare S1 Min gray  2-
38   5660   $25.0 cover-clamp S4 S1 Min gray  2-
38   5660M $15.0 cover-clamp S4 S1 Min black 2-
38a 5346   $12.0 cover #3 bare F27 00 black 2-∅12, no tubes
38b 5199   none  cover #0 bare 10236  black 2-∅12, no tubes
38c 9723   none  cover #6 bare Garelli  black 2-∅10, no tubes
38d 53056 $21.0 cover #4 assy F51 00 black 2-∅12 with #41 tubes
38e 12971 none  cover #2 bare F49  00 black
39   53051 $17.0 air cap, clip, screen set
39a 6183   $10.0 air cap only ∅58 ID
39b 6235   $6.00 clip only
40   7195   $7.00 air inlet tube small Ø8 Ø10 x 20
41   5309   $8.00 air inlet tube large Ø9 Ø12 x 50

42
42    060420 $22.0 air filter, fits 96-06 Tomos, needs a bigger jet
43C  53057   $8.00 cable choke plate set type C  43a+43b+21
43a  plate43  $6.00 cable choke plate only  type C
43b spring43 $3.00 cable choke spring only
44B  223025 $7.00 pivot shaft w/linkage  type B, gets rounded
45B  223027 $2.00 spring for pivot shaft  type B 
46B  223026 none  choke plate xxxxxxx type B
47B  223028 $7.00 choke lever external B, gets hourglass-shaped
48B  031930 $1.00 lock washer M4  B, better to weld 46,47,49
49B  031073 $1.00 nut M4-0.70      B, better to weld 46,47,49

a
50 gset50 $7.00 gasket set SHA14   10, 14, 30
51  52533 $10.0 gasket set pre-’85  10, 14, 30, 18, 18, 1a, 55, 56
51  52533 $10.0 for older SHA14 pre-1985 with 20mm clamp size
52  52579 $12.0 gasket set post-85 10, 14, 30, 18, 23e, 23e, 57
52  52579 $12.0 for newer SHA14 1985-on with 21mm clamp size

55  ring55 $2.00 square rubber ring 14 x 20 x 2.0 for some pre-85
55  ring55 $2.00 only for 20mm intakes (when no sleeve is installed)
56  ring56 $1.00 tiny rubber o-ring  3 x 6.5 x 1.75 only for  ?
57  ring57 $2.00 square rubber ring 15 x 21 x 2.0 for some post-85
57  0-ring57 $2.00 only for 21mm intakes (when no sleeve is installed)


Tomos 85-95 A3+A35
51 219374 $10.0 junction sleeve center mount
52 219373 $19.0 air box bare (silencer)
Tomos 85-91 A3  (pre-85 was Encarwi Ø9 intake)
53 214330 $12.0 intake tube Ø12.5 x 60 straight
60 025195 $1.00 intake screw M6x30 hex
61 026289 $1.00 intake screw M6x18 hex
62 031932 $0.20 washer M6
63 219371 $53.0 center intake A3
63 219564 $53.0 center intake A3 (oil inject)
64 219372 $5.00 intake gasket thin
Tomos 92-95 A35
53 223606 $9.00 inlet tube Ø12.5×110 curved
65 026566 $1.50 intake screw M5x20 allen
66 031931 $0.20 washer 5mm
67 227592 N/A     center intake A35 (oil inject)
Tomos 96-06 A35
55 229705 $14.0 junction sleeve side mount
56 229706 $2.50 inlet grommet
57 229769 $35.0 air box assy 57, 58, 59
58 044438 $1.00 air box screw
59 229704 $7.00 air filter foam
68 223748 $3.00 reed valve gasket
69 222238 $34.0 reed valve 2-petal
70 229707 N/A     side intake (no oil inject.)
71 229716 $21.0 side intake (oil injection)

An oil-injection intake has a M6-threaded hole for the oil line. A no-oil injection intake does not.
Plug the hole with a M6x8 bolt and M6 seal washer, to convert oil-injection to no oil injection. 

 

 

 

 

Encarwi Parts

October 25, 2014

encarwi

Contents:
1. A-type on Tomos
2. S-type on Batavus, others
3. H-type on Trac, others

 

 

 

Part# colors:  Tomos, Laura, Batavus, Trac, other

1. Encarwi A-type: A11, A21, A22
    A83, 88A85/102, 88A85/103

 

– On some early-70’s Laura M48 engines.
– and ’74-85 Tomos A3 mopeds.
– Serviceable from sides.
– No choke cable. Choke is part of throttle.

  #   part#    price    Encarwi A-type on Laura M48 .
00 481780 none  carburetor A11  ∅8? 1970?-
00 slide ∅14? 408, jet M3.5 52-54 M48-01 40kmh
00 481788 none  carburetor A21  ∅12 1972?-
00 slide ∅14 202, jet M3.5 56-58 M48-02 50kmh
00 481789 none  carburetor A22  ∅8? 1972?-
00 slide ∅14? 108, jet M3.5 50-52 M48-03 30kmh
  #   part#    price    Encarwi A-type on Tomos A3 .
00 209070 none  carburetor A83  ∅12 1974-76
00 slide ∅14 426, jet M3.5×15 46 Tomos A3 20,25,30
00 209070 none  carburetor A83  ∅12 1977-83
00 slide ∅14 426, jet M3.5 x 6 46 Tomos A3 20,25,30
00 209070 none  carb 88A85/102 ∅12 1980-84
00 slide ∅14 426, jet M3.5 x 6 46 Tomos A3 20,25,30
00 209616 none  carb 88A85/103 ∅12 1984-85
00 slide ∅14 426, jet M4.0 x 7 50 Tomos A3 20,25,30
01 long jets, thread 3.5, head 12, length 15:
01 481723 $12.0 orig. long jet =Bing45 0.434 mm
01 481724 $15.0 orig. long jet =Bing46 0.445 mm
02 481731 $20.0 long holder for long Encarwi 3.5 jet
03 short jets, thread 3.5, head 3, length 6:
03 209116 $18.0 orig short jet =Bing46 0.445
04 206765 $41.0 long holder for short Bing jet
06 209118 $18.0 slide Ø14 426 with hole, auto-choke
07 209003 $5.00 spring Ø9.5 x 42
08 206763 $34.0 carb top screw-on    M18x1 thread
11 206770 $35.0 float with needle       used only
12 206772 $25.0 float top with seat     new
13 206771 $6.00 gasket for float top    
14 206773 $15.0 banjo black plastic    breaks easy
14 mbanjo $12.0 banjo metal upgrade w/2 washers 
16 206775 $7.00 banjo bolt
17 206774 $15.0 fuel filter all metal    clean & reuse
18 027053 $1.30 screw M4 x 10 slot
20 027079 $5.00 clamp bolt                  
24 200384 $22.0 air filter metal mesh
25 209215 $20.0 air box (silencer)        
26 209216 $27.0 junction sleeve rubber, gets hard
27 209217 $3.00 inlet tube connector
28 209579 $3.00 inlet tube (not shown)  
30 200382  intake gasket thick      
32 217315 none  intake manifold oil inj w/M6x1 hole
33 209085 $22.0 intake manifold           OD 16, ID 12
34 031932 $0.25 lock washer M6       
35 044284 $1.40 hex bolt M6 x 22

 

Encarwi Tomos Carbs

Left, 1974-83 Tomos carb, Encarwi A83, bare.
The jet and jet holder unscrew from the side hole.
The jet can be cleaned out easy, on the roadside.
Right, 84-86 Tomos, Encarwi 88A85/103, complete.
The side hole is blocked. Jet access is from bottom.
The engine must be lowered to access the jet.
Jetting/servicing is ten times more difficult. 

 

Here is a 88A85/103 with the non-removable jet-holder-spray-tube removed. The #50 jet is a 4mm thread, not 3.5 like all the other Encarwi jets. This one was not a tight fit and needed epoxy to hold it. When the jet was unscrewed the whole brass tube turned.

 

 

2. Encarwi S-type
    S8A, S22, S23, S23A, S23B, 88S23/103,
    S25, 88S25/101, S33, S33A

 

– On some early-70’s Laura M48 engines
– and 1974-80 Batavus, 1977-78 Badger.
– Located behind and below engine.
– Needs longer throttle and choke cables.

 

  #    part#   price    Encarwi S-type on Laura M48
00 487180  none  carburetor S22  ∅12  30mph ’72-77
00 slide ∅14 405, jet M3.5×15 54-58, inlet ∅16 45-50kmh 
00 541780  none  carburetor S25  ∅12  30mph ’77-78
00 slide ∅14 167, jet M3.5 x 6 56-58, inlet ∅16 45-50kmh 
00 541780  none  carb 88S25/101 ∅12 30mph ’78-80
00 slide ∅14 188, jet M3.5 x 6 56-56, air inlet ∅16 50kmh
00 481790  none  carburetor S8A    ∅8  25mph ’72-80
00 slide ∅14 190, jet M3.5×15 52-54, air inlet ∅14 40kmh
00 486795  none  carburetor S23A  ∅8  20mph ’75-80
00 slide ∅14 190, jet M3.5 x 6 50-52, air inlet ∅14 30kmh
00 481795  none  carburetor S23B  ∅8  00mph ’75-on
00 slide ∅14 190, jet M3.5 x 6 52-54, air inlet ∅14 25kmh
00 481795  none  carburetor S23    ∅8  00mph ’72-75?
00 slide ∅14 190, jet M3.5×15 50-52, air inlet ∅14 30kmh
00 486785  none  carb 88S23/103   ∅8  00mph ’77-on
00 slide ∅14 190, jet with holder 54, air inlet ∅14 20kmh
  #    part#   price    Encarwi S-type on Flandria
00 000000  none  carburetor S33  ∅12  00mph ’72-77
00 slide ∅14 000, jet M3.5×15 52-54, inlet ∅00 40kmh
00 000000  none  carburetor S33A  ∅12  25/30 ’76-77
00 slide ∅14 000, jet M3.5 x 6 52-54, inlet ∅00 40kmh 
01 long jets, thread 3.5, head 12, length 15:
01 481723 $12.0 orig. long jet =Bing45 0.434 mm
01 481724 $15.0 orig. long jet =Bing46 0.445 mm
01 481726 none  orig. long jet =Bing50 0.478 mm
01 481727 none  orig. long jet =Bing52 0.493 25mph
01 481729 none  orig. long jet =Bing56 0.523 30mph
01 481730 $7.00 orig. long jet =Bing58 0.541 mm 
02 481731 $20.0 long holder for long Encarwi jet
03 short jets, thread 3.5, head 3, length 6:
03 486750   none orig. short jet =Bing50 0.478 20mph
03 bing51g $4.00 generic48 jet ≈Bing51 0.480 mm
03 bing52g   none generic49 jet ≈Bing52 0.490 mm
03 486752 $5.00 orig. short jet =Bing52 0.493 25mph
03 bing53g $4.00 generic50 jet ≈Bing53 0.500 mm
03 486754 $5.00 orig. short jet =Bing54 0.508
03 bing56g $4.00 generic52 jet ≈Bing56 0.520 mm
03 486756 $11.0 orig. short jet =Bing56 0.523 30mph
04 481722 $41.0 long holder for short Bing jet
06 481758 none  throttle slide #405  S22 30mph
06 561742 $35.0 throttle slide #167  S25 30mph
06 5617xx  none  throttle slide #188  88S25/101 
06 486723 none  throttle slide #190  25 & 20mph
07 481722 $5.00 spring Ø9.5 x 42
08 481721 $34.0 carb top screw-on    M18x1 thread
09 481746 $7.00 idle screw M4-0.7    can use M4
10 481747 $3.00 idle screw spring Ø4.6 Ø6.6 x 9 
11 481736 $35.0 float with needle         used only
12 481738 $25.0 float top with seat      
13 481737 $6.00 gasket for float top    
14 481740 $15.0 banjo black plastic     
14 mbanjo $12.0 banjo metal upgrade w/2 washers 
16 481742 $7.00 banjo bolt
17 481741 $15.0 fuel filter
18 481739 $1.30 screw M4 x 10 slot  
20 481724 $5.00 clamp bolt
21 481743  $7.00 choke plate
22 481745 $3.00 bolt choke pivot          
23 481744 $3.00 spring choke               
24 481732 $22.0 air filter metal mesh
25 481713 none  air box (13.5id, 16od)  N/A 30mph
25 481734 none  air box (11.5id, 14od) N/A 25/20mph
26 481733 none  rubber band              N/A
27 481735 $8.00 wire clip                     
28 481793 none  intake tube 16 id    N/A  30mph
28 486781 $5.00 intake tube 14 id      25 & 20mph

 

Left 1970’s original float, right 90’s replacement

 

 

 

3. Encarwi H-type: H12, H8 

 

– Made special for Laura M56 engine.
– Serviceable without removal.
– Used on 1978-80 Batavus Regency (M56)
– 1981-85 Trac Clipper, Eagle, Hawk (M56)

 # qty  part#  price    Encarwi H-type 1978-85
116 1 561782 $220. carburetor H12 ∅12 30, 25mph
116 1 561782 $000.  slide ∅14, jet M3.5 56 .
116 1 561787  N/A    carburetor H8    ∅8  20mph
116 1 561787 $000.  slide ∅12?, jet M3.5 46 .
118 1 481736 $35.0 =206770 float with needle, good-used
119 1 481737 $6.00 =206771 gasket for float top
120 1 561741 $35.0 float top and seat no vent use 206772
120 1 206772 $25.0 float top and seat vented
121 3 481739  =027053 screw M4 x 15 slot
122 1 mbanjo $12.0 banjo metal with 2 washers
122 2 swash8 $1.00 banjo seal washer 8mm
123 1 481741 $15.0 =206774 fuel filter
124 1 481742 $7.00 =206775 banjo bolt
125 1 561740 $5.00 idle screw M5-0.80 x 16
126 1 481747 $2.00 spring idle screw Ø5,Ø7 x 10
127 1 082510 $40.0 short holder for short Bing jet 
127 1 491722 $30.0 short holder for medium Encarwi jet 
128 short jets, thread 3.5, head 3, length 6:
128 1 486746 $18.0 orig. short jet #46 =0.445 mm
128 1 486756 $11.0 orig. short jet #56 =0.523 mm
128 1 486756 $4.00 generic subst #52 =0.520 mm
128 1 486756 none  generic subst #53 =0.530 mm
128 medium jets, thread 3.5, head 8, length 11:
128 1 566756 $12.0 orig medium jet 56 =0.523 mm
128 1 566746  N/A    orig medium jet 46 =0.445 mm
129 1 561748 $25.0 slide throttle Ø14 (H12) #3
129 1 561742  N/A    slide throttle Ø12? (H8)
130 1 046430 $7.00 rubber cover over carb top
131 1 561721 $25.0 carb top white plastic
132 2 561745 $2.00 o-ring for choke 1 x 4.0
133 1 561743  N/A    choke slide
134 1 561743  N/A    choke slide set screw M4
135 1 481759 $10.0 spring throttle Ø9.5 x 44
136 1 491724 $8.00 spring choke return
137 1 561747  choke cable wire only
138 1 561713 $5.00 air filter foam strip
139 2 561714  N/A    air filter screen
140 1 561747 $52.0 choke cable assy 132,133,134,136,137
143 1 823514 $0.70 screw M5 x 30 phillips
144 1 561795  N/A    air box with filter good used

 

Encarwi H12 carb on Trac M56 engine

Encarwi H12, with no top, on Trac M56 engine

 

Encarwi Jets: Most Encarwi carburetors use standard Bing 3.5mm jets. Those jets have a “short” head that is only 3mm long. To use a short jet, the jet holder must be for a short jet. But some Encarwi carburetors have longer 3.5mm jets with 8mm “medium” or 12mm “long” heads.

Encarwi jet holders
1  481722 long jet holder for short (Bing) jet 
2  481731 long jet holder for long Encarwi jet  can be a substitute for 3
3  491722 short jet holder for medium Encarwi jet 
4  082510 short jet holder for short (Bing) jet

 

 

 

New Tomos Transmission Service

August 10, 2014

Basic A35/A55 Transmission Service

Replacing the first speed clutch segments:

1. Once the transmission oil is drained out, and the trans cover removed, the clutch and trans are exposed.

2. The 17mm clutch nut is spun off with an impact wrench. The outer first speed clutch just pulls straight out.

3. The circular coil spring is removed. The old clutch segments are removed, preserving the orientation.

4. The new clutch segments are transferred over one at a time so as to not scramble the direction.

5. The three leaf springs are put back, with tails inside, not outside the neighbor spring’s cradle.

6. The circular coil spring is carefully stretched and maneuvered into position. See photos below.

Step 6a. Getting everything ready for the spring pre-loading (stretching).

At the gaps between the segments, the leaf springs have “cradles”. These cradles prevent the spring from wandering either way and coming off. When installing, always put the c-clamps or vise grips where you can almost get two of the three cradles. Never clamp onto the spring or the brake lining. Left, initially set the clamps like this. There’s no tension in the spring yet.

>

>

Step 6b. Gently stretch with soft thumbs then clamp it

Now with both your thumbs, gently stretch and lift the spring onto the ledge, but not yet over the cradle. You cannot let go or it will come off and maybe fly away. Hopefully you have a third needle nose vise grips within arms reach that is already adjusted and ready to clamp. Without letting the spring snap back and without taking too much time, clamp the third vise grips (a needle nose vice grips like shown here is best) to prevent the spring from flying off.

>

Step 6c. Gently pry the spring over the cradle with a small screwdriver

Just like putting a tire onto a rim, that last little bit is the most difficult. It’s very easy to damage the spring by forcing it to go when it doesn’t want to. If it gets tight, release and try to take a smaller bite. If the new spring is over stretched by rough handling during installation, it will be like having an old softer one.

>

>

7. Once it snaps over the cradle you got it. Now just push on it to snap it in it’s groove all around.

8. Place the assembled 1st speed clutch back on, tighten the nut with the impact.

9. Put the two rear shaft’s shim washers 10 & 16mm in place, clean the gasket surfaces and any sludge.

9a. For Pedal Models:  Take the left pedal crank off, or at least park the pedal in the down position. The weight of that far side pedal makes the pedal shaft point wrong, causing the transmission cover to not go on right.

9b. For Pedal Models: Make sure the U-shaped clip is in it’s slot in the case wall. The starter (pedal) shaft should move 45 degrees back and forth. If only the clutches were removed, and not the countershaft and pedal shaft assemblies, then it will still be in it’s slot, ready for the trans cover to go back on. More pictures of this will be put here soon …

10. Put the trans cover on. When everything is aligned, it makes a loud clap.

11. Then tighten the trans cover bolts. Put new ATF fluid and go try it out!

Indian Models

August 3, 2014

updated 2020-04

 

 

 

 

 

 

All Indian mopeds have the same model name, “AMI-50 Chief”, or just “AMI-50”. The service manual cover mentions a “AMI-50 2S”. This was the 2-speed that never materialized.

The 1978-81 Indian AMI50 engine is a remake of a 1975-77 Honda PC50K1 or 1975-78 Honda PF50R engine. The main difference is the Indian left case has Bosch-compatible stator plate mounts, while Honda has no stator plate. Other than the magneto-generator, and the Mikuni version head and intake, everything else is interchangeable.

Indian models are like a fast food restaurant menu, many variations from just a few ingredients.

 
The 1978 Indian Parts Manual lists the following frame colors: black, silver, burgundy, blue.
The first 1978-79 Indians had a Tillotson “pumper” type carburetor. That had problems.
Later 1979 Indians had a Keihin carburetor, with lever choke, same kind as Honda PC50.
The only 1978 decals listed are the left and right Indian heads on the tank.
The only 1978 wheels are the spoke wheels with 90mm brake drums.
 
The 1979 Indian Parts Manual lists the following frame colors: black, silver, burgundy, blue, green, white.
The 1979-later Indians had a wider rear luggage rack.
Some 1979, and all 1980-later had a Mikuni 10mm carb, with cable choke.
Early Mikuni versions had the same black-painted cylinder head with the same flange angle.
Later Mikuni versions a different silver-painted head with a flange angle more side-facing.
Those late-Mikuni silver heads came with valve stem seals, unlike the older black heads.
The 1979-later Sport Mag II aluminum wheels have the same 90mm brakes as the spoke wheels.
The 1979-later Mira Enterprises aluminum wheels have 100mm brakes, different than the others.
 
“Script” version had gold script Indian decals on the tank, and gold script Indian on the engine covers (sides).
“Stripe” version had either “warm” or “cool” color stripes, and “FOUR STROKE” in yellow slanted on the sides.
 
The 1980 Indian Parts Manual lists the following frame colors: black, silver, burgundy, blue, green, white.
Some 1979, and all 1980-later had the improved two-coil WTEMCO magneto. See Wiring Diagrams for that.
 

1978-79 Indian AMI-50 Chief  (head logo, spoke wheels) 

1978 Indian AMI50 white with spoke wheels Indian head logo on tank no other stickers

1978 Indian AMI-50
white with spoke wheels
Indian head on tank
old “four stroke” on sides

1978 Indian AMI50 black with spoke wheels They rust easily.

1978 Indian AMI-50
black with spoke wheels
Indian head on tank
  rusted bad, too bad!

1978 Indian AMI50 silver with spoke wheels Indian head logo on tank

1979 Indian AMI-50
silver with spoke wheels
Indian head on tank

 

 

 

 

 

 

 

1979-80 Indian AMI-50 Chief (gold script, spoke wheels)

1979 Indian AMI50 burgundy w/spoke wheels Indian gold script on tank

1979 Indian AMI-50
burgundy with spoke wheels
gold script on tank and sides

1979 Indian AMI50 burgundy w/spoke whls

1979 Indian AMI-50
burgundy w/spoke whls
gold script on tank+sides

1980 Indian AMI-50 black with spoke wheels gold script on tank + sides

1980 Indian AMI-50
black with spoke wheels
gold script on tank+sides

 

 

 

 

 

 

 

1979-80 Indian AMI-50 Chief (color stripes, spoke wheels)

late 1978 Indian AMI50 green with spoke wheels color stripes removed

1979 Indian AMI-50
green with spoke wheels
color stripes removed

1979 Indian AMI50 burgundy w/spoke wheels warm color stripes

1979 Indian AMI-50
burgundy w/spoke whls
with warm color stripes even on engine covers

1979 Indian AMI50 white with spoke wheels with cool color stripes gold script on sides

1979 Indian AMI-50
white with spoke wheels
with cool color stripes
gold script eng covers

 

 

 

 

 

 

 

1979-80 Indian AMI-50 Chief (gold script, Sport Mag II “8 ray” wheels)

1979 Indian AMI-50 black Sport Mag II whls gold script tank + sides

1979 Indian AMI-50
black Sport Mag II whls
gold script tank + sides

1980 Indian AMI-50 black Sport Mag II whls gold script on tank gold script on sides

1980 Indian AMI-50
black Sport Mag II whls
gold script tank + sides

Some Indians had Sport Mag II cast aluminum wheels, made in Placentia CA USA, near Myrons Mopeds. These were pretty much the only aluminum “mag” type wheel on any Indian mopeds originally sold is Southern California. For the rest of the country, the Mira Enterprises (Taiwan-made) aluminum wheels, that look like snowflakes, are the most common type of Indian moped “mag” wheel. This is easy to see in a Google image search for “indian moped”. Maybe, this was because American Moped Associates, in Irvine CA, had to unpack the bikes and swap the wheels with the local-made aluminum ones (that need all the brake and axle parts transferred from the old spoke wheels). So they only sold units with Sport Mag II wheels to local deliveries, while for far away deliveries they would sell the units with Mira snowflake wheels. That way the packaging crate was undisturbed from Taiwan, and able to withstand another long distance shipment. What you see on opposite coasts of the USA is sometimes different, like these wheel styles.

Die cast aluminum wheels for Indian mopeds made by Sport Mag II, Inc. Placentia, California

Cast aluminum wheels
for Indian mopeds

Sport Mag II wheels for Indian mopeds right side view

Sport Mag II wheels
for Indian mopeds
right side, silver or black

Sport Mag II wheels for Indian mopeds left side view

Sport Mag II wheels
for Indian mopeds
left side, silver or black

 

 

 

 

 

 

 

Sport Mag also made dual chain Puch and Peugeot 17″ wheels, and others. See Wheels.

 

1979-80 Indian AMI-50 Chief (color stripes, Sport Mag II “8 ray” wheels)

1979 Indian AMI-50 black Sport Mag II whls with warm color stripes

1979 AMI-50, black
black Sport Mag II wheels, warm stripes

1979 Indian AMI50 silver Sport Mag II whls with cool color stripes (from 1981 accessories catalog cover)

1979 Indian AMI-50
silver S. Mag II wheels
“cool” stripes, from
’81 access. catalog

1979 Indian AMI50 burgundy w/warm stripes silver Sport Mag II whls

1979 Indian AMI50
burgundy, warm stripes
silver Sport Mag II whls

 

 

 

 

 

 

 

American Moped Associates was already proud that the Indian was American-designed. With it’s long bench seat, extra large 1.6 gallon gas tank, heavy weight carrying capacity, motorcycle type forks, and plenty of chrome it was an American moped. It was a pretty good frame with a classic moped design, functional and fun to look at. Now, with the USA-made Sport Mag II wheels, the product was almost living up to the company name, American Moped.

 

1979-81 Indian AMI-50 Chief  (color stripes, Mira “snowflake” wheels)

Indian AMI50 2014-08-25 003

1980 Indian AMI-50
black with warm stripes
Mira aluminum wheels

Indian AMI50 2014-08-25 002

1980 Indian AMI-50
black with warm stripes
Mira aluminum wheels

Indian vin plate

1980 Indian, made
by Mira Enterprises

Somehow the maker of the Indian moped changed from Merida Industry Company Ltd, in 1978-79, to Mira Enterprises Ltd, in 1980-81. But nothing physically changed on the bike except the ID plate. More about this will follow…

 

 

 

1980 Indian AMI-50 white with Mira wheels warm color stripes

1980 Indian AMI-50
white with warm stripes
silver Mira “snowflakes”

1980 Indian AMI-50 black with cool stripes silver Mira snowflake whls

1980 Indian AMI-50
black with cool stripes
silver Mira snowflake whls

1979 Indian AMI50 black with warm stripes silver Mira "snowflakes"

1979 Indian AMI50
black with warm stripes
silver Mira “snowflakes”
optional front foot rest

1981 Indian AMI50 white with cool stripes Mira aluminum wheels

1981 Indian AMI50
white with cool stripes
Mira aluminum wheels

 

 

 

 

 

 

 

1980-81 Indian AMI-50 Chief  (gold script, Mira “snowflake” wheels)

1981 Indian AMI50 white with gold script silver Mira "snowflakes"

1981 Indian AMI50
white with gold script
silver Mira “snowflakes”

1981 Indian AMI50 black with gold script Mira snowflake wheels

1981 Indian AMI50
black with gold script
Mira snowflake wheels

1980 Indian AMI50 burgundy w/gold script Mira snowflake wheels

1980 Indian AMI50
burgundy w/gold script Mira snowflake wheels

 

 

 

 

 

 

 

1981 Indian AMI-50 Chief  (head logo, Mira “snowflake” wheels)

1981 Indian AMI50 white with head logo Mira snowflake wheels

1981 Indian AMI50
white with head logo
Mira snowflake wheels

1981 Indian AMI50 black with head logo Mira snowflake wheels

1981 Indian AMI50
black with head logo
Mira snowflake wheels

 

 

 

 

 

 

 

 

 

 

Honda Benelux

July 28, 2014
Honda Belgium assembly room in the late 1960's

Honda Belgium assembly room in the 1960’s

Honda vintageHonda expanded it’s production into Belgium in the mid 1960’s, after the successful Honda 50 Cub sold well worldwide. Honda Belgium produced the P50 pedal moped from 1966 to 68, and then the PC50 moped from 1969 to 77. See the Wikipedia Honda P50, and Wikipedia Honda PC50 articles. Around 1975, when parts were also produced in Netherlands and Luxemburg, the name changed from Honda Belgium to Honda Benelux (for Belgium, Netherlands, Luxemburg). The successor to the PC50 four-stroke one-speed moped (later copied by Taiwan and called Indian) was the PA50 two-stroke variable speed moped, with way more take off and hill climbing power. The PA50 was produced from 1976 to 91. See below. Here is a brochure from 1965 showing the Honda Belgium product line:1965 Honda Belgium brochure

1977 Honda Hobbit Magazine AdThe Honda PA50 Hobbit/Camino

The Honda PA50 pedal moped was produced at Honda Benelux from 1976 to 1991. The PA50 was called Camino in Europe, and Hobbit in the US. The PA50 Hobbit was sold in the US from 1978 to 1983. See the Wikipedia Honda PA50 article for more. Honda PA50 parts were originally only sold at Honda motorcycle dealerships, never at independent moped shops. Some components are interchangeable, or available for, or from, other European moped brands.

 

 

 

 

USA Models of Honda PA50

Honda PA50 info from American Honda Model Identification Catalog

1978 Honda PA50I 20mph

1978 PA50-I 20mph

 

 

 

 

 

 

 

'78 Honda PA50II 30mph

1978 PA50-II 30mph

 

 

 

 

 

 

 

 

1979 PA50I 20mph

1979 Honda PA50-I 20mph

 

 

 

 

 

 

 

1979 PA50II 30mph

1979-80 Honda PA50-II 30mph

 

 

 

 

 

 

 

1981 PA50II 30mph

1981 Honda PA50-II 30mph

 

 

 

 

 

 

 

1982 Honda PA50II

1982 Honda PA50-II 30mph

 

 

 

 

 

 

 

1983 Honda PA50II

1983 Honda PA50-II 30mph

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Honda PA50 Owners Manual cover

1983 Honda PA50 Owners Manual cover

1983 Honda PA50 Owners Manual table of contents

1983 Honda PA50 Owners Manual – Table of Contents

 

1983 Honda PA50 Owners Manual pages 1, 2, 3, 4

Honda PA50 Owners Manual pages 1, 2, 3, 4

1983 Honda PA50 Owners Manual pages 5, 6, 7, 8

Honda PA50 Owners Manual pages 5, 6, 7, 8

1983 Honda PA50 Owners Manual pages 9,10,11,12

Honda PA50 Owners Manual  9,10,11,12

1983 Honda PA50 Owners Manual pages 13,14,15,16

Honda PA50 Owners Manual 13,14,15,16

 

 

 

 

 

 

 

1983 Honda PA50 Owners Manual pages 17,18,19,20

Honda PA50 Owners Manual 17,18,19,20

Honda PA50 Owners Manual 21,22,23,24

Honda PA50 Owners Manual 21,22,23,24

Honda PA50 Owners Manual 25,26,27,28

Honda PA50 Owners Manual 25,26,27,28

1983 Honda PA50 Owners Manual pages 29,30,31,32

Honda PA50 Owners Manual 29,30,31,32

 

 

 

 

 

 

 

Honda PA50 Owners Manual 33,34,35,36

Honda PA50 Owners Manual 33,34,35,36

Honda PA50 Owners Manual 37,38,39,40

Honda PA50 Owners Manual 37,38,39,40

Honda PA50 Owners Manual 41,42,43,44

Honda PA50 Owners Manual 41,42,43,44

Honda PA50 Owners Manual 45,46,47,48

Honda PA50 Owners Manual 45,46,47,48

 

 

 

 

 

 

 

Honda PA50 Owners Manual 49,50,51,52

Honda PA50 Owners Manual 49,50,51,52

Honda PA50 Owners Manual 53,54,55

Honda PA50 Owners Manual 53,54,55

 

 

 

 

 

 

 

 

 

 

Speed Version Differences

Honda PA50 speed versions

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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