Gas Tank Parts

July 24, 2013

 CONTENTS:  Welcome    1  Gas Valves   2  Gas Caps    

Welcome to Gas valves (aka petcocks, fuel shut offs, fuel taps, fuel valves) and Gas caps (aka gas lids).

 1  G A S    V A L V E S

==========================================================================

Vacuum Petcock

Vacuum Petcock

10 Gas Valve 14x1 female spigot down

Manual Petcock

Fuel Valve (on tank): On or near the bottom of nearly every moped gas tank is a “petcock” or “gas valve” that has a lever or knob for manually shutting the fuel supply off, for when the bike is stored or transported. The reason for the shut off valve is gravity. Moped and most motorcycle gas tanks are higher than the engine and use gravity to move the gasoline out of the tank, instead of a fuel pump. The higher the liquid fuel level is above the carburetor, the higher the fuel pressure will be. If the the tank is too low, or the carb too high, no gas will come out, or it will even flow backwards. Everyone knows that liquids only flow downhill.

Vacuum Petcock (on tank): On most modern scooters and motorcycles the fuel valve is an automatic type, operated by the vacuum from the engine. When the engine stops, or whenever the suction in the vacuum line stops, the petcock shuts the gas off.

How Reserve WorksFloat Valve (inside carb): In addition to the fuel valve, there is an second device, called the float needle or float valve, in the carburetor that shuts off the gas supply automatically. On a new bike with a new carburetor and clean gasoline, the float valve works all the time, so there is no need to turn the gas valve off after each use. On most old mopeds, the float valve leaks sometimes, and needs the operator to manually turn the gas valve off after each use to prevent gasoline from leaking out.

On-Off-Reserve: Besides turning the gas on and off, most gas valves also have a third position called “reserve”. Reserve is for when the tank is very low on gas. A little tube 1 or 2 inches long sticks up from the gas valve, inside the tank. When the gas is on “ON”, it exits from the upper end of the tube. When the level of gasoline drops below the tube, no more gas comes out, and the engine dies. This is called “hitting reserve”. The operator then switches the gas valve to “RESERVE”, which make the gas exit from the lower end of the reserve tube, at the very bottom of the gas tank. There is about 5 or 15 miles of gasoline available on reserve, enough to find a gas station. If a gas tank  has rust crumbs, powder, or water droplets at the very bottom, it is better to not use the reserve because it lets dirt get through and will clog easily.

Bolt-on petcock

Bolt-on petcock, 2-bolt

Bolt on petcock, 1-bolt

Bolt on petcock, 1-bolt

Fuel Valve Types 

Bolt-on: Most modern motorcycles use the bolt-on design, where the tank has two small threaded 6mm bolt holes spaced about 30-35mm apart, with a 10mm main hole in the middle. A race track shaped rubber ring provides the seal. Angel (made in Taiwan by Tym) is the only pedal moped with a bolt on fuel valve. For some reason, bolt on fuel valves are rare on mopeds, but common on motorcycles.

Screw-on: Almost all mopeds use the screw-on design, where the tank has either a hole with internal threads, (female tank) or a fitting with external threads (male tank). For some reason, all internal thread moped gas tanks are M10x1 metric thread. External thread moped gas tanks are M12x1 (European), M14x1 (Asian), M14x1.25, M16x1, or M20x1 thread. Screw-on fuel valves do not seal at the threads like pipes, but rather have a sealing surface perpendicular to the threads, for a soft paper or plastic washer. They are tightened enough to compress the seal washer.

Female” screw-on fuel valves for external thread tanks have the ability to point in any direction, because the valve main body does not screw on, instead only the nut turns. The special nut is a “turnbuckle style” in that it has right hand threads on one end and left hand threads on the other. This allows the valve to fit in tight places. It also means the nut has a top and bottom and won’t go on upside down, unlike a regular nut.

Male” screw-on fuel valves for internal thread tanks also have the ability to point in any direction. When the seal washer is soft rubber and thick, and retained by a metal cup, it seals even when the valve is slightly loose and somewhat free to rotate.

Clamp-on: A third type of gas valve is clamp-on, found on Derbi mopeds with a plastic gas tank. It seals against the tank exit pipe semi-flexible soft plastic walls by o-rings squeezing radially inward by a hose clamp. There is an upgrade for the Derbi clamp-on valve. See Derbi parts.

Spigot PositionsSpigot Direction:  L = left    R = right    D = down    B = back  (as you face the valve). Some models have room for more than one spigot direction. Many mopeds can have any spigot direction, because there is nothing near the petcock that interferes with the fuel hose. Then there may be choices. Other kinds are only available in one spigot direction. Sometimes an original valve that was “spigot down” must be replaced with one that is “spigot left”, and a longer piece of fuel line installed. This is the case for Peugeot, for example. Sometimes, if the valve is angled, and the spigot direction of the replacement valve is uphill, the new valve can affect fuel flow when the gas tank is really low. If it cannot be rotated and angled more spigot level or downwards, then the lower part of the tank will become unavailable when the liquid level reaches the highest part of the fuel line. That is, it will run out of gas prematurely.

Naming of Gas Valves: Many screw-on gas valves sold online are named by their true size (11,13, or 15mm), rather than their nominal size (12, 14, 16mm). This is a big source of confusion. For a bolt (external or male thread) the nominal (named) size is the true size, so an M6 (metric 6mm) bolt has a diameter of 6mm. But for a nut (internal or female thread), the nominal size is greater than the true size. An M6x1 nut has an internal diameter of 5mm. A 1/4 -20″ nut has an internal diameter of 0.20 inch, not 0.25. The difference between the external and internal diameter is approximately equal to the thread pitch. So a 12×1.00 nut measures 11.00mm inner diameter, while a 12×1.50 nut measures 10.5mm.  

Gas Valves (Petcocks) for sale  

1 Gas Valve 10×1 male spigot down

1 Gas Valve
10×1 male
spigot down

1 Gas Valve 10x1 male spigot down w/extension

1a Gas Valve 1
10×1 male
spigot down
w/extender A4

2 Gas Valve 10x1 male spigot left

2 Gas Valve
10×1 male
spigot left

2a Gas Valve 2 10×1 male spigot left w/ extender A2

2a Gas Valve 2
10×1 male
spigot left
w/ extender A2

 

 

 

 

 

 

 

 

 

3 Gas Valve 10x1 male spigot left  compact

3 Gas Valve
10×1 male
spigot left
compact

4 Gas Valve 12x1 female spigot down

4 Gas Valve
12×1 female
spigot down

5 Gas Valve 12x1 female spigot left round knob

5 Gas Valve
12×1 female
spigot left
round knob

 

 

 

 

 

 

 

 

 

6 Gas Valve 12x1 female spigot left

6 Gas Valve
12×1 female
spigot left

7 Gas Valve 12x1 female spigot right round knob

7 Gas Valve
12×1 female
spigot right
round knob

8 Gas Valve 12x1 female spigot left extended knob

8 Gas Valve
12×1 female
spigot left
extended knob

9 Gas Valve 12x1 female side mount

9 Gas Valve  12×1 female side mount
often called a “Puch” gas valve

 

 

 

 

 

 

 

 

 

 

10 Gas Valve 14x1 female spigot down

10 Gas Valve
14×1 female
spigot down

11 Gas Valve 16x1 female spigot down

11 Gas Valve
16×1 female
spigot down

12 Gas Valve 16x1 female side mount

12 Gas Valve
16×1 female side mount
top: original KTM valve
bottom: 12×1 side mount plus 12-to-16 adapter

Remote gas valve with on-off-res Trac Clipper

13 Gas Valve Remote
with on-off-reserve
also for dual gas tanks
it’s an A – off – B switch

 

 

 

 

 

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
S C R E W – O N    G A S   V A L V E S
222866x 1 gas valve 10×1 male spigot down $22 Peugeot 103 1976-82,
                              continued any 10×1 tank with (enough) extension
222866 1a gas valve 10×1 male spig D + A4 extender $28 early Tomos top tanks: Bullet TT, TTLX
                              continued same apps as #2, maybe Peugeot 102?
403300 2 gas valve 10×1 male spigot left $18 Peugeot 103 1976-82,
                              continued Cimatti (must remove R tank to install)
                              continued Motron 1978-79 (tank has extension)
                              continued Tomos MC50, Cosmo Colt 3
2+A2 2a gas valve 10×1 male spig L + A2 extender $38 Peugeot 102 1980 (must have 10-10 extender)
                              continued Motron 1980 (must have 10-10 extender)
                              continued more apps
MBvalve 3 gas valve 10×1 male spigot left compact $20 Motobecane Mobylette 1974-80
                              continued same apps as #2
403100 4 gas valve 12×1 spigot down $18 Batavus/Garelli/Sears/Sachs/JC Penney
                              continued Motobecane Sebring/Kreidler/others
                              continued Cimatti (with original 10-12 adaptor)
                              continued Tomos TX50 Super Tom
                              continued fits Colombia (tube frame w/sideways valve)
229455 5 gas valve 12×1 spigot left round knob $25 Tomos A35, others
401602 6 gas valve 12×1 spigot left $20 Tomos 1976-05 A3 and A35 models
                              continued Vespa Bravo 1977-80
                              continued Colombia (tube frame w/sideways valve)
227125 6 gas valve 12×1 spigot left early Tomos N/A Tomos Bullet/A35 Sprint/Vespa Bravo
233727 7 gas valve 12×1 spigot right round knob $20 Tomos Targa LX, LX 1994-on
                              continued Tomos ST, Sprint 2007-on
401601 8 gas valve 12×1 spigot left extend knob $20 Tomos A35 Targa/Vespa Grande
229169 8 gas valve 12×1 spigot left extend knob $20 Tomos A35 Targa/Vespa Grande
401400 9 gas valve 12×1 side mount $20 Puch Maxi, Newport, Vespa Ciao 1975-86
633783 10 gas valve 14×1 spigot down $20 Honda NC50, NA50, Yamaha QT50
                              continued General 5 Star ST, AMS Sierra 50
                              continued other Asian tanks
TracIma gas valve 14×1 spigot right N/A Trac Image, others
TracEag gas valve 14×1 side mount N/A Trac Eagle, others
Diablo gas valve 14×1.25 $30 Derbi Diablo, RD50 dirt bike mopeds
408200 11 gas valve 16×1 spigot down $20 Sparta Foxi, Buddy, Flying Dutchman ’76-80
                              continued Puch Magnum ’78-84, Odyssey (Solo) ’76-79
KTMgas 12 gas valve 16×1 side mount KTM orig N/A KTM Foxi Deluxe, Salsburg, Baron 1977-79
9+A3 12 gas valve 16×1 side mount $40 KTM uses valve #9 $20 plus adapter #A3 $20
Indian gas valve 16x 1.5 side mount Indian N/A Indian 1978-83 4-stroke, see Indian parts
Honda gas valve 16x 1.5 spigot right N/A many 1970′s Hondas, many other motorcycles
Jawa gas valve 20×1 spigot down Jawa N/A Jawa
632747 13 gas valve remote with on/off/res $30 Trac Clipper 1980-85
                              continued many more apps
            F I L T E R S   a n d   H O S E
gas line gas line 3/16″ clear nylon per foot $1 all mopeds have 3/16″ (5mm) except Derbi
Yconn gas line “Y” connector 3/16 for “gauge” $2 a clear tube branch shows the liquid level
121585 F1 gas filter inline 3/16″ clear round $4 for mopeds 3/16″ id hose (5mm)
209.6 F2 gas filter inline 3/16″ clear flat green $5 for mopeds 3/16″ id hose (5mm)
151920 F3 gas filter inline 1/4″ clear round $5 for small motorcycles 1/4″ id (6.4mm)
151921 F4 gas filter inline 1/4″ clear 90deg angle $5 for small motorcycles 1/4″ id (6.4mm)

 

3/16" inline filter round clear

F1 3/16″ inline filter
round clear paper

3/16' inline filter flat clear green

F2 3/16′ inline filter
flat clear green paper

1/4" inline filter round clear paper

F3 1/4″ inline filter
round clear paper

1/4" inline filter 90 degree brass

F4 1/4″ inline filter
90 deg clear brass

 

 

 

 

 

 

 

 Popular moped gas tanks and their gas valves, for reference: 

Angel gas tank bolt-on fuel valve

Angel gas tank
bolt-on fuel valve

Batavus VA gas tank 12x1 spigot down

Batavus VA 1976-77
12×1 spigot down

 

 

 

 

 

 

 

 

Colombia Commuter 12x1 spigot right

Colombia (sheet metal)
12×1 spigot right orig.

Colombia Commuter 12x1 spigot down

Colombia (sheet metal)
12×1 spigot R or L or D

Colombia Commuter 12x1 spigot down

Colombia (sheet metal)
12×1 spigot R or L or D

Colombia (tube frame) 12x1 spigot left  mounted sideways

Colombia (tube frame)
12×1 spigot L or D or R
mounted sideways

 

 

 

 

 

 

 

 

Colombia (tube frame) with 12x1 spigot left mounted sideways close up

Colombia (tube frame) 12×1 spigot L mounted sideways, original kind

1980 Garelli VIP gas tank

Garelli VIP gas tank
12×1 spigot L or B

Garelli Basic gas tank 12x1 spigot B or L

Garelli Basic gas tank
12×1 spigot B or L or R
needs longer reserve tube
due to the tank extension

 

 

 

 

 

 

 

 

Intramotor Gloria gas valve

Intramotor Gloria Blanco
10×1 male side mount

KTM Foxi gas tank

KTM Foxi gas tank
16×1 side spigot D

Kynast Flying Dutchman M16x1 spigot back

Kynast Flying Dutchman
16×1 spigot B or D,L

 

 

 

 

 

 

 

 

Motobecane gas tank

Motobecane gas tank
10×1 male spigot left

Motron gas tank 10x1 male valve plus extension

Motron 1980 gas tank
10×1 male valve
requires extension

Motron 1978-79 gas tank 10x1 male valve no extension needed

Motron 1978-79 gas tank, 10×1 male 
no extension needed

 

 

 

 

 

 

 

 

Peugeot 102 1980-82 10x1 male valve requires extension

Peugeot 102 10×1 m spigot D or L
requires 1 inch extension piece A2

Peugeot 103 tank M10x1 male

Peugeot 103 tank
10×1 m spigot D or L

 

Puch Maxi

Puch Maxi gas tank
12×1 side mount

 

 

 

 

 

 

 

 

1979 Sachs Balboa

Sachs Balboa gas tank
12×1 spigot L or D or R

Sparta Foxi gas tank  16x1 spigot D or L

Sparta Foxi gas tank
16×1 spigot D or L,B

 

 

 

 

 

 

 

 

Tomos Bullet  12x1 spigot left

Tomos Bullet
12×1 spigot left

Tomos Targa gas tank M12x1 spigot left with 3 inch extended knob

Tomos Targa tank
12×1 spigot L extend

Trac Eagle gas tank M14?x1.25 side mount

Trac Eagle gas tank
14×1 side mount

Vespa Ciao gas tank

Vespa Ciao gas tank
12×1 side mount

 

 

 

 

 

 

 

 

Gas Valves for reference, not for sale:

Remote gas valve for Trac Clipper - some crack easy

Remote gas valve for Trac Clipper – some crack easy

M14x1 spigot right for Trac Image

M14x1 spigot R for Trac Image

9 Gas Valve M14x1 female side mount

M14x1 female side mount
original on Trac Eagle

M12x1 spigot back orig on Garelli Basic

M12x1 spigot back
original on Garelli Basic

 

 

 

 

 

 

 

D1 19.3 x 2.0 8-hole Honda Cub D2  16.3 x 3.0 4-hole Trac D3  21.8 x 2.3 4-hole Vespa D4 13.7 x 2 x 3.3 lip Karkoma

Top: D1 19.3 x 2.0 8-hole Honda Cub      
D2 16.3 x 3.0 4-hole Trac (Asian)  
D3 21.8 x 2.3 4-hole Vespa scooters
D4 13.7 x 2 x 3.3 lip Karkoma   
Bottom row: used disks for reference.
Old disks shrink, get hard, break, or tear.

Gas valve inner seal disks for sale:

Indian Gas Valve M16x1.5 side mount new Honda rubber fits with 2 holes widened

Indian Gas Valve
M16x1.5 side mount
D1 Honda Cub seal disk 19.3 x 3.0mm fits
with 2 holes widened

Remote gas valve for Trac Clipper has 16mm rubber

D2 rubber seal disk
16.3 x 3.0mm 4-hole
for Trac Clipper valve

 

 

 

 

 

 

 

Gas valve rubber disks (inner seals) for reference:

The sizes, applications, and possible sourcing of these vital rubber disks is being studied. It is hoped that some of the common moped gas valves might use the same rubber seal as some kinds of Honda, Kawasaki, Suzuki, Yamaha, or others. When that information becomes available, it will be posted here. Then anyone could order a seal disk from any nearby OEM parts dealer. 

Karkoma 16x1 spigot back with decomposed urethane disk

Karkoma 16×1 spigot back with decomposed disk

Left, an actual original 1970′s Karkoma (Germany) gas valve from a 1979 Kynast moped, with only 50 miles of use. 30+ years of sitting with old, rotten gasoline premix has completely clogged the passageways with hard tar, and decomposed the seal disk to where it broke when the valve was disassembled. Part of the seal disk shaped like a smile broke off and stuck to the movable plate with handle. Usually when these get sticky the handle ends up getting snapped off, in addition to the seal disk crumbling and the holes clogged.  This is the kind that uses a 3.3mm tall lip on the outer edge of the 2.0mm tall by 13.7mm diameter seal disk D4. Later 1980′s Karkoma valves did not have the lip. For those the D4 early seal disk lip must be carefully ground off.

 

 

 

Honda 17993

Honda 17993

OMG seal disk 13.9 x 1.6 3 rings stick up from holes they fit inside valve holes

OMG seal disk 13.9 x 1.6
3 rings stick up from holes
they fit inside valve holes
to keep disk from rotating

OMG 12x1 left front view

OMG 12×1 L front

OMG 12x1 L back

OMG 12×1 L rear

 

 

 

 

 

 

 

 

Honda gas valve rubber

Honda 16955-HA2-005

Close up of 16955-HA2-005

16955-HA2-005 up close
=? KL Supply 18-6646

Honda gas valve rubber 16955-268-020 fits a 1979 CX500

16955-268-020 fits a 78-79 CX500 valve 16×1.5

 

 

 

 

 

 

 

 

Honda 16955-268-020

Honda 16955-268-020
looks smaller

Kawasaki 92065-094

Kawasaki 92065-094
=? KL Supply 18-6646

Kawasaki 92065-055

Kawasaki 92065-055
looks different

Kawasaki 11009-1188

Kawasaki 11009-1188
= KL Supply 18-6644
22.6mm x 2.4mm

 

 

 

 

 

 

 

Suzuki 44341-18450

Suzuki 44341-18450
=? KL Supply 18-6646

Suzuki 51455-010

Suzuki 51455-010
=? KL Supply 18-6643

Yamaha 47X-24523-00

Yamaha 47X-24523-00
=? KL Supply 18-6646

Yamaha 137-24523-00

Yamaha 137-24523-00

 

 

 

 

 

 

 

 

KL Supply seal disks scaled

KL Supply seal disks scaled

Left, these four petcock inner seal disks are included in a few dozen KL Supply petcock rebuild kits, which in turn have a couple of hundred motorcycle and ATV applications. Besides those, there are about two dozen 1970′s and 80′s Asian mopeds: Taiwanese (General, Indian), Japanese (Honda, Yamaha, Suzuki), Korean (Trac, Dailim), that very likely use some of the same small parts as common Japanese motorcycles. Their rubber disks are hard and deteriorated after 30 years. The rest of their petcock is metal and lasts forever, or has round seal rings that are relatively easy to find.

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
                     A D A P T E R S
adaptA1 A1 adapter 10×1 male to 12×1 male $20 threaded 7×1 for filter, with 10×14 seal & cup
                              continued fits tight places by adapting to “turn-nut-only”
adaptA2 A2 extender 10×1 male to 10×1 fem, 26mm $20 threaded 7×1 for filter, with 10×14 seal & cup
                              continued lowers 10×1 gas valve 26mm away from tank
adaptA3 A3 adapter 12×1 female to 16×1 male $20 adapts a Puch side valve to fit KTM Foxi
adaptA4 A4 extender 10×1 male to 10×1 fem, 15mm $15 threaded 7×1 for filter, with 10×14 seal & cup
                              continued lowers 10×1 gas valve 15mm away from tank
reserve reserve tube 1/8″od soft alum. per inch $1 can be formed in a bend for side mount
                    O U T E R   S E A L S
ring+cup seal ring 10 id 14 od 6 tall w/metal cup $2 original on Motobecane
                              continued seals over a wide range of tightenings
ring10 seal ring 10 id 16 od 2 tall semi-soft $2 for 10×1 male valves
                              continued can be soft fiber, plastic, or hard rubber
ring07 seal ring 07 id 11 od 2 tall semi-soft $2 for 12×1 female valves
                              continued can be soft fiber, plastic, or hard rubber
                    I N N E R   S E A L S
diskkark D4 seal disk 13.7 x 2.0 x 3.3 lip urethane $12 Karkoma (Germany) gas valve
                              continued orig on Hercules, Kreidler, Kynast, Sparta
                              continued orig on Colombia, Odyssey, others
reference seal disk 13.9 x 1.6    OMG 3-hole w/lips N/A OMG (Italy) aftermarket gas valves
                              continued retained by raised lips, fit into valve holes
disktrac D2 seal disk 16.3 x 3.0   Trac 4-hole $15 orig on ’80-84 Trac Clipper (Korean)
                              continued more apps being investigated
reference seal disk 18.8 x 2.4 KL Supply 18-6646 N/A
diskcub D1 seal disk 19.3 x 2.0 Honda 16115-001-004 $10 orig on ’59-64 Honda C100 Cub, others
                              continued fits Indian with 2 holes widened
diskvesp D3 seal disk 21.8 x 2.3   Vespa 4-hole $10 orig on Vespa scooters , 1960-83?
reference seal disk 22.6 x 2.4 Kawasaki 11009-1188 N/A equals KL Supply #18-6644
reference seal disk 22.6 x 2.4 KL Supply 18-6644 N/A
reference seal disk 23.0 x 2.4 KL Supply 18-6645 N/A
reference seal disk 28.5 x 2.4 KL Supply 18-6643 N/A
reference seal disk xx.x x x.x Derbi mopeds N/A blue silicone 4-hole
reference seal disk xx.x x x.x Honda 17993 N/A
reference seal disk xx.x x x.x Honda 16955-HA2-005 N/A
reference seal disk xx.x x x.x Honda 16955-268-020 N/A
reference seal disk xx.x x x.x Kawasaki 92065-094 N/A
reference seal disk xx.x x x.x Kawasaki 92065-055 N/A
reference seal disk xx.x x x.x Suzuki 44341-18450 N/A
reference seal disk xx.x x x.x Suzuki 51455-010 N/A
reference seal disk xx.x x x.x Yamaha 47X-24523-00 N/A
reference seal disk xx.x x x.x Yamaha 137-24523-00 N/A

 

Adapter A1: 10×1 male to 12×1 male adapter

10x1 to 12x1 gas valve adapter

A1 10×1 to 12×1 adapter
a) separate (yellow box)
b) all together with valve
c) installed in 10×1 tank

McMaster-Carr 50915K317 brass compression tube fitting

McMaster-Carr 50915K317 fitting,  end cap discarded,
1/8 npt-17 to 1/2-24
can be rethreaded
to 10×1 and 12×1

Sometimes a gas tank has a 10 x 1 threaded gas valve hole that is close to a “wall”, preventing the gas valve from screwing on or off, unless the tank is removed. Sometimes removal of the tank is very difficult, like on a Cimatti City Bike. In those cases an adaptor fitting can be used to convert to a turn-buckle type gas valve, where only the nut turns. 

A 5/16″ OD hydraulic tube fitting has a 1/2-24 thread, that can be cut down (rethreaded) to 12 x 1.  The end cap is not used. Then it becomes a moped gas valve adapter. A tight-fitting 10mm washer made of plastic, paper, or other semi-hard material provides the seal, not the threads. The 12×1 die is not in most metric die sets.

Adapter A2: 10×1 male to 10×1 female extender, 26mm extension

A2 10x1 extender Parts and tools needed 1) M10x1 die and  tap 2) 1/8"NPT fem-fem. 3) 1/8"NPT male-male rethread, tighten, solder 4) metal cup and rubber bottom) finished A2

A2 10×1 28mm extender
Things needed to make it:
1) M10x1.00 die and tap
(not shown: M7x1 tap)
2) 1/8″ pipe NPT fem-fem
3) 1/8″ NPT male to male
rethread, tighten, solder
4) metal cup and rubber
5) assembled and ready

A2 with valve apart

A2 10×1 extender
with valve 2 apart
1 M7 screw-on filter
2 M3 reserve tube
(length determines reserve capacity)
3 M10x1 fuel valve

A2 installed on valve

A2  on valve 2
distances in mm:
rubber – rubber 26
rubber-res. tube 60
rubber-filter top 75

A2 on 1980 Peugeot 102

Original extender on 1980 Peugeot 102
Required here because there is a vertical wall that prevents installation. Required on other tanks when a wall or ceiling  interferes with the handle or lever knob.

 

 

 

 

 

 

 

 

 

 

 

On some 10×1 internal thread gas tanks, the gas valve needs to be lowered down in order to screw on and fit. The Peugeot 102 moped is the main example, where the gas valve 10×1 hole is near a “wall”. 

 Adapter A3: 16×1 female to 12 x 1 female

A3 adapter 16 to 12

A3 adapter 16 to 12

This is a turnbuckle type (LH and RH) nut like on the 12mm female gas valves, with left thread on the 12mm side and right thread on the 16mm side. It must be started in the correct position on the threads when installing, to make the inner (7 id, 12 od) seal washer (that came with the valve) and the outer (12 id, 16 od) seal washer (that comes with the adapter) both get squeezed enough when it is tightened. This replaces the 12mm turnbuckle nut that the valve came with.

 

Adapter A4: 10×1 male to 10×1 female extender, 15mm extension

A4 M10x1 extender same as A2 but short

A4 M10x1 extender
same as A2 but shorter

This 15mm short extender is one piece aluminum. It comes with gas valve #1a. Here it is shown without the upper rubber (o-ring or ring with metal cup), that seals against the tank.

Gas valve outer seals: Screw on gas valves, unlike plumbing pipes, seal by a soft or semi soft ring, that is squeezed between the gas tank and the gas valve, as the valve or nut is screwed on tight. Plumbing pipes seal by the threads only, and don’t need a flange and soft ring. The sealing surface on both the tank and the valve must be flat and straight. If a gas tank has a damaged sealing surface, then the outer seal might leak, even when the seal and valve are fine. The remedy for a warped, misaligned or scratched sealing surface, on either the tank or the valve, is careful grinding with a flat spinning disk (with all gasoline evacuated).

Gas valve low cost substitutes:  USA plumbers will recognize that the moped gas valve M10x1 thread is close to 1/8″ (named after the small inner diameter) National Pipe Thread Taper NPT . Because of the taper, a brass 1/8″ NPT (27tpi = 0.94mm) screws on and fits the 10×1 thread OK, because it’s about 9.5mm at first, tapering to 10.2mm. With teflon pipe thread tape, any 10×1 thread gas tank can be adapted with American standard pipe pieces, including shut-off valves. All of those things are sold in home improvement stores nationwide. The good side is those pipe pieces are inexpensive and easy to get. The bad side is they must be cleaned up and re-taped every time they are screwed on and off, and they don’t have any reserve feature. 

Other sources of gas valves:

Get 2 It Sales: Fuel Valves    moped and scooter gas valves, manual and vacuum, inline, screw-on, and bolt-on.

Four into One   Vintage Honda motorcycle petcocks 20×1.5 (for $75), 16×1.5 (for $17.50), bolt-ons.

 

 2  G A S    C A P S

==========================================================================

Gas caps come in 4 types. 1. Quarter turn, 2. Push in, 3. Screw on, 4. Pop up. Each type has different sizes.

Quarter turn gas lids on mopeds. L to R, 30, 40, 60mm

30 and 40mm quarter turn “regular wing”, 40mm quarter turn “external wing”. Many other quarter turn wing styles are possible. Two other moped styles are nick named “thin wing” and “wide wing”.

Quarter turn has two “wings” on opposite sides that enter two slots in the gas tank lip. Then when the gas cap is rotated 90 degrees to the right, which is one fourth of a turn, it locks on and seals the outer edge by the spring tension in the wings. The spring has a certain amount of “travel” that allows the lid to work (seal) on a range of gas tank lip thicknesses, or as the rubber or cork gasket gets thin. But sometimes a thicker rubber washer is needed to get the wings to push harder and seal better. In the 30mm size an extra 2mm thick rubber is sold here, but not for 40mm, at this time.

Push in lid gas tanks have a smooth round wall, about as deep as it is wide. The lids are usually black plastic with thin flexible circular ridges that press against the wall. The entrance has a taper for easy operation. In the 1977 USA moped standards, push in gas lids were supposedly required to be quarter turn. Puch, Cimatti, Garelli, and Sachs switched from push-in to quarter-turn but not everyone else did. Again in 2010, quarter turn gas caps are mandated in the USA, this time not for safety reasons, but for environmental ones.

 

Myrons Mopeds Gas Caps, June 2013 Back row: Quarter turn L to R 27,30,40,60mm Front row: Push-in, Screw-on, and Pop-up

Myrons Mopeds Gas Caps, Class of 2013, click to enlarge.
Back row: Quarter turn L to R 27,30,40,40 mm external
Front row: Push-in 30,32,36,40, Screw-on, Misc and Pop-up

Screw on lid gas tanks have threads. The lid must be screwed on one or more full turns clockwise. The threads on the lid can be either female (internal) or male (external). Most modern screw on lids are more like bottle cap threads, more coarse than machine threads. Also the tops and bottoms of the threads have wide plateaus. Some are at right, not listed.

Pop up gas lids are generally on top tank mopeds and modern motorcycles. Turn the key or push the button and the lid pops open.

Vent Hole: All moped gas caps are “vented”. That means they have a tiny pinhole or channel that lets air get in or out. If the pinhole is blocked, after awhile a suction will develop, the gasoline supply will stop, especially with a full tank. They all have a vent design that prevents gasoline from shooting out, like a wall or a maze, but lets air get through. Some gas caps have a vent switch, “on” or open for riding, “off” or closed for transport and storage. All vented gas lids will leak gas if the tank is too full or leaned over too far.

Shrinkage: Unless they have been kept stored in an air tight bag, many of the vintage moped plastic gas caps shrink after 20 or 40 years. The Peugeot and Colombia black plastic push-in 30mm lids become 29 or 28mm. The 32mm late Derbi black plastic push-in lid becomes 30mm. The Garelli 42mm screw-on black plastic lid becomes 41 or 40. When a push in lid shrinks, it gets loose and falls off. One remedy for that is a “leash” made out of a twist tie. Another remedy is a thin rubber o-ring, but it’s hard to find the correct size. With push-in gas caps, the actual diameter will be slightly more, about 0.5 millimeter, than the tank hole inner diameter, to make a light press fit. So a 30mm lid should be 30.5mm wide, a 40 should be 40.5. With screw on male lids there can be shrinkage and the lid will still function, because it does not seal on the loose threads. But when a female (internal thread) screw-on lid gets smaller, it becomes tight and difficult or impossible to screw on.

 

1. 1/4 turn 32mm chrome bottom view

1. qtr-turn 30mm
chrome bottom view
30 is the tank ID

1. 1/4 turn 32mm chrome top view

1. qtr-turn 30mm
chrome top view
30 is the tank ID

1a. Rubber washer 30x50x2

1a. Rubber (buna) washer 30x50x2mm for #1 lid

1a. Buna rubber replaces old cork

1a. Rubber replaces cork
on most 30mm gas lids

 

 

 

 

 

 

 

 

2. 1/4 turn 32mm locking

2. qtr-turn 30mm chrome locking

3. pop-up clamp-on

2a. pop-up clamp-on
for 45mm OD tank
Pacer Sport (Italtelai)
Baretta 22,44 (Piccoli)

3a. qtr-turn 30mm alum original on 1976 Tomos

3a. qtr-turn 30mm alum
original on 1976 Tomos

3b. qtr-turn 30mm Tomos L orig on 1980 Bullet R orig on 2000 Sprint

3. qtr-turn 30 Tomos
b. orig on 1980 Bullet
c. orig on 2000 Sprint

 

 

 

 

 

 

 

4. qtr-turn 40mm black orig on 1987-91 Tomos Golden Bullet TTLX

4. qtr-turn 40mm black
orig on 1987-91 Tomos Golden Bullet TTLX

5. qtr-turn 32mm black (with widths)

5. qtr-turn 30mm
black (with widths)

6. qtr-turn 40mm black locking

6. qtr-turn 40mm
black locking
40 is the tank ID

 

 

 

 

 

 

 

 

Puch Maxi tank qtr-turn 30mm

’78 Puch Maxi tank
qtr-turn 30mm

Puch Maxi tank push-in 32mm

1976 Puch Maxi tank
push-in 30mm

Garelli Super Sport tank quarter-turn 32mm

1978 Garelli Super Sport
quarter-turn 30mm

1980 Peugeot 102 tank 30mm push-in improv lid

1980 Peugeot 102 tank
30mm push-in improv lid

 

 

 

 

 

 

 

 

7. qtr-turn 32mm used Puch w/cup

7. qtr-turn 30mm
used chrome Puch
with oil measuring cup

8. qtr-turn 32mm used alum Puch

8. qtr-turn 30mm
used alum Puch

9. push-in 30mm black

9. push-in 30mm
black generic

10. qtr-turn 40mm chrome with qtr-turn 32mm

10. qtr-turn 40mm
(with qtr-turn 30mm)

 

 

 

 

 

 

 

 

11. pop-up locking chrome General

11. pop-up locking
chrome General
new with 2 keys

12. qtr-turn 32mm chrome Puch used

12. qtr-turn 30mm
chrome Puch used

13. screw-in Motobecane 1. dull used 2. shiny used 3. with vent on/off

13. screw-in Motobecane
a. dull used w/stick
b. shiny good used
c. with vent on/off

14. screw-in Motobecane chrome locking

14. screw-in M30x1.75 Motobecane chrome locking with two keys

 

 

 

 

 

 

 

 

1978 Vespa Ciao tank screw-on female M40x2 with PVC improv lid

1978 Vespa Ciao tank
screw-on female M40x2
with PVC improv lid

1978 Vespa Ciao tank PVC improv lid open

1978 Ciao tank
PVC improv lid

Close up of PVC lid made from a 1-1/4" PVC threaded cap sliced in half

M40x2 female PVC lid
made from a 1-1/4″
PVC threaded cap
sliced in half

15. screw-on not vented AMF Roadmaster (R eng)

15. screw-on not vented
orig on AMF Roadmaster with McCulloch R engine

 

 

 

 

 

 

 

 

16. screw-on fem M40x2 Vespa Ciao,Bravo,Grande

16. screw-on fem M40x2
orig on Vespa (Piaggio)
Ciao, Bravo, Grande

16a. screw-on fem 40x2 L is white PVC improv R is aluminum original

16a. screw-on fem 40×2
L is white PVC improv
R is aluminum original

16a. screw-on fem 40x2 PVC 1-1/4" cap is 38.5 ID fits 40x2 well, by luck!

16a. screw-on fem 40×2
PVC 1-1/4″ cap is 38.5 ID
fits 40×2 well, by luck!

16b. 1-1/2 PVC is too big for 40 (38.5id), too small  for 50 (48.5id)

16b. 1-1/2 PVC is too big for 40 (38.5ID), too small (45.0ID) for 50 (48.5ID)

 

 

 

 

 

 

 

 

17. push-in 32mm Puch aftermarket

17. push-in 30mm
Puch aftermarket

18. push-in 30mm Hercules/Sachs

18. push-in 30mm Hercules
early Sachs Westlake, Balboa
later Sachs tanks had qtr-turn

18a. qtr-turn 30 & 40mm L is 1970's Suzuki 30 R is 1970's Japan 40

18a. qtr-turn 30,40 thin
L is 1970′s Suzuki 30
R is 1970′s Japan 40

18a. qtr-turn 30 & 40 thin L is 30 with no gasket R is w/leather gasket

18a. same ones bottom
L is 30mm with no gasket
R is 40 w/leather gasket

 

 

 

 

 

 

 

 

Peugeot 103 gas tank push in 30mm gas lid

1978 Peugeot 103 tank
push in 30mm gas lid

2005 Tomos Streetmate with 32mm push in lid until

2005 Tomos Streetmate
with 32mm push in lid
until 2010 then qtr-turn

General top tank pop-up accepts 40mm push-in

1979 General top tank
accepts 40mm push-in

Derbi Variant tank 32mm

1977-89 Derbi Variant
32mm push in lid

 

 

 

 

 

 

 

 

20. push-in 40mm "Puch" Korado

19. push-in 40mm
Puch Korado (Manet)
bathtub plug shown

20. qtr-tur 40mm chrome locking

20. qtr-turn 40mm
chrome locking
with two keys

21. qtr-turn 32mm chrome Garelli

21. qtr-turn 30mm
orig on 1978-on Garelli

22. screw-in female 42x1.5 Garelli Super Sport these shrink

22. screw-on gas cap female M42x1.5
Garelli Super Sport
early top tank
these shrink
>

 

 

 

 

 

 

 

 

23. qtr-turn 40 external black locking

23. qtr-turn 40 external
black locking for TSM

26. push-in 32mm Derbi shows how some shrink to 30mm

24. push-in 32mm Derbi
shows how some shrink
to 30mm

26. Derbi 8204140 gas lid left - '76-86 not shrunk right - '86-89 shrunk to 30

25. Derbi 8204140 gas lid
left – ’76-86 not shrunk
rt – ’86-89 shrunk to 30

26. qtr-turn 60mm chrome Peugeot TSM

26. qtr-turn 40 external
chrome Peugeot TSM

 

 

 

 

 

 

 

26. qtr-turn 60mm bottom view

26. qtr-turn 40 external
view of external wings
orig on Peugeot TSM

27. push-in 36mm Derbi Laguna

27. push-in 36mm
Derbi Laguna,RD50

28. push-in 40mm Gitane/Testi

28. push-in 40mm
orig on Gitane (Testi)

29. push-in 30mm  early Puch original

29. push-in 30mm
early Puch original

 

 

 

 

 

 

 

 

30. push-in 32mm Tomos Revival

30. push-in 32mm
Tomos Revival, S.mate

31. push-in 30mm KTM Foxi original

31. push-in 30mm
orig on KTM Foxi Deluxe

31. KTM caps break easy

31. KTM caps break easy
a. broken and glued back
b. new kept in plastic bag

32. push-in 30mm Cimatti

32. push-in 30mm
pre-’78 Cimatti City Bike
(’78-on was qtr turn)

 

 

 

 

 

 

 

 

33. push-in 30mm Peugeot

33a. push-in 30mm Peugeot 103 original
Peugeot replacements 33b. plain 33c. Esso
These all shrink. Adding an o-ring fixes it.

34. qtr-turn 30mm Puch chrome w/cup

34. qtr-turn 30mm
Puch chrome w/cup

35. push-in 32mm early Garelli  missing the o-ring

35. push-in 32mm
early Garelli step-thru
shown with no o-ring

 

 

 

 

 

 

 

 

1978 Vespa Bravo tank screw-in female M40x2

1978 Vespa Bravo tank
screw-in female M40x2

Garelli Super Sport screw-in (female lid)

Garelli Super Sport
screw-in (female lid)

Garelli Super Sport tank screw-in (female lid) M42 x 1.5 thread

Garelli Super Sport tank
screw-in (female lid)
M42 x 1.5 thread

1968 Lambretino tank screw-on M40 x 2 fem

1968 Lambretino tank
screw-on M40 x 2 fem

 

 

 

 

 

 

 

 

Special rubber washer fits Garelli and Tomos 32mm push in gas caps, with some grinding.

36. Rubber (buna-N) 35mm washer fits Tomos (top) and Garelli (bottom) 32mm push in gas lids, with the outer surface ground down to diam. 33mm.
L to R, no rubber, rubber not cut, rubber cut to fit

37. screw-on M40x1.75 white, for MB Model 7

37. screw-on M40x1.75
white, for MB Model 7

37. screw-in male Motobecane new white plastic

38. screw-on M30x1.75
for Motobecane 40,50

 

39. push in 40mm 1970's Jawa original

39. push in 40mm
1970′s Jawa original

 

 

 

 

40. screw in male 40x2

40. screw in male 40×2

 

 

 

 

 

 

 

41. qtr turn 40mm wide wing regular wing at right

41. qtr-turn 40 wide wing
regular wing at right
Pacer top tank (Italtelai)

42. screw on female M50x1.5 for Demm Smily and Italian

42. screw-on fem 50×1.5
“FILL ONCE S.A.E. OIL 30
FOR EACH QT OF GAS”

42. screw in M50x1.5 bottom view 48.5mm ID

42. screw-on M50x1.5
48.5 ID for Demm Smily
Benelli (Wards Riverside)

42. screw-on fem 50x1.5 orig. on 1960's Aermacchi

42a. screw-on fem 50×2.5
orig. on 60′s Aermacchi

 

 

 

 

 

 

 

1962? Sears Allstate tank screw-on female gas lid very coarse thread

1962? Sears Allstate tank
screw-on female gas lid
very coarse thread

1965 Harley Davidson M50 tank (Aermacchi) screw-on fem M50x1.5

1965 Harley Davidson M50 tank (Aermacchi)
screw-on fem M50x1.5

1979 Motobecane 50V screw on male M30 x 2 tank ID is 28.5mm

1979 Motobecane 50V screw on male M30 x 2
tank ID is 28.5mm

Same MB tank cut away

Same MB tank cut away
inside view of fill hole
& center bulkhead wall

 

 

 

 

 

 

 

 

 

 

41 and 26 look the same on top

#41 stainless, and #26 chrome, have same tops
tanks shown below

41 and 26 are very different on bottom

#41 and #26 are very different on bottom
40 wide, 40 external

43 push-in 30mm  improv bottlecap

43. push-in 30mm
bottlecap improv

44. push-in 30mm  PVC improv no vent

44. push-in 30mm
PVC improv (no vent)
L is finished, R is raw

 

 

 

 

 

 

 

1980 Peugeot TSM tank qtr turn 40mm external

1980 Peugeot TSM tank
qtr turn 40mm external

Vintage motorcycle tank qtr-turn 40 external wing

Vintage motorcycle tank
qtr-turn 40 external wing
takes lid #26 or #23

1979 Motobecane Sebring  qtr-turn 40mm wide wing

1979 Motobecane Sebring
qtr-turn 40 wide, lid #41

 

 

 

 

 

 

 

 

45. push-in 30mm black Colombia Open Road

45. push-in 30mm black
Colombia Open Road

45. push-in 30mm Colombia left shrunk, right new

45. push-in 30 Colombia
left shrunk, right new

46. qtr-turn 40mm Trac

46. qtr-turn 40 thin wing
Trac Hawk top tank

47. qtr-turn 40mm ?? Trac DH100 top tank?

47. qtr-turn 40 thin wing
Trac DH100 top tank

 

 

 

 

 

 

 

48. qtr-turn 30mm Honda NC50 Express has vent on/off

48. qtr-turn 30mm
Honda NC50 Express
has vent on/off switch

49. qtr-turn 30mm w/cup Honda PA50 Hobbit

49. qtr-turn 30 thin wing
Honda PA50 Hobbit
has oil measuring cup

49. qtr-turn 27mm unknown origin

50. qtr-turn 27 thin wing
unknown origin

51. qtr-turn 30mm chrome Angel (Taiwan)

51. qtr-turn 30mm
Angel (TYM Taiwan)

 

 

 

 

 

 

 

 

52. push-in 30mm with large teardrop top

52. push-in 30mm with large teardrop top
for Gitane Cricket (Testi)

53. screw-on M42x1.5 with vent close switch orig on Italjet Packaway

53. screw-on fem 42×1.5
with vent close switch
orig on Italjet Packaway

54. qtr-turn 30mm Tomos orig on 1980-90 Bullet

54. qtr-turn 30 alum.
1980-90 Tomos Bullet

55. push-in 30mm locking - Avanti

55. push-in 30mm
locking for Avanti

 

 

 

 

 

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
          Q U A R T E R   T U R N
50 gas cap 1/4 turn 27mm beat up on top $8 unknown origin
206401 1 gas cap 1/4 turn 30mm (tank) chrome $10 aftermarket, Puch Tomos Sparta many
rubber 1a rubber washer 30 x 50 x 2 for cap #1 $1 can use 1 or 2 rubbers as needed
222145 5 gas cap 1/4 turn 30mm black Tomos $20 1993-03? Tomos Sprint
vintage 34 gas cap 1/4 turn 30mm chro Puch w/cup $65 78-86 Puch Maxi deluxe
vintage 8 gas cap 1/4 turn 30mm alum used Puch $30 77-79 Puch Maxi standard
vintage 12 gas cap 1/4 turn 30mm chro. used Puch $30 78-86 Puch Maxi deluxe models
vintage 7 gas cap 1/4 turn 30mm used Puch w/cup $45 78-86 Puch Maxi deluxe models
229530 2 gas cap 1/4 turn 30mm chrome locking $17 1996-on Tomos ST
vintage 21 gas cap 1/4 turn 30mm chrome Garelli $35 1978-on Garelli and other Italian
vintage 3a gas cap 1/4 turn 30mm alum Tomos $30 1976 Tomos, can be polished
vintage 3b gas cap 1/4 turn 30mm alum Tomos used $15 1980 Tomos, said “add 2% oil”
222145 3c gas cap 1/4 turn 30mm black Tomos $25 1993-on Tomos Sprint “mix 1:50 2%”
vintage 48 gas cap 1/4 turn 30mm Honda NC50 used $30 1977-83 Honda NC50 Express
vintage 49 gas cap 1/4 turn 30mm thin wing used $30 1978-82 Honda PA50 Hobbit
vintage 51 gas cap 1/4 turn 30mm Angel used $20 1977-79 Angel/Speed Bird (TYM)
vintage 18a gas cap 1/4 turn 30mm 1970′s Suzuki $20 no gasket
632610 10 gas cap 1/4 turn 40mm chrome $12 aftermarket, Puch Tomos top tanks
222785 4 gas cap 1/4 turn 40mm black $15 87-93 Tomos Golden Bullet TT
vintage 34 gas cap 1/4 turn 40mm chrome Puch $50 78-81 Puch Magnum top tank
vintage gas cap 1/4 turn 40mm Puch used w/cup $40 78-81 Puch Magnum top tank
vintage gas cap 1/4 turn 40mm Sears used w/cup $25 1978 Sears Free Spirit
229545 6 gas cap 1/4 turn 40mm black locking $25 96?-on Tomos LX top tank
223840 20 gas cap 1/4 turn 40mm chrome locking $17 Tomos top tank LX, TT, TTLX
vintage 41 gas cap 1/4 turn 40mm wide wing chrome $30 Pacer top tank, Benelli, other Italian
vintage 46 gas cap 1/4 turn 40mm thin wing locking $35 1985-87 Trac Hawk, Image
vintage 47 gas cap 1/4 turn 40mm thin wing locking $35 1986-88 Trac DH100 top tank
vintage 18a gas cap 1/4 turn 40mm thin wing chrome $40 made in Japan, leather gasket
vintage 26 gas cap 1/4 turn 40mm chro external wing $30 1979-81 Peugeot TSM top tank
vintage 23 gas cap 1/4 turn 40 locking external wing $30 vintage aftermarket France
          P U S H   I N
vintage 18 gas cap push-in 30mm Hercules/Sachs N/A pre-78 Hercules/Sachs Westlake, Balboa
vintage 25 gas cap push-in 30mm shrunk Derbi $25 1986-89 ones shrink, 1976-85 ones do not
Treats 9 gas cap push-in 30mm aftermarket Peug N/A https://www.treatland.tv/SearchResults.asp?Search=gas+cap+30mm
Treats 17 gas cap push-in 30mm aftermarket Puch N/A same link as #9 above
vintage 32 gas cap push-in 30mm Cimatti $20 1976-77 Cimatti City Bike rear tank
vintage 29 gas cap push-in 30mm Puch used $45 1974-76 Puch Maxi, some are less
vintage 31 gas cap push-in 30mm KTM grey (breaks) $60 1977-79 KTM Foxi Deluxe
vintage 31a gas cap push-in 30mm KTM broken-glued $10 1977-79 KTM Foxi Deluxe
vintage 33a gas cap push-in 30mm Peugeot (shrinks) N/A 1976-82 Peugeot 103, 102 all
vintage 33b gas cap push-in 30mm Peug spare plain N/A can add an o-ring to make it tight
vintage 33c gas cap push-in 30mm Peug spare Esso N/A can drill a hole to make a “leash”
vintage 45 gas cap push-in 30mm Colombia $30 1977 Colombia Open Road (tube frame)
improvB 43 gas cap push-in 30mm bottle cap improv $5 has vent, splash guard, outer lip, and handle
improvP 44 gas cap push-in 30mm white PVC improv $3 has no vent
vintage 51 gas cap push-in 30mm large teardrop $30 1976-78 Gitane Cricket (Testi)
vintage 35 gas cap push-in 32mm Garelli $35 pre-1978 Garelli, w/new rubber
vintage 24 gas cap push-in 32mm Derbi $35 1976-89 Derbi Variant, all step thrus
232546 30 gas cap push-in 32mm Tomos $15 2002-09 Tomos Revival, Streetmate
buna 36 buna rubber washer for #30 and #35 $4 requires grinding from 35 to 33mm
vintage 27 gas cap push-in 36mm Derbi Laguna $65 1978-88 Derbi Laguna, RD50 top tanks
vintage 19 gas cap push-in 40mm Puch Korado N/A 2000-2005 Puch Korado (made by Manet)
vintage 28 gas cap push-in 40mm Testi/Gitane $15 1976-78 Gitane (made by Testi)
vintage 39 gas cap push-in 40mm chrome/rubber $20 origin unknown, rubber ribs seal good
          S C R E W   O N
vintage 13b gas cap screw-on male 30×1.75 MB chrome $45 1976-80 Motobecane 50 and 40
vintage 13c gas cap screw-on male 30×1.75 MB chrome $35 Motobecane replacement part
vintage 38 gas cap screw-on male 30×1.75 MB plastic $30 Motobecane replacement part
vintage 13a gas cap screw-on male 30×1.75 MB used $30 1976-80 Motobecane 50 and 40
vintage 14 gas cap screw-on male 30×1.75 MB locking $40 vintage aftermarket France
vintage 37 gas cap screw-on male 40×1.75 MB white $35 1978 Motobecane Model 7
vintage 40 gas cap screw-on male M40 x 2.0 black $25 origin unknown
vintage 15 gas cap screw-on fem. AMF non vented $15 1979-80 AMF Roadmaster rear engine
vintage 16 gas cap screw-on fem. M40 x 2.0 Vespa $30 1974-84 Vespa Ciao,Bravo,Grande
vintage 16a gas cap screw-on fem. M40x2 PVC improv N/A 1974-84 Vespa Ciao,Bravo,Grande
vintage 22 gas cap screw-on fem. M42 x 1.5 Garelli $40 early Garelli top tank, lid=40.5, tank=41.5
vintage 53 gas cap screw-on fem. M42 x 1.5 Italjet $40 1977-79 Italjet Packaway folding moped
vintage gas cap screw-on fem. M50x 2.0 Vespa Si N/A 1980-88 Vespa Si (bigger gas lid)
vintage 42 gas cap screw-on fem. M50x 1.5 Demm $50 Demm, Benelli (Wards Riverside)
          P O P    U P
vintage 11 gas cap pop-up 40mm General top tank $65 1978-80 General 5 Star top tank
vintage 2a gas cap pop-up clamps on $17 Westwind (Spisni Lino), Baretta (Piccoli)

 

More gas caps, not for sale,  for your information:

55. screw-on 40mm coarse for modern ATV

60. screw-on 40mm
very coarse thread
for modern ATV

56. screw-on 50mm very coarse thread for modern ATV

61. screw-on 50mm
very coarse thread
for modern ATV

57. screw-on 50mm very coarse thread for modern ATV

62. screw-on 50mm
very coarse thread
for modern ATV

Modern ATV Gas Caps

Modern ATV Lids

 

 

 

 

 

 

 

Modern motocross tank screw-on very coarse for reference

Modern motocross tank
screw-on very coarse

 

 

 

 

 

 

 

 

==========================================================================

 


Carburetor Parts – Dellorto, Bing, Encarwi

November 25, 2012

 CONTENTS:    Welcome    1  Dellorto    2  Dellorto (Vespa)    3   Bing (Puch)    4  Bing (Sachs)

    5  Encarwi (Tomos)    6  Encarwi (Batavus)    7  Encarwi (Trac)   8  Other Carburetors   

Welcome. These are not all the carburetors, but just the common ones that have some interchangeable parts. These come in different sizes from 7mm to 14mm venturis, and from #39 to #68 main jet. A Puch carb might be a 14mm Bing with a 64 jet, while another Puch carb might be a 12mm Bing with a #60 jet. So there are different configurations. When you get a new carb, you generally have to re-configure it. That means learning about jetting. Final jet selection requires a safe, legal, operating bike that can run hard wide open. The engine temp is “sensed” or smelled or a digital temp gauge is used. Read more about that in Service.  The point is, it’s generally easier to repair the old carburetor, than to purchase and re-configure a new one. That said, many people put new Dellorto SHA14/12 or 15/15 carbs on older mopeds. They don’t leak but they’re not jetted right. Not all mopeds have the right intake pipe diameter. The carburetor must fit precisely. Getting the right adaptor sleeve is sometimes not possible. The various intake pipe diameters are listed in Dellorto sleeves applications. 

1  D E L L O R T O

================================================================================

Part # # ←picture#………Description Price           Applications
###### ### ############################# #### ##################################
D E L O R T O…S H A…C A R B U R E T O R Used on every Italian moped and others
All these carb bodies have the same parts: >>>> Unless otherwise noted below
Derbi SHA 12/12 Spain-made regular choke N/A Derbi 76-85 Variant use 14/12
Derbi SHA 12/12C Spain-made cable choke N/A Derbi 86-89 Variant Sport
Derbi SHA 12/12C? Spain cable choke flat top N/A Derbi 87-89 DS50
SHA 14/9 undersize N/A almost all Italian 20mph versions
SHA 14/14 oversize N/A from 1970′s not original on US-model mopeds
490900 SHA 15/15C oversize cable choke type $100 bigger carb upgrade for 19or21mm intakes
SHA 16/16C oversize cable choke type N/A bigger carb upgrade for 19or21mm intakes
227506 SHA 14/12P linkage choke lever $80 86-06 Tomos A3/A35 all
SHA 14/12 normal everyday “Delorto” N/A      Apps: Baretta Benelli Bianchi Carabella Cimatti
Colt Concord Cosmo Demm Fantic >>>> Garelli Intramotor Italjet Malaguti
Motobecane Sebring Moto Guzzi >>>> Motomarina Motron Negrini NVT Pacer
Rizatto Safari Snark Testi Tomos 86-06 >>>> plus engines Minarelli Morini Verona
219624 1 rubber boot for throttle cable $2 all
2 adjuster throttle cable (no elbow) $2 Minarelli w/forward carb
3 locknut M6 for adjuster or elbow $1 all
elbow 90-deg M6 for throttle cable $8 Vespa Ciao
219623 elbow 60-deg M6 for throttle cable $7 most
elbow 45-deg M6 short no adjuster $7 Garelli
219625 adjuster M5 for elbow $2 Click down the choke start the bike then
219626 lock nut M5 for adjuster $1 click off the choke by giving it full throttle
4 top screw M4 x 0.75 x 15 coarse (2) $2 Putting the top back on is difficult
5 washer M4 (2) $0 Hold the inner choke lever to the right
6 carb top $5 until the top goes all the way down Then
219596 carb top complete $20 hold it down while tightening the screws
7 hinge pin choke in carb top $2 Or else the lever #9 bends and wont release
8 spring choke in carb top $2
9 lever choke trigger $2 the slightest bend makes choke not release
219583 10 gasket for carb top $2 for resisting water…is not needed for running
11 spring throttle return $3
219580 12 slide throttle $10 can cut notch in bottom center for richer idle
13 banjo screw M5 x .75 x 15 fine $2
219780 14 seal washer M5 $1
219584 15 banjo fuel inlet plastic (no washer) $8 these crack/bend and leak or break off
15 banjo fuel inlet metal 3/16″ fuel line $12 requires seal washer M5
15 banjo fuel inlet metal 1/4″ fuel line N/A 76-89 Derbi must use 3/16 one with sleeve
219585 16 filter fuel $5
17 nut for clamp bolt $1 two styles hex or tab
219590 18 gasket for air filter $3 almost never needed
219591 19 spring for choke plate $3
20 choke plate with lever $7 comes in extended lengths for hard to reach carbs
21 pivot bolt choke $3
219593 22 hinge pin float $2 never needed except when mishandled or lost
intake sleeve 16x18mm N/A 16: Vespa (see Dellorto Vespa)
6540 23 intake sleeve 16x20mm $4 16: Morini MO-1 & 2, Demm, Verona
6540 23 continued … 16: Tomos A3 76-85, Batavus M48
219586 23 intake sleeve 18x20mm $7 18: Minnarelli, Garelli, Tomos 86-06 A3/A35
227326 23 intake sleeve 18x21mm $7 18: for SHA15/15 and 16/16 only
227326 23 continued … 18: Minnarelli, Garelli, Tomos 86-06 A3/A35
D10146 23 intake sleeve 19x21mm N/A 19: comes original on SHA15/15
D10146 23 continued … 19: Peugeot, Motobecane, Sachs, Morini M1
20: Puch (no sleeve)
24 clamp bolt M6 $2 see Service Department for idle hole location
25 idle screw $4 adjusts idling speed not mixture
219588 26 spring for idle screw $2 float needle rubber tip gets worn or warped
219589 27 float needle lets fuel in when needed $10 this and a dirty seat is what makes it leak gas
28 jet M5 #43… 0.0182″=0.462mm N/A 74-84 Vespa Ciao 80-84 Vespa Si gas sippers
28 jet M5 #45… 0.0190″=0.483mm N/A 77-83 Vespa Bravo
28 jet M5 #47… 0.0198″=0.503mm N/A
632827 28 jet M5 #48… 0.0202″=0.513mm $7
28 jet M5 #49… 0.0207″=0.525mm $7 78-83 Vespa Grande
632826 28 jet M5 #50… 0.0210″=0.533mm $7 76-80 Garelli with intake restrictors (52w/o)
219581 28 jet M5 #51… 0.0215″=0.546mm $7 85-91 Tomos A3 with Delorto
406800 28 jet M5 #52… 0.0219″=0.556mm $7 ALL OTHERS 30mph See      Apps above
TOMOS 28 jet M5 #53… 0.0223″=0.566mm $7 92-06 Tomos A35
406900 28 jet M5 #54… 0.0227″=0.577mm $7
TOMOS 28 jet M5 #55… 0.0231″=0.587mm $7
407000 28 jet M5 #56… 0.0235″=0.597mm $7 92-06 Tomos A35 with Biturbo exhaust
407100 28 jet M5 #58… 0.0242″=0.615mm $7
407200 28 jet M5 #60… 0.0247″=0.627mm $7 92-06 Tomos A35 with Biturbo+Uni filter
28 jet M5 #62… 0.0255″=0.648mm N/A
407300 28 jet M5 #64… 0.0262″=0.665mm $7
407400 28 jet M5 #66… 0.0268″=0.681mm $7 Stock mopeds need some restriction to run right
416800 28 jet M5 #68… 0.0274″=0.696mm $7 Without an air box they need 2 steps bigger jet
28 jet M5 #70… 0.0280″=0.711mm N/A A 52-stock bike would need a 56      Approximately
219582 29 float $18 never needed except when mishandled
219594 30 gasket float bowl $3 not usually the cure for gas leaks
31 float bowl used metal $5 old ones were metal new ones are plastic
32 float bowl screw M4x0.75×20 coarse (2) $2
33 clamp air filter with screw $5
219376 35 air filter $12
36 air box small thin type N/A
37 air box large thick type $18 without intake tubes/restrictors needs bigger jet
38 air box Minarelli type N/A
219625 39 adjuster M5 for elbow $2
219626 40 lock nut M5 for adjuster $1
41 elbow carb for choke cable 45deg N/A
42 lock nut M6 for elbow $1
43 choke plate cable-pull type N/A
223025 44 pivot shaft with choke linkage $6
223027 45 spring for pivot shaft $2
TOMOS 46 choke plate linkage type with post N/A
227328 47 choke lever external $6
48 lock washer M3 $1
49 nut M3 $1
632641 50 gasket set Delorto $12

 

2  D E L L O R T O    V E S P A

================================================================================

Part # # ←picture#………Description Price Applications
###### ### ############################# #### #################################
D E L O R T O …S H A….V E S P A…C A R B Used on Vespa mopeds and 83-86 Garelli VIP-N
DEL ORTO SHA 12/12 Vespa Version> N/A Vespa Grande 25 & 30mph
……………… SHA12/10 Vespa Version> N/A Vespa Ciao Bravo Si 25 & 30mph
………………… SHA12/7 Vespa Version> N/A Vespa models restricted to 20mph
SQUARE design made for Vespa mopeds >>>> Same model # as bigger rounder cousin
1 choke lever Vespa N/A comes in different lengths/shapes
6 slide throttle N/A
7 see 5mm jets above item#28
8 float N/A
219625 9 adjuster M5 for elbow $2
219626 10 lock nut M5 for adjuster $1
11 elbow 90-deg M6 for throttle cable $8 Vespa Ciao
elbow 60-deg M6 for throttle cable $7 most
12 lock nut M6 for elbow $1
13 screw M4 special for carb top (2) $1
14 carb top Vespa N/A notice there’s no carb top gasket
15 spring throttle return N/A
16 nut M6 for clamp bolt $2
219591 17 spring for choke plate $3
18 pivot bolt choke $3
19 bolt M5 for fuel inlet banjo $2
20 seal washer M5x8 $3
21 intake sleeve 16 x 18mm N/A  smaller than regular SHA carb body 20mm
22 banjo fuel inlet contains filter $12
23 fuel filter $8
24 seal washer $2
25 clamp bolt M6 $8
219588 26 spring for idle screw $2
27 idle screw $4
219593 28 hinge pin float $2 never needed except when mishandled or lost
219589 29 float needle lets fuel in when needed $10 this and a dirty seat is what makes it leak gas
219594 30 gasket float bowl $3 not usually the cure for gas leaks
31 float bowl used metal $5 old ones were metal new ones are plastic
32 float bowl screw M4 x 0.75 x 20 (2) $2
air filter screen N/A
clamp air filter with screw $5
air box Ciao 3-holes inside N/A Ciao/Bravo
air box Ciao 6-holes inside N/A Grande

3  B I N G    P U C H

==================================================================================

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part # # ←picture#………Description Price Applications
###### ### ############################# #### #################################
B I N G…P U C H…C A R B U R E T O R Used only on Puch mopeds and compatibles
intake ID=20mm…air box OD=20mm over 20 other Puch carbs…see Service Department
Marking… Jet Needle Jet Slide Needle here are all of the common 30mph 2hp carbs
14mm 1/14/152 #64jet/2.20 tube/24slide/2 N/A 1976 Maxi N/Maxi S/Nostalgic
14mm 1/14/160 #64jet/2.22 tube/24slide/1 N/A 77-79 GN/Maxi…77 Maxi-S/Newport
14mm 1/14/185 #64jet/2.22 tube/24slide/1 N/A 80-86 Maxi/Sport LS
14mm 1/14/163 #68jet/2.12Atube/11slide/2 N/A 1978 Sears Free Spirit
12mm 1/12/293 #60jet/2.22 tube/24slide/2 N/A 1978 Maxi Luxe/Sport/Newport
12mm 1/12/307 #58jet/2.12Atube/11slide/2 N/A 79-80 Maxi Luxe/Sport/Newport…78 Sport MkII
12mm 1/12/314 #56jet/2.22 tube/24slide/2 N/A 79-80 Maxi II/Sport MkII/Newport II
12mm 1/12/316 #64jet/2.12Atube/11slide/2 N/A 78-79 Magnum XK
12mm 1/12/322 #60jet/2.12Atube/51slide/2 N/A 78-80 Magnum II/MkII
14mm 1/14/196 #68jet/2.17 tube/24slide/2 N/A 84-86 Cobra/Cobra 2… 84-on had bigger jets
14mm 1/14/203 #70jet/2.17 tube/24slide/2 N/A 84-86 Cobra 2 1.5hp 84-on had bigger jets
15mm 1/15/46A #82jet/2.17 tube/24slide/1 $110 jetted rich for a modified bike with no air box
Swap the jet/needle jet/carb top/elbow >>>> from original carb to re-configure it to your model
1 jet M3.5 #46 original 0.0175″=0.445mm N/A 76-85 Tomos A3 Bullet/Silver Bullet
1 jet M3.5 #48 original 0.0182″=0.462mm N/A
1 jet M3.5 #50 original 0.0188″=0.478mm N/A
1 jet M3.5 #52 original 0.0194″=0.493mm $7 76-78 Batavus M48 VA/HS50/Mobat/Bronco/Starflite
335000 1 jet M3.5 #50 =true53 0.0195″=0.495mm $7
1 jet M3.5 #54 original 0.0200″=0.508mm $7
335200 1 jet M3.5 #52 =true55 0.0204″=0.518mm $7
1 jet M3.5 #56 original 0.0206″=0.523mm N/A 78-79 Batavus M56 80-83 Trac Clipper/Eagle/Hawk
1 jet M3.5 #58 original 0.0213″=0.541mm N/A 79-80 Puch Maxi Luxe/Sport/Newport 12mmcarb
335600 1 jet M3.5 #56 =true59 0.0217″=0.551mm $7
1 jet M3.5 #60 original 0.0222″=0.564mm N/A 78 Puch Maxi Luxe/Sport/Newport 12mmcarb
335800 1 jet M3.5 #58 =true62 0.0228″=0.579mm $7
1 jet M3.5 #62 original 0.0229″=0.582mm $7
1 jet M3.5 #64 original 0.0234″=0.594mm N/A 74-80 Puch Maxi 14mm carb 30mph version
336000 1 jet M3.5 #60 =true64 0.0235″=0.597mm $7
1 jet M3.5 #66 original 0.0239″=0.607mm N/A
336200 1 jet M3.5 #62 =true66 0.0242″=0.615mm $7
1 jet M3.5 #68 original 0.0248″=0.630mm N/A 1978 Sears Free Spirit 14mm carb 30mph version
336400 1 jet M3.5 #64 =true68 0.0248″=0.630mm $7 76-80 Kreidler Flory 12mmcarb not Puch
1 jet M3.5 #70 original 0.0254″=0.645mm N/A
336600 1 jet M3.5 #66 =true71 0.0258″=0.655mm $7
1 jet M3.5 #72 original 0.0260″=0.660mm N/A
1 jet M3.5 #74 original 0.0267″=0.678mm N/A
336800 1 jet M3.5 #68 =true74 0.0268″=0.681mm $7
1 jet M3.5 #76 original 0.0273″=0.693mm N/A
337000 1 jet M3.5 #70 =true77 0.0278″=0.706mm $7
1 jet M3.5 #78 original 0.0280″=0.711mm N/A
1 jet M3.5 #80 original 0.0287″=0.729mm N/A
1 jet M3.5 #82 original 0.0294″=0.747mm $7 Bing 15mm carb oversize can be reconfigured
2 needle jet 2.22 inner diameter $8 see carb configurations above
2 needle jet 2.12A inner diameter $18 the 2.12A flows like a 2.22 for some reason
2 needle jet 2.17 inner diameter $8 the 2.17 flows a lot less than a 2.22 this matters
3 slide throttle original #11 N/A 2.22 needle jet/60jet = 2.17 needle jet/68jet
350200 3 slide throttle original #24 $12 change from 2.17 to 2.22 lowers jet by 6 to 8 sizes
3 slide throttle original #51 $20 see carb configurations above to confirm this
4 needle throttle original 2-mark $12 see carb configurations above
350300 4 needle throttle original 1-mark $12 see carb configurations above
5 clip for throttle needle $2
6 washer $1 not needed
7 spring throttle return $8
350700 8 gasket carb top $2 for resisting water…is not needed for running
9 carb top only new race-track-shape $7
carb top assy 9+13+32 used $10
10 screw M4 for carb top (2) $1
11 adjuster M5 for elbow $2 if too loose choke will stay on loss of top speed
12 lock nut M5 for adjuster $1 if too tight engine will idle too fast or “race”
13 clip for choke rod…inside carb top $2 not shown…it’s click keeps choke in off position
14 elbow carb M6 for throttle cable long $12 74-86 Puch-Maxi/Sport/Newport/sheet frames
14 elbow carb M6 for throttle cable short $12 78-86 Puch Magnum/Sears Free Spirit/tube frames
15 lock nut M6 for elbow $1
16 idle screw $3
17 spring for idle screw $3
351700 18 float $20
351800 19 hinge pin float $4
351900 20 float needle…Viton rubber tip $22 lets fuel in only when float bowl gets low
21 float bowl used metal $8
352100 22 gasket float bowl $4
choke rod extension black not shown $5 74-86 Puch-Maxi/Sport/Newport/sheet frames
24 banjo fuel inlet steel upgrade $10
25 banjo bolt $3
26 seal washer M8 (2) paper $1
044584 26 seal washer M8 (2) copper $1
27 fuel filter $12
28 clamp bolt M5 special $3
29 tickler $3
30 spring for tickler $2
31 cottor pin for tickler spring $1
350500 32 slide choke $10
33 rod choke $4
585200 Air filter box complete Puch Maxi $25 74-86 Puch-Maxi/Sport/Newport/sheet frames
Air filter box complete Puch Magnum N/A 78-86 Puch Magnum/Sears Free Spirit/tube frames

4  B I N G   S A C H S

=================================================================================

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part # # ←picture#………Description Price Applications
###### ### ############################# #### ##################################
B I N G…S A C H S…C A R B U R E T O R Used only on Sachs moped engines
intake ID=20mm…air box-bolt-on
10mm 85/10/101 50jet old-style float+needle N/A 76-77 Sachs 504/1B and 505/1B 25kph (18mph)
10mm 85/10/101A 50jet new-style float+needle N/A 78-79 Sachs 504/1B and 505/1B 25kph (18mph)
12mm 85/12/101 52jet old-style float+needle N/A 76-77 Sachs 504/1A and 505/1A 40kph (26mph)
12mm 85/12/101A 52jet new-style float+needle N/A 78-79 Sachs 504/1A and 505/1A 40kph (26mph)
12mm 85/12/104A 58jet new-style float+needle N/A 79-80 Sachs 504/1D and 505/1D………… 30mph
12mm 85/12/115 N/A
12mm 85/12/118A N/A
old-style float is not notched old all-metal needle does not lock into float
new-style float is notched for needle new rubber tip needle locks into float notch
1 jet M4 #45 0.0171″=0.434mm N/A
1 jet M4 #50 0.0183″=0.465mm N/A 76-79 Sachs 504/1B and 505/1B 25kph (18mph)
1 jet M4 #52 0.0190″=0.483mm N/A 76-79 Sachs 504/1A and 505/1A 40kph (26mph)
1 jet M4 #55 0.0203″=0.516mm N/A
1 jet M4 #58 0.0213″=0.541mm N/A 79-80 Sachs 504/1D and 505/1D………… 30mph
2 needle jet 2.17 inner diameter $12
3 fuel filter $7
4 slide throttle $15 76-78 Sachs all others
4 slide throttle for D-engine N/A 79-80 Sachs 504/1D and 505/1D………… 30mph
5 needle throttle 33mm $8 76-78 Sachs all others
2 needle throttle 36mm for D-engine N/A 79-80 Sachs 504/1D and 505/1D………… 30mph
6 clip for throttle needle $3
7 washer $1 not needed
8 spring throttle return $10
9 gasket carb top $2 just keeps water out does not affect running
10 carb top $10
11 screw M4 for carb top (2) $2
12 elbow carb M7 for throttle cable long $12
12 elbow carb M7 for throttle cable short $12
13 locknut M7 for carb elbow $2
14 locknut M6 for cable adjuster $1
15 adjuster M6 for throttle cable $3
19 clamp bolt M6 $3
20 idle screw $5
21 spring for idle screw $3
22 float needle lets fuel in when needed N/A
351900 22 float needle rubber tip same as Puch $20
23 float with needle original new $45
24 hinge pin float $2
25 float bowl used metal $8
26 screw M4 for float bowl (2) $1
27 gasket float bowl $20 original cork one
gasket float bowl substitute $8 must stretch and place it in carefully
28 banjo fuel inlet steel upgrade $10 some just have a straight-up spigot no banjo
29 banjo bolt $12 not nut as shown
30 seal washer 8mm $1
31 tickler $5
32 spring for tickler $3
33 cottor pin for tickler spring $2
air box front half N/A
choke plate/slide fits into air box N/A
air filter original…also a spacer N/A
air filter substitute…spacer plus foam $20
air box rear half N/A
wire clip for air box N/A

 

Sachs air filter front half

Sachs air filter front half

Sachs Bing carb and air filter assembly

 

 

 

 

 

 

 

 

 

 

Above, a Sachs Bing carburetor and air filter assembly. First the grey steel plate goes inside the white plastic box front half. Then the two M5x12 screws bolt it to the carburetor. Then the choke cable is fed through the box half, The choke cable spring is slid over the end of the choke cable. Then the white plastic choke plate, at far lower left,  is attached to the small barrel end of the choke cable. This is done with the choke cable detached from the lever at the handlebar. When it’s all hooked up, squeezing the choke trigger moves the choke plate forward, blocking off the air. Releasing the choke trigger causes the spring to pull the choke plate back away, allowing full air in for normal running.

 

 

 

 

 

 

 

 

 

 

 

5  E N C A R W I    T O M O S

================================================================================

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

###### ### ############################# #### ##################################
B I N G..E N C A R W I…T O M O S..C A R B Used only on early Tomos almost same as Batavus
The simplest moped carb Services from sides without (difficult) removal
209070 A-83… 46jet servicable from the sides N/A 76-85 Tomos A3 Bullet/Silver Bullet 30mph
209116 1 jet M3.5 #46…see Bing Puch carb jets N/A choke is from a hole in the throttle slide
206765 2 jet holder $8 thumb switch lets throttle below normal “zero”
209118 3 slide throttle N/A this makes the throttle cable fully slack
209003 4 spring throttle return $3 which exposes the hole and puts on the choke
206763 5 carb top screw-on type $12
206770 11 float $22 straighten it and spin it to re-cut the tip straight
206772 12 float top $25
206771 13 gasket for float top $3
14 banjo fuel inlet steel upgrade $10 replaces plastic one but requires two seal washers
206775 16 banjo bolt $7
206774 17 fuel filter N/A
027053 18 screw M4 for float top $1
200384 19 air filter original metal mesh N/A Delorto one is close but too big
air filter substitute filter foam+screen $7 5/8″x2″round filter foam plus 1/4″wire screen
027079 20 clamp bolt $5
209216 junction sleeve rubber…carb to air box N/A without this it would need a bigger jet maybe #50
209215 air box for intake silencing $20 must remove engine to get to air box (silencer)
209217 inlet tube connector $3
209579 inlet tube under seat inside frame $3 insect cocoon often restricts air after long storage

6  E N C A R W I   B A T A V U S

================================================================================

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
B I N G..E N C A R W I…B A T A V U S Used only on 76-78 Batavus…Laura M48 engine
Located below engine…longer cables 76-78 Batavus M48 VA/HS50/Mobat/Bronco/Starflite
12mm S25… 12mm 56jet/167slide/Ø16 air box N/A 76-78 Batavus Laura M48 engine 30mph models
8mm S8A… 8mm 52jet/190slide/Ø14 air box N/A 76-78 Batavus Laura M48 engine 25mph models
8mm S23A 8mm 50jet/190slide/Ø14 air box N/A 76-78 Batavus Laura M48 engine 20mph models
1 jet M3.5 #52…see Bing Puch carb jets N/A
2 jet holder $10
3 slide throttle N/A
4 spring throttle return N/A same as Encarwi Tomos Carb above
5 carb top screw-on type $12 same as Encarwi Tomos Carb above
9 idle screw $5
10 idle screw spring $2
11 float N/A same as Encarwi Tomos Carb above
12 float top N/A same as Encarwi Tomos Carb above
13 gasket for float top $5 same as Encarwi Tomos Carb above
14 banjo fuel inlet steel upgrade $10 replaces plastic one but requires two seal washers
16 banjo bolt $7
17 fuel filter N/A
18 screw M4 for float top $1
20 clamp bolt $5
21 choke plate $7
22 bolt choke pivot $3
23 spring choke $3
24 air filter original metal mesh N/A air filter needs air box to hold it or it will fall off
air filter substitute filter foam+screen $7 5/8″x2″round filter foam plus 1/4″wire screen
25 air box 30mph inlet 16mm N/A
25 air box 25&20 inlet 14mm $35
26 rubber band for spacing and sealing N/A without this the clip is loose…air box falls off
27 wire clip for holding air box on $10 no wonder Batavus air boxes are extremely rare

7  E N C A R W I    T R A C

================================================================================

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

# ←picture#………Description Price      Applications
### ############################# #### ##################################
B I N G.. E N C A R W I…T R A C M.. 5 6 78-80 Batavus Regency Laura M56 engine
Servicable without removal 79-83 Trac Clipper/Eagle/Hawk M56 remake
H12/101 12mm 56jet N/A 30mph models case reed valve toothed belt
H12/101 12mm 56jet N/A 25mph models case reed valve toothed belt
H8/102… 8mm 46jet N/A 20mph models case reed valve toothed belt
1 jet M3.5 #56…see Bing Puch carb jets N/A
2 jet holder $15
3 slide throttle N/A
4 spring throttle return $6 carb bolts to engine case…no intake manifold
5 carb top N/A
6 rubber cover over carb top $7
7 screw carb top (1) $1
9 float $25 straighten it and spin it to re-cut the tip straight
10 float top has no vent hole unlike others $25
11 gasket for float top $4
12 banjo fuel inlet steel upgrade $10 replaces plastic one but requires 2 seal washers
13 seal washer for banjo 8mm (2) $1
14 banjo bolt $7
15 fuel filter $8
16 screw M4 for float top $2
18 idle screw $5
19 spring for idle screw $2
20 choke slide $20 super rare
21 rubber o-ring for choke slide (2) $6 tiny and thin like 1mm thick 8mm diameter
choke cable wire (univ. throttle) $6 end of choke slide unscrews, uses throttle wire
23 spring choke return $6
air box with filter…long flat plastic N/A these break near the carburetor hole
screw M5 for air box (2) $1

 

8   O T H E R    C A R B S

=====================================================================================

There are many more moped carburetors. Besides the “semi-universal” ones above, there are these carbs:

Gurtner (Motobecane) Click to link to Motobecane Parts. Scroll down to Gurtner carbs.
Gurtner (Peugeot)   under construction..
Bing (Kreidler)   under construction..
Bing (Solo)   under construction..
Bing (Allstate)   under construction..
Jikov (Jawa)   under construction..
Pacco (Kinetic)   under construction..
Pacco (Avanti)   under construction..
Keihin (Honda NC50)   under construction..
Mikuni (Yamaha QT50)   under construction..

Frame parts, seats, forks, shocks etc

October 1, 2012

CONTENTS:  Welcome    1   Seats & Parts     2 Reflectors

3  Covers & Panels     4  Forks     5  Rear Shocks   6 Frame Parts

Welcome to frame parts. 

1  S E A T S

===============================================================================

Part # # ←picture#………Description Price..      Applications
………… … S…E…A…T…S…………………
bicycle seats have a 7/8″=22mm clamp seat poles are 24-35mm w/22mm top end
many used seats for walk-in sales only coming soon: seat pole sizes &      Apps
4904 seat single w/springs $20 any moped with a bicycle-style seat pole
36096 seat single deluxe w/springs $30 any moped with a bicycle-style seat pole
36098 seat single deluxe XL with/springs $40 any moped with a bicycle-style seat pole
seat single Puch original fresh $120 Puch Maxi
seat single Puch recovered w/pleats $100 Puch Maxi
seat single Peugeot new w/1″post $40 Peugeot 103 and others with 1″ hole
36211 seat banana small black for 16″ bike $20 requires rear sissy bar Do It Yourself
36221 seat banana med black for 20″bike $20 requires rear sissy bar DIY
36296 seat banana large black for 26″bike $20 requires rear sissy bar DIY
seat long with F&R mounts $100 requires bicycle-style seat pole
front mount for Puch Maxi long seat $20 Puch Maxi replaces the pole
seat medium for Puch Sport N/A Puch Sport and Sport MkII
seat long for Batavus HS50 fresh $150 Batavus HS50/Mobat xlnt cond
seat long for Vespa Grande rough $20 covered tightly in cloth fabric

 

 

2  R E F L E C T O R S

 

===============================================================================

To be added to later. Many reflectors are available.

 

3  C O V E R S   &   P A N E L S

===============================================================================

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
………S..I..D..E…..P..A..N..E..L..S………
410200 side panel set Puch black new $50 Puch 1-spd step-thrus 74-86
side panel set Puch black used xlnt $60 Puch 1-spd step-thrus 74-86
side panel set Puch black used rough $30 Puch 1-spd step-thrus 74-86
side panel set Puch2sp black used xlnt $70 Puch 2-spd step-thrus 78-86
side panel set Puch2sp black used rough $40 Puch 2-spd step-thrus 78-86
side panel set Puch Magnum black N/A Puch top-tanks/Sears Free Spirit
204900 side panel screw w/knob Puch M5x45 $8 Puch Maxi: 2 on right 1 on left
205100 side panel screw w/knob Puch M5x35 $8 Puch Maxi: 2 on left 1 on right
632607 side panel screw w/knob Puch M5x15 $5 Puch Magnum/Sears Free Spirit
side panel screw phillips Puch M5x45 $1 replaces original costs less
side panel screw phillipsPuch M5x35 $1 replaces original costs less
side panel screw wide slot M5x15 $1 Peugeot/Puch Magnum/Sears/others
side panel set Peugeot 103 black remake $70 Peugeot 103
side panel set Peugeot 102 used good $70 Peugeot 102
side panel set Motobecane 50 used rough $80 Motobecane Mobylette 50/50V
side panel set Motobecane 40 new white $100 Motobecane Mobylette 40 hard tail
side panel screw Motobecane M5x0.9×15 N/A must tap to M5x0.8
side panel screw wide slot M5x0.8×15 $1 replaces MB after re-threading
side panel set Tomos A3 used metal N/A Tomos 75-95
side panel set Tomos A35 used plastic N/A Tomos 96-06
side panel R Tomos A35 gloss black new $55 Tomos 96-06 ST LX
side panel L Tomos A35 gloss black new $55 Tomos 96-06 ST LX
side panel R Tomos A55 gloss black new $65 Tomos 07-on Sprint ST LX non-black
side panel L Tomos A55 gloss black new $55 Tomos 07-on Sprint ST LX non-black
side panel R Tomos A55 flat black new $65 Tomos 07-on Sprint ST LX black frame
side panel L Tomos A55 flat black new $55 Tomos 07-on Sprint ST LX black frame
side panel R Tomos A55 chrome new $70 Tomos 01-on Revival Streetmate
side panel L Tomos A55 chrome new $60 Tomos 01-on Revival Streetmate
 ….E..N..G..I..N..E…..C..O..V..E..R..S…
magneto cover Sachs 504 chrome used $15 Foxi/Sachs/Flying Dutchman
magneto cover Sachs 505 bigger used $15 Sachs Balboa/Prima/General/others
magneto cover Puch used rough $15 Puch
magneto cover Peugeot alum rough $15 Peugeot
magneto cover Motobecane rough $20 Motobecane
magneto cover Batavus 76-78 N/A Batavus M48 engine
magneto cover Batavus 78-79/Trac 79-83 $20 Batavus M56 engine later became Trac

 

 

4  F R O N T   F O R K S

===============================================================================

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
…… F…R…O…N…T……F…O…R…K…S……
fork assy used straight Puch Maxi $100 Puch Maxi
fork assy used straight Motobecane $80 Motobecane
fork assy used straight Tomos early $100 Tomos 75-85
fork assy used straight Tomos N/A Tomos 86-06
fork assy used straight Batavus $100 Batavus 76-78
fork assy used straight Peugeot 103 LVS $100 Peugeot 103 LVS 76-80
fork assy used straight Peugeot 103 SP N/A Peugeot 103 SP 78-80 longer
many other used straight forks call
fork assy new Tomos Sprint/ST/LX silver Tomos 07-later Sprint/ST/LX
fork assy new Tomos Revival longer silver Tomos 07-later Revival&Streetmate
fork assy new Tomos Streetmate-R black Tomos 07-later Revival&Streetmate
fork tube one Peugeot 103 LVS new $50 Peugeot 103 LVS 76-80
fork tube one Peugeot 103 SP new $65 Peugeot 103 SP 78-80 longer
fork tube one Tomos A35 new $40 Tomos A3/A35 86-06
fork tube one used w/bushings Puch $45 Puch Maxi 75-86
fork bushing one nylon Puch Maxi $20 scarce Puch Maxi 75-86
fork top nut open hole early Puch Maxi $8 fits almost all mopeds
fork top nut closed late Puch Maxi $10 fits almost all mopeds

 

5  R E A R   S H O C K S

===============================================================================

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
…… R… E…A…R……S…H…O…C…K…S……
shocks pair 11″… …280x10mm HD chrome $75 Tomos all except Revival&Streetmate
shocks pair 2″… …305x12mm HD chrome $70 Puch Maxi requires old 8×12 sleeves
shocks pair 12.3/4″ 325x10mm HD chrome $70 raises-up a regular Tomos
221032 shock one 12.3/4″ 325x10mm StreetmateR $50 Tomos Streetmate-R compliant

 

6  F R A M E    P A R T S

===============================================================================

Included here will be steering bearings, all explained, measured, and categorized, and other frame related parts. For sure the Puch and Tomos steering tube thread is M26 x 1.0. So a Puch fork will fit a Motobecane flywheel. Ha ha. That’s all for now. Please wait..


Pistons, Rings, Top End Parts

September 29, 2012

 CONTENTS:   Welcome   1  Rings     2  Pistons     3   Top End Parts

Welcome. Break a ring, how not to: Two stroke pistons have little pins (stumps, bumps) in the piston ring grooves that prevent the rings from rotating. Knowing where each ring locating pin is, and aligning the ring gap over the pin during cylinder installation, is the key to not breaking the ring. 

Measuring wear: A new piston ring is a the best tool to measure how worn a cylinder is. Conversely, a new cylinder is the best tool to measure how worn a ring is. To measure the wear of a ring, you need a perfectly round cylinder of a precisely known bore. A worn cylinder that has not been honed will still have it’s original new bore at the very top, above where the rings rub at. A new ring in a new cylinder should have a very small end gap of .004 to .008″. A worn but still OK cylinder with a new ring will have a gap of .0010 to .018″. A worn cylinder and ring both will have an end gap of over .020″(.5mm). A badly worn cylinder and/or ring will have a huge gap, over .030″(.75mm). You measure ring gap with a feeler gauge.

Getting the right rings: If your model is not in the applications, then you must measure the bore and the ring thickness. A calipers is the best tool to measure the bore (ring diameter) and ring thickness. Sometimes your rings might not be original, for many reasons. The piston might be aftermarket with thinner rings. The cylinder might be bored out to an oversize bore. Some mopeds came with more than one piston size or ring style. 

1  R I N G S

=================================================================================

Part # #                Description Price           Applications
###### ### ############################ #### ##################################
… P I S T O N … R I N G S … FG (foro grano) = ring pin is on side of ring groove
Diameter/Thickness/Style/Width/Qty GI (grano interno) = ring pin is in center of groove
229812 ring 36.50 x 1.50 FG (side pin) each $10 Tomos MC36 36cc
SachsD ring 38.00 x 1.50 GI (center pin) each $10 Sachs 1979-later 504, 505 1C,1D (upper only)
233707 ring 38.00 x 1.5/1.3FG trapezoid W=1.6 ea $17 Tomos A55 (2001-06) superceeded to rectangular
DerbiL ring 38.00 x 1.50 FG (side pin) each $10 Tomos A35 (1991-06), A55 (2007-on)
DerbiL ……….continued Derbi 1976-1985 (lower ring only)
DerbiU ring 38.00 L-ring w=1.49/.47, h= 1.97/.97 $10 Derbi 1976-1985 (upper ring) fits Puch loose inner
PuchL ring 38.00 L-ring w=1.68/.73, h = 1.98/.98 n.a. Puch 1979-1980 deluxe models upper
203300 ring 38.00 x 2.00 FG (side pin) each $10 Puch (except hi-torque late with L-ring upper)
Sachs ……….continued Sachs 504, 505 1A,1B (both) 1C,1D (lower only)
044754 ……….continued Tomos A3 1975-1990, Solo, Morini S5K2, others
Allstate ring 38.00 x 2.50 FG (side pin) set of 2 $20 Minarelli V1 1hp 20mph, Sears Allstate, early Puch
Solex45 ring 38.00 x 2.50 flat gap n.a. Solex 45cc 1946-1954
Vespa ring 38.20 x 1.50 FG (side pin) each $20 must file down a #227758 38.5 Tomos A35 o/s
Vespa ring 38.20 x 2.00 FG (side pin) each $20 must file down a #077775 Vespa pre-78 ring
VespaL ring 38.20 L-ring w=1.85/.76 h=1.98/.99 $15 Vespa 79-later & some 78s upper ring
VespaO ring 38.40 x 1.50 FG (side pin) each $15 oversize for Vespa 79-later & some 78s
Kinetic ring 38.40 x 1.5/1.3 FG trapezoidal n.a. Kinetic (vespa copy) 95-later
077775 ring 38.40 x 2.00 FG (side pin) each $12 Vespa 77-earlier & some 78s, early Kinetic
227758 ring 38.50 x 1.50 FG (side pin) each $12 oversize for Tomos A35
044751 ring 38.50 x 2.00 FG (side pin) each $10 oversize for Tomos A3
SachsO ring 38.60 x 2.00 FG (side pin) each $15 oversize for Sachs 504, 505
4635 ring 38.70 x 1.50 FG (side pin) each $17 Minarelli V1 1.5,2hp 25,30mph (after 1979)
4640 ring 38.80 x 1.50 FG (side pin) each $20 Minarelli V1 1.5,2hp 25,30mph (until 1979)
710095 ring 39.00 L-ring w=1.65/.63 h=1.99/.99 $25 Morini S5R, S5T, S5E, S5ET kids off road, upper
710159 ring 39.00 x 1.00 GI (center pin) each $20 for some LEM dirt bikes Morini #261060
4650 ring 39.00 x 1.50 FG (side pin) each $17 1st oversize for Minarelli V1 1.5,2hp 25,30mph
261044 ……….continued $17 Morini S5R, S5T, S5E, S5ET kids off road, lower
551906 ring 39.00 x 2.00 GI (center pin) each $12 Motobecane (GI after July 1975), Jawa
MBside ring 39.00 x 2.00 FG (side pin) each $15 Motobecane (FG before July ’75)
MBside ……….continued DiBlasi folding mini-cycle
281220 ring 39.00 x 2.00 x 1.65 GI each $15 Jawa standard original
4660 ring 39.20 x 1.50 FG (side pin) each $17 2nd oversize for Minarelli V1 1.5,2hp 25,30mph
4670 ring 39.40 x 1.50 FG (side pin) each $17 3rd oversize for Minarelli V1 1.5,2hp 25,30mph
HDM50 ring 39.40 x 1.50 GI (center pin) each n.a. Harley Davidson M50 std 1966-67
Solex ring 39.50 x 1.70 flat gap w=1.6 n.a. Solex rings (3) no locating pins
mystery ring 39.50?x2.00 FG (side pin) each $12 a complete unknown like a rolling stone
mysteryL ring 39.50? L-ring w=1.59/.69 h=1.99/.99 $15 a complete unknown like a rolling stone
4680 ring 39.60 x 1.50 FG (side pin) each $17 4th oversize for Minarelli V1 1.5,2hp 25,30mph
4690 ring 39.80 x 1.50 FG (side pin) each $17 5th oversize for Minarelli V1 1.5,2hp 25,30mph
633086 ring 40.00 x 1.2/1.0 FG trapezoid w=1.6 pr $30 China 49cc two-strokes most
PGOup ring 40.00 x 1.2/1.0 GI trapezoid w=1.7 ea $17 PGO Star 50 upper, other Asian 49cc
PGOlow ring 40.00 x 1.20 GI (center pin) w=1.85 ea $15 PGO Star 50 lower, others
Honda ring 40.00 x 1.5/1.3 FG trapezoid w=1.8 n.a. upper ring for Honda NC50,PA50
Honda ……….continued upper ring for Yamaha QT50, others
551916 ring 40.00 x 1.50 FG (side pin) each $15 Batavus M48, M56, Trac
Honda ……….continued lower for Honda NC50,PA50, Yamaha QT50
Benelli ……….continued $15 Benelli, only the box says Benelli
551913 ring 40.00 x 1.50 GI (center pin) each $15 Verona (like Morini MO-1 but 40mm not 40.4)
Kreidler ……….continued Derbi 1986-1989 “Start” flat case reed, Kreidler
30702100 ring 40.00 x 2.00 FG (side pin) each $12 Casal, Garelli, Avanti (can have Trac 1.5 rings)
Peugeot ring 40.00 x 2.50 GI (center pin) each $20 Peugeot 102, 103 (almost all US models)
30802700 ring 40.20 x 2.00 FG (side pin) each $15 1st oversize for Garelli
633087 ring 40.25 x 1.00 FG (side pin) set of 2 $25 oversize for China 49cc two-strokes
Honda ring 40.25 x 1.5/1.3 FG trapezoid w=1.8 n.a. 1st oversize for Honda NC50,PA50 upper
Honda ring 40.25 x 1.50 FG (side pin) each n.a. 1st oversize for Honda NC50,PA50 lower
4643 ring 40.30 x 1.50 FG (side pin) each Minarelli V1HL, both
4641a ring 40.30 x 1.50 FG (side pin) each Minarelli V1L, lower
4641b ring 40.30 L-ring w=1.79/.67 h=1.97/1.00 Minarelli V1L, upper
551905 ring 40.40 x 2.00 FG (side pin) each $12 2os for Garelli, Batavus, Dailim DP50,DK50
30802800 ring 40.40 x 2.00 FG (side pin) each $15 2nd oversize for Garelli, original
261045 ring 40.40 x 1.50 GI (center pin) set of 2 $20 Morini MO1, MO2, M1 engines
Honda ring 40.50 x 1.5/1.3 FG trapezoid w=1.8 n.a. 2nd oversize for Honda NC50,PA50 upper
632758 ring 40.50 x 1.50 FG (side pin) each $12 2os Honda NC50,PA50 lower, Batavus oversize
PeugOS ring 40.50 x 2.50 GI (center pin) each $12 some Peugeot 102, 103, but none in California
261046/6 ring 40.60 x 1.50 GI (center pin) each n.a. 1st oversize for Morini MO1, MO2, M1 engines
4651a ring 40.60 x 1.50 FG (side pin) each $15 Minarelli V1L 1st oversize, lower
30802900 ring 40.60 x 2.00 FG (side pin) each $20 3rd oversize for Garelli
4651b ring 40.60 L-ring w=1.79/.67 h=1.97/1.00 $15 Minarelli V1L 1st oversize, upper
Honda ring 40.75 x 1.5/1.3 FG trapezoid w=1.8 n.a. 3os Honda NC50,PA50 upper, #130A4-GA6-003
Honda ring 40.75 x 1.50 FG (side pin) each n.a. 3os Honda NC50,PA50 lower, #130A4-GA6-003
261046/8 ring 40.80 x 1.50 GI (center pin) each $15 2nd oversize for Morini MO1, MO2, M1 engines
Gyro ring 41.00 x 1.20 GI (center pin) set of 2 n.a. Honda Gyro std rings #13010-GJ5-015 =set
632795 ring 41.00 x 1.5/1.3 GI trapezoid w=1.8 $15 Suzuki FY50,FZ50,FA50

 

         2  P I S T O N S

=====================================================

It’s important that the piston fits the cylinder properly. An old messed up piston that fits correctly is better than a new piston that fits too loose or too tight. Too loose will be hard to start and weak. Too tight will seize up when hot. Often a cylinder needs to be bored out slightly to fit an oversize piston. Some aluminum cylinders have plated walls that cannot be bored out. The piston diameter, measured at the skirt, is a hair smaller than the cylinder bore. The following piston/cylinder clearance limits are from the Puch factory service manual:

Plated aluminum 7-fin cylinder:  Min .0008“(.020mm)   Max .0016“(.040mm) 

Hi-tor 8-fin, Mag 9-fin cylinders:  Min .001″  (.029mm)    Max .002“(.055mm)

As the engine gets hot, the piston to cylinder clearance approaches zero.

Besides D, H, Ø, S, other things matter in piston compatibility. The ring pins must locate the ring gaps so they never pass over a port. The exhaust-side skirt must be long enough to cover the exhaust port at tdc. The intake-side skirt, on a piston port two stroke, controls the intake timing. Shorter skirt opens sooner and closes later. A longer intake skirt is one way some mopeds are restricted in power. Simply grind the excessively long piston skirt back to 30mph specification, but no farther, to de-restrict the piston. Puch, Tomos, Garelli are the main kinds that use longer pistons to lower the speed, for 25 and 20mph states or jurisdictions. 

This list contains all pistons made by original equipment manufacturers, although most of them are no longer available. The not-available ones are listed for their information, such as speed versions or piston size choices. If you happen to have an unknown piston with or without a part number, you can identify what it is from this list by measuring it and looking for matching measurements. From all these specifications, perhaps a compatible piston can be found or adapted. 

###### ################################ ### ###############################
install pistons with arrow towards exhaust < piston diameter D is measured at skirt (biggest)
or else rings can snag on ports and break < all new pistons come with new rings, clips, pin >
Abbreviations: 1.2-0F =  trapezoidal ring 1.2 x 1.0 FG gap
FG = foro grano = side pin ring gap style 1.5-3G = trapezoidal ring 1.5 x 1.3 GI gap
GI = grano interno = center pin gap style Dykes = “L” type ring, usually on upper
######  ###  1 0  m m    P I N    P I S T O N S  ###### ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price           Applications
###### ################################ ### ##################################
“38.00″ 10 18.0 24.0 37.94  2.0FG 2.0FG  Mahle n.a. Tomos A3 20mph 1.0hp (55 total, 52 at edge)
“38.00″ 10 18.0 21.0 37.94  2.0FG 2.0FG  Mahle n.a. Tomos A3 25mph 1.5hp (52 total, 49 at edge)
207403 “38.00″ 10 18.0 19.0 37.94  2.0FG 2.0FG  Mahle $50 Tomos A3 30mph 2.0hp (50 total, 47 at edge)
Vertex “38.00″ 10 18.0 19.0 37.95  1.5FG 1.5FG generic $60 aftermarket Tomos A3  (50 total, 47 at edge)
206200 “38.00″ 10 18.0 18.0 37.9x  2.0FG 2.0FG generic n.a. aftermarket Tomos A3  (49 total, 46 at edge)
202420 “38.50″ 10 18.0 19.0 38.45  2.0FG 2.0FG  Mahle $75 Tomos oversize A3 30mph 2hp
Honda “40.00″ 10 20.0 18.0 39.95 1.5-3F 1.5FG  Honda n.a. Honda NC50 Express and PA50 (has decomp cut)
Meteor “38.20″ 10 21.0 17.0 38.13  1.5FG 1.5FG  Meteor $60 aftermarket Vespa compatible but with 10mm pin
632964 “40.00″ 10 21.0 18.0 39.9x 1.2-0F 1.2-0F generic $60 E-Ton 50cc 2-stroke scooter
632965 “40.25″ 10 21.0 18.0 40.1x 1.2-0F 1.2-0F generic $60 oversize for E-Ton 50cc 2-stroke scooter
Yamaha “40.00″ 10 xx.x  xx.x 39.9x 1.5-3F 1.5FG  Yamaha n.a. Yamaha QT50 Yamahopper and PW50
######  ###  1 2  m m    P I N    P I S T O N S  ###### ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   1 6 m m   T A L L   ( P i n   t o  C r o w n )
###### ################################ ### ##################################
69707 “40.00″ 12 16.0 17.0 39.88 2.5GI 2.5GI  Peugeot $90 Peugeot original Sort A
69708 “40.00″ 12 16.0 17.0 39.89 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort B
69709 “40.00″ 12 16.0 17.0 39.90 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort C
peugAA “40.00″ 12 16.0 17.0 39.90 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort AA (=C)
69710 “40.00″ 12 16.0 17.0 39.91 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort D
peugBB “40.00″ 12 16.0 17.0 39.91 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort BB (=D)
Verona “40.00″ 12 16.0 17.0 39.92  1.5GI 1.5GI  Asso n.a. Verona (like MO1), 3mm skirt cut
69711 “40.00″ 12 16.0 17.0 39.92 2.5GI 2.5GI  Peugeot $95 Peugeot original Sort E
PeugCC “40.00″ 12 16.0 17.0 39.92 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort CC (=E)
69712 “40.00″ 12 16.0 17.0 39.93 2.5GI 2.5GI  Peugeot $95 Peugeot original Sort F
MF553-F “40.00″ 12 16.0 17.0 39.93 1.5GI 1.5GI  generic $90 MMI aftermarket for Peugeot
peugDD “40.00″ 12 16.0 17.0 39.93 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort DD (=F)
69713 “40.00″ 12 16.0 17.0 39.94 2.5GI 2.5GI  Peugeot $95 Peugeot original Sort G
peugEE “40.00″ 12 16.0 17.0 39.94 2.5GI 2.5GI  Peugeot $95 Peugeot original Sort EE (=G)
69714 “40.00″ 12 16.0 17.0 39.95 2.5GI 2.5GI  Peugeot $95 Peugeot original Sort H
peugFF “40.00″ 12 16.0 17.0 39.95 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort FF (=H)
69715 “40.00″ 12 16.0 17.0 39.96 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort I
peugGG “40.00″ 12 16.0 17.0 39.96 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort GG
peugHH “40.00″ 12 16.0 17.0 39.97 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort HH
peugII “40.00″ 12 16.0 17.0 39.98 2.5GI 2.5GI  Peugeot n.a. Peugeot original Sort II
MF553-C “40.00″ 12 16.0 17.0 39.95 1.5GI 1.5GI  generic $90 MMI aftermarket for Peugeot
MO4 “40.40″ 12 16.0 17.0 40.33 Dykes 1.5GI  Asso n.a. Mor MO2 foot shift, 3mm cut, “ASSO   1929MO4″
230125 “40.40″ 12 16.0 17.0 40.33  1.5GI 1.5GI $70 Morini MO1,MO2, 3mm skirt cut, says nothing
230125 “40.40″ 12 16.0 17.0 40.34  1.5GI 1.5GI  Asso $70 Morini MO1,MO2, 3mm skirt cut, “ASSO.W  2352″
230134 “40.40″ 12 16.0 17.0 40.34  1.5GI 1.5GI  Asso $80 Morini M1, zero skirt cut away, “ASSO W  1929M1″
230125 “40.40″ 12 16.0 17.0 40.35  1.5GI 1.5GI  Asso $70 Morini MO1,MO2, 3mm skirt cut, “ASSO  1929″
230125 “40.40″ 12 16.0 17.0 40.38  1.5GI 1.5GI  Asso $70 Morini MO1,MO2, 5mm skirt cut, “ASSO.W  2351″
69716 “40.50″ 12 16.0 17.0 40.45 2.5GI 2.5GI  Peugeot $60 Peugeot oversize original Sort K
69717 “40.50″ 12 16.0 17.0 40.46 2.5GI 2.5GI  Peugeot $60 Peugeot oversize original Sort L
69718 “40.50″ 12 16.0 17.0 40.47 2.5GI 2.5GI  Peugeot $60 Peugeot oversize original Sort M
69719 “40.50″ 12 16.0 17.0 40.48 2.5GI 2.5GI  Peugeot $60 Peugeot oversize original Sort N
69720 “40.50″ 12 16.0 17.0 40.49 2.5GI 2.5GI  Peugeot $60 Peugeot oversize original Sort P
69721 “40.50″ 12 16.0 17.0 40.50 2.5GI 2.5GI  Peugeot $60 Peugeot oversize original Sort Q
230126/6 “40.60″ 12 16.0 17.0 40.53  1.5GI 1.5GI  Asso $80 1os Mor MO1,MO2, 3mm skirt cut, “ASSO  1929″
230135/6 “40.60″ 12 16.0 17.0 40.5x  1.5GI 1.5GI  Asso n.a. 1os Mor M1, zero skirt cut away, “ASSO W  1929M1″
230126/8 “40.80″ 12 16.0 17.0 40.72  1.5GI 1.5GI  Asso $85 2os Mor MO1,MO2, 3mm skirt cut, “ASSO  1929″
230135/8 “40.80″ 12 16.0 17.0 40.7x  1.5GI 1.5GI  Asso n.a. 2os Mor M1, zero skirt cut away, “ASSO W  1929M1″
230126/0 “41.00″ 12 16.0 17.0 40.90  1.5GI 1.5GI $85 3os Mor MO1,MO2, 3mm skirt cut, says nothing
###### ################################ ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   1 7 m m   T A L L   ( P i n   t o  C r o w n )
###### ################################ ### ##################################
229803 “36.50″ 12 17.0 18.0 36.43  1.5FG 1.5FG  Vertex $60 Tomos MC36 36cc kids dirt bike
406300 “38.00″ 12 17.0 19.0 37.91  2.0FG 2.0FG  generic $50 Puch early 2000′s aftermarket, way too small
406300 “38.00″ 12 17.0 18.0 37.93  2.0FG 2.0FG  generic $50 Puch aftermarket Step II, made too small
233709 “38.00″ 12 17.0 20.6 37.95 1.5-3F 1.5-3F Vertex n.a. Tomos A55 Alu cyl, pre 2007 with trap. Rings
233709 “38.00″ 12 17.0 20.6 37.95  1.5FG 1.5FG  Vertex n.a. Tomos A55 Alu cyl = 37.98 “07-09 14140 37.98″
409000 “38.00″ 12 17.0 18.0 37.95  1.5FG 1.5FG  generic n.a. aftermarket Tomos A35
223747 “38.00″ 12 17.0 18.0 37.95  1.5FG 1.5FG  Vertex $70 Tomos A35 std, has windows on in side
8025090 “38.00″ 12 17.0 23.0 37.95  Dykes 1.5FG  Mahle n.a. Derbi std 1976-86 says “1003 E 119  A” ?
106.9/21 “38.00″ 12 17.0 20.5 37.95  2.0FG 2.0FG  Mahle n.a. Puch Alu cyl Sort 1 = 37.98  says “38  1  1019″
“38.00″ 12 17.0 20.5 37.95  2.0FG  none  Mahle $95 Puch Alu cyl Sort C = 37.99  says “38  C  1734″
106.9/22 “38.00″ 12 17.0 20.5 37.96  2.0FG 2.0FG  Mahle n.a. Puch Alu cyl Sort 2 = 37.99  says “38  2  1019″
“38.00″ 12 17.0 22.0 37.96  2.0FG 2.0FG  Mahle n.a. Puch H-T cyl Sort 11 38.00  says “38  1  1116″
“38.00″ 12 17.0 23.0 37.96  Dykes 2.0FG  Mahle n.a. Puch H-T cyl Sort 11 38.00  “38.0  11  1593a”
“38.00″ 12 17.0 22.0 37.967 2.0FG 2.0FG Mahle n.a. Puch H-T cyl Sort 22 38.007  says “38  2  1116″
“38.00″ 12 17.0 23.0 37.967 Dykes 2.0FG Mahle n.a. Puch H-T cyl Sort 22 38.007  “38.0  22  1593a”
106.9/23 “38.00″ 12 17.0 20.5 37.97  2.0FG 2.0FG  Mahle n.a. Puch Alu cyl Sort 3 = 38.00  says “38  3  1019″
“38.00″ 12 17.0 23.0 37.974 2.0FG 2.0FG Mahle n.a. Puch H-T cyl Sort 33 38.014  says “38  3  1116″
“38.00″ 12 17.0 23.0 37.974 Dykes 2.0FG Mahle $95 Puch H-T cyl Sort 33 38.014  “38.0  33  1593a”
106.9/24 “38.00″ 12 17.0 20.5 37.98  2.0FG 2.0FG  Mahle n.a. Puch Alu cyl Sort 4 = 38.01  says “38  4  1019″
106.9/24 “38.00″ 12 17.0 20.5 37.98  2.0FG 2.0FG  Mahle $80 Puch Alu cyl Sort 4 = 38.01 good used
106.9/25 “38.00″ 12 17.0 20.5 37.99  2.0FG 2.0FG  Mahle $95 Puch Alu cyl Sort 5 = 38.02  says “38  5  1019″
8025091 “38.25″ 12 17.0 20.0 38.14  Dykes 1.5FG  Mahle $80 Derbi 1os 1976-86 says “1003 E 120  B 0.25″
“38.205″12 17.0 20.0 38.15 Dykes 1.5FG  Mahle $80 Derbi 1os 1976-86 says “1002 E 030″
“38.25″ 12 17.0 20.0 38.16  Dykes 1.5FG  Mahle $95 Derbi 1os 1976-86 says “1003 E 120  A 0.25″
“38.25″ 12 17.0 20.0 38.15  Dykes Dykes Mahle $80 Derbi 1os 1976-86 says “Mahle 10   0.25″
“38.25″ 12 17.0 23.0 38.19  Dykes 2.0FG  Mahle $95 Puch H-T cyl 22 oversize says “38.25  22  1593a”
“38.25″ 12 17.0 23.0 38.19  Dykes 2.0FG  Mahle $95 Puch H-T cyl 22 oversize says “38.25  22  1593a”
8025092 “38.40″ 12 17.0 20.0 38.3?  Dykes 1.5FG  Mahle n.a. 2os for Derbi original 1976-1986
8025093 “38.70″ 12 17.0 20.0 38.6x  Dykes 1.5FG  Mahle n.a. 3os for Derbi original 1976-1986
227334 “38.50″ 12 17.0 20.5 38.4x  1.5FG 1.5FG  Vertex n.a. oversize original for Tomos A35
409001 “38.50″ 12 17.0 20.x 38.4x  1.5FG 1.5FG  generic $60 oversize aftermarket for Tomos A35
8025094 “38.90″ 12 17.0 20.0 38.8x  Dykes 1.5FG  Mahle n.a. 4os for Derbi original 1976-1986
“40.00″ 12 17.0 19.0 39.94 1.5-3F 1.5-3F Yamaha $40 Yamaha what? new, no rings, non avail.
“40.25″ 12 17.0 19.0 40.22 1.5-3F 1.5-3F Yamaha $40 Yamaha what? new, no rings, non avail.
###### ################################ ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   1 8 m m   T A L L   ( P i n   t o  C r o w n )
###### ################################ ### ##################################
2500091 “40.00″ 12 18.0 19.0 39.945 1.5GI 1.5GI  Mahle n.a. Derbi 1986-1989 flat reed eng, Sort A
2500091 “40.00″ 12 18.0 19.0 39.95   1.5GI 1.5GI  Mahle n.a. Derbi 1986-1989 flat reed eng, Sort B
2500091 “40.00″ 12 18.0 19.0 39.955 1.5GI 1.5GI  Mahle n.a. Derbi 1986-1989 flat reed eng, Sort C
2500091 “40.00″ 12 18.0 19.0 39.96   1.5GI 1.5GI  Mahle n.a. Derbi 1986-1989 flat reed eng, Sort D
2500091 “40.00″ 12 18.0 19.0 39.965 1.5GI 1.5GI  Mahle n.a. Derbi 1986-1989 flat reed eng, Sort E
50582150 “40.00″ 12 18.0 ??.?  39.9?  2.0FG 2.0FG  Asso n.a. flat top, Garelli alum cylinder 20,25mph
50882150 “40.00″ 12 18.0 ??.?  39.9?  2.0FG 2.0FG  Asso n.a. flat top, Garelli alum cylinder 30mph
50532181 “40.00″ 12 18.0 ??.?  39.9?  2.0FG 2.0FG  Asso n.a. Garelli cast iron cyl 25mph
408211 “40.00″ 12 18.0 14.0 39.95  1.5FG 1.5FG  generic $60 Batavus, Garelli, Trac, DMC, aftermarket
408201 “40.00″ 12 18.0 16.0 39.95  1.5FG 1.5FG  generic $60 Batavus, Garelli, Trac, DMC, aftermarket
480580 “40.00″ 12 18.0 16.0 39.95  1.5FG 1.5FG  Mahle n.a. Batavus M48 original says 39.95
80016 “40.00″ 12 18.0 16.0 39.9x  1.5FG 1.5FG  Mahle n.a. Batavus/Trac  M56 original Sort A
80017 “40.00″ 12 18.0 16.0 39.9x  1.5FG 1.5FG  Mahle n.a. Batavus/Trac  M56 original Sort B
80018 “40.00″ 12 18.0 16.0 39.98  1.5FG 1.5FG  Mahle n.a. Batavus/Trac  M56 original Sort C
80019 “40.00″ 12 18.0 16.0 39.9x  1.5FG 1.5FG  Mahle n.a. Batavus/Trac  M56 original Sort D
80020 “40.00″ 12 18.0 16.0 40.0x  1.5FG 1.5FG  Mahle n.a. Batavus/Trac  M56 original Sort E
“40.00″ 12 18.0 16.0 40.0x  1.5FG 1.5FG  Mahle n.a. Batavus/Trac  M56 original Sort F
00012184 “40.20″ 12 18.0 16.0 40.1x  2.0FG 2.0FG  Asso n.a. 1os for Garelli cast iron cyl 20,30mph
50532184 “40.20″ 12 18.0 ??.?  40.1x  2.0FG 2.0FG  Asso n.a. 1os for Garelli cast iron cyl 25mph
480581 “40.25″ 12 18.0 16.0 40.20  1.5FG 1.5FG  Mahle $95 1os for Batavus, original
00012182 “40.40″ 12 18.0 16.0 40.3x  2.0FG 2.0FG  Asso n.a. 2os for Garelli cast iron cyl 20,30mph
50532182 “40.40″ 12 18.0 ??.?  40.3x  2.0FG 2.0FG  Asso n.a. 2os for Garelli cast iron cyl 25mph
00012185 “40.60″ 12 18.0 16.0 40.5x  2.0FG 2.0FG  Asso n.a. 3os for Garelli cast iron cyl 20,30mph
50532185 “40.60″ 12 18.0 ??.?  40.5x  2.0FG 2.0FG  Asso n.a. 1os for Garelli cast iron cyl 25mph
00012183 “40.80″ 12 18.0 16.0 40.7x  2.0FG 2.0FG  Asso n.a. 4os for Garelli cast iron cyl 20,30mph
50532183 “40.80″ 12 18.0 ??.?  40.7x  2.0FG 2.0FG  Asso n.a. 2os for Garelli cast iron cyl 25mph
###### ################################ ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   1 9 m m   T A L L   ( P i n   t o  C r o w n )
###### ################################ ### ##################################
2150383d “40.00″ 12 19.0 15.2 39.93  1.5GI 1.5GI  Mahle n.a. Kreidler Flory Sort D “Mahle R021 40l54+”
2150383d “40.00″ 12 19.0 15.2 39.95  1.5GI 1.5GI  Mahle n.a. Kreidler Flory Sort D, cyl=39.98 “R021 40154+”
2150383f “40.00″ 12 19.0 15.2 39.96  1.5GI 1.5GI  Mahle $80 Kreidler Flory Sort F, cyl =39.99 “R021 40154+”
2150383h “40.00″ 12 19.0 15.2 39.97  1.5GI 1.5GI  Mahle n.a. Kreidler Flory Sort H, cyl=40.00 “R021 40154+”
2150383h “40.00″ 12 19.0 15.2 39.98  1.5GI 1.5GI  Mahle n.a. Kreidler Flory Sort M cyl=40.01 “R021 40154+”
230136 “40.40″ 12 19.0 17.0 40.3x  1.5GI 1.5GI  Asso n.a. Morini M101 variator engine
230136/6 “40.60″ 12 19.0 17.0 40.5x  1.5GI 1.5GI  Asso n.a. 1os for Morini M101 variator engine
230136/8 “40.80″ 12 19.0 17.0 40.7x  1.5GI 1.5GI  Asso n.a. 2os for Morini M101 variator engine
###### ################################ ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   2 0 m m   T A L L   ( P i n   t o  C r o w n )
Vespa pistons have skirt cut-outs rotated 30 deg “SC” means scoria (exhaust side)
###### ################################ ### ##################################
VespaN “38.20″ 12 20.0 16.0 38.1x  Dykes 1.5FG  Piaggio n.a. Vespa 1979-later and some 1978
Kinetic “38.40″ 12 20.0 16.0 38.30  1.5-3F 1.5-3F $50 Kinetic (Vespa copy), good used, no arrow
Vespa “38.40″ 12 20.0 16.0 38.32  2.0FG 2.0FG  Piaggio n.a. Vespa 1973-1977 & some 1978
Vespa “38.40″ 12 20.0 16.0 38.32  2.0FG 2.0FG  Piaggio $60 same but good-used with new rings
VespaN1 “38.40″ 12 20.0 16.0 38.32  Dykes 1.5FG  Piaggio $75 1os for Vespa 1979-later & some 78
Vespa1 “38.60″ 12 20.0 16.0 38.5x  2.0FG 2.0FG  Piaggio n.a. 1os for Vespa 1973-1977 & some 78
VespaN2 “38.60″ 12 20.0 16.0 38.5x  Dykes 1.5FG  Piaggio n.a. 1os for Vespa 1973-1977 & some 78
Vespa2 “38.80″ 12 20.0 16.0  38.7x  2.0FG 2.0FG  Piaggio n.a. 2os for Vespa 1973-1977 & some 78, 2.0 FG rings
VespaN3 “38.80″ 12 20.0 16.0 38.74  Dykes 1.5FG  Piaggio n.a. 2os for Vespa 1973-1977 & some 78, L-ring & 1.5 FG
VespaN3 “38.80″ 12 20.0 16.0 38.74  Dykes 1.5FG  Piaggio $60 same but without rings, upper L-ring N/A
633992 “40.00″ 12 20.0 17.0 39.9x 1.2-0F 1.2-0F  generic $60 China 49cc two-strokes
###### ################################ ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   2 1 m m   T A L L   ( P i n   t o  C r o w n )
###### ################################ ### ##################################
4541 “40.30″ 12 21.5 15.0 40.2x  Dykes 1.5FG  Minn. n.a. Minarelli V1L reed valve engine
4543 “40.30″ 12 21.5 15.0 40.2x  Dykes 1.5FG  Minn. n.a. Minarelli V1HL reed valve engine for trike
4551 “40.60″ 12 21.5 15.0 40.5x  Dykes 1.5FG  Minn. n.a. 1os for Minarelli V1L
4553 “40.60″ 12 21.5 15.0 40.5x  Dykes 1.5FG  Minn. n.a. 1os for Minarelli V1HL reed w/electric start
4561 “40.80″ 12 21.5 15.0 40.7x  Dykes 1.5FG  Minn. n.a. 2os for Minarelli V1L
4563 “40.80″ 12 21.5 15.0 40.7x  Dykes 1.5FG  Minn. n.a. 2os for Minarelli V1HL
FY50 “41.00″ 12 21.0 15.0 40.92 1.5-3G 1.3-3G Suzuki n.a. Suzuki FY50, FZ50, FA50 std
230140 “46.00″ 12 21.0 17.0 45.93  Dykes 1.5GI  Asso $70 Morini original new in box
###### ################################ ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   2 2 m m   T A L L   ( P i n   t o  C r o w n )
###### ################################ ### ##################################
552 “38.00″ 12 22.0 16.0 37.9x  2.0FG 2.0FG  Mahle n.a. 0286 378-005 Sachs 504 505 1A,1B “37.98  577″
230101 “38.00″ 12 22.0 17.0 37.9x  2.0FG 2.0FG  Asso n.a. Morini S5K2, can use Minarelli #4500?
406500 “38.00″ 12 22.0 13.5 37.91  1.5FG 2.0FG  generic $55 Sachs aftermarket 504, 505 1C,1D  says “38″
553 “38.00″ 12 22.0 14.0 37.95  1.5FG 2.0FG  Mahle n.a. 0286 378-051 Sachs 504,505 1C,1D
4500 “38.00″ 12 22.0 16.0 37.94  2.5FG 2.5FG  Asso n.a. Minarelli V1 1hp 20mph
4510 “38.20″ 12 22.0 16.0 38.1x  2.5FG 2.5FG  Asso n.a. 1os for Minarelli V1 1hp 20mph
230102 “38.20″ 12 22.0 17.0 38.1x  2.0FG 2.0FG  Asso n.a. 1os for Morini S5K2, can use Minarelli #4510?
4520 “38.40″ 12 22.0 16.0 38.3x  2.5FG 2.5FG  Asso n.a. 2os for Minarelli V1 1hp 20mph
4530 “38.60″ 12 22.0 16.0 38.5x  2.5FG 2.5FG  Asso n.a. 3os for Minarelli V1 1hp 20mph
SachsO “38.60″ 12 22.0 16.0 38.5x  2.0FG 2.0FG  Mahle $60 Sachs oversize original 504, 505 1A,1B
4535 “38.70″ 12 22.0 16.0 38.64  1.5FG 1.5FG  Minn. n.a. Minarelli V1 1979-on 1.5,2hp (some)
4540HP “38.80″ 12 22.0 15.5 38.7x  Dykes 1.5FG  Asso? n.a. Demm Smily piston, almost Minarelli
4540 “38.80″ 12 22.0 16.0 38.74  1.5FG 1.5FG  Minn. $80 Minarelli V1 1.5,2hp pre-1979
230133A “39.00″ 12 22.0 16.0 38.98  1.5FG 1.5FG  Asso n.a. Morini S5R, S5T
230133B “39.00″ 12 22.0 16.0 38.97  1.5FG 1.5FG  Asso n.a. Morini S5R, S5T
230133C “39.00″ 12 22.0 16.0 38.96  1.5FG 1.5FG  Asso n.a. Morini S5R, S5T
230133D “39.00″ 12 22.0 16.0 38.95  1.5FG 1.5FG  Asso n.a. Morini S5R, S5T
230133E “39.00″ 12 22.0 16.0 38.94  1.5FG 1.5FG  Asso n.a. Morini S5R, S5T
230133F “39.00″ 12 22.0 16.0 38.93  1.5FG 1.5FG  Asso n.a. Morini S5R, S5T
4550 “39.00″ 12 22.0 16.0 38.9x  1.5FG 1.5FG  Minn. n.a. 1st oversize for Minarelli V1
4560 “39.20″ 12 22.0 16.0  39.1x 1.5FG 1.5FG  Minn. n.a. 2nd oversize for Minarelli V1
4570 “39.40″ 12 22.0 16.0  39.3x 1.5FG 1.5FG  Minn. n.a. Harley Davidson M50 std, 3os for Min V1
4580 “39.60″ 12 22.0 16.0  39.5x 1.5FG 1.5FG  Minn. n.a. 4th oversize for Minarelli V1
4590 “39.80″ 12 22.0 16.0  39.7x 1.5FG 1.5FG  Minn. n.a. 5th oversize for Minarelli V1
4595 “40.00″ 12 22.0 16.0 39.9x  1.5FG 1.5FG  Minn. n.a. 6th oversize for Minarelli V1
Bigbore “45.40″ 12 22.0 18.0 45.33  1.5FG 1.5FG  Minn. $70 Minarelli original new in box, 1.5 FG rings
Bigbore “45.40″ 12 22.0 18.0 45.32  1.5FG 1.5FG  Minn. $40 Minarelli original new in box, no rings, none avail.
Morini “47.20″ 12 22.0 17.0 46.99 $70 Morini original new in box
Morini “47.15″ 12 22.0 17.0 47.06 $70 Morini original new in box
###### ################################ ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price   2 3 m m   T A L L   ( P i n   t o  C r o w n )
###### ################################ ### ##################################
Casal “40.00″ 12 23.0 16.0 39.95  2.0FG 2.0FG  Mahle $70 Casal, Zundapp?, bottom is flat
###### ###  1 3  m m    P I N    P I S T O N S   ##### ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price           Applications
###### ################################ ### ##################################
22273 “39.00″ 13 15.5 21.5 38.92  2.0GI 2.0GI  MBK Motobecane Sort 2 cyl 38.95 (unmarked)
22274 “39.00″ 13 15.5 21.5 38.93  2.0GI 2.0GI  MBK Motobecane Sort AA   38.96 (unmarked)
22275 “39.00″ 13 15.5 21.5 38.94  2.0GI 2.0GI  MBK Motobecane Sort A cyl 38.97 (unmarked)
22276 “39.00″ 13 15.5 21.5 38.95  2.0GI 2.0GI  MBK Motobecane Sort C cyl 38.98 (unmarked)
22277 “39.00″ 13 15.5 21.5 38.96  2.0GI 2.0GI  MBK Motobecane Sort E cyl 38.99 (unmarked)
22278 “39.00″ 13 15.5 21.5 38.97  2.0GI 2.0GI  MBK Motobecane Sort G cyl 39.00 (unmarked)
22279 “39.00″ 13 15.5 21.5 38.98  2.0GI 2.0GI  MBK Motobecane Sort J cyl 39.01 (unmarked)
22280 “39.00″ 13 15.5 21.5 38.99  2.0GI 2.0GI  MBK Motobecane Sort L cyl 39.02 (unmarked)
22281 “39.00″ 13 15.5 21.5 39.00  2.0GI 2.0GI  MBK Motobecane Sort N cyl 39.03 (unmarked)
22435 “39.00″ 13 15.5 21.5 39.01  2.0GI 2.0GI  MBK Motobecane Sort P cyl 39.04 (unmarked)
###### ###  1 4  m m    P I N    P I S T O N S   ##### ### ##################################
Part #  ”size” pin upper lower diam  ring1  ring2  maker price           Applications
###### ################################ ### ##################################
281218 “39.025″ 14 18.0 15.0 38.97  2.0GI 2.0GI  Jawa $65 Jawa std orig, 2.0 GI rings, spec D = 39.960
281218/1 “39.275″ 14 18.0 15.0 39.23  2.0GI 2.0GI  Jawa $70 Jawa 1os, spec D = 39.210 just below rings
281218/2 “39.525″ 14 18.0 15.0 39.48  2.0GI 2.0GI  Jawa $70 Jawa 2os, spec D = 39.460 just below rings
281218/3 “39.775″ 14 18.0 15.0 39.73  2.0GI 2.0GI  Jawa $70 Jawa 3os, spec D = 39.710 just below rings
281218/4 “40.025″ 14 18.0 15.0 39.9x  2.0GI 2.0GI  Jawa n.a. Jawa 4os, spec D = 39.960 just below rings

 

AssoASSO Pistons  ==========================

Asso Pistons

ASSO Pistons

Asso Factory

ASSO Factory

 

ASSO pistons were made in Italy mostly for Italian mopeds. ASSO stands for Assoluta Sicurezza Sempre Ovunque (Absolute Security Any time Anywhere). Early pistons said only “ASSO”, while later 1980′s ones said “ASSO.W”. Somehow ASSO merged with or was acquired by a German name, maybe some “kolben werke” to become ASSO Werke.

 

 

MahleCasal Pistons  ================================

Casal 40mm piston top

Casal Ø40 piston top says
<–saida       Mahle E logo
D,E,F are size increments
for Mahle nikasil cylinder

Casal 40mm piston bottom

Casal Ø40 piston bottom
says “Mahle            401″
made by Mahle for Casal

Casal Ø48 Piston top

Casal Ø48 Piston top
C,D,E are size increments

Casal Ø48 piston bottom

Casal Ø48 piston bottom
says “Mahle            481″

 

 

 

 

 

 

 

 

Casal (made in Portugal) pistons are made in Germany by Mahle. They say “saida” on top, exhaust side, Portuguese for “outlet”. They have an unusual flat bottom. They have a total height of 50mm. Top edge to pin is 23mm, plus pin 12mm, plus pin to bottom edge 15mm. There are two bore choices 40 and 48mm, each with several 0.01mm (micro!) increments to get a precise fit. A cylinder of letter “F” should get a matching “F” piston, unless it is worn, then maybe a “G” or even an “H” would be best. If the piston fit is too loose the engine will be weak, noisy, and fussy. Too tight and it will seize and do damage. Piston rings are both size 40 x 2.0 FG gap style, like Garelli. 

AssoGarelli Pistons =============================

Garelli piston markings

Garelli Pistons

Garelli 4th oversize 40.8mm piston, made by Asso, says “40.8″. You can see it’s bigger. Middle, Garelli standard 40.0mm piston, made by Asso, says “40″ and “S”. The “S” means scoria, Italian for exhaust. Right, Garelli standard 40.0mm piston, aftermarket. All three are oriented with the exhaust side down, like in the engine.

 

Asso

Morini Pistons  =============================

Morini Pistons Nov 2013

Morini Pistons Nov 2013

Morini made a variety of 50cc engines. These pistons shown here are only for 1960′s to 80′s moped-type engines Morini MO, MO1, MO2, M1, MO2 foot shift, MO4, all 40.4mm. They also fit Verona, early Gyromat, and Benelli mopeds, originally 40.0mm, as an oversize. All of the rings and ring pin locations are the same. 

Other Morini pistons 38.0, 39.0, and 46.0 are listed but not shown here.

 

 

 

 

 

 

 

Peugeot Pistons  ===============================Peugeot 1980 tiny

Peugeot 103 pistons have slightly different sizes.

Peugeot 103 pistons have slightly different sizes, aka “sorts”.
Left of the red line are the “standard” 40.0mm sorts A to II (39.88-39.98).
Right of the red line are the “oversize” 40.5mm sorts K to Q (40.45-40.50).
Upper half are chrome bore cylinders, pre-1979 with single letter sorts A to Q.
Lower half are nikasil bore cylinders, 1979-on with double letter sorts AA to II.

Peugeot 103 moped pistons are a very old design that has been in use at least since the 1950′s. The rings are thick, 2.5mm, like most old rings were. Peugeot 103 cylinders are all aluminum with a chrome plated (pre-1979) or nikasil plated (1979-on) cylinder wall. They expand along with the aluminum piston as they get hotter. Unlike a steel sleeve cylinder that fits slightly loose, when cold, and wiggles a tiny bit, these should be a light sliding fit, where the piston, without rings, pushes through by hand but does not fall through by it’s own weight. When the piston fit is too loose, it makes a tinkle sound when idling, and produces less torque. When it’s too tight, it simply won’t move easy, or at all, and when hot it will smear (melt off) the hot exhaust side and stick (seize).

The procedure for “fitting” a Peugeot piston requires a flat stone cylinder hone (not a ball hone) for first making the cylinder wall flat by removing any high spots, and a Dremmel high speed rotary cutting tool for removing burrs from the edges of the ports, and a small round file for removing burrs and high spots from the piston, especially around the wrist pin holes. Sometimes just the act of pushing the wrist pin in and out will raise the corner edge and make the piston fit tighter. The bare piston is pushed into the cylinder in different ways. The high spots are located, by feel and sometimes vision, and removed. When all high spots are removed, and the piston still does not fall through under it’s own weight, then the fit is perfect. 

Worn cylinders need slightly bigger pistons. So a worn “C” cylinder might need a D, E, or F piston. Badly worn or “gouged” cylinders need to be replaced (unless the gouges are lower than the exhaust port). Peugeot has made plenty of “oversize” (40.5mm instead of 40.0mm) pistons. But there are no 40.5 cylinders in California, only 40.0mm. That’s why Myrons Mopeds has 40.5 pistons but no cylinders. Too bad it’s expensive to bore out and re-plate a nikasil cylinder. It is an option, made possible by the half millimeter bigger pistons available.

 

3  T O P   E N D   P A R T S

=========================================================================

Part # #                Description Price      Applications
###### ###    P I S T O N   P I N   C L I P S #### ##################################
032038 10mm pin clip with tail(s) set of 2 $3 Tomos A3, others
032039 12mm pin clip with tail(s) set of 2 $3 most mopeds
633848 13mm pin clip with tail(s) set of 2 $3 Motobecane AV7
###### ###   C Y L I N D E R   S T U D S #### ##################################
205386 cylinder stud M7 x 115 $4 Tomos A3 and A35 1974-2006
Garelli cylinder stud M7 x 114 $4 Garelli all
233716 cylinder stud M6/7 x 115 N/A Tomos A55 7mm at case, 6mm at head


To follow: head nuts, exhaust studs and nuts, wrist pin needle bearings, wrist pin bushings

 


Engine Bottom End – Bearings, Seals, Hardware

September 27, 2012

CONTENTS:  Welcome   1  Seals   2  Bearings   3  Woodruff Keys   4  Engine Nuts    < scroll down to see

  5  Oil Plugs    6  Seal Washers   7  Alignment Pins   8  Case Bolts   9  Snap Rings    < grey means planned

 =============================================================================== 

Welcome. So far, seals, bearings, woodruff keys, and engine nuts are listed. YES! MYRONS HAS WOODRUFF KEYS! Drain plugs, case bolts, etc will follow. For special bearings, like ceramic bearings or odd or miniature sizes, see VXB Bearings in Anaheim CA, http://www.vxb.com/ballbearings.html?gclid=CL-4xcXM2bICFeaDQgodKnIABw  They sell online also.

You are at Parts/By Type/Engine Bottom. The following parts are NOT found here. Engine gaskets, crankshafts, clutches, crankshaft variators, transmission gears, transmission gear shafts, engine cases, cylinders, heads. Instead they are in Parts/By Brand.

The following engine parts are also NOT found here. Pistons, Rings, Piston Parts, Cylinder Studs, Head Nuts. Instead they are in Parts/By Type/Engine Top End.

 S E A L S

=================================================================================

Oil Seals are for sealing rotating or sliding shafts where they emerge from a sealed compartment. Fork seals and shifter shaft seals are sliding type. Engine seals are rotating type. Besides keeping oil from leaking out, some are also pressure seals, keeping air in (or out). On a two stroke engine, the crankshaft seals are very important because the crankcase has the mist of gasoline, oil and air inside it. When the crank seals leak, the engine won’t idle or accelerate good. The seal inner lip has a circular thin coil spring that holds onto the rotating shaft. Click to enlarge and see the little coils of the circular spring. Metric seals are specified by their inner, outer, and thickness, in mm.

Part #                Description Price              Application                  Location                 Nearby Bearing
###### ### ################### #### ############################################
E535-00-50 seal 05x30x6 $7 78-83 Indian                   shifter (engage) shaft
106019 seal 06x15x4 80-85 Morini M101                    shifter shaft
2810361 seal 10x16x4 86-89 Derbi “flat reed”             shifter shaft
###### ### #####    1 2 mm     H O L E #### ############################################
8228630 seal 12x18x3 76-86 Derbi “non & pyr reed”      shifter shaft
12x22x7 seal 12x22x7 85-88 MX3/MX5 bike motor        R crank (mag)               6202
###### ### #####    1 3 mm     H O L E #### ############################################
106021 seal 13x19x3 80-85 Morini M101
13x22x4 seal 13x22x4 76-86 Vespa variator models    rear pulley shaft           needle
###### ### #####    1 4 mm     H O L E #### ############################################
816181 seal 14x30x7 76-78 Batavus M48                   R crank (mag)                6302
###### ### #####    1 5 mm     H O L E #### ############################################
19089 seal 15x21x4 74-80 Motobecane 7,40,50,50V   L&R crank          6302QR 16mm
4790 seal 15x24x5 76-80 Minarelli V1                        pedal shaft                 none
4790                  continued >>> 76-80 Minarelli V1                      sprocket shaft              6202
106008                  continued >>> 76-80 Morini                             sprocket shaft               6202
112978                  continued >>> 74-on Vespa                             L (only) crank                6202
106003 seal 15x24x7 76-80 Morini                             sprocket shaft               6202
15x24x7                  continued >>> 77-80 Kreidler                             L crank (mag)              B015
630004000                  continued >>> 77-85 Sachs 505                             pedal shaft
15x24x7                  continued >>> 76-85 Jawa
15x25x5 seal 15x25x5 77-80 Kreidler                            R crank (clutch)            B015
E611-00-50 seal 15x25x6 78-83 Indian                               L crank (mag)             6202
15x27x7 seal 15x27x7 76-85 Jawa
B2-47 seal 15x30x5 78-85 Batavus/Trac M56               middle shaft              6202
15x30x5.5 seal 15x30x5.5 75-85 Sachs 504/505                  L crank (mag)              6202
29868000 seal 15x30x6 76-85 Garelli
8228400 seal 15x30x7 76-82 Derbi “non reed”              sprocket shaft            6203
15x30x7                  continued >>> 85-88 MX3/MX5 bike motor         L crank (clutch)           6202
15x30x7                  continued >>> 76-78 Angel/Speed Bird              R crank (mag)             6302
750015 seal 15x32x5/5.5 76-85 Sachs 504/505                  sprocket shaft
E2-45 seal 15x32x7 78-85 Batavus/Trac                    L crank (mag)              6202
15x35x7 seal 15x35x7 76-85 Sachs 504/505                   R crank (mag)            6202
15x35x7                  continued >>> 77-80 Colombia (Solo engine)       R crank (mag)
15x35x10 seal 15x35x10 76-80 Benelli/Moto Guzzi            L crank (mag)
15x42x13 seal 15x42x13 81-86 Derbi “pyramid reed”        sprocket shaft           6203
###### ### #####    1 6 mm     H O L E #### ############################################
481591 seal 16x21x4 76-78 Batavus M48                          pulley                   needle
8235300 seal 16x24x4 76-89 Derbi “non & pyr reed”      L&R  pedal shaft         none
29867100                  continued >>> 76-86 Garelli                                 L&R pedal shaft         none
106004 seal 16x24x5 76-80 Morini MO1,MO2,M1              pedal shaft             none
200266 seal 16x24x7 74-on Tomos A3,A35,A55                R pedal shaft           none
37616 seal 16x30x4.5 76-80 Peugeot 102/103                 R crank (mag)          6203
19858 seal 16.5x23x3 76-80 Motobecane 7,40,50,50V           fork                    none
###### ### #####    1 7 mm     H O L E #### ############################################
17x25x4 seal 17x25x4 76-86 Vespa Ciao (non variator) rear pulley shaft          needle
6125230 seal 17x28x6 76-86 Derbi “non & pyr reed”       R crank (clutch)        6303
6125230                  continued >>> 76-86 Derbi “non & pyr reed”       L crank (mag)           6203
17x28x7 seal 17x28x7 76-85 Jawa                                   L&R crank
17x28x7                  continued >>> 78-79 Tas Moprix/Speed Bird       R crank (mag)
29867800 seal 17x30x5 76-86 Garelli
29868100 seal 17x30x6/6.5 76-86 Garelli 1-speed                   R crank (mag)
0F02500231 seal 17x30x7 86-89 Derbi “flat reed”                L crank (mag)            6203
0F02500231                  continued >>> 86-89 Derbi “flat reed”                R crank (clutch)         6303
9023847 seal 17x35x7 78-86 Puch 2-speed                    L crank (mag)            L17
E2-48                  continued >>> 78-85 Batavus/Trac M56            sprocket shaft            6203
4710 seal 17x35x8 76-80 Minarelli V1                       L&R crank                   6203
106001                  continued >>> 76-84 Morini MO1,M1                  L&R crank                  6203
106001                  continued >>> 78-80 Morini MO2                       L crank (mag)             6203
036554                  continued >>> 76-84 Tomos A3                           L&R crank                  L17
036554                  continued >>> 85-on Tomos A3,A35,A55             L&R crank                 6203
17x35x8                  continued >>> 76-78 Demm Smily                      L&R crank                  6202
9013851 seal 17x40x7 74-86 Puch 1-speed                    L crank (mag)           6203
9013851                  continued >>> 78-86 Puch 2-speed                    sprocket shaft          6203
29868300                  continued >>> 77-86 Garelli 2-speed                   R&L crank
###### ### #####    1 8 mm     H O L E #### ############################################
S.8771 seal 18x24x4 74-86 Vespa (all)                          rear pulley               needle
###### ### #####    1 9 mm     H O L E #### ############################################
106020 seal 19x24x3.8 80-85 Morini M101                      variator drum
###### ### #####    2 0  mm     H O L E #### ############################################
E2-42 seal 20x26x4 78-85 Batavus/Trac M56              R driveshaft             bush
37004 seal 20x30x4.5 76-80 Peugeot 102/103               L crank (clutch)        6204
131511 seal 20x30x5 74-86 Vespa (all)                         rear brake drum
20x30x6 seal 20x30x6 78-83 Indian 4-stroke                   pedal shaft
3129130 seal 20x30x7 84-86 Derbi RD50                        sprocket shaft
20x30x7                  continued >>> 76-85 Jawa
20x30x7                  continued >>> 78-79 Tas Moprix/Speed Bird        L crank (clutch)
0001200341 seal 20x32x4 76-on Derbi (all)                            F&R wheels               6201
E2-46 seal 20x32x7 78-85 Batavus/Trac M56              R crank (clutch)           6202
9003849 seal 20x35x7 78-86 Puch 2-speed                    R crank (clutch)             E20
106012                  continued >>> 78-80 Morini MO2                        R crank (clutch)             6203
20x35x8 seal 20x35x8 76-80 Benelli/Moto Guzzi            R crank (clutch)
816480 seal 20x42x7 76-78 Batavus M48                     L crank (clutch)             6302
###### ### #####    2 2  mm     H O L E #### ############################################
22x31x4 seal 22x31x4 60-85 Solex (only sold with crank!)     L crank                6203
9023852 seal 22x40x7 74-83 Puch 1-speed                   R crank (clutch)       6203 w/clip
22x42x7 seal 22x42x7 76-78 Angel/Speed Bird              L crank (clutch)             6302
###### ### #####    2 4  mm     H O L E #### ############################################
0003102470 seal 24x32x7 NL 76-89 Derbi (all)                                fork                       none
F157-00-50 seal 24x33x10.5 78-83 Indian 4-stroke                         fork                none
158962 seal 24x35x6 70?-83? Vespa P200                    L crank (mag)
###### ### #####    2 5  mm     H O L E #### ############################################
9023816 seal 25x35x7 78-86 Puch 2-speed                     sprocket shaft           6203
0008330461 seal 25x40x7 76-86 Derbi “non & pyr reed”       sprocket shaft           6205
###### ### #####    2 6  mm     H O L E #### ############################################
26x35x7 seal 26x35x7 77-80 Colombia (Solo engine)       L crank (clutch)
###### ### #####    2 8  mm     H O L E #### ############################################
28x38x7 seal 28x38x7 76-85 Jawa                       L cover (inner clutch)
3211308291 seal 28x40x7 78-81 Puch Magnum MkII                      fork
116205                  continued >>> 78-85 Vespa Grande                             fork
###### ### #####    3 5  mm     H O L E #### ############################################
036620 seal 35x47x7 74-on Tomos A3,A35,A55               sprocket shaft          6006

Wow! Seals are almost done. An application chart, then prices and availability will follow. 

2   B E A R I N G S

=================================================================================

Bearings can mean ball bearings, needle bearings, and roller bearings. Needles are just thin long rollers. Ball bearings can mean individual loose balls. Or the balls can be in a ring, separate from the inner and outer races, in a “3-piece bearing”. Or everything can be all in one piece, in a “one piece bearing” or “cassette bearing”, the most common kind. The one-piece bearing shown at left, is also known as “full contact” because the balls touch the races in two wide arcs. It is also called “radial” because the center of the contact area is perpendicular or radial to the rotation. Two of the bearings listed below, L17 and E20, are “angular contact” where the contact angle is not 90 degrees to the rotation. Angular kinds are for carrying some side loads as well as radial loads.  

 

 

 

 

 

Part #                Description Price      Applications
###### ### ############################# #### ##################################
M E T R I C   B A L L   B E A R I N G S
metric ball bearings also used in wheels to remove a shield an awl pokes a hole
are for many machines besides mopeds then bends the shield to pluck it out
so they’re also sold by bearing suppliers
…………model….dimensions…style
###### ### #####      8  mm     H O L E   ######### #### ##################################
608RS bearing 608RS……08x22x07 1-R seal $8 Tomos 2sp trans cover front
608ZZ bearing 608ZZ……08x22x07 2-shield N/A skateboard wheel bearing
###### ### #####    1 0  mm     H O L E   ######### #### ##################################
6900 bearing 6900………10x22x06 open N/A
6000 bearing 6000 ….…10x26x08 open $8 Tomos 2sp trans cover rear
6000Z bearing 6000Z……10x26x08 1-shield $8
6000ZZ bearing 6000ZZ …10x26x08 2-shield $8
16100 bearing 16100……10x28x08 open $20 Puch 2sp trans cover rear
6200 bearing 6200……..10x30x09 open $8
6200ZZ bearing 6200ZZ…10x30x09 2-shield $8
6200RS bearing 6200RS…10x30x09 1-rubber seal $12
6300 bearing 6300………10x35x11 open N/A
###### ### #####    1 2  mm     H O L E   ######### #### ##################################
6901 bearing 6901………12x24x06 open N/A
16001 bearing 16001…….12x28x07 open N/A
6001 bearing 6001……..12x28x08 open $8
6001ZZ bearing 6001ZZ… 12x28x08 2-shield $8
6001-2RS bearing 6001-2RS 12x28x08 2-rubber seals $9
16101ZZ bearing 16101ZZ..12x30x08 2-shld $30 Puch snowflake R wheel bearing upgrade
6201 bearing 6201………12x32x10 open $10
6201ZZ bearing 6201ZZ …12x32x10 2-shield $10
6301 bearing 6301………12x37x12 open N/A
###### ### #####    1 5  mm     H O L E   ######### #### ##################################
6902 bearing 6902………15x28x07 open N/A
16002 bearing 16002… 15x32x08 open N/A
6002 bearing 6002… 15x32x09 open $8 Puch 2sp trans cover front
6002ZZ bearing 6002ZZ 15x32x09 2-shield $8
6202 bearing 6202… 15x35x11 open $8 Sachs Vespa R&L
6202ZZ bearing 6202ZZ… 15x35x11 2-shield $8
6202-2RS bearing 6202-2RS 15x35x11 2-rubber seals $8
6302 bearing 6302… 15x42x13 open $10
###### ### #####    1 6  mm     H O L E   ######### #### ##################################
6302QR bearing 6302QR 16x42x13 OS w/radius N/A Motobecane must cut crank to 6302
###### ### #####    1 7  mm     H O L E   ######### #### ##################################
6903 bearing 6903-2RS 17x30x07 2-rubber seals $15
16003 bearing 16003… …17x35x08 open N/A
L17 bearing L17……… 17x35x10 3-piece open N/A Puch 2sp left Tomos 75-85 Sears Allstate
6003 bearing 6003… 17x35x10 open $10
6203 bearing 6203… 17x40x12 open $10 Tomos 86-later Minarelli Puch 1sp L others
6203ZZ bearing 6203ZZ 17x40x12 2-shield $10
6203NR bearing 6203NR 17x40x12 clip groove $12 Puch 1sp right crank
6303 bearing 6303 17x47x14 open $10
###### ### #####    2 0  mm     H O L E   ######### #### ##################################
6004 bearing 6004………20x42x12 open $12
E20 bearing E20 ………20x47x12 3-piece open $30 Puch 2sp right crank
6204 bearing 6204………20x47x14 open $15
6304 bearing 6304………20x52x15 open N/A
###### ### #####    2 5  mm     H O L E   ######### #### ##################################
6005 bearing 6005………25x47x12 open $15 Puch 2sp left driveshaft
###### ### #####    3 0  mm     H O L E   ######### #### ##################################
6006 bearing 6006………30x55x13 open $18 Tomos left driveshaft
6006ZZ bearing 6006ZZ …30x55x13 2-shield $18 Tomos left driveshaft

 

 

3   W O O D R U F F    K E Y S

================================================================================

Loose your woodruff key? You’re not alone. These tiny things have a huge importance. When a magneto flywheel key is missing, and the nut is not fully tight, the flywheel can slip and cause the sparks to happen at the wrong time.



Above, some of Myrons keys for sale, made in Germany. L to R: 3.0 x 5.0 (M-86), 2.5 x 3.7 (M-82), 2.0 x 3.7 (M-81), 2.0 x 2.6 (M-80). They look smaller because of the rounded edges, plus the ruler is closer to the camera. These are the “sharp edge type”, but not “knife edge” sharp. The “chamfered edge type” are way more rounded at the circle edges only. A chamfered key will always replace a sharp key, but only sometimes will a sharp key replace a chamfered key, of the same dimensions. 

Part # #                Description Price           Applications
###### ### ############################# #### ##################################
…….. W O O D R U F F … K E Y S diameter is what the full circle would be
Width x Height x Length x Diameter CEV/Dansi/Motoplat all 80mm ID flywheels
###### ### ######### 2 . 0 mm  K E Y S  ######## #### ##################################
M-80 woodruff key 2.0 x 2.8 x 6.9 x 7.0 $2 Garelli 1-spd 273.511.0046, CEV 6933 flywheel
M-81 woodruff key 2.0 x3.7 x 9.4 x 10.0 $2 Sachs 504 (KTM), CEV 6949 flywheel
….continued > Sachs 504, sm Bosch 0212 010 001 flywheel
….continued > Kreidler, sm Bosch 0212 010 002 flywheel
….continued > Italjet + Morini, Bosch 0212 010 003 flywheel
….continued > Bat/Trac M56, sm Bosch 0212 010 004 flywheel
###### ### ######### 2 . 5 mm  K E Y S  ######## #### ##################################
???? woodruff key 2.5 x3.0 x 9.0 x 10.0 N/A Garelli 2-spd 217.018.0015, CEV 6939 flywheel
127025 woodruff key 2.5 x3.0 x 8.9 x 10.0 cham. N/A Morini MO1,MO2,M1, Dansi/CEV flywheel
M-82 woodruff key 2.5 x3.6 x 9.6 x 10.0 $2 Derbi ’76-86 Motoplat & ’86-89 CEV flywheels
###### ### ######### 3 . 0 mm  K E Y S  ######## #### ##################################
M-95 woodruff key 3.0 x3.0 x10.2 x13.0 cham. N/A
4720 woodruff key 3.0 x3.7 x 9.6 x 10.0 N/A Minarelli #4720, CEV 6932 flywheel
M-85 woodruff key 3.0 x3.6 x 9.5 x 10.0 $4 Puch #900.4503, big Bosch flywheel
….continued > Sachs 505 big Bosch flywheel
M-96 woodruff key 3.0 x5.0 x12.3 x13.0 cham. $7 Vespa flywheel & rear variator/clutch
M-86 woodruff key 3.0 x5.0 x12.3 x13.0 $2 Puch 1-sp clutch
….continued > Batavus M48 big Bosch flywheel
….continued > Batavus/Trac M56 clutch
….continued > Kinetic flywheel & rear pulley
….continued > Vespa flywheel & rear variator/clutch
M-88 woodruff key 3.0 x6.5 x15.5 x16.0 N/A Batavus/Trac M56 rear pulley
PA50key woodruff key 3.0 x3.5?x13.2?x16.0 N/A Honda Hobbit flywheel, can grind an M-86
###### ### ######### 4 . 0 mm  K E Y S  ######## #### ##################################
M-89 woodruff key 4.0 x5.0 x12.5 x13.0 N/A
M-100 woodruff key 4.0 x5.5 x18.0 x19.0 N/A
M-90 woodruff key 4.0 x6.5 x15.4 x16.0 N/A Garelli 217.036.00??, transmission
M-97 woodruff key 4.0 x6.5 x15.5 x16.0 cham. N/A
###### ### #########  M I S C    K E Y S  ######## #### ##################################
200048 roller/round key D=3 H=4 $5 Tomos all years, all flywheels
044835 straight key W=5.0 H=5.0 L=12.0 $2 Tomos countershaft key (race track shaped)


4   E N G I N E    N U T S

==============================================================================

Welcome. These are the engine nuts that go on rotating shafts, rather than stationary nuts, like the head nuts. For head nuts see Engine Top End. Some are very specific and others are more universal.   

Part # Style  Thread  Length  LH/RH  Hex Price               Applications
###### ### ############################ #### ##################################
###### ### #########   8 mm  N U T S   ####### #### ##################################
M8x1 plain nut   M8x1.00 x 8  RH hex13 $2 Sachs 504, Batavus/Trac M56 flywheel nut
3618446 flange nut M8x1.00 x 9  RH hex12 n.a. Garelli 000.361.8446 1974-76 1-sp flywheel nut
M8x1.25 plain nut   M8x1.25 x 8 RH hex13 $2 Vespa Ciao (non-variator) clutch nut
M8x1.25 ….continued > Vespa rear pulley nut, var & non-variator
Vespa thin nut    M8x1.25x 7 RH hex24 n.a. Vespa Bravo/Grande/Si variator nut
Morini thick nut M8x1.25×16 RH hex15 $10 Morini MO1,MO2,M1, Dansi flywheel nut
###### ### #########   9 mm  N U T S   ####### #### ##################################
5040 castle nut M9x1.00 x 6 RH hex14 n.a. Minarelli clutch (before 1978) stub plane clutch
6270 plain nut   M9x1.00 x 9 RH hex14 n.a. Minarelli clutch (1978 to Sep 1979) cone clutch
2050118446 flange nut M9x1.00 x 9  RH hex12 $7 Garelli 205.011.8446 1-spd flywheel nut
###### ### #########  1 0 mm  N U T S  ####### #### ##################################
???? thin nut    M10x1.00×6 RH hex14 $8 Derbi 1976-86 variator/clutch nut
???? thin nut    M10x1.00×6 RH hex17 $4 Sachs 504 & 505 clutch nut
4840 thin nut    M10x1.00 x 7 RH hex17 $3 Minarelli sprocket nut
49812 flange nut M10x1.00 x 7 RH hex21 $7 Peugeot clutch nut
9012943 flange nut M10x1.00 x 8 RH hex14 $5 Puch flywheel nut
M10x1 plain nut  M10x1.00×10 RH hex17 $2 Sachs 505 flywheel nut
….continued > Batavus M48 flywheel nut
….continued > Puch 1-spd clutch nut
….continued > Batavus/Trac M56 rear pulley nut
143195 special     M10x1.00×12 LH hex32 $10 Motobecane flywheel 1980-later
17429 special     M10x1.00 LH square 10 $12 Motobecane flywheel 1974-1979
2170180015 thick nut M10x1.00×14 RH hex14 $7 Garelli 2-spd 217.018.0015, flywheel nut
0F02600401 plain nut M10x1.00 x 8 LH hex14 n.a. Derbi rear pulley 1986-91
….continued > Derbi flywheel 1986-91 “Start” engine
46768 thick nut M10x1.00×15 RH hex16 $7 Peugeot flywheel nut
???? thick nut M10x1.00×18 RH hex17 n.a. Derbi flywheel 1976-1985
0F02610401 special     M10x1.00×30 LH hex17 n.a. Derbi clutch 1986-91 “Start” flat case reed
plain nut M10x1.25 x 8 RH hex 14 $2 Honda PA50 clutch and flywheel nut
H210-00-50 plain nut M10x1.25 x 8 LH hex14 $3 Indian flywheel nut
6275 plain nut M10x1.25×10 LH hex15 n.a. Minarelli clutch (after Sep 1979) cone clutch
4750 thick nut M10x1.25×14 RH hex15 n.a. Minarelli flywheel nut
###### ### #########  1 1 mm  N U T S  ####### #### ##################################
17454 flange nut M11x1.00 x 8 RH hex14 $6 Motobecane clutch nut (non-var)
17455 special     M11x1.00×21 RH hex14 $10 Motobecane clutch nut (variator)
###### ### #########  1 2 mm  N U T S  ####### #### ##################################
???? thin nut    M12x1.00 x 7 RH hex19 $3 Garelli clutch nut
???? thin nut    M12x1.00 x 7 RH hex19 $3 Sachs sprocket nut
???? thin nut    M12x1.25 x 6 RH hex17 n.a. Morini MO-1 sprocket nut
???? thin nut    M12x1.25×10 RH hex19 $3 Batavus/Trac M56 sprocket nut
###### ### #########  1 4 mm  N U T S  ####### #### ##################################
???? thin nut    M14x1.50 x 5 RH hex19 $8 Derbi rear pulley 1976-1986
###### ### #########  1 6 mm  N U T S  ####### #### ##################################
9022922 thin nut    M16x1.50 x 8 RH hex24 $7 Puch 2-spd clutch nut

 

Now, do you feel like an engine nut?

 

Shaun has been organizing moped parts since 1986, when he made this seal and bearing chart on his Commodore 64. This actual paper was in daily use for 26 years.

Shaun has been organizing moped parts since 1986, when he made this seal and bearing chart on his Commodore 64. This actual paper was in daily use for 26 years, at Royal Cyclery and Myrons Mopeds!



Wheel parts: Rims, Spokes, Axles, Bearings, Spacers, Nuts, Brakes

September 21, 2012

CONTENTS:   Welcome    1  Wheels    2  Wheel Parts    3 Grimeca    4  Leleu    5  Brakes    6  Spokes

Welcome to Myrons Wheel Parts Department. Moped wheels come in almost as many different styles as shoes. Before 1977 all mopeds had spoke wheels. In 1977 cast aluminum alloy wheels (mags) came out, on deluxe models. The tough and lightweight alloy (of mostly aluminum and magnesium) does not bend like a steel spoke rim does, and never has broken spokes. Some people like the chrome rim with spokes vintage look. Some people gotta have mags.

Although Myrons has about 200 moped wheels, many of the popular ones are scarce. Most of Myrons wheels are in the ”raw” state. That means they have not been serviced. Most used moped wheels have bad wheel bearings and/or bent rims and broken spokes. They all need at the very least fresh grease, cleaning, sanding the brake drum, lubing the brake cam. Once they’re made ready to sell, they sell for $100 to $200 each. An incomplete, rusted, or damaged one would be less, or course.

Because good-condition-and-correct replacement wheels are scarce, repairing the old wheel is often the best or only way. Using a wheel from a different moped can be an option, but is not as simple as swapping a car wheel. The brake anchor, the axle spacing, the rim centering, can all be different, resulting in things like tires rubbing and slowing you down, brakes not stopping good, a wobbly feel, or the chain coming off and damaging other things. When the wheel’s inner axle length is too long, the wheel is difficult or impossible to get on or off. When it’s too short, on the front, the front suspension becomes sticky or frozen as the axle nuts are tightened. When the brake anchor is too close to the frame, the brake rubs when the axle nuts are tightened. When it’s too far away, the whole brake plate/panel can suddenly detach from the frame, and rotate with the wheel, wrapping the cable around the wheel, bending the brake arm, and freezing up the rear wheel. When your wheels function and fit properly, you will enjoy riding more, with a smooth, safe, solid, and fast bike.

Sealed bearings are better than loose balls. Sealed bearings can last longer and carry more weight. They’re used on motorcycle wheels. Loose balls roll slightly more freely. They’re used on bicycle wheels. Mopeds have both kinds.

Sealed bearing upgrade: Any loose ball kind can be upgraded to sealed bearings. If the hub center is 28, 30, or 32mm then no sleeves are needed. These size bearings exist, bearing number 6001 is 12 x 28, 16101 is 12 x 30, and 6201 is 12 x 32mm. A precise 12mm shaft-type axle replaces the original 11 or 12mm threaded one. A center steel tube is custom made to fit tightly between the bearings. Other short tubes are custom made to space out the axle. Myrons sells the bearings, axle, and nuts, but not the exact right spacer tubes. You can slice sections of a steel pipe 1/2″ ID, 5/8 to 3/4″ OD. When your wheel hub center is not 28, 30, 0r 32mm, then sleeves must be custom made to make a smaller bearing fit tight and solid in the wheel center. On a Puch spoke wheel the hub is 29mm and the bearing 6001 is 28. That’s only 1mm difference in diameter, or .5mm in thickness. Because they’re so thin they deform easily when pressed in. At home you must settle for a thin strip of metal, wrapped in a circle, that’s loose enough to go in straight. But then it can work loose and come out.

Myrons offers the sealed bearing upgrade service for Puch rear Grimeca “Snowflake” mag and the Puch/Sparta/Kreidler rear Leleu spoke wheel aluminum hub. For the Leleu Myrons has 28 x 29mm precision aluminum rings, with an inner installation lip, in slightly different thicknesses, with precision 28 x 29mm installation tools, to get a tight fit without bending. For the Grimeca Myrons has 30 x 28 aluminum sleeves, with both an inner installation lip and an outer retaining lip. The installation lip prevents the sleeve from slipping out. Some aluminum hubs need thicker shims because they have been deformed by heavy use. Lastly, if the old axle was 11mm, then the 11mm brake panel axle hole must be drilled to 12mm. Cost for the wheel bearing upgrade is $110-120 parts and labor plus any brake service or spoke adjustment/rim truing. If the hub is badly damaged (flared out or eroded away in the bearing area), then either a custom tapered sleeve will need to be machined, or the hub/wheel will need to be rebored, at an additional cost, or else the wheel will need to be replaced.

1  W H E E L S

===================================================================================

Part # # ←picture#………Description Price      Applications/Condition
###### ### ############################# #### ##################################
……………W…H…E…E…L…S……………… ……TIRES ARE NOT INCLUDED…..SB=sealed bearing
wheel set 17″ Puch spoke thin rims $300 xlnt condition/narrow Maxi rims/complete
wheel set 17″ Puch spoke thick rims $325 xlnt bearings/very good cond/complete
wheel set 17″ Puch spoke sealed B rear $350 mint condition/1980 Newport II/complete
wheel set 17″ Garelli Snowflake mags $300 very good cond/xlnt bearings/clean/32T
wheel set 18/21″ Derbi RD50 w/tires $400 xlnt cond/Akront alum rims/original Pirellis/no axles
wheel set 16″ Tomos A3/A35 spoke $500 polished alum hubs, shiney 3mm spokes, good chrome
…….R..E..A..R….W..H..E..E..L..S……
wheel 17″R Puch Snowflake $200 new bearings/clean/$230 with new brakes
wheel 17″R Puch Snowflake $220 new bearings/super clean/$250 with new brakes
wheel 16″R Garelli spoke 32T $120 good bearings/straight/bad chrome all around
wheel 16″R Garelli HD SS spoke 30T $150 good bearings/straight/heavy duty SS spokes
wheel 16″R Cimatti 42T 165 axle $160 xlnt bearings/straight/good chrome
wheel 17″R Colombia Open Road 57T $110 all American made/SB/double chain/black/bad brakes
wheel 17″R Kynast Flying Dutchman 40T $200 brand new/shiney/needs fresh grease (included)
wheel 17″R Kynast Flying Dutchman 40T $130 xlnt bearings/straight/double chain/half bad chrome
wheel 17″R KTM Foxi 38T $100 good bearings/bent but useable/with brake panel
wheel 17″R Colombia Commuter 42T $120 SB/heavy duty 105mm/straight/needs brakes
wheel 16″R Vespa Bravo/no trans $120 straight/trued/xlnt chrome
wheel 16″R Vespa Grande/no trans $140 straight/trued/xlnt chrome
…….F..R..O..N..T….W..H..E..E..L..S……
wheel 16″F Italian spoke 145 axle $70 good bearings/straight/no speedo driver/bad chrome
wheel 16″F Cimatti spoke 145 axle $70 dry bearings need grease/straight/half bad chrome
wheel 16″F Cimatti spoke 145 axle $100 xlnt bearings/straight/some spots of bad chrome
wheel 16″F Garelli VIP spoke 105 hub $60 kinda straight/no brake panel
wheel 17″F Colombia Open Road $80 all American made/SB/straight/black/bad brakes
wheel 17″F KTM Foxi spoke 145 axle $120 xlnt bearings/kinda straight/fair chrome
wheel 17″F Colombia Commuter 105mm $100 SB/heavy duty 105mm/straight/needs brakes
wheel 17″F Vespa Ciao spoke 152 axle $120 good bearings, straight, OK chrome, no speedo driver
wheel 17″F Vespa Ciao spoke 152 axle $160 new, no speedo driver, spokes gray but rest is shiney
wheel 17″F Vespa Grande spoke 12×150 $130 straight/trued, almost new, xlnt chrome, no sp driver
wheel 17″F Vespa Grande spoke 12×150 $90 straight/trued, 1/2 bad chrome, no speedo driver


2  W H E E L    P A R T S

 =================================================================================

Blank 17″ 36 hole chrome dimpled rims 1.60 inner width, can be purchased for about $144 each from:

http://www.buchananspokes.net/categories/mandap_rims.asp

Part # # ←picture#………Description Price Applications
###### ### ############################# #### ##################################
…………………R…I…M…S………………
6357 rim strip 16 or 17″ rubber over spokes $2 can use electrical tape/protects tube from spokes
rim only 16″ 36 spoke holes .230″ $35 used cost less/Batavus/Sparta wider holes not .210″
rim only 17″ 36 h black powder coated $40 Motobecane original
……………A…X…L…E…S………………
222585 axle smooth M12x190 w/11×1 ends $20 76-07 Tomos rear (most)
axle smooth M12x183 w/12×1 ends $20
front axle M11x1.0/length=140mm N/A Vespa Ciao/use 145
front axle M11x1.0/length=145mm $10 Garelli/Cimatti/KTM/others
H52 front axle M11x1.0/length=150mm $12 Malaguti, Negrini, Pacer, more
front axle M11x1.0/length=155mm $12 Garelli VIP/Gulp/Puch/Sears
rear axle M11x1.0/length=165mm $15 Cimatti/others
rear axle M11x1.0/length=170mm N/A
rear axle M11x1.0/length=175mm $15
H119 rear axle M11x1.0/length=180mm $15 Puch/Sears
H119L rear axle M11x1.0/length=200mm $20
…A…X…L…E……N…U…T…S…
209277 axle nut M11x1/17hex/length=10mm $3 $2 for used/outside of frame/F or R/many mopeds
H56 axle nut M11x1/17hex/length=6mm $2 regular thin lock nut for locking cone onto axle
axle nut M11x1/17hex/length=5mm $3 special spacing for speedo drivers
H115 axle nut M11x1/24hex/length=4mm $3 large hex for rear wheel to not slip in frame
axle nut M11x1/17hex/length=3mm $3 special thin spacing for speedo drivers
axle nut M12x1/19hex/length=11mm $3 $2 for used/outside of frame/usually R/many mopeds
axle nut M12x1/24hex/length=8mm $5 large hex for rear wheel to not slip in frame/Puch
axle nut M12x1/19hex/length=6mm $2 regular thin lock nut for locking cone onto axle
axle nut M12x1/19hex/length=5mm $3 special spacing for speedo drivers
axle nut M12x1/24hex/length=4mm $3 large hex for rear wheel to not slip in frame
…A…X…L…E……W..A..S..H…E…R…S…
thin washer M11x19/length=0.8mm N/A use 1.0 thick
axle washer 11mm length=1.0mm $1 special thin
axle washer 11mm length=1.5mm $1 special thin
H55 axle washer 11mm length=2.0mm $1 .50 for used/normal axle washer
axle washer 12mm length=1.5mm $1 can also use 1/2″ SAE
axle washer 12mm length=2.0mm $1 .50 for used/normal axle washer
axle washer 12mm length=2.5mm $1 special thick
…A…X…L…E……S…P…A…C…E…R…S… can make by slicing pieces of a steel tube in a lathe
spacer ID=12.5/OD=16/length=3mm $2
H57 spacer ID=12.2/OD=16/length=4mm $2
spacer ID=12.5/OD=16/length=5mm $3
spacer ID=12.5/OD=16/length=6mm $3
spacer ID=12.5/OD=16/length=7mm $3
230668 spacer ID=12.5/OD=16/length=8mm $3 Tomos 2008-on rear, 2001-on box swingarm models
spacer ID=12.8/OD=16/length=8.4mm $2
H147 spacer ID=12.2/OD=16/length=9mm $3
spacer ID=12.6/OD=22/length=12 alum. $5
209253 spacer ID=12.2/OD=16/length=13mm $6 Tomos 1976-1991 rear outer L & R
H116B spacer ID=12.2/OD=16/length=14mm $5
222883 spacer ID=12.2/OD=21/length=16mm $6 Tomos 1996-later rear outer left, black
H116 spacer ID=12.2/OD=16/length=17mm $7
H116A spacer ID=12.2/OD=16/length=20mm $7
spacer ID=12.6/OD=20/length=25mm $7
spacer ID=12.6/OD=17/length=29mm $7
222568 spacer ID=12.2/OD=16/length=40mm $7 Tomos 1992-later front 16″ mag- Slot, 10-ray, ZCW
spacer ID=12.2/OD=18/length=57mm $8 Tomos 1976-1991 either 209262 rear or 206871 front
222569 spacer ID=12.2/OD=16/length=64mm $7 Tomos 1992-later rear 16″ mag- Slot, 10-ray, ZCW
spacer ID=12.5/OD=18/length=83mm $12 Myrons Leleu/Puch SB upgrade
…C..H..A..I..N….A..D..J..U..S..T..E..R..S…
223112 chain adjuster left spiral type 11mm $5 they can go either way
209212 chain adjuster right spiral type 11mm $5
407500 chain adjuster eyelet style 12mm $4 lolipop style, less for used
chain adjuster eyelet with back plate $7 lolipop style, less for used
…W..H..E..E..L…B..E..A..R..I..N..G..S…
bearing 6001ZZ… 12x28x08 2-shield $8 see also Engine Bearings for all sizes
bearing 16101ZZ..12x30x08 2-shld $30 see also Engine Bearings for all sizes
bearing 6201ZZ …12x32x10 2-shield $10 see also Engine Bearings for all sizes
ball steel 3/16″ bag of 26 $2
1921 ball steel 7/32″ bag of 22 $2
H67 ball steel 1/4″ bag of 20 $2

3  G R I M E C A     P A R T S

=================================================================================

Grimeca steel hubs or cast aluminum wheels (mags) are made in Italy. Grimeca is a world leader in motorcycle wheels, with many firsts, including the first disk brake, Ducati 1971, and the first light alloy wheel, Morini 1974. Grimeca single-chain moped hubs and wheels are used on every Italian moped, including Baretta, Benelli, Bianchi, Cimatti, Colt, Concord, Fantic, Gadabout, Gitane, Intramotor, Maico, Malaguti, Moto Guzzi, Motomarina, Motobecane Sebring, Motron, Negrini, Pacer, Safari, Scorpion, Snark, Soni, Testi, and others, plus some non-Italian models of AMF, Colombia, NVT, Trac, Tomos, and others. Grimeca double-chain moped hubs and wheels are used on Puch, Sears, Sachs, KTM, Kynast, Odyssey, Badger and others.

 Aluminum “mag” wheels: “Snowflake” is a common nickname for the crossed-ray “Razze Incrociate” style mag wheel that resembles a snowflake, made by Grimeca. The term usually means the Puch double chain 17″ kind, where the brake drum is in the center of the motor chain sprocket, and the opposite side has a screw-on bicycle chain freewheel sprocket. Grimeca also makes razze incrociate style mags in single chain style, in 16 and 17″, where the brake drum is on the opposite side of the sprocket, and there is no pedal chain.Other mags made by Grimeca include the “7 Razze” (7 Ray) ones used on Sachs Prima, and the “5-Razze Stella” (5 Ray Star) ones used on Tomos Silver (and Golden) Bullet (16″) and Motobecane (and Motomarina) Sebring. (17″) The term “5-star” is a nickname for the Leleu-made 17″ double-chain mag wheels used on 1980-later Puch mopeds. The Grimeca 5-stars are 16″ single-chain style. There are no doubt many more cast aluminum mag wheels made by Grimeca, such as the “10 Razze Stella” (10 Ray Star) 17″ and the “Razze Incrociate” 12 and 10 inch.

Spoke wheel hubs:  Grimeca makes stamped-steel hubs in 90mm and 105mm brake drum sizes. Within the 90mm drum size, there are at least 4 different single-chain hub bodies, with different spacings, and at least 2 different double-chain hub bodies. Each one of those hub bodies can have different axle lengths and axle spacer lengths possible. So there are dozens of configurations possible. Most 90mm Grimeca hubs have 11mm axles and axle components. Most 105mm hubs have 12mm heavy duty axles and axle cones, locknuts, nuts, washers, and spacers.

This chart unlocks the secrets of many Italian wire wheel parts. It was only in certain issues of “Moped Mart”, the newspaper-style parts catalog for moped dealers in the 1980′s, from Marina Mobili Inc. (MMI). Highlighted in yellow are the things that are different. Each column is a different wheel assembly. 

 

 

Part # # ←picture#………Description Price Applications
###### ### ############################# #### ##################################
……G..R..I..M..E..C..A……H..U..B..S…… …… Italian mopeds and others
H146 6 front hub bare 90mm x 32mmID $15 apparently only one spacing
H69 7 bearing cup Grimeca OD=32mm $5 30=Puch Snowflake rear/32=regular/35=h.d.
7 bearing cup Grimeca OD=35mm $20 Vespa Grande F/Garelli Sport HD rear/others
H67 8 ball steel 1/4″ bag of 20 $2 qty 20/wheel for 32mm cups, 22 for 35mm
H68 9 dust cover Grimeca for 32mm cup $2 keeps grease in and dirt out
9 dust cover Grimeca for 35mm cup $4 keeps grease in and dirt out
H66 10 cone Grimeca 11mm $25 this gets pitted, wears out first
10 cone Grimeca 12mm $25 this bigger one is not common
H52 11 front axle M11x1.0/length=150mm $12 Malaguti, Negrini, Pacer, more see Axles
H147 12 spacer ID=12.2/OD=16/length=9mm $3
H57 13 spacer ID=12.2/OD=16/length=4mm $2
H56 14 axle nut M11x1/17hex/length=6mm $2
H55 15 washer M11/length=2mm $1
H55A 15a axle washer 11mm length=1.0mm $1
H112 16 axle nut M11x1.0/hex17/length=10mm $3
H64 17 brakes Grimeca 90×18 $20
H64A 18 brake shoe coil spring Grimeca 90mm $1
H60 19 brake cable anchor/pinch bolt $6 see also Cables
H59 20 brake lever $5
H63 21 brake cam $5
H105 22 washer M6 0.25
H104A 23 nut M6x1.0/hex10 0.50
H58 24 front brake panel $25
H148 25 rubber inspection plug 9mm $4 these shrink after 30yrs exposed
H53 26 brake cable adjuster M6 $1 see also Cables
H51 front hub complete N/A
H120 27 rear hub complete N/A
H149 28 rear hub bare N/A several different spacings exist
H119 29 rear axle M11x1.0/length=180mm $15 see Axles
30 sprocket – different sizes see Sprockets
H122 31 sprocket locking plate $2
H124 32 bolt M7x1.0×25 $1 see Hardware
H124A 33 nut M7x1.0/hex11 $1 see Hardware
H116A 34 spacer ID=12.2/OD=16/length=20mm $7
H116B 35 spacer ID=12.2/OD=16/length=14mm $5
H116 spacer ID=12.2/OD=16/length=17mm $7
H115 36 axle nut M11x1/24hex/length=4mm $3
37 rear brake panel many styles
H114R 38 right chain adjuster $6 can go either way
H114L 39 left chain adjuster $6
 

Below, Grimeca moped hubs are drawn in cross section to show the variety of spacing. 

 

 

 

Grimeca rear 90mm hubs and wheels, identified, with MMI part numbers:

The Garelli Super Sport rear hub assy is  H-120GA (E=11mm), rear wheel is M-4GA (16″ rim, 32T for Garelli)
The Garelli Sport 90mm rear hub assy is 1184M (E=27mm), rear wheel is M-4XWB (16″ rim, 32T for Garelli)
The Malaguti 90mm rear hub assy is H-120 (E=22mm), rear wheel is M-4WB (16″ rim, 30T for Morini)
                                                                                   also on rear wheel M-4A (17″ rim, 32T for Morini)
The Cimatti 90mm rear hub assy is C2380 (E=14mm), rear wheel is M-4NB (16″ rim, 42T for Minarelli)

These hubs and wheels were distributed by MMI in the 1980′s. Myrons Mopeds does not have these hubs or wheels for sale, with a few exceptions. It’s mostly Grimeca wheel parts and information, that is offered here. 

 

Grimeca Brake Plate Picnic:

Besides the differences in the hubs and axle parts, there are many different brake plates or panels.

1. Some of these are mirror images of others. They are intended for the opposite side of the bike.

2. Some are the same but with 5 different lever arms for different brake cable styles. At right, R to L, 1) mushroom end cable fixture (Trac, Sachs) 2) endless cable Grimeca pinch bolt (most brands), 3) endless cable wrap-around pinch bolt (Tomos 6mm, Vespa 7mm), 4) barrel end cable or universal endless with sideways barrel pinch bolt (Puch) 5) clevis end cable or universal endless with clevis pinch bolt, shown (KTM and Sachs). These lever arms detach easily from the cam shaft. They can be swapped and they can be flipped over.

3. Some are the same but with different anchor arm shapes and offsets.

4. Some are the same but with different outer edge style, for brakes inside of sprockets. 

5. All of these can have either one of three possible brake shoe and spring types.

  Coil Spring: On steel hub spoke wheels, the center part of the hub is not as big, and there is room for dual small coil springs. Their advantage is they are much easier to install. Brakes can be folded like “from a taco to a tortilla” for installing and “from a tortilla to a taco” for removing. Most of the plates on the picnic table below are Coil Spring style, but some are U-Spring and V-Spring. You can’t tell from the outer side what style the brake shoes inside are. You have to take the wheel off, and the brake plate off, to tell what style the brake shoes and springs are. 

 

  U-Spring:A second type would be the same brake shoes and brake panel, but with the two spring holes near the cam drilled bigger and a free floating horse shoe spring instead of the dual coils. This design is needed for aluminum wheels that have a bigger center portion. Without the “U” shaped horseshoe spring, the coil springs rub badly against the aluminum, making the wheel weaker, the bike slower, making noise, and silvery aluminum dust on the brake.

 

  V-Spring:A third type is special plate and shoe set designed to be horseshoe spring only. The brake shoes each have a pencil size hole at one end. The stationary post (opposite the cam shaft) goes through the hole in each brake and has a notch at the end for the horseshoe spring. This non-floating horseshoe spring is more “V” shaped. It is held at the tip of the V by a rounded groove in the pivot post. The V-Spring brake shoes are also nicknamed “hole kind”.

 

 

GRIMECA 90mm BRAKE PLATES
 #  Side   Wheel  Axle  Model    Price (no shoes)
1.  L side: F spoke 11 Italian …….$30&15 n&u
2.  R side: R spoke 11 Baretta ……$30&15 n&u
3.  R side: R Mag   11 Italian ……..$30 new
4.  R side: R spoke 11 Cimatti ……$18 used
5.  R side: F spoke 11 Cimatti ……$20 used
6.  L side: R spoke 11 Garelli ……..$30&15 n&u
7.  R side: F spoke 11 Garelli ……..$30&15 n&u
8.  R side: F Mag    11 KTM ………..$25 used
9.  L side: R spoke 11 Kynast …….$40 new
10 R side: F spoke 11 Kynast …….$30 new
11 L side: R Mag   11 Sachs ……….$40 used
12 Either: Mag      11 Unknown …$15 used
13 R side: F Mag   11 Sachs ……….$20 new
14 R side: FR Mag 11 Unknown …$20 used
15 R side: R Mag   11 Tomos ……..$20 used
16 R side: F spoke 11 KTM ………..N/A
17 R side: R Mag   11 Trac  …………$22 used
18 R side: F spoke 11 Sachs? …….$15 used
19 R side: F spoke 11 Ciao C7E …$20 used
Not at Picnic but shown below:
20 R side: F spoke 11 Ciao C7N …$40 new
21 L side: R Mag    11 Puch ………..$40 used
22 L side: F Mag    11 Puch steel. $20 used
23 L side: F Mag    11 Puch alum. $20 new
24 R side: F spoke 12 Tomos …….$30&15 n&u
25 R side: R spoke 12 Tomos …….$30&15 n&u
26 L side: F spoke 10 Trac ………….$25 used
27 R side: R spoke 12 Trac ……………N/A
28 L side: R spoke 11 KTM …………….N/A
29
30
(Puch Mag means Snowflake not 5-star)

You can see there are many different Grimeca 90mm brake panels. The ones on the right side of the picnic table go on the right side of the bike. The ones on the left side go on the left side. 

Above, the back sides of those with horse shoe springs. 12 and 11 are U-Spring, the rest are V-spring (hole kind).

GRIMECA 105mm BRAKE PLATES
#  Side   Wheel  Axle  Model    Price (no shoes)
31 R side: F spoke 11 unknown ….$20 used
32 R side: R spoke 1/2″ Colombia $30 used
33 L side: R spoke 11 Garelli ……$25 new+dull
34 R side: F spoke 11 Garelli ……$25 new+dull
35 L side: F spoke 12 Grande alum $25 new
35 L side: F spoke 12 Grande steel   N/A
 (Grande means Vespa Grande)

 Here are all of MM’s Grimeca brake plates in Oct 2012, laid out and numbered.

Grimeca Compatibles

All through the 1970′s and 1980′s Tomos has made their own hubs and brake plates, Grimeca 90mm compatible. They are #24 & 25 above. By the 1990′s all wheels were cast aluminum “mags”. See also Parts/By Brand/Tomos.

Left, these are the Tomos-made cast aluminum wheels used from 1992 to 1995 on the early A35 models. They have a 90mm drum, compatible with the 1980′s Grimeca ones. The brake shoes are the V-spring type (hole kind). They were white or light grey on some models. The Tomos-made black cast aluminum brake plates are compatible with many Grimeca steel ones, such as #8 or #13 above.

 

From 1996-on, Tomos-made drum brakes were all 105mm, Grimeca compatible.  L to R: #233196 black rear, #233197 silver rear, #233124 black front, #233155 silver front. These all have a 10mm cam shaft inside a 19mm hole with a two-piece eccentric spacer, for self centering. Prices are $50-55, new with shoes. The self centering device was used from 2003 to 08, then was made solid.

This photo is all of the above photo brake plates turned over to see the inner side and the brake shoes. The last two are earlier ones. The black 105mm is a front pre- 2003 #229747, with a 12mm cam shaft hole, without the self-centering device. The far right one is a late 1980′s Grimeca made, black plated, V-spring 90mm rear, for A3 Golden Bullet, $30 plus shoes (shown with one shoe).

 

Other Grimeca Brakes: The 2005-2008 Tomos Arrow rear drum brake was 110mm made in Italy. The 2001-2002 Tomos Revival rear drum brake was 118mm Grimeca, as was the early Revival front disk brake. Later Revivals had AJP until 2007, then generic front brake. These Tomos brakes will be listed in Parts/By Brand/Tomos and here in Parts/By Type/Wheel Parts, because they have many non-Tomos applications.

Safari mopeds had 115mm Grimeca brakes. See parts/By Brand/Italian Mopeds and scroll down to Safari to see more.

Here are the Grimeca-compatible hubs and brake panels: Tomos (Slovenia) already mentioned, Trac (Korea) already mentioned, Carabella (Mexico), Colombia (USA), others.

There are only a handful of hubs that will be listed soon.

4  L E L E U     P A R T S

=================================================================================

Leleu aluminum hubs are on Puch, Peugeot, Batavus, Sparta, Motobecane, and many others.

Under construction. When done it will be about 1/2 as big as Grimeca.

 

5  B R A K E S

=================================================================================

Apparently, almost all moped brake shoes are all made aftermarket by EBC worldwide, But only the 301, 302, 322, and 501 are available in the US. The identification and cross-referencing of moped brakes is an ongoing process.

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
……………B…R…A…K…E…S………………
1 brakes Leleu…..70×16 small $40 Peugeot 102 rear
1 continued … Batavus VA, HS50, Starflite (all M48) rear
brakes Yamaha.80×17 EBC 501 $20 Yamaha QT50, PW50, Towny, others
14322 2 brakes Leleu…..80×18 EBC 322 grinded $25 Puch/Peugeot/Motobecane/Sparta/others
2 continued … Batavus VA, HS50, Starflite (all M48) front
2 continued … Batavus Regency VA, HS front & rear
383301 3 brakes Honda…80×18 EBC 301 $20 Honda NC50/General/Angel -see Honda
MB brk 4 brakes Motobecane 80×20 L&R N/A Motobecane must change panel to Leleu
Jawa brk brakes Jawa……85×20 or 90×20 see Jawa
H64 6 brakes Grimeca 90×18 $20 Grimeca 90mm spoke wheels w/coil springs
H64+drill 7 brakes Grimeca 90×18 bigger holes $25 Grimeca mag wheels with horse shoe spring
5 brakes Grimeca 90×18 hole kind $25 Puch “Snowflake” front with alum panel
W1220050 brakes Indian…90×20 spoke coil spring see Indian
W1222050 brakes Indian…90×20 mags U-spring see Indian
brakes Indian…100×20 Mira mags N/A see Indian
8 brakes Derbi…..105×25 N/A 78-89 Derbi
8 brakes Derbi…..105×25 w/no plates N/A 76-77 Derbi
230952 9 brakes Tomos…105×20 $25 96-on Tomos
229740 9 brakes Tomos…105.2×20 $25 96-on Tomos
236346 brakes Tomos…110mm $25 05-08 Tomos Arrow rear
brakes Tomos…118mm N/A 01-03 Tomos Revival A35 rear
Vespa 10 brakes Vespa….135×16 single shoe N/A Vespa Ciao/Bravo/Grande/Si
243604 brake pads Tomos Revival/Streetmate $20 03-on Tomos Revival/Streetmate/Arrow
381161 brake pads EBC FA116X early Revival $25 Tomos Revival 01-02 disk brake pads
H64A brake shoe coil spring Grimeca 90mm $1 steel Grimeca hubs & some mags

Left, an EBC322 brake shoe set, for Puch spoke wheels and many others with Leleu 80mm hubs. The right one is before grinding. The left one is after grinding. Without grinding the spring rubs and makes noise. The depth is made just deep enough so that the center of the spring never touches the brake shoes. The grinding raises the price from $20 to $25.

Another brake shoe, not listed, is the American-made Colombia, stamped steel. They look very different, but do interchange with the Grimeca 105 x 20mm cast aluminum brake shoes, used on most modern Tomos mopeds. Some sanding may be needed.

 

 6  S P O K E S

=================================================================================

Application Chart

================================================================================

Look up your brand and model to find the spoke length, diameter, and thread. Then look up the inches, price/availability, part # in the list of spokes for sale. Please verify, at least, the length with a tape measure. Sometimes wheels get swapped, or mistakes made with model names, unknown models, manufacturer substitutions, etc. If you have a calipers, please verify the thickness also.

Abbreviations:   thick = thickness (mm)   X = # of crosses   qty = # of spokes   drum = brake drum diameter (mm)

Loc = location of spoke (inner/outer/left/right)   length = length (mm)   thread = distance between threads (mm)

############### ### ### ### ### #### #### #### ######## ### ### ### ### #### #### #### ####
 F  F   F   F   F front front front   R  R   R   R   R rear rear rear
Brand…………Model Rim  X qty drum  Loc length  thick thread Rim  X qty drum  Loc length  thick thread
############### ### ### ### ### #### #### #### ######## ### ### ### ### #### #### #### ####
AMF Roadmaster 16″ 16″
AMS Sierra 50 17″ 2x 32 100 inner 174 2.6 0.45 17″ 2x 36 100 inner 162 3.2 0.65
outer 174 2.6 0.45 outer 162 3.2 0.65
AMS Tahoe 50 17″ 2x 32 100 inner 172 2.6 0.50 17″ 2x 36 100 inner 162 2.6 0.50
outer 172 2.6 0.50 outer 162 2.6 0.50
Angel 17″ 2x 32 80 177 2.6 0.45 17″ 2x 32 80 0.45
Angel Speed Bird 17″ 2x 32 80 177 2.6 0.45 17″ 2x 32 80 0.45
Batavus VA 16″ 2x 28 80 169 2.6 0.50 16″ 3x 36 70 right 168 3.0 0.60
left 165 3.0 0.60
Batavus HS50 16″ 2x 28 80 169 2.6 0.50 16″ 3x 36 70 right 168 3.0 0.60
left 165 3.0 0.60
Batavus Mobat 16″ 2x 28 80 169 2.6 0.50 16″ 3x 36 70 right 168 3.0 0.60
left 165 3.0 0.60
Batavus Bronco 16″ 2x 28 80 169 2.6 0.50 16″ 3x 36 70 right 168 3.0 0.60
left 165 3.0 0.60
Batavus Starflite 16″ 2x 28 80 169 2.6 0.50 16″ 3x 36 70 right 168 3.0 0.60
left 165 3.0 0.60
Batavus Regency 16″ 2x 28 80 169 2.6 0.50 16″ 3x 36 80 171 3.0 0.60
Cimatti City Bike 16″ 2x 36 90 155 2.5 0.65 16″ 2x 36 90 155 2.5 0.65
Cimatti Town Bike 16″ 2x 36 90 155 2.5 0.65 16″ 2x 36 90 155 2.5 0.65
Colombia Commuter 17″ 3x 36 105 185 2.6 0.45 17″ 3x 36 105 185 2.6 0.45
Colombia Imperial 17″ 3x 36 105 185 2.6 0.45 17″ 3x 36 105 185 2.6 0.45
Colombia Open Road 17″ 3x 36 105 185 2.6 0.45 17″ 3x 36 105 185 2.6 0.45
Colombia Mopet 17″ 3x 36 105 185 2.6 0.45 17″ 3x 36 105 185 2.6 0.45
KTM Foxi Deluxe 17″ 3x 36 90 188 2.5 0.55 17″ 3x 36 90 right 192 2.5 0.55
3x left 188 2.5 0.55
Garelli Eureka 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 174 2.5 0.65
Garelli Sport 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 174 3.0 0.65
Garelli Sport HD 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 105 170 3.0 0.65
Garelli Rally Sport 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 174 2.5 0.65
17″ 3x 36 188 2.5 0.65 17″ 3x 36 188 2.5 0.65
Garelli Gran Sport 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 174 2.5 0.65
17″ 3x 36 155 2.5 0.65 17″ 3x 36 188 2.5 0.65
Garelli Super Sport 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 174 2.5 0.65
17″ 3x 36 188 2.5 0.65 17″ 3x 36 188 2.5 0.65
Garelli Gulpmatic 16″ 3x 36 170 2.5 0.65 16″ 3x 36 174 2.5 0.65
Garelli VIP 16″ 3x 36 170 2.5 0.65 16″ 3x 36 174 3.0 0.65
17″ 3x 36 188 2.5 0.65 17″ 3x 36 188 3.0 0.65
General 5-Star TT 17″ 2x 32 80 inner 177 2.6 0.45 17″ 2x 32 80 inner 172 2.6 0.45
outer 177 2.6 0.45 outer 172 2.6 0.45
General 5-Star ST 17″ 2x 32 80 inner 177 2.6 0.45 17″ 2x 32 80 inner 172 2.6 0.45
outer 177 2.6 0.45 outer 172 2.6 0.45
Grycner Floozie 17″ 2x 32 80 inner 177 2.6 0.45 17″ 2x 32 80 inner 172 2.6 0.45
(gold spokes) outer 177 2.6 0.45 outer 172 2.6 0.45
Honda Express 14 2x 28 80 145 2.3 0.45 14 2x 28 80 145 2.3 0.45
Honda Hobbit 17″ 3x 36 80 160 2.3 0.45 17″ 2x 36 80 160 2.6 0.45
Indian 4-stroke 17″ 2x 32 90 inner 176 2.8 0.55 17″ 2x 32 90 inner 176 2.8 0.55
outer 176 2.8 0.55 outer 176 2.8 0.55
Jawa Babetta 16″ 2x 36 160 2.85 0.50 16″ 2x 36 160 2.85 0.50
Kreidler Flory 17″ 3x 36 80 189 2.3 0.45 17″ 3x 36 80 190 3-2.6 0.50
Kynast Flying Dutchman 17″ 2x 36 90 170 2.6 0.50 17″ 2x 36 90 right 170 2.6 0.50
left 163 2.6 0.50
Lazer Sport 50 17″ 2x 32 80 inner 177 2.6 0.45 17″ 2x 32 80 inner 172 2.6 0.45
outer 177 2.6 0.45 outer 172 2.6 0.45
Malaguti Commuter 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 171 2.5 0.65
Motobecane 7 16″ 3x 36 80 173 2.40 0.55 16″ 2x 36 70 157 3.0 0.60
Motobecane 40 17″ 2x 36 80 173 3.0 0.60 17″ 2x 36 80 173 3.0 0.60
Motobecane 50 17″ 2x 36 80 165 3.0 0.60 17″ 2x 36 80 173 3.0 0.60
Motobecane Solex 19″ no 220 2.4 0.55 19″ 73? 190 2.41 0.55
Negrini Gazelle 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 171 2.5 0.65
Negrini MX Sport 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 171 2.5 0.65
Negrini KPN 19 36 105 181 3.0 0.65 17″ 2x 36 105 152 3.0 0.65
Odyssey 16″ 2x 36 90 153 2.6 0.50 16″ 2x 36 90 153 2.6 0.50
Pacer 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 171 2.5 0.65
Pacer Super Sport 16″ 2x 36 90 155 2.5 0.65 16″ 3x 36 90 171 2.5 0.65
Peugeot 102 17″ 1x 28 80 165 2.4 0.55 17″ 1x 28 70 171 2.7 0.55
Peugeot 103 17″ 1x 28 80 165 2.4 0.55 17″ 1x 28 80 167 2.7 0.55
Puch Maxi 17″ 3x 36 80 188 2.6 0.50 17″ 3x 36 80 188 2.6 0.50
Puch 78 Maxi Luxe 17″ 3x 36 80 186 2.6 0.55 17″ 3x 36 80 186 2.6 0.55
Puch Newport 17″ 3x 36 80 186 2.6 0.50 17″ 3x 36 80 186 2.6 0.50
Puch Maxi II 17″ 3x 36 80 186 2.6 0.50 17″ 3x 36 80 186 2.6 0.50
Puch Newport II 17″ 3x 36 80 186 2.6 0.50 17″ 3x 36 80 186 2.6 0.50
Puch Magnum XK 17″ 3x 36 80 186 2.6 0.55 17″ 3x 36 80 186 2.6 0.55
Sachs Westlake (504) 17″ 3x 36 90 190 2.34 0.45 17″ 3x 36 90 right 186 2.34 0.45
Sachs Sundancer(504) left 186 2.34 0.45
Sachs Balboa (505) 17″ 3x 36 90 190 2.34 0.45 17″ 3x 36 90 right 186 2.34 0.45
Sachs Suburban (505) left 186 2.34 0.45
Sachs M4-M5-P3(505) 17″ 3x 36 90 186 2.34 0.45 17″ 3x 36 90 186 2.34 0.45
Sears Free Spirit 17″ 3x 36 80 188 2.6 0.50 17″ 3x 36 80 188 2.6 0.50
Sears Allstate 19 36 left 196 2.5 0.53 19 36 left 196 2.5 0.50
right 204 2.5 0.53 right 204 2.5 0.50
Sparta Foxi GT 16″ 2x 36 80 160 2.28 0.45 16″ 2x 36 80 std 160 2.6 0.50
2x 36 HD 160 3-2.6 0.50
Tomos Bullet 16″ 2x 36 90 152 2.72 0.55 16″ 2x 36 90 152 2.72 0.55
Tomos Revival 01-02 17″ 1x 36 D left 178 3.0 0.60 16″ 1x 36 105 left 160 3.0 0.60
right 182 3.0 0.60 right 149 3.0 0.60
Tomos Revival 17″ 1x 36 D 168 3.0 0.60 16″ 1x 36 105 150 3.0 0.60
Tomos Streetmate 17″ 1x 36 D 168 3.0 0.60 16″ 1x 36 105 150 3.0 0.60
Trac Clipper 16″ 2x 32 90 inner 160 2.6 0.45 16″ 2x 32 inner 161 2.6 0.45
outer 160 2.6 0.45 outer 161 2.6 0.45
Trac Eagle 16″ 2x 32 90 inner 160 2.6 0.45 16″ 2x 32 inner 161 2.6 0.45
outer 160 2.6 0.45 outer 161 2.6 0.45
Trac Hawk 16″ 2x 32 90 inner 160 2.6 0.45 16″ 2x 32 inner 161 2.6 0.45
outer 160 2.6 0.45 outer 161 2.6 0.45
Trac Escot 16″ 2x 32 90 inner 160 2.6 0.45 16″ 2x 32 inner 161 2.6 0.45
outer 160 2.6 0.45 outer 161 2.6 0.45
Trac Olympic 17″ 2x 36 110  A 160 2.6 0.45 17″ 2x 36 110  A 0.45
 B 160 2.6 0.45  B 0.45
Trac Liberty 17″ 2x 36 110  A 160 2.6 0.45 17″ 2x 36 110  A 0.45
 B 160 2.6 0.45  B 0.45
Trac DH100 17″ 2x 36 110  A 174 2.6 0.45 17″ 2x 36 110  A 159 3.16 0.60
 B 174 2.6 0.45  B 159 3.16 0.60
Vespa Ciao 17″ 2x 28 90 182 2.5 0.65 17″ 2x 36 135 158 3.0 0.60
Vespa Bravo 16″ 2x 28 90 170 2.5 0.65 16″ 2x 36 135 145 3.0 0.60
Vespa Grande 17″ 2x 36 105 158 3.0 0.60 16″ 2x 36 135 145 3.0 0.60

Speaking of spokes, here’s how to get the right one. Three main things specify a spoke: length, thickness, and thread. Spoke length can be measured from different points in the head, such as the inner curve, the outer curve, or total length. So some spec sheets might list the same spoke as slightly different lengths. Besides that, spokes can be a little longer or shorter and still work fine, as long as the original spoke was not already short or long. For example, pre-1977 Puch Maxi spec is 191mm, while 1977-later is 188mm, with the same rim and hub. A 1/16 inch (1.6mm) more or less is no big deal. Here, with bicycle style 90 degree bend spokes, we use the center of the head as the length end point, which is why it’s often 1-2mm different than manufacturer specification. With motorcycle style inner (less than 90 degree) and outer (more than 90 degree) types, we use the 90 degree equivalant. This way inners and outers have the same length. Otherwise inners are longer because they have less bend.

Spoke thickness usually goes by wire gauge, where 14G=2.0mm, 13G=2.35, 12G=2.6, 11G=2.9, and 10G=3.2mm. French have their own wire gauge, so Motobecane and Peugeot thicknesses are different. Italian spokes are always in even millimeters, like 2.0, 2.5, 3.0, 3.5. Italian spokes always have coarse thread, 0.65 or 0.60mm, while German and Asian ones have fine thread 0.45mm. To help identify the thread, which is difficult to even see, much less measure, the logo that raises out of the spoke head is listed as (A)or(R)=Italian, (*)=star, (♣)=clover, (O)=none/Asia, (Б)=DT/Swiss, (U)=Union/German, (C) or (B)=French. Getting the same thread and thickness allows easy replacment of  original broken spokes without even deflating the tire.

In the case of respoking an entire wheel, then the thread does not matter. Instead what matters besides length and thickness is quantity available. Most of the spokes for sale are only available in small quantities, like 1 to 10. Their price is a round number like $2.00 or 1.50. Some spokes are available in large quantities of 36, 72 or more. Their price is a “99″ number like 1.99 or 1.49. Prices are for 1-9 quantity. 10+ is 20% less. 36+ is 33% less. A “99″ price means 50% less for 72 or more. The nuts or nipples are sold separately, and follow the same price structure as the coresponding spoke.

And finally, many original spokes are not available N/A. They are for reference only, not for sale, but included so that a close enough substitute can be found. If the original spoke for your bike is not available, then first look how far into the nipples your original spoke are, to see how much longer or shorter the spokes could be. Then remove one to precisely measure it’s length. Use the drawings above to know how. Then look for a spoke a little longer (or shorter) that would substitute. A thicker one is better, but may require precise drilling of the rim hole and sometimes the hub hole. A thinner one would need a tight fitting washer to prevent the smaller nipple from pulling through the rim hole.

Spokes For Sale

=================================================================================

Part # # ←picture#………Description Price Applications
###### ### ############################# #### ##################################
………… ……S…P…O…K…E S………………
>>>> Logo … Length… Thickness Thread Years Make Wheel Models
Honda spoke (O) 4 9/16″ 116 Ø3.16 thread 0.65 $2 ……… Honda style inner
Honda spoke (O) 5 inch 127 Ø3.16 thread 0.65 $2 … …… Honda style inner
Honda spoke (O) 5.5/16″ 135 Ø3.17 thread 0.65 $2 … …… Honda style inner
Ital142 spoke (A) 5.5/8″ 142 Ø2.5 thread 0.65 N/A …… Italian
55557 spoke (O) 5.5/8″ 143 Ø2.0 bicycle 0.45 $1 77-83 Honda 14″F&R-Express/QT50 + washer
142230 spoke (A) 5 3/4″ 145 Ø3.0 thread 0.60 N/A 77-80 Vespa 16″R-Bravo/Grande nut#114216
Grande spoke (O) 5 7/16″ 148 Ø2.87 outer 0.60 $3 ……… Upgrade for Vespa Grande R + washer
Grande spoke (O) 5 7/16″ 148 Ø2.87 inner 0.60 $3 ……… Upgrade for Vespa Grande R + washer
Ital150 spoke (A) 5 15/16 150 Ø2.5 thread 0.65 $3 ……… Italian 16″F w/105mm big hub 2X 36spoke
232733 spoke (A) 5 15/16 150 Ø3.0 thread 0.60 $3 04-on Tomos 16″R-Revival/S.mate, 01-03 Revival RR
spoke (O) 6 inch 152 Ø3.4 Ø3.16 th 0.65 $3
53582 spoke (C) 6 inch 152 Ø3.06 thread 0.60 $3 76-79 Motobecane 17″front-Model 40
207079 spoke (A) 6 inch 152 Ø2.72 thread 0.55 $3 76-91 Tomos 16″F&R-A3 Bullet
Honda spoke (O) 6 inch 153 Ø3.46 thread 0.65 $2 … …… Honda style outer
207079b spoke (A) 6 1/8″ 154 Ø2.78 thread 0.55 $3 76-91 Tomos 16″F&R-A3 Bullet
Star155 spoke (*) 6 1/8″ 155 Ø2.64 thread 0.55 $2
120035 spoke (A) 6 1/8″ 155 Ø2.5 thread 0.65 $2 76-79 Cimatti 16″F&R-City Bike/Italian 16″36H 2X
spoke (Я) 6 1/8″ 155 Ø2.34 thread 0.45 $2
000932 spoke (R) 6 1/8″ 155 Ø2.5 thread 0.65 $2 76-85 Garelli 16″F-Eureka/Sport/Gran/Rally/Super
10G155 spoke (O) 6 1/8″ 155 Ø3.18 thread 0.65 $3 ……… Upgrade thicker 10 Gauge
spoke (O) 6 1/8″ 155 Ø3.44…inner 0.65 $3 ……… Upgrade thicker
Derbi spoke (O) 6.3/16 157 Ø2.86 nobend 0.60 $3 84-86 Derbi 16″F&R-SL straight spoke
23041 spoke (C) 6.3/16″ 157 Ø3.0 thread 0.60 N/A 77-79 Motobecane 16″R-Model 7
G68609 spoke (A) 6 1/4″ 158 Ø3.0 painted 0.60 N/A 78-80 Vespa 17″F-Grande nut#114216
114501 spoke (A) 6 1/4″ 158 Ø3.0 thread 0.60 N/A 74-86 Vespa 17″R Ciao nut#114216
Ex159 spoke (O) 6 1/4″ 159 Ø3.95 thread 0.80 $3 … Upgrade extremely thick
055005a spoke (♣) 6 1/4″ 160 Ø2.28 thread 0.45 $2 76-77 Sparta 16″F-Foxi GT/Flying Dutchman(Sparta)
055005 spoke (U) 6 1/4″ 160 Ø2.28 thread 0.45 $2 76-77 Sparta 16″F-Foxi GT/Flying Dutchman(Sparta)
055506 spoke (♣) 6 1/4″ 160 Ø2.60 thread 0.50 $2 76-77 Sparta 16″R-Foxi GT/Flying Dutchman(Sparta)
074016 spoke (O)…6 1/4″ 160 Ø2.60 thread 0.50 N/A 76-83 Jawa 16″F&R-Babetta
spoke (O)…6 1/4″ 160 Ø2.87 inner 0.65 $2
spoke (O)…6 1/4″ 160 Ø2.87 outer 0.65 $2
55006U spoke (♣) 6 1/4″ 160 Ø3.0 Ø2.6 thr 0.50 $2 76-77 Sparta 16″R-Upgrade thicker at head end
10G160 spoke (O) 6 1/4″ 160 Ø3.18 thread 0.65 $2 ……… Upgrade thicker 10 Gauge
11505491 spoke (O) 6 5/16″ 162 Ø2.60 outer 0.50 $2 83-84 AMS 17″R-Tahoe 50 big hubs
11505490 spoke (O) 6 5/16″ 162 Ø2.60 inner 0.50 $2 83-84 AMS 17″R-Tahoe 50 big hubs
11515470 spoke (O) 6 5/16″ 162 Ø3.16 outer 0.65 $2 83-84 AMS 17″R-Sierra 50 big hubs
11515469 spoke (O) 6 5/16″ 162 Ø3.16 inner 0.65 $2 83-84 AMS 17″R-Sierra 50 big hubs
FD163 spoke (♣) 6 3/8″ 163 Ø2.60 thread 0.50 $2 77-80 Flying Dutchman (Kynast) 17″R left 2-cross
51492 spoke (C) 6 1/2″ 164 Ø2.41 thread 0.55 $2 76-80 Peugeot 17″F-103 2-cross
40173 spoke (♣) 6 1/2″ 165 Ø3.03 thread 0.60 $3 76-77 Batavus 16″R left-VA/HS50/Mobat/Bro/Starflite
Star165 spoke (*) 6 1/2″ 165 Ø2.38 thread 0.55 $2
19625 spoke (C) 6 9/16″ 165 Ø3.0 thread 0.60 $2 76-80 Motobecane 17″F-50/50V hi-flange F hub
52951 spoke (B) 6 9/16″ 166 Ø2.65 thread 0.55 $2 76-80 Peugeot 17″R-103 thicker
Ex166 spoke (O) 6 9/16″ 166 Ø3.95 thread 0.80 $2  Upgrade extremely thick
10G167 spoke (O) 6 9/16″ 167 Ø3.16 thread 0.65 $2  Upgrade thicker 10   gauge
6513502 spoke (O) 6 5/8 168 Ø2.86 nobend 0.60 $3 76-83 Derbi 17″F&R Variant SL/TT straight spoke
40172 spoke (♣) 6 9/16 168 Ø3.03 thread 0.60 $3 76-77 Batavus 16″R right-VA/HS50/Mobat/Br/Starflite
40210 spoke (U) 6 5/8″ 169 Ø2.60 thread 0.50 $2 76-77 Batavus 16″F-VA/HS50/Mobat/Bronco/Starflite
136111 spoke (R) 6 11/16 170 Ø2.5 thread 0.65 $2 ……… Vespa 16″F-Bravo 28H 2-cross
FD170 spoke (♣) 6 11/16 170 Ø2.6 thread 0.50 $2 77-80 Flying Dutchman (Kynast) 17″F&R right 2X
503151 spoke (R) 6 3/4″ 171 Ø2.5 thread 0.65 $2 76-86 Garelli 16″F-Gulpmatic/VIP
11505470 spoke (O) 6 3/4″ 171 Ø2.6 outer 0.45 N/A 77-83 General 17″R-5 Star/Lazer Sport 50/Grycner
11505469 spoke (O) 6 3/4″ 171 Ø2.6…inner 0.45 $2 77-83 General 17″R-5 Star/Lazer Sport 50/Grycner
47143 spoke (C) 6 3/4″ 171 Ø2.7 thread 0.55 N/A 1980 Peugeot 17″R-102 SP 28H 1X
H46A spoke (A) 6 3/4″ 172 Ø2.5 thread 0.65 $2 77-80 Malaguti 16″R-Commuter Pacer/Negrini/etc
21505470 spoke (O) 6 3/4″ 172 Ø2.6 gold out 0.45 $2 78-83 Grycner 17″R-Floozie
21505469 spoke (O) 6 3/4″ 172 Ø2.6…gold in 0.45 $2 78-83 Grycner 17″R-Floozie
506851 spoke (R) 6 3/4″ 172 Ø3.0 thread 0.65 $3 76-80 Garelli 16″R-Sport(with M12 R axle)
19755 spoke (C) 6 3/4″ 173 Ø2.40 thread 0.55 $2 77-79 Motobecane 16″F-Model 7
21195 spoke (C) 6 3/4″ 175 Ø3.0 thread 0.60 $3 76-80 Motobecane 17″F&R-Model 40 R-50/50V
40221 spoke (♣) 6 11/16 173 Ø3.0 thread 0.60 $3 78-80 Batavus 16″R-Regency 11 gauge
10G173 spoke (O) 6 3/4″ 173 Ø3.16 thread 0.65 $2  Upgrade thicker 10   gauge
500601 spoke (R) 6 13/16 174 Ø2.5 thread 0.65 $2 77-80 Garelli 16″R-Rally Sp/Gran Sport/Super/Gulp
35504 spoke (O) 6 15/16 174 Ø2.58 outer 0.45 $2 86-88 Trac 17″F-DH100
35503 spoke (O) 6 15/16 174 Ø2.58 inner 0.45 $2 86-88 Trac 17″F-DH100
505701 spoke (A) 6 13/16 174 Ø3.0 thread 0.65 $3 76-80 Garelli 16″R-Sport(M11 R axle)/VIP/VIP-N
Ital176 spoke (A) 6 13/16 176 Ø2.5 thread 0.65 $2  Italian
10G176 spoke (O) 6 15/16 176 Ø3.18 thread 0.65 $3  Upgrade thicker 10   gauge
11505074 spoke (O) 6 15/16 177 Ø2.58 outer 0.45 $2 77-83 General 17″F-5 Star/Lazer Sport 50
11505073 spoke (O) 6 15/16 177 Ø2.58 inner 0.45 $2 77-83 General 17″F-5 Star/Lazer Sport 50/Angel F
1410050 spoke (O) 6 15/16 177 Ø2.82 inner 0.55 $3 78-83 Indian 17″F&R-4-Stroke
1420050 spoke (O) 6 15/16 177 Ø2.82 outer 0.55 $3 78-83 Indian 17″F&R-4-Stroke
JW177 spoke (jw) 7 inch 177 Ø3.5 thread 0.65 $2  Upgrade way thicker
Ital180 spoke (A) 7 1/16″ 180 Ø2.5 thread 0.65 $2 …… Italian
spoke (O) 7 1/16″ 180 Ø2.6 thread 0.45 $2
232798 spoke (O) 7 1/8″ 182 Ø3.0 thread 0.60 $3 01-02 Tomos Revival F-right (18) and some left (9)
142826 spoke (A) 7 1/8″ 182 Ø2.5 thread 0.65 $2 74-86 Vespa 17″F-Ciao nut #101830
Wow spoke (O) 7 1/8 182 Ø4-3.5 thread 0.65 $3 … … Upgrade thicker inners and outers
spoke (O) 7 1/8″ 183 Ø2.6 thread 0.45 N/A
Col185 spoke (O) 7 1/4″ 185 Ø2.6 thread 0.45 $2 77-80 Colombia 17″F&R-Commuter/Open Road
2411111 spoke (♣) 7 5/16″ 186 Ø2.34 thread 0.45 N/A 76-83 Sachs 17″F&R-M4/M5/P3
DT186ss spoke (Б) 7 5/16 186 Ø2.5 stainless 0.55 $3 …… Upgrade DT stainless steel
2400301 spoke (O) 7 3/8″ 186 Ø2.64 thread 0.50 $2 77-86 Puch deluxe models with wide rims
Del186 spoke (Δ) 7 3/8″ 186 Ø3.0 thread 0.60 $2
2411105 spoke (♣) 7 3/8″ 188 Ø2.34 thread 0.45 N/A 76-83 Sachs 17″R lf-Westlake/Sundancer/Balboa
503203 spoke (R) 7 3/8″ 188 Ø2.5 thread 0.65 $2 78-86 Garelli 17″F-VIP F&R-Gran/Rally/Super Sp
2400301 spoke (O) 7 7/16 188 Ø2.62 stainles 0.55 $3 78-83 Puch Magnum XK/Maxi Luxe stainless
1210071 spoke (Б) 7 7/16 188 Ø2.5 stainless 0.55 $2 77-80 KTM 17″F & L rear-Foxi Deluxe/Salsburg
5400301 spoke (O) 7 7/16″ 188 Ø2.6 thread 0.50 $2 74-86 Puch 17″F&R-Maxi/Sport/Newport/others
same spoke (O) 7 7/16″ 188 Ø2.6 thread 0.50 same 1978 Sears Free Spirit/JC Penney Pinto/Swinger
503204 spoke (R) 7 3/8″ 188 Ø3.0 thread 0.65 N/A 77-86 Garelli 17″R-VIP
Ital188 spoke (A) 7 3/8″ 188 Ø3.0 thread 0.60 N/A ……… Italian 17″R 36-spokes 3-cross
JW188 spoke (jw) 7 3/8″ 188 Ø3.5 thread 0.65 $3  Upgrade way thicker
2650102 spoke (♣) 7 7/16″ 189 Ø2.33 chro 0.45 N/A 77-80 Kreidler 17″F-Flory
spoke (U) 7 7/16″ 189 Ø2.5 thread 0.55 $2
2411107 spoke (♣)7 7/16″ 190 Ø2.34 thread 0.45 N/A 76-83 Sachs 17″R rt-Westlake/Sundancer/Balboa
61359 spoke (*) 7 7/16″ 190 Ø2.41 thread 0.55 N/A 74-80 Motobecane 19″R-Solex
2651102 spoke (♣) 7 7/16.190 Ø3.0-2.6 chro 0.45 N/A 77-80 Kreidler 17″R-Flory
spoke (O) 7 1/2″ 191 Ø2.6 thread 0.50 $2
spoke (O) 7 1/2″ 192 Ø3.03 thread 0.65 $3
10G192 spoke (O) 7 1/2″ 192 Ø3.16 thread 0.65 $2  Upgrade thicker 10   gauge
1010071 spoke (Б) 7 9/16.192 Ø2.5 stainless 0.55 $3 77-80 KTM 17″L Rear-Foxi Deluxe/Salsburg
Union spoke (U) 7 9/16″ 193 Ø2.5 thread 0.55 $3
10G196 spoke (O) 7 3/4″ 195 Ø3.16 thread 0.65 N/A  Upgrade thicker 10   gauge
JW196 spoke (O) 7 3/4″ 195 Ø3.44 thread 0.65 N/A  Upgrade way thicker
Del200 spoke (Δ) 7 13/16 200 Ø2.6 thread 0.45 $2 ……… not Sears Allstate 56TPI not 48TPI
Wow spoke (O) 7 13/16 201 Ø3.5-3.16… 0.65 $3 ………Upgrade Way thicker and longer
61358 spoke (*) 8 5/8″ 220 Ø2.41 thread 0.55 $4 74-80 Motobecane 19″F-Solex
10G245 spoke (O) 9.5/8″ 245 Ø3.17 thread 0.65 N/A  Upgrade thicker 10   gauge
10Gwash cupped washer for 10G upgrade spokes $0 …… Upgrade optional for taking up distance
Bicycle nut for (O)… 14G Ø2.0 bicycle 0.45 $0 …… …Upgrade most bicycles
Sachs nut for (Я)…… 13G Ø2.34 thread 0.45 $1 76-80 Sachs 17″F&R-Westlake/Sundancer/Balboa
Sparta nut for (U)(♣) 13G Ø2.34 thread 0.45 $1 76-77 Sparta 16″F-Foxi GT
14989 nut for (C)(*)…… Ø2.41 thread 0.55 $1 77-79 Motobecane 16″F-Model 7 many others
1009072 nut for (Б)=DT mm Ø2.5 thread 0.55 $1 76-80 KTM 17″F&R-Foxi Deluxe/Salsburg
101830 nut for (A)(R) mm Ø2.5 thread 0.65 $1 74-86 Vespa Ciao/Bravo front most Italian front
1400311 nut for (O)… 12G Ø2.6 thread 0.50 $1 74-86 Puch 17″F&R-Maxi/Sport/Newport/others
11505072 nut for (Δ)(O) 12G Ø2.60 thread 0.45 $1 77-83 General 17″F&R-5 Star/Lazer Sport 50
PuchSS nut for (O)…… 12G Ø2.64 thread 0.55 $1 78-83 Puch 17″F&R-deluxe models w/stainless
Tomos nut for (A)…… mm Ø2.75 thread 0.55 $1 75-91 Tomos 16″F&R-A3 Bullet/Bullet TT thicker
Derbi nut for (O)… 11G Ø2.86 thread 0.60 $2 76-86 Derbi 17″F&R-Variant SL/TT
Angel nut for (O)…… 11G Ø2.89 thread 0.55 $2 77-78 Angel/Speed Bird 17″R 32H 2X
114216 nut for (A)… mm Ø3.0 thread 0.60 N/A 74-86 Vespa all Rear-Ciao/Bravo/Grande
Garelli nut for (A)(R)… mm Ø3.0 thread 0.65 N/A 78-85 Garelli 16or17″Rear-VIP
Delta nut for (Δ)………mm Ø3.0 thread 0.60 $1
Batavus nut for (♣)… … mm Ø3.0 thread 0.60 $1 76-79 Batavus 16″R-VA/HS50/Mobat/Bron/Starflite
17859 nut for (C)… … mm Ø3.0 thread 0.60 $1 76-80 Motobecane 17″F&R-Model 40/50/50V
10GNut nut for (O)…… 10G Ø3.18 thread 0.65 $1 Upgrade thicker 10 gauge
9GNut nut for (O)… mm Ø3.5 thread 0.65 $2 Upgrade way thicker
8GNut nut for (O)… mm Ø3.95 thread 0.80 $2 Upgrade extremely thick

 

 Another way to get spokes is by having some custom made. Buchanans sells 10 gauge (3.17mm = 1/8″) stainless steel spokes for about $1.60 each. You will need to send them a sample spoke to copy. The rim hole and/or hub hole might need to be drilled out. You can get all shiney 1/8″ thick new spokes this way:  http://www.buchananspokes.net/products/individual_stainless_steel_spokes.asp

 

 


Drivetrain parts: pedals, cranks, chains, belts

September 19, 2012

CONTENTS:  Welcome   1 Pedals    2 Pedal Cranks    3 Pedal Items    4 Chains

5  Sprockets    6  Belts           < grey means under construction

Welcome. Way too much chain information lies below.

1   P E D A L S

================================================================================

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
… ………P…E…D…A…L…S……………
most moped pedals have 9/16-20 thread <”all” means all except MB Peugeot Derbi
some have French thread 14-1 25mm <Motobecane Peugeot Derbi only
14mm is slightly smaller than 9/16 9/16 pedal on 14 arm gets tight half way
difficult to re-thread 14 to 9/16-20 requires $50/set bicycle shop taps
41124 4 pedal set 9/16-20 basic rubber $15 all mopeds 77 Puch 77 Tomos others
400000 5 pedal set 9/16-20 block rubber Piaggio $15 all mopeds 80-88 Vespa
pedal set 9/16-20 folding push button $20 all mopeds for saving space
222655 1 pedal set 9/16-20 Tomos grey rubber $15 all mopeds 06-10 Tomos
222655 2 pedal set 9/16-20 Tomos black rubber $15 all mopeds 10-later Tomos
41367 3 pedal set 9/16-20 all aluminum $15 all mopeds
3 pedal set 9/16-20 all aluminum shiney $20 all mopeds
pedal set 14mm-1 25 French thread N/A Motobecane Peugeot Derbi only
pedal set 9/16-20 Union Germany N/A 78-later Puch and others

2   P E D A L   C R A N K S

================================================================================

Pictures and specs of pedal crank arms belong here.

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
P E D A L   C R A N K    A R M S
arm set 9/16-20 5.1/4″ chrome new $30 Tomos fits all
arm set 9/16-20 5.1/4″ black new $30 Tomos fits all
arm left 9/16-20 5.1/4″ chrome new $17 Tomos fits all
arm right 9/16-20.5.1/4″ chrome new $17 Tomos fits all
arm left 9/16-20 5.1/4″ black new $17 Tomos fits all
arm right 9/16-20.5.1/4″ black new $17 Tomos fits all
arm right 14-1 25 5.1/4″ chrome $15 Motobecane right
arm left 14-1 25L 5.1/4″ chrome $15 Motobecane left must bend to clear 50V
arm left 14-1 25L 5.1/4″ pre-bent $22 Motobecane left pre-bent for 50V
arm right 14-1 25 6.1/4″ chrome new $15 Peugeot right
arm left 14-1 25L…6.1/4″ chrome new $15 Peugeot left
arm left 9/16-20L…6.1/2″ Puch used $45 scarce Puch
arm left 9/16-20L…6.1/2″ Puch new $65 scarce Puch
arm right 9/16-20 6.1/2″ Puch new $55 scarce Puch
22011 pedal arm wedge pin 9.5mm $2 Puch Tomos Sparta others
pedal arm wedge pin 9.0mm $8 scarce MB Peugeot Italian others

 

3  P E D A L   I T E M S

================================================================================

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
…… P…E…D…A…L……I…T…E…M…S ……
1603 pedal chain 1/2×1/8.112L must cut $10 all mopeds with external pedal chain
pedal freewheel 16 tooth $15 Sparta Foxi
pedal freewheel 18 tooth $20 watch out! MB&Peug are French thread
pedal freewheel 20 tooth $20 French freewheels get tight on std hubs
pedal freewheel 22 tooth $20 Std freewheels strip out French hubs
pedal reewheel 24 tooth $20 Puch Maxi needs big to clear swingarm
pedal chain tensioner for Puch $20 Puch all not many others
pedal chain tensioner pulley wheel+bolt $7 Shimano derailler pulley wheel+M5bolt

 

Chain adjuster lolipop style with back plate

Chain adjuster, lolipop style, with back plate

Myrons has many different styles of chain adjusters. This is the generic “lolipop” style, price $4 each. The back plate is $5 more, each. Not all bikes need the back plate. There are about 10 styles of lolipop. There are also spiral type chain adjusters. All of  those will be shown later…

 

 

 

 

4  C H A I N S

================================================================================

 

How to install and remove master links.

How to install and remove master links.

To order a regular replacement chain for your moped, count the links (L) in your old chain. Tomos is around 90L -94L, Puch is around 100L, others are 102L to 106L . It’s always an even number because roller chain links come in pairs, inner and outer. Some chains have a “half link” that’s half inner and half outer. Then the link count will be an odd number.

Myrons Mopeds will cut the new chain to have the number (must be even) of links that you say, for no extra charge. If your chain is a 415H, and you need an odd number of links, a 415H half link is available for $3 extra.

 

 

RK415H 110L chain

A. RK 415H 110L modern chain from Malaysia
3.93 x 8.0

Iris 415 104L vintage chain

B. Iris 1/2 x 3/16 102L vintage chain, Spain
3.89 x 8.0

ČZ chain

C. ČZ 1/2 x 3/16 96L vintage, Czech Republic
4.14 x 9.6

Iris Copper chain

D. Iris Copper 1/2 x 3/16 106L vintage, Spain
3.89 x 8.0

 

 

 

 

 

 

Regina 415 vintage chain

E. Regina “415″ 90L vintage chain from Italy
3.89 x 8.4

Regina 415

E. The only vintage chain that says 415. Wow!

Union chain made in Germany

F. Union/Styria 100L vintage chain, Germany
4.05 x 9.0

Regina

G. Regina (thick) 95L
4.05 x 9.0  Italy

 

 

 

 

 

 

Regina Extra

H. Regina Extra 77L
click to enlarge
4.05 x 7.9

Chains Oct 2012

I. #24 is same as #D (coated with white grease)

W circled logo

J. “W-circled” chain
92L, 98L, 100L
4.05 x 7.7

 

 

 

Part # # ←picture#           chain#   pin x width       links Price      Applications
###### ### ################################# #### ##############################
         C H A I N S    f o r   s a l e for pedal chains scroll up
TYC-96      chain    TYC 42    415   3.58 x 7.0 black 96L $20 some mopeds and motor kits
TYC-100      chain    TYC 42    415   3.58 x 7.0 black 100L $22 some mopeds and motor kits
41-90      chain    MAX 41    41    3.58 x 8.9 black 90L $20 industrial (and mopeds)
41-98      chain    MAX 41    41    3.58 x 8.9 black 98L $20 industrial (and mopeds)
41-240      chain    MAX 41    41    3.58 x 8.9 black 240L $45 industrial
207012 21      chain     plain    415H   3.93 x 8.0 black 90L $18 European mopeds
16092 22      chain      KMC    415H   3.93 x 8.0 black 98L $15 European mopeds
16096 23      chain      KMC    415H   3.93 x 8.0 chrome 98L $20 European mopeds
16096+      chain      KMC    415H   3.93 x 8.0 chrome110L $30 European mopeds
340360 A      chain      RK       415H   3.93 x 8.0 black 110L $20 <<<<   very good chain!
491200      chain      CIC     415H   3.93 x 8.0 black 122L $25 European mopeds
420-120L      chain     plain     420    3.93 x 9.4 black 120L $25 Asian mopeds
RK420 25      chain      RK        420    3.93 x 9.4 black 84L $18 Asian mopeds
Tsu420      chain   Tsubaki   420    3.93 x 9.4 black 108L $25 Asian mopeds
RK428H      chain      RK        428H  4.45 x 12.0 black 120L $30 small motorcycles
Iris B vintage chain    Iris   415   3.89 x 8.0 black 102L $50 Derbi 1970′s original NOS
Iris race D vintage chain    Iris   415   3.89 x 8.0 copper 106L $75 Derbi 1980′s racing chain NOS
Regina E vintage chain Regina 415  3.89 x 8.4 black 90L $35 Tomos 1970′s original NOS
Sedis vintage chain  Sedis  415  3.93 x 7.5 black 88L $40 Peugeot 1970′s original NOS
Wcirc92 J vintage chain W-circ  415  4.05 x 7.7 black 92L $35
Wcirc98 J vintage chain W-circ 415   4.05 x 7.7 black 98L $40
Wcirc100 J vintage chain W-circ 415   4.05 x 7.7 black 100L $40 Flying Dutchman, others
RegExtra H vintage Regina Extra 415  4.05 x 7.9 black 77L $25 Italian 1970′s (has half link)
RegHD G vintage chain Regina 415  4.05 x 9.0 black 95L $35 Italian 1970′s (has half link)
Union F vintage chain Union  415  4.05 x 9.0 black 100L $80 Puch 1970′s original NOS
ČZ C vintage chain    ČZ    415   4.14 x 9.2 nickel 96L $45 Tomos 1990′s original NOS

 

Master Links

###### ### ############################# #### ##################################
     M A S T E R    L I N K S    f o r   s a l e : In order by pitch, pin size, width
                                      inner Cabinet rows 1 to 6, columns a to e
                 pitch    pin    width  model #
###### ###     3.57 Pins – light pink drawers #### ##################################
35 link  1b master link 9.53 x 3.57 x 7.7 ANSI 35 $3 #35 3/8 pitch chain
35 half  1c half link      9.53 x 3.57 x 7.7 ANSI 35 $3 #35 3/8 pitch chain
410 link  2b master link 12.7 x 3.57 x 5.8 410 (ASA 43) $2 #410 bicycle 1-speed
410noclip  2a master link 12.7 x 3.57 x 5.8 410 clipless $1 flex chain to unlock
42 link  2d master link 12.7 x 3.57 x 7.2 ASA 42 $6 Peugeot 102 original
42H half  2e half link      12.7 x 3.57 x 7.6 ASA 42H $3 holes too small for 415
41 link  3a master link 12.7 x 3.57 x 9.2 ANSI 41 $3 widest chain with 3.57 pins
###### ###     3.87 Pins – white drawer #### ##################################
415 iris  3b master link 12.7 x 3.87 x 8.3 415 Iris $7 Motobecane, Derbi original
###### ###     3.93 Pins – light yellow drawers #### ##################################
415 link  3d master link 12.7 x 3.93 x 7.9 415 Sedis $5 Peugeot 103 original
415H link  3e master link 12.7 x 3.93 x 8.5 415H $3 2004-later Tomos original
415H chr  3e master link 12.7 x 3.93 x 8.5 415H chrome $3 fits 1990-later 415H chains
415H half  3e half link      12.7 x 3.93 x 8.5 415H $3 fits 1990-later 415H chains
415 reg1  4a master link 12.7 x 3.96 x 8.8-9.2 415 Reg. $8 h. duty Italian “Regina Extra”
420 link  4b master link 12.7 x 3.93 x 9.8 420 $3 wider than 415 or 415H
420 half  4b half link      12.7 x 3.93 x 9.8 420 $5 thinner than 420H or 40
40 link  4d master link 12.7 x 3.93 x 11.1 ANSI 40 $5 40 master link also fits 420H
###### ###     4.05 Pins – lt. green – master plate “17″ #### ##################################
415 tom1  4e master link 12.7 x 4.05 x 7.9 415 W circled $5 1970′s -80′s Tomos original
415 reg2  5a master link 12.7 x 4.05 x 8.2-8.6 415 Reg. $5 Italian original “Regina Extra”
415 plain  5b master link 12.7 x 4.05 x 8.7-9.0 415 plain $5 original chain
415 puch  5c master link 12.7 x 4.05 x 9.2-9.4 415 Union $8 Puch original, Regina Extra HD
###### ###     4.14 Pins – light blue – master plate “18″ #### ##################################
415 “H”  5d master link 12.7 x 4.14 x 8.4 415 plain $2 late 1980′s standard? Not 415H
415 “H”  5e master link 12.7 x 4.14 x 8.4 415 (bag of 10) $10 late 1980′s standard? Not 415H
415 tom2  6a master link 12.7 x 4.14 x 9.4 415 W circled $6 late 1980′s Tomos original
415 CZ  6a master link 12.7 x 4.14 x 9.6 415 “ČZ” N/A late 1990′s-early 2000′s Tomos
###### ###     4.43 Pins – dark blue drawers #### ##################################
Jawa link  6c master link 12.7 x 4.42 x 9.2 Jawa $4 Jawa – thicker pin & roller
428 link  6d master link 12.7 x 4.43 x 11.4 428 $5 small motorcycles

 

Master Links Cabinet

At left is Myrons Mopeds master link cabinet, full of master links and half links from 20 other moped shops that closed in the late 1980′s in Southern California. Each of the drawers contains about 10 to 100 links. Each link was measured carefully and/or put through this gauntlet of Go/NoGo gauges, which are the actual master links and corresponding inner links contained in each drawer. From left to right, the order is smallest pitch first, smallest pin first (for that pitch), and the smallest inner width first (for that pitch and pin). Inner width for a master link is the space between the inside of the outer plates, which is slightly greater than the inner width for the chain, as in the chart below.

Notice that there are no “international” master links, like 04B (6mm) or 05B (8mm). These chains did not appear in California until the late 1990′s with the stand-up scooters, pocket bikes, and electric bikes and scooters, mostly from China.

 

 

C H A I N S   E X P L A I N E D

 

Chains

Chains for mopeds, motorized bicycles, gas or electric scooters, and minibikes are not on most application charts. For these oddball vehicles you have to measure and determine which chain size it takes, and how many links. Some Chinese made scooters and pocket bikes have 6.00mm pitch (not 6.35 = 1/4″) or 8.00mm pitch (not 9.53 = 3/8″). They look the same but don’t mesh on American sprockets. Another main source of confusion is pin diameter. Often several different chains interchange (fit the same sprocket), but have different pin diameters, pin lengths, and plate thicknesses. So while the entire chain interchanges, the individual links do not. A master link from one 415 chain often does not fit another 415 chain. Wow.

 

How to use the Myrons Complete Chain Size Chart : 

The dimensions of “every” roller chain, that might be used on motorcycles, scooters or bicycles, are listed below. The first three dimensions, pitch P (distance between pin centers), width W (distance between inside of inner plates), and the roller diameter D, are what matter for it to fit the sprocket. A wider chain (larger W) will work but not as good. European moped chains are #415 compatible. Asian moped chains are #420. Single speed bicycle chains are #410. Electric and small gas scooters are #25 (American) or #04B (International). Gas scooters and pocket bikes are #35 (American) or #06B (International). American made mini bikes are #35 or #41. American power equipment and industrial chains are #25, #35, #41, #40, #50, #60, and up. Modern motorcycle chains are #420, #428, #520, #525, #530, and #630. Small engine timing (cam) chains are #25 (American), or #04B (International).

Chain DimensionsScan up and down the chart looking for similarities. Notice how the pitch P, and roller width W, and roller diameter D, can be the same for many different chains. Too bad the pin diameter A can vary with the maker. Ouch. A pin too big won’t fit. A pin too small will fit, but will be loose. The only way to get the correct master link is by knowing the pitch P, roller width W, roller diameter D,  inner width W+2*T, and pin diameter A.

######## #### ################################ ####### #########################
Wire Gauges    MYRONS COMPLETE CHAIN SIZE CHART made from many charts combined
BS 10=3.25mm                 by Shaun Strahm  Feb 2013
US 10=3.57 Chain  ANSI     ISO std      JIS std      BS std
BS 9 = 3.66   ISO=  International Organization of Standardization ####### #########################
US 9 = 3.97   ANSI  American National Standards Institute bush B29.1   ISO 1395   JIS B1801
BS 8 = 4.06   ASA  American Standard Association (old name) roller B29.1   ISO 606     JIS B1801
US 8 = 4.37   BS =  British Standard or “Metric Chain” heavy use B29.1   ISO 3512
BS 7 = 4.47   JIS =  Japanese Industrial Standards bicycle             ISO 9633   JIS D9417   BS 228
US 7 = 4.76   JCAS  Japan Chain Association Standards motorcycle             ISO 10190  JCAS 1     BS 6715
BS 6 = 4.88   DIN=  Deutsches Institut für Normung ####### #########################
US 6 = 5.16     ISO 606 (DIN 8187) is European
    ANSI B29.1 (DIN 8188) =American
######## #### ################################ ####### #########################
           (dimensions in millimeters)       calcd master link
 Chain  A#   chain   roller   roller   pin   plate  inner  outer max     min         quotes = directly measured
  Size  or    pitch   width   diam  diam  thick  width  width pin    inner         ? = estimate or guess
 P x W ISO#  JIS#     P        W        D        A       T    W+2T     R dia  width Std   Source           Application/Notes
######## #### ################################ ####### #########################
CHAIN SIZE   #    pitch   width   roller   pin   plate  inner  outer master link     S M A L L E R      C H A I N S :
3/16 x 3/32 03C 15      4.76   2.38   4.00   1.85   0.60   3.78   6.80 ISO   hzpt.com       industrial
M5 x 2.5 03B           5.00   2.50   3.20   1.49   0.60   3.70   7.40 BS/DIN beijingthc.com
M6 x 2.8 04B           6.00   2.80   4.00   1.85   0.60   4.00   7.40 BS/DIN beijingthc.com
M6 x 2.8 04B           6.00   2.80   4.00   1.85   0.60   4.00   6.80 BS    hzpt.com       industrial
M6 x 2.8 04B           6.00   2.80   4.00   1.83   0.61   4.02   6.30 BS    Allied-Locke   industrial
1/4 x 1/8 04C 25      6.35   3.18   3.30   2.30   0.75   4.68   7.60 ANSI hzpt.com       (bush, not roller)
1/4 x 1/8 04C 25      6.35   3.18   3.30   2.29   0.76   4.70   7.92 ANSI Diamond       (bush, not roller)
1/4 x 1/8 04C 25      6.35   3.18   3.30   2.28   0.76   4.74   8.64 ANSI docstoc.com  (bush, not roller)
1/4 x 1/8 04C 25      6.35   3.18   3.30   2.30   0.75   4.68   8.60 ANSI chainsprocketpulley.com
1/4 x 1/8 04C 25      6.35   3.28   3.25   2.27   0.80   4.60   7.95 ANSI “25″ direct measure
1/4 x 1/8 04MA 25H    6.35   3.18   3.30   2.30   1.00   5.18   8.90 ANSI mdmetric.com (bush)
1/4 x 1/8 04MA 25H    6.35   3.18   3.30   2.30   1.00   5.18   9.00 ANSI hzpt.com       (bush, not roller)
1/4 x 1/8 04MA 25H    6.35   3.22   3.25   1.99   1.00   5.22   8.95 ANSI “DID 25SH”
1/4 x 1/8 04MA 25H    6.35   3.28   3.25   2.0?   1.00   5.18   8.95 ANSI “25H” (PC50 cam chain 42L)
M7.8 x 4.7 05MA 219    7.77   4.68   4.59   3.00   1.20   7.08   11.5 JCAS mdmetric.com (bush)
M8 x 3.0 05B           8.00   3.00   5.00   2.31   0.80   4.60   8.20 BS    hzpt.com       industrial
M8 x 3.0 05B           8.00   3.00   5.00   2.31   0.75   4.50   8.2? BS/DIN beijingthc.com
M8 x 3.0 05B           8.00   3.2     5.00   2.3     0.75   4.7      8.2? BS/DIN ocm.co.jp  industrial
M8 x 4.7 05T           8.00   4.70   4.73   3.05   1.25   7.20   11.0 ISO   hzpt.com       industrial
M8.5 x 4.8 05MC 270H  8.50   4.75   5.00   3.28   1.80   8.35   13.3 JCAS mdmetrics.com (bush)
3/8 x 5/32 old     9.53   4.00   6.28   3.23   1.25   6.50   10.9         “W” circled      (roller) Tomos A3
3/8 x 5/32 old     9.53   4.05   6.35   3.2?   1.30   6.65   10.6         “Regina Extra” (roller) Tomos A3
3/8 x 3/16 06C 35      9.53   4.76   5.08   3.58   1.27   7.30   11.8 3.57×7.7 ANSI Diamond       (bush, not roller)
3/8 x 3/16 06C 35      9.53   4.76   5.06   3.56   1.30   7.36   11.7 3.57×7.7 ANSI “ANSI 35″  (bush, not roller)
3/8 x 3/16 06C 35      9.53   4.76   5.08   3.58   1.27   7.30   12.7 3.57×7.7 ANSI docstoc.com  (bush, not roller)
3/8 x 3/16 06C 35      9.53   4.85   5.10   3.6?   1.35   7.55   11.9 3.57×7.7 ANSI “Regina ASA 35″ (bush)
3/8 x 3/16 06C 35      9.53   4.99   4.99   3.6?   1.10   7.19   11.7 3.57×7.7 ANSI “KMC 35″ (bush) Tomos A35/55
3/8 x 7/32 06B           9.53   5.72   6.35   3.28   1.32   8.36   13.4 BS/DIN ocm.co.jp  industrial
3/8 x 7/32 06B           9.53   5.72   6.35   3.28   1.30   8.32   13.2 BS    hzpt.com        industrial
3/8 x 7/32 06B           9.53   5.72   6.35   3.28   1.27   8.26   12.5 BS/DIN beijingthc.com
3/8 x 7/32 06BH           9.53   5.72   6.35   3.28   1.50   8.72   14.0 ISO   hzpt.com       industrial
3/8 x 1/4           9.53   6.35                               obsolete ?
3/8 x 5/16           9.53   7.94   5.03                              (bush, not roller)
3/8 x 3/8 06MA T3F    9.53   9.50   6.00   4.50   1.80   13.1   18.6        (China only) (bush)
######## #### ################################ ####### #########################
CHAIN SIZE   #    pitch   width   roller   pin   plate  inner  outer master link     B I C Y C L E   C H A I N S :
1/2×11/128           12.7   2.2?   7.75   3.6?   0.7?   3.6?   5.5 special ISO   wikipedia      bicycle 11sp Camp
1/2×11/128           12.7   2.2?   7.75   3.6?   0.8?   3.8?   5.9 special ISO   wikipedia      bicycle 10sp Camp
1/2×11/128           12.7   2.2?   7.75   3.6?   0.8?   3.8?   6.2 special ISO   KMC X10       bicycle 10 speed
1/2×11/128           12.7   2.2?   7.75   3.6?   0.9?   4.0?   6.6 special ISO   KMC Z9000   bicycle 9 speed
1/2 x 3/32           12.7   2.4?   7.75   3.58   0.9?   4.2?   7.1 special ISO   KMC Z72       bicycle 7-8 speed
1/2 x 3/32           12.7   2.4?   7.75   3.58   1.0?   4.4?   7.3 special ISO   KMC Z50       bicycle 6-7 speed
1/2 x 3/32           12.7   2.5?   7.75   3.58   1.0?   4.5?   7.8 none ISO   KMC Z30       bicycle 5-6 speed
1/2 x 3/32 082           12.7   2.40   7.75   3.63   1.0?   4.4?   8.1 none BS/DIN THC 47 beijingthc.com  bicycle
1/2 x 3/32           12.7   2.45   7.70   3.57   1.00   4.45   7.5 none ISO   “Sedisport”    bicycle 5-6 speed
1/2 x 3/32           12.7   2.55   7.71   3.58   1.00   4.55   7.9 none ISO   “W.S.  7-6″   bicycle 5-6 speed
1/2 x 1/8 081           12.7   3.30   7.75   3.66   1.10   5.50   10.2 3.57×5.8 BS/DIN hangzhou bicycle 1-spd
1/2 x 1/8 43      12.7   3.40   7.75   3.63   1.02   5.40   9.4 3.57×5.8 ANSI THC 42 beijingthc.com  bicycle
1/2 x 1/8 410    12.7   3.45   7.71   3.57   1.00   5.45   8.8 3.57×5.8 ISO  “TAVA  Taiwan” bicycle 1sp
1/2 x 1/8 old     12.7   3.46   7.74   3.57   0.95   5.36   9.2 3.57×5.8 ISO  “U” Union-Styria  bicycle 1sp
1/2 x 1/8 410    12.7   3.50   7.68   3.59   1.00   5.50   8.8 3.57×5.8 ISO  “KMC   Z”       bicycle 1-speed
######## #### ################################ ####### #########################
CHAIN SIZE   #    pitch   width   roller   pin   plate  inner  outer master link     M O P E D   C H A I N S :
1/2 x 3/16 42      12.7   4.80   7.77   3.63   1.02   6.84   10.8 3.57×7.2 ANSI OCM chain S Series
1/2 x 3/16 42      12.7   4.95   7.75   3.58   1.02   6.95  10.6 3.57×7.2 BS   “TYC 82D”    freight bicycle
1/2 x 3/16 42      12.7   5.00   7.74   3.57   1.02   7.00   11.1 3.57×7.2 old  “Sedis France” Peugeot 102
1/2 x 3/16 42H   12.7   5.00   7.72   3.58   1.27   7.54   12.? 3.57×8.0 ANSI “42 USA”
1/2 x 3/16 old     12.7   5.02   7.72   3.87   2.00   9.02   14.5        “Regina Extra”  heavy duty Italian
1/2 x 3/16 old     12.7   5.04   7.68   3.88   1.50   8.04   13.2 3.87×8.2        “IRIS”      Derbi, Motobecane
1/2 x 3/16 415     12.7   5.02   7.72   3.89   1.70   8.42   13.8        “Regina 415″ Tomos A3
1/2 x 3/16 415    12.7   5.04   7.75   3.92   1.25   7.54   11.7 3.92×7.9         “Sedis France” Peu 103, Batavus
1/2 x 3/16 415    12.7   5.03   7.71   3.95   1.25   7.53   11.8 3.92×7.9         “unmarked”  round rivets
1/2 x 3/16 415    12.7   5.05   7.73   3.96   1.25   7.55   12.2 3.92×7.9         “Sedis France” round rivets
1/2 x 3/16 415    12.7   4.88   7.75   3.96   1.30   7.48   12.5 3.92×7.9 ISO   ZHC chain     moped
1/2 x 3/16 415H  12.7   4.99   7.69   3.92   1.50   7.99   13.1 3.92×8.5 JCAS “KMC K415H”  bmx freestyle
1/2 x 3/16 415H  12.7   5.00   7.67   3.93   1.50   8.00   13.1 3.92×8.5 JCAS “C I C” Tomos A35 mid 00′s
1/2 x 3/16 415H  12.7   4.92   7.71   3.93   1.50   7.92   13.2 3.92×8.5 JCAS “RK 415H”     moped/freestyle
1/2 x 3/16 415H  12.7   4.95   7.68   3.93   1.50   7.95   13.3 3.92×8.5 JCAS “415H”  brownish color
1/2 x 3/16 415H  12.7   4.88   7.75   3.96   1.50   7.88   12.8 3.92×8.5 JCAS ZHC chain    moped
1/2 x 3/16 old     12.7   5.00   7.73   4.05   1.30   7.60   12.2 4.05×8.2        “W” circled Tomos A3 original
1/2 x 3/16 old     12.7   5.05   7.73   4.04   1.40   7.85   12.9 4.05×8.2        “Regina Extra”  Italian mopeds
1/2 x 3/16 old     12.7   5.33   7.69   4.07   1.82   8.97   14.7 4.05×9.2        “Regina (underlined)” Italian
1/2 x 3/16 084           12.7   4.88   7.75   4.09   1.80   8.48   14.8 4.05×9.2 BS    hangzhou      industrial
1/2 x 3/16 old     12.7   5.00  7.75   4.05   2.00   9.00   14.3 4.05×9.2        “Styria” Union Puch original
1/2 x 3/16 old     12.7   4.92   7.72   4.14   1.43   7.78   12.1 4.13×8.3        “unmarked”   industrial
1/2 x 3/16 old     12.7   5.11   7.72   4.14   1.90   8.91   14.5 4.13 x 9.4        “Regina (underlined)” Italian
1/2 x 3/16 old     12.7   5.35   7.68   4.14   1.90   9.15   14.5 4.14×9.6        “ČZ” silver  Tomos A35 late 90′s
1/2 x 3/16 old     12.7   4.88   7.75   4.18   1.50   7.88   12.8 4.14×8.3        chainsprocketpulley.com
1/2 x 3/16 old     12.7   5.0?   8.4?   4.43   1.4?   7.8?   14.? 4.43×9.2        “unmarked” unknown
1/2 x 3/16 Jawa  12.7   5.0?   8.43   4.43   1.82   8.6?   14.? 4.43×9.2        “unmarked” Jawa original
1/2 x 1/4 085 41      12.7   6.25   7.75   3.58   1.25   8.85   13.7 3.57×9.2 BS    hzpt.com     light duty
1/2 x 1/4 41      12.7   6.45   7.70   3.57   1.25   8.85   13.3 3.57×9.2 ANSI “MAX 41″   light duty
1/2 x 1/4 41      12.7   6.35   7.75   3.58   1.27   8.89   13.0 3.57×9.2 ANSI Diamond     light duty
1/2 x 1/4 08MA 420    12.7   6.35   7.75   3.96   1.50   9.35   14.5 3.92×9.7 ISO   ZHC chain   motorcycle
1/2 x 1/4 08MA 420    12.7   6.35   7.72   3.95   1.50   9.35   14.8 3.92×9.7 JCAS “EK 420″     Asian mopeds
1/2 x 1/4 08MA 420    12.7   6.35   7.74   3.93   1.50   9.35   14.7 3.92×9.7 JCAS “DID 420″   Asian mopeds
1/2 x 1/4 08MA 420H  12.7   6.35   7.75   3.96   1.80   10.0   15.7 3.92×11.0 ISO   ZHC chain   motorcycle
1/2 x 1/4 420H  12.7   6.35   7.70   3.96   2.00   10.4   17.3 3.92×11.0 JCAS EK chain      motorcycle
######## #### ################################ ####### #########################
CHAIN SIZE   #    pitch   width   roller   pin   plate  inner  outer master link     L A R G E R      C H A I N S :
1/2 x 5/16 08A           12.7   7.85   7.95   3.96   1.50   10.9   16.6 BS    hzpt.com      industrial
1/2 x 5/16 40      12.7   7.94   7.94   3.96   1.52   11.0   16.0 ANSI Diamond     industrial
1/2 x 5/16 40      12.7   7.9?   7.9?   3.92   1.5?   11.?   15.? ANSI “Japan 40″   industrial
1/2 x 5/16 08B           12.7   7.85   8.51   4.45   1.62   11.1   16.7 BS/DIN ocm.co.jp  industrial
1/2 x 5/16 428    12.7   7.97   8.43   4.45   1.50   11.0   16.4 JCAS “DMC 428″  motorcycle
1/2 x 5/16 08MC 428H  12.7   7.75   8.51   4.45   2.03   11.8   18.3 ISO   ZHC chain    motorcycle
1/2 x 5/16 08MC 428H  12.7   7.94   8.51   4.50   2.00   12.0   19.6 JCAS EK chain      motorcycle
5/8 x 1/4 10MA           15.9   6.25   10.2             2.40   11.1   18.9 ISO   mdmetric.com
5/8 x 1/4 520    15.9   6.35   10.2   5.24   2.00   10.4   18.6 JCAS EK chain      motorcycle
5/8 x 1/4 520    15.9   6.35   10.2   5.08   2.00   10.4   17.7 JCAS ZHC chain    motorcycle
5/8 x 1/4 520H  15.9   6.35   10.2   5.24   2.42   11.2   18.9 JCAS ZHC chain    motorcycle
5/8 x 1/4 520H  15.9   6.35   10.2   5.24   2.20   10.8   19.5 JCAS EK chain      motorcycle
5/8 x 5/16 525    15.9   7.94   10.2   5.08   2.03   12.0   18.7 JCAS ZHC chain    motorcycle
5/8 x 5/16 525H  15.9   7.94   10.2   5.24   2.42   12.8   20.4 JCAS ZHC chain    motorcycle
5/8 x 3/8 10A           15.9   9.40   10.2   5.08   2.03   13.5   20.7 BS    hzpt.com     industrial
5/8 x 3/8 10MB           15.9   9.40   10.2             2.00   13.4   20.9 ISO   mdmetric.com
5/8 x 3/8 50      15.9   9.53   10.2   5.08   2.03   13.6   20.1 ANSI Diamond      industrial
5/8 x 3/8 530    15.9   9.53   10.2   5.08   2.00   13.5   20.9 JCAS ZHC chain    motorcycle
5/8 x 3/8 530H  15.9   9.53   10.2   5.08   2.42   14.3   21.9 JCAS ZHC chain    motorcycle
5/8 x 3/8 530H  15.9   9.53   10.2   5.38   2.40   14.3   23.0 JCAS EK chain      motorcycle
5/8 x 3/8 532    15.9   9.53   11.1 JCAS                    (bigger roller)
5/8 x 3/8 10B           15.9   9.65   10.2   5.08 BS    Morse          industrial
5/8 x 3/8 12MA           19.1   9.40   11.9             2.40   14.2   25.9 ISO   mdmetric.com
3/4 x 3/8 630    19.1   9.53   11.9   5.95   3.20   15.9   25.2 JCAS EK chain      motorcycle
3/4 x 3/8 632    19.1   9.53   12.7 JCAS                    (bigger roller)
3/4 x 7/16 12B           19.1   11.7   12.1   5.72 BS    Morse          industrial
3/4 x 1/2 60      19.1   12.7   11.9   5.94   2.39   17.5   25.1 ANSI Diamond      industrial

 

==============================================================================

Vintage Moped Chains: Vintage bikes often have obsolete chains, or they specify the size in an obsolete way. Vintage equipment used the inch size, pitch x width. Modern motorcycles all use chain model numbers, like 428, 520, 630. The above chart shows that connection. In mopeds, there are 18 different chains, all size 415, or 1/2 x 3/16. They have different pin diameters and inner widths. In modern mopeds there are about 3 or 4.

Moped Chain History: When a shop installs a new chain, they throw the leftover pieces in a box. As the years go by, layers of chains accumulate, with the oldest ones at the bottom, as long as no one mixes up the pile.  That’s one way to “date” chains. At Myrons, certain boxes of parts have been untouched since about 1985 to 1995. Only one little scrap of modern 415H chain was in that material, from those years. Not even 415H master links were in that time zone. This little scrap is what Shaun believes to be the earliest example of a 415H chain. Shown below on the Motobecane sprockets, it’s gold and  says “Taiwan”. Taiwan bicycle products and machinery blossomed in the 1980′s. China made components came out about 15 years later.

Italian Chain History: At least five different Regina chains are original on 1970′s and 80′s Italian made mopeds, two that say “Regina Extra” and three that say “Regina” underlined.  See their pictures above. They all have different master links! Craziness!

Regina pin x width   plates      name                         closest master link                 next closest 
3.96  x  9.0      2.0    Regina Extra              4a.  reg1 (3.96 x 9.2-9.5)     420H (3.93 x 9.8)
3.89  x  8.4      1.7    Regina 415                3e. 415H (3.93 x 8.5) 
4.05  x  7.9      1.4    Regina Extra              5a.  reg2 (4.05 x 8.2-8.6)     415H (3.93 x 8.5)
4.05  x  9.0      1.8    Regina (underline)     5c.  puch (4.05 x 9.2-9.4)     420H (3.93 x 9.8)
4.14  x  8.9      1.9    Regina (underline)     6a. tom1 (4.14 x 9.4-9.6)

Tomos Chain History: At least seven different Tomos chains have been used over the years.

Regina Underlined Tomos A3 1970's

Regina
Italy
1970′s
3.89 x 8.4

W Circled early Tomos

W Circled
Germany
late 1970′s
4.05 x 7.9

W Circled late Tomos A3

W Circled
Germany
1980′s
4.14 x 9.4

ČZ chain Tomos A35 4.14 x 9.6

ČZ chain
Slovenia?
late 1990′s
4.14 x 9.6

CIC 415H Tomos A35 early 2000's 3.93 x 8.5

CIC 415H
Taiwan?
mid 2000′s
3.93 x 8.5

plain 415H Tomos A55 2007-on 3.93 x 8.5

415H
China?
late 2000′s
3.93 x 8.5

W Circled Germany 2013-on 4.14 x 9.6

W Circled
Germany
2013-on
4.14 x 9.6

 

Above, seven Tomos chains take three different master links. The pins range from 3.89 to 4.14mm thick. The inner width ranges from 7.9 to 9.6mm. “Inner width” means measured between the inside walls of the outer plates. A wider inner link will not fit inside a narrow outer link.

First the “Regina underlined” (3.89 x 8.4) on early A3, and “W circled” (4.05 x 7.9) also on early A3, then “W circled” (4.14 x 9.4) on late A3, then ČZ (4.14 x 9.6) on A35, then CIC 415H on late A35, and now plain 415H (3.93 x 8.5) on A55 models. The chains got thicker and wider and taller on the outside, as the decades progressed. The pins got thicker, and then thinner, and now thick again: 3.89 ->4.05 -> 4.14 -> 4.14 -> 3.93 ->3.93 ->4.14. Same thing with inner width: 8.4 -> 7.9 -> 9.4 -> 9.6 -> 8.5 ->8.5 ->9.6. Perhaps this is why Tomos stopped selling master links…

 

MB Front Sprockets With Rubbers

Motobecane front sprockets with rubber rings.
Left, the original IRIS chain, meshes correct.
Right, modern 415H, with taller plates,
rides up too high and does not mesh.

Motobecane front sprockets without rubbers.

Motobecane front sprockets without rubbers.
Left, the original IRIS still meshes good.
Right, the 415H meshes good now.
The end roller is cut away to see the fit.

 

 

 

 

 

 

 

 

 

Motobecane:  1970′s-1980′s Motobecane Mobylette 40, 50, or 50V mopeds, the front sprocket behind the large pulley has some rubber rings that interfere with modern 415H chains. Fortunately the two 1 1/4 inch rubber rings, one on each side of the sprocket, which can be removed with something like a curved dental pick. This issue of a chain not meshing because of  (unecessary) rubber noise dampener rings contacting the outer plates instead of the sprocket contacting the rollers, is one that probably occurs on other similar machines. Their name might begin with P…

Peugeot 103: Sometimes the newer “H” rated chains do not fit until after the bike is rode for a few minutes. The two rubber rings on either side of the original sprocket interfere with the larger outer plates on the 415H chain, causing the chain to run higher and not mesh well. After riding awhile the chain noise gets less, as the rubbers get squished and interfere less. Still, it is better to remove the pulley, and remove the rubber rings, shown at right, to have a smooth running chain.

Peugeot 102 front sprocket with original rubber rings. 415H chain does not mesh.

Peugeot 102/103 front sprocket with original rubber rings. 415H chain does not mesh.

Peugeot 102 front sprocket with rubber rings removed.

Peugeot 102/103 front sprocket with rubber rings removed. 415H wraps around fully.

Peugeot 102: This is the only US-model moped that uses a 42 chain, same sprocket as a 415 (1/2 x 3/16), but lighter duty (thinner pins, thinner and smaller plates). Sedis made both 415 chain for Peugeot 103, and 42 chain for the lighter weight Peugeot 102. Old Sedis chains are often cracked. Then they break/throw the chain. No fun. To use a modern 415H chain, the two rubber rings on either side of the sprocket must be removed, or it won’t mesh properly. See photos at right.

Motorized Bicycles 415 – Only Kind: Certain modern motorized bicycle gas engine kits use a 415 chain that passes very close to the engine case on both sides. These do not have enough room for the wider-on-the-outside 415H. They require a 415.

Motorized Bicycles:  415 and 410 Mixed: Certain modern motorized bicycle gas engine kits have a wide engine sprocket for 3/16 and a thin rear sprocket for a 1/8 chain. A 415 or 415H chain works but would be expected to have less retention (it would come off easier).

Motorized Bicycles:  Long Chain Runs: Motorized bicycles with long chain runs need chain guides and/or chain tensioners, or else the chain comes off when it slaps going over bumps, or when the frame or wheel flexes, or when the engine mounts shift/slip. The kits don’t usually come with any.

American Made Minibikes: There were many different manufacturers of minibikes back in the 60′s and 70′s but most of them used either a 35, 40, 0r 41 chain. Number 35 was used on most all 4-5-6 inch wheel minibikes while 41 was used on larger minicycles such as Rupp Roadster II and Speedway. Number 41 chain will not run on a number 40 sprocket. Number 40 chain will run on a number 41 sprocket but it will be wider than needed.

Fun Karts and Minibikes: Many chains have the chain size stamped directly on the chain links. #35, 40, 41 and 420 chain are used in the Fun Kart and Mini Bike industry. An 11 or 12 tooth clutch sprocket usually indicates the use of #35 chain. 10 tooth clutch sprockets usually indicate the use of #40, 41 or 420 chain.

More about ANSI chains:   http://chain-guide.com/applications/1-1-1-ansi-roller-chains.html

More about sprockets:  http://www.gizmology.net/sprockets.htm

More about International chains:  http://www.renold.com/Support/ChainInformationCentre/Chain_Standards.asp

 Why all of this madness about chains?   All through the 1970′s and 1980′s when you needed a master link for your moped, you had to get it from a dealer that sold that kind, or else you had to bring in your chain and hope they could find one that fit. If you had a Motobecane and you needed a master link, you could not get one from a Puch dealer, even if you showed them your chain. Their master links had thicker pins. For decades, owners have been frustrated when they bought a #415 master link for their chain, and it did not fit. That’s because there are 18 or so different 415-compatible chains. By the 1990′s no moped shop sold master links, instead they made you buy a whole chain. Thankfully, there is much better standardization in this century, in moped chains. But there are still a lot of older moped chains and substitutes that are all different. So it’s still not possible to tell (guess) what master link a customers moped needs over the phone. Some things never change… 

  

5   S P R O C K E T S

 

================================================================================

Coming up: How to tell the chain pitch by measuring the sprocket. Hint: the diameter at the tooth tops is not important.

Chain Pitch equals Pitch Diameter times Pi divided by the number of teeth.

Measuring the Pitch Diameter is difficult, especially with odd numbered and low numbered tooth counts.

Locating two pin centers, 180 degrees apart, and measuring the distance between, is the problem.

You have to know the roller diameter to locate the pin center. Something like a chopstick is needed…

Under construction …

 

6    B E L T S

================================================================================

Under construction …

 

 

 


Controls: Handlebars, Levers, Throttle parts, Grips

September 17, 2012

CONTENTS:   Welcome    1  Handlebars & Grips    2  Magura Controls    3  Domino Controls    4  P.V. Controls 

  5. Ci.Te. Controls  6.  O.S.L. Controls   7.  Universal Controls

Welcome. More handlebar pictures and choices are coming. These are not all of the different kinds of moped controls and levers. Motobecane, pre-1987 Derbi, Solex, Kinetic, Jawa, Indian, General, Honda, and others have different levers. But the vast majority of the European made mopeds use either Domino or Magura controls and levers.

1   B A R S   &   G R I P S

=================================================================================

Part.# # Description Price Applications
………H…A…N…D…L…E…B…A…R…S……..
110511 bar..superbike..black.2-bend.2″.rise $25.00
bar..superbike..chrome.2-bend.2″.rise $25.00
bar..drag.black.1-bend.0″.rise $25.00
bar..drag.chrome.1-bend.0″.rise $25.00
110540 bar..clubman..chrome $30.00
616564 bar..daytona..chrome.2-bend.2″.rise $25.00
616563 bar..euro..chrome.2-bend.2″rise. N/A
3346 bar..Wald.chr.2-bend.2″.rise.center.hump $15.00 fits.Tomos.07-on.not.others

>>>>>>>>>>>>>>>>> G  R  I  P  S   <<<<<<<<<<<<<<<<<<<<

Almost all small motorcycle left grips are inside diameter 22mm (7/8″), to fit the bare handlebar. Right grips are ID 25mm (1″) to fit the throttle twist tube. Moped grips are shorter than most motorcycles. The left side doesn’t matter, but the right side does. When the left grip is longer, the lever housing (perch) is moved over to make room. When the right grip is longer, it must hang over the end, or possibly make the throttle stick. Standard motorcycle grips are 115 (4 1/2″) to 130mm (5 1/4″) or more. Moped grips are 105mm long (4 1/8″). There’s not a big selection in the shorter size.

Grips

 

 

 

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
……… … …G…R…I…P…S……… motorcycle 115-130mm, moped 105-120mm
197672 2 grips 22/25 x 120 ProGrip767 gel black $12 modern gel replacement
170766 6 grips 22/25 x 140 large foam chrome ends $20 close to original on Tomos Revival and Streetmate
494200 1 grip L 22 ID x 105 Magura black ribbed $2 orig on Puch, Peugeot, Batavus, Sparta, many
494170 1 grip R 25 ID x 105 Magura black ribbed $15 orig on Puch, Peugeot, Batavus, Sparta, many
414310 grip L 22 ID x 105 Magura waffle (used) $5 orig on Puch “Sport” models
414300 grip R 25 ID x 105 Magura waffle (used) $30 used in good condition,  maybe others for less
494080 grip L 22 ID x 105 Magura block (used) $10 orig on Puch Magnum
494050 grip R 25 ID x 105 Magura block (used) $20 used in good condition,  maybe others for less
D22 grip L 22 ID x 105 Domino ribbed (used) $12 orig on Cimatti, Garelli, most Italian 1970′s
D21 grip R 25 ID x 105 Domino ribbed (used) $15 used in good condition,  maybe others for less
223712 grip R 25 ID x 130 round dome bumps $15 orig on 1992-08 Tomos
223711 grip L 22 ID x 130 round dome bumps $12 orig on 1992-08 Tomos

Many more grips are not listed or shown. Domino (Italian) grips, in several versions, are shown below in Domino Controls. Original equipment grips, some new and some used, are offered for “correct” restorations, when modern replacement grips (better material and less cost) are not desired. 

 

2   M A G U R A  L E V E R S

================================================================================

Magura is the most common moped lever. There are two main types, the Magura “Wrap Around”, where the throttle cable wire wraps around the twist tube, and the Magura “Sliding Block”, where the throttle cable goes straight in (see below).

Balls or No Balls: Early versions had no balls on the levers, and had part of the throttle twist tube exposed, such as 1960′s Puchs. The last moped to have pointed levers was the 1978 Sears Free Spirit.

Brake Light Switch or Not: Euro versions have no threaded hole for the brake light switch. US mopeds all had threaded holes in their controls. Aftermarket replacements usually do not.

Peugeot or Not Peugeot: There are two ways to stop the brake cables. The Peugeot way is to have 6mm threaded holes in the housings with 6mm adjustors stopping the cables. The non-Peugeot way is to have the housings stop the cables (or the inline Magura-type adjuster) with a slotted recess instead of threads. You can convert to Peugeot style by drilling and tapping.

 

 

 

 

 

 

 

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### #################################
……M A G U R A……L E V E R S… used on all German plus other mopeds:
…M A G U R A W R A P – A R O U N D Batavus/Colombia/Flandria/Foxi/Dutchman/Hercules
SILVER painted housings (1970s)> JCP/Kreidler/KTM/Kynast/Murray/Odyssey/Puch
Sachs/Sears/Sparta/74-84 Tomos/79-83 Trac/others
BLACK painted housings (1980s)> Puch 80-83 plain Maxi Tomos 80-85 some
412501 1 lever Magura Left folded alum w/ball $25 used or use new R lever flipped over
760169 2 lever Magura R folded alum w/ball $16 new and shiney
412871 8 lever return spring left $7 helps lever snap back nice
415771 9 lever return spring right $3 helps lever snap back nice
760014 6 lever pivot bolt & nut Magura 6/5mm $2
11 socket bolt/cable holdfast/anchor $4
101452 lever/throttle assy Mag wrap-around $60 original silver with BL switch holes
309900 13 right housing Mag wrap silver $25
309631 4 throttle twist tube Magura wrap $25 these are scarce
5 insert piece to make throttle stick leave this out or throttle won’t self-return
300520 16 lever start small black plastic $10
425030 17 start cable pinch screw 4mm $2
454890 start lever pivot pin N/A use 4mmx20 bolt+nut
118771 lever assy 70′s Magura left silver N/A some used or with R lever available
12 lever body left Magura silver $15 used available
494240 3 choke/decomp trigger locks-in off bar N/A use 430100 substitute
430100 lever substitute for choke/decomp $10 clamps on near throttle black metal
401590 10 clamping screw M6 slot head $2 non-Peugeot
10 clamping screw M6 allen head $2 Peugeot

 

This is the Magura Sliding Block throttle used on deluxe Puch mopeds:

Part.# # Description Price Applications
…M.A.G.U.R.A…S.L.I.D.I.N.G…B.L.O.C.K…
sliding-block.with.pinch-bolt.black > Puch.78-83.Luxe.Newport.Sport.Magnum
sliding-block.with.no.pinch-bolt.black > Puch.84-86.all…special.throttle.cable
123961 lever/throttle.assy..Magura.slide.black $80.00 used…good.condition
311800 right.housing..Mag..slide.black $30.00 Puch.see.above
311710 lever/throttle.twist.tube..mag..slide $20.00 Puch.see.above
311680 lever/throttle.sliding.block.w/screw $18.00 Puch.see.above
454660 lever/throttle.twist.tube.retaining.pin $2.00 Puch.see.above
lever.assy..70′s.Magura.left..black $45.00 Puch.see.above
lever.body.left.Magura..black $15.00 Puch.see.above
412811 lever..Magura.L..cast.aluminum $30.00 Puch. Magnum..not.a.copy
414961 lever..Magura.R..cast.aluminum $25.00 Puch.Magnum..not.a.copy
305991 lever..Magura.start..metal.Puch.2-spd $20.00 Puch.two.speed.models

3   D O M I N O   L E V E R S

=================================================================================

Domino levers/controls are made in Italy in the 1970′s. They are found on almost all Italian mopeds, but not any other makes. The levers are chrome, stamped from sheet metal. Early levers, such as on a 74-77 Vespa Ciao, had no balls on the ends. The throttle is a sliding block type, where the twist tube (barrel) has a spiral slot that turns the twist into a sideways motion. The sliding block also contains a pinch bolt to attach the cable wire. So there is no cable end piece needed at the throttle end, unlike a wrap around type throttle. This means the throttle cable is “universal”, one cable fits all, because the sliding block contains the pinch bolt, not the cable end. On the other hand, these throttles need frequent lubrication (oil or grease), or they become sticky and eventually wear out. Because the twist tube is steel and the sliding block is aluminum, it’s the sliding block that wears out first, causing further sticking.

Several generations and many versions of Domino levers exist. From 1974-1985 US mopeds had Domino “Chrome” levers. From about 1984-1991 US mopeds had Domino “Black” levers. See below. Domino “Chrome” housings (main bodies), left and right, were painted silver in the 1970′s, and black in about 1980-1985. Early versions had no throttle return helper spring. You can’t just add a spring to those because the housing and twist tube have no provisions for it.

European models do not have brake lights. So their housings don’t have threaded holes for brake light switches. Their levers do not come with the plate that pushes the button on the brake light switch. Their levers do not have the extra little hole punched in them to anchor the brake light switch plate.

Only early 76 Cimatti had a Domino wrap-around type throttle, not shown here.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
          D O M I N O    L E V E R S used on all Italian plus others
            1 9 7 0 ‘ s    c h r o m e
DA1 R assm Dom70s no spring/silver/ribbed $70 silver no helper spring for throttle most 70s Italian
DB1 L assm Domino70s silver ribbed grips $35 silver most 70s Italian ribbed grips
DA1A R assm Dom70s spr/blk/sw8194/D21 n.a. black w/spring and diamond switch mount grip D21
DB1A L assm Domino70s black/sw8193/D22 $35 black with diamond switch mount waffle grip D22
DA2 R assm Dom70s spring/black/grips? n.a. black with helper spring unknown grips
DB2 L assm Domino70′s black/grips? $35 black early 80s Italian unknown grips
DA3 R assm Dom70s spring/black/ribbed n.a. same as DA2 but with ribbed grip
DB3 L assm Domino70′s black/ribbed $25 same as DB2 but with ribbed grip
DA4B R assm Dom70s spr/blk/sw8194/D21B $70 same as DA1A but with D21B grip
DB4B L assm Domino70s black/sw8193/D22B $25 same as DB1A but with D22B grip
D1 26 sliding block Dom 70′s n.a. very scarce
D2 27 pinch bolt Dom 70′s $3
D3 28 barrel clamp screw $3
D4 25 barrell spacer not nec n.a.
D5 17 R housing silver plain $35 for assembly DA1 Most 70s Italian mopeds
D5A 17 R housing black plain no spring not for known assys replaces D5
D5B 18 R housing black for spring&sw8194 $35 for DA1A DA4B with diamond switch mount
D5C 18 R housing blk for switch CEV 8194 no spring not for known assys replaces D5
D6 20 throttle barrel no spring type $10 also known as the twist tube
D6A 35 throttle barrel spring type $10 longer to make room for the spring
D7 14 nut M6 flange $1
D8 12 pivot bolt M6 $2
D9 22 stepped tube bushing snaps into lever n.a. about 6x8x12mm tube with 1x1mm step at ends
D9A 21 stepped tube snaps into start lever n.a. about 6x8x10mm tube with 1x1mm step at ends
D10 33 lever R/L brake lite actuating plate $7 round tab snaps into small hole in lever
D11 24 spring R/L brake return $4
D12 23 spring start lever return $4
D13 24 pivot bolt M6 for start $3
D14 6 cable holdfast/socket bolt $4
D15 15 clamping bolt lock tube “wedge” $3 this cone digs into the bar move over to make tight
D16 16 R clamping bolt 6mm allen $1 these bolts precisely fit the cone D15
D17 16 L clamping bolt 6mm allen $1
D18 2 L housing silver plain $20 for assembly DB1 Most 70s Italian mopeds
D18A L housing black plain w/mirror hole $20 for DB2 DB3 no switch mount early 80s Italian
D18B 19 L housing black for mirror&switch8193 $20 for DB1A DB4B diamond switch mount
D19 7 lever start/clutch blade only $12
D20 5 lever R/L blade only Dom 70s chrome $8
Dlever lever complete w/D-20,9,10,11 $25
D21 3 right grip 1″ID standard style n.a.
D22 4 left grip 7/8″ID standard style n.a.
D23 34 lever/throttle return spring 2-loop $4
D24 11 adjuster M5 for throttle cable w/nut $2
D25 cover for when theres no switch $6
D26 cover screws (2) $1
D5Gar R housing silver for switch oval $25 for Garelli oval CEV switch
D5GrTS R housing gray for sw 8191 $25 for Vespa Grande rectangle CEV turn sig+stop switch
D5Ves R housing silv for kill button $25 Vespa
D18Gar L housing silver for switch 8109 $25 for Garelli oval CEV switch
D18Ves L housing gray for switch 8192 $25 Vespa

These are 1984-92 Domino ”Black” plastic levers, used mainly on Tomos, Trac, Derbi, and Garelli.

 

 

 

 

 

 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
D O M I N O    B L A C K    1 9 8 0 s
sliding-block w/built-in CEV switches
DB8K A L assembly brake only with grip $30 85-91 Tomos
DA7K B R assembly brake/throttle 85-91 Tomos 85-on Garelli
DB7K C L assembly brake/start with grip $40 85-on Garelli 86-89 Derbi 84-88 Trac
DA8K D R assembly brake/throttle/choke 84-88 Derbi 84-88 Trac
D21K 3 R grip $10 black vinyl squarish-octagon smooth
D6A 3a throttle twist tube metal $10 early 80′s type, uses D1 sliding block
D6L 3a throttle twist tube plastic late 80′s type, uses D1L sliding block
D22K 4 L grip $10 black vinyl squarish-octagon smooth
D5K 5 R housing brake/throttle for DA7K 85-91 Tomos 85-on Garelli
D5L 5a R housing brake/throttle/choke for DA8K 84-88 Derbi 84-88 Trac
D18L 6 L housing brake only for DB8K 85-91 Tomos
D18K 6a L housing brake/start for DB7K 85-on Garelli 86-89 Derbi 84-88 Trac
D20KR 7 R lever $14 smooth black plastic
D20KL 8 L lever $14 says Domino underside of lever
D1 9 sliding block for metal twist tube n.a. early 80′s type, uses D1 sliding block
D1L 9 sliding block for plastic twist tube $12 late 80′s type, uses D1L sliding block
D3 10 screw that holds throttle twist tube $3
D23 11 throttle helper spring 3-loop $7
D2L 12 pinch bolt for sliding block $3
D15 13 cone that wedges into handlebar $3
D16 14 clamp bolt M6 $3
D8 15 pivot bolt $2
D11K 16 brake helper spring R&L $4
D7 17 nut for pivot bolt M6-flange $1
D29 18 adjuster M6 for brake cables $4
D24 19 adjuster M5 for throttle&choke $2
D14K 20 brake cable holdfast/socket bolt n.a. must use a modified Magura one
D35 21 choke lever $10
D36 choke lever holdfast n.a. must use a modified Magura one
D37 choke lever retaining rivet n.a. must drill and tap
D19K 22 start lever $20
start parts same as brake lever

Here are the two different Domino sliding blocks, shown with two different views. At left is the 1970′s Domino type, part nymber D1. At right is the 1980′s Domino type, part number D1L. The older D1 kind is wider, and the “tongue” that slides in the spiral groove of the twist tube is narrower than the D1L kind. Currently the D1 is rare and expensive, but the D1L is cheap and abundant. You can’t substitute a D1L for a D1, even grinding the tongue, because it is narrower, and will cock sideways and stick. When a sliding block throttle sticks, of course, you first put oil on it. When the “tongue” wears down, one side gets rubbed, and it gets thinner, causing the throttle to stick.

 

 

 

 

Below are the 1991-2007 Tomos controls, made by Domino. They’re sliding block type with CEV integral switches.

 

 

 

 

 

 

 

 

 

###### ### ############################# #### ##################################
D O M I N O…T O M O S…1 9 9 0 s……… Tomos 92-07 A35 Bullet/Sprint/Targa/ST/LX
223701 L assembly brake no grip $45
223700 R assembly brake/throttle no grip $60
223712 R grip $10 black vinyl octagon with raised dome bumps
223706 throttle twist tube 92-08 Tomos $20
223711 L grip $10 black vinyl octagon with raised dome bumps
223703 R housing brake/throttle $30
223702 L housing brake only $30
223705 lever R Domino 92-07 Tomos black $15 black plastic levers with round bumps
223704 lever L Domino 92-07 Tomos black $15 they say TOMOS molded-in
223707 sliding block (not D1 orD1L) $25 there is a substitute/upgrade for this
223708 screw that holds throttle twist tube $1
223709 throttle helper spring 3-loop $5
223708 pinch bolt for sliding block $1
223713 cone that wedges into handlebar $3
026561 clamp bolt M6 $1
027222 pivot bolt $2
227996 brake helper spring Right $3 these break often but they still work good
223710 brake helper spring Left $3
030040 nut for pivot bolt M6-flange $1
229556 adjuster slotted M6 for brake cables $5 there are also $2 ones not knurled not slotted
M5adj adjuster M5 for throttle&choke $2
227169 brake cable holdfast/socket bolt $3 longer than other kinds

PV4   P.V.  L E V E R S

================================================================================

PV Levers exploded viewP.V. is an Italian moped lever, used on Intramotor Gloria, Testi/Gitane, Califfo and other “early” Italian mopeds. None of the parts interchange with Domino. The lever blades are all black plastic, as are the throttle twist tubes. The housings are cast aluminum. The housings break easily when the bike falls over. Instead of a pivot bolt they have a press-in 6mm roll pin.

 

 

 

 

P.V. LeversAt left are all the PV levers, out of hundreds of Magura, hundreds of Domino, and dozens of Motobecane and Taiwan levers, from 20 old moped shops inventory.

Brake lever     $25
Start lever       $40
Left housing   $45
Right housing  N/A
throttle tube     $7
socket bolt = same as Domino
sliding block = unknown
 

 

 

Ci.Te. Logo

  Ci.Te.  L E V E R S

================================================================================

Ci.Te. is an Italian moped lever used on 1960′s and early 1970′s Italian mopeds. They are similar to 1970′s Domino levers. You can see that in the side-by-side comparisons below. Domino blades have the D9 special stepped tube 6mm ID, that snaps into the 8mm pivot hole, to spread out the load over a large area. Ci.Te. levers are more primitive in that the blades rub on the pivot bolt in just two places, and so the pivot bolt gets cut by the sharp edge of the folded sheet metal.  Domino levers also have assist springs, but Ci.Te. levers do not. Ci.Te. controls have no facility for mounting brake light switches. Ci.Te. lever blades do not have balls on the end. These last two things are required on USA mopeds. So therefore Ci.Te. levers are rare in the USA. Out of almost 1000 moped levers, new and used, mostly Magura and Domino, there was only one Ci.Te. lever blade. That is how rare they are in Southern California 1970′s -1990′s 20 moped shops leftover parts inventories plus 100′s of local mopeds turned into parts.

Ci.Te. levers on 1968 Lambretta Lambretino

Ci.Te. levers on 1968 Lambretta Lambretino

Ci.Te. Levers 1

Ci.Te. levers top view
Rt assy no lever $80

Ci.Te. Levers 2

Ci.Te. levers bottom

Ci.Te. and Domino left lever assys

Ci.Te. and Domino left 1

 

 

 

 

 

Ci.Te. and Domino left lever assy 2

Ci.Te. and Domino left 2
both use M6x1 adjusters

Ci.Te. and Domino left lever assy 3

Ci.Te. and Domino left 3
Left: Ci.Te.   N/A
Rt: DB1 no ball end  $45
($35 for ball end)

Ci.Te. and Domino chrome brake levers

Ci.Te. and Domino
chrome brake levers
Ci.Te. has 6mm hole
Domino has 8mm hole
6×8 rings would adapt

Ci.Te. right lever assy on 1970's Zanetti

Ci.Te. right lever assy
on 1965 Zanetti

 

 

 

 

 

 

 

 

6   O. S. L.   L E V E R S 

==================================================================================

O.S.L. levers are heavy duty and high quality Italian controls, used on some mid to late 1980′s US model mopeds including Safari, Benvenuti, and Cosmo (Colt). They look like Domino, except for the kink in the middle of the lever. Myrons does not have any OSL controls or levers for sale. They were (almost) never on any mopeds sold in California. Out of a thousand moped levers at MM, this is the only OSL sample.

OSL left lever assy

OSL left lever assy

OSL left lever assy top side

OSL left lever assy top

OSL left lever assy bottom

OSL lever bottom

OSL left lever assy showing brake light switch plate inside lever

shows brake switch plate inside lever

 

 

 

 

 

 

 

 

6   U N I V E R S A L

==================================================================================

These are the universal throttles and levers:

 

 

 

Part.# # Description Price Applications
………..U..N..I..V..E..R..S..A..L…………
26-0321  3 throttle.mini-bike.7/8″bar.w/grips.no.lev $15.00
614630 throttle+cable.motorcycle.no.brake.lever $22.00
614631 throttle+cable.motorcycle.no.brake.lever $22.00
710001  2 throttle.assy.Domino.mini-bike
710005  1 brake.lever
throttle.motorcycle.no.brake.lever $25.00

 


Cable parts: Cables, inner wires, end pieces

September 15, 2012

CONTENTS:   Welcome   1  One-Ended Cables   2 Cable Parts: Pinch Bolts, Ends and Elbows, Adjusters, Ferrules  Bulk wire & conduit 3 Two-Ended Cables   < grey = planned

Welcome. This cable section is for control cables, that slide back and forth, not speedometer cables, that rotate. For speedometer cables, see Parts By Type/Speedometer.

Some control cable inner wires have two ends, and some have only one. The “end” is a round piece if metal, usually soldered onto the braided steel wire. When a cable inner wire has only one end, it can be removed from the conduit. When a cable inner wire has a ball of lead at both ends, then it is permanently trapped and cannot be removed without cutting one end off.

Universal cables only have one “end”. A pinch bolt is placed anywhere along the wire, where ever is correct for that application. Any stop pieces, adapters or adjusters are added, to configure it for a specific application. Then once the pinch bolt is tightened and soldered, the cable is no longer universal. It is specific for that machine and others like it. Once the pictures and diagrams are all displayed, the most common cable configurations and their applications will be listed.  

This Myrons Mopeds cable department, besides having new (NOS) and good-used cables made in the ’70s and ’80s, also has new recently made items from both motorcycle parts and bicycle parts suppliers. Usually those things are not found together, but here they are.

1  1 – E N D   C A B L E S 

==============================================================================

Row C = Cables

C1 front brake

C2 rear brake

C3 throttle cable

C4 clutch (some)

C4 clutch (some)

 

 

 

 

 

 

 

 

C5 bicycle gear cable

C5 bicycle gear cable

C5 bicycle brake cable

C6 bicycle brake cable

 

 

 

 

 

 

 

 

        part no.    description                   —-inner wire specs—-     ————-outer conduit specs————-   price
                                                           diam  end type  length    length color  diam    type        ferrules 
C1   409600  cable front brake    new  1.5mm “pear” end  39 x 48″ black  4.9mm nylon-lined  5.7mm  $12
C2   409700  cable rear brake     new  1.5mm “pear” end  62 x 69″ black  4.9mm nylon-lined  5.7mm  $12
C3   409500  cable throttle         new  1.2mm “carb” end  37 x 47″ black  4.9mm nylon-lined  5.7mm  $12
C4   409800  cable “clutch”        new  1.5mm “pear” end  43 x 51″ black  4.9mm nylon-lined  5.7mm  $12
C5   1438      univ. bicycle gear   new  1.3mm  W7 2-end  72 x 79″ black  4.7mm not lined     5.3 (1)    $5   cut off 1 end
C6   14111    univ. bicycle brake new  1.5mm  W6 2-end  60 x 65″ black  4.9mm PTFE-lined   5.7 (1)    $6   cut off 1 end
==============================================================================

Row W = Wires

W1 rear brake wire

W2 throttle wire

W6 bicycle brake

W6 univ. bicycle brake

W7 Bicycle univ. gear

W7 univ. bicycle gear

 

 

 

 

 

 

 

 

          part no.    description                                 —end specs—   –wire specs–  price
W1   500100  cable wire rear brake, new                ”pear” 6mm   1.5mm x 69″   $5   can use W1a or W6 (cut)
W1a  14238   cable wire rear brake, new                ”pear” 6mm   1.6mm x 67″   $4
W2   409900  cable wire throttle, new                   “inline” 3mm   1.2mm x 47″   $5  “inline” 3mm equals “carb” end
W3   500000  cable wire front brake, new               “pear” 6mm   1.5mm x 48″   $5   can use W1a or W6 (cut)
W4                 cable wire Peugeot throttle, NOS     “barrel” 5 x 8   1.2mm x 47″   $8
W5                 cable wire Peugeot throttle                       E1c               W2            $8
W6   1456      cable wire bicycle brake universal, new  E4b & E4c  1.5mm x 73″   $3   cut off the unused end 
W7   1457      cable wire bicycle gear universal, new    E4d & E4f  1.3mm x 79″   $2   cut off the unused end
W8                 Peugeot choke wire with end, new           E1d               W2            $6
W9   1410      cable wire bicycle tandem brake, new   E4b & E4c   1.5mm x 105″ $4   cut off the unused end
W10 14247    cable wire bike tandem gear, stainless  E4d & E4f   1.2mm x 105″ $5   cut off the unused end
W11  14651   cable wire bike tandem brake, stainless  ”pear” 6    1.5mm x 108″ $5   

 

 

2  C A B L E   P A R T S

==============================================================================

Row P = Pinch Bolts 

P1 5mm pinch bolt

P2 a,b,c 6mm pinch bolts

P3 a,b,c 7-8 pinch bolts

P4 a,b pinch bolts

P4 a,b
pinch bolts

P5 Grimeca pinch bolt

P6 a,b,c clevis pinch bolts

P6 a,b,c clevis pinch bolts

 

 

 

 

 

 

 

P7 a, b bicycle types

P7 a,b,c bicycle items

P8 a,b odd shape pinch bolts

P8 a,b odd pinch bolts

P10 and P11 loop pinch bolts

P9a (left) and P9b
loop pinch bolts

P10 and P11 taken apart

P9a (left) and P9b
disassembled

 

 

 

 

 

 
 
 
 
 
 
 
                       (barrel pinch bolt length is without bolt)
P1   121-00416 barrel pinch bolt 5mm dia 7.3 long 2.0 max wire      $2  new, for most throttles and some choke levers
P2a                  barrel pinch bolt  6mm dia 11 long 2.2 max wire      $4  good used, Motobecane brakes original
P2b                  barrel pinch bolt  6mm  dia 6 long 2.2 max wire      N/A  can grind a P1 to make shorter
P2c                  barrel pinch bolt  6mm  dia 8 long 2.2 max wire       $5  good used, Peugeot choke & throttle
P3a                  barrel pinch bolt  7mm dia 13 long 2.5 max wire      $5  good used, Peugeot brakes original
P3b                  barrel pinch bolt  7mm dia 11 long 2.5 max wire      $4  new, Vespa scooter gear shift original 
P3c                  barrel pinch bolt  8mm  dia 8 long  2.8 max wire      $4  new, with bolt end rounded 
P3c                  barrel pinch bolt  8mm  dia 8 long 2.8 max wire       $2  new, with plain bolt (slips and shreds easier)
P4a                  barrel pinch bolt  8mm dia 12 long 4.0 max wire      $3   
P4b M9            barrel pinch bolt  8mm dia 15 long 2.5 max wire      $8  long enough for Domino or Magura levers
P5   H60          Grimeca pinch bolt 9mm dia w/7mm flat sides         $7  good used, beware of too-small remakes of this
P6a                  clevis pinch bolt                                                      $6   for Sachs & KTM clevis style brake arms
P6b                  clevis pinch bolt                                                      $6   for Sachs & KTM clevis style brake arms
P6c                  clevis adapter                                                         $4   for Sachs & KTM clevis style brake arms
P7a                  bicycle pinch bolt, 8mm w/6mm flat sides               $2  too small for Grimeca brake arms
P7b                  cable wire end cap crimp on                                     $1  protects exposed braided cables 
P7c                  bicycle brake step ferrule                                    $0.50 see ferrule F6
P8a                  odd shape pinch bolt                                               $3  new, Peugeot decomp original 
P8b                  odd shape pinch bolt brass                                      $2  new, Peugeot decomp Barnett remake
P9a                  loop pinch bolt 6 pieces 7mm 11 hex                       $7  good used, Vespa moped, arm has 11mm arch  
P9b                  loop pinch bolt 6 pieces 6mm 10 hex                       $7  good used, 1974-91 Tomos, arm has 10mm hole
==============================================================================

Row E: Ends and Elbows   

E1 a, b, c, d, e, f, g, h ,i. j cable end adapters

E1 a, b, c, d, e, f, g, h ,i  cable end adapters

E1h adapter

E1h brake end adapter
Ø6 pear to Ø8 barrel

E2 a,b rod ends

E2 rod ends

 

 

 

 

 

 

 

 

E1a 25880  cable end D=8.7 L=8.2 brake adapter           $2  adapts a brake end to a 9mm barrel end
E1b Sachs   cable end D=4/6 L=13.0 Sachs adapter        $8  adapts a carb end to 4/6 barrel end
E1c Barnett throttle cable end adapter D=5.0 L=8.0        $3  adapts a carb end to a 5mm barrel end
E1d 25362  throttle cable end adapter D=6.0 L=7.0        $1  adapts a carb end to a 6mm barrel end
E1e             brake cable end adapter D=7.2 L=8.9           $2  adapts a brake end to a 7mm barrel end
E1f              brake cable end adapter D=8 L=9 slotted      $4  adapts a brake end to a 8mm barrel end
E1g             brake cable end adapter D=8 L=10 slotted    $3  adapts a brake end to a 8mm barrel end
E1h             brake cable end adapter D=8.0 L=10.2         $1  adapts a brake end to a 8mm barrel end
E1i              brake cable end adapter D=8.0 L=14.4         $4  adapts a brake end to a 8mm barrel end
E2a             threaded rod nut M6                                    $1  many Asian brakes are “rod” type
E2b             threaded rod barrel                                      $4  a threaded rod is the end of the wire
E3 elbow

E3 elbow

E4 inline oiler

E4 inline oiler

E4 a,b,c,d,e  bicycle ends

Note that the bicycle gear wire “inline barrel” end is 4mm, too big to be a motorcycle throttle wire “inline barrel” 3mm, also known as “carb” end.

Note that the bicycle brake cable “barrel” 7mm end is too big for a motorcycle throttle end “barrel” 4 to 6mm.

 
 
 
E3               M6x0.8 elbow 45 deg, no adjuster threads   $6  Dellorto and others
E3x             other elbows available, not listed         $10-$12  most
E4               in line oiler with attached cap                       $2   for putting oil into the cable
E4a            bicycle cable end  ”brake wire Campy” =”pear” type   D=3.9/6.0 L=8.0  use E5s  comes with wire 1.6mm
E4b            bicycle cable end    ”brake wire road”   =”pear” type   D=3.9/6.0 L=9.0  use E5s  comes with wire 1.6mm
E4c            bicycle cable end   “brake wire MTB”    =”barrel” type     D=7.0   L=7.0         N/A  comes with wire 1.6mm
E4d            bicycle cable end “gear wire Shimano” =”inline barrel”   D=4.0   L=4.0         N/A  comes with wire 1.2mm
E4e            bicycle cable end “gear wire Campy”   =”inline barrel”    D=4.0   L=3.0         N/A  comes with wire 1.2mm
E4f             bicycle cable end “gear wire old Huret”=”short barrel”   D=5.0   L=3.0  use E5b  comes with wire 1.2mm

These bicycle cable ends are listed here to show how much different they are from motorcycle cable ends. A bicycle gear cable 4mm end could be ground down to become a motorcycle throttle cable 3mm end. A bicycle brake cable road type interchanges with a motorcycle pear or mushroom type. A bicycle brake MTB type 7mm end fits loosely into a 8 or 9mm motorcycle brake lever, but functions OK. 

E5 a,b,c,d,e,f,g,h,i,j,k,l,m,n,o,p,q,r,s  Cable Ends for Soldering

E5 a,b,c,d,e,f,g,h,i,j,k,l,m,n,o,p,q,r,s  Cable Ends for Soldering

Cable end wires bent into an umbrella before soldering

Cable wires bent into an umbrella before soldering

 

 

 

 

 

 
 
 
 
 
E5a                   cable end ”short barrel” D=6.0 L=3.0 wire=1.7          $0.50  for soldering to 1.6mm braided cable 
E5b                   cable end ”short barrel” D=5.5 L=3.2 wire=1.7          $0.50 for soldering to 1.6mm braided cable 
E5b 620-25162 cable end ”short barrel” D=6.3 L=3.3 wire=1.6          $0.50 for soldering to 1.6mm braided cable
E5c 620-24187 cable end “ball” shape   D-4.6   wire=1.7                    $0.50  for soldering to 1.6mm braided cable
E5d 620-24162 cable end “ball” shape   D-5.4   wire=1.7                   $0.50  for soldering to 1.6mm braided cable
E5e 620-24062 cable end “ball” shape   D-6.3   wire=1.7                   $1.00  for soldering to 1.6mm braided cable
E5f  620-25063 cable end ”barrel” type D=3.9 L=7.2 wire=1.6           $1.00  for soldering to 1.6mm braided cable
E5g                   cable end ”barrel” type D=4.9 L=7.4 wire=1.8           $1.00  for soldering to 1.6mm braided cable 
E5h                   cable end ”barrel” type D=4.6 L=10.2 wire=1.4         $1.00  for soldering to 1.6mm braided cable 
E5i  620-25349 cable end “barrel” type D=6.0 L=7.0 wire=1.2           $1.00  for soldering to 1.2mm braided cable
E5j  620-25580 cable end ”barrel” type D=9.5 L=9.5 wire=2.0           $1.00  for soldering to 2.0mm braided cable
E5k 620-24755 cable end “inline barrel” D=3.2 L=4.8 wire=1.8          $1.00  “inline barrel” also known as “carb” type
E5l  620-24762 cable end “inline barrel” D=3.2 L=4.0 wire=1.7          $0.50  “inline barrel” also known as “carb” type
E5m                  cable end “pear” type 3.2/5.6 L=8.0 wire=2.0           $0.50  for soldering to 2.0mm braided cable
E5m 620-26080 cable end “pear” type 3.2/5.6 L=9.0  adapter           $0.50  for adapting an “inline barrel” 4-5mm
E5n                   cable end ”pear” type 3.8/6.0 L=6.6 wire=2.7           $0.50  for soldering to 2.7mm braided cable
E5o 620-24280 cable end ”pear” type 3.7/6.3 L=9.0 wire=2.0           $0.50  for soldering to 2.0mm braided cable
E5p                   cable end ”pear” type 3.5/6.0 L=11.0 wire=2.2         $0.50  for soldering to 2.0mm braided cable
E5q 620-26298 cable end ”pear” type 3.9/6.3 L=11.5 wire=2.3         $0.50  for soldering to 2.0mm braided cable
E5r                    cable end ”pear” type 4.0/6.3 L=10.1  adapter          $0.50  for adapting an “inline barrel” 4-5mm
E5s 620-26162 cable end ”pear” type 3.9/5.6 L=8.1  wire=1.6          $0.50  for soldering to 1.6mm braided cable
 
==============================================================================

Row A: Adjusters

A1 a,b,c M5 adjuster

A1 a,b,c,d
M5 adjuster

A2 M6 adjuster

A2   hex
M6 adjuster

A3 M6 adjuster

A3 a,b
M6 adjust.

A4   long M6 adjuster

A4   long
M6 adjuster

A5  M7 adjuster

A5 a,b
M7 adjuster

A6 M8 adjuster

A6
M8 adjuster

 

 

 

 

 

 

 

A7  adjuster nuts

A7 a,b,c,d
adjust. nuts

A8 inline adjuster

A8 inline
adjuster

A8 Magura adjuster

A9 a,b,c
Magura adjust.

 

 

 

 

 

 

 
 
 
 
 
A1a 219625 cable adjuster M5 x 0.75  (no nut)             $6  fine, for Dellorto carb elbow
       219626 cable adjuster nut only M5 x 0.75              $3   fine, for Dellorto carb elbow
A1b              cable adjuster M5 x 0.80 with nut              $4   standard, for Puch Bing
A1c  23089  cable adjuster M5 x 0.90 with nut              $3   coarse, for Motobecane
A1d              cable adjuster M5 x 1.00 with nut              $2   very coarse, not for any common moped
A2                cable adjuster M6x1.00 hex no slot            $1
A3a              cable adjuster M6x1.00 round no slot   $2-$3  good used, original Motobecane
A3b 222592 cable adjuster M6x1.00 round slotted        $5  original 1990′s Tomos dark grey
A4                cable adjuster M6x1.00 hex long used  $3-$5  Puch wheels and others
A5a              cable adjuster M7x1.00 round slotted        $5
A5b              cable adjuster M7x1.00 hex used              $4
A6                cable adjuster M8x1.25 round slotted        $5
A7a              thin nut for adjuster M5 x 0.8                   $1 
A7b              thin nut for adjuster  M6 x 1.0                  $1
A7c              thin nut for adjuster  M6 x 0.8                  $2
A8                in-line cable adjuster                                 $5  for joining two 5 or 6mm sleeves
A9a              Magura type adjuster short, good used      $6
A9b              Magura type adjuster long, good used        $6
A9c              Magura type adjuster short w/elbow          $7  for Kreidler and others                          
A10              cable adjuster M6 x 0.8 fine                      $4   Sachs Bing and others
A11              cable adjuster 1/4 – 24 aluminum            $4
A12              cable adjuster M7 x 1.0 short w/nut         $3  for Motobecane decomp
A13              cable adjuster M6 x 0.75  fine                  $4  for Dellorto and Asian carbs

==============================================================================

Row F: Ferrules

F1  F2  F3 Step Ferrules

F1 F2 F3 step ferrules

F3 step ferrule avail. in bulk

F3 step ferrules in bulk

F4 a,b,c  F5 a,b  Step Ferrules

F4 a,b,c   F1   F5 a,b   step ferrules

 

 

 

 

 

 

F6 bicycle stop

F6 bicycle cable stop

 

 

 

 

 

 

 

 

F1  15581        step ferrule 5.9-8.0 by 13mm ID=5.8                    $2-$3  for Motobecane rear brake
F1                    step ferrule 5.9-8.0 by 10mm ID=5.4                    $2-$3  for Peugeot front brake
F1                    step ferrule 6.0-9.0 by 14mm ID=6.5 aluminum         $2
F1                    A2   cable adjuster M6x1 hex  ID=6.5                          $1  good substitute for F1
F2  16944        step ferrule 4.0-7.0 by 11mm ID=5.5                         $2   for Motobecane decomp 
F3                     step ferrule 4.0-7.0 by 10mm ID=5.5 steel             $0.50  sub for F2, Peugeot R brk & decomp
F3                                                                 in bulk:                      $2/10      $10/100  
F3                     step ferrule 4.0-7.0 by 10mm ID=5.5 aluminum   $0.50  sub for F2, Peugeot R brk & decomp
F4a                   step ferrule 4.0-7.0 by 12mm ID=6.0 aluminum         $1
F4a                   step ferrule 4.0-7.0 by 10mm ID=5.7 chrome             $2
F4b                   step ferrule 4.5-7.7 by 16.7    ID=5.8 Barnett             $2 
F4c 620-21710 step ferrule 5.3-6.8 by 19.0    ID=6.2 Barnett             $2
F5a                   step ferrule 5.9-11.9 by 15.4  ID=10.4                       $2
F5b                   step ferrule miscellaneous                                 $2 most
F6                     step ferrule bicycle brake universal                   $0.50

The above step ferrules all fit loosely over the cable conduit. The end cap type ferrules below fit tight on the conduit, or are crimped on by special pliers. The end caps are supposed to fit tight, for several reasons: For strength and cable performance, to help keep out dirt and water (thus increasing lifetime), and for easier servicing. Unlike the step ferrules, which are necessary, the end cap ferrules are not necessary. Sometimes conduits need to be cut and the end cap ferrule needs to be left off. The conduit will still function good without end caps, as long as the adjuster or other stop piece hole, usually 2.5mm, is not too big. Without a 6mm OD end cap ferrule, a 5mm conduit will eventually slip through an improper stop piece hole, like 4mm instead of 2.5mm. But as long as the holes in the end pieces are the proper size, the cable does not need end cap ferrules.   

F6 a,b,c,d,e,f,g,h,i,j,k,m,n,o  Ferrules (End Caps)

F6 a,b,c,d,e,f,g,h,i,j,k,m,n,o Ferrules (Cable End Caps)

 

 

 

 

 

 

 

 

 

F6a                    ferrule ID=4.5mm with flare                   $1.00  easy to install, just press on
F6b                    ferrule ID=4.8mm no flare                      $0.50  make flare with punch, then press on
F6b                    ferrule ID=5.1mm no flare, Barnett         $0.50  make flare with punch, then press on
F6c                    ferrule ID=4.8mm no flare, Barnett         $0.50  make flare with punch, then press on
F6d                    ferrule ID=4.0mm no flare Shimano SIS  $0.50  used and pre-crimped 
F6e                    ferrule ID=4.5mm no flare, Sachs           $0.50  make flare with punch, then press on
F6f  620-20100 ferrule ID=5.0mm no flare, aluminum     $0.50  make flare with punch, then press on
F6g                    ferrule ID=5.0mm with flare, chrome      $1.00  easy to install, just press on
F6h                    ferrule ID=5.1mm with flare, used          $1.00  original on Peugeot and MB
F6i                     ferrule ID=5.0mm with flare, Puch          $1.00  easy to install, just press on
F6j                     ferrule ID=5.5mm with flare                   $1.00  easy to install, just press on
F6k                    ferrule ID=6.0mm no flare, Barnett        $0.50  make flare with punch, then press on
F6m 620-20110 ferrule ID=5.5mm no flare, aluminum    $0.50  make flare with punch, then press on
F6n                    ferrule ID=6.1mm with flare, chrome      $1.00  easy to install, just press on
F6o                    ferrule ID=7.1mm with flare, chrome      $1.00  bigger than most moped conduits
============================================================================== 

Row B: Bulk wire, conduit, and sleeve

top B5 7 x 7 braid, flexible bot.  B3 1 x 19 braid, stiff

top B5 7×7 braid, flexible
bot. B3 1×19 braid, stiff

B13 conduit with liner

B8, B10, B12, B13
conduit with nylon liner

B18 silver conduit

B18  silver 5mm conduit

 

 

 

 

 

 

 

 

Sometimes very long cables are needed, for long bikes, or very tall handlebars, or for other things that use mechanical control cables. For 1.2mm and 1.6mm thick inner wires, up to 8 feet, it is better to use bicycle wires. beacuse they already have end(s) and cost less. The same quality 5mm conduit (housing) for bicycles costs much less than for motorcycles, and comes in colors. For thicker or longer cables, the bulk motorcycle wire and black conduit is the only choice.

                 Cable inner wire from Motorcycle Parts Suppliers (Flanders):
B1   610-03080 cable wire by the foot  1.2mm 1 x 19 strand                             $0.80/ft  stiff braid (throttle)
                          cable wire   8.5 feet    1.2mm 1 x 19 strand stainless               use W10    
B2   610-03090 cable wire by the foot  1.2mm 7 x 7 strand                               $0.80/ft  soft braid (throttle)
B3   610-03100 cable wire by the foot  1.6mm 1 x 19 strand                             $0.80/ft  stiff braid (brake)
                          cable wire   9.0 feet    1.5mm 1 x 19 strand stainless               use W11  
B5   610-03110 cable wire by the foot  1.6mm 7 x 7 strand                               $1.00/ft  soft braid (throttle)
B6   610-03120 cable wire by the foot  2.0mm 1 x 19 strand                             $1.70/ft  stiff braid (brake)
                 Conduit (housing) from Motorcycle Parts Suppliers (Flanders):
B7   610-03300 cable conduit per foot 5.0 x 2.3 black          for 1.2 or 1.6 wire    $2.00/ft   use B13
B8   610-03305 cable conduit per foot 4.8 x 2.1 black,  nylon-lined, for 1.2 wire   $2.40/ft   use B13 
B9   610-03310 cable conduit per foot 5.5 x 2.9 black             for 2.0 wire            $3.00/ft
B10 610-03315 cable conduit per foot 5.5 x 2.5 black,  nylon-lined, for 1.6 wire   $3.00/ft
B11 610-03320 cable conduit per foot 6.0 x 3.3 black             for 2.5 wire            $3.50/ft
B12 610-03325 cable conduit per foot 6.0 x 2.9 black,  nylon-lined,  for 2.0 wire  $4.20/ft
                 Conduit (housing) from Bicycle Parts Suppliers (J & B Importers)
B13   1460        cable conduit per foot  4.9 x 2.0 black,  nylon-lined, for 1.6 wire   $0.50/ft
B14   1461        cable conduit per foot  4.9 x 2.0 white,  nylon-lined, for 1.6 wire   $0.50/ft
B15                   cable conduit per foot  5.7 x 2.0 brown, nylon-lined, for 1.6 wire $0.50/ft  AMF style, from 1980′s
B16   14427      cable conduit per foot  4.8 x 2.0 yellow,                for 1.6 wire    $0.50/ft
B17  14426      cable conduit per foot  4.8 x 2.0 blue,                   for 1.6 wire     $0.50/ft
B18   14339      cable conduit per foot  5.0 x 1.9 silver, nylon-lined, for 1.6 wire  $0.50/ft
                 Outer Sleeving from Industrial Suppliers
B20  1508T32  big outer sleeve 11 x 13mm black PVC, holds 3 -5mm cables    $1.00/ft   new and flexible, at last!
 
 

3  2 – E N D E D   C A B L E S

==============================================================================

Left, the two versions of the Puch double-ended throttle cable. Left cable is the “Free Spirit” kind, for the tube frame bikes like Sears Free Spirit, Murray, JC Penney Pinto, and Puch Magnum. These models have a short carb elbow because the frame is lower there. The shorter elbow requires the shorter cable exposed length. Price  is $13.00

Right cable is the “Puch Maxi” kind, for sheet metal frame Puchs with the long carb elbow shown. Price is $20. It has about 12mm more exposed wire length, as you can see. The ones sold elsewhere on the internet for “Puch” are the “Free Spirit” kind. Their inner wires are too short and cannot idle down when installed on a stock Puch Maxi.

 

 

 

Garelli Start/Clutch Cable

The Garelli double ended starter cable is tricky.

Garelli Start Lever

Garelli start lever
without socket bolt.
8mm hole size is
same as brake but
lever is thinner.

Domino Socket Bolts

Domino socket bolts
L is brake, R is start
they hold the cable in the center of the lever

Garelli Start Cables

Garelli Start Cables
showing all the pieces
upper is aftermarket
lower one is original

Garelli start cable aftermarket installed

Garelli start cable aftermarket installed
The step ferrule comes from the old cable.
Everything else is new.

 

 

 

 

 

 

 

 

 

More to follow…

 Pinch Bolts

Many of the 8mm diameter pinch bolts (item P3c above) sold on the internet will slip if the bolt is not tightened with a pliers holding onto the round 8mm barrel. This is because the 5mm bolt does not have a dome shaped end. Myrons cuts a rounded dome in the 5mm pinch bolt. This makes it gently fold the wire into a curve when the bolt is tightened.

Domed pinch bolts hold better

Domed pinch bolts hold better and don’t cut.

Domed and regular 5mm pinch bolts with 8mm barrels

Domed and regular 5mm pinch bolts with 8mm barrels. At top, the tool that holds them for cutting and a M5x0.8 die.

You pay more for a Myrons pinch bolt, but you will get a much greater benefit. Safety (it won’t pop off when you slam on the brakes), and ease of installation (don’t normally need a pliers to hold the round barrel). You can feel the cable bending as the bolt is tightened. That gentle bending is what makes it not slip. See pictures at left. 

The 5.5mm diameter pinch bolts (item P1 above) for throttles already have domes on their 3mm bolts. (cones actually). So they are designed to hold good, yet be small. Nonetheless, they often need to be soldered, in addition to the pinch bolt tightened as much as possible, in order to not slip.  

 

 

 

Under construction …


Electrical parts: Lights, Bulbs, Switches, Wiring, Horn, Battery

September 13, 2012

CONTENTS:  Welcome   1  Bulbs  2 Horns  3 Switches  4 Headlights  5 Tail Lights  6 Batteries  7 Wiring

Welcome.  Most European made mopeds from about 1970 – 2000 have high quality CEV electrical components, made in Italy. CEV is a trade mark, owned by Fratelli Pagani, that stands for Costruzioni Elettromeccaniche Venegonesi. CEV is now owned by Zadi, a maker of moped fork locks. Other European moped electrical components include switches made by Merit, tail lights, head lights and turn signals made by ULO (Germany), head lights made by Luxor (France). Some American moped electrical components are headlights, tail lights made by Peterson (USA). Asian mopeds have their own components, which are often the same as earlier Honda items. The Czech moped, Jawa, has it’s own components.  

1   B U L B S

===================================================================================

Light bulbs are very universal. Most moped light bulbs are standard automotive bulbs. Moped 4.5 inch round head lights are the same as some tractor lights, auto and motorcycle fog lights, forklift, golf cart, utility vehicle lights. Most bulbs are made in 6 volt or 12 volt versions, But finding 6V bulbs is difficult since all cars are 12V since the 1970′s.

In all of these magneto/generator powered head lights, a 12 volt bulb will replace a 6 volt one, and be almost as bright.    

bulbs
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
part#    pic#     volts watts   base#  bulb#  style                  price     applications/comments
=============================================================================
                 6  bulb  6V 0.6w     BA7s   7mm tiny bayonet              $2.00  use 12V 2W for less chance of burn-out 
ELB1262   6  bulb  6V 1.5w     BA7s   Puch speedo lite                  $1.50  use 12V 2W for less chance of burn-out 
ELB3898   6  bulb 12V 2w       BA7s   Tomos & MB speedo lite      $1.50  78-80 Motobecane/03-07 Tomos/other VDO
———————————————————————————————————————————————————————–
200002    4  bulb  6V 1w         BA9s   GE#51  9mm bayonet         $1.50
200003    4  bulb 12V 2w        BA9s   GE#53  Tomos dash           $1.00  87-on Tomos/many Japanese
ELB3893   4  bulb 12V 4w       BA9s   9mm bayonet                     $2.00
———————————————————————————————————————————————————————–
PeuSpdo        bulb  6V 1 or 2w   E10    10mm screw-in                  $1.50  76-80 Peugeot speedometer
SolexHL         bulb  6V 2 or 3w   E10    10mm screw-in yellow       $2.00  early Solex 3800 head light
———————————————————————————————————————————————————————–
ELB5006   3  bulb  6V 5w        BA15s  GE#63  Puch tail lite          $2.00  77-later Puch must have this to be bright
ELB5001   3  bulb  6V 10w      BA15s  GE#81  15mm base           $2.00
ELB57       3  bulb 12V 5w       BA15s  GE#67  15mm single          $1.50
ELB89       3  bulb 12V 10w      BA15s  GE#89  15mm bayonet      $1.50
———————————————————————————————————————————————————————- 
ELB1129   2  bulb  6V 18w      BA15s   GE#1129  1 filament         $2.00  modern 1129 is 6V 18 watt
H101C      2  bulb  6V 21w      BA15s   Puch head lite                    $2.00  1970′s 1129 was 6V 21 watt
ELB1156   2  bulb 12V 21w      BA15s  GE#1156  15mm bayonet  $2.00
———————————————————————————————————————————————————————–
vespaTL    1  bulb  6V 3/15w   BA15d  15mm dual filament           $3.00  Vespa Ciao tail light
ELB1154   1  bulb  6V 21/5w   BA15d  GE#1154  15mm dual        $2.00
ELB1157   1  bulb 12V 21/5w   BA15d  GE#1157 15 bayonet dual  $1.50
———————————————————————————————————————————————————————–
               15  bulb  6V 25/25w BA20d            20mm bayonet dual  $12.00  Derbi Variant Sport 1986-89
200018  15  bulb 12V 35/35w BA20d           20mm bayonet dual  $7.00  Tomos Revival/Streetmate
44701     15  bulb 12V 25/25w BA20d           20mm bayonet dual  $9.00  Tomos 1990-later square HL
———————————————————————————————————————————————————————–
200023         bulb 12V 15w      P26s        26 x 15 flange type        $9.00  Tomos Arrow-R and Streetmate-R (dual light)
———————————————————————————————————————————————————————–
10626.5    5  bulb  6V 1.5w      festoon  looks like fuse                    n.a.
ELB6428   5  bulb 12V 3w        SV7-8    festoon                             $2.00
200019         bulb 12V 10w      festoon  48 x 12mm approx.           $2.00
———————————————————————————————————————————————————————–
44687      7  bulb  6V 1.2w     all glass 5mm  CEV speedometer      $2.00
ELB74      7  bulb 12V 1.2w    all glass  #74  CEV speedometer       $2.00
ELB194         bulb 12V 3w       all glass wedge  #194                      $2.00
———————————————————————————————————————————————————————–
GE4667  10  bulb  6V 18w    4.5″sealed beam #4667 rear prongs    n.a.   must de-pin the 2-pin plug & use 4667-1
GE4667-1     bulb  6V 18w   4.5″sealed beam 4667-1 side prongs $10.00 Vespa
CEV171  10  bulb  6V 21w   4.5″sealed beam CEV171 rear prongs   n.a.  can cut hole in steel back for upgrade
GE4767  10  bulb  6V 25w   4.5″sealed beam #4767 rear prongs    n.a.  Peugeot original has more watts
W4158          bulb  6V 25w    4.5″sealed beam #4158 2-screws       n.a.   Motobecane 76-77 original (Westinghouse)
201008         bulb 12V 25w     4.5″sealed beam #4568  2-screws     n.a.  Motobecane 78-80 original (Westinghouse)
GE4776         bulb 12V 25w    4.5″sealed beam #4776 2-screws       n.a.  Motobecane 78-80 (General Electric)
200082         bulb 12V 35w     4.5″sealed beam #4416 spot lamp  $15.00  narrow beam, smooth glass (Wagner)
200080         bulb 12V 35w     4.5″sealed beam #4415 fog lamp    $17.00  normal beam, normal glass (Wagner)
———————————————————————————————————————————————————————–
CEV172  12  bulb  6V 25/25 4.5″sealed beam CEV172 3-prong       n.a.  can cut hole in steel back for upgrade
200084  12  bulb 12V 40/40 4.5″sealed beam #4440 3-prong   $25.00 
———————————————————————————————————————————————————————–
E8764           socket snap-on for BA15s bulbs such as #1156         $6.00  for steel-back-headlight recycling
04811     11  socket BA15s for CEV glass lens/reflector                  $13.00
18890       9  clip for CEV socket 04811                                           $1.00
CEV171R    8  glass lens/reflector CEV 171 new w/04811              $45.00 
CEVused    8  glass lens/reflector recycled w/socket                       $35.00  says either CEV171 or 172 on glass
10343           w-clip CEV for holding glass to rim uses 4-5                $1.00  for CEV rims
LuxorW         w-clip Luxor for holding glass to rim uses 4-5              $1.50  for Luxor rims
———————————————————————————————————————————————————————–

 

Bulbs are specified by their style, size, voltage, and wattage. #1,#2,#3 are bayonet style 15mm, BA15s and BA15d, where you push it in first a little, then turn it clockwise 45 degrees to go on, or counterclockwise to take off. A single filament bayonet bulb can go two ways, but a double filament only goes in one way. That’s because one prong is higher than the other on a dual filament. That’s so you can’t reverse the tail and brake lights. The BA20d hi/lo headlites are the same way. The smaller bayonets are #4, 9mm BA9S, and #6, 7mm BA7S. #5 is a festoon style bulb that looks like a glass fuse but it’s not. It’s a high beam indicator lite.

#10 and #12 are sealed beam 4 1/2″ round headlites, where the bulb is sealed inside the glass reflector and lens. Sealed beam bulbs cost much more than replaceable ones so it’s practical to upgrade to a replaceable bulb whenever possible. When your burned out sealed beam headlite is made out of metal, on the back, not glass, then Myrons Mopeds can recycle it, for $22 plus $8 parts plus shipping. Many vintage Japanese and European small motorcycles and mopeds have hard to get sealed beam bulbs, such as CEV171 or 172, with metal backs. A hole is cut and a universal bulb socket snaps in. The original wire plug(s) are re-used. The bulb is a single filament, easy to get at convenience stores, #1156. If the original had hi/lo beam, then it will have just low after the upgrade.

Above, any metal-backed (not glass) headlight can be recycled. Cut a hole and snap in a socket for an #1156 bulb.

Mopeds frequently burn out bulbs, from both vibration and surges of electricity. Because there’s no battery, the voltage varies a little. At idle the lights are very dim, but at full speed they’re bright. Hopefully they’re not bright white, as that means it might burn out soon. Yellow is good but orange is too dim. For some reason, most old 6 volt mopeds need 12 volt bulbs, or else they burn out. Some bikes need a 12V AC voltage regulator ($45) added on in addition to 12V bulbs, to help prevent bulb burn out. Only when 12V bulbs are too dim should 6V ones be used, with the following exception. The 77-later Puch needs a 6V 21W #1129 instead of a 12V 21W #1156, in order for the tail lite to be bright. Other bikes have issues where the brake light is needed for the ignition to function. Some taillights have a secret hidden resistor inside, that allows the bike to run even with a burned out or missing brake light bulb. See service section for more info about weird light behavior and what mopeds need what lights to run, if any.

 

L to R: 1) 4.5″ sealed beam, 6V 18W, #4667, 2) 4.5″ sealed beam, 12V 35W #4415, 3) 4.5″ head light fixture for a replaceable bulb. Click to enlarge.

 

 

 

2   S W I T C H E S

===================================================================================

All European mopeds, USA models, 1970′s and later, had CEV switches, except Puch, Motobecane, and Jawa.
Part.#…… # Description Price Applications
…………S…W…I…T…C…H…E…S………… many.switches.are.not.available
ELO316 switch.brake.lite..connector..sm.blade $0.50 fits.every.European.moped
in.the.bike.the.button.is.normally.in in.your.hand.the.button.is.normally.out
this.is.a.source.of.confusion. NO.installed=NC.in-hand.and.vice.versa
222002 26 switch.brake.lite..norm.open.installed $20.00 scarce..Myrons.is.making.some.soon
9342 26 switch.brake.lite..nor..closed.installed $20.00 scarce..Myrons.is.making.some.soon
227191 switch.brake.lite..norm.open.installed $12.00 longer.for.92-07.Tomos.black.levers
15863 25 switch.brake.lite..black.rubber.cover $2.00
201080 switch..universal.kill.button..clamp.on $10.00 all.mopeds
8177.1 1 switch..R.stop..CEV.round.chrome $25.00
8040.5 2 switch..L.lite/horn..CEV.round.chrome $20.00
none switch.clamp..CEV.round.chrome.R/L $6.00
none switch.cap..R.stop..CEV.round.chrome $6.00
none switch.cap..L.lite/h..CEV.round.chrome $6.00
8053.1 3 switch..turn.signal..CEV.round.chrome N/A  see below for substitute
8052.1 18 switch..60′s.CEV.clamp-on.stop/lite&h N/A
MP342 4 switch..R.stop.Merit.long.round.chrome N/A Puch Maxi
none 5 switch..L.lite.Merit.LRC..nor.open.horn $30.00 Peugeot.103/74-76 .Puch.
MP343 6 switch..L.lite.Merit.LRC..n.c.horn.Puch N/A Puch Maxi
none switch.cap..R.stop.Merit.long.round.cr $3.00 Puch Maxi
none switch.cap..L.Lite.Merit.long.round.cr $5.00 Puch Maxi
none switch.clamp.assy..Merit.LRc.style.Puch $3.00 Puch Maxi
none switch..Merit.LRC..internal.2mm.screw $1.00 Puch Maxi
MP342A 7A switch..R.stop.Merit.square.blk.plastic $20.00 78-on Puch Maxi Luxe/Newport/Magnum
MP342B 7B switch.mount..R.stop.Merit.SBp.Puch $40.00 this.is.what.breaks.easy.and.is.scarce
MP343A 8A switch..L.lite&h.Merit.square.blk.plast $30.00 good used, cleaned, serviced, checked
MP343B 8B switch.mount..L.lite&h.Merit.SBp.Puch $40.00 this.is.what.breaks.easy.and.is.scarce
none switch.mount.clamp..sBp.style.Puch. $2.00
none switch.mount.clamp.screw..sBp.takes.2 $0.50
8189 10 switch..R.stop..CEV.plastic.early.80′s $15.00 80-84.Trac
8188 11 switch..L.lite.&.horn.(n.o)..CEV.plastic $15.00
8190 12 switch..L.lite.hi/lo.&.horn..CEV.plastic $25.00
none switch.connector..CEV.plastic.takes.2-3 $1.00
none switch.mount.clamp..CEV.plastic.style $2.00
none switch.mount.clamp.screw..cp.takes.2. $0.50
8191 9 switch.in.lever..R.stop.&.turn..CEV.rect. $20.00
8192 24 switch.in.lever..L.horn..CEV.r-diamond $15.00
8193 17 switch.in.lever..L.lite&h..CEV.diamond. N/A
8194 16 switch.in.lever..R.stop..CEV.diamond. N/A
8167.2 13 switch.L.CEV.console..lt&h/hi/lo/flash $30.00
8166.1 14 switch.L.CEV.console..horn/hi/lo/flash N/A
none switch.L.CEV.console..internal.pieces in.stock
none 15 switch.mount..CEV.console..blk.alum $5.00  no clamp, no grommet, needs repainting
none switch.mount.clamp..CEV.console..al $10.00  all good but needs repainting
6x16allen switch.clamp.screw..cc.M6.allen.takes2 $0.50
none switch.console.screw..cc.M3x25.appr $1.00
8109 23 switch.in.lever.L.lite&h.CEV.oval.Garelli N/A
need 24 switch.in.lever..R.stop.CEV.oval.Garelli N/A
8215 21 switch.in.lever..R.stop&turn.CEV.lt.80s N/A
222427 19 switch.in.lever..R.stop&l.CEV.late.80′s $30.00
222426 20 switch.in.lever..L.h.&.turn.CEV.late.80′s $35.00
222429 switch.in.lever..L.horn.CEV.late.80′s $25.00
632839 switch.in.lever..R.stop.CEV.90′s $20.00
632840 switch.in.lever..L.lite.&.horn.CEV.90′s $25.00
227001 switch.in.lever..L.lite.horn.turn.CEV.90s $35.00

 

CEV 8053.1 Turn Signal Switch Substitute (made from a 8041 cap and a 8040.3 base)

CEV turn signal switch substitute

CEV 8053.1 substitute
left: 8041 switch assy
right: 8040.3 base top

CEV TS switch bottom view

CEV 8053.1 substitute
CEV 8040.3 bottom view
before cutting jumper

CEV TS switch mods

CEV 8053.1 substitute
top: original cap & base
bottom: modified ones

CEV TS switch cap R - orig CEV 2041 cap

CEV 8053.1 substitute
R – orig CEV 2041 cap
L – button cut and glued

 

 

 

 

 

The CEV 8053.1 is a handlebar mount, left side clamp-on, 3-position turn signal switch, Left-Off-Right, that came on 1970′s mopeds with CEV turn signals. It is a “round chrome” style switch that shares the same clamp with other CEV round chrome switches. For $15 you can buy the 8041 light/horn switch assy, and the 8040.3 light/horn switch base, needed to make a substitute 8053.1. Or for $25 each, you can order the substitute 8053.1 ready to install. It will have a “dummy” button that does nothing but hide the hole.

 

3   H O R N S

===================================================================================

Most mopeds do not have a battery, so the electricity is all AC alternating current. Some mopeds and almost all motorcycles have a battery, usually 12 volt. Their electricity can be all DC or part DC and part AC. An incandescent light bulb works the same on AC or DC, but a horn is made for either AC or DC. DC current horns go beeeeeeeep, like a little cute car horn. AC horns sound like the buzzer when you get a wrong answer on a TV game show. AC horns also sound like duck callers. The pitch goes up with the rpm of the engine. They’re not much louder than the engine.

It is difficult to sell used or new old stock AC horns that were made 35 years ago. If they haven’t been kept in a sealed wrapper, then they might not work good, even though they’re new. It’s because corrosion can get on the aluminum plate. Furthermore, you cannot easily tell whether a horn is good or bad. You cannot easily look inside because it is riveted together. You cannot perform a valid test of it unless you have the moped it is intended to go on, running, with working horn wires and button. Because the AC an vary from one kind to another, and from a new one to an old one of the same kind, you never know if a horn that works on a Peugeot for example, would work on a Puch, until you try it. Or it might work good on Puch at low rpm, but not high. Maybe visa versa on Garelli. It also matters whether the head light is off or on. Many AC horns will not work, or are not loud, unless the headlight is off.

Myrons Mopeds has some 6V AC horns, but they are only offered when the running good moped is present in the shop and able to easily attach the horn to test it. The price is usually $20-25 for a good used AC horn.

All modern scooters and motorcycles have 12 volt DC horns. They are common. Some older Taiwanese mopeds have 6 volt DC horns. AC buzzers are “old school” and are not on anything modern. So there are no known freshly made replacements.

 

4   H E A D L I G H T S

===================================================================================

These are the CEV 4 1/2″ round headlights. There are others:  Taiwan, Luxor/Novi, Inox (Magnum), Jawa, AMF.

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
…… H E A D… L I G H T S…… SB = sealed beam   rep = replaceable
18541 1 screw 3mm for 1211 plastic takes 3 $1
04910 2 glass lens for CEV1211 $45
04909 3 housing for CEV1211 w/bulb socket $5
3444 4 M6 lock washer
3171 5 M6 x 20 hex bolt/pair w/washers $1
19782 6 rear cover plate for CEV1211 $2
1211 7 pancake headlight CEV1211/rep-bulb $50 Derbi/Tomos/others
3309 8 M5 x 15 slot head bolt $1
04522 9 rim CEV Tipo 105 new $20 mint fresh condition
04522 9 rim CEV Tipo 105 used $10 minor scratch or dent but good
10343 10 regular headlight clip “W” type $1 takes 3 to 6, equal spaced, snaps in, no tools
10343 10 continued … this clip is different from French or Taiwan ones
04525.6B 11 round housing for CEV2143 $20 gloss black on most, matte black on Peugeot
04525.6B 11 round housing for CEV2143 used $10
2143 12 round headlight CEV2143/SB-bulb $55
2157 12 round headlight CEV2157/rep-bulb $70
2152 13 round headlight CEV2152/SB/Hi-lite N/A Kreidler
10626.5 14 hi beam indicator bulb (looks like fuse) $2 12 volt one only, festoon bulb
0007.12 15 hi beam indicator socket no jewel $7 KTM Foxi, Sparta Foxi, Cimatti, Kreidler
hi beam 16 hi beam indicator jewel w/socket new $25 these get sun damaged
17 round housing for CEV2152 (=2143 + hole) ? Kreidler
00096B 18 bullet housing for 2139/2158 $30
00096B 18 bullet housing for 2139/2158 used $15
2139 19 bullet headlight CEV2139/SB-bulb $60
2158 19 bullet headlight CEV2158/rep-bulb $75 FOR NEW TOMOS BULLET HEADLITE OPTION
2155 20 bullet headlight CEV2155 no bulb used $35 Cimatti/Foxi with hi beam indicator on top
000963B 21 bullet housing for CEV2155 used $15

==================================================================================

Far right, a CEV 2158 “bullet” headlight. It comes with a block off plate over the speedometer hole. Most European moped speedometers fit into the hole, such as CEV, VDO, Huret, Veglia. Japanese made Tatung speedos are too small. besides the beautiful classic look, hiding most of the wiring inside, the glass fixture features a replaceable bulb socket, a big benefit. With sealed beam headlights, when they (often) burn out you have to buy a whole new glass, that’s both expensive and difficult to find. But with a non-sealed beam (replaceable bulb) fixture, you can change the small 15mm bulb inside. It’s a common automotive bulb #1156 (12V 21W) or #1129 (6V21W). You can get an 1156 at all night convenience stores for $1 or $2. Another benefit is you can run an LED bulb, or any 1156 compatible. That’s a single prong bulb. No high beam, just low.

 

 

 

5   T A I L   L I G H T S

===================================================================================

Under construction…

 

 

6   B A T T E R I E S

===================================================================================

Model   V  Ah  Shape  Width  Height  Depth 
 6N2     6   2      flat    2 3/4   3 3/4   1 3/4
 6N2A   6   2     tall     2 3/4   4 1/8   1 3/4
 6N4     6   4  square  2 3/4   3 5/8   2 5/8
 6N4A   6   4     tall     2 3/8   5 1/8   2 1/8
 6N4B   6   4     flat     3 7/8   3 7/8   1 3/4
 6N4C   6   4   short?
 6N5.5  6  5.5  norm   3 3/8   3 7/8   2 5/8
 BTX4L 12   4   sealed 4 3/8   3 1/2   2 5/8
 YB4L   12   4   norm   4 5/8   3 3/4   2 3/4

The number after “6N” means the amp-hours. A 6N2 will deliver 2 amps (12 watts at 6 volts) for 1 hour. A 6N4 will deliver 4 amps (24 watts at 6 volts) for 1 hour, or 1 amp for 4 hours. The bigger the battery is, the more amp hours it can produce. 

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
…… B…A…T…T…E…R…I…E…S…… in store sales – add $5 for adding the acid
none battery 5-pack of1.2V niCad Cateye TS N/A must buy each cell and join and bundle
781090 1 battery 6V 6N2-2A without acid $15 does not have “vintage” fuse and extra wire
battery 6V 6N2-2A vintage w/acid pack $30 Honda 1978-79 NC50 Express, 65-69 Honda S65
….continued > Taiwan mopeds: Indian, Lazer, Angel
4902003 battery 6V 6N2-2A-1 with acid packet $20
781003 2 battery 6V 6N2-2A-3 without acid $15 Yamaha 1972 JT2 mini, 70-72 Kawasaki G4TR
….continued > Kawasaki 1970-71 F5, 71-72 F8, F9
781082 3 battery 6V 6N2-2A-4 without acid $15 Suzuki 80-81 FA50 Shuttle, 1968 Model 31
….continued > Suzuki 1973-77 GT185
4902010 battery 6V 6N2-2A-8 with acid packet $20
6N2A2C1 4 battery 6V 6N2A-2C-1 without acid $15 Honda 1969-70 Z50A Mini Trail
781092 5 battery 6V 6N2A-2C-3  without acid $15 Honda 1977 NC50 Express, 73 SL70, 72-73 CT70
781016 6 battery 6V 6N4-2A without acid $15 Suzuki 1968 M12,K10,K10P, 1971 AC50,AS50
….continued > Suzuki TC90, 1968 K11, 1969 A100, 76-77 A100
….continued > Suzuki B100P,1969 AC100,AS100,73-77 TC100
….continued > Suzuki B105P,KT120
781079 battery 6V 6N4-2A-4  without acid N/A Honda 1967-68 P50, 79-80 XL100S
781067 battery 6V 6N4-2A-5 without acid N/A Yamaha QT50,YSR50,MJ50,LB50,LC50,GT80
….continued > Kawasaki MC1,G3SS,KH100,G5,G4TR,G3SS,F6,F7
781084 7 battery 6V 6N4-2A-8 without acid $15 Honda 1980-83 NC50 Express, 80-81 NA50 Express II
….continued > Honda 1980-82 CT70
781015 12 battery 6V 6N4A-4D without acid $15 Yamaha many early tall
4902036 8 battery 6V 6N4B-2A with acid packet $22 does not have “vintage” fuse and extra wire
battery 6V 6N4B-2A vintage w/acid pack $32 Suzuki 1979-80 OR50, 71 TC120, 73-77 TC125
….continued > Taiwan mopeds: General, Grycner, AMS
781063 9 battery 6V 6N4B-2A-3 without acid N/A Kawasaki 1973-75 F9, F11
battery 6V 6N4B-2A-5 without acid N/A Honda 1978-83 PA50 Hobbit
781055 battery 6V 6N4C-1B without acid N/A Honda 1974-79 CT70, 81-82 Honda XL100S
781021 10 battery 6V 6N5.5-1D without acid $20 Honda 1973-75 ST90, 1969 SL90, 67-70 CL90
4902075 battery 6V B39-6 (thin) with acid packet $30 Vespa Ciao, Bravo, Grande with blinkers
6N12A 11 battery 6V 6N12A-2D without acid $30 Early Vespa scooters
battery 12V YB4L-B Yuasa without acid $40 84-85 Honda Spree
492263 13 battery 12V CTX4L-BS with acid packet $40 Tomos battery models 2001-later
581306 battery 12V YTX4L-BS Yuasa w/acid pack $60 Tomos and most modern 50cc bikes

 Vintage Battery Wires: Some of the modern replacement 6 volt batteries have the wrong wires. See the image below at right, how the modern and vintage 6N2-2A and 6N4B-2A batteries have different wires. The word “vintage” used above means it has the older wires (with fuse, double female bullet, and extra wire). The vintage versions cost $10 more because the wires must be added on. Otherwise, the old battery’s wires can be transferred onto the new battery, by the customer, saving the $10.

Battery Wire Versions Taiwan 6V Mopeds

Battery Wire Versions
Taiwan 6V Mopeds

6 Volt Battery Chart 2008

6 Volt Battery Chart 2008

Battery Acid: The batteries that say “without acid” are sold dry and sealed, for freshness and maximum strength. Battery acid must be added before use, but it is not included with the battery. It’s sold in auto parts stores. Walk-in customers get the battery filled at the time of sale for $5 more. 

Battery Charging: All lead acid batteries need to be kept charged, at least every 2-3 months, or they will become weaker and weaker with age. After 2 years of sitting they are less than 25% of their original strength. That’s why these batteries are sold dry. For a lead acid battery, life begins at the moment the electrolyte (dilute sulfuric acid) is added. Read the instructions with each battery. Wear eye and skin protection. Use baking soda to neutralize spills.

7   W I R I N G

===================================================================================

 

This is a main wiring harness for 3-or-more-coil moped magnetos (ignition, lights, brake light). It can be configured for 2-coil magnetos (ignition/brake light, lights). See below for possible configurations. It is shown as a photo and a schematic. It comes with the round chrome switches, right for engine stop, left for headlight and horn. Price is $65.

 

This is only the front main harness. A rear harness, engine to tail light, and connector block are needed to make a complete harness, but they’re not included.

Part # # ←picture#………Description Price      Applications
###### ### ############################# #### ##################################
O T H E R… E L E C T R I C A L
221582 regulator AC voltage 12V $45
regulator AC voltage 6V used MB $30
222428 flasher turn signal 12V 2-prong $7
223233 horn 12VAC black Tomos A35 N/A
201204 fuse blade 10A 5-pack $5

Under construction …