S6 E Service Manual PDF
S6 E Service Manual PDF
S6 E Service Manual PDF
S6 / E
INDEX
TECHNICAL SPECIFICATIONS 2
PERIODIC MAINTENANCE 5
LUBRICANTS 6
TROUBLESHOOTING 7 - 14
ENGINE DISASSEMBLY 16 - 24
ENGINE REASSEMBLY 23 - 33
PARTS CATALOGUE xx
Page 1
ENGINE
S6 / E
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
Page 2
ENGINE
S6 / E
SPECIAL TOOLS
BEARING INSTALLER
143176 output shaft
BEARING INSTALLER
143154 crankshaft
Page 3
ENGINE
S6 / E
SPECIAL TOOLS
Page 4
ENGINE
S6 / E
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.
Page 5
ENGINE
S6 / E
LUBRICANTS
N.B.
Use original MORINI FRANCO MOTORI spare parts only
DESCRIPTION CHARACTERISTICS
Page 6
ENGINE
S6 / E
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
Page 7
ENGINE
S6 / E
Starting problems
NO
YES
Sparking starts at a Replace the ignition coil
high r.p.m.
Page 8
ENGINE
S6 / E
NO
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
Page 9
ENGINE
S6 / E
Poor acceleration/pickup
Irregular
Check the exact number of turns
YES of the air adjusting screw on the
acceleration
carburetor.
Page 10
ENGINE
S6 / E
False air
intake from YES
carburetor
Check the integrity of the
manifold carburetor manifold gaskets.
False air
YES Check the integrity of the
intake
from engine crankshaft oil seals. Replace
crankshaft even if only slightly damaged.
oil seals
Page 11
ENGINE
S6 / E
Noisy engine
NO
NO
Transmission
noise and rear YES
wheel drag at
Check the clutch unit
idling speed.
Page 12
ENGINE
S6 / E
Noisy engine
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.
Page 13
ENGINE
S6 / E
Smokey exhaust
NO
NO
NO
Page 14
ENGINE
S6 / E
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
Page 15
ENGINE
S6 / E
ENGINE DISASSEMBLY
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 16
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
FLYWHEEL SIDE
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 17
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 18
ENGINE
S6 / E
CLUTCH SIDE
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 19
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 20
ENGINE
S6 / E
CRANKCASE “OPENING”
TOOL
DIAGRAM DESCRIPTION CODE NOTES
THE CRANKSHAFT
IS DRIVEN ONTO
THE BEARINGS.
Open the CRANKCASE 143162 OPEN THE
CRANKCASE FROM
FLYWHEEL SIDE
USING THE
PULLER TOOL
Page 21
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 22
ENGINE
S6 / E
ENGINE REASSEMBLY
CRANKCASE PREASSEMBLY
TOOL
DIAGRAM DESCRIPTION CODE NOTES
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
Page 23
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
CRANKCASE “CLOSING”
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 24
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 25
ENGINE
S6 / E
FLYWHEEL SIDE
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 26
ENGINE
S6 / E
FLYWHEEL COVER
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 27
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
BEFORE
ASSEMBLY
Assemble the CYLINDER
CHECK
THE SIZE CODE OF
THE CYLINDER
AND THE PISTON
Page 28
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
CARBURETOR UNIT
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 29
ENGINE
S6 / E
CLUTCH COVER
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 30
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 31
ENGINE
S6 / E
CLUTCH SIDE
TOOL
DIAGRAM DESCRIPTION CODE NOTES
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
Page 32
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 33
ENGINE
S6 / E
TOOL
DIAGRAM DESCRIPTION CODE NOTES
Page 34
ENGINE
S6/E
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
Page 35
ENGINE
S6/E
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
CHECK POSITION
For correct dimension control
Page 36
ENGINE
S6/E
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
N.B.
The piston rings are fragile, handle with care.
RING-TO-GROOVE MEASUREMENT.
Wear limit: 0,08 mm max.
Page 37