ENGINE

S6 / E

INDEX

TECHNICAL SPECIFICATIONS 2

SPECIAL TOOLS 3-4

PERIODIC MAINTENANCE 5

LUBRICANTS 6

TROUBLESHOOTING 7 - 14

TIGHTENING TORQUE TABLE 15

ENGINE DISASSEMBLY 16 - 24

ENGINE REASSEMBLY 23 - 33

OIL MIXER PUMP UNIT 34

ENGINE COMPONENT INSPECTION AND SERVICE 35 - 37

PARTS CATALOGUE xx

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TECHNICAL SPECIFICATIONS

SPECIFICATIONS
CYCLE ......................................................... - 2 stroke
Nr. of CYLINDERS ....................................... -1
DISPLACEMENT .......................................... - 49.908 cc.
BORE AND STROKE mm. ................... - 39 X 41.8
CYLINDER MATERIAL .................................. - Special cast iron
COMPRESSION RATIO ................................ - (11 ±0.6) : 1
SPARK PLUG ............................................... - CHAMPION L78 C
TIMING SYSTEM .......................................... - Reed valve in crankcase with 3 metal
..................................................................... flaps
MAX. R.P.M. .................................................. - 9000
CARBURETOR ............................................ - 12 mm diameter or equivalent
INTAKE MANIFOLD ..................................... - Fixed
FUEL ............................................................ - EURO UNLEADED NC 623/02 - R.O.N. 95
........................................................................... plus 2% oil
LUBRICATION MIXER OIL TYPE ................. - AGIP 2T CITY
LUBRICATION SYSTEM .............................. - automatic oil mixer pump (on request)
GENERATOR ............................................... - (on request)
IGNITION ...................................................... - Inductive electronic
PRIMARY DRIVE GEAR ................................ - Straight-tooth gears Z 14/59
..................................................................... with safety coupling
SECONDARY DRIVE GEAR ......................... - Sprocket Z 10 or Z11
..................................................................... chain type 1/2 x 3/16 roller 7.75
CLUTCH ...................................................... - Automatic centrifugal 2-shoe clutch in oil
..................................................................... bath
TRANSMISSION GEAR OIL ......................... - AGIP RADULA 68 type SAE 20 W
..................................................................... quantity 200 cc
STARTER ...................................................... - Kick starter
COOLING ...................................................... - Air cooled

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SPECIAL TOOLS

Figure Code Description

BEARING INSTALLER
143176 output shaft

BEARING INSTALLER
143154 crankshaft

143156 BEARING INSTALLER

output shaft

143179 OIL SEAL INSTALLER

output shaft

OIL SEAL INSTALLER

143180
crankshaft (flywheel + clutch)

OIL SEAL MOUNTING PROTECTION

143181 crankshaft (flywheel + clutch)

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SPECIAL TOOLS

Figure Code Description

143155 OIL PUMP SHAFT INSTALLER

(pre-assembled)

140558 FLYWHEEL REMOVER

143162 CRANKCASE PULLER

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PERIODIC MAINTENANCE

RUNNING-IN RECOMMENDATIONS:

During the running-in period, i.e. for approx. the first 500 km on the road, please note as follows:
- Do never run the engine at maximum revolutions.
- Do never keep the vehicle at maximum speed.
- Do not keep the engine at idle speed for longer time.

FIRST MAINTENANCE SERVICE:

to be carried out after 500 - 600 km.

- Replace the engine oil

- Check the carburation and adjust if necessary
- Check the tightness of nuts and bolts
(See table “tightening torques” page 15)

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LUBRICANTS

N.B.
Use original MORINI FRANCO MOTORI spare parts only

RECOMMENDED LUBRICANTS / ADHESIVES

DESCRIPTION CHARACTERISTICS

Transmission oil AGIP RADULA 68 SAE 20W

Assembly of various parts GR/SM2 GREASE

Special assembly GRAPHITISED MOLYCOTE type GREASE

Thread-locking glue LOXEAL 82-21

Clamping glue LOXEAL 83-54

N.B. TRANSMISSION OIL LEVEL CHECK

Remove the oil filler cap on the clutch cover and check the transmission oil level
through window.

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TROUBLESHOOTING

The following flow charts give a general outline of the causes and effects when the engine is not
running correctly.
Descriptions of solutions for a specific cause are general; for more details the reader should
consult the disassembly-reassembly manual.

LEGEND OF SYMBOLS

EFFECT (fault noticed by the user)

Possible CAUSE of the fault

Possible general SOLUTION to the fault

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Starting problems

Faulty spark plug YES Check spark plug and

or wrong spark plug replace if necessary.
heat rating

NO

Start the engine with the

YES throttle fully open.
Engine flooded

NO Remove the spark plug,

rev the engine, install a
NO The engine
dry spark plug and starts
restart the engine.

YES
Sparking starts at a Replace the ignition coil
high r.p.m.

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Maximum indicated running

speed cannot be reached

Disassemble, wash sponge with a

Soiled or 50:50 solution of petrol and 2T oil;
clogged YES leave to dry. Clean the filter box
filter using compressed air;
re-assemble.

NO

Silencer Check the silencer for clogging.

obstructed YES
Replace if necessary.

NO

Cylinder exhaust
Disassemble the cylinder and check
port soiled with carbon YES that the exhaust pipe is clean. If the
deposits exhaust pipe is partly obstructed by
carbon deposits, clean it thoroughly
using a scraper.

NO

Disassemble the cylinder head,

Poor
cylinder and piston.
compression
YES Remove the piston rings, place
them in the cylinder liner and check
the amount of wear.
Replace if excessively worn.

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Poor acceleration/pickup

YES Check the clutch shoe thickness

Clutch
and the clutch springs for
stretching.
If either is excessively worn they
should be replaced.
NO

Irregular
Check the exact number of turns
YES of the air adjusting screw on the
acceleration
carburetor.

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Incorrect idling speed

Adjust the RPM of the idling speed

Idling speed YES (with engine warm) by adjusting the
too high or screw on the throttle valve of the
too low
carburetor.

Disassemble the carburetor and

YES clean all the parts (nozzles, throttle
valve, jet needle, float chamber
NO and casing) with solvent and dry
using compressed air.

False air
intake from YES
carburetor
Check the integrity of the
manifold carburetor manifold gaskets.

Check the integrity of the rubber

YES coupling sleeve that connects
NO carburetor and air filter box.

YES Check the reed valve gasket

False air
YES Check the integrity of the
intake
from engine crankshaft oil seals. Replace
crankshaft even if only slightly damaged.
oil seals

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Noisy engine

Incorrect Check the assembly of all gears and

transmission
YES parts of the transmission.
gears
assembly

NO

Loose YES Check the tightening torque of the

transmission clutch nut.
nut

NO

Transmission
noise and rear YES
wheel drag at
Check the clutch unit
idling speed.

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Noisy engine

Check the oil level.

YES Refill if necessary.
Noisy gears

Check the teeth of the drive gears

YES visually.
Replace if signs of damage or wear
are evident.
NO

Check the clearance between the

Noisy YES piston and the cylinder. If it does
cylinder not correspond to the prescribed
unit value, grind the cylinder and
assemble 1st oversize piston.

NO

BEARING INSPECTION
Rotate the bearing inner race by
Noisy finger to inspect for abnormal play,
YES noise and smooth rotation while the
crankshaft
bearings bearings are mounted in the
crankcase.
Replace the bearing if anything
unsual is found.

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Smokey exhaust

Replace the fuel in the tank with

Percentage of YES new fuel mixed with 2% of the
mixer oil
type of oil indicated in the
handbook.

NO

YES Check that the oil is 100%

Mixer oil synthetic for separate oil mixer
pump use.

NO

Disassemble the cylinder and

Carbon YES remove any carbon deposits;
deposits check the silencer for clogging.

NO

Oil mixer YES Disassemble the oil mixer pump

pump and check the flow rate.

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TIGHTENING TORQUE TABLE

TORQUE
DENOMINATION
(Nm)
Crankcase bolts 10 - 12
Clutch cover bolts 10 - 12
Flywheel cover bolts 3-4
Carburetor manifold bolts 7-8
Ignition coil clamping screws 6-8
Oil mixer pump clamping screws
5-6
(for model with mixer only)
Carburetor clamping screw 4-5
Starter lever bolt 8 - 10
Oil drain plug 8 - 10
Clutch nut 50 - 55
Flywheel nut 25 - 30
Head nuts 12 - 14
Spark plug 20 - 25

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ENGINE DISASSEMBLY

CARBURETOR - CYLINDER HEAD - CYLINDER - PISTON

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Disassemble the CARBURETOR

Remove the SPARK PLUG

Loosen the SCREWS and remove the

CARBURETOR MANIFOLD including
the REED VALVE.

Disassemble the CYLINDER HEAD

and remove the HEAD-CYLINDER
GASKET

Remove the CYLINDER

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Disassembly the CIRCLIPS and the

PISTON PIN.
Remove the PISTON and the
ROLLER CAGE.

Remove the CYLINDER BASE GASKET

FLYWHEEL SIDE

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Loosen the clamping BOLTS and

remove the FLYWHEEL COVER

MIND THE BRACKET

INSIDE THE COVER

Disassemble the SPARK COIL

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Disassemble the FLYWHEEL

ROTOR (compass tool + flywheel 140558
remover)

Disassemble the SNAP RING

Remove the SPROCKET from the

OUTPUT SHAFT

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CLUTCH SIDE

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Remove the OIL DRAIN PLUG MAKE SURE TO

(cross-headed) DRAIN THE ENGINE
COMPLETELY

Loosen the clamping BOLTS on the

cover and remove the CLUTCH
COVER

Remove the SPECIAL FRONT- CLAMPED WITH

Compass tool LOXEAL
CLUTCH NUT and the BELLEVILLE
WASHER

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Disassemble the CLUTCH and the

2.5mm SPACER RING

Remove the CLUTCH BELL and

SPACER RING

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CRANKCASE “OPENING”

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Remove the cylinder STUD BOLTS if

necessary BLOCKED WITH
LOXEAL

Remove the 8 CRANKCASE BOLTS

THE CRANKSHAFT
IS DRIVEN ONTO
THE BEARINGS.
Open the CRANKCASE 143162 OPEN THE
CRANKCASE FROM
FLYWHEEL SIDE
USING THE
PULLER TOOL

Remove the DOWEL PINS and the

CRANKCASE GASKET.
Remove the crankshaft if necessary

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Remove the OUTPUT SHAFT SNAP

RING.

Remove the OUTPUT SHAFT.

Inspect the OUTPUT SHAFT

BEARING for abnormal play and
noise.
Replace the bearing if anything
unusual occurs.

Remove the SNAP RING.

Remove the BEARING by using a

standard bearing remover set. THE BEARING IS
DRIVEN INTO THE
BEARING HOUSING

To replace the CRANKSHAFT

BEARING and the OUTPUT SHAFT
ROLLER CAGE (flywheel side) follow
the same procedure as described
above.

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ENGINE REASSEMBLY

CRANKCASE PREASSEMBLY

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Drive the OUTPUT SHAFT BEARING LUBRICATE THE

143176 HOUSING
into the half crankcase clutch side and
secure with the snap ring
LEAVE THE PRINT
ON THE BEARING
VISIBLE

LUBRICATE THE
HOUSING
Drive the CRANKSHAFT BEARINGS
into the half crankcase clutch side and 143154 LEAVE THE PRINT
into the half crankcase flywheel side. ON THE BEARING
VISIBLE

LUBRICATE THE
HOUSING

Drive the ROLLER CAGE OUTPUT 143156 LEAVE THE PRINT

SHAFT into the half crankcase ON THE BEARING
flywheel side. VISIBLE

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Insert the DRIVE SHAFT in the half

crankcase clucth side

Insert the SNAP RING onto the

second output shaft slot (near
transmission gear)

Insert the OUTPUT SHAFT into the half

crankcase clutch side and secure with
SNAP RING

CRANKCASE “CLOSING”

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Insert the DOWEL PINS

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Lubricate the CRANKCASE GASKET

on both sides.

Apply the CRANKCASE GASKET on

the half crankcase clutch side using
the 2 dowel pins for centering.

Assembly the HALF CRANKCASES

Fix 1 x BOLT M6X60 in the postion DO NOT TIGHTEN

between the stud bolts and the reed
valve zone.

Fix the remaining 7 X BOLTS M6X50.

Cross-tighten the bolts using a
tightening torque of 10-12 Nm.
Check to make sure that the
crankshaft and output shaft rotate
smootly.

Grease the oil seal housing and the GREASE TYPE

oil seal lip carefully. GR/SM2
143179
Install the CRANKSHAFT OIL SEAL 143180
RINGS and the OUTPUT SHAFT OIL 143181
SEAL RING.

Trim the crankcase gasket (cylinder

zone and carburetor zone.)

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FLYWHEEL SIDE

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Mount the SPROCKET and secure

with the SNAP RING

Caulk the key seat on the crankshaft

and insert the FLYWHEEL KEY.

Clean and remove all traces of grease

from the rotor cone and the drive shaft
cone. Compass tool
Assemble the flywheel rotor using the
key as reference.
Tightening torque
Assemble the FLYWHEEL NUT and
25 - 30 Nm
tighten.

Assemble the IGNITION COIL and fit DO NOT TIGHTEN

the 2 BOLTS without tightening them.

Check the clearance between the

ignition coil and the flywheel rotor
using a thickness gauge:
CLEARANCE = 0.35 - 0.45 mm. Tightening torque
6 - 8 Nm
Tighten the bolts.

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FLYWHEEL COVER

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Drive in the 2 elastic dowel pins in

the cover. and make sure that they
do NOT INTERFERE with the
bracket mounting face.

Assemble the BRACKET on the

flywheel cover.

Assemble the FLYWHEEL COVER

placing the rubber fairleads in their
seats on the cover.

Secure the FLYWHEEL COVER using:

3 SCREWS M5X50 + WASHER.
Tightening torque 3-4 N.m.
1 SCREW M5X20 + WASHER.
Tightening torque 3-4 N.m.

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CYLINDER - PISTON - CYLINDER HEAD

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Insert the CYLINDER BASE GASKET

Assemble the ROLLER CAGE, WHEN

PISTON and PISTON PIN and INSTALLING THE
secure with CIRCLIPS. PISTON TURN
THE ARROW
ALWAYS ASSEMBLE ROLLER MARK ON THE
CAGE SIZE - 2 - 4 HEAD OF THE
PISTON TO THE
OIL THE PISTON.
EXHAUST SIDE

BEFORE
ASSEMBLY
Assemble the CYLINDER
CHECK
THE SIZE CODE OF
THE CYLINDER
AND THE PISTON

Insert the CYLINDER HEAD

GASKET

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Fit the 4 CYLINDER HEAD NUTS Tightening torque

and cross tighten. 12 - 14 Nm

Install the SPARK PLUG and tighten Tightening torque

20 - 25 Nm

CARBURETOR UNIT

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Insert the CARBURETOR MANIFOLD

BASE including the REED VALVE.

Assemble the CARBURETOR

MANIFOLD on the base and secure Tightening torque
with 4 BOLTS M6X20. 7 - 8 Nm.

Assemble the CARBURETOR and Tightening torque

tighten the CLAMP SCREW. 3 - 4 Nm.

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CLUTCH COVER

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Assemble the SPRING on the sliding

gear as shown on the figure.
143167
Lubricate the inside of the spring using
GR MU/3 grease.

Assemble the SLIDING GEAR on the

cover and secure the SPRING
between the two stops.

Assemble the SPACER RING and

O-RING on the KICK STARTER
SHAFT.

Lubricate the O-ring area using

GR MU/3 grease.

Lubricate the KICK STARTER

SHAFT in the clutch cover operating
zone using grease type MOLYCOTE.
Install KICK STARTER SHAFT in the
clutch cover and make sure that the
gear section is engaged properly with
the sliding gear.
After assembly check that the spring
of the sliding gear is correctly

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Install and load the RETURN SPRING

on the kick starter shaft.

Secure the spring on the backstop in

the clutch cover.

Assemble the SPRING WASHER and

secure with the SNAP RING.

Place the SPACER on the kick starter

shaft and secure with the snap ring.

Assemble the KICK STARTER LEVER Tightening torque

and fasten by using the bolt M7x25. 8-10 N.m.

KICK STARTER LEVER POSITION

*Steel lever = 109°
*Aluminium lever = 96°

Check axial clearance: 0.1 - 0.3 mm

KICK STARTER LEVER POSITION

*Steel lever = 109° *Aluminium lever = 96°

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CLUTCH SIDE

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Insert the 0.8mm SPACER RING on

the crankshaft clutch side.

Lubricate the clutch bell operating zone

of the crankshaft using the grease type
ROCOL ASP MOLYCOTE.

Install the CLUTCH BELL

Insert the 2.5 mm SPACER RING

CAUTION
THE PRINT ON
THE CLUTCH
Install the CLUTCH on the crankshaft SHOE AND THE
REFERENCE MARK
ON THE HUB
MUST BE ON THE
SAME SIDE AND
LEFT VISIBLE

Insert the BELLEVILLE WASHER CAUTION

and clamp the clutch using the
SPECIAL FRONT CLUTCH NUT. In order to avoid
(LEFT HAND THREAD) Compass tool any clutch hub
jamming on the
Add LOXEAL 83-54 to the clutch nut spline shaft and to
and tighten ensure any future
disassembly
Tightening torque 50-55 N.m. operation of the
clutch unit, make
Check the axial clearance of the sure to apply
clutch bell: 0.3 - 0.5 mm LOXEAL 83-54
exclusively on the
Assemble the clutch cover gasket. cluth nut and NOT
on shaft end.

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TOOL
DIAGRAM DESCRIPTION CODE NOTES

Mount the clutch cover and secure Tightening torque

with 6 BOLTS M6 x 30. 10-12 N.m.

Insert the OIL DRAIN PLUG + Tightening torque

WASHER and tighten. 8 - 10 N.m.

Pour 200 cc of oil type AGIP Recommended

RADULA 68 SAE 20W and fit the Oil type:
OIL FILLER CAP + GASKET.
AGIP RADULA 68
AFTER COMPLETED ASSEMBLY SAE 20W
CHECK THAT THE ENGINE
ROTATES SMOOTHLY

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S6 OIL MIXER PUMP

TOOL
DIAGRAM DESCRIPTION CODE NOTES

Preassemble the 2 BEARINGS and

SPACER on the OIL MIXER PUMP
DRIVE SHAFT and secure with 2
SNAP RINGS.

The print on the bearings should face

the drive end of the shaft.

Lubricate the bearing housing.

Drive the OIL MIXER PUMP DRIVE 143155
SHAFT UNIT into the half crankcase
flywheel side.

Insert the CLEARANCE SPACER.

Assemble the BEARING SNAP 143342
RING.

Insert the DRIVE BELT onto the

DRIVEN PULLEY.

Install the pulley on the oil mixer pump

shaft and the drive belt onto the splined
part of the crankshaft.

Assemble the oil mixer pump on the Tightening torque

support bracket and tighten the 5 - 6 Nm
screw M5x12.

In order to simplify the assembly

operation of the oil mixer pump,
make sure that the timing of the
driven pulley and the oil mixer
pump shaft do match.

Install the BRACKET with OIL

MIXER PUMP into the housing of the
half crankcase flywheel side.

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ENGINE COMPONENT INSPECTION AND SERVICE

CYLINDER - PISTON TABLE

Value (mm)
Part
50cc
Cylinder Ø 39
Piston Ø 39
Piston rings :
1)Piston ring 1st slot Ø 39 x 2 - 0.01 - 0.025
2)Piston ring 2nd slot Ø 39 x 1.25 - 0.01 - 0.025

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CYLINDER - PISTON
ASSEMBLY SELECTION TABLE

CYLINDER - PISTON
DIMENSIONS ASSEMBLY
SIZE CODE
(stamped on part) CLEARANCE
CYLINDER PISTON

+ 0,026 - 0,036
A (RED) ø 39 + 0,021 ø 39
- 0,040

+ 0,020 - 0,041 0.050-0.067

B (YELLOW) ø 39 + 0,016 ø 39 - 0,046 mm
- 0,047
C + 0,015
ø 39 + 0,010 ø 39 - 0,052
(NEUTRAL)
+ 0,009 - 0,053
D (GREEN) ø 39 + 0,004 ø 39 - 0,058

CHECK POSITION
For correct dimension control

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CYLINDER CHECK
-Check the internal surface of the cylinder for
signs of seizure or abnormal wear.
-Measure the internal diameter of the cylinder
using a bore gauge.
-Wear limit: Minimum indicated cylinder
selection diameter + 0.03mm.
-Take measurements in three different positions
along the axis of the cylinder.
-In each position take two measurements, one
parallel with and the other perpendicular to the
crankshaft axis.

PISTON CHECK

-Remove the piston rings and check the piston

for abnormal signs and wear.

N.B.
The piston rings are fragile, handle with care.

RING-TO-GROOVE MEASUREMENT.
Wear limit: 0,08 mm max.

PISTON BORE MEASUREMENT.

-Maximum permitted diameter:12 + 0,18 mm
+0,18
-Measure the piston outside diameter in the
direction perpendicular to the piston axis at
14,5 mm from the skirt.

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