Puch ZA50 Engine Parts

Contents:

Puch 2 speed Automatic ZA50
A. Case Parts II
B. Cylinder Parts II
C. Clutch Parts II
D. Drive Parts II
E. Gaskets, Seals, Bearings

 

9 Puch parts catalogs, for USA two speed models, are combined here using 9 quantity columns. One speed models are in a separate section above.

Price is for each.
green or light green means new
dark green means good-used

Quantity is how many of each item are specified for 1-speed models in that catalog and parts group. If the power version is listed, the quantity is only for that power version.
black means the part is for all 
light blue means for some
light grey means as needed

 

8. 3/78 ’78 Sport MkII

8. 7/78 ’78 Magnum MkII

9. 1/79 ’79 Sport MkII, Maxi II

9. 8/79 ’79 Magnum MkII

0. 1/80 ’80-83 Sport MkII, Newport II

0. 1/80 ’80-83 Magnum II, Magnum MkII

4. 1/84 ’84 Sport MkII, Newport II

5. 1/85 ’85-86 Sport LS II, MkII, Newport II

6. 1/86 ’85-86 Cobra II

6. 1/84 ’84-86 Austro Daimler II (Maxi Plus 2)

 


2A. ZA50 Case Parts II

fig    catalogs 000 
#    8899 00456  Puch part#    price
   F. Case Parts Group II
1    4444 44444 360.110.0341 $4.00 cylinder stud M6 x 103 (105)
2    1111 11111 321.210.6329 none  L case half
3    1100 00000 321.110.6311 none  case gasket note 1
3    0011 11111 321.210.6311 $8.00 case gasket note 2
4    4444 44400 0050.10.1054 $0.00 align tube 8-10-20 note 3
4a  0000 00044 321.110.0541 $0.00 align tube 7-10-12
5    1111 11000 321.110.6339 $30.0 R case half
5    0000 00100 321.310.6339 none  R case half
5a  0000 00011 321.510.6339 none  R case half 
6    1111 11100 321.110.6491 $8.00 cover gasket note 4
6a  0000 00011 321.210.6491 $1100 cover gasket note 5
7    1111 11111 364.210.6601 $3.00 oil fill plug original note 6
7    1111 11111 364.210.6601 $2.00 oil fill plug substitute note 7
8    3333 33333 000 900.3211 $0.25 spring washer M8
9    3333 33333 000 900.2021 $0.80 nut M8-1.0
10  1100 00000 321.110.6351 $0.00 cover for slot-sunk screws
10  0011 00000 321.210.6351 $0.00 cover slot-sunk to 5347646
10  0000 11100 321.310.6351 $0.00 cover phil-pan 5347647 on
10a0000 00011 321.510.6351 $0.00 cover phil-pan black
11  2222 00000 000 900.1687 $2-$1 screw M6 x 70 slot-sunk
11  0000 22222   D079850162 $0.00 screw M6 x 70 phil-pan
12  4444 00000 000 900.1684 $2-$1 screw M6 x 55 slot-sunk
12  0000 44444 000 900.9102 $0.00 screw M6 x 55 phil-pan
13  1111 11111 000 900.1305 $0.80 check plug M6 x 8
14  1111 11111 000 00 24365 $1.00 check seal washer 6 x 12
15  2222 22222 000 901.1001 $1.50 rear mount bolt M8-1.0 x 75
16  1111 11100 321.110.6701 $5.00 drain plug M14-1.5 to 5376719
16a0000 00011 000 901.1009 $5.00 drain plug M10x30 5376720 on
17  1111 11100 000 900.3797 $2.00 drain o-ring 4.3 x 2.5
17a0000 00011 000 900.3721 $2.00 drain seal washer 10-18-1.5
18  1111 11100 000 900.3720 $2.00 drain seal washer 14-22-1
19  1111 11111 000 900.1207 $1.00 case screw M6 x 40 slot-ch
20  2222 22222 000 00 24577 $0.70 case screw M6 x 25 slot-ch
21  4444 44444 000 900.1308 $1.00 case screw M6 x 50 slot-ch
22  1111 11111 000 900.1221 $0.80 case screw M6 x 60 slot-ch
23  1111 11111 000 901.1002 $1.50 front mount bolt M8-1 x 90
24  2222 22000 000 900.1509 $0.80 cover screw M4 x 10 slot
24  0000 00222   D079850132 $1.20 cover screw M4 x 10 phil

25  2222 22222 000 900.3202 $0.40 lock washer A4
26  1111 11100 349.410.0342 20-10 cover blk/grn-gold scratched
26  0000 00011 349.710.0342 42-23 mag cover chrome/black

27  1111 11100 349.210.0361 none  plastic panel grn-gold
27  0000 00011 349.410.0361 none  plastic panel black

Note 1: 321.110.6311 was a case gasket for ’78 models, 0.35 mm thick. It is superseded to 321.210.6311

Note 2: 321.210.6311 is a case gasket for ’79-86 models, 0.35 mm thick. It has more coverage near the cylinder base compared to 321.110.6311

Note 3: There are four alignment tubes, two for the case, and two for the cover.

Note 4: 321.110.6491 is a cover gasket for ’78-84 models with a vertical filler plug. It is a replacement, 0.45 mm thick, compressing to 0.40.

Note 5: 321.210.6491 is a cover gasket for ’85-86 models with a slanted filler plug. It is an original, 0.35 mm thick.

Note 6: The original filler plugs all break the first time they are removed. So they are only sold “as is”, never to be removed

None 7: Use the substitute fill plug instead. It is made from a short piece of fuel hose with a bolt in one end.

 

 


2B. ZA50 Cylinder Parts


fig    catalogs
#   8899 00456   Puch part#    price
   Cylinder Parts Group II
1   1111 11110 000 902.0728 $3.50 spark plug for 1.0 hp versions
1   1111 11110 Bosch W95T1 = W10AC = NGK B4H
1   1010 10110 000 902.0726 $3.50 spark plug for 1.5 hp versions
1   1010 10110 Bosch W145T1 = W8AC = NGK BR5HS
1   0101 01011 000 902.0724 $3.50 spark plug for 1.5 hp versions
1   1101 01011 Bosch W175T1 = W7AC = NGK BR6HS
1   1111 11111 000 902.0724 $3.50 spark plug for 2.0 hp versions
1   1111 11111 Bosch W175T1 = W7AC = NGK BR6HS
2   4444 44444 000 900.2014 $0.30 head nut M6
3   4444 44444 000 00 24804 $0.20 head washer 6
#   8899 00456   Puch part#    price
  7-fin Alu-Chr
4   1010 10110 349.210.2011 none  7f head black 1.0 hp
5   1010 10110 328.110.8041 $2.00 7f gasket 1.5 1.0 hp 1-layer note 1
6   1010 10110 349.310.2050 none  7f cyl & piston 1.0 black note 3
7   1010 10110 349.110.0069 none  7f piston 38-12-17-26 1.0 n. 4
8   2020 20220 331.110.1601 $9.00 7f piston ring 38 x 2 GN note 5
8A 1010 10110 349.115.1221 $4.00 7f intake gasket 19×15 note 6
8B 1010 10110 349.115.1221 $2.00 7f replacement 23×14
8C 1010 10111 000 050.1315 $3.50 7f exhaust gasket
#   8899 00456   Puch part#    price  shared parts

9   2222 22222 000 900.4855 none  ring gap pin ∅2 x 6 note 6
9A 1111 11111 000 901.2943 $5.00 flywheel nut M10-1 x 8 flange
9B 1111 11111 000 900.4503 $2.00 flywheel key M85 3.0 x 3.6
9C 2020 20222 000 00 24773 $0.30 intake nut M6 x 5 steel
9D 0202 02000 000 900.9006 $0.70 intake bolt M6 x 16 allen silver
9E  2222 22222 000 900.3212 $0.30 intake washer A6 curved
9F 2222 22222 000 902.2919 $2.50 exhaust nut M6 x 8 brass orig
9F 2222 22222 000 902.2919 $1.80 exhaust nut M6 x 8 brass 
9G 2222 22222 000 900.3213 $0.25 exhaust washer B6 spring
10 1111 11000 331.110.0111 $12.0 piston pin ∅12 x 31
10 0000 00111 349.110.1111 none  piston pin ∅12 x 31
11 2222 22222 000 901.4701 $1.50 piston clip B12
12 1010 10111 349.310.0131 $4.00 base gasket 0.5 Kstar 1.0
12 1010 11111 349.110.0131 $7.00 base gasket 1.0 orig. 1.5-2.0
13 1111 11111 349.110.0211 $4.00 bush 11.55 14.03 12 note 7
13 1111 11111 349.110.0213 none  bush 11.98 14.03 12 note 8
14 1111 00000 321.112.6173 $00.0 bushing   9.8-8.5-31.0 note 9
14 0011 11111 321.212.6173 $00.0 bushing 10.2-8.5-30.5 note 10
15 1111 11111 000 900.3829 $7.00 R seal xx 20-35-7
16 1111 11111 000 900.6237 $25.0 R bearing 20-47-12 E20
17 1111 11111 00000  25892 $8.00 R shim xx21-27-0.1
17 1111 11111 0000 25892.2 $7.00 R shim xx21-27-0.2
18 1111 11111 000 900.3992 $9.50 L shim xx18-24-0.05
18 1111 11111 000 900.3922 $8.00 L shim xx18-24-0.1
18 1111 11111 000 900.3923 $9.50 L shim xx18-24-0.2
18 1111 11111 000 900.3907 $4.00 L shim xx18-24-0.3
19 1111 11111 0  900.2.6007 $32.0 L bearing 17-40-10 L17
20 1111 11111 000 902.3847 $7.50 L seal xx 17-35-7
21 1111 00000 321.110.6150 $00.0 crank w/bushing note 11
21 0011 11110 321.310.6150 $00.0 crank w/bushing note 12
21 0000 00001 321.610.6159 $00.0 crank w/bearing note 13

#   8899 00456   Puch part#    price
  8-fin Hi-torque
22 1010 10000 349.310.4011 $30.0 8f head black 1.5-2.0
22 0000 00110 349.310.4011 $00.0 8f head black 2.0 hp
22 0000 00110 349.810.4011 none  8f head black 1.5 hp
22 0000 00010 349.110.4011 none  8f head silver 1.5
22 0000 00011 349.110.4011 none  8f head silver 2.0
22 0000 00001 349.710.4011 none  8f head silver 1.5
23 1000 00000 349.310.4050 $00.0 8f cyl/pist blk use 610.4050
23 0010 10100 349.610.4050 $00.0 8f cyl/pist blk use 210.6050
23 0000 00010 349.210.6050 $00.0 8f cylinder/piston black ’85-86
23 0000 00010 349.110.6050 none  8f cylinder/piston silver ’85-86
23 0000 00001 349.110.6050 none  8f cyl/p silv Cobra to 1505807
23 0000 00001 349.610.6050 none  8f cyl/p silv Cobra 1505808 on
24 1000 00000 350.310.0069 some 8f piston 38-12-17-23 note 4
24 0010 10110 349.210.5069 some 8f piston 38-12-17-23 L-ring
25 1010 10110 328.110.8041
$2.00 8f head gasket 1.5 for 1.5 hp
25 0000 00110 349.110.0041 $5.00 8f head gasket 0.4 2.0 note 14
26 4040 40442 000 901.1912 $00.0 8f ex/in stud M6 x 18    or 25?
27 1000 00000 331.110.1601 $9.00 8f upper ring 38 x 2 GN note 5
27 0010 10110 328.110.9601 $10.0 8f upper L-ring 38 x 2 L
27 0000 00001 349.110.6601 $9.00 8f upper ring 38 x 1.5 GN
28 1010 10110 331.110.1601 $9.00 8f lower ring 38 x 2 GN note 5
28 0000 00001 349.110.6601 $9.00 8f lower ring 38 x 1.5 GN
#   8899 00456   Puch part#    price
  9-fin Magnum
34 0101 01000 328.410.4011 $0.00 9f head black
35 0101 01000 349.110.0041 $5.00 9f head gasket 0.4mm note 1
36 0101 01000 328.710.4050 $0.00 9f cylinder & piston black
37 0101 01000 350.310.0069 some 9f piston 38-12-17-23 note 4
38 0202 02000 320.110.0601 $9.00 9f piston ring 38 x 2 GN note 5
42 0101 01000 328.210.5131 none  9f base gasket 0.3 mm note 15
43 0101 01000 00050.1.1014 $0.00 9f exhaust stud M6 x 16
44 0101 01000 328.110.9081 $0.00 9f centering sleeve

Note 1: 328.110.0041 is a replacement head gasket. It is a single layer, 0.4 mm. Original ones had 4 layers, each 0.1 mm.

Note 3: 349.810.0050 and 349.310.2050 are 7-fin cylinders for 1.0 hp versions. They have a restricted intake port that is made tamper resistant with a hardened steel restrictor tube with a very tight press fit. It cannot easily be removed or cut bigger.

Note 4: Pistons are listed in Engine/Pistons-and-Rings/Pistons in section 12-17. 12 is the pin diameter. 17 is the upper length from pin edge to top edge. 21, 23, or 26 is the lower length from pin edge to bottom edge. Aftermarket pistons have the same upper length and pin, but can have different lower lengths. A longer lower length opens the intake port later and closes it sooner.

Note 5: 331.110.1601 is an original 38 x 2 GN piston ring with rounded outer edges. 320.110.0601 is an original 38 x 2 GN piston ring with sharp outer edges. The replacement for both types is the same, 38 x 2 GN with sharp outer edges.

Note 6: 900.4855 is a tiny pin pressed super tight into each piston ring groove. The pin locates each ring gap in a part of the cylinder wall where there are no holes (ports) for the ring ends to catch on and do damage. The pin is a tight fit even when the piston is 400°F. A replacement pin can be made by cutting a 6.0 mm section of a 2.0 mm drill bit.

Note 7: 349.110.0211 is a bronze piston pin bushing with an 11.55 mm inner diameter. Installing requires a special press tool. It requires precision reaming with special tools  to 12.0 mm after it is pressed into the rod. It has to be pressed in first because tight fit makes it smaller after installation, and the ends get distorted by the press tool. After installing the oil hole has to be drilled.

Note 8: 349.110.0213 is a pre-reamed piston pin bushing with an 11.98 mm inner diameter. Installing requires a special press tool. It still requires light precision reaming to 12.0 mm after it is pressed into the rod. After installing the oil hole has to be drilled.

Note 9: 321.112.6173 is a special bronze bushing with an outer diameter of 9.8 mm for all ’78 models, ’79 Magnum MkII up to frame# 1602230, and some ’79 Sport MkII, Maxi II.

Note 10: 321.212.6173 is a special bronze bushing with an outer diameter of 10.2 mm for ’79 Magnum MkII from frame# 1602231, some ’79 Sport MkII, Maxi II, and all ’80-86 models. 

Note 11: 321.110.6150 is a crankshaft with a ∅12-14 piston pin bushing and a ∅9.8 clutch drum bushing. It is for all ’78 models, ’79 Magnum MkII up to frame# 1602230, and some ’79 Sport MkII, Maxi II.

Note 12: 321.310.6150 is a crankshaft with a ∅12-14 piston pin bushing and a ∅10.2 clutch drum bushing. It is for ’79 Magnum MkII from frame# 1602231, some ’79 Sport MkII, Maxi II, and all ’80-86 models except ’85-86 Cobra II. 

Note 13: 321.610.6159 is a crankshaft with a ∅12-15 piston pin bearing and a ∅10.2 clutch drum bushing. It is for ’85-86 Cobra II, but can be an upgrade for others.

Note 14: ’78-83 8-fin (hi torque) 2.0 hp models had no head gasket.

Note 15: Use base gasket 349.310.0131.

 

 
fig    catalogs   Intake Pipes 61-64 Long for ZA50 note 1
#   8899 00456  hp  Puch part#     price   carb-cyl   mount
 
61 1000 00000 1.5 349.615.6302 none    8.5-12.7 38
62 0010 10111 2.0 321.315.6301 $00.0 14.7-14.7 32-38
62 0000 00011 1.5 321.315.6301 $00.0 same
63 0101 01000 2.0 349.815.6302 $00.0 12.7-12.7 32-38 oil inj
63 0101 01000 1.5 349.815.6302 $00.0 same
63 0101 01000 1.0 349.815.6302 $00.0 same
64 1000 01000 2.0 321.415.6301 $00.0 12.7-12.7 32-38
64 0010 11100 1.5 321.415.6301 $00.0 same
64 1010 11100 1.0 321.415.6301 $00.0 same

Note 1: These are good used originals from 1978-86 US models. They are for ZA50 (2 speed) engines with 7-fin, 8-fin, or 9-fin cylinders. That means all except Austro-Daimler II (Maxi Plus). The normally flat base gets curved over time from the pressure of the mount bolts. Then fresh air can leak in. The remedy is to machine or file the base flat.

 


2C. ZA50 Clutch Parts

fig    catalogs 000 
#   8899 00456   Puch part#    price
   Clutch Parts Group .
1   1111 11111 321.112.6450 $0.00 start helix plate
2   1111 11111 321.112.6402 $0.00 start friction plate
3   1111 11111 321.112.6251 $0.00 start coil spring
4   1111 00000 321.112.6141 $0.00 washer 16.8-30.5-1.0
4   0000 11111 321.212.6141 $0.00 washer 16.8-30.5-1.0
5   1111 11111 000 900.4617 $2.00 circlip ext 17 x 1
6   1111 00000 337.113.1751 $0.00 washer 17-24-1.0
6   0000 11111 321.212.6141 $0.00 washer 16.8-30.5-1.0
7   1100 00000 321.112.6120 $0.00 plate-gear 20T 1.0 hp note 2
7   1100 00000 321.212.6120 $0.00 plate-gear 22T 1.5-2.0
7   0011 11111 321.312.6120 $0.00 plate-gear 20T 1.0 hp
7   0011 11111 321.412.6120 $0.00 plate-gear 22T 1.5-2.0
8   1111 00000 320.312.3302 none  2nd speed clutch 1.0 hp
8   1111 00000 321.112.6302 7535 2nd speed clutch 1.5-2.0
8   0000 11111 320.312.6302 none  2nd speed clutch 1.0-1.5
8   0000 11111 321.412.6302 8545 2nd speed clutch 2.0
9   1111 11111 321.112.6161 $7.00 splined spacer 23-28-5
10 1111 11000 321.112.6202 $40.0 1st speed clutch open
10 0000 00111 321.212.6202 $45.0 1st sp clutch covered
11 1111 11111 321.112.6281 $0.00 tab washer 16
12 1111 11111 000 902.2922 $7.00 clutch nut M16-1.5 x 6.5 hex 24
13 1111 00000 321.112.6022 $0.00 drum 13T 1.0 hp  note 1, 3
13 1111 00000 321.212.6022 $0.00 drum 16T 1.5-2.0 note 1, 3
13 0011 11111 321.312.6022 $0.00 drum 13T 1.0 hp  note 1, 4
13 0011 11111 321.412.6022 $0.00 drum 16T 1.5-2.0 note 1, 4
14 1111 11000 321.113.6271 none  shim washer 15-22-0.6
14 1111 11000 321.213.6271 $7.00 shim washer 15-22-0.8
14 1111 11000 321.313.6271 $8.00 shim washer 15-22-1.0
14 0000 00111 321.113.6279 none  shim kit
15 1111 11111 000 900.6186 $15.0 bearing 6002 15-32-9
15a0011 11111 321.110.6371 $0.00 washer 6-31.5-0.2 
16 1111 11111 321.112.6461 $5.00 start torsion spring

 

Note 1: 1st speed gear teeth are 13/73 for 1.0 hp, and 16/70 for 1.5 and 2.0 hp. Each gear set totals 86.

Note 2: 2nd speed gear teeth are 20/66 for 1.0 hp, and 22/64 for 1.5 and 2.0 hp. Each gear set totals 86.

Note 3: 321.112.6022 and 321.212.6022 are clutch drums with a 9.8 mm ID. These are for all ’78 models, ’79 Magnum MkII up to frame# 1602230, and some ’79 Sport MkII, Maxi II.

Note 4: 321.312.6022 and 321.412.6022 are clutch drums with a 10.2 mm ID. These are for ’79 Magnum MkII from frame# 1602231, some ’79 Sport MkII, Maxi II, and all ’80-86 models.

 

 


2D. ZA50 Drive Parts

fig    catalogs 000 
#   8899 00456   Puch part#    price
   Drive Parts Group .
1   1111 11111 000 900.6005 $15.0 bearing 6005 25-47-12
2   1111 11111 321.113.7040 $0.00 shaft 14-66T 1.0 hp note 2
2   1111 11111 321.213.7040 $0.00 shaft 14-64T 1.5-2.0 note 2
3   3333 33333 000 900.9308 $0.00 screw M6 x 10 slot-sunk
4   1111 11111 321.113.7061 $0.00 left plate 35-76-1.5
5   3333 00000 321.113.7031 $0.00 cushion ∅20 x 8?  note 3
5   0000 33333 321.213.7031 $0.00 cushion ∅20 x 8? Atomic
6   1111 11111 321.113.7041 $0.00 2nd gear 66T 1.0 hp note 2
6   1111 11111 321.213.7041 $0.00 2nd gear 64T 1.5-2.0 note 2
7   1111 11111 321.113.7072 $0.00 right plate 35-76-7.5
8   1111 11111 321.113.6241 $9.00 washer 16-27.8-1
9   2222 22222 000 900.6884 $18.0 needle bearing HK1612 16-22-12
10 1111 00000 321.113.6002 $0.00 1st gear 73T 1.0 hp note 1
10 1111 00000 321.213.6002 $0.00 1st gear 70T 1.5-2.0 note 1
10 0000 11111 321.313.6000 $0.00 1st gear 73T 1.0 hp note 1
10 0000 11111 321.413.6000 $0.00 1st gear 70T 1.5-2.0 note 1
11 1111 11111 321.113.6521 $0.00 shift cage
12 7777 77777 321.113.6501 $0.00 shift spring
13 1111 11111 321.113.6491 $0.00 shift cover
14 7777 77777 000 900.6129 $0.00 shift roller 8 x 8
15 1111 11111 321.113.6511 $0.00 shift nut ∅24 left-hand
16 1111 11111 321.513.6471 $7.00 thrust plate 4.2
16 1111 11111 321.113.6471 $7.00 thrust plate 4.4
16 1111 11111 321.213.6471 $7.00 thrust plate 4.6
16 1111 11111 321.313.6471 $7.00 thrust plate 4.8
16 1111 11111 321.413.6471 $7.00 thrust plate 5.0
16 1111 11111 321.613.6471 $7.00 thrust plate 5.2
17 1111 00000 321.113.6371 $7.00 shim washer 10-20-0.6
17 1111 00000 321.213.6421 $8.00 shim washer 10-20-0.8
17 1111 00000 321.213.6371 $7.00 shim washer 10-20-1.0
17 0000 11111 321.113.6379 none  shim kit

18 1111 11111 000 900.6239 none bearing 16100 10-28-8
19 1111 00000 000 900.6885 none  needle bearing SCE810 note 4
19 0000 11111 000 900.6888 none  needle bearing Y8 810
20 1111 00000 321.113.6202 $0.00 drive shaft
20 0000 11111 321.213.6202 $0.00 drive shaft
21 1111 11111 000 900.4740 $0.00 circlip int. 40 x 1.75

22 1111 11111 000 900.6203 $6.00bearing 6203 17-40-12
23 1111 11111 000 902.3816 $5.00 seal 25-35-7

24 1111 11111 321.113.6231 $0.00 sleeve 17-25-14.6

25 1111 11111 349.113.1182 20-10 sprocket 18T 1.0-1.5-2.0
26 1111 11111 000 900.4616 $1.50 circlip ext. 16 x 1

 
16.
thrust plate, 5. shift cushions

Note 1: 1st speed gear teeth are 13/73 for 1.0 hp, and 16/70 for 1.5 and 2.0 hp. Each gear set totals 86.

Note 2: 2nd speed gear teeth are 20/66 for 1.0 hp, and 22/64 for 1.5 and 2.0 hp. Each gear set totals 86.

Note 3: The polyurethane “pucks” or “dampers” or “shift cushions” are oil-resistant rubber disks 20mm in diameter. They decompose after 20 or 30 years. With decomposed or missing cushions, during the shift the engine can chatter and shake the bike. This can cause the gear teeth to break off, or the ring of ramps at the center of the large first speed gear to crack. Those are both disasters. Every old 2-speed should have new pucks before being rode after years of sitting, or at least be operated at low power during the shift. 

Note 4: 900.6885 is an inch size needle bearing SCE810, not metric. ID 8/16, OD 11/16, length 10/16″= 12.7, 17.46, 15.88 mm.

 

 


2E. ZA50 Gaskets, Seals, Bearings

 


Gaskets and Gasket Sets

Head Gasket: On ’75-86 Puch (US models) there are five stock head gasket versions, 1.5 mm, 0.8, 0.4, 0.2 and 0.0 (no gasket). The head gasket is not needed as a pressure seal. Instead it’s secret purpose is a spacer, to fine tune the power by moving the head farther or closer to the piston. That changes the compression ratio (CR), which changes the horsepower. If the CR was 9.0 with no head gasket, then adding a 0.4 mm gasket would lower the CR to 8.4. Adding a 1.5 mm gasket would lower the CR to 7.2. See Note 1 below.

Base Gasket: On ’75-86 Puch (US models) there are five stock base gasket versions with two different thicknesses, 1.0 and 0.5 mm. A thicker base gasket raises the cylinder and the ports. That makes the exhaust and transfer ports open sooner and close later, but makes the intake port open later and close sooner. The purpose is to fine tune the engine power and characteristics. Raising the cylinder with a thicker base gasket also lowers the compression ratio which causes lower power. 

Why so many? Changing the base gasket and head gasket thicknesses is an easy and economical way to comply with power and speed limits for each country (or US state).

 

 



fig      catalogs    Intake Gasket
#   8899 004566 part number    price  description
#   8899 004566 for cylinder version
#   8899 004566 for horsepower version

1  8899 004566 349.115.1221 $4.00 original
8A 1010 101100 7-fin Maxi II, Sport MkII, Newport II
1   8899 014566 1.0 hp use #4

2  8899 004566 349.215.1221 $6.00 original
29 1010 101110 8-fin Maxi II, Sport MkII, Newport II, Cobra II
2   8899 014566 1.5-2.0 hp use #1 or #4

3   8899 004566 329.115.3221 none  original
45 0101 010000 9-fin Magnum II, MkII

4   8899 004566 349.115.1221r $2.00 generic
8B 1010 101110 7-fin, 8-fin Maxi II, Sp. MkII, New. II, Cobra II

5   8899 004566 345.115,5221 none  3-bolt original
00 0000 000001 10-fin Austro Daimler II

 



fig      catalogs    Exhaust Gasket
#   8899 004566   part number    price  description
#   8899 004566   for cylinder version

1   8899 004566 000 050.1315 $3.50 ∅20 x 42 generic
8C 1010
101110 7-fin, 8-fin Maxi II, Sp. MkII, New. II, Cobra II

2   8899 004566 368.116.8151 $4.00 ∅23 x 42 generic
46 0101 010000 9-fin Magnum II, MkII

3  8899 004566 345.116.5041 none  
00 0000 000001 10-fin Austro Daimler II

 



fig      catalogs    Exhaust Pipe Gasket
#   8899 004566 part number    price  description
#   8899 004566 for cylinder version

1   8899 004566 349.116.0191 $4.00 ∅26 x 34 
00 1010 100000
 7-fin, 8-fin ’78-84 Maxi II, Sport MkII, Newport II

2  8899 004566 345.116.0191 $4.00 ∅22 x 34 
00 0000 000110
 8-fin ’85-86 Sport LS II, Cobra II
00 0000 000001
10-fin ’85-86 Austro Daimler II

3   8899 004566 321.316.4191 none  ?? x ?? note 1
00
0000 010000 9-fin ’80-82 Magnum II, MkII

Note 1: 321.316.4191 is a gasket for Magnum tail pipe. It’s sold as a flat strip that you roll into a circle during installation. But all have become hard and brittle. They break instead of bending into a circle.

 

 



fig      catalogs    Head Gasket
#   8899 004566   part number    price   description
#   8899 004566   for cylinder version

1   8899 004566 328.110.8041 $2.00 1.5 mm original
5   0000 001100 7-fin 1.0 hp Sport MkII, Newport II
25 1010 101100 8-fin 1.5 hp Maxi II, Sport MkII, Newport II

2   8899 004566 349.310.0041 $6.00 0.8 mm original
25 0000 000010 8-fin 1.5 hp ’84-86 Cobra II
00 0000 000001 10-fin 1.5 hp ’84-86 A-D II

3  8899 004566 349.110.0041 $5.00 0.4 mm generic
5   1010 101100 7-fin 1.0 hp Maxi II, Sport MkII, Newport II
25 0000 001110 8-fin 2.0 hp Sport LS II, Cobra II note 10

35 0101 010000 9-fin 1.0-1.5-2.0 hp Magnum MkII, II
00 0000 000001 10-fin 2.0 hp ’84-86 A-D II

4   8899 004566 349.210.0041 $6.00 0.2 mm 2-layer
00 8899 004566 349.210.0041 $3.00 0.1 mm ½ of #4
5   0000 000000  7-fin 1.5-2.0 hp early Maxi

Note 10: ’78-83 8-fin (hi torque) 2.0 hp models had no head gasket.

 

 



fig      catalogs    Cylinder Base Gasket
#   678899 004566 part number    price   description
#   678899 004566 for cylinder version

1   678899 004566 349.110.0131 $7.00 1.0 mm original
12 111010 111110 8-fin 1.5-2.0 hp ’78-85 Maxi II, Sport MkII, Newport II,
12 111010 111110 8-fin 1.5-2.0 hp ’84-86 Sport LS II, Cobra II

2  678899 004566 349.310.0131 $6.00 0.5 mm original
12 111111 101100 7-fin 1.0 hp ’78-85 Maxi II, Sport MkII, Newport II,
12 111111 101100 7-fin 1.0 hp ’85-86 Sport LS II

3  678899 004566 349.210.5131 none  0.3 mm original
42 000101 000000 9-fin 1.0-1.5-2.0 ’80-82 Magnum II, MkII

4  678899 004566 328.310.0131 none  0.5 mm original
00 000000 000001 10-fin 1.5-2.0 hp ’83-84 Dart, ’84-86 A-D

5  678899 004566 328.110.0131 $6.00 1.0 mm original
00 000000 000001 10-fin 1.5-2.0 hp ’84-86 A-D II

6   678899 00456  349.310.0131r $3.00 0.5 mm generic
12 111111 111111 replacement

 

 


Top End Gasket Sets

set# price     dimensions 0000 black is original
set# price head base  int  exh   blue is generic 

 

1. for ’75-86 Maxi series with 1.0 hp 7-fin cylinder
use the 2.0 hp set S14 for a small increase in power
S11 $16.0 1.5, 0.5, 19-38, 20
S1r $10.0 1.5, 0.5, 23-38, 20

 

2. for ’78-86 Maxi series with 1.5 hp 8-fin cylinder
use the 2.0 hp set S17 for a small increase in power
S12 $18.0 1.5, 1.0, 14-38, 20
S1r $10.0 1.5, 0.5, 23-38, 20  

 

3. for ’78-82 Magnum II, MkII  with 1.0 hp 9-fin cylinder
use the 2.0 hp set S16 for a small increase in power
S13 none  1.5, 0.5, 14-32, 23

 

4. for ’75-86 Maxi series with 1.5-2.0 hp 7-fin cylinder
S14 $18.00.4, 1.0, 19-38, 20
S2r $12.0 0.4, 0.5, 23-38, 20

 

5. for ’84-86 Sport LS2, Cobra 2 with 2.0 hp 8-fin cylinder
use the 2.0 hp set S17 for a slight increase in power
S15 $20.00.4, 1.0, 14-38, 20
S2r $12.0 0.4, 0.5, 23-38, 20

 

6. for ’78-82 Magnum II, MkII with 1.5-2.0 hp 9-fin cylinder
S16 none  0.4, 1.0, 14-32, 23

 

7. for ’78-86 with 2.0 hp 8-fin cylinder (except Sport LS2, Cobra 2)
S17 $17.0 none 1.0 14-38, 20
S3r $8.00 none 0.5 23-38, 20

 

 

Note 1: Here is the calculation of compression ratio with (CRg) and without (CR) a head gasket.

bore = 38 mm  stroke = 42 mm   CR = (Vt +Vs)/Vt = 9.00

Vs = swept volume = 3.14*(38/2)²*42 = 47610 mm³ = 47.61 cc
Vt = trapped volume=Vs/(CR-1)=47610/8.00=5950 mm³=5.95 cc
CR = (Vt +Vs)/Vt = (5.95 + 47.61)/5.95 = 9.0

Vtg = Vt + 0.4 gasket = 3.14*(39/2)²*0.4 + 5950=6428 mm³=6.43 cc
CRg = (Vtg +Vs)/Vtg = (6.43 + 47.61)/6.43 = 8.4

Vtg = Vt + 1.5 gasket = π*(39/2)²*1.5 + 5950=7740 mm³=7.74 cc
CRg = (Vtg +Vs)/Vtg = (7.74 + 47.61)/7.74 = 7.2

 

 


Seals and Seal Sets

 


fig      catalogs    Seals and Seal Sets
#   8899 004566  part number   price  size  location

15 1111 111111 000 900.3829 $7.00 20-35-7 R crank
20 1111 111111 000 902.3847 $7.50 17-35-7 L crank
23 1111 111111 000 902.3816 $5.00 25-35-7 drive
00 1111 111111 000 900.0000 $18.0 seal set 3-piece

 

 

 


Bearings and Bearing Sets


fig      catalogs    Bearings and Bearing Sets
#   8899 004566 part number  price  size    bearing#  location

16 1111 111111 0 900.6237 $25.0 20-47-12 E20 R crank
19 1111 111111 900.2.6007 $32.0 17-40-10 L17 L crank
15 1111 111111 0 900.6186 $15.0 15-32-9   6002 front cover
18 1111 111111 0 900.6239 none  10-28-8   16100 rear cover
1   1111 111111 0 900.6005 $15.0 25-47-12 6005 L countershaft
9   2222 222222 0 900.6884 $18.0 16-22-12 HK1612 needle bearing
19 1111 000000 0 900.6885 none  needle bearing SCE810 note 4
19 0000 111111 0 900.6888 none  needle bearing Y8 810
22 1111 111111 0 900.6203 $6.00 17-40-12 6203bearing

 

Note 4: 900.6885 is an inch size needle bearing SCE810, not metric. ID 8/16, OD 11/16, length 10/16″= 12.7, 17.46, 15.88 mm.