Minarelli Motor

August 26, 2012

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1972 Minarelli GP50

1972 Minarelli GP50

Welcome. Minarelli made 50cc engines for 1970’s-80’s mopeds and mini-motorcycles.

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Minarelli Campione

3-time Italian champ
and 12 world records

From Wikipedia: Minarelli was founded in Bologna Italy in 1951 by Vittorio Minarelli. In 1956 Minarelli switched to exclusively manufacturing two-stroke engines, in a 20,000 sq. ft. purpose-built factory. It employed 20 technical staff and produced 70 engines a day. These were sold to companies in Italy, other parts of Europe and South America. In 1967 the company changed its name to Motori Minarelli and opened a new plant in Calderara di Reno. By the 1970s engine production had reached 250,000 units a year. Minarelli successfully competed in Grand Prix motorcycle racing with Spanish rider Ángel Nieto winning 125cc world championships in 1979 and 1981. In 1990 the company began a business relationship with Yamaha. Five years later it employed 350 people and engine production had reached 450,000 units a year. In 2002, following changes in the world motorcycle market, Motori Minarelli became a member of the Yamaha Group.

 

Contents:   1. Minarelli V1    2. Minarelli V2    3. Minarelli C2   4. Minarelli P4 and P6


1. Minarelli V1

(49cc 1-speed automatic with pedals)

Welcome. The Minarelli V1 engine is used on many mopeds, such as Cimatti, Gitane, Testi, Concord, Motron, Fantic, General, AMF, Baretta, Gadabout, Motomarina, and Safari. It is well made, performs good, and is easy to work on.

Minarelli V1 Parts for Sale

grey = Minarelli V1 parts, blue = later version or substitution, orange = 1.0 hp, 20 mph version

Minarelli V1 engine

Minarelli V1 engine

Minarelli V1 engine

Minarelli V1 engine

Diag qty PN Price  Description
2820 1 2820 $25 Oil seal set 5-piece see Seals
2820 1 2820 n.a. 2–4710 17x35x8, 3–4790 15x24x52
4240 1 4240  $4  Intake manifold gasket
4440 1 4440 n.a. Crank pin Ø16 (comes with crank)
4450 1 4455 n.a. Large end bearing (comes with crank) 
4460 1 4410 $95 Stub plane crank M9 -1.00 RH (pre-1978)
4460 1 4460 n.a. Cone type crank M9 -1.00 RH (’78-Sep79)
4460 1 4465 n.a. (made for Ø15 small end bushing)
4460 1 4465 n.a. Late cone crank M10-1.25 LH (Sep79-on)
4460 1 4465 n.a. (made for Ø15 small end bearing)

Minarelli V1 crankshaft versions

4470 1 4470 n.a. Small end bushing Ø12×15 (pre-1978)
4470 1 4475 n.a. Small end bearing Ø12×15 (post-’78)
4480 1 4480  $8  Piston pin see Eng. Hardware  Ø12 x 31.3
4490 2 4490  $1  Piston pin clip  see Eng. Hardware  Ø12
4540 1 4500 piston kit Ø38.0 (V1 1.0hp) see Pistons 22 tall
4540 1 4535 piston kit Ø38.7 (V1 some) see Pistons 22 tall
4540 1 4540 piston kit Ø38.8 (V1, V1H) see Pistons 22 tall
4540 1 4550 piston kit Ø39.0 (V1, V1H) see Pistons 22 tall
4540 1 4560 piston kit Ø39.2 (V1, V1H) see Pistons 22 tall
4540 1 4570 piston kit Ø39.4 (V1, V1H) see Pistons 22 tall
4540 1 4570 piston kit Ø39.4 (V1, V1H) see Pistons 22 tall
 4640 1 4600 ring set Ø38.0×2.5 (V1 1.0hp) see Pistons
4640 1 4640 ring set Ø38.8×1.5 (V1, V1H) see Pistons
4640 1 4635 ring set Ø38.7×1.5 (V1 some) see Pistons
4700 2 4700 Crank bearing 6302   see Bearings 17mm
4710 2 4710 Crankshaft oil seal see Seals  17x35x8
4720 1 4720 Flywheel key see Eng. Hardware  M85
4740 3 4740  .50 Stator plate screw M4-0.7×20?
4750 1 4750 Flywheel nut see Eng.hardware  M10x1.25
4760 1 4760 $35 Drive shaft
4770 2 4770 Drive shaft bearing see Bearings  6202
4780 1 4780   $8  Shim washer 22 x 35 x 1
4790 3 4790 Oil seal see Seals 15x24x5      
4820 1 4800 $12  9 tooth sprocket (1hp, 20mph)
4820 1 4810 $20 10 tooth sprocket (25 or 30mph)
4820 1 4820 $15 11 tooth sprocket (2hp, 30mph)
4820    4822 $30 12 tooth sprocket
4820    4823 $25 13 tooth sprocket (for C2)
4830 1 4830  $2  Sprocket Washer 10.15 x 21.8 x 0.8
4840 1 4840  $2  Sprocket Nut M10x1.25 x 7 RH hex17
4850 2 4850  $6 Shim 15.2 x 20.9 x 0.3mm
4860 2 4860  $3 Snap ring 15mm
4870 1 4870  $7  Drive clutch
4880 1 4880 n.a. Drum 4900 and gear 4890
4890 1 4890 $65 53 tooth gear
4900 1 4900 $60 Clutch drum
4950 2 4950  $7  Clutch shoe bare
4960 2 4960 $10 Clutch shoe complete
4970 2 4970  $2  Clutch shoe plate
4980 2 4980  $1  Clutch shoe plate screw
4990 4 4990  $1  Brake pad spring
5000 4 5000  $1  Brake pad
5010 2 5010  $1  Clutch shoe spring
5020 4 5020 n.a. Spring retaining pin
5030 1 5030  $2 Washer   Ø9   9.3x19x1.5 (pre-Sep79)
5030 1 5032  $1 Washer Ø10 10.1x19x1.5 (post-Sep79)
5040 1 4430  $4 S-clutch plain nut M9-1.0 x 9 RH (early)
5040 1 5040 n.a. S-clutch castle nut M9-1×6 RH (pre-1978)
6270 1 6270 n.a. C-clutch lock nut M9-1×9 RH (78-Sep79)
6275 1 6275  $1 C-clutch lock nut 10-1.25×6 LH (Sep79-on)
5050 1 5050 n.a. cottor pin for 5040 castle nut (pre-1978)
5060 1 5060  $7 Plate return spring
5070 1 5070  $5 Return spring cap
5080 1 5080 $45 Clutch pressure plate
5090 1 5090 $12 Pressure plate lock ring
5100 1 5100 n.a. Start shaft-lever long 38 c-c
5100 1 5105 n.a. Start shaft-lever short 28 c-c
5110 1 5110 n.a. Start shaft-lever O-ring
5120 1 5120 n.a. Return spring for 5100
5120 1 5125 n.a. Return spring for 5105
5130 1 5130  $4 Start shaft set screw M4 special
5140 1 5140 25¢ Start shaft set screw washer M4
5150 1 5150  $2  Cable pinch bolt M5 dome-end
5160 1 5160  $8  Cable stop bridge
5170 1 5170  $2  Cable adjuster M6
5180 1 5180  $6  Upper pressure leaf (short)
5190 1 5190  $12 Lower pressure leaf (long)
5200 1 5200 n.a. Right case half
5202 1 5202 n.a. Case set 5200+5220 (for Ø80 stator)
5220 1 5210 n.a. Left case half for Ø94 stator plate (early)
5220 1 5220 n.a. Left case half for Ø80 stator (most USA)
5230 1 5230  $8  Center case gasket
5240 3 5240  $8  Center case dowel Ø10/8 x 40
5250 9 5250  $1 Case bolt M6x30 allen
5250 2 5250  $1 Case bolt M6x35 allen top rear two
5260 1 5260 $45 Clutch cover grey/natural
5260 1 5262 n.a. Clutch cover black
5270 1 5270  $4  Clutch cover gasket
5280 1 5280  $2  Oil filler cap, no vent, must drill hole
5280 1 5280  $8  Oil filler cap with vent, brown or black
5280 1 5285  $8  Oil filler cap with vent, long black
5290 1 5290  $2  Oil fill gasket ring
5300 1 5300  $2  Oil drain bolt
5310 1 5310  $1  Oil drain gasket ring
5320 3 5320  $1 Bolt M6x15 allen (metal fan base)
5320 3 7055  $2 Bolt M6x16 sunk (plastic/late fan base)
5330 6 5330 $1 Bolt M6x35 allen
5360  1Magneto/generator, several kinds, see below
5370 1 5370 n.a. Wire grommet for internal HT coil
5380 1 5380  $3 Wire grommet for external HT coil
5390 1 5390 $30 Metal base mount (for metal cover)
5390 1 5400 $60 Early plastic base (for early plastic cover)
5390 1 5405 $60 Late plastic base (for late plastic cover)
5410 1 5410 $40 Fan (early 1970-1979)
5410 1 5415 n.a. Fan (late 1979-1990)
5420 4 5420  $1 Fan screw M4x7 sunk
5420 4 threads length must be 5 to 8mm
5430 1 5430 $80 Aluminum fan cover
5430 1 5440 $80 Plastic (early) fan cover
5430 1 5445 $60 Plastic (late) fan cover
5450 3 5450  $1 Aluminum cover bolts M6x30 allen
5450 3 7050  50¢ Plastic fan cover bolts M4x22 sunk
5460 1 5460  $5 Cylinder base gasket (V1 1970-90)
5480 1 5470 n.a. Cylinder Ø38.0   (V1 1hp)
5480 1 5480 n.a. Cylinder Ø38.8 (V1 2hp)
5480 1 5475 n.a. Cylinder Ø38.7 (V1 late)
5480 1 548x n.a. Cylinder Ø38.8 (V1-H)
5490 1 5490 $12 Head spacer ring 39.0 x 53.8 x 0.7
5500 1 5500 $40 Cylinder head “round” good used
5500 1 5505 n.a. Cylinder head “square”
5510 1 B6HS Spark plug see Spark Plugs  NGK B6HS
5520 1 5520 Spark plug boot see Ignition Parts
5530 1 5530  $6  Cylinder stud M6x136 (V1 1970-90)
5540 1 5540  .50 Cylinder stud washer M6
5550 1 5550  $1  Cylinder stud nut M6 (7mm tall)
5560 1 5560 $35 Connecting rod assy with bushing
5600 1 5580 $22 Ø12 side manifold
5600 1 5585 $25 Ø12 front manifold
5600 1 5590 $10 Ø9 side manifold
5600 1 5595 $20 Ø9 front manifold
5600 1 5600 n.a. Ø7 side manifold

5600 1 5605 n.a. Ø7 front manifold
5610 2 5610  $1  Manifold bolt M6x20 allen
5620 1 5620 n.a. Wire guide
5630 1 5630 n.a. Grommet
5640 1 5640 Carburetor Ø9  (1.0/1.5 47/49) see Dellorto
5640 1 5650 Carburetor Ø12 (2.0hp 52 jet) see Dellorto
5660 1 5660 $15 Air cover (Malossi-made Minarelli-type)
5670 1 5670  $6  Exhaust gasket
5680 1 5680 n.a. Pancake exhaust
5690 1 5690  $1  Pancake exhaust bolt M7x12
5700 1 5700 .50 Washer Ø7
5710 1 5710 $30 Idler
5720 1 5720 $20 Idler pin
5730 1 5730 n.a. Shim Ø12 x 17 x 0.4
5740 1 5740 $45 Pedal shaftpin

Minarelli V1 clutch and crank versions

5750 1 5750 n.a. Pedal gear
5760 1 5760 n.a. Side gear
5770 1 5770 n.a. Spring
5780 1 5780 n.a. Spring pin guide
5790 3 5790  $5 Shim 16.1 x 26 x 0.6
5800 1 5800 n.a. Pedal shaft circlip
5810 1 H132 Right pedal crank see Pedal parts
5820 1 H131 Left pedal crank see Pedal parts
5830H134  $2  Pedal crank wedge pin Ø9.0
5840 1 5840  $1  Spring leaf bolt
5850 1 5850  $7 Pedal shaft cap
5860 1 5860 n.a. Lock washer
5870 1 5870  $2 Exhaust stud M6
5890 1 5890 n.a. Engine gasket set

Minarelli V1-H ID number

Minarelli V1-H

Minarelli V1-H

Minarelli V1-H

6000 1 6000  $1 C-clutch snap ring 14 x 1
6020 2 6020 n.a. C-clutch shim 14.6 x 21.0 x 0.75
6020 2 5570 n.a. S-clutch shim 13.6 x 20.8 x 0.75
6040 1 6040 $25 C-clutch bushing Ø14 x Ø17 x 17
6040 1 4920 $25 S-clutch bushing  Ø13 x Ø17 x 17
6180 1 6180 $60 Cone clutch (C-clutch) complete
6180 1 4930 $80 Stub plane clutch (S-clutch) comp.
6200 1 6200 $38 Cone clutch (C-clutch) housing
6200 1 4940 $58 Stub plane clutch housing

V1H parts:

The 1986-88 Minarelli V1H was a V1 with an aluminum cylinder, still with piston port intake. The cylinder and head fins were bigger. There was no fan. Everything else was the same as a “late” V1.

 

Minerelli V1-L specific Parts

Minerelli V1-L specific Parts

V1L, V1HL, V1HLE parts:

4241  $8 Intake manifold gasket
4242 $12 Reed valve gasket
4461 n.a. Crankshaft pork chop type
4463 n.a. Crankshaft full circle type
4473 n.a. Piston bearing
4481 $12 Piston pin see E.H. Ø12×34.5
4541 piston Ø40.3 see Pistons 22 tall
4541 (upper Dykes “L”, lower 1.5 FG)
4543 piston Ø40.3 see Pistons 21 tall
4543 (rings 1.5/1.5, with port window)
4641 ring set Ø40.3 L/1.5 see Rings
4643 ring set Ø40.3 1.5/1.5 see Rings
5201 n.a. Engine case set
5203 n.a. Case set for electric starter
5215 $40 Reed valve
5231 n.a. Center case gasket
5262 n.a. Clutch cover grey
5323 n.a. Cover base screw
5401 n.a. Fan cover base mount
5443 n.a. Flywheel cover

Minarelli V1HL and V1HLE parts

Minarelli V1HL and V1HLE parts

5453 n.a. Cover screw
5471 n.a. Cylinder Ø40.3 all iron
5473 n.a. Cylinder Ø40.3 iron/alum
5491 n.a. Head gasket ring
5493 n.a. Head gasket ring
5501 n.a. Cylinder head Ø40.3 “square”
5503 n.a. Cylinder head Ø40.3
5551 n.a. Cylinder stud nut
5591 n.a. Intake manifold (side)
5596 n.a. Intake manifold (front)
5611 n.a. Intake manifold stud
5623 n.a. Plug wire clip
7110 n.a. Electric starter motor
7115 n.a. Flywheel Cover base
7120 n.a. Starter motor wire
7130 n.a. Rubber cap
7140 n.a. Wire guide
7150 n.a. Wire guide grommet
7160 n.a. Shim washer

 

 

 

 

 

 

Minarelli Magnetos:

CEV 6876 Ø94 stator, Ø80 flywheel (V1 early) see CEV Magneto
CEV 6932 Ø80 stator, Ø80 flywheel (V1 USA) see CEV Magneto
Bosch 0212-010-005 Ø80, Ø80 (V1-H and V1-L)

 

 

Minarelli Intakes:

Minarelli V1 intakes look the same on the outside, but can have different inner sizes.

Minarelli V1 intake pipes

Minarelli V1 side-mount intake pipes
Left,  #5590 13 – 9mm – 12 inner diameter
Right #5580 14 – 12mm – 12 inner diameter

Minarelli V1 center mount intake pipes

Minarelli V1 center mount intake pipes
Right #5595 9 – 10mm – 12 inner diameter (25mph)
Left, #5585 14 – 12mm – 12 inner diameter (30mph)

 

 

 

 

 

 

 

 

 

 

 

Minarelli Exhausts:

Minarelli Exhausts

Minarelli Exhausts

This is unfinished. More later…

 

 

 

 

 

 

 

 

 

 

 

 

Minarelli V1 versions “a,b,c,d,e,f”:

Minarelli Engines

a. Middle: 1970-77 V1 “metal” fan cover (natural aluminum)
b. Left: 1977-1980 V1 “early plastic” fan cover (grey or black)
c. Right: 1979-1986 V1 “late plastic” fan cover (always black)

 

 

 

V1 Fan Covers and Screws

V1 Fan Covers and Screws

Minarelli V1 Fan Cover versions:

a. 1970-1977 had metal fan cover 5430
metal fan base 5390, “early plastic” fan 5410.

b. 1977-1979 had plastic fan cover 5440
plastic fan base 5400, “early plastic” fan 5410.
Most of these are light grey, some are black.

c. 1979-1985 had “late plastic” cover 5445
“late plastic” base 5405, “late plastic” fan 5415.
All of these are black.

d. 1980-1986 also had “Fantic” cover 5445F
“Fantic” base 5405F, “late plastic” fan 5415.
All of these are black.

The individual pieces do not interchange.

 

 

 

 

Minarelli V1 clutch and crank versions

V1 Cone and Stub Plane Clutch

Minarelli V1 Clutch Hub versions:

a. 1970-1977 had “stub plane” clutch assy 4930 and “stub plane” crankshaft 4410

b. 1978-1979 had “cone type” clutch assy 6180 and “cone type” crankshaft 4460

c. 1979-1990 had “cone type” clutch assy 6180 and “late cone” crankshaft 4465

 

 

 

Carabela Engine

Carabela with Minarelli V1 “d”

Carabela V1 (re-made in Mexico)

d. 1974-1979 Carabela Motomatic 49cc pedal or 60cc kickstart, Carabela Carerra (top tank)

These were made in Naucalpan Mexico, by Acer Mex S.A. under license from Minarelli. They have the left case for the bigger 94mm stator plate (earlier and harder to work on). They have metal fan covers. So this version “f” is a late 1970’s copy of a mid 1970’s V1 version “a”.

Carabela had two different cylinders, both with more fins. More later on what internals might be different …

 

 

 

V1 heads, left “round”, right “square”

Minarelli V1 Head and Kick versions:

a,b,c,d 1970-1980 had “round” head 5500, with pedals

e. 1980-1986 Fantic had “square” head 5505, with pedals

f. 1980-1986 Fantic had “square” head 5505, with kickstart

1980 Fantic Pepi Sport Minarelli V1-L engine

1980 Fantic Pepi Sport
Minarelli V1 “e” engine

1986 Fantic Issimo kick start Euro model

1986 Fantic Issimo
Minarelli V1 “f” engine

 

 

 

 

The “Fantic V1” engine version is from 1980 to 1986, shown at left. Square head, Fantic fan cover, late crank and clutch. Here we call it V1 “e” for pedal, or V1 “f” for kick.

 

 


1987 Safari 300MT Minarelli V1-H motor

1987 Safari 300MT
Minarelli V1H

1985 Safari 300MT Turbo

1985 Safari 300MT Turbo
Minarelli V1H engine

Minarelli V1H

In 1986-87 Minarelli introduced the V1H, a V1 “c” with an improved cylinder, head, and no cooling fan. The cylinder was still piston port induction (where the intake manifold feeds the cylinder, and the bottom edge of the piston opens and closes off the port hole to make a net suction inward). The bigger uncoated aluminum cooling fins, cast over the cast iron cylinder core, carried plenty of heat away.

The problem with the V1 exposed cooling fan, was the fan blades would all break off, if the fan cover was struck with the engine running. 

 


1989 Motomarina with Minarelli V1L

same 1989 Motomarina
V1L all iron cyl with fan

1989 Motomarina Sebring with Minarelli V1L

1988-89 Motomarina
V1L, all iron cylinder

Minarelli V1L

In 1988-89, Minarelli introduced the V1L, a V1 “e” with a crankcase two-petal reed valve. The cylinder was still fan cooled, a V1 all cast iron type, but without any intake port, and a bigger bore, 40.3 instead of 38.8mm. This engine had “crankcase reed valve induction”, a modern design that made more torque, especially take-off. Morini already had success with it’s M1 reed motor eight years earlier, so Minarelli was several years late.

 


1990 Safari 300MT Minarelli V1L engine

1990 Safari 300MT
V1HL alum cyl. no fan

V1H and V1HL cylinder comparison

V1H and V1HL cylinder comparison

Minarelli V1HL

In 1988-90, Minarelli made the V1HL, a V1H with a reed valve and no cooling fan. The bore and stroke were the same 40.3 and 42.0.  The cylinder was a V1H type with cast iron core, black powder coated aluminum cooling fins, but without any intake port. The unused intake side of the cylinder wall has a shallow “boost port”. In conjunction with a window high up on the intake side of the piston, the boost port provides a third transfer path from below the piston to above. It is visible at the lower right in the above photo.

 


80's MotoMarina Tri-Power Minarelli V1-LHE with electric start

1987 MotoMarina Tripower
Minarelli V1HLE engine

Minarelli V1HLE

Also in 1987-90, Minarelli made the V1HLE (also called V1HL). It was a V1HL (case reed and no cooling fan) with an electric start mechanism, for use on trikes, which are difficult to pedal start. The Minarelli V1HLE electric start high torque one speed was used on late 1980’s Motomarina three wheeled mopeds. 

Minarelli Logo small

 

 

By the late 1980’s, mopeds were out of style, and scooters were popular. Minarelli made 49cc two-stroke scooter engines with variators all through the 1990’s and most of the 2000’s. Minarelli has always been behind the scenes, making engines for “everybody”, but not advertising or taking much credit. Many people who own certain scooters don’t know their engine is made by humble and wise Minarelli.

 


Minarelli V2

1977 Minarelli V2 Owners Manual, in Italian.
Uso E Manutenzione (Use and Maintenance) del motore 50cc 2 t. con frizone automatico (with automatic clutch) con variatore automatico di velocità (with automatic speed variator).

2. Minarelli V2

(49cc 2-speed automatic with pedals)

1980 Testi Cricket V2 Minarelli V2 variator eng

1980 Testi Cricket V2
Minarelli V2 engine

 

 

 

 

 

 

The V2 mythical creature is real…

For some reason the Minarelli V2 is was not sold in California, or anywhere, other than this one model one year, a 1980 Testi Cricket V2. Other major makes offered automatic moped engines in both one and two speed versions, like Garelli, Puch, Peugeot, Motobecane, Morini. But Minarelli always offered only a one speed. 

Myrons does not have specific parts for Minarelli V2, other than those parts that are the same as on a V1.

 


Minarelli C2

Minarelli C2

3. Minarelli C2

(49cc 2-speed automatic with pedals)

The C2 was on only a few deluxe US moped models.

1983 Safari Variomatic

1983 Safari Variomatic
Minarelli C2 engine

1983 General C2 Minarelli C2 engine

1983 General C2
Minarelli C2 engine

 

 

 

 

 

 

 

Minarelli C2 specs

The C2 has the same all-iron cylinder, piston, “square” head, intake, carburetor, fan, and magneto as a “late” 1979-1985 V1. But the transmission and engine case is much different and longer. The bore is 38.8, not 38.7. The sprocket is 13T, not 11T.

Once again Minarelli made a two speed moped engine, but sales were less than they hoped for. The huge extra cost of the variator drive made it less affordable for most people. Morini had also made the M101, a two speed variator engine, and the MO2 two speed. But the Morini M1 reed valve one speed had better average acceleration than the Morini MO1 piston port two speed did, for a much lower cost and weight. By the late 1980’s, wise Minarelli gave up on two speeds, and “saw the light” of the one speed with case reed induction. 

Myrons does not have specific parts for Minarelli C2, other than those parts that are the same as on a V1.

 

 


1975 Minarelli P6

1975 Minarelli P6

4. Minarelli M4, P4, P6

(49cc 4 or 6-speed manual with kickstart)

These 49cc motorcycle engines were not limited in power, like the 49cc moped engines were. These had 4 to 8 horsepower, instead of 1 to 2.

1981 Testi Cricket 4M Minarelli P4 engine

1981 Testi Cricket 4M
Minarelli M4

1976 Moto Meteora Minarelli M4 4-speed tubone type frame

1976 Moto Meteora
Minarelli M4

 

 

 

 

 

 

 

Here are some images and parts lists from a Minarelli P4 parts manual, in Italian.

Myrons does not have specific parts for Minarelli M4, P4, P6, except for parts that are the same as on a V1.

024

024

025

025

026

026

027

027

 

 

 

 

 

 

 

028

028

029

029

030

030

031

031

 

 

 

 

 

 

 

040

040

041

041