Peugeot Engine Parts

October 7, 2017

Contents:
1. Peugeot 103
2. Peugeot 102

 

Source: All of the illustrations and information below are from the 1980 Cycles Peugeot Spare Parts Catalog 64390.

Peugeot 103: Photo The engine swings on the pivot for the rear suspension. So the exhaust has to be short and compact because it swings with the engine.  On a 103 no-variator model, the engine can swing, but does not, because the front pulley does not vary in size. On a 103 variator model, the engine swings as the front pulley varies in size. When the bike is stopped or going slow, the front pulley is small and the engine is forward. As the rear wheel speeds up, the front pulley gets bigger and the engine swings backward. Above 15 or 20mph the variable pulley is at maximum size and the engine is fully back. 

Peugeot 102: Photo The engine does not swing. It is bolted solid to the frame. So the exhaust can be long. There is no variator on a 102. 

Batavus models: Photo Early 1980’s Batavus Mondial and Gran Prix had Peugeot 103 motors.

 

 

1. Peugeot 103

 

 

abcdefgh  part#  price   E N G I N E S
10000000 63575 none  a 1.0hp no-vari. for 103 L2 U1, -LS
01000000 63578 none  b 1.5hp variator for 103 LVS U2
00100000 63574 none  c 2.0hp variator for 103 LVS U3
00010000 63579 none  d 1.5hp no-vari. for 103 L2 U2
00001000 60697 none  e 2.0hp no-vari. for 103 L2 U3
00000100 63577 none  f  1.5hp variator for 103 SP U2, -B, -R
00000010 63573 none  g 2.0hp variator for 103 SP U3, -B, -R
00000001 64420 none  h 2.0hp variator for TSM U3

Each model family a to h has a column for the part quantity.
The part quantity can be 0, 1 or more, or 1 (as required).

 


00 abcdefgh part#  price  H E A D
01 11010100 51944 $48.0 head assy 103 U1,U2 (1.0 mm deeper)
01 00101010 48498 $52.0 head assy 103 U3 new
01 00101010 48498 $29.0 head assy 103 U3 good-used
02 00000001 68836 $79.0 head assy TSM U3
03 44444444 32115 $0.50 head nut M7-1.0 hex10
04 44444444 58011 $0.20 plain washer M7
05 11111111 32135 $0.50 decomp pivot pin
06 11111111 00000 $9.00 decomp arm
07 11111111 00000 $8.00 decomp spring
08 11111111 00000 $7.00 decomp body
09 11111111 40594 $0.00 decomp o-ring
10 11111111 31152 $3.00 decomp gasket
11 11111111 00000 none  decomp valve shaft
12 11111111 51012 $25.0 decompression valve assy

 


00 abcdefgh part#  price  P I S T O N
13 22222222 22309 $1.50 piston clip
14 22222222 38315 $14.0 piston ring   40.0 x 2.5 GI
14 00000000 00000 $15.0 aftermarket ring 40.0 x 1.5 GI
14 00000000 33648 $12.0 o.s. piston ring   40.5 x 2.5 GI
15 11111111 27194 $10.0 piston pin Ø12
16 11111111 69707 none  piston assembly A, XX xx39.88
16 11111111 69708 none  piston assembly B, XX xx39.89
16 11111111 69709 none  piston assembly C, AA xx39.90
16 11111111 69710 $60.0 piston GOL ebly D, BB xx39.91
16 11111111 69711 none  piston assembly E, CC xx39.92
16 11111111 69712 $75.0 piston assembly F, DD xx39.93
16 11111111 69713 none  piston assembly G, EE xx39.94
16 11111111 69714 $75.0 piston assembly H, FF xx39.95
16 11111111 69715 none  piston assembly I, GG xx39.96
16 11111111 69715 none  piston assembly J, HH xx39.97
16 11111111 69716 $60.0 piston oversize  K, XXxx 40.45
16 11111111 69717 $60.0 piston oversize  L, XXxx 40.46
16 11111111 69718 $60.0 piston oversize  M, XXxx40.47
16 11111111 69719 $60.0 piston oversize  N, XXx  40.48
16 11111111 69720 $65.0 piston oversize  P, XXxx 40.49
16 11111111 69721 $60.0 piston oversize  Q, XXx  40.50
00 abcdefgh part#  price  C Y L I N D E R
18 11111111 36123 $6.00 head gasket
19 11010100 47972 $130  U2,U1 cylinder II and piston H
19 00101011 47226 $140  U3 cylinder C and piston assy A
19 00101011 47226 $175  U3 cylinder C, piston C, 1.5 rings
19 00101011 47226 $140  U3 cylinder DD, piston aftermarket
19 00101011 47226 $150  U3 cylinder DD ported, piston DD
19 00101011 47226 $140  ported in a good way, not “ruined”
19 00101011 47226 $140  U3 cylinder EE and piston assy C
19 00101011 47226 $150  U3 cylinder G and piston assy FF
19 00101011 47226 $125  U3 cylinder G, piston F, 1.5 rings
19 00101011 47226 $16 0 broken fins at left rear
19 00101011 47226 $140  U3 cylinder FF and piston assy E
19 00101011 47226 $160  U3 cylinder  I  and piston assy I
19 00101011 47226 $175  U3 cylinder II and piston HH
20 11111111 46467 $5.00 cylinder base gasket

 


00 abcdefgh part#  price  C R A N K S H A F T
21 10011000 53596 none  crankshaft non-variator
21 01100111 53594 $140  crankshaft for variator
22 11111111 54198 $16.0 piston needle bearing
23 11111111 14403 $12.0 ball bearing 20x47x14 #6204
24 11111111 37004 $7.00 seal ring 20 x 30 x 4.5(or 5)
25 11111111 37034 $7.00 thrust washer 28 x 47 x 0.40
26 11111111 14292 $16.0 ball bearing 17x40x12 #6203C3
27 11111111 37742 $8.00 thrust washer 27 x 40 x 0.30
28 11111111 37616 $3.00 seal ring 16 x 30 x 4.5(or 5)
29 11111111 37615 $3.00 felt ring

 


00 abcdefgh part#  price  E N G I N E   M O U N T
31 11111111 51271 $25.0 engine bracket with 2 of 32
32 22222222 51221 $9.00 sleeve bushing
33 11111111 51220 $8.00 pivot tube
34 22222222 57361 $5.00 stepped ring
35 11111111 48890 $5.00 spring
36 11111111 51367 $5.00 thrust plate
37 22222222 01136 $0.80 hex screw M7 x 28
38 22222222 56091 $0.50 lock washer M7
39 22222222 41003 $0.80 nut M7 square
40 01100111 58818 $5.00 spring clip
41 01100111 58224 $4.00 thrust bolt
42 01100111 59258 $7.00 special plastic nut
76 11111000 51277 $0.00 belt cover spacer see Belt Cover 

 


00 abcdefgh part#  price  C R A N K C A S E
46 11111000 53395 $95.0 case assembly with 87, 88
56 11111100 same but has bolts for plastic belt cover
51 00000111 64351 $70.0 case assy without 87, 88
46 00000011 same but has bolts for metal belt cover
47 11111111 47224 $15.0 case gasket
48 11111111 01131 $1.00 case bolt M6 x 65
49 00000111 01130 $1.20 case bolt M6 x 60
49 11111000 01122 $1.20 case bolt M6 x 55
50 00000111 01130 $1.20 case bolt M6 x 60
50 11111000 01122 $1.20 case bolt M6 x 55
51 11111111 58141 $2.00 centering bolt M6
52 00000111 01131 $1.00 case bolt M6 x 65
52 11111000 01130 $1.20 case bolt M6 x 60
53 11111111 56165 $3 - 2 case bolt M6 x 70 flange
54 22222222 53331 $0.20 plain washer M6
57 33333333 53331 $0.20 plain washer M6
58 33333333 56060 $0.25 lock washer M6
59 66666666 32087 $0.30 case bolt nut M6
60 44444444 27022 $2.50 cylinder stud M7 x 112
61 33333333 27012 $2.00 reed valve stud M5 x 19
62 11111111 27016 $3.00 reed valve stud M5 x 45
63 10000000 57453 $12.0 intake manifold U1
63 01111111 48924 $22.0 intake manifold U2, U3
64 11111111 50490 $2.00 intake (upper) gasket
65 11010100 51737 none  reed valve U1, U2
65 00101011 47229 $17.0 reed valve U3
66 11111111 47241 $3.00 reed valve (lower) gasket
67 44444444 56058 $0.25 lock washer M5
68 44444444 32085 $0.40 nut M5
70 11111111 50602 $3.00 seal retaining plate
71 22222222 16027 $1.00 plate screw 3.5 x 9.5

 


00 abcdefgh part#  price  B E L T   C O V E R
72 22222200 08025 $2.00 cover screw short M5 x 10
73 11111111 08049 $2.00 cover screw long M5 x 35
74 33333300 53086 $0.25 plain wide washer M5
75 33333333 56058 $0.25 lock washer M5
76 11111000 51277 $5.00 plastic belt cover spacer 
77 00000111 57927 $50.0 metal belt cover mount
78 10011000 48982 $0.00 plastic belt cover non-variator
79 01100000 48910 $0.00 plastic belt cover variator
80 00000110 57584 $35.0 metal belt cover silver
80 00000001 57584 $0.00 metal belt cover black
81 00000111 58477 none  VARIATEUR sticker
82 00000111 01429 1- .50 hex bolt M5 x 30
83 00000111 00000 1- .60 hex bolt M5 x 55
84 00000111 01092 $0.60 hex bolt M5 x 10
85 00000111 59377 $8.00 screw-in spacer metal
86 00000111 59528 $5.00 metal belt cover spacer
87 11111000 48917 $15.0 front plastic belt cover bracket
88 11111000 48918 $15.0 rear plastic belt cover bracket
89 03300000 07013 $2.00 variator cover screw M4 x 8
90 01100000 48985 $10.0 variator cover chrome

 


000 abcdefgh part#  price  P U L L E Y – C L U T C H
101 10011000 53593 $150  pulley-clutch assy no-variator
102 11111111 45795 $5.00 flat sided washer 1.5 thick
102 11111111 47610 $7.00 flat sided washer 1.8 thick
103 11111111 45777 95-75 clutch drum
104 11111111 45818 $0.00 shim washer 16.2 x 30 x 0.4
104 11111111 45819 $0.00 shim washer 16.2 x 30 x 0.6
104 11111111 45820 $0.00 shim washer 16.2 x 30 x 0.8
104 11111111 45821 $0.00 shim washer 16.2 x 30 x 1.0
105 11111111 42012 $30.0 running clutch friction plate
106 11111111 45770 $15.0 running clutch 4-star leaf spring
107 11111111 45810 $12.0 running clutch pressure plate
108 11111111 45771 $12.0 running clutch thrust plate drum
109 66666666 42020 $1.00 running clutch steel ball Ø12
110 10011000 53526 $10.0 stepped spacer no-var.
111 10011000 46712 $3.00 nylon washer 16.0-31.7 x 0.45
112 11111111 50520 $5.00 starting clutch locking ring
113 22222222 56058 $0.20 starting clutch lock washer M4
114 22222222 32085 $1.00 starting clutch thin nut M4
115 11111111 45791 $35.0 starting clutch shoe set
116 22222222 43286 $7.00 starting clutch spring
117 10011000 53466 $0.00 pulley assembly no-variator
118 10011000 49457 $0.00 needle bearing no-var. 15x21x14
119 11111111 53527 $0.00 inner sleeve
120 10011000 46319 $3.00 nylon washer 15.0-25.7 x 0.45
121 10011000 44922 $3.00 nut no-var. M11-1.0 x 5 hex17
122 22222222 47252 $0.00 starting clutch washer
123 10011000 48063 $0.00 outer washer no-var.
124 66666666 49898 $0.00 running clutch spring clip 
125 22222222 55926 $0.00 starter clutch bumper

 


000 abcdefgh part#  price  V A R I A T O R
129 01100111 53799 $180  pulley-clutch-variator assy
130 01100111 53526 $0.00 washer
131 01100111 53539 $0.00 stepped spacer
132 01100111 53491 $0.00 tab washer
133 01100111 48615 $0.00 nut
134 01100111 49816 $7.00 outer nylon spacer ring
135 01100111 49812 $5.00 clutch nut M11-1.0 x 7 hex21
136 01100111 69829 $0.00 spacer ring
137 02200222 51893 $0.00 needle bearing 15 x 21 x 14
138 01100111 45750 $0.00 inner sleeve
139 01100111 53527 $0.00 inner sleeve
141 01100111 48613 $0.00 inner pulley half
142 01100111 48983 $0.00 outer pulley half
143 01100111 48611 $0.00 centrifugal driver
144 02200222 53058 $0.00 centrifugal weight
145 04400444 48680 $0.00 cent. weight bushing
146 02200222 53052 $0.00 cent. weight brake
147 02200222 48696 $0.00 cent. weight pivot pin
148 02200222 48699 $0.00 locking piece
149 01100111 50530 $0.00 holder plate

 

 

 

2. Peugeot 102

 

 

ab  part#  price   E N G I N E S
10 63482 none  a 2.0hp no variator  for 102 SP U3, -B
01 63484 none  b 1.5hp no variator  for 102 SP U2

Each model family a to b has a column for the part quantity.
The part quantity can be 0, 1 or more, or 1 (as required).

 

 


00 ab  E N G I N E   T O P   E N D
01 11 48494 $45 head assy 102 U2, U3

03 to 18: same as 103 above, 3 to 18

19 11 68833 $170  102 cylinder BB and piston BB
19 11 68833 $170  102 cylinder CC and piston CC
19 11 68833 $90.0 102 cylinder B only, good-used 39.92
20 11 46467 $5.00 cylinder base gasket
21 11 32097 $0.30 nut M6
22 11 27010 $2.00 intake stud M5 short
23 11 27013 $2.00 intake stud M5 long
24 11 56060 $0.25 lock washer M6
25 10 56278 none  intake pipe U2
25 01 46070 $35.0 intake pipe U3, good-used
26 11 46031 $8.00 intake gasket
27 11 56058 $0.25 lock washer M5
28 11 32085 $0.40 nut M5
29 11 01105 1- .50 hex bolt M6 x 12

 


00 ab   C R A N K S H A F T   a n d   C A S E
31 11 53596 140 crankshaft non-variator

32 to 39: same as 103 above, 22 to 29

41 11 53398 $$$ crankcase assy
42 44 27022 $2.50 cylinder stud M7 x 112
43 11 44893 $5 case gasket
44 22 01122 $1.20 case bolt M6 x 55
45 11 01130 $1.20 case bolt M6 x 60
46 11 01131 $1.00 case bolt M6 x 65
47 11 01339 $1.20 case bolt M6 x 70
48 11 45636 $2 centering bolt M6
49 66 32087 $0.30 nut M6
50 33 56060 $0.25 lock washer M6
51 11 50602 $3.00 seal retaining plate
52 22 16027 $1.00 plate screw 3.5 x 9.5
54 11 46803 $0.00 right engine bracket
55 11 45870 $0.00 left engine bracket
56 11 46340 $0.00 front fixing bracket
57 11 46341 $0.00 rear fixing bracket
58 22 01154 $1.50 bolt M7 x 65
59 22 48670 $0.20 washer M7
60 22 56105 $0.50 lock washer M7
61 22 32094 $0.60 nut M7

 


00 ab   B E L T   C O V E R
71 11 61821 $00 belt cover see below
72 22 08025 75¢ screw M5 x 10
73 22 53086 25¢ plain washer
74 22 56058 25¢ lock washer
75 11 61822 none decal


#71  61821 belt cover, several choices:
1  $13  good-used, has some paint spray
2  $15  almost new, has a rough area
3  $17  good-used, has the decal
4  $15  good-used, has decal, scratched
5  $15  good-used, has decal, scratched
6  $12  good-used, scratched
7  $12  good-used, sun-faded, has a rough area

 


00 ab   P U L L E Y – C L U T C H

101 to 125: same as 103 above, 101 to 125

 

 

 

 

 

Trac Parts

August 26, 2017

Contents:   1. Trac Parts 1982-86 models with Laura M56 engine

Contents:   2. Trac Parts 1984-90 models with Daelim DP50 or DK50 engine

 

 

1. Trac Parts 1982-86 with Laura M56 engine

Many Trac parts are offered elsewhere, by type:

Tires    see Tires and Tubes  2.25-16 Clipper, Eagle, Hawk

M56 engine   see Laura Engine  scroll down to Laura M56
xxx Rings     see Pistons and Rings  scroll down to 40 x 1.5 FG
xxx Piston     see Pistons and Rings  scroll down to 12 pin 18 upper
xxx Bearings, seals  see Bearings and Seals  
xxx Keys, clips, nuts, shims see Engine Hardware 

Encarwi carb   see Carburetors/Encarwi  scroll to Encarwi H12 (25, 30 mph)
Encarwi carb   see Carburetors/Encarwi  scroll to Encarwi H8 (20 mph)

Ignition   Spark plug   see Spark Plugs and Points  NGK B6HS
xxx Points   xxx     see Spark Plugs and Points scroll to M31
xxx Condenser       see Spark Plugs and Points scroll to M32
Bosch magneto     see Magnetos/Bosch scroll to 0212-010-004

Chain   see Chains  #415H (1/2 x 3/16″) 98 links for 17 and 39 tooth sprockets (25, 30 mph)
Chain   see Chains  #415H (1/2 x 3/16″) 97 links for 13 and 39 tooth sprockets (20 mph)

Spokes
25006  000 x 2.6 12g  front A inner  Olympic, Liberty
25007  000 x 2.6 12g  front B outer  Olympic, Liberty

25054  160 x 2.9 11g  rear  A inner  Olympic, Liberty
25055  160 x 2.9 11g  rear  B outer  Olympic, Liberty

25506  158 x 2.6 12g  front A inner  Clipper, Escot
25505  158 x 2.6 12g  front B outer Clipper, Escot

25578  159 x 2.6 12g  rear  A inner  Clipper, Escot
25577  159 x 2.6 12g  rear  B outer Clipper, Escot

35503  173 x 2.6 12g  front A inner  DH100
35504  173 x 2.6 12g  front B outer  DH100

35604  158 x 3.2 10g  rear  A inner  DH100
35605  158 x 3.2 10g  rear  B outer  DH100

 

Three Trac models with M56 engine and Magura controls

Three Trac M56 models with Domino controls

 

 

 

 

 

 

Six models are combined here. Each has a quantity column with these header codes:

C = Clipper with Magura controls                                  c = Clipper with Domino controls
E = Eagle    with Magura controls                                 e = Eagle   with Domino controls
H = Hawk   with Magura controls                                 h = Hawk  with Domino controls

 

 

diag.#  Trac #  Daelim part # xx C c E e H h  price xxx description xxxx specs xxxx remarks

F1-01-1 00000 50100-M56-8950  0 0 1 1 0 0  none frame for Eagle stamped sheet metal with tank
F1-01-1 00000 50100-MT1-0000  0 0 0 0 1 1  none frame for Hawk welded tubes top-tank
F1-01-2 00000 50100-MT2-0000  1 1 0 0 0 0  none frame for Clipper welded tubes step-thru
F1-02-1 20651 53212-M56-8900  1 1 1 1 1 1  $$$  steering race lower cone see steering scroll to 1″-24 Trac
F1-03-1 20648 96211-05000 XW  1 1 1 1 1 1  $$$  steering balls quantity 52  see steering 5/32″ 26 per race
F1-04-1 20650 50302-M56-8900  1 1 1 1 1 1  $$$  steering race lower cup see steering scroll to 1″-24 Trac
F1-05-1 20649 50301-M56-8900  1 1 1 1 1 1  $$$  steering race upper cup see steering scroll to 1″-24 Trac
F1-03-1 20648 96211-05000 XW  1 1 1 1 1 1  $$$  steering balls quantity 52  see steering 5/32″ 26 per race
F1-06-1 20647 53211-M56-8900  1 1 1 1 1 1  $$$  steering race upper cone see steering scroll to 1″-24 Trac
F1-07-1 20645 90503-M56-8900  1 1 1 1 1 1  $$$  steering washer xxxxxx see steering scroll to 1″-24 Trac
F1-08-1 20644 90304-M56-8900  1 1 1 1 1 1  $$$  steering lock nut xxxxx see steering scroll to 1″-24 Trac
F1-09-1 20646 90305-M56-8900  1 1 1 1 1 1  $$$  steering top nut xxxXx see steering scroll to 1″-24 Trac
F1-10-1 00000 50401-M56-8900  0 0 1 1 0 0  none frame molding
F1-11-1 00000 50402-M56-8900  0 0 9 9 0 0  none frame molding clip
F1-12-1 26530 52400-M56-8900  2 2 2 2 0 0  $45  rear shock Eagle and Clipper Ø10 x 310, Ø5.7 coil
F1-12-1 00000 52400-M56-8950  0 0 0 0 2 2  $40  rear shock for Hawk Ø10 x 320, Ø6.0 coil (heavier)
F1-13-1 21204 17620-M56-8900  1 1 1 1 0 0  $$$  gas cap Eagle and Clipper see gas caps 27mm qtr turn
F1-16-1 26533 84706-M56-8900  0 0 1 1 1 1  none carrier catch assy Eagle and Hawk
F1-20-1 01616 92000-06016 XW  2 2 2 2 4 4  50¢  hex bolt luggage rack M6 x 16
F1-21-1 06060 94111-06500 XW  2 2 2 2 2 2  25¢  spring washer Ø6.5
F1-22-1 00000 92000-10040 XW  0 0 2 2 0 0  $$1  hex bolt upper shock M10 x 40
F1-23-1 26531 92000-10036 XW  2 2 2 2 2 2  $$1  hex bolt lower shock M10 x 36
F1-24-1 05100 94101-10500 XW  6 6 6 6 6 6  35¢  plain washer Ø10.5
F1-26-1 20270 94201-10000 XW  2 2 0 0 2 2  $$6  hex cap nut M10-1.25
F1-27-1 84014 81200-MT1-0000  0 0 0 0 1 1  none luggage rack (extender) for ’84-85 Hawk
F1-28-1 00000 81311-MT2-0000  1 1 0 0 0 0  none front basket for 1983-84 Clipper
F1-29-1 00000 81312-MT2-0000  2 2 0 0 0 0  none leg shield bracket 1985 Clipper
F1-30-1 25614 92000-06025 XW  2 2 2 2 4 4  50¢  hex bolt M6 x 25
F1-31-1 05060 94101-06500 XW  4 4 0 0 0 0  25¢  plain washer Ø6.5
F1-32-1 00000 00000-M56-0000  2 2 2 2 2 2  none pedal shaft bushing 16 x 20?
F1-34-1 00000 83551-HD2-890?  2 2 0 0 2 2  none  fuel hose grommet Clipper, Hawk/Sprint

F2-23-1 84030 50500-M56-8900  0 0 1 1 0 0  $45  center stand ’82-83 Trac Eagle and ’76-80 Batavus
F2-23-1 84031 50500-MT1-0000  1 1 0 0 1 1  none center stand Clipper and Hawk
F2-23-2 84032 50500-M56-8930  0 0 1 1 0 0  none center stand ’84-86 Trac Eagle (upgrade for ’82-83)
F2-24-1 84033 50522-M56-8900  1 1 1 1 1 1  $12  center stand spring
F2-25-1 84034 50526-M56-8900  0 0 1 1 0 0  $10  stand pivot pipe short for ’82-83 Eagle Ø12 x 72
F2-25-1 84035 50526-MT1-0000  1 1 1 1 1 1  $$8  stand pivot pipe Clipper,Hawk,’84-86 Eagle Ø12 x 85
F2-26-1 20635 94101-12000 XW  1 1 1 1 1 1  $$1  plain washer M12
F2-27-1 84036 94201-30180 XW  1 1 1 1 1 1  50¢  split pin 3.0 x 18
F2-28-1 84037 50524-397-0000 x1 1 1 1 1 1  $14  center stand rubber bumper ’84-on (goes on stand)

E3-22-1 06050 94111-05000 XW  2 2 2 2 2 2  20¢  spring washer ignition coil mount M5
E3-21-1 82017 93500-05022 XW  2 2 2 2 2 2   70¢  pan phillips screw for coil mount M5 x 22

M1- 1-1 84015 8131?-MT2-0000  1 1 0 0 0 0  none leg shield blue for 1985 Clipper (not shown)
M1- 1-2 84016 8131?-MT2-0000  1 1 0 0 0 0  none leg shield wineberry ’85 Clipper (not shown)
M2-2-1 02616 95700-06016-05 x 2 2 0 0 0 0   70¢  flange hex bolt for leg shield  M6 x 16

 

 

diagram  Trac#  Daelim part # xx C c E e H h  price xxx description xxxx specs xxxx remarks

F2-01-1 86001 52100-M56-8900  0 0 1 1 1 1  $50  swing arm ’82-83 Eagle, ’83-86 mag wheel models threaded axles
F2-01-1 86002 52100-M56-8930  1 1 1 1 1 1  $50  swing arm for 1984-86 spoke wheel models with slide-out axles
F2-02-1 86003 90121-M56-8900  1 1 1 1 1 1  $$8  swing arm pivot bolt M10-1.25 x 108 plus spring anchor
F2-03-1 86004 50308-M56-8900  2 2 2 2 2 2  $12  swing arm bushing 10 x 22 x 29 long
F2-04-1 05100 94101-10000 x0x 1 1 1 1 1 1  25¢  plain washer M10
F2-05-1 06100 94111-10000 x0x 1 1 1 1 1 1  25¢  spring washer M10
F2-06-1 20234 94001-10000 x0x 1 1 1 1 1 1  40¢  hex nut M10-1.25
F2-07-1 84020 50230-M56-8900  1 1 1 1 1 1  $22-$15 front engine hanger
F2-08-1 84021 50312-M56-8900  1 1 1 1 1 1  $20  motor mount right
F2-09-1 84022 50313-M56-8900  1 1 1 1 1 1  $20  motor mount left
F2-10-1 84023 50314-M56-8900  2 2 2 2 2 2  none motor mount rubber
F2-11-1 84024 90131-M56-8900  1 1 1 1 1 1 1.50  hex bolt M6 x 95
F2-12-1 05060 94101-06000 x x01 1 1 1 1 1  25¢  plain washer M6
F2-13-1 06060 94111-06000 x x01 1 1 1 1 1  25¢  spring washer M6
F2-14-1 04060 94001-06000 xx 01 1 1 1 1 1  25¢  hex nut M6
F2-15-1 84025 92000-08085 x 0x1 1 1 1 1 1 01 1.50  hex bolt M8 x 85
F2-16-1 05080 94101-08000 x 0x2 2 2 2 2 2  25¢  plain washer M8
F2-17-1 06080 94111-08000 x 0x1 1 1 1 1 1  25¢  spring washer M8
F2-18-1 04080 94001-08000 x 0x1 1 1 1 1 1  25¢  hex nut M8
F2-19-1 84026 92000-06072 x 0x2 2 2 2 2 2 1.50  hex bolt M6 x 72
F2-20-1 05060 94101-06000 x 0x2 2 2 2 2 2  25¢  plain washer M6
F2-21-1 04060 94001-06000 x 0x2 2 2 2 2 2  25¢  hex nut M6
F2-22-1 00000 94104-M56-800 02 2 2 2 2 2   $$$  washer 10.5 x ?

 

 

 

 


fig    CcEeHh    Daelim part#    price   F4 Pedal Parts
1-0   111111 41111.M56.8900 $15-8 right pedal Union block type
2-0   111111 41113.M56.8900 $15-8 left pedal Union block type
3-0   111111 41101.M56.8900 $15.0 right pedal arm 504R
4-0   111111 41102.M56.8900 $15.0 left pedal arm 504L
5-0   001100 41009.M56.8900 40-28 pedal shaft Eagle
5-1   110011 41009.MT1.8900 $40.0 pedal shaft Clipper-Hawk
6-0   111111 41109.M56.8900 $7.00 pedal chain 3/8 x 5/32 x 32L
7-0   110011 41106.M56.8900 $00.0 left spacer Clip-Hawk (shown on right)
7-1   001100 41106.MT1.8900 $00.0 left spacer 2.0″ Eagle (shown on right)
8-0   222222 41108.M56.8900 $1.50 wave washer
9-0   222222 41105.M56.8900 $2.00 pedal pin 9.0mm with 10,11
12-0 111111 40535.M56.8900 $00.0 tensioner spring
13-0 111111 40532.M56.8900 $00.0 tensioner guide
14-0 111111 40537.M56.8900 $00.0 tensioner bolt
15-0 111111 40538.M56.8900 $00.0 tensioner washer

 

 

 

 

 

 

 

 

 

 

diagram#  Trac #  Daelim part # xxC c E e H h  price xxx description xxxx specs xxxx remarks 

F11-01-1  00000 53100-M56-8900  1 1 1 1 1 1  none handlebar
F11-02-1  00000 53131-028-0000 x2 2 2 2 2 2  $10  handlebar clamp upper
F11-03-1  00000 53132-056-0001 x2 2 2 2 2 2  $10  handlebar clamp lower
F11-04-1  00000 92000-06028 x x  4 4 4 4 4 4  $$1  hex bolt M6 x 28
F11-05-1  00000 94101-06500 xx   4 4 4 4 4 4  25¢  plain washer Ø6.5
F11-07-1  00000 94111-10500 xx   2 2 2 2 2 2  40¢  spring washer Ø10.5
F11-08-1  00000 94001-10000 x x  2 2 2 2 2 2  $$1  hex nut M10-1.25
F11-09-1  00000 94101-10500 xx   2 2 2 2 2 2  40¢  plain washer Ø10.5
F11-09-1  00000 53134-M56-8900  2 2 2 2 2 2  $$4  upper rubber cushion ’84-86
F11-10-1  00000 53135-M56-8900  2 2 2 2 2 2  $$4  lower rubber cushion ’84-86
F11-11-1  00000 35300-M56-8950  1 0 1 0 1 0  $$$  light/horn switch plastic clamp-on x  see Switches CEV 8188
F11-12-1  00000 35301-M56-8950  1 0 1 0 1 0  $$$  light/horn switch clamp bracket xxx  see Switches CEV 8188
F11-13-1  00000 35150-M56-8950  1 0 1 0 1 0  $$$  engine stop switch plastic clamp-on  see Switches CEV 8189
F11-15-1  00000 93500-05000 x x  2 0 2 0 2 0  60¢  screw pan-head phillips M4 x 28
F11-16-1  00000 35155-M56-8950  1 0 1 0 1 0  $$$  engine stop switch cord (wires)
F11-17-1  00000 35305-M56-8950  1 0 1 0 1 0  $$$  light/horn switch cord (wires)
F12-01-1  84510 45464-M56-8950  1 0 1 0 1 0  $$$  right control front brk,throttle,choke  see Magura 0
F12-02-1  84511 45451-M56-8950  1 0 1 0 1 0  $$$  right brake lever aluminum xxxxxxxx see Magura 2
F12-03-1  84512 17921-M56-8950  1 0 1 0 1 0  $$$  choke thumb lever/trigger xxxxxxxxx see Magura 3
F12-04-1  84515 93500-06015 xx   2 0 2 0 2 0  $$$  screw pan slotted special M6 x 16 xx  see Magura 10
F12-05-1  84514 92700-M56-8950  2 0 2 0 2 0  $$2  choke cable pinch bolt 5.5 x 7 
F12-07-1  23218 94001-05000 xx   2 0 2 0 2 0  $$$  brake lever pivot nut xxxxxxxxxxxxx  see Magura 7a
F12-08-1  84516 45452-M56-8950  2 0 2 0 2 0  $$$  brake lever pivot bolt xxxxxxxxxxxxx see Magura 6
F12-09-1  84517 45453-M56-8950  2 0 2 0 2 0  $$$  brake lever cable anchor xxxxxxxxx   see Magura 11
F12-13-1  84550 45463-M56-8950  1 0 1 0 1 0  $$$  left control rear brake, start(clutch)   see Magura 0
F12-14-1  84551 45461-M56-8950  1 0 1 0 1 0  $$$  left brake lever aluminum xxxxxxxxx see Magura 1
F12-15-1  84552 17931-M56-8950  1 0 1 0 1 0  $$$  start lever black plastic xxxxxxxxxxx see Magura 16
F12-16-1  84558 35351-M56-8950  2 2 2 2 2 2  $$$  brake light switch cord (wires)
F12-17-1  84557 35350-M56-8950  2 2 2 2 2 2  $$$  brake light switch NC when installed see Switches CEV 9342
F12-19-1  84568 45466-M56-8950  1 0 1 0 1 0  $$$  left lever helper spring xxxxxxxxxxx  see Magura 8
F12-19-1  84569 45466-M56-8950  1 0 1 0 1 0  $$$  right lever helper spring xxxxxxxxxx  see Magura 9
F12-20-1  23229 35352-M56-8950  2 2 2 2 2 2   $$$ brake light switch rubber boot xxXx see Switches bottom
F12-24-1  84554 17932-M56-8950  1 0 1 0 1 0  $$$  start lever cable screw xxxxxxxxxxxx see Magura 17
F12-25-1  84555 17933-M56-8950  1 0 1 0 1 0  $$$  start lever pivot roll pin xxxxxxxxxxx see Magura 18
F12-26-1  84556 53166-M56-8950  1 0 1 0 1 0  $$$  left hand grip ribbed black xxxxxxxx  see Magura 14
F12-27-1  20525 38100-M56-8950  1 1 1 1 1 1  $$$  horn
F12-28-1  84560 38105-M56-8950  1 1 1 1 1 1  $$$  horn wires
F12-29-1  84562 45470-M56-8900  1 1 1 1 1 1  $$5  cable cover (sleeve) 17 inch long black holds 3 cables
F12-30-1  84563 45460-M56-8950  1 0 1 0 1 0 Magura type xxxX   cable  Ø   C x E      
F12-30-1  84563 45460-M56-8950  1 0 1 0 1 0 M56 Cables xxxx     ends mm inches   
F12-30-1  84563 45460-M56-8950  1 0 1 0 1 0  $$$  rear brake cable  2  5  61.0 3.3 says nothing
F12-31-1  84566 17920-M56-8950  1 0 1 0 1 0  $12  choke cable xxx  1  5  38.8 4.7 says nothing
F12-32-1  84565 17910-M56-8950  1 0 1 0 1 0  $25  throttle cable xX 2  5  38.8 2.7 says nothing
F12-33-1  84567 17930-M56-8950  1 0 1 0 1 0  $$$  starter cable xxx 1  5  40.2 4.2 says nothing
F12-34-1  84564 45450-M56-8950  1 0 1 0 1 0  $25  front brake cable 2  5  39.1 3.3 says nothing

diagram  Trac#  Daelim part # xx C c E e H h  price xxx description xxxx specs xxxx remarks    1984-86 models

F12-35-1 23510 00000-000-0000  0 1 0 1 0 1  $$$  left control assy, rear brake, clutch(start) see Domino DB7K
F12-36-1 23226 00000-000-0000  0 1 0 1 0 1  $$$  left hand grip 22 i.d. octagon stylexxxxx  see Domino D22K
F12-37-1 23220 00000-000-0000  0 3 0 3 0 3  $$$  pivot screw M6 special type xxxxxxxxxxx see Domino D8
F12-38-1 23511 00000-000-0000  0 1 0 1 0 1  $$$  left control housing (perch) xxxxxxxxxxx see Domino D18K
F12-39-1 23224 00000-000-0000  0 2 0 2 0 2  $$$  cable adjuster slotted M6-1.0 xxxxxx see Cable parts A3b
F12-40-1 23225 00000-000-0000  0 3 0 3 0 3  $$$  pivot screw nut M6 flangexxxxxxxxxxxxx see Domino D7
F12-41-1 23223 00000-000-0000  0 3 0 3 0 3  $$$  cable anchor (holdfast) xxxxxxxxxxxxxx  see Domino D36
F12-42-1 23227 00000-000-0000  0 1 0 1 0 1  $$$  left brake lever black plasticxxxxxxxxxxx see Domino D20KL
F12-43-1 23512 00000-000-0000  0 1 0 1 0 1  $$$  left lower start lever black plasticxxxxxxx see Domino D19K
F12-44-1 84575 00000-000-0000  0 1 0 1 0 1  $$$  right control front brake, throttle, choke xsee Domino DA8K
F12-45-1 23221 00000-000-0000  0 2 0 2 0 2  $$$  clamp (wedge) bolt M6 xxxxxxxxxxxxxxx see Domino D16
F12-45-1 23222 00000-000-0000  0 2 0 2 0 2  $$$  wedge (cone) for clamp bolt xxxxxxxxxx  see Domino D15
F12-46-1 84576 00000-000-0000  0 1 0 1 0 1  $$$  right control (throttle) housing  xxxxxxxx see Domino D5L 
F12-47-1 23214 00000-000-0000  0 1 0 1 0 1  $$$  special screw that holds twist tubexxxxxx see Domino D3
F12-48-1 23213 00000-000-0000  0 1 0 1 0 1  $$$  right brake lever black plasticxxxxxxxxxx see Domino D20KR
F12-49-1 23217 00000-000-0000  0 1 0 1 0 1  $$$  throttle cable adjuster M5-0.8 xxxxxx see Cable parts A1b
F12-50-1 84577 00000-000-0000  0 1 0 1 0 1  $$$  throttle helper spring 3-loop xxxxxxxxxxx see Domino D23
F12-51-1 84578 00000-000-0000  0 1 0 1 0 1  $$$  choke lever pivot rivet xxxxxxxxxxxxxxxx see Domino D37
F12-52-1 84579 00000-000-0000  0 1 0 1 0 1  $$$  choke cable pinch bolt (binding screw) see Cable parts P5
F12-53-1 84580 00000-000-0000  0 1 0 1 0 1  $$$  choke lever right thumb  xxxxxxxxxxxxxx see Domino D35
F12-54-1 23211 00000-000-0000  0 1 0 1 0 1  $$$  throttle twist tube metal bare (not shown) see Domino D6A
F12-54-1 23211 00000-000-0000  0 1 0 1 0 1  $$$  right grip 24 i.d. octagon style xxxxxxxxx  see Domino D21K
F12-55-1 23215 00000-000-0000  0 1 0 1 0 1  $$$  slider screw (cable pinch screw) xxxxxxxx see Domino D2L
F12-55-1 23216 00000-000-0000  0 1 0 1 0 1  $$$  throttle slider (sliding block) xxxxxxxxxxx see Domino D1
F12-56-1 84585 17910-M56-8960  0 1 0 1 0 1 Domino type x    cable  Ø   C x E
F12-56-1 84585 17910-M56-8960  0 1 0 1 0 1 M56 Cables x x   ends mm inches    
F12-56-1 84585 17910-M56-8960  0 1 0 1 0 1  $12  throttle cable  1  5 38.9 2.4 says M56 896, pre-cut wire
F12-57-1 84586 17920-M56-8950  0 1 0 1 0 1  $12  choke cable x  1  5 38.8 4.7 says nothing, same as F12-31
F12-58– 84589s 45460-M56-895S  0 0 0 1 0 0  none rear brk cable 2  5 60.8 2.8 says M56 895S for Eagle
F12-58- 84589d 45460-M56-895D  0 0 0 1 0 0  none rear brk cable 2  5 61.1 3.3 says M56 895D for Eagle dlx
F12-58-1 84589 45460-MT1-895S  0 0 0 0 0 1  none rear brk cable 2  5 59.5 2.8 says MT1 895S for Hawk
F12-58-1 84589 45460-MT1-895D  0 0 0 0 0 1  none rear brk cable 2  5 59.5 3.3 says MT1 895D for Hawk dlx
F12-58-1 23517 45460-CL1-0000   0 1 0 0 0 0  none rear brk cable 2  6 58.8 3.6 says ESCOT xx for Clipper
MM  Trac rear brake cable Domino  0 1 0 1 0 1  $25  rear brk cable 2  5 61.0 3.6 says nothing, replaces 84589 xx
F12-59– 84588s 45450-M56-895S  0 0 0 1 0 0  none fr. brake cable 2  5 39.1 2.8 says M56 895S for Eagle
F12-59- 84588d 45450-M56-895D  0 0 0 1 0 0  none fr. brake cable 2  5 39.1 3.3 says M56 895D for Eagle dlx
F12-59-1 84588 45450-MT1-895S  0 0 0 0 0 1  none fr. brake cable 2  5 37.5 2.8 says MT1 895S for Hawk
F12-59-1 84588 45450-MT1-895D  0 0 0 0 0 1  none fr. brake cable 2  5 37.5 3.3 says MT1 895D for Hawk dlx
F12-59-1 23515 45450-CL1-0000   0 1 0 0 0 0  $25  fr. brake cable 2  6 37.1 3.6 says ESCOT xx for Clipper
MM Trac front brake cable Domino  0 1 0 1 0 1  $25  fr. brake cable 2  5 39.0 3.6 says nothing, replaces 84588 xx
F12-60-1 84587 17930-M56-8960  0 1 0 1 0 1  none starter cable x 2  5 40.6 2.9 says M56 896

Clipper, Eagle, Hawk brake plates. S and D type

These 1985-86 Trac double-ended brake cables, for M56 engine models with Domino controls, came in two versions, D or S. The D-type inner wire was 0.5 inch longer than S-type, because the Grimeca brake on the aluminum (Deluxe type) wheels was different from the Duck Chang brake plate on the (Standard type) spoke wheels. See photo at right.

The 1985-86 (M56 engine) Eagle and Hawk with cable codes M56 and MT1, had incorrectly-made replacement brake cables, front and rear. The inner wire was 0.8 inch too short. In the listing the incorrect exposed lengths “E” are crossed out. Trac forgot to include the distance of the removable slotted adjuster 23224. 

The 1984-86 (M56 engine) Clipper and 1984-89 (DMC engine) Escot, Sprint, Image with cable codes CL1 and HA1 had correctly-made replacement brake cables. The CL1 or HA1 inner wire was 0.3 inch longer than a M56-895D, or 0.8 inch longer than a M56-895S.

The 1984-89 (DMC engine) Liberty, Olympic, Blitz with cable codes HD2 had different brake cables with threaded rods at the wheel end.

Trac cables have been terribly confusing since the 1980’s. You can see why; 3 kinds of part numbers, 4 kinds of brake cables not mentioned in parts manuals, and 8 kinds of incorrectly made replacement brake cables. Finally the clouds have cleared and the sun shines again!

MM offers correctly made replacement cables. They work on both brake types D and S, thanks to the long lower cable adjuster and the upper slotted adjuster. For an S type (spoke wheel) the cable adjuster would be screwed 0.5 inch farther out than on a D type (mag wheel). That is no problem because there is plenty of adjustment range, like about 2 inches total.

 

 

 

 

 

 

 

 

## x Trac #  Daelim part # xx C c E e H h  price xxx description xxxx specs xxxx remarks

 

Trac SpeedometersSpeedometers: 

Row 1: Trac DH100 console with turn, hi-beam and neutral light, 70mph speedo, no key switch $80

Row 2 left: Trac 1983-85 Hawk, no key switch, new $80

Row 3 left: Trac 1985-89 Olympic, Sprint, Clipper, Image, Liberty, Escot console, with key switch, (not available).

Row 3 right: Trac 1982-85 Eagle, Clipper, used $45

 

 

 

 

 

 

 

 

 

2. Trac Parts 1984-90 with Daelim engine

Most Trac parts are in Parts, by type, like tires, spokes, rings, etc.

Tires    see Tires and Tubes
xxxxxxx 2.25-16 Clipper, Hawk, Sprint, Escot, Image
xxxxxxx 2.25-17 Olympic, Liberty, Blitz    2.75-10 Metro

Daelim engine   see
xxx Rings     see Pistons and Rings  scroll down to 40 x 1.5 trapezoidal FG
xxx Piston     see Pistons and Rings  scroll down to 12 pin 18 upper
xxxBearings, seals  see Bearings and Seals 
xxx Keys, clips, nuts, shims see Engine Hardware

Mikuni carb   see Mikuni VM13 (under construction)

Ignition   Spark plug   see Spark Plugs and Points  NGK BR6HS
xxx CDI ignition (no points no condenser)

Chain   see Chains  #420H (1/2 x 1/4″)
xxxxxxx 96 links for 12 and 42 tooth sprockets on Clipper, Hawk, Sprint, Escot, Image
xxxxxxx 98? links for 12 and 42 tooth sprockets on Olympic, Liberty, Blitz

 

Four Trac DP50 models (1-speed pedal start)

Five Trac DK50 models (2-speed kick start)

 

 

 

 

 

Nine models are combined here. Each has a quantity column, with these single-digit header codes:

C = Clipper, O = Olympic,                       H = Hawk or Sprint,  B = Blitz     (Daelim DP50 pedal-start engine)
C = DPCL,x  O = DPOL,xxx                      H = DPHA        < Daelim 4-digit codes in parts manual

E = Escot,    L = Liberty, S = Liberty LS,   I = Image,               M = Metro      (Daelim DK50 kick-start engine)
E = DKES,    L = DKLI,x S =  DKLE,xxxxx  I = DKIM        < Daelim 4-digit codes in parts manual

DP50 (pedal) part quantities are black. DK50 (kick) part quantities are green. The Blitz and Metro models were not in the 1986 blue dealer notebook. For now there is no parts catalog for those 1988-90 late models. That is why Blitz and Metro part quantities are “?” and light gray.

 

 

 

diagram#  Trac #  Daelim part # x  L E I S O C H B M  description

F4-01-1  23210 Domino 903.03 xX  1 1 1 1 1 1 1 1 1  right control (front brake and throttle) see Domino DA7K
F4-02-1  23010 Domino 904.04 xX  1 1 1 1 1 1 1 1 1  left control (rear brake only) DK50, late DP50 Dom. DB8K
F4-02-2  23510 Domino 908.06 xX  0 0 0 0 1 1 1 1 0  left control (rear brake, starter) early DP50 Domino DB7K

For Domino parts 3 to 30 see above. The diagram numbers are different there. The parts are the same.

diagram#  Trac #  Daelim part # x L E I S O C H B M price  description x  cable  Ø   C x E   for models   cable
diagram#  Trac#   Daelim part # x L E I S O C H B M price  description  x ends mm inches  for models    says

F4-31-1 23015 45450-HD2-890AM 1 0 0 1 1 0 0 1 ?  $27 front brake cable x 2  6 42.9 5.7 Lib, Olym, Bl K.C.C.
F4-31-2 23515 45450-CL1-000xxx 0 1 0 0 0 1 0 0 ?  $25 front brake cable x 2  6 37.1 3.6 Escot, Clipper ESCOT
F4-31-3 23516 45450-HA1-000AM 0 0 1 0 0 0 1 0 ?  $22 front brake cable x 2  6 35.5 4.1 Im, Hawk, Sp IMAGE
F4-32-1 23016 43450-HD2-890AM 1 0 0 1 1 0 0 1 ? none rear brake cable x  2  6 46.5 15  Lib, Olym, Bl K.C.C.
F4-32-2 23517 45460-CL1-000xxx 0 1 0 0 0 1 0 0 ? none rear brake cable x  2  6 58.8 3.6 Escot, Clipper ESCOT
F4-32-3 23518 45460-HA1-000AM 0 0 1 0 0 0 1 0 ? none rear brake cable  x 2  6 58?  4.1 Im, Hawk, Sp IMAGE
F4-37-1 23021 17910-HD2-890AM 1 0 0 1 1 0 0 1 ? none throttle cable xxx   1  5 40?  4.7 Lib, Olym, Bl K.C.C.
F4-37-2 23022 17910-HA1-000xX  0 1 1 0 0 0 0 0 ?  $22 throt cable+cover x1  5 37.8 4.7 Escot, Image HA1-CL1
F4-37-3 23519 17910-HA1-010xX  0 0 0 0 0 1 1 0 ? none throttle cable xxxx 1  5 37.8 4.7 Clip,Hawk,Sp HA1-CL1
F4-38-1 23023 17950-HD2-892AM 1 0 0 1 1 0 0 1 ?  $25 choke cable+knob  2  5 29.2 3.0 Lib, Olym, Bl K.C.C.
F4-38-2 23024 17950-HA1-000xxx 0 1 1 0 0 0 0 0 ? none c cable+knob+cov 2  5 29.2 3.0 Escot, Image HA1-CL1
F4-38-3 23520 17950-HA1-010xxx 0 0 0 0 0 1 1 0 ?  $25 choke cable+knob 2  5 29.2 3.0 Clip,Hawk,Sp HA1-CL1
F4-39-1 23521 17930-M56-896xX  0 0 0 0 0 1 1 0 0 none start cable xxxxxx 2  5 40.6 2.9 ’86 Clip,Hawk M56 896
F4-39-2 23522 17930-DKM-890AM 0 0 0 0 1 0 0 1 0 none start cable xxxxxx 2  5 42?  2.9 1986 Olympic K.C.C.

DK50 and DP50 choke: These 1984-90 Trac models with Daelim engines and Domino controls, have a Honda type push-pull choke knob, located to the lower left of the speedometer. Other 1985-86 Trac models with Laura M56 engines and Domino controls, listed above, have a right thumb lever for the choke. So when the engine changed, the choke cable changed from simple, single-ended, inexpensive and easy to get, to complicated, double-ended, expensive and hard to get.

Early DP50 start cable: The early Daelim DP50 engine models (mostly 1986) had a starting cable #39 and lever. Late DP50 models (most 1987 and all 1988-90) did not have a starting lever or cable. More on this later…

 

diagram#  Trac #  Daelim part # xx  L E I S O C H B M  price       description         specs         remarks

F14-01-1  20140 50500-005-890 xX  1 0 0 1 1 0 0 ? ?  $48 center stand for Liberty, Olympic
F14-01-2  20630 50500-HA1-000 xx  0 1 1 0 0 1 1 ? ?  $58 center stand Escot,Image,Clipper,Hawk/Sprint
F14-02-1  20141 50526-HD2-890AM  1 0 0 1 1 0 0 ? ?  $12  pivot pipe Ø12 x 75 for Liberty, Olympic
F14-02-2  20631 50526-HA1-000 xXx0 1 1 0 0 1 1 ? ?  $12  pivot pipe Ø12 x 81 Escot,Image,Clipper,Hawk/Sprint
F14-03-1  20265 95014-71502 xxxXx1 1 1 1 1 1 1 1 1  $10  center stand spring 115 mm
F14-04-1  25034 94201-30250-05xX 1 1 1 1 1 1 1 1 1  50¢  pivot pipe split pin 3.0 x 25
F14-05-1  20142 50610-HD2-890AMx1 0 0 0 0 0 0 0 ?  none step bar for Liberty
F14-05-2  20632 50610-HA1-890AM  0 1 1 0 0 0 0 0 ?  none step bar for Escot, Image
F14-05-3  20804 50610-HS1-890AxM0 0 0 1 0 0 0 0 ?  none step bar for Liberty LS
F14-06-1  20266 50661-001-890AXM2 2 2 2 0 0 0 0 2  none step bar rubber
F14-07-1  20633 40592-HA1-000 Xx 0 1 1 0 0 0 0 0 ?  none chain cover for Escot, Image
F14-08-1  20634 92000-06030-OD x 0 1 1 0 0 0 0 0 ?  50¢  hex bolt M6 x 30 Escot, Image
F14-09-1  06060 94111-06500 xxXx 0 1 1 0 0 0 0 0 ?  50¢  spring washer Ø6.5 Escot, Image
F14-10-1  05060 94101-06500 xxXx 0 1 1 0 0 0 0 0 ?  50¢  plain washer Ø6.5 Escot, Image
F14-11-1  20635 94101-12500 xxXX 0 1 1 0 0 1 1 ? ?  50¢  plain washer Ø12.5 Escot,Image,Clipper,Hawk/Sprint
F14-12-1  20805 50620-HS1-890 xX 0 0 0 1 0 0 0 0 0  none starter motor cover for Liberty LS
F14-13-1  00616 93481-06016-05 xx0 0 0 1 0 0 0 0 0  none shoulder bolt M6 x 16 for Liberty LS

 

diagram#  Trac #  Daelim part # xx  L E I S O C H B M  price       description         specs         remarks

F20A-1-1  20150 50100-HD2-891AM  1 0 0 0 1 0 0 ? 0  none frame Olympic or Liberty (black)
F20A-1-2  20151 50100-HD2-891AM  1 0 0 0 1 0 0 ? 0  none frame Olympic or Liberty (red)
F20A-1-3  20810 50100-HS1-891AM  0 0 0 1 0 0 0 ? 0  none frame Liberty LS (electric start) (black)
F20A-1-4  20811 50100-HS1-891AM  0 0 0 1 0 0 0 ? 0  none frame Liberty LS (electric start) (red)

 

 

 

diagram#  Trac #  Daelim part # xx  L E I S O C H B M  price       description         specs         remarks

F20B-1-1  20640 50100-HA1-0100 x 0 0 1 0 0 0 1 0 ?  none frame for Hawk, Sprint or Image (black)
F20B-1-2  20641 50100-CL1-010 X   0 1 0 0 0 1 0 0 ?  none frame for Clipper or Escot (blue)
F20B-1-3  20642 50100-CL1-010 X   0 1 0 0 0 1 0 0 ?  none frame for Clipper or Escot (red)

 

 

 

 

 

 

Model codes

M56   1982-86 Eagle
MT1   1983-86 Hawk
MT2   1983-86 Clipper
CL1    1984-89 Escot,1986-89 Clipper
HA1   1986-86 Hawk, 1986-89 Sprint, 1984-89 Image
HD2   1986-89 Olympic, 1984-89 Liberty
HS1   1986-88 Liberty LS
????   1988-90 Blitz
????   1988-90 Metro

under construction …

Bosch Magnetos 90mm

July 16, 2017

Bosch  Contents:
        1. Magnetos
        2. Parts

 

 

1. Magnetos

A. 90mm  i.d. flywheel (rotor), 90mm stator plate 
magneto# 0  rot wires  for  engine
0212 110 002 ⇒ ♦♦♦♦♦♦ EU Puch xx E50
0212 112 019 ⇐ ♦♦♦  Ο EU Sachs x 505/1A, ANL, B, C, D
0212 112 053 ⇒ ♦♦♦  Ο EU Laura  x M48
0212 112 053 ⇒ ♦♦♦♦♦♦ US TYM  xx M48
0212 112 070 ⇒ ♦♦♦  Ο EU Garelli   G2
0212 112 095 ⇐ ♦♦♦  Ο EU Sachs x 505A, ANL, B, C, D
0212 115 023 ⇒ ♦♦♦  Ο EU Flandria dry clutch
0212 120 020 ⇒ ♦♦♦  Ο UK Garelli   G2
0212 120 021 ⇒ ♦♦♦  Ο US Laura  x M48
0212 120 023 ⇒ ♦♦♦  Ο US Volvo-P marine
0212 120 026 ⇐ ♦♦♦♦♦♦ US Sachs x 505/1B
0212 120 027 ⇐ ♦♦♦♦♦♦ UK Puch xx Monza
0212 120 029 ⇐ ♦♦♦♦♦♦ US Sachs x 505/1B
0212 122 006 ⇐ ♦♦♦  Ο EU Sachs x 505/1C
0212 122 030 ⇒ ♦♦♦  Ο CA Laura  x M48
0212 122 053 ⇒ ♦♦♦  Ο CA Laura  x M54
0212 124 014 ?  ♦♦♦♦♦♦ US Sachs x 1251/6A
0212 124 015 ⇒ ♦♦♦♦♦♦ EU Sachs x 501/4A?
0212 124 038 ⇒ ♦♦♦♦♦♦ US Puch xx E50
0212 124 039 ⇒ ♦♦♦♦♦♦ US Solo  xx 236, 237, 254, 255
0212 124 040 ⇐ ♦♦♦♦♦♦ US Sachs x 505/1A, B, D
0212 124 041 ⇒ ♦♦♦♦♦♦ US Laura  x M48
0212 124 042 ⇒ ♦♦♦♦♦♦ US Puch xx E50
0212 124 043 ⇒ ♦♦♦♦♦♦ US Puch xx E50
0212 124 044 ⇐ ♦♦♦♦♦♦ US Puch xx ZA50
0212 124 045 ⇐ ♦♦♦♦♦♦ US Sachs x 505/1A, B, D
0212 124 057 ⇐ ♦♦♦♦♦♦ EU Sachs x 505/1B
0212 124 062 ⇐ ♦♦♦♦♦♦ EU Sachs x 505/1B, BX, D
0212 124 066 ⇒ ♦♦♦♦♦♦ EU Puch xx E50
0212 ???  ???  ⇐ ♦♦♦♦ Ο EU Puch ?
0212 125 001 ⇐ ♦♦♦  Ο US Puch MS,E50  LM/URC1/116/27/5 L1
0212 125 ???  ⇐ ♦♦♦  Ο US Puch MS,E50  LM/UR  1/115/17    L5
0212 125 ???  ⇐ ♦♦♦♦♦♦ US Puch MS,E50  1M/URP1/116/29/18L1
0212 125 ???  ⇐ ♦♦♦♦♦♦ US Puch MS,E50  LM/URP1/115/27     L1

B. ?? mm i.d. flywheel (rotor), ?? mm stator plate
magneto# 0  LM/UR0 rot wires  engine
0212 441 006 ⇐ ???♦♦♦ US Sachs 1001/4A?

 

 

 

1. Magnetos


Bosch 0204-110-002   
Puch Magnum X,  4401271-on Puch E50 engine
1-wire 1-coil clockwise

Same as 0212-124-043 with no lights coils.

 

 
Bosch 0212-112-019   superseded by 0212-112-095 
non-US models, no brake light Sachs 505/1A, ANL, B, C, D
2-wire 2-coil anticlockwise 6V 18W, internal ignition ground

#  qty     Sachs #      Bosch part #     solder type
01  1  0283 130 001 1217 031 439 stator assembly
03  1  0000 000 000 1217 031 000 stator base plate bare
06  1  0265 113 003 1214 210 042 generator armature 18W (yellow)
09  1  2783 039 001 1217 013 021 points late type one piece (black)
14  1  0265 052 003 1237 330 035 condenser short solder type
17  1  0265 142 002 2204 211 045 ignition armature-transformer

 

 
Bosch 0212-112-053 
non-US models with no brake light  Laura M48 engine
2-wire 2-coil clockwise 6V 17W internal ignition ground

# qty  Laura #   Bosch part #     solder type
01  1  48 18 22 1217 031 344  stator assembly 
02  1  48 18 23 0000 000 000 spark plug wire  
03  1  48 18 28 1217 031 000 stator base plate bare 
05  3  82 34 00 0000 000 000 base plate screw M4 x 14
06  1  48 18 29 1214 210 ??? generator armature 17W (yellow)
07  7  84 74 00 0000 000 000 washer M4
08  4  82 34 22 0000 000 000 coil screw M4 x 22
09  1  48 18 26 1217-013-012 points early type, no pivot post
11  1  48 18 21 0000 000 000 flywheel
12  1  48 18 31 0000 000 000 condenser-to-points wire
13  1  48 18 32 0000 000 000 cond.-to-stop-switch wire (black)
14  1  48 18 30 1237 330 035 condenser short solder type
15  1  48 18 34 2201 005 007 oil wick
16  1  48 18 24 0000 000 000 rubber boot for ignition coil
17  1  48 18 25 2204 210 ???  ignition armature-transformer

This early 70’s Bosch magneto was modified and reused in the late 70’s on Angel and Speed Bird mopeds, US models made in Taiwan. See below.

 


Bosch 0212-112-053
Angel (TYM) ’78-83 US models  Laura M48 remake
3-wire 2-coil clockwise 6V 25/10W external ignition ground

# qty  Angel part#   Bosch part #     solder type
00  1  78601 40100 0212 112 053 magneto assembly
01  1  00000-00000 1217 031 344 stator assembly
03  1  00000-00000 1217 031 000 stator base plate bare
06  1  00000-00000 1214 210 ???  generator armature 25W (yellow)
09  1 4811POINTS   1217 013 021 points late type one piece
14  1 4811CONDEN  1237 330 035 condenser short solder type
17  1 4811COIL 000 0000 000 000 ignition armature (black & brown)

This was an early 70’s 0212-112-053 with different coils. The ignition armature had more windings and an external ignition ground for powering a brake light. The lighting armature had more windings and more watts. 

Comparison of Laura M48 Flywheels:

Left is 0212-112-053. Right is 0212-124-041. They have the same cam position, relative to the key groove. That is the ignition timing angle. They also have almost the same magnet timing angle. They have the same key groove width and center taper

 


Bosch 0212-112-070
Garelli ’70’s Gulp (Euro) Garelli Gulp engine
2-wire 2-coil clockwise 6V 18W internal ignition ground

#  qty     Sachs #      Bosch part #     solder type     
01  1  0283 130 001 1217 031 439 stator assembly
03  1  0000 000 000 1217 031 000 stator base plate bare
06  1  0265 113 003 1214 210 042 generator armature 18W (yellow)
09  1  2783 039 001 1217 013 021 points late type one piece (black)
14  1  0265 052 003 1237 330 035 condenser short solder type
17  1  0265 142 002 2204 211 045 ignition armature-transformer

 

Bosch 0212-112-095 
non-US models, no brake light Sachs 505/1A, ANL, B, C, D
2-wire 2-coil anticlockwise 6V 18W internal ignition ground

#  qty     Sachs #      Bosch part #     description
01  1  0283 130 004  0000 000 000 stator assembly
03  1  0000 000 000 1217 031 000 stator base plate bare
06  1  0265 113 004 1214 210 042 generator armature 17W (yellow)
09  1  0283 116 002 0000 000 000 points late type with eyelet-wire (black)
14  1  0265 052 007 2207 330 041 condenser with screw post for eyelet-wires
17  1  0265 142 004 0000 000 000 ignition armature-transformer with eyelet-wire

This solder-less magneto has eyelet connector wires on ignition coil and points, and screw-post type condenser.

Bosch 0212-115-023  
Flandria Bermuda  Flandria dry-clutch engine
3-wire 3-coil  clockwise 6V 20/5W internal ignition ground

# qty  Flandria#  Bosch part #     description      same illustration
01  1  00 00 00   1217 031 ???  stator assembly
03  1  00 00 00   1217 031 000 stator base plate bare
06  1  00 00 00   1214 210 ???  generator armature 20W (yellow/red)
09  1  00 00 00   1217 013 021 points late type one piece (black)
14  1  00 00 00   1237 330 037 condenser tall solder type
17  1  00 00 00   2204 211 ???  ignition armature-transformer
20  1  00 00 00   1214 210 ???  generator armature 5W (green/red)

 


Bosch 0212-120-020
Garelli ’73-75+ Concorde Bimatic (UK)
2-wire 2-coil clockwise 6V 24W internal ignition ground

 

 


Bosch 0212-120-021  
Batavus ’72-75 early US models Laura M48 engine
3-wire 3-coil clockwise  6V 20/5W internal ignition ground

# qty  Laura #   Bosch part #     description      same illustration
01  1  48 18 22 1217 031 286 stator assembly
03  1  48 18 28 1217 031 000 stator base plate bare
06  1  48 18 36 1214 210 ???  generator armature 20W (yel/red)
7a  2  00 00 00 0000 000 000 bush (spacer tube) Ø8 x 12
8a  2  00 00 00 0000 000 000 upper coil screw M4 x 34
8b  2  82 34 22 0000 000 000 lower coil screw M4 x 28
09  1  48 18 26 1217 013 021 points late type one piece (black)
14  1  48 18 40 1237 330 037 condenser tall solder type
17  1  48 18 25 2204 210 013 ignition armature-transformer
20  1  48 18 37 1214 210 ???  generator armature 5W (grn/red)

 

Bosch 0212-120-023
Volvo-Penta marine outboard made in Sweden
2-wire 2-coil clockwise  12V 30W internal ignition ground   

# qty  Bosch part #     description
01  1  0000 000 000 stator assembly 
06  1  0000 000 000 generator armature 12V 30W (yellow)
09  1  1217 013 012 points early type, no pivot post (black)
14  1  1237 330 035 condenser short solder type
15  1  2201 005 007 oil wick
17  1  2204 211 041 ignition armature-transformer

 

Bosch 0212-120-026  superseded by 0121-120-029 
mid-80’s US 1.0hp models Sachs 505/1B engine
4-wire 4-coil anticlockwise 6V 19-5/10W internal ign. ground

 

Bosch 0212-120-027
Puch ’70’s Monza (UK model) Puch 1-speed kick engine
5-wire 4-coil anticlockwise 6V 19-5/10W internal ign. ground

black = ignition
yellow = lights
green = brake light?
lilac and lilac/black = battery?

 

Bosch 0212-120-029   
mid-80’s US 1.0hp models Sachs 505/1B engine
4-wire 4-coil anticlockwise 6V 19-5/10W internal ign. ground

These have 4 coils like the Laura one above. The ignition coil is also the transformer (spark) coil.

 

Bosch 0212-122-006  
mid-70’s models Sachs 505/1C
3-wire 3-coil anticlockwise 6V 18/5W  

#  qty  Sachs part#    Bosch part #     description 
01  1  0286 254 002 1217 031 ???  stator assembly
03  1  0000 000 000 1217 031 000 stator base plate bare
06  1  0265 139 001 1214 210 055  generator armature 18W (yellow/red)
09  1  2783 039 001 1217 013 021 points late type one piece (black)
14  1  0265 052 003 1237 330 035 condenser short solder type
17  1  0265 142 002 2204 210 000 ignition armature-transformer
20  1  0265 139 006 1214 210 ???  generator armature 5W (green/red)

 

 
Bosch 0212-122-030
Batavus ’78 Bingo Canada model Laura M48-02
Batavus ’74 Go-Go Canada model Laura M48-02
2-wire 2-coil clockwise  6V 17/5W

 


Bosch 0212-122-053
Solex ’74 Tenor Canada model Laura M54
2-wire 2-coil clockwise  6V 17/5W

 

Bosch 0212-124-014 
Sachs ’70’s 1251/6A engine 125cc
5-wire? 4-coil           6V 35/10w 

ignition armature    1.3 Ω  is Bosch 1214-210-069 = Sachs 0265-139-012
lights armature       0.2 Ω
tail light armature   7.2 Ω or 5.9 for new
stop light armature 0.9 Ω or 0.9 for new
test leads shorted <0.2 Ω

 

 

 
Bosch 0212-124-015
Attex ’72-73 (Coleman) Sport 5.3 Sachs 50S
4-wire 4-coil  clockwise 6V 25-4/5W

gray = tail light
grn/red = brake light
yel/red = head light
lite blue = ignition

 


Bosch 0212-124-038   
Puch ’74-75 N up to #6547172 US model Puch 1-speed E50
Puch ’74-75 S, Nostalgic to #8421028 US model Puch E50
4-wire 4-coil clockwise 6V 22-5/18W CEV 9350 tail light 

#  qty  Puch part#    Bosch part #     description  
00  1  349.150.8000 0212 124 038 magneto assembly
01  1  349.150.8102 0000 000 000 flywheel-rotor
02  1  000.000.0000 1217 031 414 stator assembly
18  1  366.150.0122 1214 210 069 ignition armature (blue)
16  1  349.250.8142 1214 210 492 gen. arm. 10W (green & grn/blk)
20  1  349.250.8112 1214 210 064 generator armature 22W (yellow)
21  1  349.150.8192 1214-210-460 generator armature 05W (gray)
23  1  500.250.0132 1237 330 037 condenser tall solder type
26  1  302.350.0150 1217 013 021 points late type one piece

 


Bosch 0212-124-039
Odyssey US models Solo 236, 237, 254, 255
Colombia US models Solo 254, 255 engine
5-wire 4-coil clockwise 6V 22-5/10W  

#  qty   Solo #    Bosch part #     illustration 124-040
00  1  23 00 395 0212 124 039 magneto assembly
02  1  00 00 000 1217 031 415 stator assembly
18  1  05 20 148 1214 210 069 ignition armature xxxxxx (blue)
16  1  05 20 151 1214 210 492 gen. arm. 10W (grn & grn/blk)
20  1  05 20 149 1214 210 064 generator armature 22W (yellow)
21  1  05 20 150 1214 210 490 generator armature 05W (gray)
23  1  05 20 147 1237 330 037 condenser tall solder type
26  1  05 20 146 1217 013 021 points late type one piece

 


Bosch 0212-124-040    
Hercules US models Sachs 505/1A, 1B, 1D
Columbia US models Sachs 505/1A, 1B, 1D
Grycner (some) US models Sachs 505/1A
5-wire 4-coil anticlockwise 6V 22-5/10W

#  qty     Sachs #      Bosch part #     description
01  1  0283 129 000 1215 254 ???  flywheel-rotor
02  1  0283 130 001 1217 031 431 stator assembly, bare wires
02  1  0283 130 000 1217 031 429 stator Grycner, bullet plugs
03  3  0240 106 100 0000 000 000 base plate screw M4 x 14
04  3  0244 108 000 0000 000 000 plain washer 4.1 x 9 x 1.2
14  4  0240 122 002 1213 429 042 coil screw fillister head M4x31
15  5  0245 023 000 0000 000 000 lock washer M4
16  1  0265 139 021 1214 210 492 gen. arm. 10W (grn & grn/blk)
17  2  0247 106 005 0000 000 000 bush (spacer tube) Ø8 x 9
18  1  0265 139 020 1214 210 069 ignition armature xxxx (blue)
19  2  0232 115 000 0000 000 000 bush (spacer tube) Ø8 x 6
20  1  0265 139 022 1214 210 064 generator armature 22W (yel)
21  1  0265 139 023 1214 210 490 generator armature 5W (gray)
22  1  2865 008 000 2201 005 007 lubricating felt
23  1  0965 091 000 1237 330 037 condenser tall solder type
24  1  0241 021 004 0000 000 000 points screw fillister head M4x10
25  1  0644 031 000 0000 000 000 plain washer 4.3 x 8 x 0.5
26  1  2783 039 001 1217 013 021 points late type one piece

 


Bosch 0212-124-041
Batavus ’76-80 US models Laura M48 engine
Flandria ’76-80 Bermuda US model Flandria engine
5-wire 4-coil clockwise 6V 22-5/10W

# qty  Laura #  Bosch part #     description
150  1  48 18 95 0212 124 041 magneto assembly
152  1  48 18 51 1214 210 069 ignition armature (blue)
153  1  48 18 55 1214 210 064 generator armature 22W (yellow)
154  1  48 18 54 1214 210 492 gen. arm. 10W (grn & grn/blk)
155  1  48 18 56 1214 210 490 generator armature 5W (gray)
156  1  48 18 40 1237 330 037 condenser tall solder type
157  1  48 18 53 1215 254 ???  flywheel says 0212 124 041
158  1  48 18 52 1217 031 415 stator assembly with blade plugs
159  1  48 18 26 1217 013 021 points late type one piece (black)
160  1  82 34 04 0000 000 000 points screw M4 x 10
161  1  84 34 00 0000 000 000 ondulated washer M4
162  1  82 74 01 0000 000 000 plain washer M4
163  3  82 34 00 0000 000 000 stator screw M4 x 14
164  3  84 74 00 0000 000 000 plain washer M4
165  2  82 37 30 0000 000 000 lower coil screw M4 x 30
166  2  84 34 00 0000 000 000 coil screw washer M4
167  2  48 18 58 0000 000 000 lower distance tube Ø8 x 6
168  2  82 37 30 0000 000 000 upper coil screw M4 x 31
169  2  84 34 00 0000 000 000 coil screw washer M4
170  2  48 18 59 0000 000 000 upper distance tube Ø8 x 9
171  1  48 18 34 2201 005 007 oil felt

 


Bosch 0212-124-042  
Puch ’75-76 N after #6547172 US model Puch 1-speed E50
Puch ’75-76 S, Nostalgic after #8421028 US model Puch 
Puch ’76-77 Rigid, Maxi, Maxi-S, Newport US model Puch 
all with ULO 250-2 two-bulb tail light
5-wire 4-coil clockwise 6V 22-5/10W

#  qty  Puch part #    Bosch part #     description
01  1  349.250.8102 1215 254 635 flywheel 042 for 1-speed
02  1  000.000.0000 1217 031 431 stator assembly, no wire plugs
18  1  349.250.8122 1214 210 069 ignition armature xxxxxx (blue)
16  1  349.250.8142 1214 210 492 gen. arm. 10W (green & grn/blk)
20  1  349.250.8112 1214 210 064 generator armature 22W (yellow)
21  1  349.250.8192 1214 210 490 generator armature   5W (gray)
22  1  364.450.6181 2201 005 007 lubricating felt
23  1  500.250.0132 1237 330 037 condenser tall solder type
26  1  302.350.0150 1217 013 021 points late type one piece

 


Bosch 0212-124-043
Puch ’77-86 US models Puch 1-speed E50 engine
Sears ’78 Free Spirit US model Puch E50 engine
JC Penney ’78-79 US model Puch E50 1-sp engine
Murray ’78-80 US model Puch 1-speed E50 engine
 6-wire 4-coil clockwise 6V 26/5/10W external ignition ground

Bosch 0212-124-044 
Puch ’78-86 US models Puch 2-speed ZA50 engine
6-wire 4-coil anticlockwise 6V 26/5/10W external ignition ground

#  qty  Puch part#    Bosch part #     description
00  1  000.000.0000 1217 031 438 stator assy, no wire plugs
04  1  349.210.8122 0000-000-000 rubber grommet for 1-speed
4a  1  321.110.6101 0000-000-000 rubber grommet for 2-speed
05  1  349.350.8122 1214 210 554 ignition armat. (blu & blu/blk)
06  1  364.450.5132 1237 330 035 condenser short solder type
07  3  000.901.3941 0000-000-000 washer M4 x 8 x 2.1
08  3  000.900.3253 0000-000-000 serrated lock washer M4
09  3  000.00.27458 0000-000-000 pan head screw M4 x 15
10  1  349.350.8112 1214 210 556 generator armature 26W (yel)
11  1  349.350.8142 1214 210 555 gen. arm. 10W (grn & grn/blk)
12  1  349.350.8192 1214 210 557 generator armature 5W (gray)
13  1  349.350.8102 1215 254 658 flywheel 043 for 1-speed
13  1  321.150.8102 1215 254 674 flywheel 044 for 2-speed
14  1  000.900.4503 0000-000-000 woodruff key 3 x 3.7
15  1  000.901.2943 0000-000-000 hex nut with flange M10-1.0
16  1  302.350.0150 1217 013 021 contact set (points) late type
17  1  364.450.6181 2201 005 007 lubricating felt pad
27  4  000.000.0000 0000 000 000 coil screw phillips head M4 x 31
28  4  000.000.0000 0000 000 000 bush (spacer tube) Ø8 x 8

 


Bosch 0212-124-045
General ’79-85 (most) US model Sachs 505/1A,D
Grycner ’78-79 (some) US model Sachs 505/1A
Sachs ’80 Prima US model Sachs 505/1A,B,D
3-wire 2-coil  anticlockwise 6V 23/15W  external ignition ground

#  qty  Sachs part#    Bosch part #     description
01  1  0283 130 002 1217 031 449 stator assembly
02  1  0283 129 002 1215 254 ???  flywheel
14  4  0240 105 000 0000 000 000 coil screw phillips head M4 x 22
16  1  0265 139 024 1214 210 554 ignition arm. (blu & blu/blk)
17  1  0265 139 025 1214 210 532 generator arm. 23W (yellow)
18  1  0965 091 000 1237 330 037 condenser tall solder type
19  1  2865 008 000 2201 005 007 lubricating felt
20  1  0241 021 004 0000 000 000 points screw fillister head M4x10
21  1  0644 031 000 0000 000 000 plain washer 4.3 x 8 x 0.5
22  1  2783 039 001 1217 013 021 points late type one piece

 

Bosch 0212-124-057 superseded by 0212-124-062
early-80’s non-US models, with brake light Sachs 505/1B
3-wire 3-coil anticlockwise 6V 19/10W has different armature coils

Bosch 0212-124-062
early-80’s non-US models, with brake light Sachs 505/1B, BX, D
3-wire 3-coil anticlockwise 6V 19/10W internal ignition ground

#  qty  Sachs part#    Bosch part #     description
01  1  0283 129 006 1215 254 ??? flywheel
02  1  0283 130 006 1217 031 ???  stator assy
14  2  0240 122 002 0000 000 000 coil screw phillips head M4 x 30
16  1  0265 139 032 1214 210 ??? generator arm. 10W
17  2  0247 106 005 0000 000 000 distance bush
18  1  0265 142 006 1214 210 554 ignition armature (blue)
19  1  0265 139 033 1214 210 ??? generator arm. 19W (yellow)
21  1  0265 052 007 2207 330 041 condenser M32 screw-post type
22  1  2865 008 000 2201 005 007 lubricating felt
25  1  0283 116 002 0000 000 000 points M19B late type with eyelet wire

 

Bosch 0212-124-066
 mid-80’s non-US models, with brake light  Puch 1-speed E50
3-wire   clockwise 6V 19/10W    

#  qty  Bosch part #     description
21  1  2207 330 041 condenser M32 screw-post type
25  1  0000 000 000 points M19B late type with eyelet wire

 

Bosch 0212-???-???   internal spark coil
Puch late 60’s Puch engine
4-wire 3-coil anticlockwise 6V 25/2/3W?

#  qty  Puch part#    Bosch part #     description
00  1  000.000.0000 1217 031 282 stator assy

ignition = black
headlight = yellow
brake light = green
tail light = grey

This early Puch stator is identified by the grommet. The ignition-spark coil is missing. 

 

 
Bosch LM/UR 1/115/17 L5 internal spark coil
Sears Allstate Mo-Ped Puch# 050.5000.0
3-wire   anti-clockwise 6V 27/5w?

Same timing and interchanges with 1970’s Puch 1-speed 0212-124-043 (except for fan screw holes). 

 


Bosch 0212-125-001
= Bosch LM/URC1/116/27/5 L1 internal spark coil
Sears Allstate Puch# 302.2.50.010.2
3-wire  anti-clockwise 6V 17/5W?
wires have bare ends for a screw terminal strip

The Sears Allstate Parts Manual is where this specification and illustration are from. It lists the light bulbs: head 6V 15/15W and tail 6V 2.4W, brake 6V 3W. So the magneto rating must be close to 6V 17/3W.

Notice how the 1972-75 Batavus magneto 0212 120 021 is identical to this except for the points.  

 

Bosch 90mm flywheel for Sears Allstate front view Bosch 90mm flywheel for Sears Allstate
Bosch 1M/URP1/116/29/18L1
Bosch 1M/URCP1/116/29/18L1
Sears Allstate Mo-Ped Puch# 364.1.50.600.0
3-wire 3-coil anticlockwise 6V 29/18W

 

 


Bosch LM/URP1/115/27L1
Sears ’58-60 Allstate Mo-Ped Puch 
3-wire 3-coil anticlockwise 6V 27/5W

 


Bosch 0212-441-006  
Sachs 1960’s 100cc engine
??-wire  anticlockwise 6V 40/6W

 

 

 

2. Parts for Sale

Price colors: new, used. N/A or none is not available.

 

Flywheel Nut $2.00 nut M10-1.0, hex 17 (most)

Flywheel Puller $19.0 puller M26-1.50 thread

Bosch# 00000 Magnetos (∅90 rotor and ∅90 stator)
0212 005 007 none  superseded to 0212-005-024
0212 112 070 $210  Garelli Gulp (Euro)  2-wire 2-coil internal transformer
0212 120 021 $210  Laura 48 18 ?? 000  3-wire 3-coil internal transformer
0212 124 038 $220  Puch 349.150.8000 4-wire 4-coil
0212 124 039 $210  Solo 23 00 395 000 5-wire 4-coil
0212 124 040 none  Sachs 0212 024 040 5-wire 4-coil
0212 124 041 $210  Laura 48 18 95 000 5-wire 4-coil
0212 124 042 $180  Puch 349.250.8000 5-wire 4-coil
0212 124 043 $180  Puch 349.350.8000 6-wire 4-coil
0212 124 044 $180  Puch 321.150.8000 6-wire 4-coil
0212 124 045 $230-180 Sachs  3-wire 2-coil external ignition ground

Bosch# 00000 Points (contact set) for ∅90, aftermarket
0217 013 012 $14.0 Laura 48 18 26 xxxx M19A early, no pivot post
0217 013 021 $16.0 Laura 48 18 26 xxxx M19 no wire
0217 013 ???  $15.0 Sachs 0283 116 002 M19B with wire

0217 013 012
early type

0217 013 021
late type

early with post

late plate no post

 

 

 

 

 

 

Points: 1950’s-60’s had “early” points, no pivot post. The early pivot post was part of the base plate, but it unscrews. 1970’s-80’s had “late” points, with pivot post. These replace the older points, once the post is removed. The early and late points have the same Laura part number, because the new parts replace and supersede. 

Bosch# 00000 Condenser (capacitor) ∅18 aftermarket
1237 330 035 $15.0 Laura 48 18 30 M32A ∅18 x 21
1237 330 037 $12.0 Laura 48 18 40 M36 tall ∅18 x 31
2217 330 041 none  superseded to 2217 330 050
2217 330 050 $15.0 Laura 56 18 30 M32 ∅18 x 21

1237 330 035

1237 330 037

2207 330 050

 

 

 

 

 

 

Eyelet Connectors (ring terminals)
60¢ each #8 hole, uninsulated, at left
50¢ each #6 hole, insulated, at middle
80¢ each #6 hole, uninsulated, at right

Condenser: 1950’s-60’s had short solder-type condensers, but can have long. 1970’s-80’s had short or long solder-type condensers. Either solder-type can be replaced with a screw-on type, by adding eyelet connectors to the wire ends.

All 3 condensers have the same diameter 18.0 mm. So a short can replace a tall type, and a screw-post can replace a solder type. They all interchange, except for the tall type, which only fits “big” Bosch Ø90 magnetos.

 

Bosch# 00000 Flywheels (rotors) ∅90 inner diameter
1215 254 ???  none  for 0204 110 002 Puch Magnum X use 042
1215 254 ???  none  for 0212 112 053 Laura (Euro) use 041
1215 254 ???  0$90  for 0212 112 070 Garelli Gulp (Euro)  
1215 254 ???  $130  for 0212 124 038 Puch 349.150.8102 use 042
1215 254 ???  $140  for 0212 124 039 Solo 05 20 ???
1215 254 ???  none  for 0212 124 040 Sachs 0283 129 000 use 045
1215 254 ???  $110  for 0212 124 041 Laura 48 18 53
1215 254-635 0$90  for 0212 124 042 Puch 349.250.8102
1215 254 658 $110  for 0212 124 043 Puch 349.350.8102 use 042
1215 254 734 $100  for 0212 124 044 Puch 321.150.8102
1215-254 ??? $100  for 0212 124 045 Sachs 0283 129 002  

Bosch# 00000 Stators Base Plate ∅90 outer diameter
1217 031 000 0$40  base plate bare, 3-screw

Bosch# 00000 Stator Assemblies ∅90 
1217 031 286 $150  for 0212 120 021 Laura 48 18 22, 3-male-pin plug
1217 031 414 $120  for 0212 124 038 Puch, no plugs use 415
1217 031 415 $120  for 0212 124 039 Solo, no plugs use 431
1217 031 429 none  for 0212 124 040 Sachs-General, bullet plugs
1217 031 431 $120  for 0212 124 040 Sachs 0283 130 001, no plugs
1217 031 415 $130  for 0212 124 041 Laura 48 18 52, blade plugs
1217 031 431 $120  for 0212 124 042 Puch, no plugs use 438
1217 031 438 0$90  for 0212 124 043 Puch, no plugs use 431
1217 031 438 0$90  for 0212 124 044 Puch, no plugs
1217 031 449 none  for 0212 124 045 Sachs 0283 130 002, 4-blade plug
1217 031 449 $130  for 0212 124 045 Sachs-General, bullet plugs

“no plugs” means no connectors on the wire ends. They attach to a screw-terminal strip, instead of plugging in.
These have good wires. But some cost $10-$20 less, because the wires are cut or damaged.
Points are not worn out. Everything is cleaned, prepared and tested. Condenser is good, as are coils and wires. 

Bosch# 00000 Ignition Armatures (source coils) 54 hole spacing
1214 210 069 $80-50 Sachs 0265 139 020  1-wire
1214 210 554    $75    Puch 349.350.8122  2-wire

1214-210-069

1214-210-554

 

 

 

 

 

 

 

Bosch# 00000 Lighting Armatures (source coils)
1214 210 042 none Sachs 0265 113 003 17W 1-wire
1214 210 055 none Sachs 0265 139 001 18W 1-wire
1214 210 064   $30 Sachs 0265 139 022 22W 1-wire
1214 210 490   $40 Sachs 0265 139 023 05W 1-wire
1214 210 492   $35 Sachs 0265 139 021 10W 2-wire
1214 210 555   $45 Puch   349.350.8142 10W 2-wire
1214 210 556   $30 Puch   349.350.8112 26W 1-wire
1214 210 557   $50 Puch   349.350.8192 05W 1-wire

1214-210-064

1214-210-490

1214-210-492

 

 

 

 

 

1214-210-555

1214-210-556

1214-210-557

 

 

 

 

 

Bosch# 00000 Armature-Transformers (spark coils)
2204 210 013 0$90 Sachs 0265 142 002
2204 211 045 $100 Sachs 0265 142 002

Bosch# 00000 Coil Screws for ∅90
1213 429 042 $0.50 Sachs 0240 122 002 M4 x 31 phillips 
1213 429 ???  $0.50 Laura 00 00 00 xxxx M4 x 34 phillips
Bosch# 00000 Bushes (spacer tubes) for ∅90  
0000 000 000 $2.00 Sachs 0232 115 000 Ø8 x 6
0000 000 000 $2.00 Sachs 0247 106 005 Ø8 x 9
0000 000 000 $4.00 Laura 00 00 00 xxxx Ø8 x 12
Bosch# 00000 Bushes (spacer tubes) for ∅80  
0000 000 000 $2.00 Sachs 0247 106 002 Ø8 x 8

 

 

Spark Plugs, Plug Wires and Coils

July 16, 2017

updated 2020-06

Contents:

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

 

 

 

1. Spark Plugs

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

10 mm x 12.7 (½”)

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

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

12 mm x 12.0

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

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

12 mm x 19.0 (¾”)

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

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

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

 

14 mm x 9.5 compact

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

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

 

14 mm x 9.5


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

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

 

14 mm x 12.7 (½”)

4110 NGK B4H     none  
4210 NGK B5HS   none   =Champion L90C =Bosch W8AC =ND W16FS
3722 NGK BR5HS $5.00 = B5HS substitute, resistor type 
7534 NGK B6HS   none   =Champion L86C =Bosch W7AC =ND W20FS
3922 NGK BR6HS $5.00 = B6HS substitute, resistor type
1052 NG. B6HS-10 none   = B6HS with a wider gap 0.040″ not 0.020″
5110 NGK B7HS   $3.50 =Champion L82C =Bosch W5AC =ND W22FS
5510 NGK B8HS  $4.00 =Champion L87   =Bosch W3AC =Bosch W240T1 
  Bosch W240T1   $2.00

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

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

 

14 mm x 12.7 (½”) projected tip

3511 NGK BP4HA   none   
3611 NGK BP4HS   $3.50 =Champion L95Y   =ND W14FP-U
0o0   ND W14FP-U $2.50 =Champion L95Y   =NGK BP4HS
4111 NGK BP5HS   $3.50 =Champion L95YC =Bosch W8BC
7331 NGK BP6HS   $3.50 =Champion L92YC =Bosch W7BC or W6BC
7022 NGK BPR5HS none   
7022 NGK BPR6HS none   =Champion L92YC =Bosch WR7BP

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

 

14 mm x 12.7 (½”) fine wire tip

7067 NGK BR7HIX $14.0

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

 

14 mm x 19.0 (¾”)

6410 NGK B5ES   $3.50 =ND W16ES-U =Bosch W8CC 
00   ND W16ES-U $2.50 =Bosch W8CC =NGK B5ES
7432 NGK B6ES   $4.00 =Champion N5C =Bosch W7C
0000 Bosch W7C  $2.00 =Champion N5C =NGK B6ES
1111 NGK B7ES   $3.50 =Champion N4C =Bosch W5CC
2411 NGK B8ES   $3.50 =Champion N3C =Bosch W4CC
0  Bosch W240T2 $2.00
2611 NGK B9ES   $3.50 =Champion N2C =Bosch W3CC
5866 NGK BR5ES $4.50   
4922 NGK BR6ES none    
0000 NGK BR7ET $3.00 this obsolete plug has three outer electrodes, not just one!
5422 NGK BR8ES $3.50

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

 

14 mm x 19.0 (¾”) projected tip

7832 NGK BP5ES   none  =Champion N11YC =Bosch W8DC
0000 Bosch W8D   $1.00 =Champion N11YC =NGK BP5ES
7333 NGK BP6ES   $3.50 =Champion N9YC =Bosch W6DC
0000 Bosch W7D   $2.00 =Champion N11YC =NGK BP6ES
1034 NGK BP7ES   $3.50 =Champion N7YC =Bosch W5DC
2912 NGK BP8ES   none   =Champion N6YC =Bosch
7131 NGK BPR6ES none   =Champion RN9YC =Bosch WR6DC
2023 NGK BPR7ES none   =Champion RN7YC =Bosch WR5DC

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

 

14 mm x 19.0 (¾”) fine wire tip

0000 NGK BR7EIX $14.0

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

 

 

2. Spark Plugs and Spark Checking

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

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

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

Bosch spark plugs obsolete in 1978

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

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

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

1979 Spark Plug Chart page 1

1979 Champion Motorcycle Spark Plug Chart page 1

1979 Spark Plug Chart page 2

1979 Champion Motorcycle Spark Plug Chart page 2

1979 Spark Plug Chart page 3

1979 Champion Motorcycle Spark Plug Chart page 3

 

 

 

 

 

 

 

 

 

 

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

 

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

 

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

 

3. Spark Plug Caps and Wires

Spark Plug Cap Screw-On

Screw post goes into wire core.

NGK Plug Caps Explained

NGK Spark Plug Caps

 

 

 

 

 

 

 

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

 

C1

Spark Plug Cap Rubber

C2

 

 

 

 

 

C3

Spark Plug Cap LB05F

C4

C5

 

 

 

 

 

 

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

 

W1

W5

 

 

 

 

 

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

 

4. Ignition Spark Coils (Transformers)

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

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

  1. Eliminate the spark plug as the cause by testing for spark with another known good spark plug.
  2. Eliminate the spark plug cap and wire end, by removing the cap, exposing a short piece of braided copper, placing that between two cooling fins, and testing for spark. Sparks should jump 1/4 inch, or at least 1/8 inch. If no spark at all, then the cause is before the coil.
  3. Eliminate the points being adjusted badly, by observing with your eyes, as the wheel is turned around, that they open and close, and not always stay open or always stay closed.
  4. Eliminate the ignition timing being way off, by first finding which direction is forward, by moving the rear wheel forward and engaging the starter clutch, finding top dead center by using a pencil in the spark plug hole that touches the top of the piston, then seeing with your eyes if the points open a little before top, going in the forward direction.

  5. Try cleaning the points. Without performing continuity tests with an ohmmeter, one last “hail Mary” attempt to get spark, easy and zero cost, is to clean the points with a strip of paper. Cut a strip of plain paper. Rotate the wheel until the points are open. Place the paper in between the points. Rotate the wheel gently until the points touch the paper gently, the pull the strip of paper out. It might have black or grey spots of burnt oil film. Recheck for spark. Realize that even though the points were just cleaned, they could still be “dirty”. A hard white coating can be on them, that paper does not wipe off. A points file, or a folded-into-two-sided piece of emery cloth, is needed to clean points, followed by paper to remove grit.

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

Indian Magneto Testing

Vespa ignition wire behind points corroded

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

The details of that are in Ignition Service Information 

 

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

 

Dansi Ignition Coil

H79 Dansi

Bosch Coil

H79A Bosch

Ignition Coil Remake

H79G generic

Motoplat Ignition Coil

H79M Motoplat

 

 

 

 

 

 

CEV 6309 Ignition Coil

CEV 6309

CEV 6313

CEV 6317 Ignition Coil

CEV 6317

 

 

 

 

 

 

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

 

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

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

 

 

Vespa (Piaggio) Electrical Service

April 8, 2017

A. Wiring Diagrams

Original wiring diagrams were scanned from original Owners Manuals, or Assembly and Preparation Manuals.

 

Original Wiring Diagrams for models without turn signals

No original available
1972-75 Vespa Ciao
4-wire magneto with
external ignition ground

Original wiring diagram
1976-80 Vespa Ciao
 4-wire magneto with
external ignition ground

Original wiring diagram
1977-80 Vespa Bravo
4-wire magneto with
external ignition ground

Original wiring diagram
1978-80 Vespa Grande
4-wire magneto with
external ignition ground

 

 

 

 

 

 

 

 

 

Original wiring diagram
1979-83 Vespa Si
4-wire magneto with
external ignition ground

Original wiring diagram
1980-83 Vespa Grande
4-wire magneto with
 external ignition ground

Original wiring diagram
1980-85 Vespa Ciao PX
4-wire magneto with
external ignition ground

All of these have an external ignition ground, which is the blue magneto wire. It must be connected to ground in order to have “spark”.

 

 

 

 

 

 

 

 

Original Wiring Diagrams for models with turn signals

No original available
72-75 Ciao with blinkers
4-wire magneto with
external ignition ground

No original available
76-77 Ciao with blinkers
4-wire magneto with
external ignition ground

No original available
1977 Bravo with blinkers
 6-wire magneto with
external ignition ground

Original wiring diagram
78-80 Ciao with blinkers
 6-wire magneto with
internal ignition ground

 

 

 

 

 

 

 

 

 

Original wiring diagram
78-80 Bravo w/ blinkers
 6-wire magneto with
internal ignition ground

Original wiring diagram
78-80 Grande w/blinkers
6-wire magneto with
external ignition ground

Original Wiring Diagram
80-83 Grande w/blinkers
 6-wire magneto with
internal ignition ground

Most of these have an external ignition ground, which is the blue magneto wire. It must be connected to ground in order to have “spark”.

 

 

 

 

 

 

 

Myrons Wiring Diagrams

Making these wiring diagrams was difficult and took over 150 hours of study. Some original diagrams were not available. To produce them, 1) all the Vespa USA-models and years had to be identified, 2) the parts catalogs and amendments were studied to make the table of electrical part numbers, 3) actual parts from Myrons inventory were photographed, or images from the internet were collected, to identify every electrical part, 4) some of the parts, especially switches, were tested to determine their internal wiring and function, 5) some actual wirings from stripped out mopeds were photographed and studied, matching each actual wire to the diagrams. 

 

1972-75 Vespa Ciao
4-wire 2-coil magneto with external ignition ground

1972-75 Vespa Ciao with blinkers
4-wire 2-coil magneto with external ignition ground

 

 

 

 

 

 

 

 

 

 

 

1976-80 Vespa Ciao and Bravo
4-wire 2-coil magneto with external ignition ground

1976-77 Vespa Ciao with blinkers
4-wire 2-coil magneto with external ignition ground

 

 

 

 

 

 

 

 

 

 

 

1977 Vespa Bravo with blinkers
6-wire 3-coil magneto with external ignition ground

1978-80 Vespa Grande with blinkers
6-wire 3-coil magneto, external ignition ground

 

 

 

 

 

 

 

 

 

 

1978-83 Vespa Grande, Grande MX
4-wire 2-coil magneto, external ignition ground

1978-80 Vespa Ciao and Bravo with blinkers
6-wire 4-coil magneto, internal ignition ground

 

 

 

 

 

 

 

 

 

 

 

1980-83 Vespa Ciao PX
4-wire 2-coil magneto, external ignition ground

1980-83 Vespa Grande MX with blinkers
6-wire 4-coil magneto, internal ignition ground

 

 

 

 

 

 

 

 

 

 

 

 

B. Electrical Service

Magneto-Generator and Engine Wires

Top coil is ignition source coil. One end (red with eyelet) goes to the points. The other end goes to ground, either internally or externally.

Bottom coil is lights source coil. One end is grounded internally. The other end (with red plug) goes to the main lights.

Side coil is auxiliary lights, only on turn signal models. Both ends go to a rectifier for battery charging.

1976-80 Vespa Ciao

1978-80 Vespa Grande

1978-80 Vespa Grande
with turn signals

 

 

 

 

 

 

 

 

Vespa Ciao with blinkers, ignition wire behind points is corroded badly

Bad wires: 1970’s Vespa moped wires are often corroded badly. They all have faded brittle insulation that breaks in places, exposing the braided copper core. Here is a turn signal model Ciao with a vital wire shorting out secretly behind the points. All of the wires near the engine are cracked and corroded badly, in places. They break like glass when you try to bend them.

 

 

 

Vespa Ciao with blinkers, brittle and badly corroded condenser wires

Bad wires: The bad wire shown above is this condenser wire. This is a turn signal model Ciao, with the condenser mounted externally. Non-turn-signal models have internal mounted condensers. This poor wire is actively shedding green flakes of copper oxides. Also note that the blue wire (external ignition ground) is faded to dark grey. It is also cracked open and corroding. Both of these wires are needed to run.

 

 

 

Replacing engine wires: Many 1970’s Vespa mopeds need their engine wires replaced. Many have intermittent or no spark, or dim or flickering lights, because of bad wires. Some electronic or hardware stores sell braided copper wire by the foot, but some only have 50 ft rolls. The old connectors can be cleaned and re-soldered to the new wire. That requires good flux-core solder and some skill.

Indian Service

April 8, 2017

updated 2020-12

Indian Service

Selected Topics

 

 

 

1978 Dealer Service Manual free pdf 

 

Tightening Torques

This is from the Haynes “Honda 4-Stroke Mopeds 49cc PC and PF OHV models 1970-on” service manual. It is the same engine as Indian.

xmm-0.0..0 ft-lbs   torque specification
0M5-0.0  5.1-8.0  valve adjust nuts
0M6-0.0  5.8-8.7  valve cover nuts
0M6-0.0  6.5-8.7  head nuts
0M6-0.0  5.1-8.7  case and cover bolts
0M6-0.0  6.5-8.7  camshaft and intake bolts
M10-0.0    22-28  flywheel and clutch nuts
M12-0.0    15-22  oil drain plug

 

Compression test

The Indian service manual does not state the compression pressure or the compression ratio. But the Indian motor is a copy of an earlier Honda PC50K1 motor. The Haynes “Honda 4-Stroke Mopeds 49cc PC and PF OHV models 1970-on” service manual does state the compression ratio, 8.5 to 1.

The compression test pressure can be calculated from the compression ratio, the displacement (swept volume), atmospheric pressure at sea level (14.7 psi), and the ideal gas law.

P2/P1=V1/V2   P2/14.7=8.5  P2=125 psi  relative to a vacuum

Minus the atmosphere, about 15 psi   P=125-15=110 psi  this is the ideal pressure

Actual “new” compression pressure would be 5-10 psi less than ideal because of leaks and the small additional volume of the pressure gauge hose. 

So Pnew = 100 to 105 psi   So over 95 psi is good, under 90 psi is bad

 

Ring Gap

A new ring in a new cylinder has a gap of 0.007 inch (7 thousandths).

Place a used ring at the very top of the cylinder where there is no wear. A gap of 0.007″ to 0.011″ is OK. Over about 0.011″ indicates excessive ring wear.

Place that same ring about 5/8″ below the top. That is the maximum wear area. Compare the ring gap there with the ring gap at the very top. A difference of over about 0.005″ indicates excessive cylinder wear.

 

Indian Crankcase Vent

Crankcase vent

Here is an Indian engine, minus head and magneto. Red arrow is a crankcase vent. If it is blocked off or clogged, the bike will only run for a while. Blow-by past the rings causes the pressure to increase. The high crankcase pressure cancels some or most of the intake vacuum suction pressure.

 

 

Cylinder Wear

Right, close up of the fresh cylinder wall. You can see the reflection of the marks on the piston crown on the exhaust side (back) cylinder wall. A new Indian 42mm ring with a gap of only 0.007″ shows there is almost no wear.

The Haynes PC50 manual states the cylinder wear specs):

42.00 – 42.02 mm Cylinder (cast iron) bore diameter   wear limit 42.1
41.98 – 42.00 mm Piston (aluminum) skirt diameter
0.10 mm (0.004″) Ring gap minimum 

 

Valve Timing

At right is page 14 from the Indian Service Manual showing the timing marks on the cam.

Valve Adjustment

From the service manual, the valve clearance when cold is adjusted to be 0.002 inch (two thousandths). It can be a little more than that without any harm, other than the valve will open a tiny bit less.

 

 

 

Indian Magneto Service

A. Indian Moped: 4-Coil Magneto – Wires Service 

The entire Indian WTEMCO flywheel/magneto is Bosch compatible. Indian has the same engine, controls, switches, and wiring as a Honda PC50. It looks like the light green wire goes to the ignition armature, but there is no connection. The ignition armature has a support tab for the battery charging coil next to it. That tab is the black dot in the wiring diagram, where the light green wire originates.

Indian Magneto 1

Indian Magneto 1
After the lite green and blue cut wires were repaired, the solid copper source coil wire with the white cloth sheath was ready to break off of the blue ignition wire.

Indian Magneto 2

Indian Magneto 2
The black condenser wire was partially melted under the source coil, and smashed flat against the stator plate. Here shows the resin that was poured over the coils, after the wires were in position.

Indian Magneto 3 (hi res)

Indian Magneto 3 (big)
The excess resin is grinded off. All wires are exposed. Any loose connections are cleaned and re-soldered. Lite green is for battery charging. It goes through both small outer coils, in series. Yellow is (main) lights. Blue is ignition.

Indian Magneto 4

Indian Magneto 4
The 3 branches from the points are 1) blue wire to outside coil, 2) black wire to condenser, 3) white cloth wire to source coil. The ignition ground is on the bottom left coil bolt, shown here at top right.

 

 

 

 

 

 

 

 

 

 

 

 

Indian Magneto 6

Indian Magneto 5
The blue wire plus white wire eyelet, and the black wire eyelet go on the points, but cannot touch anything metal nearby.

Indian Magneto 6

Indian Magneto 6
All 3 wires get fatigued where they pass through the hole in the stator plate. Here the points are back on. The light green will go through the hole next, then the lower two coils bolted on after that.

Indian Magneto 7

Indian Magneto 7
Coils are on. Ignition ground is checked, top right (bottom left when installed). Next the loose wires will be tucked in under the coil. Yours first might need rearranging. Don’t let sharp edges rub.

Indian Magneto 8

Indian Magneto 8
Points wire bolt and nut are both 5.5mm hex. Be careful to keep the leaf spring centered while tightening, by holding the bolt solid with the needle nose pliers while tightening the nut.

 

 

 

 

 

 

 

 

 

 

 

 

Indian Magneto 9

Indian Magneto 9
Still oriented upside down. Tested and ready for flywheel installation, after stator screws are in.

Indian 4-coil Magneto

Indian 4-coil Magneto

 

 

 

 

 

 

 

 

 

 

 

Testing for spark is done with the essential wires connected. Stationary testing for continuity is done with the essential wires disconnected, as shown below.

 

Indian Magneto Testing

Indian Magneto Testing

When each test is performed, the wires are wiggled and prodded to see if the ohms reading changes. Sometimes a conductor will conduct until it is moved a certain way. Sometimes an insulator will insulate until it is moved a certain way. During each test the tester is tested by either disconnecting or connecting the test leads. Most ohmeters do not have a sensitive enough scale to go down below 1 or 2 ohms. Sometimes “testing the tester” by shorting the test leads, shows the slight difference. 

 

 

 

 

 

 

 

 

 

B. Indian Moped: 2-Coil Magneto – Wires Service 

The entire Indian WTEMCO flywheel/magneto is Bosch 90mm compatible. Early Indians had 4-coil, while most have 2-coil. The 2-coil magneto has the ignition coil (45mm bolt spacing) on the bottom and the lighting coil (52mm bolt spacing) on top, like the 4-coil. But the two outboard battery charging armatures on the 4-coil have been incorporated into the single lighting coil on the 2-coil. The connections and function is all the same, as is the troubleshooting.  One good thing about Indian magnetos is that both kinds have an internal ignition ground. It is on the lower left armature bolt. On many mopeds it is external, and part of the brake light. 

Indian 2-coil mag assembled from new separate parts - not final

Indian 2-coil magneto:
Condenser wire passes near top left bolt, so the lights coil doesn’t pinch it.
White cloth ignition wire gets soldered to the condenser. Then the blue and white get “tucked in”.

Indian 2-coil Magneto

Indian 2-coil Magneto

 

 

 

 

 

 

 

 

 

 

 

 

Once again, the ignition part of it is the same. In fact, schematically it’s the same for all points-magneto ignitions. Imagine a fork with 3 prongs: one prong is points, one prong is condenser, one prong is source coil (armature). The three prongs join together as one, the handle of the fork, which is the wire going to the ignition coil (transformer). To static test each prong separately with an ohm meter or continuity tester, the wires detach at the points with eyelet connectors. See above for the exact same procedure. As a reminder, checking for spark is completely different and separate from checking the ignition components for continuity. Checking for spark is done with everything assembled and connected, with essential wires grounded, if any, and “kill” wires left disconnected.

When a condenser is replaced, the lights coil is unbolted, and the new condenser wire is laid under it, to prevent it from rubbing against the rotating flywheel points cam. The thicker lights coil will pinch the condenser wire unless it is positioned in the corner before the coil bolts are tightened. Verify it and all other wires are not being pinched by tugging on them and feeling or seeing if they can move freely. 

Indian WTEMCO 2-coil magneto

Indian WTEMCO 2-coil magneto is actually 3-coil because the lights coil and battery coil are one unit.

Indian WTEMCO 2-coil stator plate

Indian stator plate says WTEMCO FHA 11035, same on 2-coil and 4-coil, but 2-coil has wire clamp

Indian WTEMCO 2-coil magneto top view of lighting armature

Indian WTEMCO 2-coil magneto top view of lighting armature showing wire clamp and improved wire routing

Indian WTEMCO 2-coil magneto

Indian magneto wires: blue=ignition (internal ground), yellow=lights, green=battery charging

 

 

 

 

 

 

 

 

 

Indian Magneto Substitution

timing angle

The entire 82mm WTEMCO magneto is a 90mm Bosch compatible. Any 90mm Bosch magneto will bolt on and fit, both the 3-bolt stator plate and the flywheel. However, the ignition timing in the flywheel is different on the various Bosch flywheels. An Indian flywheel has the same timing angle as a Tomos. Both of those bikes can take an entire Puch magneto, but it must be installed without the woodruff key, and positioned at the correct timing angle. It must be very tight, and can still slip later. Many of the modern CDI ignitions require that the woodruff key be left off, and the flywheel positioned at a particular angle on the crank. Such is the case if someone wanted to run a modern CDI ignition made for a Puch, on an Indian. Some more talk about this is in the Indian parts section.

The stationary part of the magneto, the stator, can not be substituted with a 90mm Bosch moped stator, such as one for a Puch.

If the entire magneto is substituted, the 5 or 6 Puch wires will have to become 3. On a Puch 6-wire stator, 2 of the output wires are actually grounds (green/black = brake light ground, and blue/black = ignition ground). Once they are grounded, and the grey tail light wire is left unused, then a Puch 6-wire will directly substitute for Indian 3-wire, blue for blue, yellow for yellow, and green for green. Knowing this should help many Indian owners that have very bad stators or none at all.

The armatures on a Bosch stator (Puch) are 54mm hole spacing, both upper and lower mounts. The WTEMCO Indian ones are 52mm on the upper (lights) and 45mm on the lower (ignition). So Puch armatures don’t interchange with Indian ones.

 

Notes about Indian magneto substitution:

With the piston is parked at top dead center, the rod is in the 12 o’clock position, straight up in this view. The woodruff key for the magneto flywheel is in the 1:15 position, or about 38 degrees. A Puch 1-speed crank has the same size and taper, but the key in the 12:00 position. However, a Tomos crank does have the same size, taper and key position as an Indian. Too bad early Tomos magnetos are scarce because they get rusty from trapped water. 1996-2006 Tomos A35 CDI-ignition, with 70 watts of lights power, magnetos would substitute if the coil is changed to the Tomos A35 coil with CDI unit built-in.

 

 

 

 

Ignition Coil Substitution

Indian coil original

Indian ignition coil made by Wtemco

Wtemco coil bottom view

Wtemco coil bottom view

Wtemco and Bosch coils top view

Wtemco and Bosch coils top view

Wtemco and Bosch coils front view

Wtemco and Bosch coils front view

 

 

 

 

 

 

 

 

The Wtemco coil bolt hole centers are 58mm apart. The Bosch coil holes are 53mm. That is not so bad, but the metal plates are taller. Since the Wtemco coil plates are already up against the floor plate of the frame, there is no room for a Bosch coil in the same location. It would have to be hung with one bolt, at an angle. Furthermore the Bosch bolt holes are for 5mm bolts, whle the Wtemco ones are 6mm. So a special step stud 5-6mm is needed. Fortunately there are some 5-6 step studs on a Motobecane, that are the correct length.