Odyssey Models

December 27, 2020

  US Models 

Identification: 2-speed has pulley screws, Regular does not

32/1-R  32kph (20mph), Regular transmission
11 x 53T sprockets, Solo 254 engine, thin exhaust
link   switches   head light  tail light  colors
’76 195 & 8177 ULO xxxxx CEV 9350 orange

’77 8040, 8177 CEV bullet  ULO 250 orange
’78 8040, 8177 CEV bullet  ULO 248 blue
’78 343 & 342  ULO xxxxx ULO 248

40/1-R  40kph (25mph), Regular transmission
14 x 53T sprockets, Solo 255 engine
link   switches   head light  tail light  colors
’76 195 & 8177 ULO xxxxx CEV 9350 orange

’77 343 & 342  ULO xxxxx ULO 250 red
’78 343 & 342  ULO xxxxx ULO 248

40/2-R  47kph (29mph), Regular transmission
15 x 50T sprockets, Solo 255 engine
link   switches   head light  tail light  colors
’76 195 & 8177 ULO xxxxx CEV 9350 orange
’77 8040, 8177 CEV bullet  ULO 250 orange

’78 343 & 342  ULO xxxxx ULO 248 black/chrome

32/1-2  32kph (20mph), 2-speed transmission
11 x 53T sprockets, Solo254 engine, thin exhaust
link   switches   head light  tail light  colors
’76 195 & 8177 ULO xxxxx CEV 9350 orange

’77 343 & 342  ULO xxxxx ULO 250 yellow
’78 343 & 342  ULO xxxxx ULO 248 red/chrome

40/1-2  40kph (25mph), 2-speed transmission
14 x 53T sprockets, Solo 255 engine
link   switches   head light  tail light  colors
’76 195 & 8177 ULO xxxxx CEV 9350 orange

’77 8040, 8177 CEV bullet  ULO 250 green
’77 343 & 342  ULO xxxxx ULO 250 orange
’78 343 & 342  ULO xxxxx ULO 248 red/chrome

40/2-2  47kph (29mph), 2-speed transmission
15 x 50T sprockets, Solo 255 engine
link   switches   head light  tail light  colors
’76 195 & 8177 ULO xxxxx CEV 9350 orange
’77 8040, 8177 CEV bullet  ULO 250 orange
’77 343 & 342  ULO xxxxx ULO 250 orange
’78 343 & 342  ULO xxxxx ULO 248 red/chrome

 

 

1977 Odyssey 32/1-R

1977 Odyssey 32/1-R

Odyssey 32/1-2

1977 Odyssey 32/1-2

1978 Odyssey 32/1-R

1978 Odyssey 32/1-R

 

 

 

 

 

 

 

 

1977 Odyssey 40-1-R

1977 Odyssey 40/1-R

1978 Odyssey 40/1-R

 

 

 

 

 

 

 

 

 

1977 Odyssey 40/2-R

1977 Odyssey 40/2-2

Odyssey 40-2-R

1978 Odyssey 40-2-R

1978 Odyssey 40/2-2

1978 Odyssey 40/2-2

 

 

 

 

 

 

 

 

 

 

 


Derbi Engines and Speed Versions

December 27, 2020

 

1976-85 Derbi moped engines (for sale in the USA) came in three speed versions:
30mph (2.0hp) 12mm xxx no restrictor,  1 – 1mm variator limiting washer (gas mileage 117 mpg)
25mph (1.5hp)  10mm intake restrictor,  1 – 4mm variator limiting washer (gas mileage 130 mpg)
20mph (1.0hp)  10mm intake restrictor,  2 – 4mm variator limiting washers

1985-89 Derbi moped engines (for sale in the USA) came in one speed version:
30mph (2.0hp) 10mm intake restrictor,  1 mm variator limiting washer
43mph actual when de-restricted!

 


Peugeot Speed Versions

December 27, 2020

 

US-model Peugeot mopeds were made in three different speed and power versions to comply with different state laws. For example, mopeds in California go 30mph, but in Nevada or Arizona they go 25mph. Each state has different moped laws. Peugeot moped speed versions are referred to by the speed version codes U1, U2 and U3. The speed version code appears after the model on the I.D. plate, on the frame behind the headlight. For example, a 103 LVS U2 is a 25mph moped with 1.5 horsepower.

U1 is 20 mph and 1.0 hp, U2 is 25 mph and 1.5 hp, U3 is 30 mph and 2.0 hp

76-80 103 L2S U3 carb  jet  intake  reed
 6-80 103 L2S U3  size  size  pipe   valve xx cylinder  cyl. head x exhaust x clutch/variator  gearing x seat  wheels


102 No Variator
79-80 102 SPB U2   10  220  8.5  none xxx xx 102 all same xxx 102 all same  fixed pulley  11 x 50T  long  spoke
79-80 102 SPB U3   12  245   12  none xxx xx 102 all same xxx 102 all same  fixed pulley  11 x 42T  solo  spoke
79-80 102 SPB U3   12  245   12  none xxxxx  102 all same xxx 102 all same  fixed pulley  11 x 42T  long  spoke
103 No Variator
76-77 103 LSS U1  8.5  240  8.5  restricted  restricted  lo-comp  restricted xx  fixed pulley  11 x 48T  solo  spoke
78-83 103 L2S U1  8.5  240  8.5  restricted  restricted  lo-comp  restricted xx  fixed pulley  11 x 48T  solo  spoke
78-80 103 L2S U2   12  245   12  restricted  restricted  lo-comp  long baffle xx fixed pulley  11 x 40T  solo  spoke
78-80 103 L2S U3   12  245   12  restricted  normal xx normalx  long baffle xx fixed pulley  11 x 36T  solo  spoke
103 Variator
76-83 103 LVS U2   12  245   12  restricted  restricted  lo-comp  long baffle xx U2 weightsx 11 x 52T  solo  spoke
78-80 103 SPS U2   12  245   12  restricted  restricted  lo-comp  long baffle xx U2 weightsx 11 x 56T  solo  spoke
79-80 103 SPB U2   12  245   12  restricted  restricted  lo-comp  long baffle xx U2 weightsx 11 x 56T  long  spoke
80-83 103 SPR U2   12  245   12  restricted  restricted  lo-comp  long baffle xx U2 weightsx 11 x 56T  long  mags
76-78 103 LVS U3   12  245   12  normal x.  normal xx normal x short baffle X U3 weightsx 11 x 52T  solo  spoke
78-83 103 LVS U3   12  245   12  normal x.  normal xx normal x long baffle xx U3 weightsx 11 x 52T  solo  spoke
77-78 103 SPS U3   12  245   12  normal x.  normal xx normal x short baffle x U3 weightsx 11 x 52T  solo  spoke
78-80 103 SPS U3   12  245   12  normal x.  normal xx normal x long baffle xx U3 weightsx 11 x 52T  solo  spoke
79-80 103 SPB U3   12  245   12  normal x.  normal xx normal x long baffle xx U3 weightsx 11 x 52T  long  spoke
80-83 103 SPR U3   12  245   12  normal x.  normal xx normal x long baffle xx U3 weightsx 11 x 52T  long  mags
79-80 1oo TSM U3   12  245   12  normal x.  TSM xxxx normal x TSM long xxx U3 weightsx 11 x 56T  long  spoke

 

Cylinder: 102 U2 and U3 are the same, but 103 U1,U2 have a different cylinder than 103 U3, with a slightly smaller exhaust port. A U1,U2 cylinder can be converted to U3 by mild “porting”, by grinding the top pf the port, at the cylinder wall, higher by 1.0 mm, and each side wider by 0.5mm.

Head: The 103 U1,U2 low compression head can be converted to U3 by milling off 1 or maybe 2 mm. Leaving off the head gasket instead, is a quick and beneficial way to increase the compression ratio. But when the head is moved closer to the piston, contact can happen. Care must be taken. A squish clearance of 0.6mm (0.024″) is recommended when cold. A minimum combustion chamber volume of 5.0cc is recommended for a 50cc swept volume, to have a maximum compression ratio of (50+5)/5 equals 11 to 1. 

Reed Valve:  The 103 U1 and U2 small round reed plate holes can be widened to “normal” round holes. Furthermore a Tomos A35 reed valve fits, and gives even more power increase because the reed plate holes are rectangles with more area. Expect a stock healthy 103 LVS U3 to go 4-5 mph faster and accelerate quicker, with just a Tomos reed valve, with no side effects.

Carburetor: To upgrade an 8.5 to a 12mm carburetor you can replace the bare body. It is too difficult to carve out because the non-removable brass spray tube is in the way.

Intake Pipe: To upgrade an 8.5 to a 12mm intake manifold you can carve out the inside, or replace it. On a Peugeot 102 the only difference between a U2 and U3 is the intake manifold.

Exhaust: The 103 U1 muffler is gloss black and has a U-turn in the removable baffle, and a hemispherical end cap. The 103 U2 and U3 muffler is dull black, with a straight tube removable baffle and a vertical channel end cap. The wider end of the vertical channel should face down, or the bike will go slower.

Baffle tube: Early 103 U3 models came with a short baffle tube. These went 35mph and were the fastest moped. Then in 1978 Peugeot had to slow all the bikes down to meet 30mph DOT requirements. They issued a recall to all 103 U3 owners to bring their mopeds into their dealer to have the long baffle put in. All later 103 U3 models were made with long baffles. Simply removing the baffle makes it only a little bit louder, but adds 2-3 mph in speed.

Belt Pulleys: The front pulley is the same on all 102 and 103-no-variator models. The variable front pulley on 103-variator models is the same except for the centrifugal variator weights are different on U2 and U3 models. All 102’s have the same 7 inch rear pulley. All 103’s have the same 8″ rear pulley.

Sprockets: All Peugeot’s have an 11 tooth front sprocket. 102 rear sprockets have smaller center holes than 103 rear sprockets (because the rear hub is smaller). 103 rear sprockets can interchange with Puch or Motobecane, except for the bolt holes. On both 102 and 103 Peugeot uses a special 5-hole pattern that is unique. They did not want people to easily change to a 6-hole Puch 45 tooth rear sprocket. It can be done with drilling.

Gearing: A smaller rear sprocket makes higher gearing, and higher possible speed. But if the gearing is already optimum, then higher gearing alone will not make any more speed, except on downhills and with tail winds. It takes a greater amount of driving force to push through the air at a greater speed, but higher gearing decreases the rear wheel driving force. So the engine has to make much more torque to achieve the higher speed.

Gearing: 102 and 103 no-variator have the same size front pulley, but the rear pulley is bigger on the 103, about 8 inch, while 102 is about 7 inch. So a 102 rear sprocket must be bigger by 8/7 to have the same overall gearing as a 103. That is why 102 rear sprockets are bigger than 103 no-variator ones.

 

 

 

 

 

 

 


Peugeot Models

December 27, 2020

 

1976-77 Peugeot 103 (US models)

1976 Peugeot 103 LVS red with white trim

1976 Peugeot 103 LVS
fire red with white trim
rouge tison (cinder red)

1976 Peugeot 103 LVS blue with white trim

1976 Peugeot 103 LVS
bright blue with white
bleu radieux (radiant blue)

1977 Peugeot 103 LVS

1977 Peugeot 103 LVS
bright blue with white
bleu radieux (radiant blue)

 

 

 

 

 

 

 

 

1977 Peugeot 103 L2 (hard tail), modified engine and handlebars
bright blue with white trim, bleu radieux (radiant blue)

 

 

 

 

 

 

 

 

103 L2 has no rear suspension and no variator, 103 LS has rear suspension, but no variator, 103 LVS has rear suspension and a variator.

 

1977 Peugeot 103 Ad

1977 Cycles Peugeot (USA) flyer

Cycles Peugeot Paint Colors

TS rouge tison (cinder red)
BX bleu radieux (radiant blue)
VK vert kentucky (Kentucky green)
VD vert dore (golden green)
BS bleu sidéral (sidereal blue)
IP ivoire persan (Persian ivory)
CM ciel métalisé (sky metallic)
OM orange métalisé (orange metallic)
AM amande métalisé (almond metallic)
BZ blanc irisé (iridescent white)

Peugeot Colors Chart

 

 

 

 

 

 

 

 

 


1978-79 Peugeot 103 (US models)

1978 Peugeot 103 LVS red with white trim

1978 Peugeot 103 LVS
fire red with white trim
rouge tison (cinder red)

1978 Peugeot 103 Ad

1978 Peugeot Ad

1978 Peugeot 103 SP
grass-green and black
vert dore (golden green)

1978 Peugeot 103 SPB
grass-green and black
restored by Jam Mam
vert dore (golden green)

 

 

 

 

 

 

 

 

 

The L models (L2, LS, LVS) are 3 inches lower than the SP (SP, SPB, SPR) models. They have less suspension travel, and less chrome.

 

1979 Peugeot 103 LVS green with white trim

1979 Peugeot 103 LVS
bright green with white trim
vert kentucky (kentucky green)

1979 Peugeot 103 SP aqua blue metallic

1979 Peugeot 103 SP
candy aqua & black trim
bleu sidéral (sidereal blue)

1979 Peugeot 103 SP aqua/black with long seat

1979 Peugeot 103 SPB
aqua/black with long seat
bleu sidéral (sidereal blue)

 

 

 

 

 

 

 

 

 


1980-83 Peugeot 103 (US models)

1980 Peugeot 103 LVS restored by B. Small

1980 Peugeot 103 LVS
restored by B. Small

1980 Peugeot 103 LVS restored by B. Small

1980 103 LVS, ivory & olive-silver
ivoire persan (persian ivory)

 

 

 

 

 

 

 

 

 

 

1980 Peugeot 103 LVS silver-blue with black

1980 Peugeot 103 LVS
silver-blue with black trim
ciel métalisé (sky metallic)

1980 Peugeot 103 LVS red with black trim

1980 Peugeot 103 LVS
fire red with black trim
rouge tison (cinder red)

1980 Peugeot 103 LVS orange with black trim

1980-83 Peugeot 103 LVS
met. orange with black trim
orange métalisé (o. metallic)

 

 

 

 

 

 

 

 

 

1980 Peugeot 103 LVS close-up of engine

1980 Peugeot 103 LVS
silver-blue, black trim
ciel métalisé (sky metallic)

1980 Peugeot 103 SP olive-silver w/black trim

1980 103 SP, olive-silver, black trim
amande métalisé (almond metallic)

1980 Peugeot 103 SPB olive-silver w/black trim

1980 103 SPR, olive-silver & black
amande métalisé (almond metallic)

 

 

 

 

 

 

 

 

 

103 SP has a solo seat and spoke wheels, 103 SPB has a long seat and spoke wheels, 103 SPR has a long seat and mag wheels. 

 


1980-82 Peugeot 102, TSM (US models)

1980 Peugeot 102 SP

1980 Peugeot 102 SPB
candy aqua & black trim
bleu sidéral (sidereal blue)

1980 Peugeot 102 SP

1980 Peugeot 102 SPB
silver-blue & black trim
ciel métalisé (sky metallic)

1980 Peugeot 102 SP
candy aqua & black trim
bleu sidéral (sidereal blue)

 

 

 

 

 

 

 

 

102 SP has a solo seat, 102 SPB has a long seat. That is the only difference. Neither came with a speedometer.

1980 Peugeot TSM

1980 TSM, top tank tube frame
blanc irisé (iridescent white)

1980 Peugeot TSM, provided by Sunday Morning Motors
blanc irisé (iridescent white)

 

 

 

 

 

 

 

 

 

 


Non-US Models

Info Peugeot Euro

Info Peugeot Euro

Peugeot Vogue

Peugeot Vogue

 Peugeot Vogue

Peugeot Vogue

 

 

 

 

 

 

 

 

 

 


Bing Allstate

December 11, 2020

bing crown Sears Allstate 6.  B I N G    A L L S T A T E     C A R B S

There are 3 Bing 12mm carburetors on Sears Allstate mopeds.

1. 050.1.1500.2/58  ∅12 jet 58, cable choke (1-ended cable)
for M1 engine with intake silencer (air box) Puch MS50

on ’56-58 Mo-Ped 810.94000, 810.94001
on ’63-64 Econo Mo-Ped 810.94011, 810.94018

3. 364.1.15.001.0/62  ∅12 jet 62, cable choke (2-ended cable)
for M3 engine with no intake silencer Puch MS50V

on ’58-61 Mo-Ped 810.94010, 810.94019  
on ’59-61 Mo-Ped 810.94020  
on ’62-63 Mo-Ped 810.94030, 810.94039
on ’64-65 Mo-Ped 810.94040, 810.94049 

6. 360.1.15.500.0/62  ∅12 jet 62, lever choke (no choke cable)
for M6 engine with no intake silencer Puch MS50VDK

on ’64-65 Campus 50 810.94090, 810.94099

 Allstate Bing
136 fig  00.00.000.0/00 price  
100 050.1.1500.2/58 0  none  M1 carb ∅12 jet 58, cable choke

010 364.1.15.001.0/62  none  M3 carb ∅12 jet 62, cable choke
001 360.1.15.500.0/62  none  M6 carb ∅12 jet 62, lever choke

111 01 050.1520 000    $4.00 cable adjuster A1b M5-0.80
111 02 900.2115 000    $0.40 adjuster nut M5-0.80 =050.1517
111 03 050.1519 000    none  top cover outer M18-1.0
111 04 050.1518 000    none  top inner with tube bend M6-0.75
111 05 050.1531 0000  $10.0 throttle spring
111 06 050.1513 0000  $3.00 throttle needle clip
011 6a 350.1.15.014.1  none  throttle disc ∅11 x 0.5
111 07 050.1516 000    none  throttle needle (state 1 or 2 marks)
111 07 050.0516 000    none  throttle needle 31mm 1-mark
111 08 050.1515 000    none  throttle slide (state #)
111 08 050.1515 000    $33.0 throttle slide #16
111 09 050.1555 000    none  choke spring
111 10 050.1552 000    none  choke shoulder screw
011 11 050.1529 000    none  air filter clip
011 12 050.1540.2 00   none  air filter screen
100 14 050.1558 000    none  choke pinch screw

010 15 350.4.15.056.1  none  choke cable nipple
110 16 050.1559 000    none  choke locking plate
110 17 050.1553 000    none  choke slide
100 18 050.1509/58      none  main jet size 58
011 18 050.1509/62      none  main jet size 62
222 19 050.1535 000    $1.30 float top screw M4 x 10 slot
100 20 050.1532 000    none  float top with seat
011 20 364.1.15.032.2  none  float top with seat and tickler
111 21 050.1536 000    none  float chamber gasket
111 22 050.1530 000    none  float needle (no bulb)
111 23 050.1525 000    none  float bulb (no needle)
110 24 050.10.1501 0   none  carburetor body bare
222 25 900.1107 000    $1.00 hex bolt M6 x 25
222 26 24804 000000   $0.20 plain washer M6
111 27 050.1521 0000  $9.00 intake gasket/heat block
111 28 050.1508 000    none  needle jet (state #)  Bing Jawa 14,15
111 29 27071 00000     $1.50 seal washer 10 x 14mm
111 30 050.1523 000    none  screw plug M10-1.0
111 31 050.1511 000    $7.00 idle screw M4-0.7
111 32 24771 00000     $0.40 idle screw nut M4-0.7
100 33 050.1570.0 00   none  intake silencer complete
100 00 050.1574 000    none  spring for air filter
100 00 050.1575 000    $0.80 washer ∅3 ∅6 x 1
200 34 3770 000000     $0.80 washer ∅5 ∅9 x 1
200 35 900.1323 000    $0.80 screw M5 x 40 slot
100 36 050.1576 000    none  seal ring ∅52 ∅45 x 2
100 37 050.1.1577 00   none  junction sleeve
100 38 050.1540.2 00   none  air filter screen

 

 
 
 
Allstate Bing Diagram

Here is a beautiful cut-away illustration from the Danish website veteranknallertklub.dk. The venturi is 12mm diameter. The curved pipe is about 13mm. The jet and jet holder are a single piece, like the Bing “early Sachs”. The choke cable and plate are the same as Bing “Solo”, with a “carb” end on the choke cable. The screw-on top cap is M18x1.0 thread and M6x0.75 cable elbow/stop, Ø14.5 slide with slot facing the intake (like other early Bings), and jet needle, are interchangeable with Bing “Solo” and Bing “Jawa or early Sachs”.

From the left drawing, sliced vertically front to back, you can see the little pin that locates the throttle slide, near where the choke cable comes in at. Like the other early Bings “Solo” and “Jawa”, the slot in the throttle slide faces the intake, so the throttle slides interchange (but not with “1970’s Sachs” and “Kreidler”). 

  
 

Puch used this Bing “Allstate” 12mm carburetor on the MS50 (Moped Stahlblech – steel sheet) series from the 1950’s to the 1970’s. In 1969 Puch indroduced the Maxi moped, with an all new carburetor design. That carburetor, called Bing “Puch” or “round Bing” was in use from 1969 to 1986. It is way more familiar to Americans because of the moped buying frenzy in the late 1970’s. In the early 1980’s Puch developed their advanced technology future moped. But sales were down, and something like internal fraud contributed to Puch going out of business after over a century. If they had kept going, we would have an abundance of parts for the Bing “Austro Daimler” carburetor.

 

Minarelli Cables

November 30, 2020

Minarelli

Minarelli is the name of the engine. Only the lower end of the throttle and start cables are for the engine. The cables upper ends are for whatever controls that are on the bike’s handlebars. The brake cables lower ends are for whatever brakes the bike has. The cable lengths depend on the frame and handlebars.

Cables for mopeds with Minarelli V1 engines, 1970’s Domino controls and Grimeca brakes, are in Cimatti.

Cables for mopeds with Minarelli V1 engines, 1970’s Taiwan controls and brakes, are in General or Lazer.

 


Torque Specs

September 17, 2020

updated 2020-12

Contents:

1. General Torque Specs
 Metric Bolts     Stud Bolts     Spark Plugs

2. Moped Torque Specs
    Garelli   Honda   Minarelli   Morini   Peugeot
    Puch       Sachs       Tomos     Vespa (Piaggio)

 

Three main things affect the tightening torque:
1) Smaller (thinner) bolts require less torque than big (thicker) ones.
2) Weak (low grade) bolts require less torque than strong (high grade).
3) Bolts with Dry threads require more torque than lubricated ones. 

Torque Units: 1.00 n-m (newton meter) is equal to 0.102 kg-m (kilogram meter), or 0.738 ft-lb (pound foot)
All torques listed here are converted to ft-lb. That allows easy comparison of multiple sources.

 

 

1. General Torque Specs from Internet


x thread  x   4.8 00 4.8   8.8/9.8  8.8/9.8  10.9 0 10.9 0 12.9 0 12.9  ⇐  class (grade)
x thread  x lubed x  dry x  lubed x  dry x   lubed x  dry x lubed x dry 
METRIC BOLTS
x thread  x
 ft-lbs x ft-lbs   ft-lbs     ft-lbs    ft-lbs x ft-lbs   ft-lbs   ft-lbs 0
 hex sizes
0M4-0.70    0.7 00 0.8 00  1.7 00   2.3 01   2.4 01 
3.2 11 2.8 01 3.8 01 0
0M5-0.80    1.3 00 1.8 00  3.4 01   4.5 01   4.9 01  6.5 01 5.7 01 7.6 01 08  

0M6-1.00    3.5 00 4.5 00  6.5 01   8.5 01   9.5 01  12.0  11.50  12.501  09 10 
0M7-1.00    6.0 00 8.0 00  11.20    13.20    17.01   21.01  18.01  22.01  10 11  
0M8-1.25    8.5 00 11.5 0  16 00    20 00    24 01   30 01  25 01  28 01  12 13 14
M10-1.50    17  00 21  01  32 00    40 00    47 01   60 01  55 01  70 01  14 15 17
M12-1.75    29  00 39  01  55 00    70 00    80 0   140 01  95 0  120 01  17 19
M14-2.00    47  00 60  01  88   110 0    130 0   165 0  150 0  190 01  19 21

 

 


x thread  x alum. x alum.  steel x steel   STUD BOLTS threaded into
x thread  x lubed x  dry x  lubed x dry   
aluminum or steel (iron)
x
thread  x
 ft-lbs x ft-lbs   ft-lbs   ft-lbs  0
 hex sizes
0M4-0.70    1.0 00 1.3 00 1.5 00 2.0 01 0
0M5-0.80    00.11  00.11   00.01  00.01  08  

0M6-1.00    04.01  05.01   06.01  08.01  09 10 
0M7-1.00    07.01  09.00   10.00  13.00  10 11  
0M8-1.25    09.00  12.00   14.00  18.00  12 13 14
M10-1.50    18.00  24.00   28.00  37.00  14 15 17
M12-1.75    32.00  43.00   49.00  65.00  17 19
M14-2.00    51.00  68.00   78.0  104.00  19 21

 


M10 – 1.00 000M12 – 1.25 000M14 – 1.25  
alum 0 iron  000 alum 0 iron  000 alum 0 iron 
head 0 head 000 head 0 head ooo head o head

ft-lbs x ft-lbs x0  ft-lbs x ft-lbs x0  ft-lbs x ft-lbs   SPARK PLUGS
07-9 x 07-11 00 11-15   11-18 18-22   18-25

 

 

Moped Torque Specs from Service Manuals

Here blue text means engine and black text is non-engine. 


xmm-0.0..0 ft-lbs  1979 torque specifications  GARELLI
0M6-0.0  0.0-5.8  side cover screws
0M6-0.0  0.0-5.8  crankcase screws
0M7-0.0  0.-10.9  head nuts
0M9-0.0   
22-25  H-cyl. flywheel nut
M10-0.0    22-25  V-cyl. flywheel nut
M12-0.0    25-29  clutch nut

M14-0.0    43-47  sprocket nut
M14-0.0    58-61  V-cyl. countershaft nut


xmm-0.0..0 ft-lbs  1979 torque specifications  HONDA Express
0M6-0.0  6.5-8.7  head nuts
M10-0.0    21-25  clutch nut
M10-0.0    22-29  pivot shaft nut
M12-0.0    00-00  rear wheel nut

xmm-0.0..0 ft-lbs  1975 torque specifications  HONDA PC50
0M5-0.0  5.1-8.0  valve adjust nuts
0M6-0.0  5.8-8.7  valve cover nuts

0M6-0.0  6.5-8.7  head nuts
0M6-0.0  5.1-8.7  case and cover bolts
0M6-0.0  6.5-8.7  camshaft and intake bolts
M10-0.0    22-28  flywheel and clutch nuts
M12-0.0    15-22  oil drain plug

 


xmm -0.00 ft-lbs   1978 torque specifications  MINARELLI
0M4-0.0  1.3-1.5  V1 clutch lever pinch bolt #5130
0M6-0.0  3.6-4.3  V1 oil check and drain plugs
0M6-8.8  7.3-8.7  V1 case and side cover bolts, head nuts #5550
0M6-8.8  7.3-8.0  V1 intake bolts #5610, start leaf screw #5840
0M9-0.0  0- 21.7  V1 cone clutch nut #6270
M10-0.0    32-33  V1 sprocket #4840
M10-0.0    33-35  V1 flywheel nut #4750

 


xmm -0.00 ft-lbs  1977 torque specifications  PACER w/MORINI
0M5-0.0   00-04  MO1 
exhaust nuts
0M60.0   00-04  MO1  pedal pin nuts
0M60.0   00-0MO1  handlebar clamp bolts

0M6-0.0   00-07  MO1  head nuts
0M6-0.0 7.0-8.5  MO1  case and cover bolts
0M8-0.0   25-29  MO1  flywheel nut
0M10-0.0 25-29  MO1  clutch nut
0M10-0.0 25-25  MO1  shock bolts

0M11-0.0 25-29  MO1  axle nuts

0M12-0.0 25-29  MO1  sprocket nut


xmm -0.00 ft-lbs  1977 torque specifications  PEUGEOT
0M6-6.8    00-0103 case bolts
0M6-8.8    00-0103 case bolts
M10-0.0    00-18  103 flywheel nut (16 hex)
M11-0.0    00-25  103 clutch nut (21 hex)
M20-0.0    00-32  103 variator nut (32 hex)


xmm-0.00 ft-lbs  1980 torque specifications  PUCH
0
M5
-0.0  00-04  Fender bolts
0M6-0.0  00-05  Pedal pin nuts
0M6-0.0  00-0Crankcase  and clutch cover screws, Kickstand  and manifold bolts
0M6-0.0  00-0Cylinder head nuts
0M7-0.0  10-12  Handlebar bolts
0M8-0.0  00-09  Rear shock bolts
0M8-0.0  00-11  Fork top bolts
0M8-8.8  00-29  Swing arm bolts
0M8-8.8  00-23  Engine mounting bolts
M10-0.0  00-25  Flywheel nut
M10-0.0  00-20  Clutch nut 1 speed
M10-8.8  00-40  Fork clamp bolts (Magnum MkII)
M11-0.0  00-20  Front axle nuts
M12-0.0  00-20  Rear axle nuts
M12-0.0  25-36  Countershaft 2 speed nut
M16-0.0  21-24  Clutch nut 2 speed
M24-0.0  00-20  Fork top plugs (Magnum MkII)
M26-0.0  00-30  Steering head nut


xmm-0.0..0 ft-lbs  1977 torque specifications  SACHS
0M4-0.0  2.2-3.0  stator screws
0M6-0.0  5.9-7.4  cylinder nuts

0M6-8.8  7.4-8.8  case screws
0M8-0.0   
17-20  504 flywheel nut
M10-0.0    27-30  505 flywheel nut, clutch nut
M12-0.0    37-44  sprocket nut


xmm-0.00 ft-lbs  1988 torque specifications  TOMOS
0M6-0.0  00-0A3 Engine cover screws
0M7-0.0  00-0A3 Cylinder head nuts
0M8-8.8  00-18  Engine mount bolts
M10-0.0  00-22  A3 Flywheel nut
M10-0.0  00-18  A3 Clutch nut, rear shock bolts
M11-0.0  00-24  Axle nuts
M12-8.8  00-26  Swing arm bolt, fork top bolts
M14-0.0  00-13  Spark plug
M14-0.0  00-59  A3 Countershaft nut
M22-0.0  00-44  A3 Sprocket nut


xmm -0.0 ft-lbs  1970 torque specifications  VESPA
0M8-0.0  10-24  Fixed pulley nut 13 hex

0M8-0.0  14-18  Crankshaft nut, Variator pulley nut
M10
-8.8  26-39  Rear wheel mount bolts 17 hex
M11-0.0  28-30 
Ciao front axle nut 17 hex
M14-0.0  40-43 
Freewheel hub nut 36 hex
M25-0.0  22-29 
Ciao steering nut 32 hex

 

 

 

 

 


Tomos Grid Tool (takes a minute to load)

May 11, 2018

Tomos Parts List with Applications Grid

All Tomos USA moped and off-road parts are listed, from the year 2012. Each part number is one row, out of 2382. Each parts catalog (or parts group) is one column, out of 34. So the grid size is 2382 by 34.

How it’s made: In most Tomos parts catalogs there is an index list of every part number contained in that catalog. These index lists were used to create this massive applications grid.

Each row is a part: with a part number, description, and 34 characters, lined up in columns. A “” character means that item is in the Tomos parts catalog for that model, in other words it is original equipment. A “o” character means that item is not in the parts catalog.

Beware of “some”: Tomos parts catalogs cover several models. Sometimes a part is only on some of the models in a parts catalog, not on all. This grid does not show that. It shows if a part if it is on any of the models in that catalog or group. Sometimes that would seem incorrect. 

Sometimes there are different parts used on the same model. Like in 1993-94 when they had 3 or 4 different magnetos. The parts catalog did not say which ones had which part specifically. It was a “specifications subject to change without notice” situation. 

Years can overlap: Often the parts changed during the year, rather than at the end of the year. Then a particular year model would be in two different columns. For example, early 2008 is like 2007, while a late 2008 is like 2009.

Part omissions: Over the years hundreds of obsolete items, no longer sold, have been deleted from this Parts Price List. There are still many that have not been deleted, but instead say “OB” obsolete, or “NLA” no longer available.  

App omissions: Sometimes a part belongs in an app column (parts group or catalog), but does not appear there, for different reasons. Maybe the part was improved so the number changed, or the item was not sold separately anymore, or was simply omitted. Those items will have a “” character, instead of ““. Clover shape means it is a correction, not from a parts manual.

Painted parts: Some painted parts were sold primer coated, not painted. Before the 2000’s if the color was not specified when ordering, some replacement parts were primer coated (unpainted). Sometimes the primer replacement had the next higher or lower part number, and sometimes it had the same number as the finish-painted item.   

Painted parts from before 2000’s did not have part numbers with color suffixes, like 229317BLK. Those early A35 and A3 models will have a “” character for their colored parts, instead of ““. Diamond shape means that particular color item was determined from sales brochures or other official literature, not from a parts manual.

 

 

 

 

 

For parts 240255 and up, see Grid Tool 2

 

 

 


Spark Plugs, Plug Wires and Coils

July 16, 2017

updated 2020-06

Contents:

1. Spark Plugs
2. Spark Plug Info
3. Plug Caps and Wires
4. Spark Coils

 

 

 


1. Spark Plugs

Resistor plugs came out in the 1980’s on engines with electronic ignition. They have an R in the plug number, and are not specified in any 1970’s manual. They help protect the electronic unit from damage and reduce radio interference. Points ignitions do not need resistor plugs, but work fine with them. As the years go by more and more non-resistor plugs are becoming obsolete, in favor of resistor types. In 2019 NGK stopped making B5HS and B6HS, which are for most mopeds. Whenever those are specified, it is OK, and now required, to use BR5HS or BR6HS instead.


10 mm x 12.7 (½”)

3228 NGK C6HSA   $4.00 =Champion 
4629 NGK C7HSA   $4.00 =Champion   Z10YC =Bosch U4BC
2983 NGK CR6HSA none   
4549 NGK CR7HSA $3.50 =Champion RZ10YC =Bosch UR3AS

This size is on very small 4-stroke motorcycle engines, 50-70cc per cylinder. C6HSA is on 1968-78 Honda Z50A, 1979-81 Honda Z50R. CR6HS is on 1982-99 Honda Z50R. C7HSA is on 1979-83 Indian, 1970-74 Honda PC50, PF50, 1980-81 Honda C70.  CR7HS is on 1982-83 Honda C70 Passport. 


12 mm x 12.0

6512 NGK D6HA $3.50 =Champion P8Y
7112 NGK D8HA none   =Champion P7

This size is on small 4-stroke engines, mostly vintage Honda, 80 – 125cc. D6HA is on 1962-63 Honda CB92, 1964-69 S90, 1967-69 CL90, 1973-75 ST90. D8HA is on 1966-79 Honda CT90, 1963-66 CA200, 1964-66 CT200, 1966-69 CM91


12 mm x 19.0 (¾”)

7912 NGK D7EA   none   =Champion P8Y
2120 NGK D8EA   none   =Champion A8YC
7162 NGK DR8EA none   =Champion RA8YC

This size is on small 4-stroke motorcycle engines, 80 – 500cc per cylinder. D8EA is on 1970-72 Honda CB100, CL100, 1973-74 Honda CL125, and many 1970’s Honda models.

12 mm x 19.0 (¾”) projected tip
5829 NGK DP8EA-9   $3.50 =Champion
4929 NGK DPR8EA-9 none   =Champion

 


14 mm x 9.5 compact

5921 NGK BM6A $3.50 =Champion CJ11 = Bosch WS8E
6521 NGK BM7A $3.50 =Champion

This has a short reach (3/8″ = 9.5mm) and a short insulator, for compact or hand-held equipment. BM6A is on many bicycle motors, such as MX5 and Safari Fox. Most are hand-held gardening equipment engines.

 


14 mm x 9.5


3210 NGK B4     $3.50 
0000 NGK BP5S $3.50
3510 NGK B6S   none   =Champion J8J
  Champion J8J $2.00
3710 NGK B7S   none   =Champion J4J
  Champion J4J $2.00

This has a short reach (3/8″ = 9.5mm), mostly for marine engines. 

 


14 mm x 12.7 (½”)

4110 NGK B4H     none  
4210
NGK B5HS   none   =Champion L90C =Bosch W8AC =ND W16FS
3722
NGK BR5HS $4.50 = B5HS substitute, resistor type 
7534 NGK B6HS   none   =Champion L86C =Bosch W7AC =ND W20FS
3922
NGK BR6HS $4.50 = B6HS substitute, resistor type
1052 NG. B6HS-10 none   = B6HS with a wider gap 0.040″ not 0.020″

5110 NGK B7HS   $3.50 =Champion L82C =Bosch W5AC =ND W22FS
5510 NGK B8HS   $3.50 =Champion L87   =Bosch W3AC =Bosch W240T1 
 
Bosch W240T1   $2.00

This size is mostly on small air-cooled 2-stroke motorcycle engines 50-150cc per cylinder. B4H is on 20mph 1.0hp Puch mopeds, and Angel, Speed Bird. B5HS is on mopeds with Laura M48 and M56 engines (20 and 25mph), Batavus, Trac mopeds with Minarelli V1 engines, including AMF 140, Baretta, Bianchi, Carabela, Cimatti, Concord (Fantic), Cosmo (some), Gadabout, General, Gitane,  Motomarina, Maico, Motron, Safari, Testi, and mopeds with Puch engines (all 1.5 hp and some 2.0 hp), Puch, Sears Free Spirit, JC Penney, Murray, and mopeds with Sachs 504/1 and 505/1 engines, Columbia, General (and aliases), Hercules (Sachs), KTM Foxi, Kynast (Flying Dutchman), Lazer, Sparta, and mopeds with Solo engines, Columbia, Odyssey, and on many other mopeds Benelli, Bermuda (Flandria), Garelli (most), Jawa 207, Motobecane, Moto Guzzi, Tomos (A3 and A35 engine). B6HS is on Benelli, Bermuda (Flandria), Kreidler Flory, Motobecane (30mph 2hp), Peugeot 102 U3, 103 U3 (30mph 2hp), Puch 30mph 2.0 hp models Cobra, Magnum, Maxi, Sport MkII, Rizzato Califfo, on mopeds with Sachs 504/1 and 505/1 engines (30mph 2hp), Columbia, General (and aliases), KTM Foxi, Kynast, Lazer, Sparta,  on mopeds with Solo engines (30mph 2hp) Columbia, Odyssey, and on mopeds with Laura engines (30mph 2hp), Batavus, Trac. B7HS is on 1988-92 Yamaha YSR50, and many other small vintage Yamaha’s.

You can see the progression here: 20mph bikes use heat range “4”, 25mph use “5”, 30mph use “6”, 45mph use “7”. This obeys the “spark plug heat range rule of thumb”. More restricted, less powerful engines need hotter spark plugs. Less restricted, more powerful engines need colder spark plugs.

 


14 mm x 12.7 (½”) projected tip

3511 NGK BP4HA   none   
3611 NGK BP4HS   $3.50 =Champion L95Y   =ND W14FP-U
0o0
   ND W14FP-U $2.50 =Champion L95Y   =NGK BP4HS

4111 NGK BP5HS   $3.50 =Champion L95YC =Bosch W8BC
7331 NGK BP6HS   $3.50 =Champion L92YC =Bosch W7BC or W6BC
7022 NGK BPR5HS none   

7022 NGK BPR6HS none   =Champion L92YC =Bosch WR7BP

BP4HA is on 1981-84 and 1987-91 Suzuki FA50 Shuttle. BP4HS is on 1979-88 Yamaha QT50 Yamahopper, 1981-00 Yamaha PW50, 1970-71 Suzuki F50 Cutlass, BP5HS is on 1977-83 Honda NC50 Express, 1978-83 Honda PA50 Hobbit

 


14 mm x 12.7 (½”) fine wire tip

7067 NGK BR7HIX $14.0

These super-plugs have a ultra-fine wire center electrode which lowers the voltage required. This makes a stronger spark at very low rpms, for easier starting. They also increase horsepower, typically ½ to 1 mph speed increase on a 30-40mph bike. The fine wire has a cap of precious metal, iridium, that resists erosion and allows the thin wire electrode to last thousands of miles. The down side is iridium costs more than platinum or gold, so the spark plug price is four times as much as a regular NGK spark plug. BR6HIX replaces BR6HS, BP6HS and B6HS. BR7HIX replaces BR7HS, BP7HS, and B7HS. 

 


14 mm x 19.0 (¾”)

6410 NGK B5ES   $3.50 =ND W16ES-U =Bosch W8CC 
00
   ND W16ES-U $2.50 =Bosch W8CC =NGK B5ES

7432 NGK B6ES   $4.00 =Champion N5C =Bosch W7C
0000
Bosch W7C  $2.00 =Champion N5C =NGK B6ES

1111 NGK B7ES   $3.50 =Champion N4C =Bosch W5CC
2411 NGK B8ES   $3.50 =Champion N3C =Bosch W4CC
0
  Bosch
W240T2 $2.00
2611 NGK B9ES   $3.50 =Champion N2C =Bosch W3CC
5866 NGK BR5ES $4.50   

4922 NGK BR6ES none    
0000 NGK BR7ET $3.00 this obsolete plug has three outer electrodes, not just one!
5422 NGK BR8ES $3.50

This size is on many motorcycle engines, 4-stroke with over-125cc per cylinder, many 2-stroke air-cooled, and all 2-stroke liquid-cooled. B5ES is on Puch Dart and Maxi Plus (Austro Daimler). B6ES is on Garelli Monza GT.

 


14 mm x 19.0 (¾”) projected tip

7832 NGK BP5ES   none  =Champion N11YC =Bosch W8DC
0000
Bosch W8D   $1.00 =Champion N11YC =NGK BP5ES
7333 NGK BP6ES   $3.50 =Champion N9YC =Bosch W6DC
0000
Bosch W7D   $2.00 =Champion N11YC =NGK BP6ES

1034 NGK BP7ES   $3.50 =Champion N7YC =Bosch W5DC
2912 NGK BP8ES   none   =Champion N6YC =Bosch
7131
NGK BPR6ES none   =Champion RN9YC =Bosch WR6DC
2023 NGK BPR7ES none   =Champion RN7YC =Bosch WR5DC

This size is on many motorcycle engines, 4-stroke with over-125cc per cylinder, many 2-stroke air-cooled, and all 2-stroke liquid-cooled. BP5ES and B5ES are on mopeds with Morini MO1, MO2, M1 engines, including Bianchi, Colt, Cosmo, F. Morini, Italvelo, Intramotor, Italjet, Lem, Malaguti, Motobecane Sebring, Motomarina Sebring, Negrini, NVT, Pacer (Italtelai), Scorpion, and on Beta, and others.

 


14 mm x 19.0 (¾”) fine wire tip

0000 NGK BR7EIX $14.0

These super-plugs have an ultra-fine wire center electrode which lowers the voltage required. This makes a stronger spark at very low rpms, for easier starting. They also increase horsepower, typically ½ to 1 mph speed increase on a 30-40mph bike. The fine wire has a cap of precious metal, iridium, that resists erosion and allows the thin wire electrode to last thousands of miles. The down side is iridium costs more than platinum or gold, so the spark plug price is four times as much as a regular NGK spark plug. BR7EIX replaces BR7ES, BP7ES and B7ES.

 

 


2. Spark Plugs and Spark Checking

Spark Plugs are important. They’re also cheap and easy to change. The spark plug is the first thing you look at when a motor won’t start. Spark, compression, and fuel are the three main ingredients. Spark plugs come in different sizes and styles. 

Spark Plugs are the #1 selling part on a moped. It’s good to have a spare. Spark plugs under normal conditions last for thousands of miles. A plug gets worn out when the sharp corners on the center electrode become rounded from erosion.

Fouling: A new spark plug might only last 1 mile in a “sick” engine, if the insulator becomes fouled, or coated with semi-conductive carbon (black instead of brown or white). Once the white porcelain insulator becomes fouled, the plug no longer functions. 

Bosch spark plugs obsolete in 1978

Non-resistor: Vintage engines with points ignition, mostly before 1982, have non-resistor type spark plugs.

Resistor: Modern engines with electronic ignition, mostly after 1990, have resistor type spark plugs. The resistor inside the spark plug helps protect the electronic unit from burning out. But many modern motorcycles with electronic ignition do not need resistor plugs, and instead come with and specify non-resistor spark plugs.

Obsolete numbers: Many or most spark plug numbers specified in vintage owners manuals or application charts are obsolete. For example, in the 1979 Champion spark plug application chart below, most of the moped spark plugs specified are no longer made. The obsolete Champions are L89CM (=B5HS), N4 (=B7ES), N5 (=B6ES), and N9Y (=BP6ES). The only non-obsolete Champion is L82 (=B6HS or B7HS). In Bosch, at right is a list of 160 obsolete spark plugs, from the 1978 Puch Service Manual. Many or most of those upgraded spark plug numbers are now themselves obsolete. This situation can make it difficult to learn what modern spark plug is correct for a vintage motorcycle or moped.

1979 Spark Plug Chart page 1

1979 Champion Motorcycle Spark Plug Chart page 1

1979 Spark Plug Chart page 2

1979 Champion Motorcycle Spark Plug Chart page 2

1979 Spark Plug Chart page 3

1979 Champion Motorcycle Spark Plug Chart page 3

 

 

 

 

 

 

 

 

 

 

Heat range errors: Fortunately there are spark plug cross-reference websites. But there are small errors in heat range that occur when spark plugs are “translated” from one brand to another, or from vintage to modern. The heat range of the replacement can be half of a number higher or lower than the original. For example Champion L82 translates to a NGK 6.5 heat range, half way between B6HS and B7HS. So some spark plug cross reference charts will say L82 = B6HS, some will say L82 = B7HS, and some will say L82 = B6HS or B7HS. It’s an error that looks bad on paper, but does not matter much.

 

Reading spark plugs: The condition of the spark plug tells you about the condition of the engine. A normal spark plug has a light brown coating on the white porcelain insulator, and sharp corners on the center electrode. A high mileage spark plug in a healthy engine looks the same but the electrode corners are rounded. Sparks like to jump from pointy things. A rounded center electrode or way too big a gap might make the engine hard to start. 

 

Checking for Spark: Remove the spark plug, connect the cap to it, and lay it on the engine so the metal shell touches the engine. Turn the engine over either by pedal starting or by flicking the flywheel with your hand. Little momentary light blue sparks should be jumping the gap, making a “snap” sound each time the piston goes up and down. Modern CDI ignitions are hard to see in bright sunlight, so check for spark in the shade. A bright white, pink, or yellowish spark is bad. That usually indicates a fouled plug. Dim and blue is good, especially if the snap snap snap sound is loud.     

 


3. Spark Plug Caps and Wires

Spark Plug Cap Screw-On

Screw post goes into wire core.

NGK Plug Caps Explained

NGK Spark Plug Caps

 

 

 

 

 

 

 

Mopeds have copper core spark plug wires, that last “forever”. Cars have carbon core wires, that break down when they get old. Moped spark plug caps and ignition coils attach differently. Most screw into the end of the wire. Some spark plug caps have a pointed screw that pokes sideways into the wire near the end. The ends of the copper core get wore out from vibration or burned from arcing. Usually there is enough length to cut off the bad end and reuse the old wire. Always make a pilot hole with a something like a dental pick, before attempting to screw a cap onto a freshly cut wire.  

 

C1

Spark Plug Cap Rubber

C2

 

 

 

 

 

C3

Spark Plug Cap LB05F

C4

C5

 

 

 

 

 

 

C1  $4.00 Cap rubber poke-thru, xxxxxxx  requires nut W5 on plug
C2  none   Cap rubber,  screw-on, xxxxxxx  requires nut W5 on plug
C3  $8.00 Cap C1 with wire 29 inch, xxxx  requires nut W5 on plug
C4  $8.00 Cap NGK LB05F screw-on, 5k resistor, for no W5 on plug
C5  $6.00 Cap generic, xxscrew-on,   5k resistor, for no W5 on plug
C5  $5.00 Cap generic, xxscrew-on,   no resistor, for no W5 on plug

 

W1

W5

 

 

 

 

 

W1  $2.00 spark plug wire 7mm copper core black, per foot
W2  $1.00 spark plug wire 5mm copper core red, per foot
W3  $1.50 spark plug wire rubber boot for cap 7 x 12 mm
W4  $2.00 spark plug wire adapter sleeve 5 to 8mm with lip
W5  $0.25 spark plug terminal nut, comes with new plugs

 


4. Ignition Spark Coils (Transformers)

Be advised. These transformer coils do not go bad and completely loose spark. If you have no spark at all, and you replace the spark coil, 98% of the time you will still have no spark with a new coil. Even if you have power or voltage on the coil wire, yet no spark, replacing the coil will not help (because it needs interrupted power). Read more in Ignition Service Information

Initial troubleshooting: Performed first to eliminate some possible causes, using only fingers, eyes, pencil and paper.

  1. Eliminate the spark plug as the cause by testing for spark with another known good spark plug.
  2. Eliminate the spark plug cap and wire end, by removing the cap, exposing a short piece of braided copper, placing that between two cooling fins, and testing for spark. Sparks should jump 1/4 inch, or at least 1/8 inch. If no spark at all, then the cause is before the coil.
  3. Eliminate the points being adjusted badly, by observing with your eyes, as the wheel is turned around, that they open and close, and not always stay open or always stay closed.
  4. Eliminate the ignition timing being way off, by first finding which direction is forward, by moving the rear wheel forward and engaging the starter clutch, finding top dead center by using a pencil in the spark plug hole that touches the top of the piston, then seeing with your eyes if the points open a little before top, going in the forward direction.
  5. Try cleaning the points. Without performing continuity tests with an ohmmeter, one last “hail Mary” attempt to get spark, easy and zero cost, is to clean the points with a strip of paper. Cut a strip of plain paper. Rotate the wheel until the points are open. Place the paper in between the points. Rotate the wheel gently until the points touch the paper gently, the pull the strip of paper out. It might have black or grey spots of burnt oil film. Recheck for spark. Realize that even though the points were just cleaned, they could still be “dirty”. A hard white coating can be on them, that paper does not wipe off. A points file, or a folded-into-two-sided piece of emery cloth, is needed to clean points, followed by paper to remove grit.

  6. Beyond these tests an ohmmeter or continuity tester is required to test for loose, corroded, or pinched wires or dirty points, and more.

Indian Magneto Testing

Vespa ignition wire behind points corroded

If these steps (tests) did not reveal the cause of “no spark” then there are more troubleshooting tests needed using an ohmmeter or continuity tester.

The details of that are in Ignition Service Information 

 

Spark Coil Interchangeability: Ignition (transformer) coils for magneto-points ignition, like on vintage mopeds and off-road bikes, interchange except for the mount. So a German moped will run fine with an Italian coil, and an Italian moped will run fine with a German coil, attached temporarily with clip leads and wires. There are one-wire and two-wire types. On one-wire types, the mount is the “second wire”, and must be grounded to the frame. On two-wire types, either wire is the points wire, and the other must be grounded to the frame. So a Bosch 2-wire coil would replace any 1-wire coil, by adding a short ground wire, except for possibly the mount. The replacement might need a different mount or mount location. Or it might need to be mounted with on only mount bolt, instead of two.

 

Dansi Ignition Coil

H79 Dansi

Bosch Coil

H79A Bosch

Ignition Coil Remake

H79G generic

Motoplat Ignition Coil

H79M Motoplat

 

 

 

 

 

 

CEV 6309 Ignition Coil

CEV 6309

CEV 6313

CEV 6317 Ignition Coil

CEV 6317

 

 

 

 

 

 

H79   Dansi  $75-$40 2 wire male blades, plug wire unscrews,  16-20 x 5 slots, made in Italy
H79A Bosch $60-$45 2 wire male blades, plug wire unscrews,       53 x 5 holes, made in Germany
H79B Dansi     N/A      1 wire male blade,   plug wire molded in,
H79G generic  N/A      1 wire male blade,   plug wire molded in,      32 x 5 holes, weaker than Bosch
H79M Motoplat    $45 1 wire male blade,   plug wire molded in, 15-25 x 6 slots, made in Spain
6309  CEV   O0$55.0 1 wire screw post,    plug wire molded in,      48 x 5 holes, made in Italy
6313  CEV   $95-$65 1 wire male blade,   plug wire molded in, 12-34 x 6 slots, made in Italy
6317  CEV   $90-$65 1 wire male blade,   plug wire molded in, 13-25 x 6 slots, made in Italy

 

A detachable wire that unscrews, is a big advantage. If your dog chews up your spark plug wire, you don’t have to buy a whole new coil (with molded-in wire). It is possible to solder on a new wire, but it will be prone to sparks leaking at the joint. As long as there’s no path to ground nearby, that it not a problem. Any of these coils will function well on any other type of moped or small vintage motorcycle with points and magneto ignition. They are just transformers with different mounting brackets. The Bosch coils seem to give the strongest spark, and are not sensitive to heat, and last “forever”. The only bad thing is the two mounting holes are usually too far apart. To get around this, you can use only one bolt with a  nylock nut.

The spark coil should have 2-3 ohms between the points wire and ground, and a few thousand ohms between the spark plug wire and ground. Often the very end of the plug wire loses some strands of braided copper core where the spark plug cap attaches. Remove the cap and make sure there is copper at the very end. Test it without the plug cap.

 

 


Motobecane Controls

April 11, 2016

Contents:   1. 1970’s controls
Contents:   2. 1960’s controls
Contents:   3. Parts Manuals

 


1. 1970’s Motobecane (model 40, 50, 7)

New price is green, used price is dark green.

 #   1978#  price   description   RIGHT SIDE
01x 53412 $75-50 right control assy silver #2 to 22, no grip
01x 54161 $75-50 right control assy black #2 to 22, no grip
02x 53414 $10-5 right brake lever chrome
02x 53414 $12.0 right brake lever chrome long
03x 22095 $2.00 throttle and brake pinch screw
04x 19692 $6.50 throttle slider bare
04x 23114 $8.00 throttle slider with screw
05x 19695 $7.00 twist tube metal
06x 16639 $3.00 twist tube retaining screw and nut
07x 23122 $3.00 spacer for decomp pinch bolt 8mm long

08x 21654   N/A   right grip grey  ribbed original 100mm long
08a 24028   N/A   right grip black ribbed original 100mm long
08b  #3&4 $12.0 set of black ribbed 70’s Magura grips 100mm
09x 23123 $6.50 decomp pinch bolt and nut 17mm long
10x 53416 $24.0 decomp knob, says engine stop, new, can use #40
10x 53416 $18.0 decomp knob, says engine stop, used
10a 53416   N/A   decomp black rubber cover pre-77, says M
11x 14903   N/A   throttle/choke cable adjuster 60’s style M5-0.9
11x 23089 $5.00 throttle/choke cable adjuster 70’s type M5-0.9
11a 23089 $5.00 decomp adjuster (pre-77 & 78-80) M5-0.9
11b 53819 $7.50 decomp adjuster (most 1976-77) M7-1.0
12x 21222 $4.50 brake adjuster A3c with nut
13x 21157 $1.50 star nut black plastic for brake adjuster M6-1.0
14x 52437 $3.50 clamp and pivot step-screw, right 27mm
15x 00057 $2.00 thin washer (see note below) Ø6 x Ø10 x 0.5?
16x 54168 $5.00 thumb lever left or right 77-on
16x 52326 $6.00 right (decomp) thumb lever pre-77

17x 53413 $40-25 right control housing silver
17x 54162 $35-20 right control housing black
18x 13392 $0.50 screw M5 x 10 slot
19x 53512 $2.00 stop light switch holder
20x 53415 $5.00 right brake helper spring
21x 20960 $2.50 pivot bolt chrome and nut
22x 01511 $1.50 nut for pivot bolt M5 flange

 #   1978#  price    description   LEFT SIDE
31x 53382 $75-50 left control assy silver #11 to 44, no grip
31x 54163 $70-45 left control assy black #11 to 44, no grip

33x 21457 $30-18 left control housing silver
45x 23428 $18-12 left control housing black
36x 20103 $3.50 clamp and pivot step-screw, left 23mm
37x 20053 $3.50 choke pinch bolt spacer 3mm long
38x 14322 $7.00 choke pinch bolt and nut 12mm long
39x 54168 $5.00 thumb lever left or right 77-on

36x
20025 $7.00 left (choke) thumb lever pre-77
40x 53417 $6.00 choke lever black rubber cover, says choke
41x 53417 $8.00 thumb lever white rubber cover, says M
43x 22337 $19-14 left brake lever chrome
43x 22337 $22-17 left brake lever chrome long
44x 21877 $13.0 left brake helper spring
46x 21655 $15-10 left grip grey  ribbed original used 100mm
46a 24029 $12-10 left grip black ribbed original used 100mm
46b  #3&4 $12.0 set of black ribbed 70’s Magura grips 100mm

 

#15 washer: 00057 goes under the lever, not over like shown.
It needs to be left out if the lever binds when the screw is tight.

Motobecane right (start) and left (choke) thumb levers.
Before 1977, right 53206 and left 20025 were different.
From 1977 on, both were the same 54168, but flipped.
54168 and 53206 are the same except for the handle.
Simply bend the handle to make one from the other.
20025 is from the 1960’s, and has a different fold.

1970’s Motobecane chrome steel brake levers,
135 mm long with brake light tab for US models.
Long levers 150 mm were only on 1980 bikes.
They were not in any ’78-’80 parts catalogs.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


2. 1960’s Motobecane (Wards Riverside)

Cable parts are listed in Cables, Hardware/Cables K-Z

1979# 1960#  price   description  RIGHT SIDE
21654 15511    N/A   right grip grey ribbed
19695 16547    N/A   twist tube metal
53413 16546    N/A   right housing
20960 15517    N/A   pivot bolt
53414 15515    N/A   right brake lever aluminum
19692 15584    N/A   throttle slider
22095 00691  $0.00 throttle pinch screw

 

 

1979# 1960#  price   description  LEFT SIDE
21655 00000    N/A   left grip grey ribbed
20960 15517    N/A   pivot bolt
22337 50032    N/A   left brake lever aluminum
21457 15513    N/A   left housing
20025 15519    N/A   choke lever
20103 15520    N/A   choke pivot screw

 

 

 

 

 

 


3. Parts Manuals

1961 Wards Riverside Manual

These manuals are the source of the parts illustrations and information.

 

 

 

Translations:
In 1960’s Motobecane parts manuals,
“control” means cable (outer conduit and inner wire)
“cable” means inner wire
In 1970’s Motobecane parts manuals,
“cable complete” means cable (conduit and inner wire)
“cable (inner)” means inner wire
“handgrip” means control, “handgrip rubber” means grip
“handgrip body” means control housing

 

1979 Motobecane 50 Parts

1979 Motobecane 40 Parts

1977 Motobecane 40 and 50 Parts